2TLA020046R0000

**Catalog 2013** 

ABB Safety Handbook Machine Safety - Jokab Safety products 

ABB Safety Handbook Machine Safety - Jokab Safety products 

> Introduction 1 Directives and Standards, PL, SISTEMA, SIL, Training 

> Pluto Safety PLC 2 Pluto, Gateway, Safe Encoder, IDFIX, program examples 

> Pluto AS-i 3 Pluto AS-i, Urax 

> Pluto Manager 4 Software for programming of Pluto 

> Vital and Tina safety systems 5 Vital, Tina, connection examples 

> Safety Relays 6 RT series, JSB series, Safety timers, Expansion relays, connection examples 

> Light curtains/Light grids/Light beams 7 Focus, Spot, Bjorn, WET, BP-1, connection examples 

> Stop time measurement and machine diagnosis 8 Smart, Smart Manager 

> Sensors/Switches/Locks 9 Eden, Sense, Magne, Dalton, Knox, MKey 

> Control devices 10 JSHD4, Safeball, JSTD20 

> Emergency stop devices 11 INCA, Smile, Smile Tina, Compact, EStrong, LineStrong 

> Contact Edges/Bumpers/Safety mats 12 Contact Edges, Bumper, Mats, electrical connections 

> Fencing systems 13 Quick-Guard, Quick-Guard Express, SafeCAD, Roller doors 

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## Introduction 

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We develop innovative products and solutions for machine safety 1/4 1<br>Safety history 1/6<br>Directives and Standards  1/8<br>Working method as specified in EN ISO 13849-1  1/14<br>Case studies  1/18<br>What defines a safety function?  1/24<br>SISTEMA   1/26<br>Safety relay, Vital or Pluto?  1/27<br>Applying EN 62061  1/28<br>A mechanical switch does not give a safe function!  1/29<br>We train you on safety requirements  1/30<br>**----- End of picture text -----**<br>


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## We develop innovative products and solutions for machine safety 

We make it simple to build safety systems. Developing innovative products and solutions for machine safety has been our business idea since the company Jokab Safety, now ABB AB, was founded in Sweden in 1988. Our vision is to become “Your partner for machine safety – globally and locally”. 

Many industries around the world, have discovered how much easier it has become to build protection and safety systems with our components and guidance. 

## Experience 

We have great experience of practical application of safety requirements and standards from both authorities and production. We represent Sweden in standardisation organisations for machine safety and we work daily with the practical application of safety requirements in combination with production requirements. You can use our experience for training and advice. 

## Systems 

We deliver everything from a safety solution to complete safety systems for single machines or entire production lines. We combine production demands with safety demands for production-friendly solutions. 

## Products 

We market a complete range of safety products, which makes it easy to build safety systems. We develop these innovative products continuously, in cooperation with our customers Our extensive program of products, safety solutions and our long experience in machine safety makes us a safe partner. 

Mats Linger and Torgny Olsson founded Jokab Safety AB in Sweden in 1988, together with Gunnar Widell 

## Standards and regulations 

## We help to develop standards 

Directives and standards are very important to machinery and safety component manufacturers. We therefore participate in several international committees that develop standards, for among other things industrial robots, safety distances and control system safety features. This is experience that we absorb so that the standards will present requirements that benefit production efficiency allied to a high level of safety. We are happy to share our knowledge of standards with our customers. 

Do you need to learn about the new safety requirements for robots? If so, please contact us. 

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## Our products revolutionise the market 

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Flexibility<br>Programmable<br>Pluto AS-i<br>Not programmable<br>Vital Pluto All-Master<br>Dynamic "doubled up"  Safety PLC with static and dynamic<br>safety signal that tests a  safety inputs.<br>sensor, for example, 200<br>times per second.<br>|<br>Master<br>Safety relay<br>Double static inputs that  bik Slaves<br>only test the switches<br>each time they are used. Traditional safety PLC<br>Master-Slave with static inputs<br>I<br>Number of machines/different stops<br>**----- End of picture text -----**<br>


Our dynamic safety circuits and our comprehensive safety PLC are probably the most revolutionary ideas that have happened in the safety field in the control and supervision of protection, in many respects: 

- They save on inputs: a dual safety circuit with one conductor instead of two. In addition, many protection devices can be connected to the same input while maintaining the highest level of safety. 

- Reliability is better. Our electronic sensors have much longer lives than mechanical switches 

- They are safer, since our dynamic safety sensors are checked 200 times per second. Traditional switches on a door can only be checked each time they are used, for example once per hour or even once a month. 

- With the All-Master Safety PLC it is easy to connect and disconnect machinery from a safety viewpoint. Common emergency stop circuits and sensors can be created as soon as the buses are interconnected between our safety PLCs. 

We are continuously designing safety systems for difficult environments and also to create new safety solutions where practical solutions are missing. New technical improvements give new possibilities and therefore we continuously develope new products. 

## We train both machine builders and machine operators 

## Do you construct machinery? 

We can provide the training you need to construct machinery that meets the requirements. Example subjects: 

- Practical implementation of the requirements in the new Machinery Directive 2006/42/EC, which is valid for machines that was delivered/put into service from the 29th of december 2009 

- Risk analysis – in theory and practice 

- Control systems safety, standards EN ISO 13849-1 and EN 62061 

## Do you purchase and use machinery? 

As a machinery user it is your responsibility to ensure that the correct requirements are complied with – regardless of whether your machinery is “new” or “old”, i.e. CE-labelled or not. Unfortunately many have purchased CE-labelled machinery that does not meet the requirements. This must not be used. Having it brought into compliance by the supplier can take a long time and be expensive in terms of loss of production, etc. We can educate you on this and help you to set the right demands when buying new or even second-hand machinery. 

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## Safety history 

## Developments of the 70's 

Our background in safety started in the seventies when there was a significant focus on the safety of manually operated presses, the most dangerous machine in those days. The probability of loosing a finger or hand while working with these machines was very high. New safety solutions for both safety devices as well as for the control systems for presses were developed and introduced on both old and new machines. We were directly involved in this work through the design of TwoHand devices, control systems for presses, making safety inspections for the Health and Safety authorities and writing regulations for safety of these machines. This work provided an excellent base for our knowledge in machinery safety. 

The numbers of accidents involving presses decreased significantly during these years however there is still room for new ideas to enable safety equipment become more practical and ergonomic. 

## Developments of the 80's 

...of the 70's 

We protected people from loosing fingers or/and hands in dangerous machines. 

...of the 80's 

During the eighties, industrial robots (Irb’s) started to become commonplace in manufacturing industry. This meant that workers were outside of the dangerous areas during production but had at certain times to go inside the machine in order to e.g. adjust a product to the correct position, inspect the production cycle, troubleshoot and to programme the Irb. New risks were introduced and new safety methods required. It was for example hard to distinguish whether production machines had stopped safely or simply waiting for the next signal, such as a sensor giving a start signal while a product was being adjusted into the correct position. Mistakes in safety system design resulting in serious accidents were made, such as the omission of safety devices to stop the Irb, unreliable connection of safety devices and unreliable safety inputs on the Irb. 

In the mid eighties the standards committee for safety in Industrial Robot Systems EN 775/ISO 775 was started. This was the first international standard for machine safety. In order to give the correct inputs to the standard, work around Irb’s was closely studied in order to meet production integrated safety requirements. The introduction of a production oriented safety stop function was made, using for example, software to stop machines smoothly and then safety relays/contactors to disconnect the power to the machines actuators after the machine had stopped. This technique allows easy restart of production after a stop situation by the machine safeguards. 

Three-position enabling devices were also introduced for safety during programming. 

There were a lot of discussions as to whether one could have both safety and practical requirements in a standard, such as a safe stop function, which allowed an easy restart of the machine. Three-position enabling devices were also introduced for safety during programming, testing and trouble shooting of Irb’s and other equipment. In the robot standard the three-position enabling function was first defined by only allowing for hazardous machinery functions in the mid switch position. Releasing or pressing the three-position push button in panic leading to a stop signal. 

## Developments of the 90's 

In Europe, during the nineties, the machinery directive was the start of a tremendous increase in co-operation across borders to get European standards for safety for machinery and safety devices. The experience from different European countries has led to a wide range of safety standards and this has made work in safety much easier. With the integration of Europe it is now only necessary for a safety company such as ourselves to get one approval for our components for all of Europe instead of one per country. 

## Developments 2000 – 

...of the 90's European standards for safety for machinery and safety devices. @ | 

...2000 – 

Internationally the work on safety has now been intensified within ISO. The objective is to have the same structure of safety requirements and standards within ISO as within EN. ABB Jokab Safety is active both internationally and nationally in different standard working groups. The co-operation between countries is leading to better safety solutions, making it much easier to create safe working environments around the world. 

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## Jokab Safety‘s developments 

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Jokab Safety‘s first  Jokab Safety‘s first  ...of the 80's<br>safety relay steel fencing system<br>1<br>...of the 90's<br>ceconcee, (GEE (EEeEEEEEEEEEEEEE E T \BHE lseesenee Barren Sie Ge<br>Timer reset and first light beam Smallest safety relays  RT series universal relays<br>JSBT5 and JSBR4<br>Three-position  3-position  Safeball - ergonomic  Stop time measu- SafeCad for  Quick-Guard aluminium<br>switch for robots devices control device rement Quick-Guard fencing system<br>**----- End of picture text -----**<br>


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Pluto All-Master safety PLC ...2000 –<br>AS-i<br>20 I/O 46 I/O 42 I/O 12 I/O(A/D) + 31 AS-i nodes<br>Sensors with inte-<br>grated AS-i safety<br>nodes<br>i a aaa =i = payne b<br>Pluto Ma-<br>Safety nodes for<br>nager<br>connection of sensors on<br>the AS-i cable<br>Vital with dynamic safety circuits<br>PI a S a<br>Vital 1 Vital 2 Vital 3<br>eg ies er e =a ns<br>sp eo<br>**----- End of picture text -----**<br>


Non-contact sensor Eden, guard locks, Focus light beam, E-stops Inca and Smile, Smart for machine diagnosis and three-position device with hand detection 

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## Directives and Standards 

Directives and standards are of great importance for manufacturers of machines and safety components. EU Directives giving requirements for the minimum level of health and safety  are mandatory for manufacturers to fulfil. In every member country the Directives are implemented in each countries legislation. 

Machines which have been put on the market since december 29, 2009, must comply with the new Machinery Directive 2006/42/EC. Before that, the old Machinery Directive 98/37/EC was valid. 

The objectives of the Machinery Directive, 2006/42/EC, are to maintain, increase and equalise the safety level of machines within the members of the European Community. Based on this, the free movement of machines/products between the countries in this market can be achieved. The Machinery Directive is developed according to “The New Approach” which is based on the following principles: 

- The directives give the basic health and safety requirements, which are mandatory. 

- Detailed solutions and technical specifications are found in harmonised standards. 

- Standards are voluntary to apply, but products designed according to the harmonised standards will fulfil the basic safety requirements in the Machinery Directive. 

## Harmonised standards 

Harmonised standards give support on how to fulfil the requirements of the Machinery Directive. The relationship between the Machinery Directive and the harmonised standards is illustrated by the diagram below. 

Within ISO (The International Organization for Standardization) work is also going on in order to harmonise the safety standards globally in parallel with the European standardisation work. 

ABB Jokab Safety takes an active part in the working groups both for the ISO and EN standards. 

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2006/42/EC<br>Examples of standards The Machinery<br>Directive<br>EN ISO 12100<br>Giving basic concepts, principles for design, and general<br>A-standard<br>aspects that can be applied to all machinery<br>EN ISO 13857<br>EN 349<br>EN ISO 13849-1EN ISO 13855 B1-standard B1: Standards on particular safety aspects (e.g. safety distan-<br>ces, surface temperature, noise)<br>B2-standard<br>B2: Standards on safeguards,e.g. two-hand controls, interlo-<br>EN ISO 13850 cking devices, pressure sensitive devices, guards<br>EN 1088<br>EN 60204-1<br>Dealing with detailed safety requirements for a particular<br>EN ISO 10218-1<br>EN 692 machine or group of machines<br>EN 693<br>C-standard<br>**----- End of picture text -----**<br>


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The Machinery Directive; for machines and safety components 

## From 2006/42/EC 

|From|2006/42/EC|
|---|---|
|1 §|This Directive applies to the following products:|
|a)|machinery;|
|b)|interchangeable equipment;|
|c)|safety components;|
|d)|lifting accessories;|
|e)|chains, ropes and webbing;|
|f)|removable mechanical transmission devices;|
|g)|partly completed machinery.|



The Machinery Directive gives the following definition: 

- a) machinery’ means: 

- an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or animal effort, consisting of linked parts or components, at least one of which moves, and which are joined together for a specific application, 

- an assembly referred to in the first indent, missing only the components to connect it on site or to sources of energy and motion, 

- an assembly referred to in the first and second indents, ready to be installed and able to function as it stands only if mounted on a means of transport, or installed in a building or a structure, 

- assemblies of machinery referred to in the first, second and third indents or partly completed machinery referred to in point (g) which, in order to achieve the same end, are arranged and controlled so that they function as an integral whole, 

- an assembly of linked parts or components, at least one of which moves and which are joined together, intended for lifting loads and whose only power source is directly applied human effort; 

## Requirements for the use of machinery 

For a machine to be safe it is not enough that the manufacturer has been fulfilling all valid/necessary requirements. The user of the machine also has requirements to fulfil. For the use of machinery there is a Directive, 89/655/EEC (with amendment 96/63/EC and 2001/45/EC). 

About CE-marked machinery the Directive gives the following requirement 

## From 89/655/EEC (with amendment 96/63/EC and 2001/45/EC) 

1. Without prejudice to Article 3, the employer must obtain and/or use: 

- (a) work equipment which, if provided to workers in the undertaking and/or establishment for the first time after 31 December 1992, complies with: 

- (i) the provisions of any relevant Community directive which is applicable; 

- (ii) the minimum requirements laid down in Annex I, to the extent that no other Community directive is applicable or is so only partially; 

This means that when repair/changes are made on the machine it shall still fulfil the requirements of the Machinery Directive. This doesn´t have to mean that a new CE-marking is required. (Can be required if the changes are extensive) 

NOTE! This means that the buyer of a machine also has to make sure that a new machine fulfills the requirements in the directives. If the machine does not fulfill the requirements the buyer is not allowed to use it. 

## “Old” machines 

For machines delivered or manufactured in the EEA before 1 January 1995 the following is valid. 

## CE-marking and Declaration of conformity 

Machines manufactured or put on the market fro december 29, 2009, shall be CE-marked and fulfil the requirements according to the European Machinery Directive 2006/42/EC. This is also valid for old machines (manufactured before 1 January 1995) if they are manufactured in a country outside the EEA and imported to be used in a country in the EEA. 

For machines manufactured and/or released to the market between january 1, 1995,  and december 28, 2009, the old Machinery Directive (98/37/EC) is valid. 

NOTE! The point in time when the Machinery Directive was implemented in each Member Country varies. Machines have to be accompanied by a Declaration of Conformity (according to 2006/42/EC, Annex II 1.A) that states which directive and standards the machine fulfils. It also shows if the product has gone through EC Type Examination. 

Safety components have to be accompanied with a Declaration of Conformit. 

(b) work equipment which, if already provided to workers in the undertaking and/or establishment by 31 December 1992, complies with the minimum requirements laid down in Annex I no later than four years after that date. 

(c) without prejudice to point (a) (i), and notwithstanding point (a) (ii) and point (b), specific work equipment subject to the requirements of point 3 of Annex I, which, if already provided to workers in the undertaking and/or establishment by 5 December 1998, complies with the minimum requirements laid down in Annex I, no later than four years after that date. 

Annex l contains minimum requirements for health and safety. There can also be additional national specific requirements for certain machines. NB The point in time when the Machinery Directive was implemented in each Member Country varies. Therefore it is necessary to check with the national authorities in ones own country, to find out what is considered as “old” and respectively “new” machines. 

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## "Old" machines "New" machines 

Machine that is put on the market or put into service before 1995  in the EEA. 

Council Directive 89/655/EEC Possible national legislation (with amendment 96/63/EC on specific machines and 2001/45/EC) a concerning the minimum safety and health requirements for the use of work equipment by workers at work. 

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1. Machine that is put  2. All machines that<br>on the market or put  are imported to the<br>into service after  1/1  EEA irrespective of<br>1995  in the EEA.  date of origin.<br>CE-marking +<br>Declaration of<br>conformity<br>Council Directive 89/655/EEC<br>(with amendment 96/63/EC  Low Voltage Directive<br>and 2001/45/EC)  concerning  2006/95/EC<br>the minimum safety and health<br>requirements for the use of work<br>equipment by workers at work.<br>N.B! Not annex 1, instead use<br>applicable directives.<br>Ik<br>The Machinery Directive EMC-directive  Possibly<br>98/37/EC 2004/108/EC more<br>(Jan 1, 1995 - Dec 28, 2009) directives<br>2006/42/EC<br>(from December 29, 2009)<br>**----- End of picture text -----**<br>


Risk assessment – an important tool both when constructing a new machine and when assessing risks on older machines 

A well thought-out risk assessment supports manufacturers/ users of machines to develop production friendly safety solutions. One result of this is that the safety components will not be a  hindrance. This minimizes the risk of the safety system being defeated. 

## New machines 

The following requirement is given by the Machinery Directive 

The manufacturer of machinery or his authorised representative must ensure that a risk assessment is carried out in order to determine the health and safety requirements which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment. 

## Machines in use 

Risk assessment must be carried out on all machines that are in use; CE-marked as well as not CE-marked. 

To fullfil the requirements from Directive 89/655/EEC (concerning the minimum safety and health requirements for the use of work equipment by workers at work) risk assessment have to be made. 

## Documentation of risk assessment 

The risk assessment shall be documented. In the assessment the actual risks shall be analysed as well as the level of seriousness. 

The standard EN ISO 12100 gives guidance on the information required to allow risk assessment to be carried out.The standard does not point out a specific method to be used. It is the responsibility  of the manufacturer to select a suitable method. 

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## Protection or warning? 

How is it possible to choose safety measures that are production friendly and in every way well balanced? The Machinery Directive gives an order of priority for the choice of appropriate methods to remove the risks. Here it is further developed in a five step method. 

Prioritize safety measures according to the five step method 

1. Eliminate or reduce risks by design and construction 

2. Move the work tasks outside the risk area 

3. Use guards/safety devices 

4. Develop safe working routines/information/education 

5. Use warnings as pictograms, light, sound etc. 

The further from middle of the circle, the greater the responsibility for the safety is put onto the user of the machine. If full protection is not effectively achieved in one step, one has to go to the next step and find complementary measures. 

What is possible is dependant on the need for accessibility, the seriousness of the risk, appropiate safety measures etc. 

Example on prioritizing according to the 5-step-method 

|Priority                            Example of hazard and safety measure taken|Priority                            Example of hazard and safety measure taken|Priority                            Example of hazard and safety measure taken|
|---|---|---|
|**1. Make machine safe by**|Hazard:|Cuts and wounds from sharp edges and corners on machinery|
|**design and construction**|||
||Safety measure:|Round off sharp edges and corners.|
|**2. Move the work tasks**|Hazard:|Crushing of fingers from machine movements during inspection of|
|**outside the risk area**||the production inside the risk area|
||Safety measure:|Installation of a camera.|
|**3. Use guard/safety**|Hazard:|Crushing injuries because of unintended start during loading of|
|**devices**||work pieces in a mechanical press|
||Safety measure:|Install a light curtain to detect operator and provide safe stop of the|
|||machinery.|
|**4. Safe working routines/**|Hazard:|Crushing injuries because  the machine can tip during installation|
|**information**||and normal use.|
||Safety measure:|Make instructions on how the machine is to be installed to avoid|
|||the risks. This can include requirements on the type of fastening,|
|||ground, screw retention etc.|
|**5. Warnings**|Hazard:|Burns because of hot surfaces in reach|
||Safety measure:|Warning signs|



The possibilities will increase to achieve a well thought-through safety system if each risk is handled according to the described prioritizing. 

Combine the five step method with production friendly thinking. This can give you e.g. 

- fast and easy restart of machines after a stop from a safety device 

- enough space to safely program a robot 

- places outside the risk area to observe the production 

- electrically interlocked doors, instead of guards attached with screws, to be able to take the 

- necessary measures for removing production disturbances 

- a safety system that is practical for all types of work tasks, even when removing production 

- disturbances 

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Examples of regularly used EN/ISO standards 

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EN ISO 12100 Safety of machinery - General principles  Part 1: This standard defines basic terminology and methodology used in achieving safety<br>(replaces EN  for design - Risk assessment and risk  of machinery. The provisions stated in this standard are intended for the designer.<br>ISO 12100-1/- reduction Part 2: This standard defines technical principles to help designers in achieving safety in<br>2 and EN ISO  the design of machinery.<br>14121-1)<br>EN ISO 13857 Safety of machinery - Safety distances to  This standard establishes values for safety distances to prevent danger zones being<br>prevent hazard zones being reached by  reached by the upper limbs. The distances apply when adequate safety can be achieved<br>upper and lower limbs by distances alone.<br>EN 349 Safety of machinery – Minimum gaps to  The object of this standard is to enable the user (e.g. standard makers, designers of<br>(ISO 13854) avoid crushing of parts of the human body machinery) to avoid hazards from crushing zones. It specifies minimum gaps relative to<br>parts of the human body and is applicable when adequate safety can be achieved by this<br>method.<br>EN ISO 13850 Safety of machinery – Emergency stop –  This standard specifies design principles for emergency stop equipment for machinery. No<br>Principles for design account is taken of the nature of the energy source.<br>EN 574 Safety of machinery – Two-hand control  This standard specifies the safety requirements of a two-hand control device and its logic<br>devices – Functional aspects – Principles  unit. The standard describes the main characteristics of two-hand control devices for the<br>for design achievement of safety and sets out combinations of functional characteristics for three<br>types.<br>EN 953 Safety of machinery – Guards – General  This standard specifies general requirements for the design and construction of guards<br>requirements for the design and construc- provided primarily to protect persons from mechanical hazards.<br>tion of fixed and movable guards<br>EN ISO 13849-1 Safety of machinery – Safety related parts  This standard provides safety requirements and guidance on the principles for the design<br>(replaces EN  of control systems –   (see 3.11 of EN 292-1:1991) of safety-related parts of control systems. For these parts it<br>954-1) Part 1: General principles for design specifies categories and describes the characteristics of their safety functions. This inclu-<br>des programmable systems for all machinery and for related protective devices. It applies<br>to all safety-related parts of control systems, regardless of the type of energy used, e.g.<br>electrical, hydraulic, pneumatic, mechanical. It does not specify which safety functions and<br>which categories shall be used in a particular case.<br>EN ISO 13849-2 Safety of machinery. Safety-related parts of  This standard specifies the procedures and conditions to be followed for the validation by<br>control systems. Validation analysis and testing of:<br>• the safety functions provided, and<br>• the category achieved of the safety-related parts of the control system in compliance with<br>EN 954-1 (ISO 13849-1), using the design rationale provided by the designer.<br>EN 62061 Safety of machinery. Functional safety of  The standard defines the safety requirements and guiding principles for the design of<br>safety-related electrical, electronic and pro- safety-related electrical/electronic/programmable parts of a control system.<br>grammable electronic control systems<br>EN ISO 13855 Safety of machinery - Positioning of  This standard provides parameters based on values for hand/arm and approach speeds<br>(replaces EN  safeguards with respect to the approach  and the methodology to determine the minimum distances from specific sensing or actua-<br>999) speeds of parts of the human body ting devices of protective equipment to a danger zone.<br>EN 1088 Safety of machinery. Interlocking devices  This standard specifies principles for the design and selection - independent of the nature<br>and EN 1088/ associated with guards. Principles for  of the energy source - of interlocking devices associated with guards. It also provides<br>A1 design and selection requirements specifically intended for electrical interlocking devices. The standard covers<br>the parts of guards which actuate interlocking devices.<br>EN 60204-1 Safety of machinery. Electrical equipment  This part of IEC 60204 applies to the application of electrical and electronic equipment and<br>of machines. General requirements systems to machines not portable by hand while working, including a group of machines<br>working together in a co-ordinated manner but excluding higher level systems aspects (i.e.<br>communications between systems).<br>**----- End of picture text -----**<br>


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## New standards for safety in control systems 

Building a protection system that works in practice and provides sufficient safety requires expertise in several areas. The design of the safety functions in the protection system in order to ensure they provide sufficient reliability is a key ingredient. As help for this there is, for example, the EN ISO 13849-1 standard. The purpose of this text is to provide an introduction to the standard and its application in conjunction with our products. 

## Introducing the new standard 

The generation change for standards on safety in control systems introduces new concepts and calculations for machine builders and machine users. The EN 954-1 standard has been phased out and is replaced by EN ISO 13849-1 (PL, Performans Level) and EN 62061 (SIL, Safety Inegrity Level). 

To calculate which level the PL system achieves you need to know the following: 

- The system’s structure (categories B, 1-4) 

- The Mean Time To dangerous Failure of the component (MTTFd) 

- The system’s Diagnostic Coverage (DC) 

## PL or SIL? What should I use? 

The standard you should use depends on the choice of technology, experience and customer requirements. 

## Choice of technology 

- PL (Performance Level) is a technology-neutral concept that can be used for electrical, mechanical, pneumatic and hydraulic safety solutions. 

- SIL (Safety Integrity Level) can, however, only be used for electrical, electronic or programmable safety solutions. 

## Experience 

EN ISO 13849-1 uses categories from EN 954-1 for defining the system structure, and therefore the step to the new calculations is not so great if you have previous experience of the categories. EN 62061 defines the structures slightly differently. 

## You will also need to: 

- protect the system against a failure that knocks out both channels (CCF) 

- protect the system from systematic errors built into the design 

- follow certain rules to ensure software can be developed and validated in the right way 

- The five PL-levels (a-e) correspond to certain ranges of PFHD values (probability of dangerous failure per hour). These indicate how likely it is that a dangerous failure could occur over a period of one hour. In the calculation, it is beneficial to use PFHD-values directly as the PL is a simplification that does not provide equally accurate results. 

What is the easiest way of complying with the standard? 

## Customer requirements 

If the customer comes from an industry that is accustomed to using SIL (e.g. the process industry), requirements can also include safety functions for machine safety being SIL rated. 

We notice that most of our customers prefer PL as it is technology-neutral and that they can use their previous knowledge in the categories. In this document we show some examples of how to build safety solutions in accordance with EN ISO 13849-1 and calculate the reliability of the safety functions to be used for a particular machine. The examples in this document are simplified in order to provide an understanding of the principles. The values used in the examples can change. 

## 1. Use pre-calculated components. 

As far as it is possible, use the components with pre-calculated PL and PFHD-values. You then minimise the number of calculations to be performed. All ABB Jokab Safety products have pre-calculated PFHD-values. 

## 2. Use the calculation tool. 

With the freeware application SISTEMA (see page 16) you avoid making calculations by hand. You also get help to structure your safety solutions and provide the necessary documentation. 

## 3. Use Pluto or Vital 

## What is PL (Performance Level)? 

PL is a measure of the reliability of a safety function. PL is divided into five levels (a-e). PL e gives the best reliability and is equivalent to that required at the highest level of risk. 

Use the Pluto safety PLC or Vital safety controller. Not only is it easier to make calculations, but above all it is easier to ensure a higher level of safety. 

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## Working method as specified in EN ISO 13849-1 

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Start<br>Step 1<br>Determine the system's scope<br>(space, usage, time, environment)<br>Identify risk sources<br>(all work operations during the life cycle)<br>Estimate the risk<br>(determine PLr with S, F and P)<br>Evaluate the risk Yes<br>(is action required?)<br>No<br>Are new risks<br>generated?<br>Has the risk  Yes<br>been adequately  End<br>reduced?<br>Step 2 No<br>No<br>Is the measure<br>Yes<br>Reduce the risk dependent on the<br>(redesign, use protection, information) control system?<br>Risk analysis<br>Risk assessment<br>**----- End of picture text -----**<br>


## Risk assessment and risk minimisation 

According to the Machinery Directive, the machine builder (anyone who builds or modifies a machine) is required to perform a risk assessment for the machine design and also include an assessment of all the work operations that need to be performed. The EN ISO 12100 standard (combination of EN ISO 14121-1 and EN ISO 12100-1/-2) stipulates the requirements for the risk assessment of a machine. It is this that EN ISO 13849-1 is based on, and a completed risk assessment is a prerequisite for being able to work with the standard. 

## Step 1 – Risk assessment 

A risk assessment begins with determining the scope of the machine. This includes the space that the machine and its operators need for all of its intended applications, and all operational stages throughout the machine’s life cycle. 

All risk sources must then be identified for all work operations throughout the machine’s life cycle. 

A risk estimation is made for each risk source, i.e. indication of the degree of risk. According to EN ISO 13849-1 the risk 

is estimated using three factors: injury severity (S, severity), frequency of exposure to the risk (F, frequency) and the possibility you have of avoiding or limiting the injury (P, possibility). For each factor two options are given. Where the boundary between the two options lies is not specified in the standard, but the following are common interpretations: 

- **S1** bruises, abrasions, puncture wounds and minor crushing injuries 

- **S2** skeletal injuries, amputations and death **F1** less frequently than every two weeks **F2** more often than every two weeks **P1** slow machine movements, plenty of space, low power 

- **P2** quick machine movements, crowded, high power 

By setting S, F and P for the risk, you will get the PLr Performance Level (required) that is necessary for the risk source. 

Finally, the risk assessment includes a risk evaluation where you determine if the risk needs to be reduced or if sufficient safety is ensured. 

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PL<br>Risk estimation r<br>low risk<br>To calculate the performance level required (PLr). P1 a<br>S  Severity of injury F1<br>S1  slight (normally reversible injury) P2<br>S2  serious (normally irreversible injury or death) S1 b<br>F2 P1<br>F  Frequency and/or exposure to hazard P2<br>F1 seldom to less often and/or exposure time is short c<br>F2 frequent to continuous and/or exposure time is long P1<br>P Possibility of avoiding hazard or limiting harm S2 F1 P2 d<br>P1 possible under specific conditions<br>P2 scarcely possible F2 P1<br>P2 e<br>high risk<br>**----- End of picture text -----**<br>


## Step 2 – Reduce the risk 

If you determine that risk reduction is required, you must comply with the priority in the Machinery Directive in the selection of measures: 

## 1. Avoid the risk already at the design stage. 

(For example, reduce power, avoid interference in the danger zone.) 

Step 3 zone.) 2.  Use protection and/or safety devices. Identify the safety functions (For example, fences, light grids or control devices.) 3.  Provide information about how the machine can be usedsafely. (For example, in manuals and on signs.) Determine PLr If risk reduction is performed using safety devices, the control system that monitors these needs to be designed as specified Design and implement the solution in EN ISO 13849-1. for the safety function Step 3 - Design and calculate the safety functions To begin with you need to identify the safety functions on the Calculate PL machine. (Examples of safety functions are emergency stop and monitoring of gate.) Verify that No For each safety function, a PLr should be established (which PL ≥ PLr has often already been made in the risk assessment). The solution for the safety function is then designed and impleYes mented. Once the design is complete, you can calculate the PL the safety function achieves. Check that the calculated PL Validate No Have other require me ~~nts~~ is at least as high as PLr and then validate the system as per the validation plan. The validation checks that the specificabeen met? ~~&~~ tion of the system is carried out correctly and that the design complies with the specification.You will also need to verify that Yes the requirements that are not included in the calculation of the PL are satisfied, that is, ensure that the software is properly developed and validated, and that you have taken adequate steps to protect the technical solution from systematic errors. 

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PFH PL<br>D<br>10 [-4]<br>a<br>10 [-5]<br>1 b<br>a: 3x10 [-6] [none MTTFlow d<br>c<br>10 [-6] | A lit MTTFmediumd<br>d<br>MTTF<br>10 [-7] d<br>high<br>tte e<br>10 [-8] al<br>DC DC DC DC DC DC DC<br>none none low medium low medium high<br>Cat. B Cat. 1 Cat. 2 Cat. 3 Cat. 4<br>jj tf tt<br>**----- End of picture text -----**<br>


The relationship between categories, the DCavg, MTTFd for each channel and PL. The table also shows the PFHD-range that corresponds to each PL. 

## PL calculation in Step 3 

When you calculate the PL for a safety function, it is easiest to split it into separate, well defined blocks (also called subsystems). It is often logical to make the breakdown according to input, logic and output (e.g. switch - safety relay - contactors), but there may be more than three blocks depending on the connection and the number of components used (an expansion relay could for example create an additional logic block) . 

For each block, you calculate a PL or PFHD-value. It is easiest if you obtain these values from the component manufacturer, so you do not have to calculate yourself. The manufacturer of - switches, sensors and logic devices often have PL and PFHD values for their components, but for output devices (such as 

contactors and valves) you do not usually specify a value as it depends on how often the component will be used. You can then either calculate yourself according to EN ISO 13849-1 or use the pre-calculated example solutions such as those from ABB Jokab Safety. 

To calculate PL or PFHD for a block, you need to know its category, DC and MTTFd. In addition, you need to protect yourself against systematic errors and ensure that an error does not knock out both channels, and generate and validate any software used correctly. The following text gives a brief explanation of what to do. 

## Safety function (SF) 

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Input Logic Output<br>PL/PFHD PL/PFHD PL/PFHD<br>PFH = PFH +  PFH +  PFH<br>D, Total  D, Input D, Logic D, Output<br>**----- End of picture text -----**<br>


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## Category 

The structure for the component(s) in the block is assessed to determine the category (B, 1-4) it corresponds to. For category 4, for example, individual failures do not result in any loss of the safety function. 

In order to achieve category 4 with contactors, you need to have two channels - i.e., two contactors - that can cut the power to the machine individually. The contactors need to be monitored by connecting opening contacts to a test input on, for example a safety relay. For monitoring of this type to work, the contactors need to have contacts with positive opening operation. 

When MTTFd is calculated from a B10d-value, also consider that if the MTTFd-value is less than 200 years, the component needs to be replaced after 10% of the MTTFd-value (due to the T10d-value). That is, a component with MTTFd = 160 years needs to be replaced after 16 years in order for the conditions for achieving PL to continue to be valid. This is because EN ISO 13849-1 is based on a “mission time” of 20 years. 

## Common Cause Failure (CCF) 

In Appendix F of EN ISO 13849-1 there is a table of actions to be taken to protect against CCF, to ensure a failure does not knock out both channels. 

## Systematic errors 

## Diagnostic Coverage (DC) 

A simple method to determine DC is explained in Appendix E in EN ISO 13849-1. It lists various measures and what they correspond to in terms of DC. For example, DC=99 % (which corresponds to DC high) is achieved for a pair of contactors by monitoring the contactors with the logic device. 

## Mean Time To dangerous Failure (MTTFd) 

The MTTFd-value should primarily come from the manufacturer. If the manufacturer cannot provide values, they are given from tables in EN ISO 13849-1 or you have to calculate MTTFd using the B10d-value, (average number of cycles until 10% of the components have a dangerous failure). To calculate the MTTFd, you also need to know the average number of cycles per year that the component will execute. 

|Calculation|Calculation|of the average number of cycles is as|
|---|---|---|
|follows:||B10d|
|MTTFd=|||
|||0,1•nop|
|_where_|||
||dop|•hop •3600|
|nop=||tcycle|
|nop|=|Number of cycles per year|
|dop|=|Operation days per year|
|hop|=|Operation hours per day|
|tcycle|=|Cycle time (seconds)|



Example: dop= 365 days, hop= 24 hours and tcycle= 1,800 seconds (2 times/hour) which gives nop= 17,520 cycles. With a B10d=2·106 this gives a MTTFd=1,141 year which corresponds to MTTFd=high. 

Note that when you calculate MTTFd you have to calculate according to the total number of cycles the component will be working. A typical example of this is the contactors that frequently work for several safety functions simultaneously. This means that you must add the number of estimated cycles per year from all the safety functions that use the contactors. 

Appendix G of EN ISO 13849-1 describes a range of actions that need to be taken to protect against incorporating faults into your design. 

## PL for safety functions 

PL is given in the table on the facing page. If you want to use an exact PFHD-value instead, this can be produced using a table in Appendix K in EN ISO 13849-1. 

Once you have produced the PL for each block, you can generate a total PL for the safety function in Table 11 of EN ISO 13849-1. This gives a rough estimate of the PL. If you have calculated PFHD for each block instead, you can get a total of PFHD for the safety function by adding together all the values of the blocks. The safety function’s total PFHD corresponds to a particular PL in Table 3 of EN ISO 13849-1. 

## Requirements for safety-related software 

If you use a safety PLC for implementing safety functions, this places demands on how the software is developed and validated. To avoid error conditions, the software should be readable, understandable and be possible to test and maintain. 

A software specification must be prepared to ensure that you can check the functionality of the program. It is also important to divide the program into modules that can be tested individually. Paragraph 4.6 and Appendix J of EN ISO 13849-1 specify requirements for safety related software. 

The following are examples of requirements for software from EN ISO 13849-1: 

- A development life cycle must be produced with validation measures that indicate how and when the program should be validated, for example, following a change. 

- The specification and design must be documented. 

- Function tests must be performed. 

- Validated functional blocks must be used whenever possible. 

- Data and control flow are to be described using, for example, a condition diagram or software flow chart. 

ABB Safety Handbook | 2TLC172001C0202 1/17 

## CASE STUDY – SAFETY RELAY RT9 

## Protection layout for a packaging machine with low risks. 

1 

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Key switch MKey8<br>Monitors that the door is<br>closed.<br>**----- End of picture text -----**<br>


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Safety relay RT9<br>Monitors safety components.<br>**----- End of picture text -----**<br>


## Step 1 – Risk assessment 

Food to be packaged is loaded into the cell manually through the rear door. A batch is prepared for the packing conveyor in the infeed hopper. The cell is reset and restarted. The packaging machine with conveyor belt only operates hen both doors are closed and when the protection system has been reset. 

In the risk assessment it was established that the machine is to be operated in three shifts (8 hours per shift) 365 days a year. It is assumed that operational disturbances were resolved in less than one minute in the danger zone. This can be carried out two times per hour (F2). Unexpected start-ups are not deemed to cause serious injury but rather minor healable injuries (S1). The operator is deemed not to have the possibility of avoiding injury as the machine moves quickly (P2). 

The number of cycles for the safety function = 365 days/year • (3 • 8) hours/day • 2 cycles/hour = 17,520 cycles/year The assessment for the safety function required for access to the machine is PLr= c (S1, F2, P2). In addition to this safety function, an emergency stop function is needed. This is also assessed as PLr=c. 

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Emergency stop button<br>To stop the machine in<br>case of danger.<br>**----- End of picture text -----**<br>


## Step 2 – Reduce the risk 

As protection, an interlocked door is selected with the key switch MKey8. Downtime is short enough for the dangerous movement to have stopped before the operator can access it. The emergency stop is placed within easy reach, on both sides of the cell near the locked doors. 

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PLr<br>low risk<br>P1 a<br>F1 P2<br>S1 F2 P1 b<br>P2 c<br>P1<br>S2 F1 P2 d<br>F2 P1<br>P2 e<br>f=a high risk<br>Assessment of the PLr necessary for the safety function with interlo-<br>cked door for this example.<br>**----- End of picture text -----**<br>


NOTE! The assessment needs to be made for each safety function. 

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S1   S2<br>Emerg. Stop Emerg. Stop<br>><br>Q1<br>K1<br>Contactor<br>RT9<br>=<br>L — — \ —<br>Q2<br>Contactor<br>B2  B1<br>Key switch Key switch * Monitoring of contactors with K1<br>[| J) CD<br>*<br>**----- End of picture text -----**<br>


- Monitoring of contactors with K1 

## Step 3 - Calculate the safety functions 

The starting block that is composed of double unmonitored contactors has been calculated at 2.47 • 10[-8] . The safety functions are represented by block diagrams. 

## How safe is a mechanical switch? 

A mechanical switch must be installed and used according to its specifications in order to be reliable. 

- Life expectancy only applies if correctly installed. 

Safety functions 1 and 2 are identical. Therefore, only safety function 1 is shown. 

- The locking head must be fixed so that it will not loosen. 

- The environment around the lock housing must be kept clean. 

– Safety functions 3 and 4 are identical. Therefore, only safety function 3 is shown. same reason. 

- Two mechanical switches on a door can also fail for the 

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Safety function 1 Input Logic Output Result<br>B1  K1 Q1/Q2<br>PLr=c Key switch MKey8 Safety relay RT9 Redundant monitored contactors PL  c<br>PL c PL e PL e<br>PFH  + PFH  + PFH  = 1.14 • 10 [-6]  + 9.55 • 10 [-9]  + 2.47 • 10 [-8]  = 1.18 • 10 [-6]  PL c<br>eo" D, MKey8 D, RT9 D, Q1/Q2<br>Input Logic Output Result<br>Safety function 3<br>S1 K1 Q1/Q2<br>PLr=c E-Stop button Safety relay RT9 Redundant monitored contactors PL  c<br>PL c PL e PL e<br>PFHD + PFHD, RT9+ PFHD, Q1/Q2= 1.34 • 10 [-6 ] + 9.55 • 10 [-9]  + 2.47 • 10 [-8]  = 1.37 • 10 [-6]  PL c<br>oes<br>The reason for not achieving more than PL c with this solution is that you use one key switch per door. PL d could be<br>achieved by using two key switches per door, but further action on the monitoring of each switch will be required as well.<br>Note: If the risk assessment had shown that a serious injury, S2, could occur, the outcome would have been PLr= e.  This<br>would have meant that the above solution was inadequate. For the emergency stop function, PL d can be achieved provi-<br>ded that certain failure exclusions can be made. These safety functions can be downloaded from our website as a SISTE-<br>MA project, www.abb.com/jokabsafety.<br>**----- End of picture text -----**<br>


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CASE STUDY – SAFETY CONTROLLER VITAL 

## Protection layout for a robot cell with high risks. 

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1<br>**----- End of picture text -----**<br>


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Non-contact sensor, Eden Safety controller, Vital<br>Monitors that the door is  Monitors safety<br>closed. components in series.<br>( > Ok<br>DINE ase<br>Emergency stop<br>button, Smile Tina<br>To stop the machine<br>in case of danger.<br>Emergency stop<br>button INCA Tina<br>Light curtain, Focus (with  To stop the machine in<br>integrated muting function) case of danger.<br>Prevents passage.<br>**----- End of picture text -----**<br>


## Step 1 – Risk assessment 

The workpieces are fed into the equipment and transported out again following an error-free test. With the help of a robot the workpieces are added to a machine for testing. Unauthorised workpieces are positioned by the robot for post-machining in a manual discharge station. The work that needs to be done in the robot cell is to correct operational disturbances for the test equipment and the conveyor belt (about once an hour), post-machining and unloading from the manual station (about once an hour), program adjustments (once/week) and cleaning (once/week) (F2). Unexpected start-ups of the robot are expected to cause serious injury (S2). The operator is deemed not to have the possibility of avoiding injury as the robot moves quickly (P2). The assessment for the safety function required for access to the machine is PLr=e (S2, F2, P2). 

The coming ISO 10218-2 standard for robot systems/cells specifies the requirement PL d for the safety functions to be used (if the risk analysis does not show a different PL). For the robot safety stop and emergency stop inputs, the requirement is at least PL d (according to the EN ISO 10218-1 standard). However, in this case risk assessment  is PLr= e. 

## Step 2 – Reduce the risk 

As protection, an interlocked door is selected with the Eden non-contact sensor. To protect against entering the cell the wrong way, transport of materials in and out is protected and 

provided with muting to distinguish between material and people. The emergency stop is also a safety function that is required. The power source to all hazardous machinery functions has to be cut using all safety functions. 

The solution with Vital makes it possible to implement a robot application with only one safety controller, which does not need to be configured or programmed. Vital makes it possible to connect up to 30 safety functions in a single loop, with PL e in accordance with EN ISO 13849-1. 

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PL r<br>low risk<br>P1 a<br>F1 _ P2<br>S1 b<br>F2 P1<br>P2<br>P1 c<br>S2 F1 P2 d<br>F2 P1<br>P2 e<br>( = | high risk<br>Assessment of the PLr required for the safety function with interlocked<br>door.<br>**----- End of picture text -----**<br>


NOTE! The assessment needs to be made for each safety function. 

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B1<br>Focus with Tina 10A<br>|<br>B5<br>Eden<br>K1<br>Vital<br>S1<br>Inca Tina<br>B2<br>Focus with Tina 10A<br>S2<br>Smile Tina<br>B3<br>B4 Focus with Tina 10A<br>Focus with Tina 10B with muting unit MF-T<br>T e e se e_|<br>with muting unit MF-T<br>**----- End of picture text -----**<br>


## Step 3 - Calculate the safety functions 

The PFHD-value of the robot’s safety stop input is 5.79 • 10[-8] (the value applies to ABB industrial robots with IRC5 control- 

Safety function 3 When calculating the safety function the PFHD- values for both the light curtain and the muting unit shall be inclu- 

ler). The safety functions are represented by block diagrams. ded in the same function. See safety function 3 below. 

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Safety function 1 Input Logic Output Result<br>B5 K1 Q1<br>PLr=e Non contact safety  Safety controller Machine stop input for  PL e<br>sensor Eden PL e Vital PL e robot, redundant PL e<br>PFH  + PFH  + PFH  = 4.5 • 10 [-9]  + 2.74 • 10 [-8]  + 5.79 • 10 [-8]  = 8.98 • 10 [-8]  PL e<br>D, Eden D, Vital D, Robot<br>Seen<br>Safety function 2 Input Logic Output Result<br>S2 K1 Q1<br>PLr=e E-Stop button Safety controller Machine stop input for  PL e<br>Smile Tina PL e Vital PL e robot, edundant PL e<br>PFH + PFH  + PFH  = 4.66 • 10 [-9]  + 2.74 • 10 [-8]  + 5.79 • 10 [-8]  = 9.0 • 10 [-8]  PL e<br>D, Smile Tina D, Vital D, Robot<br>eS Safety function 3 Input oc Logic Output Result<br>B4 Q1<br>K1<br>Light curtain Focus  Tina 10B Machine stop input<br>PLr=e with muting unit MF-T  PL e Safety controller for robot, redundant  PL e<br>Vital PL e<br>PL e PL e<br>PFH  + PFH  + PFH  + PFH  = 2.5 • 10 [-9]  + 4.5 • 10 [-9]  + 2.74 • 10 [-8]  + 5.79 • 10 [-8]  = 9.23 • 10 [-8]  PL e<br>D, Focus D, Tina 10 D, Vital D, Robot<br>**----- End of picture text -----**<br>


These safety functions with Vital meet PL e in accordance with EN ISO 13849-1. Note that the above functions are only selected examples of the safety functions that is represented in the robot cell. 

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## CASE STUDY © – SAFETY-PLC PLUTO Safety system using Pluto 

Protection layout for a machining tool and industrial robot with high risks. 

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Safety PLC Pluto<br>Monitors safety<br>components. Door 4<br>i<br>Le<br>Station 2<br>Door 1<br>**----- End of picture text -----**<br>


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Door 3<br>Door 2<br>af<br>Station 1<br>**----- End of picture text -----**<br>


## Step 1 – Risk assessment 

The workpieces to be machined are fed into the cell through a conveyor belt and positioned by the operator in the pneumatic machining tool in station 1. The operator starts station 1 manually. The pneumatic machining tool performs work on the workpiece in station 1. The operator then places the machined workpiece on the conveyor belt for transfer to station 2. The robot then takes the workpiece that is placed in the hydraulic press. The workpiece leaves the cell by transport out onto the conveyor. The work that needs to be done in station 2 is, for example, to address operational disturbances in the press and the robot (a few times a week, F2). 

Unexpected start-ups of the robot are expected to cause serious injury (S2). The operator is deemed not to have the possibility of avoiding injury as the robot moves quickly (P2). The assessment for the safety function required for access to station 2 is PLr=e (S2, F2, P2). This assessment would still be the same in respect of the press. For the safety function for the risks associated with the conveyor belt, the assessment S1, F2, P1 is made giving PLr= b. 

## Step 2 – Reduce the risk 

As protection, interlocked doors are selected with the Eden non-contact sensor. Station 1 with the pneumatic machining tool is operated by a two-hand device. When the two-hand device is released, the dangerous movement will be stopped safely. Station 2 can be in automatic mode, when a light 

curtain (Focus) and a non-contact sensor at door 4 (Eden) protects the entry. If the door is opened or the light curtain is breached, station 2 stops in a safe manner. By opening doors 2 and 3 (also monitored by Eden) the conveyor belt and the pneumatic machining tool will stop safely. Manual reset must always be done after actuation by any safety device. 

When the protection system requires a number of safety devices and that multiple machines must be checked, safety PLC Pluto is the most effective solution. If the protection system also has to work by zones and in different modes of operation, this is another compelling reason to use Pluto. With Pluto, PL e can be achieved regardless of the number of connected safety devices. 

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PLr PLr<br>Robot Conveyor belt<br>low  low<br>P1 a risk P1 a risk<br>F1 P2 F1 P2<br>S1 F2 P1 b S1 F2 P1 b<br>P2 c P2 c<br>P1 P1<br>S2 F1 P2 d S2 F1 P2 d<br>F2 P1 F2 P1<br>_ P2 e _ P2 e<br>G e l high risk | high risk<br>PLr= e for the robot and hydraulic press and PLr=b for the conveyor belt.<br>**----- End of picture text -----**<br>


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S1 S2–S4 B1–B3 B4–B5<br>Two-hand device,  Emergency stop,  Non-contact sensor  Non-contact sensor<br>Safeball Smile Tina Eden Eden/Light curtain Focus<br>with Tina 10A<br>Q1 Q3<br>Q2<br>Robot Pneumatic<br>Hydraulic press<br>machining tool<br>**----- End of picture text -----**<br>


Step 3 - Calculate the safety functions for the robot cell The PFHD-value for the robot’s safety stop input is 5.79 • 10[-8 ] (the value applies to ABB industrial robots with IRC5 controller). 

Only safety functions to help cut the power to the industrial robot are shown below. This is only a subset of the safety functions. When the power is to be cut to multiple machines in a cell, the safety functions can be defined in different ways depending on the risk analysis. The safety functions are represented by block diagrams. 

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Safety function 1 Input Logic Output Result<br>B1  Q1<br>K1<br>Non contact safety Machine stop input<br>PLr= e sensor Eden Safety-PLC  Pluto for robot, redundant PL  e<br>PL e<br>PL e PL e<br>PFH + PFH  + PFH  = 4.5 • 10 [-9]  + 2 • 10 [-9]  + 5.79 • 10 [-8]  = 6.44 • 10 [-8]  PL e<br>D, Eden  D, Pluto D, Robot<br>Safety function 2 Input Logic Output Result<br>S2  K1  Q1<br>PLr= e E-Stop button  Safety-PLC Pluto Machine stop input  PL  e<br>Smile Tina PL e for robot, redundant<br>PL e PL e<br>PFH  + PFH + PFH  = 4.66 • 10 [-9 ] + 2 • 10 [-9]  + 5.79 • 10 [-8] = 6.46 • 10 [-8]  PL e<br>D, Smile Tina D, Pluto D, Robot<br>Safety function 3<br>Input Logic Output Result<br>B5  K1  Q1<br>PLr= e Light curtain Focus PL e Tina 10APL e Safety-PLC  Pluto PL e for robot, redundant Machine stop input  PL  e<br>PL e<br>PFH  + PFH  + PFH  = 2.5 • 10 [-9]  + 2 • 10 [-9]  + 5.79 • 10 [-8]  = 6.24 • 10 [-8]  PL e<br>D,Focus D, Pluto D, Robot<br>**----- End of picture text -----**<br>


These safety functions with Pluto meet PL e in accordance with EN ISO 13849-1. Note that the above functions are only selected examples of the safety functions that appear in the robot cell. 

ABB Safety Handbook | 2TLC172001C0202 1/23 

## What defines a safety function? 

1 

Calculating that you have achieved the PLr that is required is not difficult, especially if you use “pre-calculated” safety devices and logic units. But what parts should then be included in each safety function? 

This must be resolved before you start calculating phase. To summarise in simple terms you can say that each safety device gives rise to a safety function for each machine that is affected by the safety device in question. Three safety devices that all cut the power to three machines in a cell is therefore equal to nine safety functions. In the section that follows, we explain the background. 

## Multiple safety functions for a machine 

Multiple safety devices are often used on a machine in order to provide satisfactory and practical protection for the operators. In the following example, the machine is protected by three safety devices connected to a logic device. The following figure illustrates this interconnection schematically. 

Three safety functions (SF) are defined for the machine and are calculated as: 

SF1: PFH + PFH + PFH = PFH D, F1 D, K1 D, Q1 D, SF1 SF2: PFH + PFH + PFH = PFH D, B1 D, K1 D, Q1 D, SF2 SF3: PFH + PFH + PFH = PFH D, S1 D, K1 D, Q1 D, SF3 

**==> picture [371 x 110] intentionally omitted <==**

**----- Start of picture text -----**<br>
SF1<br>F1<br>Light curtain<br>B1 K1 Q1<br>SF2<br>Interlocked switch Logic unit Machine<br>S1<br>E-Stop button<br>SF3<br>**----- End of picture text -----**<br>


## Multiple safety functions for multiple machines in a cell 

More commonly, several machines in a single cell/zone are to be protected by multiple safety devices. The following figure illustrates the interconnection schematically for an example. Each of the machines Q1 – Q3 is shut down separately and independently of K1. 

If the operator enters the cell, he is exposed in this case to the same type of risk from all three machines. The power to all three machines must be cut when the operator enters the cell through the door interlocked by B1. 

**==> picture [353 x 108] intentionally omitted <==**

**----- Start of picture text -----**<br>
F1 Q1<br>Light curtain Machine 1<br>B1 K1 Q2<br>Interlocked switch Logic unit Machine 2<br>S1 Q3<br>E-Stop button Machine 3<br>**----- End of picture text -----**<br>


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## Theoretical approach for multiple machines 

The theoretical approach to calculate the safety function is as follows: 

**==> picture [244 x 28] intentionally omitted <==**

**----- Start of picture text -----**<br>
B1 K1 Q1 Q2 Q3<br>Interlocked switch Logic unit Machine 1 Machine 2 Machine 3<br>**----- End of picture text -----**<br>


For the full safety function to be performed you require all the components to be working. Note that if B1 or K1 has a dangerous malfunction, the entire safety function is disabled. However, if for example machine Q1 has a dangerous malfunction, and is not shut down, machines Q2 and Q3 will still be shut down. One disadvantage in considering the safety function in this way is that you may have trouble achieving the PLr required. But if you achieve the PLr required, you can use the theoretical approach. 

## Sources: 

www.dguv.de/ifa/de/pub/grl/pdf/2009_249.pdf www.bg-metall.de/praevention/fachausschuesse/ infoblatt/deutsch.html (No 047, Date 05/2010) 

## Practical approach for multiple machines 

A more practical approach is to divide the safety function into three parts, one for each of the three machines. 

**==> picture [244 x 92] intentionally omitted <==**

**----- Start of picture text -----**<br>
B1 K1 Q1<br>Interlocked switch Logic unit Machine 1<br>B1 K1 Q2<br>Interlocked switch Logic unit Machine 2<br>B1 K1 Q3<br>Interlocked switch Logic unit Machine 3<br>**----- End of picture text -----**<br>


This is an approach that can provide a more accurate way of looking at the safety functions, especially where a different PLr is required for the safety functions above. If machine Q1 is a robot and machine Q2 is a conveyor which is designed to have negligible risks, the different PLr required to protect against risks from Q1 and Q2 will also be different. This practical approach is therefore the one recommended. The interpretation is based on information provided by IFA (Institut für Arbeitsschutz der Deutschen Gesetzlichen Unfallversicherung). For more information on this and other issues, see Sources. 

## Example of safety functions for multiple machines in a cell 

For a cell with three machines (one robot, one hydraulic press and one pneumatic machining tool) a risk assessment is made resulting in different PLr for the individual machines. The robot and the hydraulic press requires PLr = e, while the pneumatic machining tool requires PLr = d. One of the safety functions is that a non-contact sensor 

(Eden) supervised by a safety PLC (Pluto) shall disconnect the energy to all three machines in the hazard zone: 

- Eden B1 (PFHD, B1 = 4.5 • 10[-9] ) 

- – Pluto K1 (PFHD, K1 = 2 • 10[-9] ) 

- Robot Q1 (PFHD, Q1 = 5.79 • 10[-8] ) 

- Hydraulic press Q2 (PFHD, Q2 = 8 • 10[-8] ) 

- – Pneumatic machining tool Q3 (PFHD, Q3 = 2 • 10[-7] ). 

## Practical approach 

If you use the practical approach the safety functions are as follows: Robot: 

PFH + PFH + PFH = 4.5 • 10[-9] + 2 • 10[-9] + 5.79 • 10[-8] = 6.44 • 10[-8] PL e D, B1 D, K1 D, Q1 Hydraulic press: 

PFH + PFH + PFH = 4.5 • 10[-9] + 2 • 10[-9] + 8 • 10[-8] = 8.65 • 10[-8] PL e D, B1 D, K1 D, Q2 Pneumatic machining tool: PFH + PFH + PFH = 4.5 • 10[-9] + 2 • 10[-9] + 2 • 10[-7] = 2.07 • 10[-7] PL d D, B1 D, K1 D, Q3 

This is to be done in a similar way with other safety functions for the cell. For each safety device, you define the machines it affects, and establish the various safety functions according to this. 

## Theoretical approach 

How would it have worked if you had used the theoretical approach? Would the safety function have achieved PL e? All machines: 

PFH + PFH + PFH + PFH + PFH D, B1 D, K1 D, Q1 D, Q2 D, Q3 

= 4.5 • 10[-9] + 2 • 10[-9] + 5.79 • 10-8 + 8 • 10[-8] + 2 • 10[-7] = 3.44 • 10[-7] PL d 

In this case, the safety function would therefore have not achieved a total PL e, which was required for the risks associated with the robot and hydraulic press. 

## Conclusions 

- Use the practical approach. 

- Use safety devices/logic units with high reliability (low PFHD) to make it easy to achieve the PLr required. 

- With Vital or Pluto, it is easier to achieve the PLr required. 

_Please note that the examples on these pages are simplified in order to explain the principles. Values of products can also change._ 

ABB Safety Handbook | 2TLC172001C0202 1/25 

## SISTEMA A tool for determining performance level (PL) and generating technical documentation 

EN ISO 13849-1 requires calculations. To do this in a manageable way a software tool provides excellent help. ABB 1 Jokab Safety has chosen to use SISTEMA, a software tool developed by BGIA, now called IFA, in Germany. The tool is freeware and can be downloaded from the IFA website, www.dguv.de/ifa. With SISTEMA it is possible to “build” safety functions, verify them and generate the technical documentation required. 

To work with SISTEMA in a rational way, we have developed a library of our products for download from our website www. abb.com/jokabsafety. In order to have access to the latest version, visit this page periodically to check for updates and new releases. 

To download SISTEMA go to www.dguv.de/ifa/en/pra/softwa/ sistema/index.jsp or search the Internet for “sistema”. 

Screenshot from SISTEMA. 

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Safety relay, Vital or Pluto? Various benefits in comparison to EN ISO 13849-1 

**==> picture [396 x 214] intentionally omitted <==**

**----- Start of picture text -----**<br>
Flexibility<br>Programmable<br>Pluto AS-i<br>Not programmable<br>Vital Pluto All-Master<br>Dynamic "doubled up"  Safety PLC with static and dynamic<br>safety signal that tests a  safety inputs.<br>sensor, for example, 200<br>times per second.<br>1<br>Master<br>Safety relay<br>><br>Double static inputs that  Slaves<br>only test the switches<br>each time they are used. Traditional safety PLC<br>Master-Slave with static inputs<br>7<br>Number of machines/different stops<br>**----- End of picture text -----**<br>


To achieve PL e using a conventional safety relay, such as RT9, you need to use both channels on the input side and only connect a single safety device. Under certain conditions PL d can be achieved by connecting multiple two-channel devices to a safety relay, but this is not a generally accepted method. Vital is a safety controller that allows you to connect 

and monitor a variety of safety components in series, and to achieve PL e to EN ISO 13849-1. The Vital module is based on a dynamic single-channel concept and can replace multiple safety relays. A similar solution, although more flexible, is safety PLC Pluto. Pluto, like Vital, is able to make use of dynamic signals to achieve maximum reliability. 

## Benefits of Vital 

- It is possible to connect up to 30 safety components through a channel in line with PL e 

- No programming required 

- The option of combining various safety components (e.g. emergency stop button and door contact) 

- Easy configuration of the circuit 

- Electromechanical switches can also be used (with the addition of the Tina adaptation device) 

## Benefits of Pluto 

- Pluto is an all-master-system with communications across a separate safety bus 

- Greater flexibility facilitates the design of protection systems 

- One software for all systems 

- Easy programming for PL e by using function blocks (certified by TÜV) 

More than 70 000 Vital systems have been successfully installed. 

More than 30 000 Pluto systems have been successfully installed. 

ABB Safety Handbook | 2TLC172001C0202 1/27 

## Applying EN 62061 

1 

If one chooses to design a safety function in accordance with EN 62061, the level of reliability is expressed as the Safety Integrity Level, SIL. There are a total of 4 levels, but in the EN 62061 standard SIL 3 is the highest level. SIL also (similar to the Performance Level PL), is expressed as the Probability of Dangerous Failure Per Hour. 

**==> picture [528 x 55] intentionally omitted <==**

**----- Start of picture text -----**<br>
Safety Integrity Level, SIL Probability of dangerous Failure per Hour (PFHD)<br>3 ≥10 [-8]  to <10 [-7]<br>2 ≥10 [-7]  to <10 [-6]<br>1 ≥10 [-6]  to <10 [-5]<br>**----- End of picture text -----**<br>


There is a method in EN 62061 for assigning the Safety Integrity Level. 

**==> picture [528 x 82] intentionally omitted <==**

**----- Start of picture text -----**<br>
Severity (Se) Class (Cl)<br>3-4 5-7 8-10 11-13 14-15<br>4 SIL2 SIL2 SIL2 SIL3 SIL3<br>3 (OM) SIL1 SIL2 SIL3<br>2 (OM) SIL1 SIL2<br>1 (OM) SIL1<br>**----- End of picture text -----**<br>


Cl=Fr+Pr+Av  OM=Other Measures 

The seriousness of injury that can occur is defined at one of four levels. Class is the addition of the values of frequency (Fr, stated as a value between 1 and 5, where 5 represents the highest frequency), probability that a dangerous event will occur (Pr, stated as a value between 1 and 5, where 5 represents the highest proability) and the possibility of avoiding or limiting injury (Av, stated as a value of 1, 3 or 5, where 5 represents the least chance of avoiding or limiting an injury). 

The safety function that is to be designed must at least fulfil the SIL that has been assigned to it in the analysis. The safety function consists of a number of sub-elements. Example: a door is interlocked by a non-contact sensor which is in turn monitored by a Pluto safety PLC, with outputs that break the power to two supervised contactors. The sensor is subelement 1, Pluto is sub-element 2 and the two supervised contactors are sub-element 3. If in the analysis it has been established that SIL2 shall be used, every individual sub-element in the safety function must fulfil the SIL2 requirements. The safety function must then in its entirety fulfil the SIL2 requirements. 

## Definition of protective safety in accordance with EN 62061 

"Function of a machine whose failure can result in an immediate increase of the risk(s)" 

If the SIL requirements are not fulfilled in any of the sub-elements or by the safety function in its entirety, there must be a re-design. 

## Finally 

This is just a brief introduction to the EN ISO 13849-1 and EN 62061 standards. You are welcome to contact us so that we can prepare suitable training and guide you in how to apply the standards to our products. 

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## A mechanical switch does not give a safe function! 

## A mechanical switch does not give a safe function! 

When it comes to mechanically operated interlocked switches, it has long been accepted a Category 1 switch is adequate for many installations, which is also supported by several standards. However some companies have now re-evaluated this and have instead started to demand two mechanical switches or non-contact switches/sensors, where they previously accepted single mechanical switches. Many reported incidents form the background to this. The requirements for switches to provide safe functioning are that they are mounted correctly and that their positions do not change during their life-cycle, in other words, ideal conditions.  In many installations the location of hatches or doors changes over time. This has led to a switch not giving a stopping signal when an interlocked gate has opened. The reasons for this are many, but they can be summarized in mechanical deterioration or physical damage to a door/hatch. In turn this has led to an interlocked switch being affected by higher stress than the switch manufacturer’s specifications. To avoid this type of malfunction it is more appropriate to use non-contact switches/sensors because mechanical deterioration does not affect the safety function, i.e. the stop signal is given directly if the position is wrong. 

A non-contact switch/sensor does not have a guided function and is designed to fulfill the requirements in another way. The requirements are fulfilled either with dynamic sensors where the safety signal is monitored all the time and a fault directly leads to a stop signal or with a magnetic switch which has two independent contact elements which are monitored every time a gate opens. From the user's perspective the dynamic function is preferable because several sensors can be connected to a single safety module and still achieve PL e. Also the sensor’s safety function is monitored without having to open a gate. For a magnetic switch the requirements for PL e are only fulfilled if one switch per monitoring unit is used and if the gate is opened regularly. 

If PL e is to be achieved with electromechanical switches, maximum two switches can be connected to one safety relay. 1 This means that it is only with Eden that several doors can be supervised with one safety module and achieve PL e. 

Since the standard EN 954-1 was written, development has progressed and the costs to fulfill category 4 have dropped dramatically. Generally mechanical switches are replaced with non-contact sensors to increase the reliability of production equipment. The same goes for the safety side.  With electronic non-contact switches, with a transmitter and a receiver, one avoids the problems of deterioration and excessive stress which harm the sensor. For that kind of sensor dynamic monitoring is required to enable a safe function. This means that its function is constantly being monitored, hundred of times per second. The reaction time for a safe stop will then be the same during a malfunction as during the activation of a stop (e.g. a gate opening). The monitoring frequency will also be astronomical compared to that of mechanical switches and magnetic switches, which are only monitored every time they are used. In the new EN ISO 13849-1, which has replace 954-1, probability calculations are used together with different category levels to compare different “performance levels”. Even when using EN ISO 13849-1 it can be so that one achieves reasonably high theoretical reliability with an electromechanical switch, although this presumes correct installation, proper use and otherwise ideal conditions. A noncontact switch instead provides high levels of both theoretical and practical reliability. 

## Our conclusion, use dynamic signals! 

Our conclusion is that today it is more cost effective, safer and more reliable to work with dynamic signals to achieve category 4 for sensors and monitoring units. In that case it is also possible to fulfill the Machinery Directive, 1.2.7. requirement:  “A fault in the control circuit logic, or failure of or damage to the control circuit, must not lead to dangerous situations”. Also one does not have to discuss whether the correct safety category has been chosen! 

**==> picture [220 x 119] intentionally omitted <==**

**----- Start of picture text -----**<br>
Door 1 Door 2 Door 3 *Dynamic monitoring,<br>Dynamic  Vital/Pluto<br>sensors<br>*<br>**----- End of picture text -----**<br>


Up to 30 doors (Eden sensors) can be connected to the dynamic monitoring maintaining category 4. 

**==> picture [165 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
**Static monitoring,<br>Interlocked switch e.g.  RT6<br>**<br>Door 1<br>**----- End of picture text -----**<br>


Maximum 1 door (2 interlocked switches) can be connected to the static monitoring for category 4 to be maintained for the entire system. 

ABB Safety Handbook | 2TLC172001C0202 1/29 

## We train you on safety requirements - enhance your knowledge! 

What requirements are there today? 

For international companies there are many new standards 1 and regulations with which to comply. There have also been changes and revisions of existing standards and directives. 

As a business and designer one is obliged to know about and to follow all the regulations. But it can be difficult for each individual company to keep track of all the new regulations and how they should be applied. 

Your local ABB Jokab Safety sales office can help you with training and analysis during a build-up phase or as a continuous consulting assignment. 

Our course trainers have a extensive experience in machine safety 

A distinguishing feature of all the engineers at ABB Jokab Safety is that they work daily with practical applications of standards and regulations. This is true for everything from safety components for individual machines to entire deliveries of safety systems for larger production lines. Within the company there is also a very good knowledge of machine control and production. We are also represented in standardisation groups which decide on European and International standards concerning machine safety. Because ABB Jokab Safety is represented globally, we have the knowledge of safety requirements in different countries. 

## Training in machine safety 

Are you building machines for sale or for your own use?  Are you a user of machines? Are you working with automation of production plants or do you make technical evaluations of machines prior to purchase? 

Regardless of the purpose, there is a need for knowledge concerning what requirements and regulations exist in respect of machine safety, and how they should be applied. 

We offer company-adapted training in the following fields: 

- Product liability and its consequences 

- CE-labelling 

- The Machine Directive and how to apply it 

- Choice of certification procedure with examination of the parts which are required in order to be able to CE-label a machine 

- Harmonised standards and the applications of these, e.g. 

   - EN ISO 13849-1/-2 

   - Machine safety analysis; method and cases 

   - Choice of safety measures/safety devices 

   - Requirements for manufacturer´s technical documentation 

   - Requirements for manuals 

   - Requirements for ”old machines” 

   - Specific interpretation cases, e.g. re-construction of machines 

   - Changes in the Machine Directive 

- EN ISO 12100 

- EN 60204-1 

- EN ISO 13850 

- EN ISO 13857 

- EN ISO 13855 (previously EN 999) 

## Company-adapted training in machine safety 

Contact your local sales office with questions and your current training needs. Together with you, we will customize the training to your specific company requirements. 

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## Training in risk analysis 

We regularly have training courses in our offices. One of these covers risk analysis and how to choose production adapted measures. 

A course in risk analysis contains the following: 

- Risk analysis - from theory to practice 

- What durability towards errors shall the safety system have? 

- Standard EN ISO 13849-1/-2 

- Safety distances for fencing systems and safety components - how do you choose? 

- Cases,  practice and briefing of risk analysis and choice of actions 

## Product training 

Our unique Pluto Safety PLC gives new and great possibilites to build-up a cost effective and flexible safety system. With this also comes the demands of higher knowledge. For you as a customer to be able to quickly get started using Pluto in the most effective way and to learn about its possibilities, we regularly offer trainings at our local sales offices. In the training course cost is included a Pluto, software for Pluto and full documentation. We also offer training on the other ABB Jokab Safety products such as the Vital solution, safety relays and light beams/ curtains. 

## Training - Pluto and other ABB Jokab Safety products 

Contact your local sales office with questions and your current training needs. Together with you, we will customize the training to your specific company requirements. 

## Consulting 

Do you need assistance in CE-marking a machine? Do you want a third party to carry out a risk analysis on a machine line? Do you have the need of a partner to examine how various regulations effect the safety of your machines? 

We can offer assistance and support in both short and longer assignments. Here are a few examples of what we can offer you: 

- Risk analysis with proposal of measures. We do this together with the customer and it is often done as a pilot-project so that the company afterwards themselves can carry out analysis. 

- Guide the customer business through a CE-marking of machine/plant. 

Stopping time measurement is required in order to be able to determine the correct safety distance. 

- Write/review technical documentation/manuals 

- Interpret standards and regulations 

- Stopping time measurement - We can measure the stopping time on your machines with our Stopping time and motion analyser tool. 

   - Knowledge of the stopping time is a prerequisite to be able to determine the correct safety distance. EN ISO 13855 (previously EN 999) gives the requirements. 

- Programming of Pluto Safety-PLC. 

## Consulting - Contact us 

Come to us with your needs and we will plan with you a suitable project programme. You can also contact us with short questions which we can solve directly over the phone or via e-mail. 

ABB Safety Handbook | 2TLC172001C0202 1/31 

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Pluto Safety PLC With dynamic safety concept 

|Whyshouldyou have Pluto safetyPLC?|2/3||
|---|---|---|
|Connection examples for Pluto|2/5||
|Pluto safety PLC||2|
|Pluto|2/7||
|Function Blocks for Analogue inputs Pluto D20 and D45|2/9||
|Counter inputs|2/10||
|Input connection|2/11||
|Output connector expansion|2/12||
|I/O overview|2/12||
|Technical data|2/15||
|Application examples|2/17||
|Gateway|||
|Gate P2 - Profibus DP|2/23||
|Gate D2 - DeviceNet|2/25||
|Gate C2 - CANOpen|2/27||
|Gate E2 - Profinet,Ethernet/IP,Modbus TCP|2/29||
|Safe Encoder|||
|Safe Encoder|2/31||
|IDFIX|||
|IDFIX|2/35||



ABB Safety Handbook | 2TLC172001C0202   2/2 

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## Why should you have Pluto safety PLC? 

## – for simplifying the design of and changes to safety systems! 

Pluto is an ”All-Master” safety PLC concept, that simplifies the design of safety systems and achieves the highest safety level PL e according to EN ISO 13849-1 and SIL 3 according to EN 62061 and EN 61508. The key difference between Pluto and conventional safety PLCs is that there is no "Master-Slave" relationship between the control units connected to the safety bus. Each Pluto is a ”Master” unit and can see the other Plutos' inputs and outputs, and can thereby make decisions about its own safety environment. 

This concept enables simple communication, programming and changes to the safety system. With the use of a ”Gateway” device, a Pluto can communicate with other bus systems and thereby form part of a larger network. Gateway units are available for several different bus systems, such as Profibus, CanOpen, DeviceNet, Profinet, Ethernet/IP and Modbus TCP. With a Pluto AS-i, both safety slaves and standard slaves can be handled. 

Pluto offers an economic solution for both single machines and for major machine systems. 

## Our solution with All-Master 

**==> picture [77 x 65] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto All-MasterPluto All-Master<br>Pluto All-MasterPluto All-Master<br>Pluto All-MasterPluto All-Master<br>**----- End of picture text -----**<br>


## Traditional safety PLC 

**==> picture [56 x 89] intentionally omitted <==**

**----- Start of picture text -----**<br>
MasterMaster<br>a<br>as<br>     Slaves<br>**----- End of picture text -----**<br>


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**----- Start of picture text -----**<br>
Pluto – All Master<br>20 I/O + 20 I/O + 20 I/O<br>Ppocpecgpeccocogpesscogy<br>()<br>()<br>() Se a Pa<br>\\ serie: serie sexily; ty<br>S<br>() vvvv vvvv vvvyv<br>() 4 + 4 + 4<br>0)<br>()<br>()<br>()<br>()()p 12 I/O safety nodes31 AS-i<br>+<br>() pr <q==)><br>f<br>() ae<br>() ee i ia eaeeaes = =<br>() — Ss<br>() Peis<br>()<br>\() vvvv 4 Pluto AS-i<br>()<br>()()<br>()<br>()<br>()<br>()<br>()<br>() 46 I/O + 20 I/O<br>p<br>oo as ae<br>ee<br>eg ene Pere ee<br>vvvvvyv vvvv<br>6 + 4<br>Safe bus<br>**----- End of picture text -----**<br>


2/3   2TLC172001C0202 | ABB Safety Handbook 

– to supervise safety devices! 

**==> picture [497 x 22] intentionally omitted <==**

**----- Start of picture text -----**<br>
Light beams Light grids/curtains 3-position  Sensors/ Two-hand  Emergency Strips Mats<br>devices switches controls stops<br>**----- End of picture text -----**<br>


Most safety devices on the market can be connected directly to Pluto units. By using dynamic signals with sensors from ABB Jokab Safety only one input is needed to achieve the highest level of safety, compared to two inputs for other manufacturers' PLCs. It is also possible to connect up to 10 sensors in series to a single input on Pluto and still achieve 

the highest level of safety. For example non-contact Eden sensors, Spot light beams and Tina emergency stop buttons 2 can all be connected in series to a single Pluto input. Even mechanical switches can be connected to the ”dynamic” safety circuit using ABB Jokab Safety's various Tina adapters. Pluto also has IO connections that can be used as both inputs and outputs. 

**==> picture [492 x 366] intentionally omitted <==**

**----- Start of picture text -----**<br>
– to save on inputs! Dynamic signals<br>Dynamic signals 1-10 sensors<br>PL e– 1–10 doors with one Eden per door fy gay 2?Ly| PL e<br>" nes re<br>Sion<br>Pluto has inputs for static and<br>—PLUTO B20 v2<br>dynamic sensors. Several sen-<br>sors can be connected to one<br>dynamic input in accordance<br>with PL e.<br>One input<br>One input<br>Two inputs<br>One connection<br>**----- End of picture text -----**<br>


**==> picture [42 x 41] intentionally omitted <==**

**----- Start of picture text -----**<br>
One connection<br>**----- End of picture text -----**<br>


IO connections Pluto has IO connections that can be used in three ways: 

Static inputs (mechanical switches) 2 for each door = PL e 

- input 

- output 

- both input and output at the same time (e.g. for a reset button with lamp indication) 

**==> picture [32 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
input/output<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   2/4 

2 

## Connection examples for Pluto with safety bus 

1. Gateway – For two-way safe bus communication between Pluto and other control systems. 

2. Absolute encoder – 8 single turn or multi turn absolute encoders can be connected directly to the safety bus. 

**==> picture [65 x 10] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto Manager<br>**----- End of picture text -----**<br>


Free software at  www.abb.com/jokabsafety, Ladder with TÜV‑approved function blocks. 

**==> picture [335 x 264] intentionally omitted <==**

**----- Start of picture text -----**<br>
Gateway<br>Profibus DP<br>DeviceNet<br>CANopen RY | ' aa /<br>Ethernet<br>Safety bus for connection of   20 I/O<br>up to 32 Pluto units<br>V 1 \ j Pluto B20 ) 3<br>— =<br>i ane i () i ane ts<br>Ria ) | oa<br>Garo e -P2 () anteca<br>—<br>mex 4 mal | o-<br>= F_) re<br>7<br>. 2<br>“- - vVvvvV 4 independent<br>failsafe outputs<br>**----- End of picture text -----**<br>


## Connection examples for Pluto without a safety bus 

**==> picture [200 x 146] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto S20<br>6 66<br>=<br> sl ek obs ~~, ~~<br>2<br>**----- End of picture text -----**<br>


Pluto S46 

**==> picture [7 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
7<br>**----- End of picture text -----**<br>


## 6. Stand alone Pluto 

Same functionality as other Plutos, but without safety bus connections. 

## 7. IDFIX – Identifies Pluto 

If IDFIX PROG is used for single-Pluto, there is the option of copying a PLC program via the identification circuit over to Pluto without having to connect a computer. 

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3. Pluto bridge – With a Gateway it is possible to: 

- increase the safety bus length 

- use different bus speeds for each section 

- filter information from one section to reduce the load on the safety bus. 

4. HMI  – An HMI operator panel can communicate with Pluto in both directions. Connection can be made direct to the front of the Pluto. 

5. Pluto AS-i – Can either be AS-i master on the AS-i bus or work together with an AS-i master as a monitor. It includes AS-i nodes, analogue and digital outputs, as well as safety outputs. Also available as Pluto B42 AS-i for more I/O. For more information see the AS-i safety chapter. 

**==> picture [22 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
46 I/O<br>**----- End of picture text -----**<br>


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4<br>Fy<br>**----- End of picture text -----**<br>


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Safe bus 12I/O Approvals<br>as | EN 61508, SIL 3<br>\ Pluto B46 \ Pluto AS-i EN ISO 13849-1, PL e<br>_<br>5<br>_<br>7H Ow - erage scereEITOn ait a on " san & [  ______L__  Nuww—O—_O_<br>Safety Monitor/<br>31 AS-i safety slaves<br>Master<br>——-<br>VV VV VV Viv f c l  cteae<br>6 independent   4 independent   PP | |<br>failsafe outputs failsafe outputs<br>**----- End of picture text -----**<br>


Overview Pluto Safety-PLC 

|Model|S20|S46|A20|B22|D20|D45|B20|B46|AS-i|B42<br>AS-i|
|---|---|---|---|---|---|---|---|---|---|---|
|Number of I/O|20|46|20|22|20|45|20|46|12|42|
|Failsafe inputs|8|24|8|14|8|24|8|24|4|20|
|Failsafe inputs or<br>non-failsafe outputs|8|16|8|8|8|15|8|16|4|16|
|Analogue inputs 0-10V/4-20mA|-|-|-|-|4|8*|-|-|-|-|
|Counter inputs|-|-|-|-|-|4*|-|-|-|-|
|Analogue inputs (0-27V)|1|3|1|1|1|3|1|3|4|3|
|Failsafe relay outputs|2|4|2|-|2|4|2|4|2|4|
|Failsafe transistor outputs|2|2|2|-|2|2|2|2|2|2|
|Pluto bus|-|-|||||||||
|Pluto AS-i bus|-|-|-|-|-|-|-|-|||
|Current monitoring|-|-|2|-|-|-|-|-|-|-|
|Dimensions (b x h x d) mm|45 x 84<br>x 118|90 x 84<br>x 118|45 x 84<br>x 118|45 x 84<br>x 118|45 x 84<br>x 118|90 x 84<br>x 118|45 x 84<br>x 118|90 x 84<br>x 118|45 x 84<br>x 118|90 x 84<br>x 118|
|Supply voltage|24VDC|24VDC|24VDC|24VDC|24VDC|24VDC|24VDC|24VDC|24VDC|24VDC|



*4 of the analogue inputs can be configured as counter inputs. The total number of analogue inputs + counter inputs = 8. 

ABB Safety Handbook | 2TLC172001C0202   2/6 

TÜV Rheinland 

2 

## Safety PLC Pluto 

## Approvals: 

## Control of: 

- Safety products in dynamic and static circuits 

- Electrically controlled actuators such as contactors, valves, motors 

- Indicators and buttons 

## Features: 

- A Safety-PLC for each system part 

- Dispersed constructions of machines 

- Great flexibility 

- Up to 10 sensors in series connected to one input 

- Software Pluto Manager free of charge 

## Pluto Safety PLC facilitates the design of your safety systems 

Pluto is an All-Master system for dynamic and static safety circuits where inputs and other information are shared over the bus. Multiple safety sensors can be connected to a single input and still achieve the highest level of safety. Pluto has inputs suited for every safety product on the market, and each input function is configured in the accompanying software Pluto Manager. 

Besides failsafe inputs (I) Pluto has a number of failsafe relay and transistor outputs (Q). On every Pluto unit there is also a possibility of using a number of terminals as failsafe inputs, non-failsafe outputs or both in and output simultaneously (IQ). The characteristics of the terminals are easily configured in Pluto Manager. 

## Safety in large and small systems 

Pluto models with bus communication can be connected to the Pluto bus where up to 32 Pluto units can interact and control large as well as small safety systems. The fact that Pluto is an All-Master system means that each Pluto unit controls their outputs locally, while it is as easy to read other Pluto units‘ inputs as their own. It is also easy to both read and write to global memory locations available across the Pluto bus. 

Gateways can be connected to the Pluto bus for communication with other systems. The gateway models GATE D2 and C2 can also be used as an extension of the bus cable to 

- Handles conventional circuit breakers as well as dynamical sensors 

- Custom made safety bus 

extend the Pluto network. You can also connect speed and position sensors via the Pluto bus. 

Pluto is primarily designed to satisfy the requirements of EU Machinery Directive (2006/42/EG) regarding safety in control systems, but the system can also be used in other areas as in the process industry, boiler plants etc which have similar requirements. 

## Single Pluto - Pluto without safety bus 

The Pluto models S20 and S46 without bus communication are stand alone units which are perfectly suited for smaller systems that do not require communication with other Pluto units or gateways. In all other ways the S20 has the same functionality as the B20 model, and the S46 as the B46 model – but without a safety bus connection. 

## Current monitoring (Pluto A20 only) 

Pluto A20 differs from the other models in that it can monitor the current through the IQ16 and IQ17 outputs. The function is designed for, but not limited to, ensuring that the muting lamps are working. The hardware for current monitoring is not designed with individual redundancy, which means that the function must be used dynamically if it is to be used in a 

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safety function. This means that the current must be read and evaluated both when the output is enabled and disabled. 

## Pluto for the AS-i system 

Pluto AS-i can either be AS-i master on the AS-i bus or work together with an AS-i master as a monitor. It includes AS-i nodes, analogue and digital outputs, as well as safety outputs. Also available as Pluto B42 AS-i for more I/O. For more information see the AS-i safety chapter. 

## Pluto D20 and D45 - with analogue inputs 

Pluto D20 is equipped with 4, and Pluto D45 with 8, safe 4-20mA/0-10V analogue inputs. These  can be configured as either “ordinary” failsafe inputs, as analogue inputs 0-10V or as analogue inputs 4-20mA.  For an application to reach SIL 3/PL e it is required that two sensors in parallel with one input each are being used. 

## Counter inputs Pluto D45 

For Pluto D45 four of the analogue inputs can be configured as counter inputs (pulse counting) which work for frequencies up to 14000 Hz. As counter inputs IA0 – IA3 can be used in two ways, Up counting or Up/Down counting. 

## Pluto B22 - expansion module with increased number of inputs 

Pluto B22 is an expansion module without safety outputs. It is equipped with 14 safe inputs and 8 safe inputs or non-safe outputs. 

Technical info - Dynamic signal 

**==> picture [15 x 27] intentionally omitted <==**

**----- Start of picture text -----**<br>
+24 V<br>0 V<br>**----- End of picture text -----**<br>


A dynamic signal makes it possible to achieve the highest level of safety with only one conductor. By transmitting a square wave and then evaluating the signal when it comes back to the controller you achieve the redundancy required. The signal is inverted once at each safety sensor (if the protection is OK) which makes it possible to detect short circuits across a sensor. When the signal switches between high (+24 V) and low (0V) it can be evaluated and tested about 200 times per second. 

Pluto can generate three unique dynamic signals; A pulse, B pulse or C pulse. Short circuits between two different dynamic signals are detected whenever the signal that is created is different from the expected signal in Pluto. The kind of signal Pluto expects at the input terminal is determined in Pluto Manager (A, B or C pulse and if the signal should be inverted or not). 

## Technical info - Static signal 

Static signals (+24 V or 0 V) can be connected to all inputs on Pluto. The kind of signal Pluto expects at the input terminal is determined in Pluto Manager. To achieve a two-channel structure according to EN ISO 13849-1 you need two inputs. 

## Technical info - OSSD-signal 

+24 V 0 V 

There are safety products with internal monitoring of dual OSSD signals (the device detects its own faults rather than Pluto doing this). From these devices, at least one of the two signals is connected to an I-input in Pluto, i.e. both signals must not be connected to the IQ-terminals. The terminal blocks are then configured in Pluto Manager to expect static inputs (OSSD signals are filtered internally in Pluto). 

## IQ – individual failsafe inputs and non-failsafe outputs 

The IQ terminals can be used either as individual failsafe input or non-failsafe output (e.g. for indicator light or status signal). The terminal blocks can also be used as both input and output simultaneously, which is useful for example for push buttons (input) with indicator light (output). This function is designed primarily for reset buttons to reduce the number of used terminal blocks on the controller. 

## Technical info - I - individual failsafe inputs 

All inputs are individually failsafe as each input is connected separately to both processors in Pluto. In order to maintain the redundancy required for two-channel structure and the highest level of safety, the dynamic signal must be used. When using static signals, two inputs must be used to achieve two-channel structure. The expected signal to the terminals blocks is determined in Pluto Manager (static or dynamic signal). 

## Technical info - Q - individual failsafe outputs 

All Q outputs are individually safe and are independently programmable. There are both relay outputs and transistor outputs. 

## Technical info - Transistor outputs (-24 VDC) 

The transistor outputs are just like the relay outputs, that is individually safe and independently programmable. However, the transistor outputs are different from the relay outputs as the internal connection provides the nominal input voltage -24 VDC, which is primarily intended for controlling electromechanical components such as contactors and valves. As -24 VDC is a unique signal in the majority of electrical cabinets and the fact that the output is monitored by Pluto, short circuits with other potentials can be detected right away. 

## Technical info - Pluto-bus 

The Pluto-bus is a CAN-bus with its own safety protocol. The bus cable can be up to 600 m long at the minimum bus speed, and up to 150 m at 400 kb/s. The bus can be both extended and connected to other types of buses through gateways. 

ABB Safety Handbook | 2TLC172001C0202   2/8 

2 a 

## Function Blocks for Analogue inputs Pluto D20 and D45 

## Configuration in Pluto Manager 

The inputs can be configured under “I/O Options” in Pluto Manager. As analogue inputs they can be configured either as 0-10V inputs, or as 4-20mA inputs. For Pluto D45 they can also be configured as Counter inputs. 

**IA0.0 and IA0.1 are configured as Analogue input 0-10V, and IA0.2 and IA0.3 are configured as Analogue input 4-20mA.** 

## ReadVoltage and ReadCurrent function blocks 

For analogue input 0-10V the function block “ReadVoltage” is needed, and for analogue input 4-20mA the function block “ReadCurrent” is needed. There are also 32-bit versions of these function blocks (“ReadVoltage_32” and “ReadCurrent_32”) for use with Double Registers. As output from the blocks there is one output with the absolute value in V or mA, and one output which can be scaled as desired. The picture and table below shows the “ReadCurrent” function block only, but “ReadVoltage” works in the same way. 

ReadCurrent function block. Description of inputs and outputs: 

|inp|Input connected to the block.|
|---|---|
|Value 4mA|Input value for scaling. At 4mA the output “Scaled value” will<br>show this value.|
|Value 20mA|Input value for scaling. At 20mA the output “Scaled value” will<br>show this value.|
|Q|OK output. Value is within range.|
|Current|Output with calibrated absolute value inµA.|
|Scaled Value|Output with scaled value.|



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## Counter inputs Pluto D45 

For Pluto D45 the inputs IA0 – IA3 can be configured as counter inputs (pulse counting). As counter inputs IA0 – IA3 can be used in two ways, Up counting or Up/Down counting. 

## Sensor types 

The upper frequency limit is dependent on the type of senor. For incremental encoders with HTL output (“push – pull”) the counter inputs work for frequencies up to 14 kHz. 

For photocells, proximity switches, inductive sensors etc. which normally do not have a “push – pull” output the maximum frequency might typically be 1 – 4 kHz, but the limit is also dependent on the output resistance, the cable length etc. 

## Function blocks for speed monitoring 

## **Configuration of counter input** 

For inputs configured as Up count the function block “HS_ SpeedCount_Up” shall be used. 

## Up count 

When the input is configured for Up count Pluto counts the pulses on the input. Via a function block the user gets the pulse rate which for example can represent a speed. The sensor can be anything, like an inductive sensor, photocell or incremental encoder (HTL, 24V). 

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**----- Start of picture text -----**<br>
Pluto<br>+24V<br>0V IA0 rc µA<br>se---4 IIIT<br>bs µB<br>T +24V<br>1 0V fee IA1 µA<br>R µB<br>es IA3 oe µA<br>µB<br>a----f IA4 bocce µA<br>an µB<br>**----- End of picture text -----**<br>


For inputs configured as Up/Down count the function block “HS_SpeedCount_Dir” shall be used. 

**Example of speed monitoring. The sensors can for example be proximity switches or photocells. Any of the inputs IA0..IA3 can be used.** 

## Up/Down count 

With the function Up/Down count it is possible to detect the direction of the movement. A pair of inputs, IA0/IA1 and/or IA2/IA3 can be configured as Up/Down counters. In order to make up/down counting it requires that the sensors can produce A/B-pulses. A/B-pulses are two square wave signals that are 90° phase shifted to each other. The sensor is typically an incremental encoder with HTL (24V) interface. 

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**----- Start of picture text -----**<br>
Pluto<br>+24V<br>re A 0V IA0 coccr µA<br>B µB<br>Ju ee“Le---<br>rr IA1 ae µA<br>µB<br>+24V<br>0V<br>A T-Lre- — IA2 tee µA<br>B ru a µB<br>IA3 a µA<br>s----4 EDIII<br>a µB<br>**----- End of picture text -----**<br>


The function block “SpeedMon1” is intended to be used for redundant speed monitoring, but has also functions for stand still monitoring and safe low speed. It has two inputs for speed values. These input registers can take their values from different sources such as the function blocks for incremental encoders, absolute encoders, analogue inputs etc. The input “Speed” is a primary input for a speed value and “CompSpeed” is a secondary channel for monitoring the correctness of the primary speed value. 

**Example of speed monitoring with incremental encoders leaving A and B pulses to two inputs, IA0-IA1 or IA2-IA3. The direction is then possible to measure.** 

ABB Safety Handbook | 2TLC172001C0202   2/10 

## Input connection 

The system offers solutions for both single and two-channel safety devices. In order to monitor wiring short-circuits it is possible to use up to three different dynamic signals and static voltage (+24 V) to supply the inputs. The inputs are then programmed to only accept one of the signal types. 

- In a two-channel system both channels will be measured, using two different signals. The system will thereby be able to detect 

- 2 a short-circuit between the channels. 

In a single channel system the dynamic signal is modified at each sensor. A short-circuit between the input and the output of the sensor will be detected at the Pluto input. PL e according to EN ISO 13849-1 can thus be achieved by using only one channel and one input. 

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**----- Start of picture text -----**<br>
Emergency<br>. stop with  Pp Eden sensor<br>Tina<br>Spot light<br>VIR beam Ten [oe<br>q 1 |«<br>Emergency<br>stop with<br>Tina<br>‘ fo pe<br>(. I. IL. I. I. I. I.<br>1a. Id. ie<br>F Ws,<br> Two-channel system Single channel dynamic system<br>**----- End of picture text -----**<br>


Input connection alternative in accordance with PL e EN ISO 13849-1. 

## Reset button that uses the combined input and output facility 

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**----- Start of picture text -----**<br>
3| !<br> 2 Resetting with a lamp !<br>a£a|||<br>|| input/output |<br>1010 ...1Q17<br>|||<br>iII<br>||<br>L--=_--_~__J !<br>!<br>I<br>l<br>|<br>(Current monitoring)<br>**----- End of picture text -----**<br>


Both a lamp and a pushbutton can be connected to the same terminal. This function is for resetting safety devices and to reduce the number of I/Os used. 

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## Output connector expansion 

Using an expansion relay, such as BT50, the number of safe outputs in Pluto can be expanded. The connection shall be made as shown in the figure. Several expansion relays can be connected to a single Pluto safety output while retaining the safety level. 

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**----- Start of picture text -----**<br>
24V Supp DC ly: Mv aput A1 Tes X4 t<br>Type: BT50 ~  ——" JOK A B S AF ETY<br>**----- End of picture text -----**<br>


## I/O Overview 

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**----- Start of picture text -----**<br>
Transistor output,<br>Pluto bus 1) Inputs,  individual failsafe individual failsafe<br>CH CL B B<br>I0 I1 I2 I3 I4 I6 I7<br>I5 A A<br>AI<br>Pluto A20, B20, S20 SR41 Q2 Q3<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 Q0 Q1<br>A A<br>B B<br>ID 0V +24V<br>I L 3B o| e3 1|<br>2) Identifier<br>Current monitored Relay output, input Power<br>individual failsafe<br>**----- End of picture text -----**<br>


Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs 

1)  Not S-models, S20,... 2)  Current monitored only on A20 

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Inputs,  individual failsafe Transistor output,<br>individual failsafe<br>Pluto bus<br>0-10V/4-20mA<br>mm Po ~—— ———<br>IA0 IA1 IA2 IA3 I4 I5 I6 I7<br>CH CL B B<br>DI DI DI DI DI DI DI DI<br>A A<br>AI AI AI AI AI<br>Pluto D20 0-24V Q2 Q3<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 Q0 Q1<br>A A<br>B B<br>ID 0V +24V<br>SEAtI<br>Identifier<br>Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs Relay output, input Power<br>individual failsafe<br>**----- End of picture text -----**<br>


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**==> picture [522 x 422] intentionally omitted <==**

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Inputs,  individual failsafe<br>Pluto bus<br>CH CL<br>I0 I1 I2 I3 I4 I6 I7 I20 I21 I22 I23 I24 I25<br>I5<br>AI<br>Pluto B22 SR41<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17<br>ID 0V +24V<br>Identifier<br>Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs input Power<br>Digital inputs, individual failsafe<br>Analogue inputs 0-10V/4-20mA<br>Inputs, individual failsafe Inputs, individual failsafe<br>Fast counter<br>DI AI DI AI DI AI DI AI DI AI DI AI DI AI DI AI I30 I31 I32 I33 I34 I35 I36 I37 I40 I41 I42 I43 I44 I45 I46 I47<br>IA0 IA1 IA2 IA3 IA4 IA5 IA6 IA7<br>+24V Q0 A B<br>Power<br>0V 0L<br>0V supply Q1 A B<br>Pluto D45<br>1L<br>ID Identifier IDFIX<br>Safety outputs Q4 A B<br>CH Q5 A B<br>CL Pluto bus<br>CS (Shield) 4L<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 IQ20 IQ21 IQ22 IQ23 IQ24 IQ25 IQ26 Q2<br>A B<br>Q3<br>A B<br>**----- End of picture text -----**<br>


Failsafe inputs / Outputs (not failsafe) / Dynamic outputs 

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Inputs,  individual failsafe<br>Inputs,  individual failsafe Inputs,  individual failsafe<br>Digital/Analogue<br>I0 I1 I2 I3 I4 I5 I6 I7 I30 I31 I32 I33 I34 I35 I36 I37 I40 I41 I42 I43 I44 I45 I46 I47<br>AI AI AI<br>A B<br>+24V SR41 SR45 SR46 Q0<br>0V0V supplyPower Pluto B46, S46 Q1 A B 0L<br>1L<br>ID Identifier IDFIX Safety outputs Q4 A B<br>CH A B<br>Pluto bus 1) Q5<br>CL<br>4L<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 IQ20 IQ21 IQ22 IQ23 IQ24 IQ25 IQ26 IQ27 Q2<br>A B<br>Q3<br>A B<br>**----- End of picture text -----**<br>


Failsafe inputs / Outputs (not failsafe) / Dynamic outputs 

1)  Not S46 

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**----- Start of picture text -----**<br>
IDFIX<br>**----- End of picture text -----**<br>


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Inputs,  individual failsafe<br>AS-Interface Inputs,  individual failsafe Inputs,  individual failsafe<br>Digital/Analogue<br>ASi+ ASi+ I0 I1 I2 I3 I30 I31 I32 I33 I34 I35 I36 I37 I40 I41 I42 I43 I44 I45 I46 I47<br>AI AI AI<br>A B<br>+24V SR41 SR45 SR46 Q0<br>Power<br>0V 0L<br>0V supply Q1 A B<br>Pluto B42 AS-i<br>1L<br>ID Identifier IDFIX Safety outputs Q4 A B<br>CH Q5 A B<br>CL Pluto bus<br>4L<br>CS<br>IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 IQ20 IQ21 IQ22 IQ23 IQ24 IQ25 IQ26 IQ27 Q2<br>A B<br>Q3<br>A B<br>**----- End of picture text -----**<br>


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**----- Start of picture text -----**<br>
Failsafe inputs / Outputs (not failsafe) / Dynamic outputs<br>**----- End of picture text -----**<br>


- ID: Connection for identifier, which has a unique ID number that can be read by the system. 

- I.. Safety inputs (24 VDC) that are individually failsafe. This means that the highest level of safety can be achieved with only one input if ABB Jokab Safety dynamic safety components are used. 

   - Otherwise two inputs are required for each safety function. 

- IQ.. I/O that can be used for safety inputs or signal outputs, e.g. to indicate or control functions that are not  safety-related. For IQ.. as safety inputs, refer to I.. 

- Q0, Q1:  Failsafe relay outputs that are individually failsafe and individually programmable. 

- Q2, Q3:  Failsafe transistor outputs (-24 VDC) that are individually failsafe and individually programmable. Intended for electromechanical components such as contactors and valves. 

- Q4, Q5  Failsafe relay outputs with common potential that are individually failsafe and individually programmable. 

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Technical data - type-specific 

|Pluto A20<br>20 I/O<br>Current monitoring|Pluto A20<br>20 I/O<br>Current monitoring|Pluto B20|Pluto B22|D20|S20|
|---|---|---|---|---|---|
|||20 I/O|22 I/O|20 I/O<br>Analogue inputs|20 I/O<br>Without safety bus|
|Article number|2TLA020070R4500|2TLA020070R4600|2TLA020070R4800|2TLA020070R6400|2TLA020070R4700|
|Failsafe inputs|8 (I0..I7)|8 (I0..I7)|14 (I0..I7, I20..I25)|8 (I0..I7)|8 (I0...I7)|
|Failsafe inputs or<br>non-failsafe outputs|8 (IQ10..IQ17)<br>Max total load 2.5 A|8 (IQ10..IQ17)<br>Max total load 2.5 A|8 (IQ10..IQ17)<br>Max total load 2.5 A|8 (IQ10..IQ17)<br>Max total load 2.5 A|8 (IQ10...IQ17)<br>Max total load 2.5 A|
|Analogue inputs<br>(0-10V/4-20 mA)|–|–|–|4|–|
|Counter inputs|–|–|–|–|–|
|Analogue inputs (0-27V)|1 (I5)|1 (I5)|1 (I5)|1 (I5)|1 (I5)|
|Failsafe relay outputs|2 (Q0..Q1)|2 (Q0..Q1)|–|2 (Q0..Q1)|2 (Q0..Q1)|
|Failsafe transistor outputs|2 (Q2..Q3)|2 (Q2..Q3)|–|2 (Q2..Q3)|2 (Q2..Q3)|
|Current monitoring|2  (IQ16,  IQ17)<br>0-1.0 A ±10%|–|–|–|–|
|Pluto safety bus|•|•|•|•|–|
|Pluto AS-i bus|–|–|–|–|–|
|Own current consumption|100...300 mA|100...300 mA|100...300 mA|100...300 mA|100...300 mA|
|Recommended external<br>fuse|6A|6A|6A|6A|6A|
|Dimensions (w x h x d)|45 x 84 x 118 mm|45 x 84 x 118 mm|45 x 84 x 118 mm|45 x 84 x 118 mm|45 x 84 x 118 mm|



## Technical data - general 

|Technical data - general||
|---|---|
|Colour|Grey|
|Operating voltage|24 VDC ±15%|
|Installation|35 mm DIN rail|
|Electrical insulation|Category II in accordance with IEC<br>61010-1|
|Safety level<br>EN 954-1<br>EN ISO 13849-1<br>EN 61508<br>EN 62061|Cat. 4<br>PL e/Cat. 4<br>SIL 3<br>SIL 3|
|PFHD<br>Relay output<br>Transistor output:0|2.00×10-9<br>1.50×10-9|
|Failsafe inputs I & IQ<br>I0..7 (I30..37, I40..47)<br>IQ10..17 (IQ20..27)<br>Current at 24 V<br>Max. overvoltage|+24 V (for PNP sensors)<br>+24 V (for PNP sensors)<br>IQ also configurable as non-failsafe<br>outputs.<br>5.1 mA<br>27 V continuous|



Failsafe outputs Q 

Q2, Q3 Output voltage tolerance Q0, Q1, (Q4, Q5) 

Non-failsafe outputs Q IQ10..17 (IQ20..27) 

Max. current/output 

Indicator 

Input/output LED Display 

Pluto safety bus Max number of Pluto units on the databus Databus type Databus speeds Databus cable length 

Transistor, –24VDC, 800 mA Supply voltage - 1.5 V at 800 mA Relay outputs VAC-12: 250 V/1.5 A VAC-15: 250 V/1.5 A VDC-12: 50 V/1.5 A VDC-13: 24 V/1.5 A 

Transistor +24V, PNP "open collector" also configurable as failsafe inputs. 800 mA 

1 per I/O (green) 7-segments, two characters 

32 CAN 100, 125, 200, 250, 400, 500, 800, 1000 kb/s Up to 600 m, 150 m at 400 kb/s 

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|Pluto B46|Pluto D45|Pluto S46|Pluto AS-i|Pluto B42 AS-i|
|---|---|---|---|---|
|46 I/O|45 I/O<br>Analogue/counter inputs|46 I/O<br>Without safety bus|AS-i bus|AS-i bus|
|2TLA020070R1700|2TLA020070R6600|2TLA020070R1800|2TLA020070R1100|2TLA020070R1400|
|24 (I0..I7, I30..I37, I40..I47)|24 (I0..I7, I30..I37, I40..I47)|24 (I0..I7, I30..I37, I40..I47)|4 (I0..I3)|20 (I0..I3, I30..I47)|
|16 (IQ10..IQ17, IQ20..IQ27)<br>Max total load 2A|15 (IQ10..IQ17, IQ20..IQ26)<br>Max total load 2A|16 (IQ10..IQ17, IQ20..IQ27)<br>Max total load 2A|4 (IQ10..IQ13)<br>Max total load 2A|16 (IQ10..IQ27)<br>Max total load 2A|
|–|4*|–|–|–|
|–|8*|–|–|–|
|3 (I5..I7)|3 (IQ10..IQ12)|3 (I5..I7)|4 (IQ10..IQ13)|3 (I1..I3)|
|4 (Q0..Q1 & Q4..Q5)|4 (Q0..Q1 & Q4..Q5)|4 (Q0..Q1 & Q4..Q5)|2 (Q0..Q1)|4 (Q0..Q1 & Q4..Q5)|
|2 (Q2..Q3)|2 (Q2..Q3)|2 (Q2..Q3)|2 (Q2..Q3)|2 (Q2..Q3)|
|–|–|–|–|–|
|•|•|–|•|•|
|–|–|–|•|•|
|100...500 mA|100...500 mA|100...500 mA|100 mA|150 mA|
|10A|10A|10A|6A|10A|
|90 x 84 x 118 mm|90 x 84 x 118 mm|90 x 84 x 118 mm|45 x 84 x 118 mm|90 x 84 x 118 mm|



*4 of the analogue inputs can be configured as counter inputs. The total number of analogue inputs + counter inputs = 8. 

Pluto AS-i bus Master profile M2 Number of slave units 31/62* Bus operation mode Master Safety monitor Safety monitor, slave and safe I/O module. Bus cable length: Up to 500 m 100 m between each repeater 

Additional Response times Databus between Pluto units 10 ms Databus between Pluto units 10–40 ms at fault condition Enclosure classification Enclosure IP40, IEC 60 529 Connection terminals IP20, IEC 60 529 

The terminal blocks are detachable without needing to disconnect the wiring. The units shall be assembled with a gap of at least 5 mm. 

Temperature Ambient temperature –10˚C to +50˚C Storage and transport –25˚C to +55˚C 

Response times Dyn. A or static input to relay output Dyn. A or static input to transistor output Dyn. B or Dyn. C input to relay output Dyn. B or Dyn. C input to transistor output Software setting "NoFilt" 

AS-i bus to relay output AS-i bus to transistor output 

<20.5 ms + program exec. time <16.5 ms + program exec. time <23 ms + program exec. time <19 ms + program exec. time 

5 ms shorter response time on I & IQ inputs <33 ms + prog. execution time <29 ms + prog. execution time 

ABB Safety Handbook | 2TLC172001C0202   2/16 

2 

## APPLICATION EXAMPLE - Pluto 

## Robot cell with Pluto 

## Description 

The example describes a processing machine served by a robot. The machine safety system consists of one (Pluto 1) to which all protection has been connected. The robot has been equipped with a (Pluto 0) to which the cell protection has been connected. The Pluto for the machine has been connected via a databus cable to the robot's Pluto so that common functions, such as emergency stop, can be used by the whole cell. 

## Function 

Emergency stop takes priority and will stop both the machine and the robot. The machine hatch acts as the zone divider, when the hatch is closed the machine forms one zone and the robot another zone. When the machine hatch is open, both the machine and the robot belong to the same zone. If the door is opened when the machine hatch is open, the machine and the robot will both stop, but if the machine hatch is closed, only the robot will be stopped. 

After the door has been opened, the system must be reset by means of the reset button on the outside of the door. Emergency stop is reset when the pressed-in button is pulled out. NOTE. The cell operating cycle must not however start immediately on resetting the emergency stop or the door. 

2/17   2TLC172001C0202 | ABB Safety Handbook 

2 

## Electrical connections 

ABB Safety Handbook | 2TLC172001C0202   2/18 

2 

## APPLICATION EXAMPLE - Pluto 

PLC code Pluto 0 – Robot cabinet 

1 

Start 2 Two channel monitoring with automatic reset of emergency stop at the door. P0_ES1_Ch1 TC1S P0_ES_OK I0.0 GM0.0 In1 Q P0_ES1_Ch2 I0.1 In2 Start _GM0.0=P0_ES_OK Emergency stop OK in Pluto 0 I0.0=P0_ES1_Ch1 Emergency stop 1 channel 1 - Static I0.1=P0_ES1_Ch2 Emergency stop 1 channel 2 - Dynamic A non-inverted_ 

3 Emergency stop of robot. When the emergency stop is actuated the robot will make an emergency stop. In order to restore safety requires the emergency stop button needs to be reset. An emergency stop from the machine panel will also emergency stop the robot. 

P0_ES_OK P1_ES_OK P0_ES GM0.0 GM1.0 Q0.3 

_GM0.0=P0_ES_OK Emergency stop OK in Pluto 0 GM1.0=P1_ES_OK Emergency stop OK in Pluto 1 Q0.3=P0_ES Robot emergency stop - Expansion BT50 relay_ 

||||||
|---|---|---|---|---|
|Auto stop of robot.<br>|||||
|When the door to the robot cell is opened the robot is auto stopped.<br>|||||
|To reset the safety the door needs to be closed and the reset button pressed and released.<br>|||||
|Note that IQ15 of the Pluto is used both as a button in and to indicate diffirent reset states.<br>|||||
|Constant light means reset is not possible, safety not ok.<br>|||||
|Flash 0.4 s high, 0.6 s low means reset is possible but not performed.<br>|||||
|No light means reset has been performed and the safety is ok.|||||
|I0.2<br>P0_Eden1<br>N<br>I0.15<br>P0_LB1_In|||ResetT||
||||||
||||||
||||Q<br>In1<br>||
||||||
||||||
||||Reset<br>Test<br>IndRese||



4 Auto stop of robot. 

_Reset Door - Light button input - Dynamic A Door Eden sensor - Dynamic A Reset Door - Light button output - Static Robot auto stop - Expansion BT50 relay_ 

_I0.15=P0_LB1_In I0.2=P0_Eden1 Q0.15=P0_LB1_Out Q0.2=P0_AS_OK_ 

2/19   2TLC172001C0202 | ABB Safety Handbook 

2 

**==> picture [596 x 35] intentionally omitted <==**

## 5 Alarm 03 - Machine hatch open. 

To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto. A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors. 

P1_Hatch_OK P0_AS_OK SR_ErrorCode=0 SR_PlutoDisplay=203 GM1.1 Q0.2 SR0.11=0 SR0.10=203 

_GM1.1=P1_Hatch_OK Hatch closed Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no SR0.11=SR_ErrorCode Error code_ 

- 6 Alarm 02 - Door open. 

To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto. A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors. 

P0_Eden1 SR_ErrorCode=0 SR_PlutoDisplay=202 I0.2 SR0.11=0 SR0.10=202 

_I0.2=P0_Eden1 Door Eden sensor - Dynamic A SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no SR0.11=SR_ErrorCode Error code_ 

7 Alarm 01 - Emergency stop actuated. 

To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto. 

A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors. 

P0_ES_OK SR_ErrorCode=0 SR_PlutoDisplay=201 GM0.0 SR0.11=0 SR0.10=201 _GM0.0=P0_ES_OK Emergency stop OK in Pluto 0 SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no SR0.11=SR_ErrorCode Error code_ 

ABB Safety Handbook | 2TLC172001C0202   2/20 

APPLICATION EXAMPLE - Pluto 

2 

## PLC code Pluto 1 – Machine cabinet 

1 

|1||||||||||
|---|---|---|---|---|---|---|---|---|---|
|||Start||||||||
|2||Two channel monitoring with automatic reset of emergency stop at the machine hatch.||||||||
|||P1_ES1_Ch1|||||TC1S||P1_ES_OK|
|||I1.1|||||||GM1.0|
|||||||In1||Q||
|||P1_ES1_Ch2||||||||
|||I1.2||||||||
|||||||In2||||
|||||||Start||||
|||||||||||



||_GM1.0=P1_ES_OK_|_GM1.0=P1_ES_OK_|_GM1.0=P1_ES_OK_|_Emergency stop OK in Pluto_|_Emergency stop OK in Pluto_|_1_|||||
|---|---|---|---|---|---|---|---|---|---|---|
||_I1.1=P1_ES1_Ch1_|||_Emergency stop 1 channel 1- Dynamic A non-inverted_|||||||
||_I1.2=P1_ES1_Ch2_|||_Emergency stop 1 channel 2 - Static_|||||||
|3|Two channel monitoring with automatic reset of||||interlocking switch of the machine hatch.||||||
||P1_IS1_Ch1||||||TC1S|||P1_Hatch_OK|
||I1.3|||||||||GM1.1|
||||||||In1|Q|||
||P1_IS1_Ch2||||||||||
||I1.4||||||||||
||||||||In2||||
||||||||Start||||
||||||||||||



_GM1.1=P1_Hatch_OK Hatch closed I1.3=P1_IS1_Ch1 Interlocking switch channel 1 - Dynamic A non-inverted I1.4=P1_IS1_Ch2 Interlocking switch channel 2 - Static_ 4 Emergency stop of machine. When the emergency stop is actuated the machine will make an emergency stop. In order to restore safety requires the emergency stop button needs to be reset. An emergency stop from the robot will also emergency stop the machine. P1_ES_OK P0_ES_OK P1_ES GM1.0 GM0.0 Q1.0 _GM0.0=P0_ES_OK Emergency stop OK in Pluto 0 GM1.0=P1_ES_OK Emergency stop OK in Pluto 1 Q1.0=P1_ES Machine Emergency Stop_ 

- 5 Monitoring of the hatch. 

When the hatch is opened the monitoring of the hatch is inactive. To reset the safety the hatch needs to be closed and the reset button pressed and released. Note that IQ15 of the Pluto is used both as a button in and to indicate different reset states. Constant light means reset is not possible, safety not ok. Flash 0.4 s high, 0.6 s low means reset is possible but not performed. No light means reset has been performed and the safety is ok. P1_Hatch_OK ResetT HB_Hatch_OK GM1.1 M1.0 In1 Q P1_LB1_In HB_Ind_Hatch_OK I1.15 M1.1 N Reset IndReset Test 

2/21   2TLC172001C0202 | ABB Safety Handbook 

2 

**==> picture [596 x 35] intentionally omitted <==**

_GM1.1=P1_Hatch_OK Hatch closed I1.15=P1_LB1_In Reset Hatch - Light button input - Dynamic A M1.0=HB_Hatch_OK Help Bit - Hatch closed M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch_ 

6 Light button indication of the reset of the hatch. 

If the robot cell's door is closed and reset no light indication is needed inside the cell. HB_Ind_Hatch_OK P0_AS_OK P1_LB1_Out M1.1 Q0.2 Q1.15 

_M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay Q1.15=P1_LB1_Out Reset Hatch - Light button output - Static_ 

|Protective stop of the machine.|Protective stop of the machine.|Protective stop of the machine.|Protective stop of the machine.|
|---|---|---|---|
|Either the hatch is closed and reset or the door to the robot cell is closed and reset.||||
|This means the cell can work with the hatch both open or closed as long as the cell's door is closed and reset.||||
|HB_Hatch_OK|||P1_PS|
|M1.0|||Q1.1|
|P0_AS_OK||||
|Q0.2||||
|||||



- 7 Protective stop of the machine. 

_M1.0=HB_Hatch_OK Help Bit - Hatch closed Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay Q1.1=P1_PS Machine Protective Stop_ 

|8|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|Alarm 03 - Machine hatch open.|
|---|---|---|---|---|---|---|---|---|
|To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.<br>A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.<br>GM1.1<br>P1_Hatch_OK<br>Q0.2<br>P0_AS_OK<br>SR1.11=0<br>SR_ErrorCode=0<br>SR1.10=203<br>SR_PlutoDisplay=203<br>_GM1.1=P1_Hatch_OK_<br>_Hatch closed_<br>_Q0.2=P0_AS_OK_<br>_Robot auto stop - Expansion BT50 relay_<br>_SR1.10=SR_PlutoDisplay_<br>_Pluto display figure. For user error: 200+no_<br>_SR1.11=SR_ErrorCode_<br>_Error code_|To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.||||||||
||A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.||||||||
||||||||||
||||||||||
||GM1.1<br>P1_Hatch_OK<br>Q0.2<br>P0_AS_OK<br>SR1.11=0<br>SR_ErrorCode=0||||||SR1.10=203<br>SR_PlutoDisplay=203||
||||||||||
||||||||||
||||||||||
||_GM1.1=P1_Hatch_OK_||||_Hatch c_||_losed_||
||||||_Robot a_||_uto stop - Expansion BT50 relay_||
||_SR1.10=SR_PlutoDisplay_<br>_Pluto display figure. For user error: 200+no_||||||||
|9|Alarm 02 - Door open.||||||||
|To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.<br>A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.<br>I0.2<br>P0_Eden1<br>SR1.11=0<br>SR_ErrorCode=0<br>SR1.10=202<br>SR_PlutoDisplay=202<br>_I0.2=P0_Eden1_<br>_Door Eden sensor - Dynamic A_<br>_SR1.10=SR_PlutoDisplay_<br>_Pluto display figure. For user error: 200+no_<br>_SR1.11=SR_ErrorCode_<br>_Error code_|To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.||||||||
||A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.||||||||
||||||||||
||I0.2<br>P0_Eden1<br>SR1.11=0<br>SR_ErrorCode=0|||||SR1.10=202<br>SR_PlutoDisplay=202|||
||||||||||
||||||||||
||||||||||
||_I0.2=P0_Eden1_|||||_Door Eden sensor - Dynamic A_|||
|||||||_Pluto display figure. For user error: 200+no_|||
||_SR1.11=SR_ErrorCode_|||||_Error code_|||
||||||||||
|0|Alarm 01 - Emergency stop actuated.||||||||
|To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.<br>A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.<br>GM1.0<br>P1_ES_OK<br>SR1.11=0<br>SR_ErrorCode=0<br>SR1.10=201<br>SR_PlutoDisplay=201<br>_GM1.0=P1_ES_OK_<br>_Emergency stop OK in Pluto 1_<br>_SR1.10=SR_PlutoDisplay_<br>_Pluto display figure. For user error: 200+no_<br>_SR1.11=SR_ErrorCode_<br>_Error code_|To generate User Errors (UE) a value|||||of 200 - 299 can be written to the display of the Pluto.|||
||A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.||||||||
||||||||||
||GM1.0<br>P1_ES_OK<br>SR1.11=0<br>SR_ErrorCode=0|||||SR1.10=201<br>SR_PlutoDisplay=201|||
||||||||||
||||||||||
||||||||||
||_GM1.0=P1_ES_OK_|||||_Emergency stop OK in Pluto 1_|||
|||||||_Pluto display figure. For user error: 200+no_|||
||_SR1.11=SR_ErrorCode_|||||_Error code_|||



10 

ABB Safety Handbook | 2TLC172001C0202   2/22 

2 

## Pluto gateway GATE-P2 

## Use: 

- Bi-directional status information from the Pluto safety PLC 

- For Profibus 

**==> picture [213 x 175] intentionally omitted <==**

**----- Start of picture text -----**<br>
ace<br>Lo Profibus DP<br>DeviceNet<br>on<br>CANopen<br>Profinet<br>Ethernet/IP<br>t<br>Modbus TCP<br>**----- End of picture text -----**<br>


Pluto gateway is a unit providing two-way communication between a Pluto safety PLC and other field buses. 

The Pluto gateway is a compact unit mounted on a DIN rail, and can be connected anywhere in a Pluto safety bus. The unit has a common interface with Pluto, i.e. the same cabling, and the Pluto Manager PC program can be used for servicing and where necessary programming. Normally, however, all the settings are made via DIP switches, which means that programming tools are not required to put the gateway itself into operation. 

## Features: 

- Two-way communication 

- Built-in filter function, shared network 

- Only 22.5 mm wide 

- Can be located anywhere in the databus 

- Common interface with Pluto 

- Ready-made function blocks 

## PLC function blocks 

To simplify the integration of a Pluto gateway PROFIBUS into the supervisory PLC system, ABB Jokab Safety provides ready-made function blocks for several popular brands of PLC. The function blocks make it easier to receive and send information to the Pluto system. The function blocks are supplied as open units with full access for the customer to change and add functions. These function blocks can be obtained via www.abb.com/jokabsafety. 

For programming Pluto there are ready-made function blocks which, via a Pluto gateway, send and receive data from the supervisory system. 

## Data from Pluto 

Via PROFIBUS a supervisory PLC system can have access to the I/O and other variables in a Pluto safety PLC. Global I/O in a Pluto safety PLC are accessible via PROFIBUS modules in the gateway, one module for each Pluto unit. Local data in Pluto units can be read by a "local data” module together with the PLC codes in the supervisory system. 

## Data to Pluto 

Via PROFIBUS a supervisory PLC system can transmit nonsafety-related information to a Pluto safety PLC. A total of 64 Boolean values and 8 different 16-bit registers can be transmitted. Function blocks for these functions are available in Pluto Manager. 

**==> picture [87 x 94] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto safety bus LED<br>"K" button<br>PC port<br>Profibus LED<br>Profibus connector<br>**----- End of picture text -----**<br>


2/23   2TLC172001C0202 | ABB Safety Handbook 

2 

Technical data - GATE-P2 

**==> picture [294 x 299] intentionally omitted <==**

**----- Start of picture text -----**<br>
|||
|---|---|
|Article number|2TLA020071R8000|
|Databuses|-Pluto safety bus CAN (isolated)|
|-PROFIBUS RS485 (isolated)|
|Pluto safety bus speeds|100, 200, 250, 400, 500, 800 and 1000 kbit/s|
|(automatic speed detection)|
|PROFIBUS speed|Up to 12 Mbit/s (automatic speed detection)|
|PROFIBUS address|Setting via DIP switches (0-99)|
|PROFIBUS version|DP slave, DP-V0|
|Connections|Top, 3-pole terminal for Pluto safety bus (included)|
|Front, standard 9-pole PROFIBUS connection.|
|Bottom, 2-pole terminal for 24 VDC (included)|
|Status indication|Pluto safety bus status indication via LED|
|PROFIBUS status indication via LED|
|Operating voltage|24 VDC, -15% till +20%|
|Current at 24 V|< 100 mA (recommended fuse ≤6 A)|
|Dimensions (w x h x d)|22.5 x 101 x 119 mm|
|Installation|35 mm DIN rail|
|Operating temperature|
|(ambient)|-10°C to + 55ºC|
|Temperature, transport and|
|storage|-25°C to + 55ºC|
|Humidity|EN 60 204-1 50% at 40ºC (ambient 90% at 20ºC)|
|Enclosure classification|Enclosure IP20 - IEC 60 529|
|Terminals IP20 - IEC 60 529|

**----- End of picture text -----**<br>


Gateway block schematic diagram - Pluto Profibus 

**==> picture [74 x 124] intentionally omitted <==**

**----- Start of picture text -----**<br>
119 mm<br>{<br>b 101 mm<br>S|<br>as<br>ke 22.5 mm<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   2/24 

2 

## Pluto gateway GATE-D2 

## Use: 

- Bi-directional status information from the Pluto safety PLC 

- For DeviceNet and Pluto bridge 

**==> picture [118 x 140] intentionally omitted <==**

**----- Start of picture text -----**<br>
Profibus DP<br>DeviceNet<br>[<br>CANopen<br>Profinet<br>Ethernet/IP<br>Modbus TCP<br>**----- End of picture text -----**<br>


Pluto gateway is a unit providing two-way communication between a Pluto safety PLC and other field buses. 

The Pluto gateway is a compact unit mounted on a DIN rail, and can be connected anywhere in a Pluto safety bus. The unit has a common interface with Pluto, i.e. the same cabling, and the Pluto Manager PC program can be used for servicing and where necessary programming. Normally, however, all the settings are made via DIP switches, which means that programming tools are not required to put the gateway itself into operation. 

## Features: 

- Two-way communication 

- Built-in filter function, shared network 

- Only 22.5 mm wide 

- Can be located anywhere in the databus 

- Common interface with Pluto 

- Ready-made function blocks 

## Pluto bridge 

A GATE-D2 can also be used to advantage as a CAN bridge when it is required to divide a Pluto safety bus into several sections. This is particularly useful when long databus cables are needed. 

There is also a built-in filter function which makes it possible to block any data that is not required for use on the other side of the bridge, which reduces the databus loading in the other sections and thereby permits longer databus cables. 

## ABB Robotics IRC5 

For programming Pluto there are ready-made function blocks which, via a Pluto gateway, send and receive data from the supervisory system. 

PLUTO GATE-D2 has support for integration into an ABB Robotics IRC5-system. The documentation that describes this integration can be obtained via www.abb.com/jokabsafety. 

## Data from Pluto 

Via DeviceNet a supervisory PLC system can have access to the I/O and other variables in a Pluto safety PLC. Global I/Os in a Pluto safety PLC are accessible via DeviceNet ”implicit” messages. Local data in Pluto units can be read via DeviceNet ”explicit” messages. 

## Data to Pluto 

Via DeviceNet a supervisory PLC system can transmit nonsafety-related information to a Pluto safety PLC. A total of 64 Boolean values and 8 different 16-bit registers can be transmitted (via DeviceNet ”implicit” or ”explicit” messages). Function blocks for these commands are available in Pluto Manager. 

**==> picture [82 x 95] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto safety bus LED<br>"K" button<br>PC port<br>DeviceNet LED<br>DeviceNet connector<br>**----- End of picture text -----**<br>


2/25   2TLC172001C0202 | ABB Safety Handbook 

2 

Technical data - GATE-D2 

|Technical data - GATE-D2||
|---|---|
|Article number|2TLA020071R8200|
|Databuses|-Pluto safety bus CAN (isolated)<br>-DeviceNet CAN (isolated)|
|Pluto safety bus speeds|100, 200, 250, 400, 500, 800 and 1000 kbit/s<br>(automatic speed detection)|
|DeviceNet speed|125, 250 and 500 kbit/s (set via DIP switch)|
|DeviceNet address|Setting via DIP switches (1-63)|
|DeviceNet Version|ODVA version 2.0|
|Connections|Top, 3-pole terminal for Pluto safety bus (included)<br>Front, 5-pole terminal for DeviceNet (included)<br>Bottom, 2-pole terminal for 24 VDC (included)|
|Status indications|Pluto safety bus status indication via LED<br>DeviceNet MNS status indication via LED|
|Operating voltage|24 VDC, -15% till +20%|
|Current at 24 V|< 100 mA (recommended fuse ≤6 A)|
|Dimensions (w x h x d)|22.5 x 101 x 119 mm|
|Installation|35 mm DIN rail|
|Operating temperature (ambient)|-10°C to + 55ºC|
|Temperature,<br>transport and storage|-25°C to + 55ºC|
|Humidity|EN 60 204-1 50% at 40ºC (ambient 90% at 20ºC)|
|Enclosure classification|Enclosure IP20 - IEC 60 529<br>Terminals IP20 - IEC 60 529|



Gateway block schematic diagram - Pluto DeviceNet 

**==> picture [62 x 124] intentionally omitted <==**

**----- Start of picture text -----**<br>
119 mm p<br>@<br>fl<br>osS| 101 mm<br>22.5 mm<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   2/26 

2 5 

## Pluto gateway GATE-C2 

## Use: 

- Bi-directional status information from the Pluto safety PLC 

- For CANopen and Pluto-bridge 

**==> picture [116 x 143] intentionally omitted <==**

**----- Start of picture text -----**<br>
Profibus DP<br>DeviceNet<br>CANopen<br>Profinet<br>Ethernet/IP<br>Modbus TCP<br>**----- End of picture text -----**<br>


Pluto gateway is a unit providing two-way communication between a Pluto safety PLC and other field buses. 

The Pluto gateway is a compact unit mounted on a DIN rail, and can be connected anywhere in a Pluto safety bus. The unit has a common interface with Pluto, i.e. the same cabling, and the Pluto Manager PC program can be used for servicing and where necessary programming. Normally, however, all the settings are made via DIP switches, which means that programming tools are not required to put the gateway itself into operation. 

## Features: 

- Two-way communication 

- Built-in filter function, shared network 

- Only 22.5 mm wide 

- Can be located anywhere in the databus 

- Common interface with Pluto 

- Ready-made function blocks 

## Pluto bridge 

A GATE-C2 can also be used to advantage as a CAN bridge when it is required to divide a Pluto safety bus into several sections. This is particularly useful when long databus cables are needed. 

There is also a built-in filter function which makes it possible to block any data that is not required for use on the other side of the bridge, which reduces the databus loading in the other sections and thereby permits longer databus cables. 

For programming Pluto there are ready-made function blocks which, via a Pluto gateway, send and receive data from the supervisory system. 

## Data from Pluto 

Via CANopen a supervisory PLC system can have access to the I/O and other variables in a Pluto safety PLC. Global I/ Os in a Pluto safety PLC are accessible via CANopen PDO messages. Local data in Pluto units can be read via CANopen SDO messages together with the PLC codes in the supervisory system. 

## Data to Pluto 

Via CANopen a supervisory PLC system can send non-safetyrelated information to a Pluto safety PLC. A total of 64 Boolean values and 8 different 16-bit registers can be transmitted (CANopen PDO or SDO messages). Function blocks for these commands are available in Pluto Manager. 

**==> picture [82 x 97] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto safety bus LED<br>"K" button<br>PC port<br>CANopen LED<br>CANopen connector<br>**----- End of picture text -----**<br>


2/27   2TLC172001C0202 | ABB Safety Handbook 

2 

## Technical data - GATE-C2 

|Technical data - GATE-C2||
|---|---|
|Article number|2TLA020071R8100|
|Databuses|-Pluto safety bus CAN (isolated)<br>-CANopen CAN (isolated)|
|Pluto safety bus speeds|100, 200, 250, 400, 500, 800 and 1000 kbit/s<br>(automatic speed detection)|
|CANopen speeds|125, 250 and 500 kbit/s (set via DIP switch)<br>10, 20, 50, 100, 125, 250, 500, 800 and 1000 kbit/s (via software)|
|CANopen address|Setting via DIP switches or software (1-63)|
|CANopen version|”Version 4.02 of the CiA Draft Standard 301”|
|Connections|Top, 3-pole terminal for Pluto safety bus (included)<br>Front, 5-pole terminal for CANopen (included)<br>Bottom, 2-pole terminal for 24 VDC (included)|
|Status indications|Pluto safety bus status indication via LED<br>CANopen status indication via LED|
|Operating voltage|24 VDC, -15% till +20%|
|Current at 24 V:|< 100 mA (recommended fuse ≤6 A)|
|Dimensions (w x h x d)|22.5 x 101 x 119 mm|
|Installation|35 mm DIN rail|
|Operating temperature (ambient)|-10°C to + 55ºC|
|Temperature, transport and<br>storage|-25°C to + 55ºC|
|Humidity|EN 60 204-1 50% at 40ºC (ambient 90% at 20ºC)|
|Enclosure classification|Enclosure IP20 - IEC 60 529<br>Terminals IP20 - IEC 60 529|



Gateway block schematic diagram - Pluto CANopen 

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119 mm<br>a<br>SS<br>p<br>|b 101 mm<br>|@<br>oe 1S]@\7<br>=<br>22.5 mm<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   2/28 

## Pluto gateway GATE-E2 

## Use: 

- Bi-directional status information from the Pluto safety PLC 

- Profinet, Ethernet/IP, Modbus TCP 

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Profibus DP<br>DeviceNet<br>CANopen<br>Profinet<br>Ethernet/IP<br>Modbus TCP<br>**----- End of picture text -----**<br>


Pluto gateway is a unit providing two-way communication between a Pluto safety PLC and other field buses. 

The Pluto gateway is a compact unit mounted on a DIN rail, and can be connected anywhere in a Pluto safety bus. The unit has a common interface with Pluto, i.e. the same cabling, and the Pluto Manager PC program can be used for servicing and where necessary programming. Normally, however, all the settings are made via DIP switches, which means that programming tools are not required to put the gateway itself into operation. 

For programming Pluto there are ready-made function blocks which, via a Pluto gateway, send and receive data from the supervisory system. 

## Features: 

- Two-way communication 

- Built-in filter function, shared network 

- Can be located anywhere in the databus 

- Common interface with Pluto 

- Ready-made function blocks 

## Data from Pluto 

Via one of the Ethernet protocols a supervisory PLC system can have access to the I/O and other variables in a Pluto safety PLC. Global I/Os in a Pluto safety PLC are accessible via the usual I/O transfer in the respective protocol. Local data in Pluto units can be read by special commands together with the PLC codes in the supervisory system. 

## Data to Pluto 

Via the Ethernet protocol a supervisory PLC system can transmit non-safety-related information to a Pluto safety PLC. A total of 64 Boolean values and 8 different 16-bit registers can be transmitted. Function blocks for these functions are available in Pluto Manager. 

## Protocol 

PLUTO Gateway GATE-E2 handles the status from and to Pluto safety PLCs via Ethernet protocols EtherNet/IP, PROFINET, Modbus TCP and a simple binary protocol that uses TCP/IP. 

For IP-address configuration, etc. there is a simple web server and a terminal server. 

Pluto safety bus LED "K" button PC port Ethernet LED Ethernet connector 

2/29   2TLC172001C0202 | ABB Safety Handbook 

Technical data - GATE-E2 

|Technical data - GATE-E2||
|---|---|
|Article number|2TLA020071R8300|
|Buses|Pluto-bus CAN (isolated)<br>Profinet (isolated)<br>Ethernet/IP (isolated)<br>Modbus TCP (isolated)|
|Pluto safety bus speeds|100, 200, 250, 400, 500, 800 and<br>1000 kbit/s<br>(automatic speed detection)|
|Ethernet|10/100 Mbit/s<br>Half and full duplex|
|Ethernet protocol|Status from and to Pluto safety PLC<br>- EtherNet/IP<br>- PROFINET<br>- Modbus TCP<br>- Binary server (TCP/IP)<br>Note that certain combinations of<br>server protocols cannot be used<br>simultaneously.<br>Gateway status and IP address<br>configuration<br>- Web server<br>- Terminal server (TCP/IP)|
|EtherNet/IP|According to ODVA “CIP Edition 3.2”<br>and “EtherNet/IP Adaption of CIP<br>Edition 1.3”.<br>Minimum RPI of 50 ms|
|PROFINET|PROFINET|
|Modbus TCP|According to the Modbus orga-<br>nisation, version 1.0b (approx. 20<br>messages per second).|
|Binary server (TCP/IP)|Simple TCP/IP protocol to send<br>status from/to the Pluto system.|



|Web server|For simple sharing of IP<br>addresses.|
|---|---|
|Terminal server (TCP/IP)|Simple server with the same com-<br>mands as via the serial programming<br>port in the unit.|
|IP address|Static sharing via web server or via<br>programming port.|
|Gateway configuration|Takes place via EtherNet/IP, PROFI-<br>NET, Modbus TCP or<br>via the binary TCP/IP server.|
|Connections|Top, 3-pole terminal for Pluto safety<br>bus (included)<br>Front, Ethernet connection via RJ-45<br>(screened cable cat. 5e FTP)<br>Bottom, 2-pole terminal for 24 VDC<br>(included)|
|Status indications|Pluto safety bus status indication via<br>LED (Pluto safety bus)<br>Ethernet module status indication via<br>LED (Mod Status)<br>Ethernet network status indication<br>via LED (Net Status)|
|Operating voltage|24 VDC, -15 % till +20 %|
|Current at 24 V|< 150 mA (recommended fuse ≤6 A)|
|Dimensions (w x h x d)|35 x 101 x 120 mm|
|Installation|35 mm DIN rail|
|Operating temperature (ambient)|-10°C to + 55ºC|
|Temperature, transport and storage|-25°C to + 55ºC|
|Humidity|EN 60 204-1 50 % at 40ºC (ambient<br>90 % at 20ºC)|
|Enclosure classification|Enclosure IP20 - IEC 60 529<br>Terminals IP20 - IEC 60 529|



Gateway block schematic diagram - Pluto Ethernet 

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PLC<br>Ethernet, non safety<br>GATE-E1PLUTOBUS 119 mm<br>fo°} K 1 (\ <=><br>9gfo U) PRStatusModStatusNet 4 —>eae<>SES<br>[)<br>Gateway<br>101 mm<br>Pluto CAN bus, safety<br>OO] Lex 1)h<br>I Z SSal<br>OSB z  |SSO OSS |S89 O89 : |SSS. se ——_.=<br>C H I1 I3 |SSSS] I6 IQ10 Q2 Soo C H I1 occs) I3 I6 IQ10 Q2 Essg C H I1 I3 essg) I6 IQ10 Q2 Ldi<br>I0 I2 I4 I5 I7 IQ11 Q3 C L I0 I2 I4 I5 I7 IQ11 Q3 C L I0 I2 I4 I5 I7 IQ11 Q3 es<br>IQ14 IQ16 Q0 Q1 IQ12 IQ14 IQ16 Q0 Q1 IQ12 IQ14 IQ16 Q0 Q1<br>IQ13 IQ15 IQ17 ID 0V +24V IQ13 IQ15 IQ17 ID 0V +24V IQ13 IQ15 IQ17 ID 0V +24V<br>DDBPAIDDPDO) DDWDIDDDO) IDDDDIPBD)<br>QO | GOO GOO QO |GOOGOO GO@ |WDWD<br>35 mm<br>PROFINET EtherNet/IP Modbus TCP<br>**----- End of picture text -----**<br>


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C H I1 I3 I6 IQ10 Q2 C H I1 I3 I6 IQ10 Q2 C H I1 I3 I6 IQ10 Q2<br>C L I0 I2 I4 I5 I7 IQ11 Q3 C L I0 I2 I4 I5 I7 IQ11 Q3 C L I0 I2 I4 I5 I7 IQ11 Q3<br>IQ12 IQ14 IQ16 Q0 Q1 IQ12 IQ14 IQ16 Q0 Q1 IQ12 IQ14 IQ16 Q0 Q1<br>IQ13 IQ15 IQ17 ID 0V +24V IQ13 IQ15 IQ17 ID 0V +24V IQ13 IQ15 IQ17 ID 0V +24V<br>DDBPAIDDPDO) DDWDIDDDO) IDDDDIPBD)<br>QO | GOO GOO QO |GOOGOO GO@ |WDWD<br>Pluto Pluto Pluto<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   2/30 

2 

## Pluto Safe Encoder 

## Use: 

- Safe position and speed determination of machine movements. 

## Features: 

- High resolution 

- Selectable resolution 

- Connected directly to the Pluto safety bus 

- Ready-made function blocks 

Rotational absolute value sensor for safe positioning Together with a Pluto safety PLC, this rotational absolute encoder can be used for safe position determination. This is particularly useful with equipment such as gantry robots, industrial robots, etc. Also in eccentric shaft presses, existing cam mechanisms can be replaced by absolute value position sensors for safe positioning. The sensors are available in single and multi-turn versions. 

Up to 16 absolute encoders can be connected to a Pluto CAN databus. A Pluto on the databus reads the sensor values, which are evaluated. With a special function block in the PLC code, it is possible to design two-channel solutions with the sensors. The user can obtain safe values for position and speed from these values. This enables supervision of stationary and overspeed conditions. 

The absolute value sensors are standard sensors with modified software to meet the safety requirements. 

Example of an application where 2 sensors provide safe position determination in a gantry robot. 

2/31   2TLC172001C0202 | ABB Safety Handbook 

2 

Technical data – Safe Encoder RSA 597/RHA 597 

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Article number 2TLA020070R3600<br> 2TLA020070R3300<br>2TLA020070R3400<br>2TLA020070R5900<br>Ambient temperature -40°C .. +70°C<br>Temperature, transport and<br>storage -30°C .. +70°C<br>Ingress protection class IP-67 in accordance with IEC 60529<br>At shaft inlet IP-66 in accordance with IEC 60529<br>Vibration (55 to 2000 Hz) < 300 m/s [2]  in accordance with IEC 60068-2-6<br>Shock (6ms) < 2000 m/s [2]  in accordance with IEC 60068-2-27<br>Material, enclosure Aluminium<br>Surface treatment Painted and chromed or anodised<br>Weight Approx. 300 g<br>Accuracy and resolution<br>Resolution 13 bits, 8192 positions per rotation<br>Accuracy ± ½ LSB (Least Significant Bit)<br>Operating voltage 9-36 VDC<br>Polarity-protected Yes<br>Short-circuit protected Yes<br>Databus speed 5 kbit/s - 1 Mbit/s, preset at 500kbit/s<br>Address input Active low<br>Code type Binary<br>Programmable functions Resolution, 0 position<br>Direction, Databus speed<br>Current consumption 50 mA at 24 VDC<br>Max current consumption 100 mA<br>**----- End of picture text -----**<br>


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Ordering details<br>Shaft Conncection Type Order code<br>Ø 10 mm with face 12-pole connector RSA 597 2TLA020070R3600<br>Ø 6 mm with face 1.5 m cable RSA 579 2TLA020070R3300*<br>RSA 597<br>Hollow shaft Ø 12 mm 2 m cable RHA 597 2TLA020070R3400*<br>Hollow shaft Ø 12 mm 10 m cable RHA 597 2TLA020070R5900*<br>**----- End of picture text -----**<br>


*Ordering product 

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ABB Safety Handbook | 2TLC172001C0202   2/32 

2 

Technical data – Safe Encoder RSA 698/RHA 698 

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Article number 2TLA020070R3700<br>2TLA020070R7800<br>2TLA020070R7900<br>Ambient temperature -40°C .. +70°C<br>Temperature, transport and storage -30°C .. +70°C<br>Ingress protection class IP67 in accordance with IEC 60529<br>At shaft inlet IP66 in accordance with IEC 60529<br>Vibration (55 to 2000 Hz) < 100 m/s [2]  in accordance with IEC 60068-2-6<br>Shock (6ms) < 2000 m/s [2]  in accordance with IEC 60068-2-27<br>Material, enclosure Aluminium<br>Surface treatment Anodised<br>Weight Approx. 400g<br>Accuracy and resolution<br>Resolution, total 25 bit<br>13 bits, 8192 positions per rotation<br>12 bits, 4096 rotations<br>Accuracy ± 1 LSB (Least Significant Bit)<br>Operating voltage 9-36 VDC<br>Polarity-protected Yes<br>Short-circuit protected Yes<br>Databus speed 10 kbit/s - 1 Mbit/s<br>Code type Binary<br>Programmable functions Resolution, 0 position<br>Current consumption 50 mA at 24 VDC<br>Max current consumption 100 mA<br>**----- End of picture text -----**<br>


## Ordering details 

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Shaft Conncection Type Order code<br>Ø 10 mm round M12 5-pole connector RSA 698 2TLA020070R3700<br>Ø 6 mm round M12 5-pole connector RSA 698 2TLA020071R7800*<br>Hollow shaft Ø 12 mm M12 5-pole connector RHA 698 2TLA020071R7900*<br>**----- End of picture text -----**<br>


*Ordering product 

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2/33   2TLC172001C0202 | ABB Safety Handbook 

2 

## Safe Encoder 

## Descriptions of inputs and outputs 

Function block for two single-turn encoders that generates safe position and speed values. 

## Function 

The block reads and evaluates two absolute encoders. The position value is sent to the 'Position' output. The 'Speed' output is the average value for the speed, at the rate of pulses/10 ms. If an error occurs, the 'OK' output is set to zero. In certain applications the values of 'Position' and 'Speed' are used in conjunction with the 'OK' output. 

- AdrEncoderA: Encoder A node address 

- AdrEncoderB: Encoder B node address 

- MaxDiff: Max allowed deviation between the encoders (max 2% of Range) 

- Range: Number of increments per revolution 

- OK: Set when encoders are working OK and 

the position values are within the margin set by 'MaxDiff' 

- Position: Position value 

- Speed: Speed value as increments/10ms 

- A: Encoder A position. Must not be used in PLC program! 

- B: Encoder B position. Must not be used in PLC program! 

NOTE! Position values from single encoders are only available for adjustment purposes and must NOT be used for safety. 

NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and the OK output will be reset. 

## Safe Encoder Multiturn 

## Descriptions of inputs and outputs 

Function block for two multi-turn encoders that generates safe position and speed values. 

## Function 

The block reads and evaluates two absolute encoders. The average value for the two sensors is calculated and sent to the 'Position' output. The 'Speed' output is the average value for the speed, at the rate of pulses/10 ms. The block monitors that the encoder position values do not differ by more than the input value set by 'MaxDiff'. If an error occurs, the 'OK' output is set to zero. In certain applications the values of 'Position' and 'Speed' are used in conjunction with the 'OK' output. 

- AdrEncoderA: Encoder A node address 

- AdrEncoderB: Encoder B node address 

- MaxDiff: Max allowed deviation between the encoders (max 2% of IncrPerRev) 

- IncrPerRev: Number of increments per revolution 

- OK: Set when encoders are working OK and 

- the position values are within the margin set by 'MaxDiff' 

- Position: Position value 

- Speed: Speed value as increments/10ms 

- A: Encoder A position. Must not be used in PLC program! 

- B: Encoder B position. Must not be used in PLC program! 

NOTE! Position values from single encoders are only available for adjustment purposes and must NOT be used for safety. 

NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and the OK output will be reset. 

## Encoder Cam 

## Function block for electronic cam gear. 

## Descriptions of inputs and outputs 

## Function 

Output Q is activated if the value of the input register 'PosReg' is within the limits for ’MinPos’ and ’MaxPos’. NOTE! It is possible to specify a value that defines the sensor's zero position. Position <0 is not permitted. Example: If MinPos = 3000 and MaxPos = 200, Q is activated when the position is greater than 2999 or less than 201. 

- PosReg: Input for the position value 

- MinPos: Minimum limit value 

- MaxPos: Maximum limit value 

ABB Safety Handbook | 2TLC172001C0202   2/34 

## Pluto identifier IDFIX 

## Use: 

- Gives each Pluto unit an identity on the bus 

- For storage of the PLC program 

- For storage of the AS-i safety codes 

2 | 

IDFIX is an identifier circuit which gives each Pluto an address on the bus. It contains an identification code which can be read by the system. The identification code is declared in the PLC program so that the correct part of the PLC program is executed by each specific Pluto. The use of IDFIX is mandatory in a multi-Pluto project, but voluntary if a unit works alone. If one Pluto in a multi-Pluto project needs to be replaced it is possible to let the new Pluto self load the PLC program from another Pluto on the bus. The IDFIX will ensure that the new Pluto has the correct address on the bus. 

## Five different versions of IDFIX 

- R is preprogrammed. 

- RW is programmable. 

- DATA is programmable and can also store the AS-i safety codes. 

- PROG 2k5 is for single-Pluto projects only, and has a 2.3 kbyte memory for storage of the PLC program. It can also store the AS-i safety codes in the same way as IDFIXDATA. 

## IDFIX–DATA 

IDFIX-DATA is for Pluto AS-i and B42 AS-i, and contains a memory for storage of the AS-i safety codes. 

## IDFIX–PROG 

IDFIX-PROG contains a memory for storage of the PLC program for single-Pluto projects. When a program is downloaded to Pluto the IDFIX-PROG will automatically be updated. If the Pluto unit needs to be replaced, the new Pluto can self load the PLC program from IDFIX-PROG by pressing the K button (in the same way as a Pluto can self load the program over the CAN bus). Only one Pluto is allowed in the project and the IDFIX code is always EEEEEEEEEEE0. IDFIX-PROG can also store the AS-i safety codes in the same way as IDFIX-DATA. 

NOTE! “Single-Pluto project” means that the PLC program only contains one Pluto. It is still possible to connect several “Single-Pluto projects”, each with its own program and IDFIXPROG, together via the Pluto bus. 

- PROG 10k works in the same way as PROG 2k5, but it has a larger memory (10 kbyte). 

IDFIX is connected between the input terminals ID and 0V. 

2/35   2TLC172001C0202 | ABB Safety Handbook 

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ABB Safety Handbook | 2TLC172001C0202   2/36 

2 

ABB Safety Handbook | 2TLC172001C0202   2/36 

3 

3/1    2TLC172001C0202 | ABB Safety Handbook 

AS-i Safety Two-wire bus system 

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Why should I use the bus system at component level?  3/3<br>Pluto AS-i Safety – Safety is now simple!  3/5<br>A Pluto AS-i can be used in three ways  3/7<br>Sensors with built in AS-i safety nodes  3/8<br>Safety node Urax<br>Urax-A1/A1R  3/9 3<br>Urax-B1R  3/11<br>Urax-C1/C1R  3/13<br>Urax-D1R  3/15<br>Urax-E1  3/17<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   3/2 

## Why should I use the bus system at component level? 

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## – to save installation time 

Components designed for the AS-i bus system can easily connect to the network wherever this is required. The required function is then selected in the control system. 

## – as it provides a flexible system 

You can use the AS-i cable to move, replace or add new safety products anywhere as needed. Additional monitors such as Pluto AS-i can also be connected in the same way. 

## – provides simplicity in the construction of systems 

The AS-i system provides benefits both when the system is planned and installed. A single network can, for example, be divided into monitoring and control of different work zones. The zones can be dependent on each other or not, even though they are controlled and are connected to the same general process. 

## – in order to easily expand the system 

The system‘s construction allows, where necessary, the easy extension or expansion of the network. Cable is added which thereby extends the production line without any additional controllers being installed. 

3/3    2TLC172001C0202 | ABB Safety Handbook 

3 

How does the bus system AS-Interface work? 

The AS-i system is distinguished by its special yellow profile cable. The cable connects all sensors, transducers and actuators on the network to a master system. The component parts of a system can include both non-safe and safe products. This means that both operational and safety related products can be mixed in a network. The bus system drives a MasterSlave (node) configuration where each I/O module corresponds to a common master. 

Communication takes place through the yellow cable which also provides the nodes with supply voltage. The installation of the cable is usually done along a production line or centrally around the AS-i system's I/O products. After commissioning the system can always be expanded by adding branches or extensions to the cable. In a similar way, more products can be added, moved or replaced. The changes are easily made in the software to the controller. With the AS-i concept, decentralised systems can be designed with all products, non-safe and safe monitored by a device. This advantage means that the system can be handled as zones where one zone can be down, another can be in operation and a third manually operated. Without degrading operation and safety or influencing each other's zones. 

Why is the AS-i Safety so good from a safety perspective? The simple connection to a cable also applies to safety components. The risk of incorrect wiring is thereby minimised. Each safety node, i.e. safety product, has its own address on the AS-i bus along with a unique safety code. 

The additional requirement for an AS-i system to cope with safety products is that there must be extra safe monitoring. The control ("Master") does not need to be safe, but is complemented with a safety Monitor (however, safety PLC Pluto AS-i can act as both Master and/or Monitor). 

The advantage of safety within AS-i is that it is easy to introduce changes without significant costs compared to traditional safety systems that require new cable running from the electrical cabinet for each new protection. Moreover, experience shows that most safety systems need to be retrofitted to adapt the protection to suit the changes to production. 

The AS-interface makes it easy to connect and remove products to and from the AS-i bus. 

## Voltage and communications 

The AS-i network is maintained by a special AS-i power supply unit that generates a regulated DC output voltage between 29.5 and 31.6 V. This supplies voltage to the network nodes at the same time as communications are transmitted in a superimposed manner. 

## Nodes 

Safety nodes (maximum 31) and A / B-nodes (maximum 62) are connected to the AS-i for both inputs and outputs. 

## Two-wire cable 

The AS-i cable is a two-wire cable (2x1.5mm[2] ) that is not shielded. Connection is made using piercing technology, whe- 

re the cable housing is self-restoring if a connection is moved. The cable retains enclosure protection class IP67 in this way. 

## Adaptation devices 

For the AS-i cable it is possible to connect the adaptation devices that act as a link between a component and the AS-i system. These adaptation devices are available as both safety nodes and nodes for non-safe products. 

## Sensors with integrated safety nodes 

Some AS-i adapted components have nodes directly built into the product, for example, there is one safety node in the customised Smile Emergency Stop. 

ABB Safety Handbook | 2TLC172001C0202   3/4 

3 = 

## Pluto AS-i – Safety is now simple! 

Pluto AS-i is a version of Pluto with AS-i bus connection. It can either be a master on the AS-i bus or work together with another AS-i master as a monitor. It has digital and analogue inputs and safe outputs. Pluto AS-i can also operate as a safe I/O module for the AS-i bus. 

## Safety level 

Pluto, Urax and products with integrated safety nodes achieve safety level PL e/Cat. 4 in compliance with EN ISO 13849-1. 

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Gateway<br>_ Profibus DP<br>DeviceNet<br>CANopen<br>Ethernet<br>**----- End of picture text -----**<br>


## The AS-i system 

The AS-i cable can be connected to the safety products separately or through the adaptation device Urax. Some components have an integrated AS-i node and are connected via an M12 connection directly to the yellow AS-i cable. Traditional products without an integrated AS-i node need to be connected via the safety node Urax. 

Adaptation device Urax with integrated safety node Urax is an adaptation device for safety components that cannot be directly connected to the AS-i bus. You can connect safety components, local reset, and non-safe controls, such as process locks to Urax. Urax is available in several versions, adapted to suit specific safety products. 

## Possible connections for a complete system: 

In both cases, the highest level of safety is maintained. The AS-i cable is powered by 30 VDC power supply and connected to a special AS-i power supply unit. Some components have power requirements that are higher than the AS-i cable is able to supply. Therefore, there is also a black cable (AUX 24 VDC) with secondary supply voltage that is able to supply more current. 

- all our sensors for AS-i via Urax 

- all Pluto PLCs, gateways and absolute encoders through Pluto’s safety bus to the Pluto AS-i 

- operator panel via the programming port on Pluto 

- expansion relay for multiple outputs 

3/5    2TLC172001C0202 | ABB Safety Handbook 

3 

## Simple connections to the AS-i cable 

Adaptation devices are clamped directly to the AS-i cable. Transition from the AS-i cable to M12 units is made via a T connector on the AS-i cable. Cable branches or extensions of the AS-i cable are made using a splitter box. 

## AS-interface - an intelligent cable running system 

The field bus system AS-interface came to light in the 90s. The system was the result of a collaboration between several component manufacturers for machine control. The idea was a bus system at a component level where the goal was simplicity and flexibility. Since the system was launched, many new and innovative ideas have been added. 

## Sensors with integrated AS-i safety nodes 

Some of our products can be ordered with integrated AS-i node. 

These are connected to the yellow cable with a M12 contact directly to the yellow AS-i cable via a screw terminal which is clamped to the cable. More information can be found under each product. 

## AS-International Association 

In 1991, the AS-International Association for organisational cohesion and marketing was founded. The AS-i association works in both an advisory and auditing capacity to ensure the AS-i standard is maintained. 

The goal of the AS-i Association is that the AS-interface is to become a world standard for easy communication for components within the automation industry. 

The distinguishing feature of the AS-interface is that data communication is mixed with the power supply. This is done in a simple two-wire cable. In 2001 safety was integrated in the AS-interface via the work group Safety at Work, which also includes ABB Jokab Safety. 

ABB Safety Handbook | 2TLC172001C0202   3/6 

## Pluto AS-i A Pluto AS-i can be used in three ways - as Safety Master, Safety Monitor or as Safety I/O 

## 1. Pluto as Safety Master* 

The master distributes and controls communication on the AS-i bus and acts simultaneously as Safety Monitor. 

## 3. Pluto as Safety I/O* 

Multiple safe inputs and/or outputs are controlled and communicate with a safe master or monitor across the AS-i bus. 

## 2. Pluto as Safety Monitor* 

The monitor listens to what is happening on the AS-i bus and 3 _ controls the safe outputs. 

*Whether Pluto is used as a Master, Monitor or I/O it can simultaneously control and monitor the safety of a machine. 

## Gateway 

Gateways allow you to communicate easily with other bus systems. 

## Bus connection 

Pluto AS-i can be connected with other Pluto units both via the AS-i bus and through the Pluto safety bus. 

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AS-i  Master AS-i  Monitor Pluto without AS-i AS-i  Monitor<br>**----- End of picture text -----**<br>


AS-i  Monitor 

How large can you build the system? 

From a technical aspect there are no constraints on the size of the system you can build. A Pluto PLC can, in addition to processing a complete AS-i bus, communicate with another Pluto either through a Pluto safety bus or through the AS-i bus. 

Through Pluto's safety bus, each Pluto can be a party to the I/Os of others and a total of 32 Plutos can be linked in this way. If two Plutos are connected to each other via the AS-i bus, each Pluto can be connected to 31 other Plutos. 

Using Gateways the system can be expanded further to other bus systems for information exchange. 

3/7    2TLC172001C0202 | ABB Safety Handbook 

3 

## Sensors with built-in AS-i safety nodes 

## Eden,  a non-contact safety sensor with built in AS-i node 

Eden is a non-contact safety sensor for use on interlocked gates, hatches etc. Eden consists of two complementary parts called Adam and Eva. The sensor is only activated if the gate or hatch is closed, when Adam and Eva are within sensing distance. Eden is constantly communicating between the two parts and any failure will directly lead to a stop signal 

## Safeball, a control device with a built-in AS-i node 

Our globally-unique control device with ergonomic design fits all hands and offers many grip options. Safeball has double safety for each hand, i.e. two buttons on each ball need to pressed. It can be used for either one or two hand operation. 

## Smile, a small and robust emergency stop with built in AS-i node 

Smile has a width of 40 mm and its centered mounting holes make installation easy especially in aluminium profiles that are often used for machine construction and machine protection. Smile also has LED indication. 

## Three-position device with built in AS-i node 

The three-position device JSHD4 with sensors that ensure that it is a human hand thats grips the device (fraud-proof) is available with a built in AS-i node. The device is usted for settings, fault tracking and test running when no other protection is possible or feasible. 

The Urax safety node has safety inputs for sensors and reset buttons, and outputs such as process locks. 

Urax safety node is available in several versions, and is designed for a variety of safety components. Urax has the capability to connect multiple sensors in series to the highest level of safety PL e in compliance with EN ISO 13849-1. 

|Model Urax|A1|A1R|B1R|C1|C1R|D1R|E1|
|---|---|---|---|---|---|---|---|
|Dynamic sensor (Eden, Tina)|3|3|10|||||
|Two-channel sensors||||||||
|Sensors with OSSD Signals||||||||
|Two-hand station||||||||
|Local reset function||||||||
|External power source||||||||
|Non-safe outputs|1|1|3|||3|3|



ABB Safety Handbook | 2TLC172001C0202   3/8 

3 

Safety node Approvals: Urax-A1/A1R **TÜV Rheinland** Application: – Adapts dynamic sensors to the AS-i bus Features: – Enables dynamic sensors on z ~~=~~ the AS-i bus – Multiple sensors in series with maintained safety level – Possibility of local reset – Outputs of non-safe control, e.g. process locks Adaptation device for dynamic sensors for AS-i. Urax-A1/A1R is a safety node for the AS-i bus, where it is possible to connect up to three dynamic sensors, such as Eden, in series in compliance with PL e EN ISO 13849-1. 

Switches adapted to dynamic sensors such as Smile Tina can also be connected to the safety circuit. 

Urax-A1/A1R also has an output for non-safe control, where it is possible to control non-safety critical equipment such as process locks. Urax-A1R has an additional feature that provides local reset button (R) with LED indicator. 

The dynamic safety sensors are controlled by Urax over one hundred times per second which gives a high level of safety. 

Urax-A1/A1R has LED indication for the dynamic loop and can be addressed on the bus via the ADDR contact. 

Reset 

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Urax-A1 Urax-A1R<br>**----- End of picture text -----**<br>


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3/9    2TLC172001C0202 | ABB Safety Handbook 

## Connections for Urax-A1 and A1R 

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Connector 1<br>I 1 +24V Dyn. sensor<br>1 Q1 23 Dyn outp0V<br>loeme) Tt 45 InpOut1 (AS-i)<br>-A1<br>AS-i [oxe) FAULT [oxe) COn 4 1<br>ADDR 5<br>O s URAX-A1Safety 3               2<br>= A<br>Connector 1<br>I Reset 1 +24V Dyn. sensor<br>1 Q1 R.Ind 2 23 Dyn outp0V 4 1 5<br>iy | S 45 InpOut1 (AS-i) e ) 3               2 @<br>Connector 2 Reset<br>1 Dyn outp Auto reset<br>AS-i fore) FAULT oof COn | a 23 Ind. outp.0V Reset ind. 7<br>ADDR iP URAX-A1R ool Safety | ma 45 E Inp  =e ] 4|<br>**----- End of picture text -----**<br>


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**----- Start of picture text -----**<br>
-A1R<br>**----- End of picture text -----**<br>


## The concept of dynamic signal 

The concept is a safety circuit that is based on a singlechannel dynamic signal. The dynamic signal along with the adapted sensor makes it possible to build large systems with sensors in series while maintaining the highest level of safety. The safety principle is based on each sensor inverting the signal, making it possible to detect faults such as short circuits and defective sensors. 

## Odd or even number of sensors on Urax 

The dynamic signal is generated in Urax and goes out to the sensors and then back again. The fact that the number of sensors may vary and that each sensor inverts the signal make it necessary for Urax-A1/A1R to be configured so that it takes into account whether it is an odd or even number of sensors that are connected to the safety loop. This is done via the AS-i node parameter settings. 

## Non-safe outputs 

Urax-A1/A1R is fitted with a non-safe output. This can be used for diverse control or indicators and is controlled directly from the AS-i master. 

The output is located on the same contact as the safety sensor, i.e. on contact 1 and controlled on pin 5. For example, you can connect a Dalton or Knox to this contact. 

Technical data – Urax-A1/A1R 

|Article number<br>Urax-A1<br>Urax-A1R|2TLA020072R0000<br>2TLA020072R0100|
|---|---|
|Colour|Yellow and black|
|Weight|155 g|
|AS-i data<br>AS-i profile Urax-A1/A1R<br>Addressing<br>Slave address upon delivery<br>:<br>i|S-7.B.E<br>Jack plug<br>0<br>:<br>i|
|Voltage supply<br>Voltage<br>Insulation<br>Total current consumption<br>Current limit for the outputs in total<br>|<br>:<br>;<br>:|AS-i yellow cable, 30 VDC.<br>Tolerance 26.5 – 31.6 VDC.<br>0 V is common with AS-i and must<br>not be connected to the protective<br>earth. (The AS-i voltage is floating.)<br><260 mA (Own consumption, sensor<br>and outputs)<br>180 mA (Sensors, outputs and reset<br>indicator)<br>|<br>:<br>;<br>:|
|Output (non-safe)<br>Output voltage<br>Current|indicator)<br>24-28 VDC at nominal AS-i voltage,<br>30V.<br>Depending on load.<br>See total current consumption|
|Reaction time<br>Reaction time (off)*|12 ms (excluding sensors and other<br>peripheral components)|
|Reaction time including Eden<br>sensor (Normal)<br>Reaction time including Eden<br>sensor (Worst case)|<20 ms<br><34 ms|
|Sensor info<br>Number of Eden sensors (max)<br>Cable to sensor, total length|3<br><30 m|
|Enclosure<br>Enclosure protection class<br>Ambient temperature<br>Enclosure dimensions|IP67<br>–25…+65°C<br>96x60x25 (HxWxD)|
|Safety/Harmonised standards<br>IEC/EN 61508-1..7<br>EN 62061<br>EN ISO 13849-1<br>EN 954-1<br>Certification|SIL3, PFDavr: 1.5x10-4,<br>PFH: 1.7x10-9, Share of SIL3: 15 %<br>SIL3<br>PL e/Cat. 4<br>MTTFd: high<br>Cat. 4|



*NOTE: The above reaction time refers only to the Urax device. In calculating the total reaction time, all the component parts in the safety chain must be taken into account. 

## Reset 

Urax-A1R has an input for local reset on contact 2 that can be configured using parameter settings for either automatic or manual reset. 

## Auto reset 

If auto reset has been selected, pins 1-4 on contact 2 must be bridged. 

## Manual reset 

If manual reset has been selected, the reset input must be switched on and off within 2 seconds in order for Urax to be enabled (generate safety code). 

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30<br>One)Y~|0 0| ZN ID1F<br>fox \O 0|<br>a | (| = ASI<br>loxe) [oxe)<br>ADDR AUX<br>Os ol URAX-  | Safety (|<br>60 8 12 36<br>(2) J |<br>25<br>96<br>73<br>4.5<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   3/10 

3 . 

## Safety node Urax-B1R 

## Approvals: 

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TÜV Rheinland<br>**----- End of picture text -----**<br>


## Application: 

- Adapts dynamic sensors with higher current requirements to the AS-i bus 

## Features: 

- Enables dynamic sensors on the AS-i bus 

- Up to 10 sensors connected in series while maintaining the highest level of safety 

- Possibility of local reset 

- Outputs of non-safe control, e.g. process locks 

## Adaptation device for dynamic sensors for AS-i. 

Urax-B1R is a safety node for the AS-i bus, where it is possible to connect up to ten dynamic sensors, such as Eden, in series in compliance with PL e EN ISO 13849-1. 

Switches designed for dynamic safety circuit, such as Smile Tina, can also be connected. 

Urax-B1R also has three outputs for non-safe control. Through these it is possible to control non-safety critical equipment such as the process lock Magne. 

Urax-B1R will be supplied with an auxiliary power supply (AUX), which means that more power-consuming equipment can be connected to the node. 

An additional feature is that it is possible to connect a local reset button (R) with LED indicator. 

The dynamic safety sensors are controlled by Urax over one hundred times per second which gives a high level of safety. 

Urax-B1R has LED indication for the dynamic loop and can be addressed on the bus via the ADDR contact. 

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Reset<br>Urax-B1R<br>**----- End of picture text -----**<br>


**0V 24V** 

3/11    2TLC172001C0202 | ABB Safety Handbook 

3 

## Connections for Urax-B1R 

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Connector 1<br>1 +24V Dyn. sensor<br>I Reset 2 Dyn outp<br>1 Q1 R.Ind 2 3 0V<br>4 Inp<br>a lo_ol & sy Connector 25 Out1 (AS-i) Reset<br>3 Q2 Q3 4 12 Dyn outpInd. outp. Auto reset<br>3 0V Reset ind.<br>4 Inp<br>AS-i 00 FAULT AUX oof COn | a 5 -7<br>ADDR 4 ey URAX-B1R ol Safety | Connector 3 s 3124 +24V0VOut2 (AS-i)<br>O= 7 | Sb. 5<br>Connector 4<br>4 1 12 +24V<br>5 34 0VOut3 (AS-i)<br>3               2 5<br>**----- End of picture text -----**<br>


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-B1R<br>**----- End of picture text -----**<br>


## The concept of dynamic signal 

The concept is a safety circuit that is based on a singlechannel dynamic signal. The dynamic signal along with the adapted sensor makes it possible to build large systems with sensors in series while maintaining the highest level of safety. The safety principle is based on each sensor inverting the signal, making it possible to detect faults such as short circuits and defective sensors. 

## Odd or even number of sensors on Urax 

The dynamic signal is generated in Urax and goes out to the sensors and then back again. The fact that the number of sensors may vary and that each sensor inverts the signal make it necessary for Urax-B1R to be configured so that it takes into account whether it is an odd or even number of sensors that are connected to the safety loop. This is done via the AS-i node parameter settings. 

## Non-safe outputs 

Urax-B1R is fitted with three non-safe outputs. These can be used for diverse controls or indicators and are controlled directly from the AS-i master. 

Output 1 is located on the same contact as the safety sensor, i.e. contact 1 and controlled on pin 5. For example, you can then connect a Dalton or Knox to this contact. Outputs 2 and 3 have non-safe control on pin 4 of contact 3 and 4 respectively. 

## Reset 

Urax-B1R has an input for local reset on contact 2 that, with parameter settings, can be configured for either automatic or manual reset. 

## Technical data – Urax-B1R 

|Technical data – Urax-B1R||
|---|---|
|Article number<br>Urax-B1R|2TLA020072R0200|
|Colour|Yellow and black|
|Weight|155 g|
|AS-i data<br>AS-i profile Urax-B1R<br>Addressing<br>Slave address upon delivery<br>~~sovoeuntsnunesnansnianisnianisnuansniansniansniansnuansnisefeuonaniananenanienanienaninianinianseansnansnannensies~~|S-7.B.E<br>Jack plug<br>0<br>~~sovoeuntsnunesnansnianisnianisnuansniansniansniansnuansnisefeuonaniananenanienanienaninianinianseansnansnannensies~~|
|Voltage supply<br>Voltage AS-i (Yellow cable)<br>Voltage AUX (Black cable)<br>Insulation<br>Current limit (+24 V)<br>Total current consumption AS-i<br>~~sovoeuntsnunesnansnianisnianisnuansniansniansniansnuansnisefeuonaniananenanienanienaninianinianseansnansnannensies~~<br>:<br>:|30 VDC. Tolerance 26.5 – 31.6 VDC.<br>24 VDC (±15 %)<br>0V is common with –AUX which shall<br>be connected to protective earth at<br>power supply.<br>700 mA<br><30mA<br>~~sovoeuntsnunesnansnianisnianisnuansniansniansniansnuansnisefeuonaniananenanienanienaninianinianseansnansnannensies~~<br>:<br>:|
|Output (non-safe)<br>Output voltage<br>Current|24 VDC (AUX)<br>700|
|Reaction time<br>Reaction time (off)*<br>Reaction time including Eden<br>sensor (Normal)<br>Reaction time including Eden<br>sensor (Worst case)<br>Sensor info<br>Number of Eden sensors (max)<br>Cable to sensor, total length|12 ms (excluding sensors and other<br>peripheral components)<br><20 ms<br><34 ms<br>10<br><30 m|
|Enclosure<br>Enclosure protection class<br>Ambient temperature<br>Enclosure dimensions|IP67<br>–25…+65°C<br>96x60x25 (HxWxD)|
|Safety/Harmonised standards<br>IEC/EN 61508-1..7<br>EN 62061<br>EN ISO 13849-1<br>EN 954-1<br>Certification|SIL3, PFDavr: 1.5x10-4,<br>PFH: 1.7x10-9, Share of SIL3: 15 %<br>SIL3<br>PLe/Cat. 4<br>MTTFd: high<br>Cat. 4|



*NOTE: The above reaction time refers only to the Urax device. In calculating the total reaction time, all the component parts in the safety chain must be taken into account. 

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30<br>@l 1® YN)<br>= a<br>B= 10 _ O| ZA<br>Oe @ i<br>a (| = ASI<br>[oxe) fexe}<br>ADDR 4 ool | (| AUX<br>On URAX-Safety<br>60 8 12 36<br>25<br>96<br>73<br>4.5<br>**----- End of picture text -----**<br>


## Auto reset 

If auto reset has been selected, pins 1-4 on contact 2 must be bridged. 

## Manual reset 

If manual reset has been selected, the reset input must be switched on and off within 2 seconds in order for Urax to be enabled (generate safety code). 

ABB Safety Handbook | 2TLC172001C0202   3/12 

3 

## Safety node Urax-C1/C1R 

## Approvals: 

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TÜV Rheinland<br>**----- End of picture text -----**<br>


## Application: 

- Adapts switches/E-stop with two-channel structure to the AS-i bus 

- Oo 

## Features: 

- Suitable for both normally open (NO) and normally closed (NC) contacts 

- Possibility of local reset 

Adaptation device for sensors with two-channel structure on AS-i Urax-C1/C1R is a safety node for the AS-i bus that enable the connection of switches or emergency stops. Connections can be made so that Urax-C1/C1R together with the switch comply with PL e EN ISO 13849-1. 

Urax-C1/C1R is configurable depending on the switch you prefer to use. The safety node's two-channel structure works with both NO+NO and NO+NC contacts. 

Urax-C1R has an additional feature that allows the connection of a local reset button (R) with LED indicator. 

The safety switches' contacts are controlled by Urax each time they are actuated, for example when a door is opened and closed. 

Urax-C1/C1R has LED indicators for all channels and can be addressed on the bus via the ADDR contact. Urax-C1 Urax-C1R wens eS 

3/13    2TLC172001C0202 | ABB Safety Handbook 

## Connections for Urax-C1 and C1R 

Technical data – Urax-C1 and C1R 

|Article number<br>Urax-C1<br>Urax-C1R|2TLA020072R0300<br>2TLA020072R0400|
|---|---|
|Colour|Yellow and black|
|Weight|150 g|
|AS-i data<br>AS-i profile Urax-C1/C1R<br>Addressing<br>Slave address upon delivery|S-0.B.0<br>Jack plug<br>0|
|Voltage supply<br>Voltage<br>Total current consumption AS-i<br>~~8~~|AS-i yellow cable, 30 VDC (26.5 – 31.6)<br><150 mA<br>:<br>:<br>~~8~~|
|Reaction time<br>Reaction time (off)*<br>~~8~~<br>~~:~~<br>~~=~~|12 ms (excluding sensors and other<br>peripheral components)<br>:<br>~~8~~<br>~~:~~<br>~~|~~<br>~~=~~<br>:|
|Enclosure<br>Enclosure protection class<br>Ambient temperature<br>Enclosure dimensions<br>Safety/Harmonised standards|IP67<br>–25…+65°C<br>96x60x25 (HxWxD)<br>:|
|Safety/Harmonised standards<br>IEC/EN 61508-1..7<br>EN 62061<br>EN ISO 13849-1<br>EN 954-1<br>Certification|SIL3, PFDavr: 1.5x10-4,<br>PFH: 1.7x10-9, Share of SIL3: 15 %<br>SIL3<br>PLe/Cat. 4<br>MTTFd: high<br>Cat. 4<br>:<br>:<br>:<br>~~:~~|



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Connector 11 Dyn outp 1 AS-i data<br>V 1 / s [omxe) I1 XQ ~ 23 Input 1Dyn outp 2 AS-i profile Urax-C1/C1R S-0.B.0<br>4 Input 2 Alt 1 Addressing Jack plug<br>5 Slave address upon delivery 0<br>I2 Connector 3<br>3 12 Dyn outp 2Input 2 Alt 2 Voltage supply<br>AS-i oo FAULT oo COn -C1 wo 345 VoltageTotal current consumption AS-i : <150 mA<br>ADDR my 1oxe) | Reaction time :<br>8= 4 P 1URAX-C1 D Safety a Connector 1 : 1234 Dyn outputInput 2Input 1 Reaction time (off)* : peripheral components)<br>5 5 Enclosure<br>3               2 @ Change over contact mode (Drawing shows OFF position) |= Enclosure protection class IP67<br>Ambient temperature –25…+65°C<br>Enclosure dimensions 96x60x25 (HxWxD)<br>Connector 1<br>V 13 eEXx (omme)\O I2I1 ResetR.Ind 0 aN 2 Connector 2 = 1234512 Dyn outp 1Input 1Dyn outp 2Input 2Dyn outp 1Ind. outp. Reset Alt 1 Auto reset EN ISO 13849-1EN 62061Safety/Harmonised standardsIEC/EN 61508-1..7 :: PFH: 1.7x10SIL3PLe/Cat. 4SIL3, PFDavr: 1.5x10 [-9] [-4] ,<br>34 0VInp Reset ind. EN 954-1 MTTFd: high<br>AS-i FAULT COn 5 Certification Cat. 4<br>ADDR (eke)A ei [oxe) |q ai Connector 3 os_ 1 Dyn outp 2 _ _— : :<br>URAX-C1R 2 Input 2 Alt 2<br>Om Safety MylIIIITI2 3<br>u ( 0) J) o 4 *NOTE: The above reaction time refers only to the Urax device. In calculating the total<br>5<br>-C1R 3 reaction time, all the component parts in the safety chain must be taken into account.<br>4 1 Connector 11 Dyn output<br>3               2 e 5 TI 71 THIus= 2345 1 Input 2Input 1 S 30<br>Change over contact mode (Drawing shows OFF position)<br>**----- End of picture text -----**<br>


*NOTE: The above reaction time refers only to the Urax device. In calculating the total reaction time, all the component parts in the safety chain must be taken into account. 

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30<br>fel Je)=aVE aN | DIF|z<br>A \ |©.©|<br>P| 6 CLG (| = ASI<br>foxe) lore}<br>ADDR 4 ool | (| AUX<br>Om URAX-Safety<br>Ad<br>60 8 12 36<br>| | 25 |<br>96<br>73<br>4.5<br>**----- End of picture text -----**<br>


## Two-channel input 

Urax-C1 is designed for safety components with two-channel switches. The channels are supplied with individual dynamic signals which enables the detection of short circuits between channels. It is possible to either connect a two-channel component exclusively to contact 1, or to connect two separate single-channel components to contact 1 and contact 3. 

## Contact function, NO+NO/NO+NC 

Urax-C1/C1R can work in either of the two operating modes NO + NO, with two closing contacts, or NO+NC with one closing and one opening contact. This selection is made using parameter settings. 

## Reset 

## Filtration of contact bounce 

Urax-C1R has a function to filter contact bounce ("debounce") which is active irrespective of the parameter settings. After both channels (I1 and I2) have been enabled, it is accepted for 1 second that they turn off/on. In other words, the channel monitoring is disabled during the first second after being enabled. 

Urax-C1R has an input for local reset on contact 2 that can be configured using parameter settings for either automatic or manual reset. 

## Auto reset 

If auto reset has been selected, pins 1-4 on contact 2 must be bridged. 

## Concurrency requirements 

Urax-C1R also has the capability of monitoring concurrency requirements. Both channels must then change status within 2 seconds. This setting is made via the node's parametrisation. 

## Manual reset 

If manual reset has been selected, the reset input switch must be switched on and off within 2 seconds in order for Urax to be enabled (generate safety code). 

3 

ABB Safety Handbook | 2TLC172001C0202   3/14 

3 

## Safety node Urax-D1R 

## Approvals: 

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**----- Start of picture text -----**<br>
TÜV Rheinland<br>**----- End of picture text -----**<br>


## Application: 

- Adapts safety products with transistor outputs (OSSD) to the AS-i bus 

## Features: 

- Handles safety products with transistor outputs (OSSD) 

- Monitors test pulses 

- Possibility of local reset 

- Outputs of non-safe control 

Adaptation device for sensors with transistor outputs (OSSD) for the AS-i bus Urax-D1R is a two-channel safety input slave for the AS-i bus that enables the connection of different protection with OSSD outputs. Examples of components of this type are light curtains, light grids and scanners. Connections can be made so that the safety node together with the sensor comply with PL e EN ISO 13849-1. 

The safety node is also fitted with three non-safe outputs. 

Urax-D1R has an additional feature that allows the connection of a local reset button (R) with LED indicator. 

Urax-D1R has LED indicators for all OSSD outputs and can be addressed on the bus via the ADDR contact. 

**==> picture [34 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
Urax-D1R<br>**----- End of picture text -----**<br>


3/15    2TLC172001C0202 | ABB Safety Handbook 

3 

## Connections for Urax-D1R 

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**----- Start of picture text -----**<br>
Connector 1 Receiver<br>1 +24V<br>1 Q1I1 ResetR.Ind 2 23 Inp 20V OSSD2<br>4 Inp 1 OSSD1<br>5 Out1 (AS-i)<br>I2 Connector 2 Reset<br>3 4 1 Dyn outp 1 Auto reset<br>Wy Q2 Os Q3 Wee) —_ 2 Ind. outp. -<br>3 0V Reset ind.<br>4 Inp<br>ADDRAS-i 9 FAULT ° ig, AUX lole)OO COn |q -_ Connector 3 os_ 51 +24V al Transmitter -4<br>URAX-D1RSafety 32 0V<br>4 Out2 (AS-i)<br>4 1 Connector 4 os 51 +24V Lod<br>2<br>5 44 34 0VOut3 (AS-i) ---- 4<br>3               2 -D1R + 5 ----o<br>**----- End of picture text -----**<br>


## Monitoring of short circuits (test pulses) 

The safety device that connects to Urax-D1R must be capable of detecting both short circuits between the channels and short circuits to the supply voltage. These types of faults are not detected by Urax! The most common way for the safety device to detect this is by transmitting test pulses on the outputs (OSSD). 

## Detection of test pulses 

You can configure Urax-D1R to detect whether the test pulses are transmitted from the connected device or not (see Table, "Parameter settings and safety codes"). If Test Pulse Detection is selected, Urax will be disabled if these test pulses are missing. This feature is a safeguard against fraud. 

## Technical data – Urax-D1R 

|Technical data – Urax-D1R|Technical data – Urax-D1R|
|---|---|
|Article number<br>Urax-D1R|2TLA020072R0500|
|Colour|Yellow and black|
|Weight|150 g|
|AS-i data<br>AS-i profile Urax-C1/C1R<br>Addressing<br>Slave address upon delivery|S-0.B.0<br>Jack plug<br>0|
|Voltage supply<br>Voltage AS-i (Yellow cable)<br>Voltage AUX (Black cable)<br>Insulation<br>Current limit (+24 V)<br>Total current consumption AS-i<br>:<br>:<br>:<br>:|30 VDC. Tolerance 26.5 - 31.6 VDC.<br>24  VDC (±15%)<br>0V is common with –AUX which shall<br>be connected to protective earth at<br>power supply.<br>700 mA<br><30 mA<br>:<br>:<br>:<br>:|
|Output (non-safe)<br>Output voltage<br>Current<br>i|24 VDC (AUX)<br>700<br>i|
|Reaction time<br>Reaction time (off)*|12 ms (excluding sensors and other<br>peripheral components)|
|Enclosure<br>Enclosure protection class<br>Ambient temperature<br>Enclosure dimensions|IP67<br>–25…+65°C<br>96x60x25 (HxWxD)|
|Safety/Harmonised standards<br>IEC/EN 61508-1..7<br>EN 62061<br>EN ISO 13849-1<br>EN 954-1|SIL3, PFDavr: 1.5x10-4, PFH: 1.7x10-9,<br>Share of SIL3: 15 %<br>SIL3<br>PLe/Cat. 4<br>MTTFd: high|



*NOTE: The above reaction time refers only to the Urax device. In calculating the total reaction time, all the component parts in the safety chain must be taken into account. 

## Non-safe outputs 

Urax-B1R is fitted with 3 non-safe outputs. 

These can be used for diverse controls or indicators and are controlled directly from the AS-i master. 

Output 1 is located on the same contact as the safety sensor, i.e. contact 1 and controlled on pin 5. For example, you can then connect a Dalton or Knox to this contact. Outputs 2 and 3 have non-safe control on pin 4 of contact 3 and 4 respectively. 

**==> picture [163 x 107] intentionally omitted <==**

**----- Start of picture text -----**<br>
30<br>OfOmnlal<br>@'@|[oxe) [oxe} q f ASI<br>ADDR 4 ool | [| AUX<br>Os URAX-Safety<br>60 8 12 36<br>25<br>96<br>73<br>4.5<br>**----- End of picture text -----**<br>


## Reset 

Urax-D1R has an input for local reset on contact 2 that, with parameter settings, can be configured for either automatic or manual reset. (See table, parameter settings and safety codes.) 

## Auto reset 

If auto reset has been selected, pins 1-4 on contact 2 must be strapped. 

## Manual reset 

If manual reset has been selected, the reset input must be switched on and off within 2 seconds in order for Urax to be enabled (generate safety code). 

ABB Safety Handbook | 2TLC172001C0202   3/16 

## Safety node Urax-E1 

## Approvals: 

## **TÜV Rheinland** 

## Application: 

– Adapts two-hand devices to the AS-i bus 3 ~~a.~~ Features: – Handles two-hand devices with two channels – Simultaneity requirement Adaptation device for two-hand stations for the AS-i bus Urax-E1 is a dual channel safety input slave to the AS-i bus, which is designed to connect the two-hand station in compliance with EN 574 model IIIC. Connections can be made so that the safety node with two-hand station complies with PL e EN ISO 13849-1. 

Urax-E1 has LED indicators for all channels and can be addressed on the bus via the ADDR contact. 

- Urax-E1 

- Tee 

3/17    2TLC172001C0202 | ABB Safety Handbook 

## Connections for Urax-E1 

**==> picture [181 x 143] intentionally omitted <==**

**----- Start of picture text -----**<br>
Connector 1 Left hand<br>NO 1 Dyn outp 1<br>2 Inp channel 1, NC<br>1 NC > ol) o 3 ne<br>4 Inp channel 1, NO<br>Arn|0_0 NO us 5<br>3 NC Connector 3 a 1 Dyn outp 2 Right hand mT<br>2 Inp channel 2, NC<br>3<br>AS-i 00 FAULT. oof COn | 4 4 Inp channel 2, NO<br>ADDR 5<br>4 gs ol | 3<br>URAX-E1<br>Safety -E1<br>4 1<br>5<br>3               2<br>**----- End of picture text -----**<br>


## Inputs for two-hand stations 

Urax-E1 has two inputs for each hand, one for closing and one for opening contact. For safe activation (generating safety code), all four inputs are required to be enabled within 0.5 seconds. All inputs are monitored, and if Urax is disabled (stops generating safety code) this requires that all four inputs are disabled before a restart is possible. ("Open" condition for a opening (NC) contact is closed contact, and "Open" condition for a closing (NO) contact is open contact.) 

## Technical data – Urax-E1 

|Technical data – Urax-E1||
|---|---|
|Article number<br>Urax-E1|2TLA020072R0600|
|Colour|Yellow and black|
|Weight|150 g|
|AS-i data<br>AS-i profile Urax-C1/C1R<br>Addressing<br>Slave address upon delivery|S-0.B.0<br>Jack contact<br>0|
|Voltage supply<br>Voltage<br>Total current consumption AS-i<br>:|AS-i yellow cable, 30 V DC (26.5 – 31.6)<br><150 mA<br>:|
|Total current consumption AS-i<br>Output (non-safe)<br>Output voltage<br>Current<br>:|24V DC (AUX)<br>700<br>:|
|Reaction time<br>Reaction time (off)*|12 ms (excluding sensors and other<br>peripheral components)|
|Enclosure<br>Enclosure protection class<br>Ambient temperature<br>Enclosure dimensions|IP67<br>–25…+65°C<br>96x60x25 (HxWxD)|
|Safety/Harmonised standards<br>IEC/EN 61508-1..7<br>EN 62061<br>EN ISO 13849-1<br>EN 954-1<br>Certification|SIL3, PFDavr: 1.5x10-4, PFH: 1.7x10-9,<br>Share of SIL3: 15 %<br>SIL3<br>PLe/Cat. 4<br>MTTFd: high<br>Cat. 4|



*NOTE: The above reaction time refers only to the Urax device. In calculating the total reaction time, all the component parts in the safety chain must be taken into account. 

**==> picture [163 x 106] intentionally omitted <==**

**----- Start of picture text -----**<br>
30<br>fer i@\ | |p<br>@l<@| i<br>ASI<br>ADDR 4 oo| | (| AUX<br>URAX-Safety<br>On |<br>60 8 12 36<br>25<br>96<br>73<br>4.5<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   3/18 

4 

4/1    2TLC172001C0202 | ABB Safety Handbook 

4/3 

4 

## Pluto Manager 

Pluto Manager 

ABB Safety Handbook | 2TLC172001C0202   4/2 

## Programming tool Pluto Manager 

## Use: 

– Gates 

– Hatches 

## Features: 

- Free software 

- Downloaded from www.abb.com/jokabsafety 

- Ready to use function blocks for your safety components 

4 

- Contains TÜV-approved function blocks 

- Provides an overview of the current projects and your Plutos 

- Easy programming through ladder language 

## A programming tool for your safety functions 

Pluto Manager is a software tailored for the safety PLC Pluto. Programming is done in ladder and together with the function block creates the structure of your safety functions. The software comes with predefined function blocks approved by TÜV to facilitate the work on designing the safety functions. Pluto Manager offers the possibility to split the program into different program blocks in order to separate various program functions from each other, and it gives you a structured overview of Plutos, gateways and peripheral components in large and small projects. It gives you an overview and control of the sensors and actuators, and the reactions between them. Pluto Manager also contains manuals for the software and hardware that are connected and needs to be handled through the program. The interface gives the option to connect to one of the  Plutos in the net, and go online and view the status for Pluto’s two bus options, AS-i and Pluto bus. There are also diagnostic functions and the option to export data. 

Systematic working method through project management Step 1 - Configuration of I/O 

In every started project, each Pluto is defined individually. Its inputs and outputs are configured as desired and depending on what they connect to. Pluto’s IQ ports are also configured here as inputs or outputs, dynamic or static signals. 

## Step 2 - Naming of variables 

After configuration the systems variables are determined. Inputs (I), outputs (Q), remanent memories (M), global auxiliary memories for bus communication (GM) and registers (R) are given names that can be used in place of the actual variable designation in the PLC program. 

## Step 3 - Ladder programming 

The program is built using the named variables connected to inputs and outputs. The programming language has a full range of instructions, similar to standard PLCs on the market, with timers, arithmetic, sequence programming etc. 

The project is then downloaded to Pluto via a programming cable. This program is distributed simultaneously through bus communication to the other Plutos in the project. In this way, you need only access a single Pluto where each Pluto gets the right information specified in your project. 

Pluto Manager is included when purchasing the safety PLC Pluto. The software is Windows based and can be downloaded free from www.abb.com/jokabsafety. 

4/3    2TLC172001C0202 | ABB Safety Handbook 

4 

## List of standard and special function blocks for Pluto Manager 

The safety designer has complete freedom to program the safety functions or to use TÜV-approved pre-defined safety function blocks. 

## Standard library “func05”: 

- 6 different blocks for two-channel function. (With or without start input, test input, reset input, output for two-channel fault, monitoring of simultaneous operation.) 

- 3 different blocks for single-channel function. (With output for reset button indication, with or without start input, test input.) 

- 2 different blocks two-channel function with time limitation. 

- Block for division. 

- Block for monitoring of selector switch. 

- 2 blocks for validation of exported register value sent over bus. (For register or for double registers.) 

## Library “AS-i01”: 

- Blocks for Pluto AS-i and B42 AS-i. (Control of, and reading of AS-i slaves, AS-i locks etc.) 

Library “Ext01”: 

- Block for single-channel prereset. 

- Block for two-channel prereset. 

- 4 different blocks for muting (bypass). 

- Block for two-hand control. 

- 2 Counter blocks (up-count and down-count). 

- 4 different blocks for muting lamp. (Pluto A20 only.) 

- Block for off-delay function. 

- 2 Blocks for light curtains. 

- Block for multiplication. 

- Blocks for communication with external devices (gateways, HMI etc.) 

## Library “Analog01”: 

- Blocks for reading of analogue inputs. (Pluto D20 and D45 only.) 

Library “Counter01”: 

- Blocks for speed monitoring via counter inputs. (Pluto D45 only.) 

Library “Encoder01”: 

- Blocks for absolute encoders. 

Special function blocks: 

- Program library with blocks for eccentric shaft presses. 

## Example: Function block TC2RTI Two-channel function with test, reset inputs and reset indication. 

- In1 and In2 are safety inputs, to which the safety device outputs are connected. 

- Test is an input condition which must be true at the start up moment and can be used for monitoring of external components. Test must switch on before In1 and In2, i.e. the function block cannot be initiated by Test. 

- Reset is a monitored reset input which must switch on-off (reset on negative edge) after all other inputs, in order to switch on the output of the function block. 

- IndReset is an output for indication which is ON when the function block is switched off and In1, In2 or Test is off, and flashes when the function block is ready for activation with reset. 

- TCfault is on at two-channel fault, i.e. when the function block is on, and only one of In1 or In2 switches off and on again. 

## Example: Function block Twohand1 

Two-hand control for actuators with NO/NC + NO/NC contacts. 

– Right_NO is right hand NO contact Twohand1 – Right_NC is right hand NC contact, etc. Right_NO Q 

- Test is an input condition that must 

   - be on before any of the other inputs changes from the initial position Right_NC and can be used for monitoring of external components. 

Left_NO 

## Function: 

- In initial position shall: 

- Right_NO be off, 

– Right_NC be on, Left_NC 

- Left_NO be off and 

- Left_NC be on 

Test 

To start the output (Q), these four inputs must change state in 0.5 

seconds and remain in that position. After stop, all inputs must come to the initial position to enable restart. 

## Description 

The function block works as a conventional safety relay with redundant and monitored inputs (In1, In2). 

ABB Safety Handbook | 2TLC172001C0202   4/4 

5 

5/1    2TLC172001C0202 | ABB Safety Handbook 

Safety system - Vital Supervision of dynamic safety signals 

5 

|Safetysystem - Dynamic safetycircuit - Vital-Tina|5/3|
|---|---|
|Safety Controller - Vital||
|Whyshouldyou use the Vital safetysystem?|5/5|
|How does a dynamic circuit of Vital work?|5/6|
|SafetyController - Vital|5/7|
|Adaptation unit - Tina||
|Whyshouldyou use the Tina adaptation units?|5/21|
|Tina is available in several versions|5/22|
|Tina 1A|5/23|
|Tina 2A/B|5/24|
|||
|Tina 3A/APS|5/25|
|Tina 4A|5/26|
|Tina 5A|5/27|
|Tina 6A|5/29|
|Tina 7A|5/30|
|Tina 8A|5/31|
|Tina 10A/B/C|5/33|
|Tina 11A|5/35|
|Tina 12A|5/36|
|Accessories|5/37|
|Example of safetysensors connections based on ’Y’ branch|5/38|
|Connection examples|5/40|



ABB Safety Handbook | 2TLC172001C0202   5/2 

5 

## Safety system Dynamic safety circuit – Vital and Tina 

Vital is a safety controller with a dynamic safety circuit that can monitor up to 30 sensors, such as Eden, in accordance with the highest safety level. Vital has selectable manual or automatic resetting and dual outputs. (The Pluto safety PLC has many inputs for dynamic safety circuits.) 

Each active sensor and Tina unit has LEDs that indicate OK (green), broken safety circuit (red) or flashing if the loop has been broken by another earlier sensor. 

**==> picture [394 x 436] intentionally omitted <==**

**----- Start of picture text -----**<br>
Active safety sensors for dynamic safety circuits<br>oP) «Se<br>Vital<br>Safety circuit category up to PL e<br>according to EN ISO 13849-1<br>Patented<br>solution<br>=f<br>Dynamic safety —_ Tina units that convert static/OSSD to dynamic signals<br>Dynamic safety signal<br>that tests a sensor 200<br>times per second.<br>0V 24V Sensors with static or OSSD outputs that are<br>connected via Tina units ws 0 |<br>**----- End of picture text -----**<br>


5/3    2TLC172001C0202 | ABB Safety Handbook 

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## Vital is available in three versions 

## Vital 1 

**==> picture [33 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
Dynamic<br>circuit 1<br>**----- End of picture text -----**<br>


- Up to 30 sensors can be connected to the same dynamic safety circuit 

## Vital 2 

- Two safety circuits are monitored by one module 

**==> picture [97 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
Dynamic  Dynamic<br>circuit 1 circuit 2<br>**----- End of picture text -----**<br>


- Simple system with extensive functionality 

- Up to 10 sensors can be connected to each dynamic safety circuit 

- Output group 2 can be set for time delay 

- Three different modes of operation 

## Vital 3 

**==> picture [91 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
Contact Dynamic<br>circuit 1 circuit 2<br>**----- End of picture text -----**<br>


- Two safety circuits are monitored by one module 

- Devices with two-channel, opening contacts can be connected to one circuit 

- Simple system with extensive functionality 

- Output group 2 can be set for time delay 

- Three different modes of operation 

## One Vital supervises the entire robot cell! 

This example shows a cell that consists of dynamic protection sensors connected to a Vital with the following functions: 

## Two charging stations 

At each charging station a light cu ~~rtain~~ checks for anyone putting their hand into a risk area, and an Eden sensor checks whether a robot is inside the same risk area. This means that a stop is only ordered if a robot ~~and~~ a ~~p~~ ers ~~o~~ n are in the sa ~~me~~ area. When the station is clear, the person presses t ~~he~~ reset button connected to the light curtain. 

**==> picture [219 x 83] intentionally omitted <==**

**----- Start of picture text -----**<br>
ver<br>»-<br>-~<ico<br>er<br>A —ooS<br>B<br>**----- End of picture text -----**<br>


## Fence with Eden-interlocked door 

If the door is opened, the robot stops. To reset the robot system, the door must be closed and a supervisory reset button operated. 

## Three emergency stops with Tina units 

If any of the emergency stop buttons is pressed, the robot performs an immediate emergency stop. 

ABB Safety Handbook | 2TLC172001C0202   5/4 

## Why should you use the Vital safety system? 

**==> picture [6 x 10] intentionally omitted <==**

**----- Start of picture text -----**<br>
5<br>**----- End of picture text -----**<br>


— to be able to connect several safety components in series (up to PL e, cat. 4) and supervise them with only one safety controller! 

Vital is the heart of a solution which makes it possible to install/connect many different types of safety device in the same safety circuit and still achieve PL e according to EN ISO 13849-1. The Vital module is based upon a dynamic single-channel concept as opposed to conventional dual-channel safety relays. Up to 30 dynamic sensors can be connected directly in the safety circuit and be supervised by only one Vital module.The Vital therefore replaces several safety relays. Safety components with output contacts can be connected to the Vital via low cost Tina adaptors. 

The Vital also has automatically or manually supervised reset selection, dual safety outputs, and an information output for reset indication and status information for PLC´s. 

— to supervise safety components! 

Most safety components on the market can be connected to the Vital module. Dynamic sensors enable safety PL e to be achieved in a single-channel system. For example ABB Jokab Safety´s dynamic non-contact Eden sensor, Spot light beam and emergency stops (via Tina adaptors) can be used. Even mechanical switches can be connected to Vital with the aid of ABB Jokab Safety´s Tina adaptors. 

— for easy installation and assembly of a safety system! Vital is a small electronic safety controller that dynamically supervises a number of safety components. Vital´s detachable connector blocks simplify the connection, trouble-shooting and exchange of modules. The Vital and other safety components can be connected together using standard cables and with cables having M12 connections. 

## Reasons to choose Vital 

- PL e, according to EN ISO 13849-1 dynamic safety circuit 

- Can accommodate long cable lengths 

- Manually supervised or automatic reset 

- Two NO safety outputs 

- Detachable connector blocks 

- LED indication of: power supply, dynamic signal and outputs 

- Information output with two functions 

- Cost-effective cable routing/connections 

5/5    2TLC172001C0202 | ABB Safety Handbook 

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## How does a dynamic circuit of Vital work? 

**==> picture [478 x 419] intentionally omitted <==**

**----- Start of picture text -----**<br>
The Eden sensor<br>monitors that doors<br>are closed<br>Emergency stop INCA Tina<br>To stop the machine in case of<br>danger<br>SIN] NS Ze Sx ss "y<br>: b aSNS aeon :<br>Smile Tina<br>emergency stop<br>to stop machinery<br>when there is a hazard<br>Light Curtain Focus<br>Prevents passage with  Safety module Vital<br>integrated muting function monitors the safety sensors<br>in series according to PL e<br>EN ISO 13849-1.<br>**----- End of picture text -----**<br>


The dynamic signal consists of a square wave that is transmitted through the safety circuit. The signal is inverted at each safety component and is monitored 200 times per second by Vital or Pluto. 

The dynamic signal is transmitted as single channel throughout all the protection in the same safety circuit between input terminals T1 and R1. If a protection breaks, the dynamic signal is not transmitted which is detected by Vital which breaks its safe outputs. Even short circuits across a protection are detected when the signal is inverted in each sensor (the 

protection is then OK), while Vital expects a correctly inverted signal at the right time. In this case, an even number of sensors are connected to the safety loop which means that the dynamic signal will be inverted an even number of times when it is evaluated by Vital. This is determined by the terminal inputs S1 and B1 being connected together. If an odd number of sensors have been connected, connection of S1 is not required. As the signal is evaluated by Vital at each pulse, i.e. more than 200 times per second, faults and short circuits are detected within a few milliseconds. 

ABB Safety Handbook | 2TLC172001C0202   5/6 

5 

## Safety controller Vital 

## Approvals: 

**TÜV Nord** – Vital 1 **TÜV Rheinland** – Vital 2 and 3 

## Application: 

- Entire safety system based on the dynamic safety circuit. 

## Features: 

- Easy installation 

- Flexible 

- Cost effective 

- Display for troubleshooting (Vital 2 and 3) 

- A wide range of safety sensors can be connected into the circuit 

- Several safe outputs 

- Information output 

- Outputs with time delay (Vital 2 and 3) 

Vital is based on a single channel safety concept where multiple safety sensors can be connected in series and monitored with a single safety controller. A dynamic signal is sent from Vital through all connected sensors, and then returned to Vital which then evaluates the received signal. As each safety sensor inverts the signal, it is possible to detect short circuits or faults in any of the sensors. Vital is designed for use with ABB Jokab Safety Eden sensors, Tina components and Spot light grids or similar products. Vital 2 and 3 are both safety controllers with two safe input functions and two output groups, the only difference between the two models being in the input configuration. 

5/7    2TLC172001C0202 | ABB Safety Handbook 

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## Vital 1 Safety controller 

**==> picture [220 x 48] intentionally omitted <==**

**----- Start of picture text -----**<br>
Dynamic<br>circuit 1<br>|<br>**----- End of picture text -----**<br>


- Up to 30 sensors can be connected to the same dynamic safety circuit 

## Vital 2 Safety controller 

- Two safety circuits are monitored by one module 

**==> picture [95 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
Dynamic Dynamic<br>circuit 1 circuit 2<br>**----- End of picture text -----**<br>


- Simple system with extensive functionality 

- Up to 10 sensors can be connected to each dynamic safety circuit 

- Output group 2 can be set for time delay 

- Three different modes of operation 

## Vital 3 Safety controller 

- Two safety circuits are monitored by one module 

Contact Dynamic circuit 1 circuit 2 

- Devices with two-channel, opening contacts can be connected to one circuit 

- Simple system with extensive functionality 

- Output group 2 can be set for time delay 

- Three different modes of operation 

ABB Safety Handbook | 2TLC172001C0202   5/8 

5 

## Reset connections – Vital 1 

Manually supervised reset 

Automatic reset 

Testing external contactor status 

**==> picture [11 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
B1<br>**----- End of picture text -----**<br>


The manually supervised reset contact connected to input X1 must be closed and opened in order to activate the relay outputs. 

Automatic reset is selected when B1, X1 and X4 are connected. The relay outputs are then activated at the same time as the inputs. 

Contactors, relays and valves can be supervised by connecting ‘test’ contacts between B1 and X1. Both manually supervised and automatic reset can be used. 

## Output connections – Vital 1 

Relay outputs 

Information outputs 

**==> picture [332 x 105] intentionally omitted <==**

**----- Start of picture text -----**<br>
a s<br>Y14<br>+24V l +24V B1 |<br>+24V B1 Y14 0V B2 Vital  1<br>_ poo Ya<br>0V B2 Vital  1<br>L—————4 : ty Jo<br>PLC<br>0V 0V<br>0V<br>**----- End of picture text -----**<br>


The Vital 1 has two (2 NO) safety outputs. In order to protect the output contacts it is recommended that loads (inductive) are suppressed by fitting correctly chosen VDR’s, diodes etc. Diodes are the best arc suppressors, but will increase the switch-off time of the load. 

## Connection of S1 

Even number of units in series (Eden+Spot+Tina) requires a connection between B1 and S1. S1 is not connected at odd number of units. See drawing below figure A and other examples in the book 

Vital 1 has a switching relay output for information. The function is determined by a DIP switch. 

The DIP switch position 1 (original position) is the information output Y14 internally connected to 0V and +24 V as per: 

- Y14 is closed to 0V (B2) internally when Vital 1 has not been reset. 

- Y14 is closed to +24 V (B1) when Vital 1 has been reset. 

In DIP switch position 2 (the purpose of the function is to start/restart block, RES) the information output Y14 is internally connected to 0V and +24 V as per: 

- Y14 is internally closed to 0V (B2) when the dynamic safety loop is open or when the dynamic safety loop is closed and Vital 1 has been reset. 

- Y14 is internally closed to +24 V (B1) when the dynamic safety loop is closed but Vital 1 has not been reset (RES). 

5/9    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – Vital 1 

|Technical data – Vital 1||||
|---|---|---|---|
|Article number||||
|Vital 1|||2TLA020052R0000|
|Level of safety<br>EN ISO 13849-1<br>EN 62061<br>IEC/EN 61508-1…7|||PL e/Cat. 4<br>SIL 3<br>SIL 3|
|PFHD|||2.74×10-8|
|Colour|||Grey|
|Weight|||220g|
|Power supply<br>Vital, A1-A2<br>From Vital to sensors/units, B1-B2|||24 VDC ±15%<br>24 VDC|
|Fuse<br>An external fuse should be fitted in<br>the supply to A1|An external fuse should be fitted in||3 AT|
|Max line resistance<br>at nominal voltage to X1|||150 Ohm|
|Power consumption<br>DC supply, nominal voltage (wit-<br>hout load)<br>DC supply, nominal voltage (with<br>max load)|||3 W<br>48 W|
|Dynamic safety circuit<br>T 1<br>R 1|||Output signal<br>Input signal|
|Reset input X1<br>Supply for reset input<br>Reset current<br>Minimum contact closure time for<br>reset|||+24 VDC<br>30 mA max. (inrush current 300 mA<br>during contact closure)<br>150 ms|
|Connection of S1||||
|Even numbers of sensors (Eden + Spot T/R + Tina) require a connection||||
|between B1 and S1. S1 is not connected for odd numbers of sensors.||||
|Odd number, no connection between B1 and S1.||||
|Number of sensors<br>Max. number of Eden/Tina to<br>Vital 1<br>Total max. cable length to Eden/<br>Tina<br>Max. number of Spot T/R to Vital<br>Total max. cable length to Spot<br>T/R|‘||30<br>1000 m<br>Up to 6 pairs<br>600 m<br>~~;~~|
|Maximum number of units varies depending on the installation and cable||||
|size. For more information, see the examples in this chapter.|size. For more information, see the examples in this chapter.|||
|Response time<br>At Power on<br>When activating (input-output)<br>When deactivating (input-output)<br>At Power loss|||< 65 ms<br>< 40 ms<br>< 48 ms<br>< 55 ms|
|Relay outputs||||
|NO|||2|
|Max switching capacity, resistive||||
|load|||6A/250 VAC/1500 VA/150W|
|Minimum load|||10 mA/10V|
|Contact material|||AgCdO|
|Mechanical life|||>107operations|
|External fuse (EN 60947-5-1)|||6.3A or 4A slow|



Relay information output (changeover contact) Y14 –(0V) Indicates Vital is not reset +(24V) Indicates Vital is reset Max. load on Y14 200 mA (Internal automatic fuse) LED indication On Fixed light: supply voltage OK, Flashing light: under-voltage or overload. T R T: Signal out OK.  R: Signal in OK. 4 1 Ba 2 Indicates that the output relays have been activated Mounting DIN rail 35 mm DIN rail Operating temperature range -10°C to + 55°C Connection blocks (detachable) Max screw torque 1 Nm Max connection area: Solid conductors 1x4 mm[2 ] / 2x1,5 mm[2 ] / 12AWG Conductor with socket contact 1x2,5 mm[2 ] / 2x1 mm[2] Air and creep distance 4kV/2 DIN VDE 0110 Protection class Enclosure IP40 IEC 60529 Connection blocks IP20 IEC 60529 Conformity EN ISO 12100-1, -2, EN 954-1, EN ISO 13849-1, EN 62061, EN 60204-1, IEC 60664-1, EN 61000-6-2, EN 61000-6-4 EN 60947-5-1, EN 1088, EN 61496-1, IEC/EN 61508-1…7 

Connector blocks are detachable (without cables having to be disconnected) 

ABB Safety Handbook | 2TLC172001C0202   5/10 

Connection examples of safety devices to Vital 1 

**==> picture [24 x 28] intentionally omitted <==**

**----- Start of picture text -----**<br>
5<br>**----- End of picture text -----**<br>


**==> picture [43 x 32] intentionally omitted <==**

Connection of units and cable lengths to Vital 1 

**==> picture [98 x 273] intentionally omitted <==**

**==> picture [105 x 200] intentionally omitted <==**

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5/11    2TLC172001C0202 | ABB Safety Handbook 

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## Three connection alternatives 

According to PL e (EN ISO 13849-1), connection of sensors/ adaptor units in the Vital safety circuit must be made as the connection examples. 

## Example 

Us ~~e~~ s ~~epara~~ te connect ~~io~~ n cables from each sensor/a ~~d~~ aptor unit to the ~~V~~ ital safet ~~y~~ controller. Interconnections to ~~b~~ e made via suitabl ~~e termina~~ l ~~s~~ in the contr ~~o~~ l cabinet. 

## Example 

Use Tina4A/Tina8A c ~~on~~ nector ~~blo~~ cks to s ~~i~~ mp ~~l~~ if ~~y th~~ e ~~c~~ onnection ~~of~~ externally mo ~~unted s~~ en ~~sors/~~ a ~~d~~ a ~~ptor unit~~ s. ~~On~~ ly ~~Tina4A/~~ Tina8A connector blocks may be use ~~d~~ . ~~Use~~ of any other conne ~~ctor blocks~~ w ~~ill~~ not meet the ~~sa~~ fety ci ~~rcu~~ i ~~t require~~ m ~~ents.~~ 

## Ex ~~am~~ ple 

~~Use M~~ 12- ~~3A and M12~~ - ~~3B ’Y~~ ’ co ~~n~~ n ~~e~~ ctor ~~s to conn~~ ect sensors in serie ~~s~~ /p ~~a~~ rall ~~e~~ l. 

C ~~able~~ l ~~e~~ ngths and nu ~~mb~~ er of s ~~en~~ s ~~o~~ r/ ~~adap~~ t ~~o~~ r units for th ~~e~~ th ~~re~~ e ~~c~~ o ~~nne~~ c ~~tion exa~~ m ~~p~~ l ~~e~~ s ~~.~~ 

In ~~o~~ rder to deter ~~m~~ ine the num ~~b~~ er of sensor ~~/a~~ da ~~p~~ tor u ~~n~~ its that ~~can b~~ e conn ~~ec~~ te ~~d to a~~ Vital ~~1 uni~~ t it ~~mus~~ t be ~~r~~ e ~~me~~ mbered that ~~1~~ ( ~~on~~ e) Spot T/R i ~~s~~ e ~~qu~~ iv ~~a~~ len ~~t t~~ o 5 ( ~~five~~ ) Eden or Tina units. ~~Un~~ i ~~ts~~ i ~~n~~ parallel ~~ar~~ e e ~~qual~~ to one unit. The foll ~~ow~~ i ~~ng~~ examples provide guidance ~~as~~ to possible configurations and cable lengths using s ~~uita~~ bl ~~e cab~~ les. 

## Example 

~~U~~ p ~~to 1000 me~~ tres (0. ~~7~~ 5 mm[2] or 0.34 mm[2] conduct ~~or~~ s) in total can ~~be~~ connect ~~ed to~~ the sensors/units in this ~~e~~ xample. The conne ~~ction~~ is equivalent to 9 Eden or Tina units. 

A maximu ~~m of 30~~ Eden or T ~~ina un~~ its can be ~~connect~~ ed t ~~o~~ the Vital 1 unit on a m ~~a~~ ximum cable length of 500 ~~me~~ tres (0.75 ~~m~~ m[2] conductor ~~s~~ ) or 300 ~~metr~~ es (0.3 ~~4 mm~~[2] conductors). 

## E ~~xample~~ 

Up ~~to 600~~ me ~~t~~ r ~~es~~ (0.7 ~~5~~ mm[2] conductors) ~~t~~ o ~~T~~ i ~~na 8~~ A and 10 ~~m~~ etre ~~cab~~ l ~~es~~ ty ~~pe M1~~ 2- ~~C1~~ 012 (0.34 mm[2] ) to e ~~ac~~ h sensor/ unit conne ~~c~~ ted to the Tina 8A. This con ~~nect~~ i ~~on ex~~ ample is equivalent to 17 Eden or Tina un ~~it~~ s. 

A maximum of 3 Tina 8A units, equivalent to 27 Eden/Tina units (= 3 x 8 connected to Tina 8A + 3 Tina 8A) can be connected to one Vital 1 with a total cable length of 600 metres (0.75 mm[2] ). Up to 6 Tina 4A units can be connected to one Vital 1 (equivalent to 30 Eden/Tina units) with a total cable length ~~of~~ 600 metres (0.75 mm[2] ) to Tina 4A. 

## Example 

Either 2 ~~x~~ 500 m ~~e~~ tre ~~cab~~ l ~~e~~ s (0.75 mm[2] ) from the control cabi ~~net~~ an ~~d 10 m~~ etre cabl ~~e~~ s (0.34 mm[2] ) to each sensor/unit or 2 x 10 me ~~tr~~ e ca ~~b~~ les (0.75 mm[2] ) from the control cabinet and 200 metre ~~ca~~ ble ~~s~~ ( ~~0.~~ 7 ~~5~~ mm[2] ) to each sensor/unit. The c ~~o~~ n ~~nec~~ t ~~io~~ n is equivalent to 16 Eden or Tina units. 

A Total ~~o~~ f ~~3~~ 0 Eden ~~/T~~ ina units can be connected using a maxi ~~mu~~ m ca ~~b~~ le length of 1000 metres (0.75 mm[2] ) or 400 metres (0. ~~34~~ mm[2] ). If ~~t~~ he power ~~su~~ pply is only fed from one direc ~~tio~~ n (f ~~rom one~~ end ~~o~~ f the network) the total cable length is reduc ~~e~~ d to appr ~~ox~~ 300 metres (0.75 mm[2] ) and 100 metres (0.34 mm[2] ~~)~~ . 

Connecti ~~on adv~~ ice ~~f~~ o ~~r d~~ ynamic sensors to Pluto and Vital. ~~S~~ en ~~so~~ rs ca ~~n b~~ e connected in many different ways. Here is some advice th ~~at~~ ca ~~n make~~ connection better and more stable. The advice is general, but particularly applicable to the use of Tina 4A and Tina 8A uni ~~ts~~ . 

- Never have more than the recommended number of sensors in the loop. 

- If possible use a switched mains power supply that can deliv ~~e~~ r a stable 24 VDC. 

- In t ~~h~~ e s ~~ensor~~ system, use as short cables as possible. 

- When conne ~~c~~ ting a Tina 4A or Tina 8A unit, the supply volta ~~g~~ e at the terminal (out at the unit) must not be less th ~~an~~ 20 ~~Vol~~ t ~~s.~~ 

- Use scree ~~ne~~ d cable, preferably 0.75 mm[2] or thicker, from the apparatus enclosure and ground it at one end, for example at the apparatus enclosure, not at both ends. 

- Do not route the signal wiring close to heavy current cabli ~~n~~ g or close ~~to~~ equipment that gives off a lot of interfere ~~nc~~ e, su ~~ch~~ as frequency converters for electric motors. 

- Neve ~~r~~ connect “spare” conductors. 

- If ~~M1~~ 2- ~~3B ar~~ e used for connection of a parallel loop, with supp ~~ly~~ to the se ~~n~~ sors from two directions, the loop must be as s ~~hort~~ as possible. This is because the conductors ~~t~~ hat are not being used are also connected, which increases th ~~e~~ c ~~apa~~ citive load and reduces the stability of the system. 

ABB Safety Handbook | 2TLC172001C0202   5/12 

## Vital 2 

5 

Vital 2 is a safety controller that combines functionality with the quick and easy installation of safety sensors. With two safe input functions and two different output groups, Vital 2 offers the capability to exclusively control smaller machine safety systems that would otherwise have required a programmable controller or multiple safety relays. How the two output groups are controlled by the input functions depends on which of the three operating modes is selected (see Selection of operating mode). 

## Input function 1 

A dynamic safety circuit where ABB Jokab Safety's safety sensors such as Eden, Tina and Spot can easily be connected in series. Up to 10 Eden or Tina devices can be connected in series per input function. 

## Input function 2 

The same function as input function 1. 

## Output group 1 

A safe relay output in a duplicated series and a safe transistor output with output voltage of -24 VDC. 

## Output group 2 

A safe relay output in a duplicated series and a safe transistor output with output voltage of -24 VDC. In addition, output group 2 contains a non-safe transistor output with output voltage of +24 VDC, intended for information. The output group can have time delay from 0 to 1.5 s. 

## Selection of operating modes 

Vital 2 can be configured to operate in one of three operating modes M1, M2 or M3. The selection of operating modes is done by connecting one of the terminals M1, M2 or M3 to +24 V. 

5/13    2TLC172001C0202 | ABB Safety Handbook 

5 

## Operating mode M1 - Separate function Vital 2 

Input function 1 controls output group 1, and input function 2 controls output group 2. 

Operating mode M2 - Input 1, master function Vital 2 

Input function 1 stops all outputs, and input function 2 stops output group 2. 

Operating mode M3 - Parallel function Vital 2 

Input function 1 and input function 2 operate in parallel and control all outputs. Reset/Auto reset 1 resets both input functions (Reset/Auto Reset 2 is not used). 

**==> picture [258 x 215] intentionally omitted <==**

**==> picture [258 x 228] intentionally omitted <==**

**==> picture [258 x 215] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   5/14 

Connection of protection/sensors - Vital 2 

5 

Depending on the input function and the number of sensors connected to the safety circuit (odd or even number), the dynamic signal is connected between different terminals; 

## Input function 1 

A dynamic signal is transmitted from T1, and depending on the number of sensors in the safety circuit, the signal connects back to R1 (odd number of sensors) or R2 (even number of sensors). 

**==> picture [89 x 62] intentionally omitted <==**

**----- Start of picture text -----**<br>
T1 R1 R2<br>T11 R11 R12<br>**----- End of picture text -----**<br>


## Input function 2 

A dynamic signal is transmitted from T11, and depending on the number of sensors in the safety circuit, the signal connects back to R11 (odd number of sensors) or R12 (even number of sensors). 

## Connection of outputs - Vital 2 

## Connection of safe transistor output (-24 V) 

**==> picture [520 x 98] intentionally omitted <==**

**----- Start of picture text -----**<br>
The safe transistor outputs Q2 (output group 1) and Q12 (output group 2) have an output voltage<br>of -24 V. -24 V<br>Q2<br>Q12 1L Q1<br>Connection of safe relay output  11L Q11<br>The safe relay outputs that are duplicated in series break between 1L-Q1 (output group 1) and<br>11L-Q11 (output group 2). The loads that break should be fitted with spark arresters to protect  +24 V<br>the outputs. The correct selection of VDR circuit, RC circuit or diode is appropriate. Note that the  Q13<br>diode extends the disconnection time of the load.<br>**----- End of picture text -----**<br>


## Connection of information output 

The non-safe transistor output Q13 is high (+24 V) when the outputs from output group 2 are active. The function is therefore dependent on the operating mode selected (see Selection of operating mode). 

## Connection of reset - Vital 2 

There are two separate reset functions; Reset 1 and Reset 2. The function of these is dependent on the operating mode selected (see Selection of operating mode). Reset 1 and Reset 2 can be configured for manual or automatic reset independently of each other by means of the input's Auto reset 1 and Auto reset 2. 

## Manual monitored reset 

||||||0|V|
|---|---|---|---|---|---|---|
||||||||
||||||||
|+24||V|X1||X4||
||||X11||X14||
|+24||V|X1||X4||
||||X11||X14||



For manual resetting, a push button must be connected between X1 (Reset 1) or X11 (Reset 2) and +24 V. The monitoring contactors for external devices are to be connected in series with the push button. For manual reset, X4 (for Reset 1) and X14 (for Reset 2) serve as output for resetting the indicator lamps. 

## Automatic reset 

For automatic reset, X1 and X4 (Auto reset 1) or X11 and X14 (Auto reset 2) must be connected to +24 V. Monitoring contacts for external devices must be connected between +24 V and X1 (Auto reset 1) or X11 (Auto reset 2) . If monitoring contacts are not used, X1 and X11 must be connected to +24 V. 

## Time delay - Vital 2 

Output group 2 can have disconnection delay by connecting inputs 0.5s and 1.0s being connected to +24 V. The system is binary, which means that the time values of the inputs are added together to give the total delay time. 

**==> picture [461 x 19] intentionally omitted <==**

**----- Start of picture text -----**<br>
+24 V 0.5s 1.0s +24 V 0.5s 1.0s +24 V 0.5s 1.0s +24 V 0.5s 1.0s<br>No delay 0.5 s delay 1.0 s delay 1.5 s delay<br>**----- End of picture text -----**<br>


5/15    2TLC172001C0202 | ABB Safety Handbook 

5 

Technical data – Vital 2 

|Technical data – Vital 2|||||||
|---|---|---|---|---|---|---|
|Article number||2TLA020070R4300|Non-safe transistor output||||
|Level of safety|||(Q2, Q12)|||11 – 20 ms|
|EN ISO 13849-1||PL e/Cat. 4|Relay outputs||||
|EN 62061||SIL 3|Number of outputs|||2 NO|
|IEC/EN 61508-1…7||SIL 3|Max. load capacity, res. load|||6A/250 VAC|
|EN 954-1||Cat. 4|Max. load capacity, ind. load|||AC-12:  250 V/1,5 A|
|PFHD||||||AC-15:  250 V/1,5 A|
|Relay output||2.00 × 10-9||||DC-12:  50 V/1,5 A|
|Transistor output||1.50 × 10-9||||DC-13:  24 V/1,5 A|
|Colour||Grey|Safe transistor outputs||||
|Weight||390g|Number of outputs|||2|
|Power supply||24 VDC ±15%|Output voltage (rated)|||–24V|
|Fuse|||Output voltage (at load)|||> 22V at 800 mA/24V|
|An external fuse must be con-||||||supply voltage|
|nected in series with the supply||||||23.3V at 150 mA/24V|
|voltage to A1||6 A||||supply voltage|
|Max line resistance<br>at nominal voltage to X1||150 Ohm|Max. load<br>Short circuit protection|||800 mA|
|Power consumption<br>Total current consumption<br>Input function 1<br>(dynamic safety circuit)||300 mA|Output – 0V<br>Output – +24V<br>Non-safe transistor output (infor-<br>mation)|||Yes<br>Normal (not guaranteed)|
|Dynamic output signal||T1|Output voltage (rated)|||+24 VDC|
|Dynamic input signal||R1 (odd number of sensors in a|Max. load|||1 A|
|||circuit)<br>R2 (even number of sensors in a|Mounting<br>DIN rail|||35 mm DIN rail|
|Input function 2<br>(dynamic safety circuit)<br>Dynamic output signal||circuit)<br>T11|Operating temperature range<br>Connection blocks (detachable)<br>Max screw torque<br>Max connection area:|||-10°C to + 55°C<br>1 Nm|
|Dynamic input signal||R11 (odd number of sensors in a<br>circuit)<br>R12 (even number of sensors in a<br>circuit)|Solid conductors<br>Conductor with socket contact<br>Air and creep distance<br>Protection class|||1x4 mm2/ 2x1,5 mm2/ 12AWG<br>1x2.5 mm2/ 2x1 mm2<br>4kV/2 DIN VDE 0110|
|Reset input X1/X11|||Enclosure|||IP40 IEC 60529|
|Voltage at X1/X11 when reset<br>Reset current<br>Minimum contact closure time<br>for reset<br>Number of sensors||+24 VDC<br>30 mA (300 mA peak during contact<br>closure)<br>80 ms|Connection blocks<br>Approved standards|||IP20 IEC 60529<br>EN ISO 13849-1/EN 954-1, EN ISO<br>13849-2, EN 62061, EN 61496-1, EN<br>574, EN 692, EN 60204-1, EN 50178,<br>EN 61000-6-2, EN 61000-6-4, EN|
|Max. number of Eden or Tina units<br>per input function<br>10<br>Total max. cable length (depen-<br>ding on the number of Eden/Tina<br>units)<br>500 m<br>Max. number of light beams (Spot<br>T/R) per input function<br>Spot 10<br>1<br>Spot 35<br>3<br>Total max. cable length (depen-<br>ding on the number of Spot T/R)<br>100 m<br>Maximum number of units varies depending on the installation andcable<br>~~unnnnunuununsnunsnnnnnnnnnuunuudunnnnnnnn~~|||61000-4-, IEC/EN 61508-1…7<br>“420<br>RAR<br>AAS<br>boad|000d)<br>——a<br>Se<br>—<br>(o00¢00d |<br>a) OD||||
|size. For more information, see the examples in this chapter.<br>~~ccsussasesssneseenuusasuesisnasassssesagesevessuimuusussssssvsssianssassesessessesesessteniuuusussveessees~~||||4|||
|Response time|||||||
|Relay output (Q1, Q11)||15 – 24 ms|Connector blocks are detachable||||
|Safe transistor outputs|||(without cables having to be disconnected)||||
|(Q2, Q12)||11 – 20 ms|||||



ABB Safety Handbook | 2TLC172001C0202   5/16 

5 

## Vital 3 

Vital 3 is a safety controller that combines functionality with the quick and easy installation of safety sensors. With two safe input functions and two different output groups, Vital 3 offers the capability to exclusively control smaller machine safety systems that would otherwise have required a programmable controller or multiple safety relays. How the two output groups are controlled by the input functions depends on which of the three operating modes is selected (see Selection of operating mode). 

## Input function 1 

A two-channel safety circuit designed for opening contacts, e.g. two-channel emergency stop or ABB Jokab Safety's safety switch JSNY5. One channel is fed with the dynamic signal and the other with static +24 VDC. 

## Input function 2 

A dynamic safety circuit where ABB Jokab Safety's safety sensors Eden, Tina and Spot can easily be connected in series. Up to 12 Eden or Tina devices can be connected in series per input function. 

## Output group 1 

A safe relay output in a duplicated series and a safe transistor output with output voltage of -24 VDC. 

## Output group 2 

A safe relay output in a duplicated series and a safe transistor output with output voltage of -24 VDC. In addition, output group 2 contains a non-safe transistor output with output voltage of +24 VDC, intended for information. The output group can have time delay from 0 to 1.5 s. 

## Selection of operating modes 

Vital 3 can be configured to operate in one of three operating modes M1, M2 or M3. The selection of operating modes is done by connecting one of the terminals M1, M2 or M3 to +24 V. 

5/17    2TLC172001C0202 | ABB Safety Handbook 

5 

## Operating mode M1 - Separate function Vital 3 

Input function 1 controls output group 1, and input function 2 controls output group 2. 

Operating mode M2 - Input 1, master function Vital 3 

Input function 1 stops all outputs, and input function 2 stops output group 2. 

Operating mode M3 - Parallel function Vital 3 

Input function 1 and input function 2 operate in parallel and control all outputs. Reset/Auto reset 1 resets both input functions (Reset/Auto Reset 2 is not used). 

**==> picture [258 x 212] intentionally omitted <==**

**==> picture [258 x 224] intentionally omitted <==**

**==> picture [258 x 216] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   5/18 

Connection of protection/sensors - Vital 3 

5 

Depending on the input function and the number of sensors connected to the safety loop (odd or even number), the dynamic signal is connected between different terminals; 

## Input function 1 

One of the two opening contacts is connected between T1 and S1 (dynamic signal). The second opening contact is connected between +24 V and S2 (static signal). 

**==> picture [82 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
+24 V<br>T1 S1 S2<br>T11 R11 R12<br>**----- End of picture text -----**<br>


## Input function 2 

A dynamic signal is transmitted from T11, and depending on the number of sensors in the safety loop, the signal connects back to R11 (odd number of sensors) or R12 (even number of sensors). 

## Connection of outputs - Vital 3 

## Connection of safe transistor output (-24 V) 

**==> picture [520 x 107] intentionally omitted <==**

**----- Start of picture text -----**<br>
Connection of safe transistor output (-24 V)<br>The safe transistor outputs Q2 (output group 1) and Q12 (output group 2) have an output  -24 V<br>voltage of -24 V. Q12Q2<br>1L Q1<br>11L Q11<br>Connection of safe relay output<br>The safe relay outputs that are duplicated in series break between 1L-Q1 (output group 1) and  +24 V<br>11L-Q11 (output group 2). The loads that break should be fitted with spark arresters to protect  Q13<br>the outputs. The correct selection of VDR-circuit, RC circuit or diode is appropriate. Note that<br>the diode extends the disconnection time of the load.<br>**----- End of picture text -----**<br>


## Connection of information output 

The non-safe transistor output Q13 is high (+24 V) when the outputs from output group 2 are active. The function is therefore dependent on the operating mode selected (see Selection of operating mode). 

## Connection of reset - Vital 3 

There are two separate reset functions; Reset 1 and Reset 2. The function of these is dependent on the operating mode selected (see Selection of operating mode). Reset 1 and Reset 2 can be configured for manual or automatic reset independently of each other by means of the input's Auto reset 1 and Auto reset 2. 

**==> picture [133 x 53] intentionally omitted <==**

**----- Start of picture text -----**<br>
0 V<br>+24 V X1 X4 +24 V X1 X4<br>X11 X14 X11 X14<br>**----- End of picture text -----**<br>


## Manual monitored reset 

For manual resetting, a push button must be connected between X1 (Reset 1) or X11 (Reset 2) and +24 V. The monitoring contactors for external devices are to be connected in series with the push button. For manual reset, X4 (for Reset 1) and X14 (for Reset 2) serve as output for resetting the indicator lamps. 

## Automatic reset 

For automatic reset, X1 and X4 (Auto reset 1) or X11 and X14 (Auto reset 2) must be connected to +24 V. Monitoring contacts for external devices must be connected between +24 V and X1 (Auto reset 1) or X11 (Auto reset 2) . If monitoring contacts are not used, X1 and X11 must be connected to +24 V. 

## Time delay - Vital 3 

Output group 2 can have disconnection delay by connecting inputs 0.5s and 1.0s being connected to +24 V. The system is binary, which means that the time values of the inputs are added together to give the total delay time. 

+24 V 0.5s 1.0s +24 V 0.5s 1.0s +24 V 0.5s 1.0s +24 V 0.5s 1.0s No delay 0.5 s delay 1.0 s delay 1.5 s delay 

5/19    2TLC172001C0202 | ABB Safety Handbook 

5 

Technical data – Vital 3 

|Technical data – Vital 3|||||||
|---|---|---|---|---|---|---|
|Article number|||2TLA020070R4400|Relay outputs|||
|Level of safety||||Number of outputs||2 NO|
|EN ISO 13849-1|||PL e/Cat. 4|Max. load capacity, res. load||6A/250 VAC|
|EN 62061|||SIL 3|Max. load capacity, ind. load||AC-12:  250 V/1,5 A|
|IEC/EN 61508-1…7|||SIL 3|||AC-15:  250 V/1,5 A|
|EN 954-1|||Cat. 4|||DC-12:  50 V/1,5 A|
|PFHD||||||DC-13:  24 V/1,5 A|
|Relay output|||2.00×10-9|Safe transistor outputs|||
|Transistor output|||1.50×10-9|Number of outputs||2|
|Colour|||Grey|Output voltage (rated)||–24V|
|Weight|||390g|Output voltage (at load)||> 22V at 800 mA/24V|
|Power supply|||24 VDC ±15%|||supply voltage|
|Fuse||||||23.3V at 150 mA/24V|
|An external fuse must be con-||||||supply voltage|
|nected in series with the supply||||Max. load||800 mA|
|voltage to A1|||6 A|Short circuit protection|||
|Max line resistance||||Output – 0V||Yes|
|at nominal voltage to X1|||150 Ohm|Output – +24V||Normal (notguaranteed)|
|Power consumption<br>Total current consumption|||300 mA|Non-safe transistor output (infor-<br>mation)|||
|Input function 1<br>(two channel, normally closed<br>circuit)<br>Dynamic output signal<br>Dynamic input signal<br>Static input signal (+24 V)<br>Input function 2<br>(dynamic safety circuit)|||T1<br>S1<br>S2|Output voltage (rated)<br>Max. load<br>Mounting<br>DIN rail<br>Operating temperature range<br>Connection blocks (detachable)<br>Max screw torque||+24 VDC<br>1 A<br>35 mm DIN rail<br>-10°C to + 55°C<br>1 Nm|
|Dynamic output signal|||T11|Max connection area:|||
|Dynamic input signal|||R11 (odd number of sensors in a<br>circuit)<br>R12 (even number of sensors in a|Solid conductors<br>Conductor with socket contact<br>Air and creep distance||1x4 mm2/ 2x1.5 mm2/12AWG<br>1x2.5 mm2/ 2x1 mm2<br>4kV/2 DIN VDE 0110|
|Reset input X1/X11|||circuit)|Protection class<br>Enclosure||IP40 IEC 60529|
|Voltage at X1/X11 when reset|||+24 VDC|Connection blocks||IP20 IEC 60529|
|Reset current<br>Minimum contact closure time<br>for reset|||30 mA (300 mA peak during contact<br>closure)<br>80 ms|Approved standards||EN ISO 13849-1/EN 954-1, EN ISO<br>13849-2, EN 62061, EN 61496-1, EN<br>574, EN 692, EN 60204-1, EN 50178,<br>EN 61000-6-2, EN 61000-6-4, EN|
|Number of sensors||||||61000-4-, IEC/EN 61508-1…7|
|Max. number of Eden or Tina units|Max. number of Eden or Tina units||||||
|per input function 2|||10||||
|Total max. cable length (depen-|||||||
|ding on the number of Eden/Tina|||||||
|units)|||500 m||||
|Max. number of light beams (Spot|||||||
|T/R) per input function 2|||||||
|Spot 10|||1|“420|||
|Spot 35<br>3<br>Total max. cable length (depen-<br>ding on the number of Spot T/R)<br>100 m<br>Maximum number of units varies depending on the installation andcable<br>size. For more information, see the examples in this chapter.<br>:||||IN<br>S4<br>pandjoood|Connector blocks are detachable<br>(without cables having to be disconnected)||
|Response time<br>Relay output (Q1, Q11)<br>Safe transistor outputs<br>(Q2, Q12)<br>Non-safe transistor output|:<br>:<br>:||15 – 24 ms<br>11 – 20 ms|eS<br>ya<br>jo00e (bo09| |<br>P|<br>OX|||
|(Q2, Q12)|||11 – 20 ms||||



ABB Safety Handbook | 2TLC172001C0202   5/20 

## Why should you use the Tina adapter units? 

**==> picture [6 x 10] intentionally omitted <==**

**----- Start of picture text -----**<br>
5<br>**----- End of picture text -----**<br>


**==> picture [498 x 285] intentionally omitted <==**

**----- Start of picture text -----**<br>
Up to 30 Tina-units in series.  Individual indication for<br>every connected safety<br>mat, strip or bumper.<br>1<br>2<br>Tina 2A Tina 2B Tina 3A Tina 7A Tina 10A Tina 10 B/C<br>Tina 6A<br>——_=<br>Vital/Pluto safety circuit,<br>PL e, using Tina adapter units<br>Pluto Vital 3<br>Tina 4A Tina 1A Tina 8A Tina 11A Tina 12A<br>weGS Wee a Mas a<br>4<br>Tina 5A  Bypassing & lamp supervision Simple connection arrangements<br>**----- End of picture text -----**<br>


## — to adapt safety sensors to the dynamic single channel circuit according to PL e! 

## — as a connection block for simplified connection to a dynamic circuit! 

The Tina 4A/8A connection blocks are available with 4 or 8 M12 connections. They are used to enable several safety sensor having M12 connection terminated cables to be connected together. The blocks are connected with a suitable multi-core cable, that contains status information from each safety component, to the control cabinet. This enables simplified wiring. The connection block contains electronic circuits which modify the coded dynamic signal in the safety circuit. Note Several connection blocks can be connected to one Vital/Pluto. Using Tina 4A/8A connection blocks eliminates connection faults and can significantly reduce system cable costs. 

The Tina devices adapt safety sensors with mechanical positive forced disconnecting contacts, such as emergency stops, switches and light grids/curtains with dual outputs to the dynamic safety circuit in Vital and Pluto. This means Pluto complies with EN ISO 13849-1 and SIL 3 in EN 62061 and EN 61508 for the connected safety sensors with the Vital/ Pluto controller. Note that ABB Jokab Safety's dynamic safety sensors, such as Eden and Spot can be connected directly to the Vital/Pluto circuit without intermediate Tina devices. 

— for bypassing of safety sensor in a dynamic circuit! The Tina 5A bypass unit is used for bypassing of safety sensor in a dynamic circuit and provides the possibility for supervision of bypass lamp indication. During bypassing of safety devices e.g. a light grid or an interlocked gate switch/ sensor, it must only be possible to allow the bypass function if a lamp indication is given. The lamp indication must therefore be supervised. With this system it is possible to bypass one or more safety sensor at the same time. 

5/21    2TLC172001C0202 | ABB Safety Handbook 

5 

## Tina is available in several versions 

Tina is available in several versions depending on the type of safety component that is connected to the Vital or Pluto circuit. Also available is a bypassing unit, three connector blocks with 2, 4 or 8 M12 connectors, and a blind plug for unused connections. As an accessory there is a Y-connector for series or parallel connection and even for connection of light beams with separate transmitter and receiver. Tina units are also included in emergency stop models Smile Tina and INCA Tina. This is to adapt ABB Jokab Safety's products to dynamic safety circuits. 

All Tina units are designed to decode the dynamic signal in the safety circuit of Vital/Pluto. 

**==> picture [204 x 99] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>Tina 2A Tina 2B Tina 3A<br>Tina 7A Tina 10A Tina 10 B/C<br>**----- End of picture text -----**<br>


**==> picture [200 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
3<br>Tina 4A Tina 1A Tina 8A<br>Tina 11A Tina 12A<br>**----- End of picture text -----**<br>


Tina 2A/B, Tina 3A and Tina 7A are used to connect safety components with mechanical positive forced disconnecting contacts, such as emergency stops, switches and light curtains/light beams with relay outputs. NOTE! In order to maintain safety category 4 and to reduce the risk of electrical interference, Tina 2 A, 3A and 7A units must be installed within the same physical encapsulation as the safety component that is to be monitored, and this is to be connected to the Tina unit with as short a cable as possible. 

Tina 4A, Tina 8A, Tina 11A and Tina 12A  are used as terminal blocks and simplify connection to a Vital safety circuit. Each safety component is connected to the terminal block via an M12 connection. A terminal block is connected to the apparatus enclosure by means of a cable that also contains status information from each safety component that is connected to Tina 4A/Tina 8A and summed information from Tina 11A/Tina 12A. Tina 1A must be used as a blanking plug in unused M12 connections. 

Tina 10A/B/C units are used for connection of Focus light beams/curtains to Vital or Pluto. Tina 10B has an extra M12 connector that enables reset, a reset lamp and switching of the Focus supply voltage. The Tina 10C has an additional M12 connector that permits a Focus transmitter to receive power. 

**==> picture [88 x 47] intentionally omitted <==**

**----- Start of picture text -----**<br>
2<br>Tina 6A<br>**----- End of picture text -----**<br>


**==> picture [52 x 19] intentionally omitted <==**

**----- Start of picture text -----**<br>
4<br>Tina 5A<br>**----- End of picture text -----**<br>


Tina 6A is used to connect door sensitive edges and safety mats, and provides an indication for each unit (Tina 7A may also be used). If a Tina 6A is connected close to the edge or mat, the risk of electrical interference is reduced. 

Tina 5A is used to bypass the safety sensors in Vital security loop and for monitoring the indicator light switch off. Tina 5A bypass units are used for bypassing of safety sensors in a dynamic circuit and provides the possibility for supervision of bypass lamp indication. 

## Reasons to choose Tina 

- Safety circuit, PL e, EN ISO 13849-1 

- Individual status indication of every connected unit in the safety circuit 

- Supervision of lamp indicating bypassing of safety device 

- Quick release M12 connector 

ABB Safety Handbook | 2TLC172001C0202   5/22 

5 

## Blanking plug for connection block Tina 1A 

## Approvals: 

## TÜV NORD 

## Application: 

- Is used as a blanking plug in unused M12 connectors at connection blocks 

## Features: 

- Indication of status by LED 

## Technical data – Tina 1A 

|Technical data – Tina 1A|||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|Article number|2TLA020054R0000||||||||||||||||||||
|Level of safety<br>IEC/EN 61508-1…7|SIL3||||||||||||||||||||
|EN 62061<br>EN ISO 13849-1<br>PFHD<br>Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal<br>operation (protection OK) and 24<br>VDC supply voltage|SIL3<br>PL e/Cat. 4<br>4.50 × 10-9<br>24 VDC + +15%, -25%<br>17 mA (27 mA with max information<br>output)<br>Information output: Max 10 mA<br>t < 60 µs<br>Dynamic input: between 9 and 13<br>volt (RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)<br>Information output: ~ 23 VDC|Description<br>Tina 1A is a device that is designed for use with the connec-<br>tion blocks Tina 4A or Tina 8A where it is used as a blind plug<br>in unused M12 connections. The device is fitted with a LED<br>for status indication of the dynamic safety circuit.|||||||||||||||||||
|Protection class|IP67||||||||||||||||||||
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C||||||||||||||||||||
|Humidity range|35 to 85 % (with no icing or conden-<br>sation)||||||||||||||||||||
|Housing material|Based on polyamide, Macromelt<br>OM646(V0)||||||||||||||||||||
|Connector<br>Size<br>Weight<br>Colour|M12 5-pole male<br>48 × 23 × 15 mm(L x W x H)<br>~20g<br>Black|1<br>2<br>3||||||||||||||||LED|24, 5|5-pin M12 male contact<br>1. +24 VDC<br>2. Dynamic input signal<br>3. 0 VDC|
|Approved standards|European Machinery Directive|4||||||||||||||||||4. Dynamic output signal|
||2006/42/EC|11, 2<br>5||||||||47||||32||||||5. Not used|
||EN ISO 12100-1:2003,<br>EN ISO 12100-2:2003,<br>EN 60204-1:2007,<br>EN ISO 13849-1:2008,<br>EN 62061:2005||||||||||||||||||||
|Certificates|TÜV Nord||||||||||||||||||||



Tina 1A is a device that is designed for use with the connection blocks Tina 4A or Tina 8A where it is used as a blind plug in unused M12 connections. The device is fitted with a LED for status indication of the dynamic safety circuit. 

5/23    2TLC172001C0202 | ABB Safety Handbook 

5 

## Adaptation unit Tina 2A/B 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


- Application: – Adaptation of safety sensors with mechanical contacts to the dynamic safety circuit. 

- Example: – Emergency stops 

- – Switches – Light beams / light curtains with relay outputs 

- _— 

## Features: 

- Simplifies the system as well as maintaining the safety level 

## Technical data – Tina 2A 

- Indication of status by LED 

|Article number<br>Tina 2A<br>Tina 2B|2TLA020054R0100<br>2TLA020054R1100|– Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|Indication of status by LED|
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061|Description<br>Tina 2A/B is a device that adapts the safety sensors with<br>SIL3<br>SIL3||Tina 2A/B is a device that adapts the safety sensors with||||||Tina 2A/B is a device that adapts the safety sensors with||||||||||
|EN ISO 13849-1<br>PFHD|mechanical positive forced disconnecting contacts, such as<br>emergency stops, switches and light curtains/light grids with<br>PL e/Cat. 4<br>4.50 × 10-9||||||||||||||||||
|Power supply|their own relay outputs to the dynamic safety circuit.||||||||||their own relay outputs to the dynamic safety circuit.||||their own relay outputs to the dynamic safety circuit.||||
|Operating voltage<br>Total current consumption|Tina 2A is fitted with M20 contact which simplifies connection<br>24 VDC + 15 %, –25 %<br>17 mA (27 mA with max information||Tina 2A is fitted with M20 contact which simplifies connection||||||||||Tina 2A is fitted with M20 contact which simplifies connection||||||
|Time delay t (in/out)|to safety sensors prepared for M20 connection. Tina 2B is<br>very small and can often be placed in the safety components'<br>output)<br>Information output: Max 10 mA<br>t < 60 µs|||||to safety sensors prepared for M20 connection. Tina 2B is<br>very small and can often be placed in the safety components'|||||||||||to safety sensors prepared for M20 connection. Tina 2B is<br>very small and can often be placed in the safety components'||
|Voltage supply at normal|enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for<br>Dynamic input: between 9 and 13||enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for||||||enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for||||enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for||||||
|operation (protection OK) and 24<br>VDC supply voltage|status indication of the dynamic safety circuit.<br>volt (RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)<br>Information output: ~ 23 VDC||||||||||status indication of the dynamic safety circuit.||||||||
|Protection class|IP67||||||||||||||||||
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C||||||||||||||||||
|Humidity range|35 to 85 % (with no icing or conden-<br>sation)||||||||||||||||||
|Housing material|Based on polyamide, Macromelt<br>OM646 (V0)|M20x1,5<br>1|||||||||||||||||
|Connector|5 x 0.34 mm2wires,0.15 m|2|||||||||||||||||
|Size|Tina 2A: 43 × 24 × 24 mm<br>Tina 2B: 28 × 21 × 7 mm(L x W x H)|3|||||||||||||||26, 5||
|Weight|Tina 2A: ~30 g|4|||||||||||||||||
|Colour|Tina 2B: ~20g<br>Black|11, 2<br>24<br>5||||45, 3<br>36, 3|||||||||||||
|Approved standards|European Machinery Directive||||||||||||||||||
|Certificates|2006/42/EC<br>EN ISO 12100-1:2003, EN ISO 12100-<br>2:2003,<br>EN 60204-1:2007, EN 954 1:1996,<br>EN ISO 13849-1:2008,EN 62061:2005<br>TÜV Nord|21<br>26<br>6,8<br>LED<br>1<br>2<br>3<br>4<br>5<br>Cable connection:<br>Brown: +24 VDC<br>White: Dynamic input signal<br>Blue: 0 VDC<br>Black: Dynamic output signal<br>Grey: Information<br>~~+a~~<br>~~‘ee~~|||||||||||||||||



Tina 2A/B is a device that adapts the safety sensors with mechanical positive forced disconnecting contacts, such as emergency stops, switches and light curtains/light grids with their own relay outputs to the dynamic safety circuit. 

Tina 2A is fitted with M20 contact which simplifies connection to safety sensors prepared for M20 connection. Tina 2B is very small and can often be placed in the safety components' enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for status indication of the dynamic safety circuit. 

ABB Safety Handbook | 2TLC172001C0202   5/24 

5 

## Adaptation unit Tina 3A/Aps 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Adaptation of mechanical positive forced disconnecting contacts to the dynamic safety circuit. 

Example: 

- Emergency stops 

- Switches 

- Light beams / light curtains with relay outputs 

## Technical data – Tina 3A 

|Technical data – Tina 3A||– Emergency stops<br>– Switches<br>– Light beams / light curtains<br>with relay outputs|
|---|---|---|
|Article number<br>Tina 3A<br>Tina 3Aps|2TLA020054R0200<br>2TLA020054R1400|Features:|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061|SIL3<br>SIL3|– Simplifies the system as well|
|EN ISO 13849-1|PLe/Cat. 4|as maintaining the safety level|
|PFHD|4.50 × 10-9|– Indication of status by LED|
|Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)|24 VDC + +15%, -25%<br>47 mA (57 mA with max information<br>output)<br>Information output: Max 10 mA<br>t < 70 µs|Description|
|Current through safety device<br>contacts|12 mA|Tina 3A/Aps is a device that adapts the safety sensors with|
|Short circuit current between||mechanical positive forced disconnecting contacts, such as|
|contacts<br>Voltage supply at normal operation<br>(protection OK) and 24 VDC supply|10 mA<br>Dynamic input: between 9 and 13 volt<br>(RMS)|emergency stops, switches and light curtains/light grids with<br>their own relay outputs to the dynamic safety loop.|
|voltage<br>Protection class<br>Ambient temperature<br>Humidity range|Dynamic output: between 9 and 13 volt<br>(RMS)<br>Information output: ~ 23 VDC<br>IP67<br>Storage: -30…+70°C<br>Operation: -10…+55°C<br>35 to 85 % (with no icing or conden-<br>sation)|Both Tina 3A and Tina 3Aps are fitted with M20 contacts<br>which simplifies connection to safety sensors prepared for<br>M20 connection. The devices are then easily connected to<br>the dynamic safety loop through a 5-pin M12 contact to the<br>Tina device. Tina 3Aps has an extra conductor for the supply<br>voltage to the safety sensor.|
|Housing material|Based on polyamide, Macromelt<br>OM646 (V0)||
|Connectors|M12 5-pole connector<br>Green loop wires (A1 & A2)<br>Orange loop wires (B1 & B2)<br>Brown (+24 VDC), Blue (0 VDC) wires<br>(Tina 3Aps only)|26, 5<br>LED×2<br>M20×1,5<br>1<br>2<br>3<br>4<br>1<br>2<br>3<br>4<br>2|
|Size<br>Weight|54 × 24 × 24 mm (L x W x H)<br>~30 g|~~36~~,~~3~~<br>~~47, ~~1<br>56, 1<br>~~M12~~<br>5<br>11,~~2~~<br>24<br>5<br>3<br>4<br>~~T~~ina 3<br>~~A~~ps|
|Colour|Black|6|
|Approved standards|European Machinery Directive|5-pin M12 ma~~l~~e contact:<br>Cable connection:|
||2006/42/EC, EN ISO 12100 1:2003,|1. +24 VDC<br>1. Safety circuit A1-A2|
||EN ISO 12100-2:2003, EN 60204-|2. Dynamic input signal<br>2. Safety circuit A1-A2|
||1:2007,  EN ISO 13849-1:2008,|3. 0 VDC<br>3. Safety circuit B1-B2|
|Certificates|EN 62061:2005<br>TÜV Nord|4. Dynamic output signal<br>5. Not used<br>4. Safety circuit B1-B2<br>5.  Brown: +24 VDC (only Tina 3 Aps)<br>6. Blue: 0 VDC (only Tina 3Aps)|



- Simplifies the system as well as maintaining the safety level 

- – Indication of status by LED 

Tina 3A/Aps is a device that adapts the safety sensors with mechanical positive forced disconnecting contacts, such as emergency stops, switches and light curtains/light grids with their own relay outputs to the dynamic safety loop. 

Both Tina 3A and Tina 3Aps are fitted with M20 contacts which simplifies connection to safety sensors prepared for M20 connection. The devices are then easily connected to the dynamic safety loop through a 5-pin M12 contact to the Tina device. Tina 3Aps has an extra conductor for the supply voltage to the safety sensor. 

   4. Dynamic output signal 

6. Blue: 0 VDC (only Tina 3Aps) 

5/25    2TLC172001C0202 | ABB Safety Handbook 

Connection block Tina 4A 

5 

## Approvals: 

## TÜV NORD 

## Application: 

- Connection block for up to four safety sensors adapted to the dynamic safety circuit. 

## Features: 

- Simplifies cable routing and reduces cable costs. 

- Allows branching of up to four safety sensors to the dynamic safety circuit. 

## Technical data – Tina 4A 

|Technical data – Tina 4A||
|---|---|
|Article number<br>Tina 4A|2TLA020054R0300|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1|SIL3<br>SIL3<br>PL e/Cat. 4|
|PFHD|4.50 × 10-9|
|Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage|24 VDC + +15%, -15%<br>10 mA (20 mA with max information<br>summary output)<br>Information output: Max 10 mA<br>t < 60 µs<br>Dynamic input: between 9 and 13<br>volt (RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)<br>Information output: ~ 23 VDC|
|Protection class|IP67|
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C|
|Humidity range<br>Housing material|35 to 85 % (with no icing or conden-<br>sation)<br>Based on polyamide, Macromelt|
|Housing material|Based on polyamide, Macromelt<br>OM646 (V0)|
|Connectors|M12 5-pole female (4x)<br>9-pin connection block|
|Size|99 × 50 × 43 mm (L x W x H)|
|Weight|~100 g|
|Colour|Black|
|Approved standards|European Machinery Directive<br>2006/42/EC<br>EN ISO 12100-1:2003,<br>EN ISO 12100-2:2003,<br>EN 60204-1:2007,<br>EN ISO 13849-1:2008,<br>EN 62061:2005|
|Certificates|TÜV Nord|



Tina 4A is a connection block with four 5-pin M12 connections. It is used to connect multiple safety sensors with M12 contacts via a single cable to a controller or PLC. This simplifies cable running and reduces cable costs. Multiple connection blocks can be connected to a Vital/Pluto. Tina 1A is used for unused M12 connections. 

5-pin M12 female contact (x4): 

   1. +24 VDC 

   2. Dynamic input signal 

2. Dynamic input signal 

   3. 0 VDC 

   4. Dynamic output signal 

4. Dynamic output signal Cable shield 

   5. Information 

5. Information (contact #1) 

6. Information (contact #2) 

7. Information (contact #3) 

8. Information (contact #4) 

13. Summarized information (contact #1-4) 

ABB Safety Handbook | 2TLC172001C0202   5/26 

5 

## Adaptation unit Tina 5A 

## Approvals: 

## TÜV NORD 

## Application: 

- Bypassing of safety device connected to the dynamic safety circuit and for supervision of lamp indication. 

## Features: 

- One or more safety devices can be bypassed 

- supervised lamp indication 

- Indication of status by LEDs 

## Function 

The Tina 5A is designed for bypassing of safety devices connected to the Vital/Pluto safety circuit and for supervision of lamp indication. 

During bypassing of safety devices e.g. a light grid or an interlocked gate, it must only be possible to allow the bypass function if a lamp indication is on. The lamp indication must therefore be supervised. Whether indication is required depends on the specific situation and result of risk analysis. 

## S2 is used if: 

- an odd number of dynamic safety units is to be bypassed using an odd number of dynamic safety units, i.e. the sum of Tina + Eden and Spot units (incl. Tina 5A). See drawing HE3824C 

- an even number of dynamic safety units is to be bypassed using an even number of dynamic safety units, i.e. the sum of Tina + Eden and Spot units (incl. Tina 5A). See drawing HE3824F 

## S3 is used if: 

When the Tina 5A receives a coded dynamic signal to S1 and the bypass indication lamp is on (connected across L1-L2), a bypassing output signal is provided on S2 and S3. A broken or short circuit in the indication lamp leads to an interruption of the bypass output signal on S2 and S3, therefore stopping the bypassing. 

The dynamic signal to S1 on Tina 5A must be the input signal from the first of the safety devices intended to bypass. The signal can be connected via output contacts from a safety relay, a safety timer or be initiated via a unit providing the dynamic coded signal as for example an Eden sensor or a Spot light beam. The dynamic output from S2 or S3 is connected to the output of the safeguards to be bypassed 

- an odd number of dynamic safety units is to be bypassed using an even number of dynamic safety units, i.e. the sum of Tina + Eden and Spot units (incl. Tina 5A). See drawing HE3824D 

- an even number of dynamic safety units is to be bypassed using an odd number of dynamic safety units, i.e. the sum of Tina + Eden and Spot units (incl. Tina 5A). See drawing HE3824E 

The total number of dynamic safety units is calculated by adding the number of Eden, Spot and Tina units connected in the Vital circuit. See the connection examples HE3824C, D, E, F or G. 

5/27    2TLC172001C0202 | ABB Safety Handbook 

5 

Technical data – Tina 5A 

|Technical data – Tina 5A||
|---|---|
|Article number|2TLA020054R1900|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1|SIL3<br>SIL3<br>PL e/Cat. 4|
|PFHD|4.50 × 10-9|
|Power supply<br>Operating voltage<br>Current consumption, A1-A2<br>Bypass connection<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage|24 VDC + +10%, -10%<br>No bypass: 10 mA<br>Bypass using a 5 W indication lamp: 240 mA<br>Tina 5A can bypass max. 30 Eden/Tina-units or 6 Spot T/R<br>t < 260 µs<br>Dynamic input: between 9 and 13 volt (RMS)<br>Dynamic output: between 9 and 13 volt (RMS)<br>Information output: ~ 23 VDC|
|Protection class|Enclosure: IP40<br>Connection block: IP20|
|Ambient temperature|-10…+55°C|
|Humidity range|35 to 85 % (with no icing or condensation)|
|Housing material|Based on polyamide, Macromelt OM646 (V0)|
|Connectors|Connection blocks with a total of 8 terminals (2 x 4)|
|Mounting|35 mm DIN rail|
|Size|120 × 84 × 22.5 mm (L x W x H)|
|Weight|~135 g|
|Colour|Grey|
|Approved standards|European Machinery Directive 2006/42/EC, EN ISO 12100-1:2003, EN ISO 12100-2:2003, EN 60204-1:2007,<br>EN ISO 13849-1:2008, EN 62061:2005, EN 61496-1:2004 + A1:2008|
|Certificates|TÜV Nord|



## Bypassing of Eden and Tina units 

If one or more Eden or Tina units are bypassed by a Tina 5A, a diode, such as a 1N4007 must be inserted with forward current out from pin 4 of the last bypassed unit. If one or more Eden or Tina units are bypassed by one or more Eden or Tina units direct to each other, a diode, such as a 1N4007 must be inserted by the last unit in both loops with forward current out from pin 4. Refer to example HD3801A.In the case of bypassing of a Tina 10A, B or C or of more than one unit towards each other, it is recommended that a Tina 5A or M12-3M is used. See the examples HE3824C, D, E, F or G. 

- **Connections:** +A1: +24 VDC Y14: Information of bypass L1-L2:  Bypass lamp (or 820 ohm/2W resistor) 

- -A2: 0 VDC S1: Dynamic signal in S2: Dynamic signal out, transcoded 

- S3: Dynamic signal out, transcoded twice 

ABB Safety Handbook | 2TLC172001C0202   5/28 

5 

## Adaptation unit Tina 6A 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Short circuit monitoring and adaptation of safety sensors to the dynamic safety circuit 

- For example: 

- Contact edges Bumpers Safety mats 

## Features: 

## Technical data – Tina 6A 

Article number 2TLA020054R0600 Level of safety IEC/EN 61508-1…7 SIL3 EN 62061 SIL3 EN ISO 13849-1 PL e/Cat. 4 PFHD 4.50 × 10[-9] Power supply Operating voltage 24 VDC + +15%, -25% Total current consumption 47 mA (57 mA with max information output) Information output: Max 10 mA 

Current through safety device contacts 

12 mA 

Short circuit current between contacts 

10 mA 

Time delay t (in/out) Voltage supply at normal operation (protection OK) and 24 VDC supply voltage 

t < 70 µs 

Voltage supply at normal operaDynamic input: between 9 and 13 tion (protection OK) and 24 VDC volt (RMS) Dynamic output: between supply voltage 9 and 13 volt (RMS) Information output: ~ 23 VDC Protection class IP67 Ambient temperature Storage: -30…+70°C Operation: -10…+55°C Humidity range 35 to 85 % (with no icing or condensation) Housing material Based on polyamide, Macromelt OM646 (V0) Connectors M12 5-pole male M12 5-pole female Size 63 × 31 × 15 (L × W × H) Weight ~30 g Colour Black Approved standards European Machinery Directive 2006/42/EC EN ISO 12100-1:2003, EN ISO 12100-2:2003, EN 602041:2007, EN ISO 13849-1:2008, EN 62061:2005 Certificates TÜV Nord 

- Simplifies the system as well as maintaining the safety level 

- – Indication of status by LED 

## Description 

Tina 6A monitors short circuits. It is used to adapt the safety sensors with safety contact strips and safety mats with relay outputs to the dynamic safety circuit. The device is fitted with a LED for status indication of the dynamic safety circuit. 

**==> picture [170 x 65] intentionally omitted <==**

**----- Start of picture text -----**<br>
1 1<br>2 M12 M12 2<br>3 3<br>4 4<br>5 5<br>11, 2 33 LED<br>× 2<br>62, 2<br>33<br>**----- End of picture text -----**<br>


   - 5-pin M12 female contact: 

- 5-pin M12 male contact: 

   1. Safety circuit A1-A2 

1. +24 VDC 

   2. Safety circuit A1-A2 

2. Dynamic input signal 

   3. Safety circuit B1-B2 

3. 0 VDC 

   4. Safety circuit B1-B2Not used 

4. Dynamic output signal Information 

5/29    2TLC172001C0202 | ABB Safety Handbook 

Adaptation unit Tina 7A 

5 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Adaptation of safety sensors with mechanical contacts to the dynamic safety circuit. 

- For example: 

- Emergency stops Switches Light beams / light curtains with relay outputs 

## Features: 

- Simplifies the system as well as maintaining the safety level 

## Technical data – Tina 7A 

|Technical data – Tina 7A|||||||||||||||||||– Simplifies the system as well<br>as maintaining the safety level|
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|Article number|||2TLA020054R0700||||||||||||||||as maintaining the safety level|
|Level of safety|||||||||||||||||||– Indication of status by LED|
|IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1|||SIL3<br>SIL3<br>PL e/Cat. 4||||||||||||||||– Adapted for easy installation<br>on 35 mm DIN rail in cabinets|
|PFHD|||4.50 × 10-9|||||||||||||||||
|Power supply||||||||||||||||||||
|Operating voltage|||24 VDC + +15%, -25%|||||||||||||||||
|Total current consumption|||47 mA (57 mA with max information|||||||||||||||||
|Current through safety device<br>contacts|||output) Information output: Max 10 mA<br>12 mA|Description<br>Tina 7A is a device that adapts the safety sensors with||||||||||||||||
|Short circuit current between||||mechanical positive forced disconnecting contacts, such as||||||||||||||||
|contacts|||10 mA|emergency stops, switches and light curtains/light grids with||||||||||||||||
|Time delay t (in/out)<br>Voltage supply at normal opera-|||t < 70 µs<br>Dynamic input: between 9 and 13 volt|their own relay outputs to the dynamic safety circuit.|||||their own relay outputs to the dynamic safety circuit.|||||||||their own relay outputs to the dynamic safety circuit.||
|tion (protection OK) and 24 VDC|||(RMS)|||||||||||||||||
|supply voltage|||Dynamic output: between 9 and 13|The device is designed for installation in an equipment||||The device is designed for installation in an equipment||||||||||The device is designed for installation in an equipment||
|Protection class<br>Ambient temperature|||volt (RMS) Information output: ~ 23<br>VDC<br>IP20<br>Storage: -30…+70°C<br>Operation: -10…+55°C|cabinet where it can be mounted directly on a 35 mm DIN<br>busbar, and the conductors are then connected directly to<br>the screw terminals.||||||||||||||||
|Humidity range|||35 to 85 % (with no icing or conden-<br>sation)|||||||||||||||||
|Housing material|||Based on polyamide, Macromelt|||||||||||||||||
||||OM646 (V0)||||||||||||||62|||
|Connectors<br>5-pin connection block (power sup-<br>ply, dynamic in/out, info)<br>4-pin connection block (safety loop<br>A1-A2, B1-B2)<br>Mounting<br>DIN rail<br>Size<br>61 × 46 × 14 (L × W × H)<br>Weight<br>~35 g<br>Colour<br>Black<br>:<br>cssossnsssstvanssnsansvsnsnnsnsnantssnesaniasousaniassisansueuanissossnuinsisansisnussianisseunnseussesuseuaee||||||45, 7<br>35, 5<br>2<br>4<br>3<br>1<br>5<br>6<br>7<br>Connection block:<br>1. +24 VDC<br>2. Dynamic input signal<br>3. 0 VDC<br>4. Dynamic output signal<br>5. Information<br>6. Safety circuit A1-A2<br>7. Safety circuit A1-A2<br>~~Gece fosod ug~~<br>~~| +~~<br>ABB<br>~~NP]~~<br>TINATA,<br>~~= ~~~||||||||||||||
|Approved standards|||European Machinery Directive<br>2006/42/EC, EN ISO 12100-1:2003,<br>EN ISO 12100-2:2003, EN 60204-<br>1:2007, EN ISO 13849-1:2008,<br>EN 62061:2005||i~~iseza ~~||||||||||||13<br> ~~isvezi! |),~~||8<br>9<br>~~8~~. Safety circuit B1-B2<br>~~9~~. Safety circuit B1-B2<br> ~~—~~|
|Certificates|||TÜV Nord|||||||||||||||||



- Adapted for easy installation on 35 mm DIN rail in cabinets 

Tina 7A is a device that adapts the safety sensors with mechanical positive forced disconnecting contacts, such as emergency stops, switches and light curtains/light grids with their own relay outputs to the dynamic safety circuit. 

The device is designed for installation in an equipment cabinet where it can be mounted directly on a 35 mm DIN busbar, and the conductors are then connected directly to the screw terminals. 

4. Dynamic output signal 

ABB Safety Handbook | 2TLC172001C0202   5/30 

5 

## Connection block Tina 8A 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Connection block for up to eight safety sensors adapted to the dynamic safety circuit. 

## Features: 

- Simplifies cable routing and reduces cable costs. 

- Allows branching of up to four safety sensors to the dynamic safety circuit. 

## Technical data – Tina 8A 

Tina 8A is a connection block with eight 5-pin M12 connections. It is used to connect multiple safety sensors with M12 contacts via a single cable to a controller or PLC. This simplifies cable running and reduces cable costs. Multiple connection blocks can be connected to a Vital/Pluto. Tina 1A is used for unused M12 connections. 

|Article number|2TLA020054R0500|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|Tina 8A is a connection block with eight 5-pin M12 connec-|
|---|---|---|---|---|---|---|---|---|
|Level of safety||tions. It is used to connect multiple safety sensors with M12|||tions. It is used to connect multiple safety sensors with M12|||tions. It is used to connect multiple safety sensors with M12|
|IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1<br>PFHD<br>Power supply|SIL3<br>SIL3<br>PL e/Cat. 4<br>4.50 × 10-9|contacts via a single cable to a controller or PLC. This simpli-<br>fies cable running and reduces cable costs. Multiple connec-<br>tion blocks can be connected to a Vital/Pluto. Tina 1A is used<br>for unused M12 connections.|||||||
|Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage|24 VDC + +15%, -15%<br>15 mA (25 mA with max information<br>summary output)<br>Information output: Max 10 mA<br>t < 60 µs<br>Dynamic input: between 9 and 13 volt<br>(RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)|1<br>2<br>3<br>4<br>5<br>6<br>12<br>~~2 ESE~~<br>~~Seles~~||||||~~ESE~~|
||Information output: ~ 23 VDC|13<br>~~@~~|||||||
|Protection class|IP67|Shield|||||||
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C|5-pin M12 female contact (x8):<br>Connection block:||5-pin M12 female contact (x8):||||5-pin M12 female contact (x8):|
|Humidity range|35 to 85 % (with no icing or conden-|1. +24 VDC<br>1. +24 VDC|||||||
|Housing material|sation)<br>Based on polyamide, Macromelt<br>OM646(V0)|2. Dynamic input signal<br>3. 0 VDC<br>4. Dynamic output signal<br>2. Dynamic input signal<br>3. 0 VDC<br>4. Dynamic output signal<br>Cable shield|||||||
|Connectors<br>Size<br>Weight<br>Colour|M12 5-pole female (8x)<br>13-pin connection block<br>149 × 50 × 43(L × W × H)<br>~140g<br>Black|5. Information<br>5. Information (contact #1)<br>6. Information (contact #2)<br>7. Information (contact #3)<br>8. Information (contact #4)<br>9. Information (contact #5)<br>10. Information (contact #6)|||||||
|Approved standards|European Machinery Directive|11. Information (contact #7)|||||||
||2006/42/EC, EN ISO 12100-1:2003,|12. Information (contact #8)|||||||
||EN ISO 12100-2:2003, EN 60204-<br>1:2007, EN ISO 13849-1:2008,<br>EN 62061:2005|13.  Summarized information (contact #1-8)|||||||
|Certificates|TÜV Nord||||||||



**==> picture [234 x 78] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>2<br>3<br>4<br>5<br>6 Seles ©<br>2 ESE 12<br>@ 13<br>Shield<br>**----- End of picture text -----**<br>


Connection block: 5-pin M12 female contact (x8): 1. +24 VDC 1. +24 VDC 2. Dynamic input signal 2. Dynamic input signal 

5/31    2TLC172001C0202 | ABB Safety Handbook 

5 

## Connection examples of safety sensors to Tina 8A 

**==> picture [228 x 49] intentionally omitted <==**

**----- Start of picture text -----**<br>
Tina 4A<br>Safety controller,<br>Vital<br>**----- End of picture text -----**<br>


## Connection 1 

One Eden is connected directly to the Tina 8A. The Eden status is shown by an LED on the Adam sensor. A status information signal is also connected to Tina 8A. 

## Connection 5 

One Smile is connected to the Tina 8A. The information shown by an LED on the Smile is also connected to the terminal block on the Tina 8A. 

## Connection 2 

One Focus safety light grid  is connected to the Tina 8A via a Tina 10A.  The output from the Tina 10A is via a M12 connector. The connection between Tina 10A and Tina 8A is achieved using a cable with M12 connectors on each end.The Tina 10A has  two LED’s  which show the status of the light grid. The same status information signal is connected to the Tina 8A. Tina10A and the Focus transmitter are connected, via an M12-3B, to Tina8A. 

## Connection 6 

A safety interlock switch is connected via a Tina 3A mounted directly on the switch. The output from the Tina 3A  is via a M12 connector. The connection between the Tina 3A and the Tina 8A is therefore simply made with a cable with M12 connectors on each end. On the Tina 3A there is a LED which shows the status of the switch. The same information signal is connected to the Tina 8A. 

## Connection 7 

## Connection 3 

A Spot 10  light beam is connected directly to Tina 8A. A ’Y’ connector M12-3B for M12 plugs is connected to the transmitter and the receiver. The status information shown on the Spot LED is also connected to Tina 8A. 

A Spot 35, transmitter and receiver are connected directly to the Tina 8A  via a M12-3B ’Y’ connector. The status information  shown by the LED on the Spot is also connected to the Tina 8A. 

## Connection 8 

## Connection 4 

A safety mat (same for safety strip and safety bumper) is connected via a Tina 6 A to the Tina 8A. Two  LEDs in Tina 6A shows the status of the mat. The same status information signal is connected to Tina 8A. 

Tina 1A is a plug which has to be connected to Tina 8A inputs when no sensor is required,  in order to complete the safety connection circuit. 

NOTE! All input connectors on the Tina 8A must be connected to sensors or have Tina 1A plugs fitted. 

ABB Safety Handbook | 2TLC172001C0202   5/32 

5 

## Adaptation unit Tina 10A/B/C 

## Approvals: 

## TÜV NORD 

## Application: 

- Adaptation of safety sensors with OSSD outputs to the dynamic safety circuit. 

- For example: 

- Focus lightcurtain/lightbeam 

## Features: 

- Simplifies the system as well as maintaining the safety level 

- – Indication of status by LED 

Tina 10 A/B/C are three connection units with M12 connections, that make it easy to connect a light curtain or light beam Focus with OSSD outputs to the dynamic safety circuits of Vital and Pluto. This also enables complete external interconnections, with M12 cabling, which reduces the cabling to and connections in the apparatus enclosure. Tina 10 A/B/C has LEDs for function indication, with green, red or flashing green/red indications. 

Tina 10A: has two M12 connections that are connected to 1: Vital/Pluto and 2: a light curtain/light beam Focus receiver. See the connection examples HH3300F, HR7000L-01. 

Tina 10B: has three M12 connections that are connected to 1: Vital/Pluto and 2: a light curtain/light beam Focus receiver, and 3: An external reset button and muting lamp, such as unit FMI-1C.See the connection examples HR7000L-01. 

Tina 10C: has three M12 connections that are connected to 1: Vital/Pluto and 2: a light curtain/light beam Focus receiver, and 3: a light curtain/light beam Focus Transmitter. See the connection examples HH3302D, HR7000L-01. 

5/33    2TLC172001C0202 | ABB Safety Handbook 

Technical data – Tina 10A/B/C 

Tina 10A, 10B and 10C connections 

**==> picture [201 x 109] intentionally omitted <==**

**----- Start of picture text -----**<br>
White +24VDC Tina 10A  Tina 10B  Tina 10C<br>2 2<br>ern +24VDC rr? Sa<br>_ ossp1 5 1<br>Pink OSSD2<br>Red LMS<br>1 1 1<br>/ Pluto 3 = wo<br>BrownWhite +24VDC 44 3<br>**----- End of picture text -----**<br>


**==> picture [144 x 246] intentionally omitted <==**

**----- Start of picture text -----**<br>
N ey , a,<br>11,2<br>46,5<br>13,4<br>77<br>( 1 ) [LEI ape eel ee<br>©aN ) aC2 TINA 108 1| eB=<br>\ =| OS —_—<br>11,2 46,5<br>13,4 77<br>Vy@, LitBi ABB || 1 comm<br>©) = F ro 40 C ‘ ie<br>D 11,2  e l 46,5 !<br>13,4 77<br>36<br>36<br>36<br>4,5<br>**----- End of picture text -----**<br>


|Article number<br>Tina 10A<br>Tina 10B<br>Tina 10C|2TLA020054R1200<br>2TLA020054R1300<br>2TLA020054R1600|
|---|---|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1<br>|<br>s~~essestssueescsstssieessssisusescsstistessasisseessnsesitessssseseesos~~|SIL3<br>SIL3<br>PL e/Cat. 4<br>|<br>~~oscesessssesseeessnssseeesssnisseessssssiteeesssiiuiteessaseeseesetsiees~~|
|PFHD<br>|<br>s~~essestssueescsstssieessssisusescsstistessasisseessnsesitesssssesees os~~<br>:|4.50 × 10-9<br>|<br>~~os~~ ~~cesessssesseeessnssseeesssnisseessssssiteeesssiiuiteessaseeseesetsiees~~<br>:|
|Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage<br>:<br>:<br>:<br>:<br>ci~~ceeceeeseeeecceseeecseeeseeecsesceseeeseeevsteseieeessetsessteeseteeeseresi~~|24 VDC + +20%, -20%<br>60 mA (70 mA with max. info signal out)<br>Info signal out: Max. 10 mA<br>t < 120 µs<br>Dynamic input signal: 9 to 13 V (RMS)<br>Dynamic output signal: 9 to 13 V<br>(RMS)<br>Info signal out: ~23 VDC<br>:<br>:<br>:<br>:<br>~~iceceeceeeeceeseecceseeevseseeecseeesseeetsseeeseeveceeseietetieesesseetseeeeesiees~~|
|Protection class<br>ci ~~ceeceeeseeeecceseeecseeeseeecsesceseeeseeevsteseieeessetsessteeseteeeseres i~~<br>:<br>~~eee~~<br>EEEEEEEEESEESEESESSSSSSSSSSESONSOSSOOESOOSOOSOOOEOSS~~oe~~|Info signal out: ~23 VDC<br>IP67<br>~~i ce ceeceeeeceeseecceseeevseseeecseeesseeetsseeeseeveceeseietetieesesseetseeeeesiees~~<br>:<br>~~oe EEE~~TEESEEEEEESOEEOSSSSOEOOSSSOSEOOSSOSSOOOSOOSSOOSSOOSOOOSSOSEOOSON|
|Ambient temperature<br>~~eee~~<br>EEE EEE EEESEES EES ESSSSSSSSSSESONSOSSOOESOOSOOSOOOEOSS ~~oe~~<br>:|Storage: –10…+55° C<br>Operation: –10…+55° C<br>~~oe EEE~~ TEESEEE EEESOEEOSSSSOEOOSSSOSEOOSSOSSOOOSOOSSOOSSOOSOOOSSOSEOOSON<br>:|
|Humidity range<br>~~ee~~|35 to 85 % (without icing or condesa-<br>tion)|
|Housing material<br>Size<br>~~ee~~<br>i|Based on polyamide, Macromelt<br>OM646 (V0)<br>74 × 36 × 11 mm (L × W × H)<br>i|
|Weight|~40 g|
|Colour|Black|
|Number of units connected to<br>Vital 1<br>Max. number of Tina 10A:<br>Max. number of Tina 10B/C:<br>|<br>:|6<br>4 when Focus is supplied by Vital and<br>a reset lamp is used<br>6 when Focus is supplied separately<br>|<br>:|
|Number of units connected to<br>Pluto, Vital 2 or 3, per input<br>Max. number of Tina 10A/B/C:<br>:|6 when Focus is supplied separately<br>or no reset lamp is used<br>2<br>:|
|Connectors<br>Tina 10A<br>Tina 10B<br>Tina 10C<br>|<br>|<br>,|1: for Vital or Pluto<br>2: for Focus receiver<br>1: for Vital or Pluto<br>2: for Focus receiver<br>3: for Reset unit<br>1: for Vital or Pluto<br>2: for Focus receiver<br>3: for Focus transmitter<br>|<br>|<br>,|
|Approved standards|European Machinery Directive<br>2006/42/EC<br>EN ISO 12100-1:2003,<br>EN ISO 12100-2:2003,<br>EN 60204-1:2007,<br>EN ISO 13849-1:2008,<br>EN 62061:2005, EN 61496-1:2004 +<br>A1:2008|
|Certificates|TÜV Nord|



ABB Safety Handbook | 2TLC172001C0202   5/34 

5 

## Terminal block Tina 11A 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Terminal block for connection of two safety sensors with 5-pin M12 connectors and adaptation to the dynamic safety circuit. 

## Features: 

- Simplifies cable routing and reduces cable costs. 

## Technical data – Tina 11A 

|Technical data – Tina 11A||
|---|---|
|Article number|2TLA020054R1700|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1|SIL3<br>SIL3<br>PL e/Cat. 4|
|PFHD|4.50 × 10-9|
|Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage|24 VDC + +15%, -15%<br>17 mA (27 mA with max information<br>output)<br>Information output: Max 10 mA<br>t < 60 µs<br>Dynamic input: between 9 and 13 volt<br>(RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)<br>Information output: ~ 23 VDC|
|Protection class|IP67|
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C|
|Humidity range|35 to 85 % (with no icing or conden-<br>sation)|
|Housing material<br>Connectors<br>~~ce~~<br>:<br>:|Based on polyamide, Macromelt<br>OM646 (V0)<br>Out: M12 5-pole male (nr 2)<br>~~ce~~<br>:<br>:|
|Size<br>Weight<br>:<br>~~ee~~|In: M12 5-pole female (nr 1,3)<br>74 × 36 × 11 mm (L × W × H)<br>~40 g<br>:|
|Colour|Black|
|Approved standards|European Machinery Directive<br>2006/42/EC<br>EN ISO 12100-1:2003, EN ISO 12100-<br>2:2003,<br>EN 60204-1:2007,<br>EN ISO 13849-1:2008,<br>EN 62061:2005|
|Certificates|TÜV Nord|



- Allows connection of two safety sensors to the dynamic safety circuit. 

## Description 

Tina 11A is a connection block with two 5-pin M12 connections. It is used to connect two safety sensors with M12 contacts via a single cable to a controller or PLC. This simplifies cable running and reduces cable costs. Multiple connection blocks can be connected to a Vital/Pluto. 

**==> picture [200 x 71] intentionally omitted <==**

**----- Start of picture text -----**<br>
1 1<br>2<br>3<br>ot 4 \ Soc 2 +<br>CL)\ S 5 SD Y = app g y IFlimeS ca0 3 on<br>©) + 12 © || | 4 -<br>(Th wv 3 \EP j , mane LS ar<br>45 5<br>11, 2 46, 5<br>13, 4 77<br>36<br>**----- End of picture text -----**<br>


- 5-pin M12 female connector (contact #2-3) 

   - 5-pin M12 male connector (contact #1): 

1. +24 VDC 

   1. +24 VDC 

2. Dynamic input signal 

   2. Dynamic input signal 

3. 0 VDC 

   3. 0 VDC 

4. Dynamic output signal 

   4. Dynamic output signal 

5. Information 

5. Summarized information (contact #2-3) 

5/35    2TLC172001C0202 | ABB Safety Handbook 

5 

## Terminal block Tina 12A 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Terminal block for connection of two safety sensors with 8-pin M12 connectors and adaptation to the dynamic safety circuit. 

- For example: 

- Dalton Magne 

## Features: 

## Technical data – Tina 12A 

|Technical data – Tina 12A||
|---|---|
|Article number|2TLA020054R1800|
|Level of safety<br>IEC/EN 61508-1…7<br>EN 62061<br>EN ISO 13849-1|SIL3<br>SIL3<br>PL e/Cat. 4|
|PFHD|4.50 × 10-9|
|Power supply<br>Operating voltage<br>Total current consumption<br>Time delay t (in/out)<br>Voltage supply at normal opera-<br>tion (protection OK) and 24 VDC<br>supply voltage|24 VDC + +15%, -15%<br>60 mA (70 mA with max information<br>output)<br>Information output: Max 10 mA<br>t < 60 µs<br>Dynamic input: between 9 and 13 volt<br>(RMS)<br>Dynamic output: between 9 and 13<br>volt (RMS)<br>Information output: ~ 23 VDC|
|Protection class|IP67|
|Ambient temperature|Storage: -30…+70°C<br>Operation: -10…+55°C|
|Humidity range|35 to 85 % (with no icing or conden-<br>sation)|
|Housing material|Based on polyamide, Macromelt<br>OM646 (V0)|
|Connectors<br>:|To Vital/Pluto:<br>M12 8-pole male (nr 2)<br>From safety device:<br>M12 8-pole female (nr 1,3)<br>:|
|Size<br>Weight<br>:|M12 8-pole female (nr 1,3)<br>74 × 36 × 11 mm (L × W × H)<br>~40 g<br>:|
|Colour<br>:|Black<br>:|
|Approved standards<br>:<br>:<br>:|European Machinery Directive<br>2006/42/EC<br>EN ISO 12100-1:2003, EN ISO 12100-<br>2:2003,<br>EN 60204-1:2007,<br>EN ISO 13849-1:2008,<br>EN 62061:2005<br>:<br>:<br>:|
|Certificates|TÜV Nord|



- Simplifies cable routing and reduces cable costs. 

- Allows connection of two safety sensors to the dynamic safety circuit. 

## Description 

Tina 12A is a connection block with two 8-pin M12 connections. It is used to connect two process locks Dalton or Magne 2A/B with integrated Eden sensors via a single cable to a controller or PLC. This simplifies cable running and reduces cable costs. Multiple connection blocks can be connected to a Vital/Pluto. 

Tina 12A has three 8-pin M12 contacts that connect to 1: Pluto/Vital, information for sensors and locks and lock signals 

- 2: Dalton with Eden No 1 

- 3: Dalton with Eden No 2 

**==> picture [142 x 44] intentionally omitted <==**

**----- Start of picture text -----**<br>
“7h (ET, TINA 1 28 .<br>h 11,2 a d =| 46,5 °°°»;x|}¥”v<br>13,4 77<br>36<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   5/36 

5 

## Accessories 

’Y’ branch with M12 connection and M12-connection device with screw connectors 

**==> picture [239 x 180] intentionally omitted <==**

**----- Start of picture text -----**<br>
M12-3A M12-3B<br>Female Female Female<br>2<br>= <~ 1, [1<br>2 3<br>im i co<br>ii TLOom<br>3<br>1 “am —<br>1<br>Female<br>Male Male<br>See the connection examples  See the connection<br>HA3306C, D examples HA3306C, D.<br>HH3300A, D  HH3300D, F.<br>HH3302D<br>**----- End of picture text -----**<br>


**==> picture [241 x 171] intentionally omitted <==**

**----- Start of picture text -----**<br>
M12-3D M12-3E<br>Female Female Female<br>2<br>col — —<br>3<br>2<br>im m a<br>aa a<br>1 3<br>dmb am i<br>1<br>Male Female Male<br>See the connection examples   See the connection examples<br>HB0008A HB0001A, 2A, 4A and 6A<br>HR7000O, L.<br>**----- End of picture text -----**<br>


**==> picture [281 x 88] intentionally omitted <==**

**----- Start of picture text -----**<br>
M12-C01 M12-C02 M12-C03 M12-C04<br>* * * *<br>Female Male Female Male<br>**----- End of picture text -----**<br>


**==> picture [105 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
Female Male<br>**----- End of picture text -----**<br>


## Cabling 

## Advantages 

Many of ABB Jokab Safety's products are connected using standard M12 connectors. This facilitates installation, saving a lot of time, and also dramatically reduces the risk of incorrect connection. 

- Area 0.34 mm[2] and 0.25 mm[2] 

- Always screened cable 

- The screen is always connected to negative in male 

   - connectors. 

- The guide pin in the small connector is indicated by a 

We have therefore developed cables with 5 conductors, 5 x 0.34 mm + screening or 8 conductors; 8 x 0.34 mm + screening which offer the advantages that we believe a good cable should have. These are available in any length and in various standard lengths, with moulded straight or angled male or female connectors. Particularly suitable cables for the Tina 4A and Tina 8A units are C9 and C13. They have thicker, 0.75 mm[2] conductors for the feed line and 0.5 mm[2] for the other conductors + screening. Refer to the component list for the variants that are available. 

   - recessed arrow that is easy to recognise. 

- Convenient cable in PVC 

- The cable is also available in bulk length. 

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## Example of safety sensor connections based on ’Y’ branch 

**==> picture [482 x 188] intentionally omitted <==**

**----- Start of picture text -----**<br>
2 3 2<br>2<br>rn i \<br>2 3<br>M12-3B<br>- §'08e8<br>3<br>1 1 1 1<br>pokey<br>2 2 2 2 2 2<br>M12-3A<br>3 3 3 3 3 3<br>1 1 1 1 1 1<br>Tina-11A Tina-10C Tina-6A<br>**----- End of picture text -----**<br>


Vital 1 safety controller 

ABB Safety Handbook | 2TLC172001C0202   5/38 

5 

5/39    2TLC172001C0202| ABB Safety Handbook 

## Connection examples 

**==> picture [258 x 382] intentionally omitted <==**

**----- Start of picture text -----**<br>
HA3300A-01 Connection example Vital 1  5/41<br>HA3301A Vital 1 with several Eden   5/41<br>HA3302A Vital 1 and Tina 4A with 4 Eden   5/42<br>HA3302B-01 Vital 1 and 2 Tina 4A and 4 Eden and emergency stop  5/42<br>HA3303A Vital 1 with emergency stop/Tina 2A   5/43<br>HA3304A Vital 1 with emergency stop/Tina 3A   5/43<br>HA3305A Vital 1 with Eden and lightgrid Focus/Tina 10C   5/44<br>HA3306C Vital 1 with 2 lightbeams Spot  5/44<br>HA3306D Vital 1 with 3 lightbeams Spot   5/45<br>HA3307A Vital 1 with Eden, lightgrid/Tina 3A and e-stop/Tina 7A   5/45<br>HD3800A-01 Vital 1 with safety light beam Spot   5/46<br>HD3801A-01 Vital 1, series and parallel   5/46<br>HE3811B-01 Safety light beam Spot with time-limited reset   5/47<br>HE3824C-01 Lightbeam with time-limited bypass 0.2–40 s.   5/47<br>HE3824D-01 Eden and bypassed lightbeam with Eden   5/48<br>HE3824E-01 Lightbeams with time-limited bypass 0.2–40 s.   5/48<br>HE3824F-01 Eden and 2 bypass lightbeams with Eden   5/49<br>HE3824G-01 Eden and 2 separetely bypassed lightbeams   5/49<br>HH3300A Vital 1 with different types of safety devices and M12–3A   5/50<br>HH3300D Vital 1 with Tina 4A and different types of safety devices   5/50<br>HH3302D-01 Vital 1 with Tina 8A and different types of safety devices  5/51<br>HH3301E-01 Connection example Vital 1   5/51<br>HH3400A2 Vital 1 solutions   5/52<br>HB0005A-01 Vital with Eden and Inca e-stop, with separate reset   5/52<br>HB0006A-01 Vital with 4 Eden units + Reset via M12-3E and Tina 4A   5/53<br>HB0007A Vital with two Dalton units via Tina 12A   5/53<br>HB0001A-01 Pluto with Smile e- stop, Reset and Adam via Tina 4A   5/54<br>HB0002A-01 Pluto with Eden units, two zones via M12-3E and Tina 4A  5/54<br>HB0003A-01 Pluto with e-stop units, via Tina 11A and Tina 4A   5/55<br>HB0004A Pluto with different zones for Eden  + Reset and Eden units   5/55<br>HH3301D-01 Vital 1 and Tina 8A with different safety device types   5/56<br>**----- End of picture text -----**<br>


5 

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5 

## Connection examples 

HA3300A-01 Connection example Vital 1 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

## HA3301A Vital 1 with several Eden 

**==> picture [371 x 251] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HA3302A-01 Vital 1 and Tina 4A with 4 Eden 

**==> picture [359 x 241] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HA3302B-01 Vital 1 and 2 Tina 4A and 4 Eden and emergency stop 

**==> picture [361 x 241] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HA3303A Vital 1 with emergency stop/Tina 2A 

**==> picture [360 x 228] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HA3304A Vital 1 with emergency stop/Tina 3A 

**==> picture [364 x 238] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HA3305A Vital 1 with Eden and lightgrid Focus/Tina 10C 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HA3304A Vital 1 with emergency stop/Tina 3A 

**==> picture [361 x 238] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HA3306D Vital 1 with 3 lightbeams Spot 

**==> picture [362 x 238] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HA3307A Vital 1 with Eden, lightgrid/Tina 3A and emergency stop/Tina 7A 

**==> picture [360 x 239] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HD3800A-01 Vital 1 with safety light beam Spot 

**==> picture [366 x 14] intentionally omitted <==**

**----- Start of picture text -----**<br>
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and<br>local codes/regulations. Subject to change without notice.<br>**----- End of picture text -----**<br>


HD3801A-01 Vital 1, series and parallel 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HE3811B-01 Safety light beam Spot with time-limited reset 

**==> picture [182 x 48] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HE3824C-01 Lightbeam with time-limited bypass 0.2–40 s. 

**==> picture [156 x 50] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HE3824D-01 Eden and bypassed lightbeam with Eden 

**==> picture [262 x 63] intentionally omitted <==**

**==> picture [367 x 14] intentionally omitted <==**

**----- Start of picture text -----**<br>
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and<br>local codes/regulations. Subject to change without notice.<br>**----- End of picture text -----**<br>


HE3824E-01 Lightbeams with time-limited bypass 0.2–40 s. 

**==> picture [158 x 51] intentionally omitted <==**

**==> picture [366 x 13] intentionally omitted <==**

**----- Start of picture text -----**<br>
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and<br>local codes/regulations. Subject to change without notice.<br>**----- End of picture text -----**<br>


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## Connection examples 

HE3824F-01 Eden and 2 bypass lightbeams with Eden 

**==> picture [48 x 47] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HE3824G-01 Eden and 2 separetely bypassed lightbeams 

**==> picture [48 x 47] intentionally omitted <==**

**==> picture [64 x 45] intentionally omitted <==**

**==> picture [47 x 47] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HH3300A Vital 1 with different types of safety devices and M12–3A 

**==> picture [361 x 245] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HH3300D Vital 1 with Tina 4A and different types of safety devices 

**==> picture [371 x 268] intentionally omitted <==**

**----- Start of picture text -----**<br>
a b c a b<br>Dominate<br>It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and<br>local codes/regulations. Subject to change without notice.<br>**----- End of picture text -----**<br>


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## Connection examples 

HH3302D-01 Vital 1 with Tina 8A and different types of safety devices 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HH3301E-01 Connection example Vital 1 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HH3400A2 Vital 1 Solutions 

**==> picture [370 x 257] intentionally omitted <==**

**==> picture [359 x 13] intentionally omitted <==**

**----- Start of picture text -----**<br>
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and<br>local codes/regulations. Subject to change without notice.<br>**----- End of picture text -----**<br>


HB0005A-01 Vital with Eden and Inca emergency stop, with separate reset 

**==> picture [273 x 42] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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5 

## Connection examples 

HB0006A-01 Vital with 4 Eden units + Reset via M12-3E and Tina 4A 

**==> picture [262 x 94] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HB0007A Vital with two Dalton units via Tina 12A 

**==> picture [164 x 58] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

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## Connection examples 

HB0001A-01 Pluto with Smile emergency stop unit + Reset via M12-3E and Adam via Tina 

**==> picture [277 x 34] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HB0002A-01 Pluto with five Eden units, for two zones via M12-3E and Tina 4A 

**==> picture [274 x 81] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

ABB Safety Handbook | 2TLC172001C0202   5/54 

5 

## Connection examples 

HB0003A-01 Pluto with Smile and Inca emergency stop units, via Tina 11A and Tina 4A 

**==> picture [271 x 80] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

HB0004A Pluto with different zones for Eden + Reset and two Eden units +via M12-3E 

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

5/55    2TLC172001C0202| ABB Safety Handbook 

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## Connection examples 

HH3301D-01 Connection example – Vital 1 and Tina 8A with different safety device typesTina 4A 

**==> picture [361 x 213] intentionally omitted <==**

It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and local codes/regulations. Subject to change without notice. 

ABB Safety Handbook | 2TLC172001C0202   5/56 

6 

6/1    2TLC172001C0202 | ABB Safety Handbook 

## Safety Relays 

**==> picture [258 x 344] intentionally omitted <==**

**----- Start of picture text -----**<br>
Why should you use Safety relays?  6/3<br>The most flexible safety relays on the market!  6/4<br>Safety relay summary 6/5<br>Safety relay - RT-Series<br>RT6   6/7<br>RT7   6/11<br>RT9   6/15<br>JSBRT11  6/19<br>Safety relay - JSB-Series<br>JSBR4   6/21<br>JSBT4  6/23<br>BT50 (T) 6/25<br>BT51 (T) 6/27<br>JSBT5 (T) 6/29<br>Safety timers<br>JSHT1  6/31<br>JSHT2  6/33<br>Expansion relays<br>E1T   6/35<br>JSR1T  6/37<br>JSR2A  6/39<br>JSR3T  6/41<br>Connection examples  6/44<br>**----- End of picture text -----**<br>


6 

ABB Safety Handbook | 2TLC172001C0202   6/2 

6 

## Why should you use safety relays? 

## – to meet existing safety standards! 

”A fault in the hardware or the software of the control system does not lead to hazardous situations”. This is the requirement in the EU´s Machinery Directive 2006/42/EC under the heading 1.2.1. Safety and reliability of control systems. The directive implies that no person should be put at risk if for example, a relay sticks or if a transistor or two electrical conductors short-circuit. 

A safety relay will fulfill these requirements. A safety relay has, for example, inputs that are checked for short-circuits and 

dual redundant circuits that are checked at each operation. This can be compared to the dual brake circuits in a car. If one of the circuits is faulty the other will stop the car. In a safety relay there is an additional function which only allows a machine to start if both circuits are ok. 

The standard for safety related parts of the control system describes various safety categories depending on the level of risk and application. One single universal relay with selectable safety categories solves this. 

## – to supervise safety devices! 

**==> picture [490 x 18] intentionally omitted <==**

**----- Start of picture text -----**<br>
Light beams Light curtains/Light  Three position  Safety interlock  Two-hand Emergency Safety strips Safety mats<br>grids devices switches    devices stop & Bumpers<br>**----- End of picture text -----**<br>


## – for safe stops and reliable restarts! 

Dual stop signals when the gate is opened. 

Entering or putting a hand or limb into a hazardous area must cause all machinery that can cause personal injury to stop safely. Many serious accidents occur when machinery is believed to have stopped but is in fact only pausing in its program sequence. The safety relay monitors the gate interlock switch and cables and gives dual stop signals. 

Supervised reset when there can be a person within the risk area. 

To make sure that nobody is within the restricted area when activating the reset button. A supervised reset button must be pressed and released before a reset can occur. Many serious accidents have been caused by an unintentional and unsupervised reset. 

Timed reset when you cannot see the entire risk area. 

Sometimes a double reset function is necessary to make sure that no one is left behind in the risk area. First, after ensuring no other person is inside the hazardous area, the pre-reset button must be activated, followed by the reset button outside the risk area within an acceptable time period e.g 10 seconds. A safety timer and a safety relay can provide this function. 

Automatic reset for small hatches. 

Where body entry is not possible through a hatch, the safety circuit can be automatically reset. 

The safety relays are reset immediately when the hatch interlock switch contacts are closed. 

6/3    2TLC172001C0202 | ABB Safety Handbook 

6 

## The most flexible safety relays on the market! 

We have the most flexible safety relays on the market. Our first universal relay was developed in 1988. Nowadays, the flexibility is even greater and size has been reduced by 85 %. 

**==> picture [217 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
Inputs for various  Input for manual or<br>safety devices. automatic resetting.<br>**----- End of picture text -----**<br>


A universal relay is a safety relay with various input options for various safety devices and risk levels. 

Internally, the safety relay is of the highest safety level (PL e according to EN ISO 13849-1). A machine supplier can therefore, with one single safety relay, select the input configuration that best suits their customers' safety requirements. In addition, our safety relays have detachable connector blocks for ease of replacement and testing. As our universal relays incorporate all input options, they are compatible with all our previous safety relays as well as with other manufacturers' products. 

Is a universal relay expensive? No, our latest patented construction is extremely simple and the number of major components is less compared to our previous universal relays. This means that the safety relays are even more reliable than before. 

**==> picture [41 x 26] intentionally omitted <==**

**----- Start of picture text -----**<br>
Detachable<br>connector<br>blocks.<br>**----- End of picture text -----**<br>


RT7: the most flexible safety relay  on the market! 

Outputs for program stop, Safety outputs for immediate and gate opened or closed delayed stops at optional times. and reset indication. 

We also have a great deal of experience from safety solutions in our own system developments. It would be our pleasure to share these experiences with you! Please see the complete safety solutions in the section “Connection examples”. Please do not hesitate to contact us if you should  require any other safety solutions. 

Some of the advantages with ABB Jokab Safety’s safety relays 

- Universal relays 

- Excellent reliability 

- Approved in Europe, USA, Canada 

- Supervised reset 

- Time reset 

- Small and compact 

- Detachable connector blocks 

- Low power consumption 

- Permits the use of long emergency stop cables 

- EX compatibility 

- Functions set by external hardwired links 

- LED indication for inputs and outputs 

- Powerful switching capacity 

ABB Safety Handbook | 2TLC172001C0202   6/4 

6 

## Summary Safety Relays 

## Which safety relay should you choose? 

First of all, we would recommend the selection of one of our latest universal relays in the RT-series. These are both practical and cost effective. 

To facilitate the choice of safety relay or combinations of safety relays, please see: 

- the table below dividing the safety relays into application fields 

- the table on the opposite page showing possible input and output options 

- the relevant data sheet giving comprehensive information about each specific safety relay 

- the circuit diagram for various applications in the section “Connection examples”. 

Note! All earlier types of relays that can now be replaced by those in this manual are still kept as stock items and can be supplied upon request. 

**==> picture [522 x 354] intentionally omitted <==**

**----- Start of picture text -----**<br>
Application fields<br>Safety relays Safety timers Expansion relays<br>Interlocking switch/Gate/ • • • • • • • •<br>Hatch<br>Light curtains • • • •<br>Light beams • • • •<br>Safety mats • • • • •<br>Contact strips • • • • •<br>Two-hand control device •<br>Emergency stop • • • • • • • •<br>Hold to run/enabling device • • • • • • •<br>Foot control device • • • • • • •<br>Area supervision • • • • • •<br>Time resetting •<br>Time bypassing • •<br>Inching •<br>Output expansion • • • • • • • • • •<br>Delayed output • • • • •<br>RT6 RT7 RT9 JSBRT11 JSBR4 JSBT4 JSBT5T, BT50T, BT51T JSBT5, BT50, BT51 JSHT1A/B JSHT2A/B/C E1T JSR1T JSR2A JSR3T<br>**----- End of picture text -----**<br>


Input alternatives (see also technical data on the next page) 

Single-channel, 1 NO Two-channel, 2 NO from +24 V from +24 V Category 3, up to PL d Category 1, up to PL c 

Both the inputs must be closed before the outputs The input must be can be activated. A stop signal is given if one or closed before the outboth of the inputs are opened. Both the inputs puts can be activated. must be opened and reclosed before the outputs A stop signal is given can be reactivated. A short-circuit between the when the input is inputs is not monitored by the safety  relay. Cateopened. gory 4 can only be achieved if a safety device with short circuit monitored outputs is connected. 

Two-channel, 1 NO & 1 NC from +24V Category 4, up to PL e 

One input must be closed and one must be opened before the outputs can be activated. A stop signal is given if one or both of the inputs change position or if the inputs short-circuit. Both inputs must be put into their initial position before the outputs can be reactivated. 

Two-channel, 1 NO from 0 V & Category 4, up to PL e 

Both the inputs must be closed before the outputs can be activated. A stop signal is given if one or both of the inputs are opened. Both the inputs must be opened and reclosed before the outputs can be reactivated.  A Stop signal is given  if there is a short-circuit between the inputs. 

6/5    2TLC172001C0202 | ABB Safety Handbook 

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## **Technical data** 

**==> picture [515 x 528] intentionally omitted <==**

**----- Start of picture text -----**<br>
Safety relays Safety timers Expansion relays<br>Safety category 1-4 1-4 1-4- 1-4 4 4 1-4° 1-4° 1-4° 1-4° 1-4° 1-4 1-4 1-4 1-4 1-4 1-4<br>Safety input<br>Single-channel, 1 NO from  • • • • • • • • • • • • • • •<br>+24 V<br>Two-channel, 2 NO from  • • • •<br>+24 V<br>Two-channel, 1 NO & 1 NC  • • • •<br>from +24 V<br>Two-channel, 1 NO from 0 V  • • • • • • • • • • • •<br>& 1 NO from + 24 V<br>Contact strips/Safety mats • • • • •<br>Reset & test input<br>Monitored manual • • • • • •<br>Automatic/Unmonitored  • • • • • • • • • •<br>manual<br>Testing of contactors, re- • • • • • • • • • • • • •<br>lays, valves, etc.<br>Output<br>NO 3 2 2 7 3 3 3 4 4* 4* 4<br>NO delayable 2 3 [†] 3 4 4* 4* 2 [¤]<br>NO impulse outputs 2 [¤] 2 [¤]<br>NC info 1 1 2 1 1 1 1* 1<br>NC info delayable 1 [†] 1 1*<br>Info. output 2 3 1 1 1<br>Switching capacity (resistive  4 3 2 9 4 4 4 4 [‡ ] 4 [‡] 4 4 4 5<br>load)<br>6A/250VAC/1500VA/150W 2 [¤] 2 [¤] 2 [¤]<br>4A/250VAC/1000VA/100W 2 [‡]<br>6A/250VAC/1380VA/138W 5<br>Width (mm)  45 45 22.5 100 45 45 22.5 22.5 22.5 22.5 22.5 45 45 22.5 45 45 22.5<br>10A/250VAC/1840VA/192W<br>Supply voltage<br>12VDC •<br>24VDC • • • • • • • • • • • • • • • • •<br>24VAC • • • •<br>115VAC • • • • •<br>230VAC • • • • •<br>RT6 RT7 RT9 JSBRT11 JSBR4 JSBT4 JSBT5T BT50T BT51T BT50 BT51 JSHT1A/B JSHT2A/B/C E1T JSR1T JSR2A JSR3T<br>**----- End of picture text -----**<br>


* Indicates the possibility of selecting delayed outputs     ¤ Indicates one relay contact per output (other relays having two contacts per output) ‡ delay-able     ° Category 4 depending on connection (When used as expansion relay with Pluto Safety PLC, then Category 4)     † fixed 0.5 s delay 

Contact strips/Safety mats Category 3, up to PL d 

For an unpressurised mat/strip, both the relay inputs must be closed for the outputs to be activated. In the case of an activated mat/strip and short-circuit input channels, the relay will be deenergized. Current limitation prevents the safety relay from being overloaded when the channels short-circuit. 

Monitored manual reset 

A monitored reset means that the safety relay will not be reset if the reset button gets jammed when pressed in or if the input shortcircuits. In order for the resetting to be complete, the input must be closed and opened before the outputs can close. 

**==> picture [42 x 31] intentionally omitted <==**

Automatic/unmonitored  manual reset 

Automatic reset means that the outputs are closed immediately when both the input conditions are satisfied and the test input is closed. 

**==> picture [91 x 33] intentionally omitted <==**

Testing of contactors, relays & valves 

Can be carried out with both automatic and manual reset. 

ABB Safety Handbook | 2TLC172001C0202   6/6 

6 

## Safety relay RT6 

## Approvals: TÜV NORD cc ~~€@~~ 

## Safety relay for: 

- Emergency stops 

- Light curtains 

- Three position devices 

- Interlocked gates/hatches 

- Magnetic switches 

- Light beams 

- Safety mats 

- Contact strips 

- Foot operated switches 

## Features: 

- Five input options 

- Single or dual channel input 

Would you like a single safety relay for all your safety applications? Then choose the RT6 universal relay to supervise both your safety devices and the internal safety of your machinery. In addition you can select the safety level required for each installation. All this is possible because the RT6 has the most versatile input option arrangement available on the market. Many other relays can therefore be replaced by the RT6. 

The relay also comes with other options such as manual or automatic reset. Manual supervised reset can be used for gates and other safety devices that can be bypassed. Automatic reset can be used for small hatches, if deemed acceptable from risk assessment. 

The RT6 also has information outputs that follow the inputs and outputs of the relay. These outputs will for example indicate if a gate is open or closed and if the safety relay needs to be reset. 

- Manual supervised or automatic reset 

- Test input for supervision of external contactors 

- Width 45 mm 

- LED indication of supply, inputs, outputs, shortcircuit and low voltage level. 

- 3 NO/1 NC relay outputs 

- Two voltage free transistor information outputs 

- Supply 24 VDC, 24, 115 or 230 VAC 

- Quick release connector blocks 

The RT6 is designed with a minimum amount of components thus keeping both production costs and component acquisitions to a minimum. 

Choose the RT6 to simplify your safety circuits and reduce your costs. 

6/7    2TLC172001C0202 | ABB Safety Handbook 

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## RT6 Technical information 

## Inputs 

The inputs from the safety devices must be connected according to one of the following options in order to fulfill the expected safety level and to avoid unsafe situations. 

**1.** Single channel, 1NO contact from +24 VDC, category 1, up to PL c 

**2.** Dual channel, 2NO contacts from +24 VDC, category 3, up to PL d 

**3.** Dual channel 1NO, 1 NC contact from +24 VDC, category 4, up to PL e 

**4.** Dual channel, 1NO contact from 0V and 1NO contact from +24 VDC, category 4, up to PL e 

**5.** Safety mats/contact strips 1 ‘contact’ from 0V and 1 ‘contact’ from +24 VDC, category 3, up to PL d 

When the input/inputs are activated and the test/supervised reset is complete, relays 1 and 2 are energized. Simultaneous activation is not required where there are dual channels. The two relays are de-energized when the input/inputs are de-activated in accordance with the input option chosen or in case of a power failure. Relays 1 and 2 must both be de-energized before the outputs can be activated again. 

## Indication of low voltage 

The ‘On’ LED will flash if the relay supply voltage falls below an acceptable level. This indication will also be given if a monitored safety mat/contact strip is actuated. See connection option 5. 

## Safety level 

The RT6 has internal dual and supervised safety functions. A short-circuit, internal faulty component or external interference will not present a risk to options with the highest safety level. A manual reset requires that the reset input is closed and opened before the safety relay outputs are activated. A shortcircuit or a faulty reset button is consequently supervised. 

When the RT6 is configured for dual channel input, both the inputs are supervised for correct sequence operation before the unit can be reset. 

The input options 3 and 4 have the highest safety levels as all short-circuits and power failures are supervised. This in combination with internal current limitation makes the relay ideal for supervision of safety mats and contact strips. 

## Regulations and standards 

## Transistor output status information 

The RT6 has two voltage free transistor outputs that can be connected to a PLC, computer or other monitoring device. These outputs give the input and output status of the relay. 

## Reset and testing 

The RT6 is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, see the section “Connection examples”. 

The RT6 has two reset options; manual and automatic. The manual supervised reset is used when the RT6 is monitoring safety devices that can be bypassed, i.e. to ensure that the outputs of the safety relay do not close just because a gate is closed. The automatic reset should only be used if deemed an acceptable risk. 

In addition, the RT6 can also test (supervise) whether, for example, contactors and valves etc are de-energized/de-activated before a restart is allowed. 

**Only for AC supply 

## Connection of supply - RT6 

DC supply 

AC supply 

## DC-supply of AC-units 

The RT6 DC option should be supplied with +24 V on A1 and 0 V on A2. 

The RT6 AC option should be supplied with the appropriate supply voltage via connections A1 and A2. 

The S23/ must be connected to protective earth. 

All AC-units can also be supplied by +24 VDC to S53 (0VDC to S23). 

NOTE! With both DC and AC modules, if cable shielding is used this must be connected to an earth rail or an equivalent earth point. 

ABB Safety Handbook | 2TLC172001C0202   6/8 

6 

## Connection of safety devices - RT6 

## 1. SINGLE CHANNEL, 1 NO from +24V 

The input (contact to S14) must be closed before the outputs can be activated. When the input contact is opened the relay safety output contacts open. 

## 2. DUAL CHANNEL, 2 NO from +24V 

Both input contacts (S14 and S34) must be closed before the relay outputs can be activated. The safety relay contacts will open if one or both of the input contacts are opened. Both the input contacts must be opened and reclosed before the relay can be reset. A short-circuit between inputs S14 and S34 can only be supervised if the device connected to the inputs has JOKAB Focus light curtains. 

## 3. DUAL CHANNEL, 1 NO, 1 NC from +24V 

One input contact must be closed (S14) and one opened (S44) before the relay outputs can be activated. The safety relay contacts will open if one or both of the inputs change state or in case of a short-circuit between S14 and S44. Both inputs must return to their initial positions before the relay outputs can be reactivated. Both ‘contact’ inputs from a inactivated safety mat/contact strip must be made in order to allow the RT6 relay outputs to be activated. When the safety mat/contact strip is activa 

## 4. DUAL CHANNEL, 1 NO from +24V, 1 NO to 0V 

Relay functions as for option 2, but a short-circuit, in this case between inputs S14 and S24, is supervised (safety outputs are opened). 

## 5. Safety mat/Contact strip 

Both ‘contact’ inputs from a inactivated safety mat/contact strip must be made in order to allow the RT6 relay outputs to be activated. When the safety mat/contact strip is activated or a short-circuit is detected across S14-S23, the relay will deenergize (safety outputs open) and the ‘ON’ LED will flash. As output S13 has an internal current limit of 70 mA, the RT6 will not be overloaded when the mat/contact strip is activated or a short-circuit is detec 

Manual supervised reset Automatic reset $53. 5,Ox1 OX4 *connected to S13 for Ssss Dre xa safety mat/contact strip 

## Reset connections - RT6 

The manual supervised reset contact connected to input X1 must be closed and opened in order to activate the relay outputs 

Automatic reset is selected when S53, X1 and X4 are linked. The relay outputs are then activated at the same time as the inputs. 

Testing external contactor status 

Contactors, relays and valves can be supervised by connecting ‘test’ contacts between S53 and X1. Both manual supervised and automatic reset can be used. 

## Relay outputs 

## Output connections - RT6 

The RT6 has three (3 NO) safety outputs and 1 NC information output. In order to protect the output contacts it is recommended that loads (inductive) are suppressed by fitting correctly chosen VDR’s, diodes etc. 

Transistor outputs 

Diodes are the best arc suppressors, but will increase the switch off time of the load. 

The RT6 has two(2) voltage free transistor outputs for information. 

The transistor outputs are supplied with voltage to Y13, either from S53 (+24V) or an external 5-30 VDC supply. Y14 and Y24 follow the relay inputs and outputs as follows: 

***Note These outputs are only for information purposes and must not be connected to the safety circuits of the machinery. 

- Y14 becomes conductive when the relay input conditions are fulfilled. 

- Y24 becomes conductive when both the output relays are activated. 

6/9    2TLC172001C0202 | ABB Safety Handbook 

6 

Technical data - RT6 

Short-circuit proof +5 to +30 VDC Indicates that the input conditions have been fulfilled Indicates that the output relays are activated 15 mA /output 

Transistor outputs External supply to Y13 Y14 Y24 

Article number Transistor outputs RT6 24 VDC 2TLA010026R0000 External supply to Y13 RT6 24 VAC 2TLA010026R0200 Y14 RT6 48 VAC 2TLJ010026R0300 RT6 115 VAC 2TLA010026R0400 Y24 RT6 230 VAC 2TLA010026R0500 Colour Grey Maximum load of Y14, Y24 Weight 335 g (24 VDC) Maximum voltage drop at maximum 485 g (24-230 VAC) load 2.4 V Supply LED indication Voltage (A1-A2) 24 VDC +15/-20%, On 24/115/230 VAC, +15/-10%, 50-60 Hz In1 In2 Power consumption DC supply, nominal voltage 2.3 W 1 2 AC supply, nominal voltage 5.2 VA Connection S13 Short-circuit protected voltage output, 70 mA ± 10% curMounting rent limitation. Is used for the inputs S14, S34 and S44. Rail Connection S53 Short-circuit protected voltage output, internal automatic Connection blocks (detachable) fuse 270 mA. Is used for the reset and autoreset inputs X1 and X4 Maximum screw torque 1 Nm Connection S23 0V connection for input S24 Maximum connection area: Solid conductors Safety inputs Conductor with socket contact S14 (+) input 20 mA Protection class S24 (0V) input 20 mA Enclosure S34 (+) input 20 mA Connection blocks S44 (+) input 30 mA Operating temperature range Reset input X1 Supply for reset input + 24 VDC Operating humidity range Reset current 300 mA current pulse at contact, then 30 mA Impulse withstand Voltagegee 2.5kV Minimum contact closure time for 100 ms Pollution degreegreeree 2 reset Performance (max.) The relays must be cycled at least Maximum external connection once a year. E-08 cable resistance at nominal voltage for Conformity S14, S24, S34 300 Ohm S44, X1 150 Ohm Response time At Power on DC/AC <90ms/<220ms When activating (input-output) : <20 ms 120, When deactivating (input–output) <20 ms At Power Loss <150 ms A bbip WO Relay outputs NO 3 NC 1 Maximum switching capacity Resistive load ACInductive load AC :: 6A/250 VAC/1500 VAAC15 240 VAC 2A eeepoorood!nraola | P22) | Resistive load DC 6A/24 VDC/150 W Inductive load DC DC13 24 VDC 1A Maximum total switching capacity Connector blocks are detachable Resistive load 12A distributed on all contacts (without cables having to be disconnected) Minimum load 10mA/10 V (if load on contact has not exceeded 100 mA) Contact material Ag+Au flash Fuses Output (External) 5A gL/gG Conditional short-circuit current (1 kA) 6A gG Mechanical life >10[7] operations 

2.4 V 

Supply voltage OK, the LED is on. Flashing light in case of under-voltage or overload 

Indicates that the input conditions are fulfilled. 

Indicates that the output relays are activated. 

Mounting Rail 35 mm DIN rail Connection blocks (detachable) Maximum screw torque 1 Nm Maximum connection area: Solid conductors 1x4 mm[2 ] / 2x1.5 mm[2 ] / 12AWG Conductor with socket contact 1x2.5mm[2] /2x1mm[2] Protection class Enclosure IP40 IEC 60529 Connection blocks IP20 IEC 60529 Operating temperature range -10°C to + 55°C (with no icing or condensation) Operating humidity range 35% to 85% Impulse withstand Voltagegee 2.5kV Pollution degreegreeree 2 Performance (max.) PL e/Cat. 4  (EN ISO 13849-1:2008) The relays must be cycled at least SIL 3 (EN 62061:2005)PFHD 1.35 once a year. E-08 Conformity 2006/42/EC, 2006/95/EC, 2004/108/EC, EN 62061:2005, EN ISO 138491:2008 

ABB Safety Handbook | 2TLC172001C0202   6/10 

6 

## Safety relay RT7 

## Approvals: 

**==> picture [28 x 18] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Safety relay for: 

- Emergency stops 

- Light curtains 

- Three position devices 

- Interlocked gates/hatches 

- Magnetic switches 

- Light beams 

- Safety mats 

- Contact strips 

- Foot operated switches 

## Features: 

- 4 NO / 1 NC relay outputs, 2 NO outputs can be delayed for soft stops 

## Universal relay with delayed outputs 

The RT7 is a universal relay that can be used to supervise both safety devices and the internal safety of your machinery. In addition, you can select the safety level that is required for each installation. All this is possible because the RT7 has the most versatile input options arrangement available on the market. The RT7 can therefore replace many other relays. 

The RT7 has four (4 NO) dual safety outputs of which two may be delayed for up to three seconds in order to achieve a safe and ‘soft’ stop. A ‘soft’ stop allows machinery to brake and stop gently before power is removed. A ‘soft’ stop has many benefits: the machinery life will be prolonged, processed products will not be damaged, and restarts from the stopped position are made possible and easier. 

Another option with the RT7 is manual or automatic resetting. A manual supervised reset is used for gates and other safety devices that can be bypassed, while an automatic reset is used for small safety hatches if deemed appropriate from a risk point of view. 

- Delay times RT7A 0; 0.5; 1.0; 1.5 s RT7B 0; 1.0; 2.0; 3.0 s 

- Five input options 

- Single or dual channel input 

- Manual supervised or automatic reset 

- – Test input for supervision of external contactors 

- Width 45 mm 

- LED indication of supply, inputs, outputs, short-circuit and low voltage level 

- Three voltage free transistor information outputs 

- Supply 24 VDC, 115 or 230 VAC 

- Quick release connector blocks 

In addition, the RT7 has information outputs that follow the inputs and outputs of the relay. These outputs indicate if for example a gate is opened or closed, if there is a delay or if the relay needs to be reset. 

Choose the RT7 to simplify your safety circuits and reduce your costs. 

6/11    2TLC172001C0202 | ABB Safety Handbook 

6 

## RT7 A/B Technical information 

## Inputs 

The RT7 can be configured to operate in either of the following input options: 

**1.** Single channel, 1 NO contact from +24 VDC, safety category 1, up to PL c 

**2.** Dual channel, 2 NO contacts from +24 VDC, category 3, up to PL d 

**3.** Dual channel, 1 NO, 1 NC contact from +24 VDC, category 4, up to PL e 

**4.** Dual channel, 1 NO contact from 0V and 1 NO contact from +24 VDC, category 4, up to PL e 

**5.** Safety mats/contact strips, 1 ‘contact’ from 0V and 1 ‘contact’ from +24 VDC, category 3, up to PL d 

When the input/inputs are activated and the test/supervised reset is complete, relays 1,2,3 and 4 are activated. Relays 1 and 2 are immediately de-energized when the inputs are deactivated in accordance with the input option selected. Relays 3 and 4 are either de-energized immediately or after the selected time delay. All the relays (1,2,3 and 4) must be de-energized before the RT7 can be reset. 

## Indication of low voltage 

The ‘On’ LED will flash if the relay voltage falls below an acceptable level. This indication will also be given if a monitored safety mat contact strip is actuated. See connection option 5. 

## Safety level 

The RT7 has internal dual and supervised safety functions. Power failure, an internal faulty component or external interference will not present a risk to options with the highest safety level. A manual reset requires that the reset input is closed and opened before the safety relay outputs are activated. A short-circuit or a faulty reset button is consequently supervised. 

When the RT7 is configured for dual channel input, both the inputs are supervised for correct sequence operation before the unit can be reset. The input options 3 and 4 have the highest safety levels as all short-circuits and power failures are supervised. This in combination with internal current limitation makes the relay ideal for supervision of safety mats and contact strips. 

## Regulations and standards 

## Transistor output status information 

The RT7 has three(3) voltage free transistor outputs that can be connected to a PLC, computer or other monitoring device. These outputs give the input and output status of the relay. 

## Reset and testing 

The RT7 is designed and approved in accordance with appropriate directives and standards. Se tekniska data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, see the section “Connection examples”. 

The RT7 has two reset options; manual and automatic. The manual supervised reset is utilised when the RT7 is used to monitor safety devices that can be bypassed, i.e. to ensure that the outputs of the safety relay do not close just because the gate is closed. 

The automatic reset should only be used if acceptable from a risk point of view. The RT7 can also test (supervise), if for example, contactors and valves etc are de-energized/deactivated before a restart is allowed. 

**Only for AC supply 

Connection examples – RT7 

DC supply 

AC supply 

DC-supply of AC-units 

The RT7 DC option should be supplied with +24 V on A1 and 0 V on A2. 

The RT7 AC option should be supplied with the appropriate supply voltage via connections A1 and A2. 

All AC-units can also supplied by +24 VDC to S53 (0 VDC to S23). 

The S23/ must be connected to protective earth 

ABB Safety Handbook | 2TLC172001C0202   6/12 

## Connection of safety devices - RT7 A/B 

## 1. SINGLE CHANNEL, 1 NO from +24V 

The input (contact to S14) must be closed before the outputs can be activated. When the input contact is opened the relay safety output contacts open. 

## 2. DUAL CHANNEL, 2 NO from +24V 

Both input contacts (S14 and S34) musbe closed before the relay outputs can be activated. The safety relay contacts will open if one or both of the input contacts are opened. Both the input contacts must be opened before the relay can be reset. A short-circuit between the inputs S14 and S34 can only be supervised if the device connected to 6 the inputs has short-circuit supervised outputs, e.g. ABB Jokab Safety´s Focus light curtains. 

and S24, is supervised (safety outputs are opened) 

are opened) 3. DUAL CHANNEL, 1 NO, 1 NC from iz oo cu sas Gera Qys24 \ 7 het Osa J eben 

3. DUAL CHANNEL, 1 NO, 1 NC from 

+24V 

## 5. Safety mat/Contact strip 

One input contact must be closed (S14) and one opened (S44) before the relay outputs can be activated. The safety relay contacts will open if one or both of the inputs change state or in the case of a short-circuit between S14 and S44. Both inputs must be returned to their initial positions before the relay outputs can be reactivated. 

Both ‘contact’ inputs from an inactivated safety mat/contact strip, must be made in order to allow the RT7 relay outputs to be activated. When the safety mat/contact strip is activated or a short-circuit is detected across S14S23, the relay will de-energize (safety outputs open) and the ‘ON’ LED will flash. As output S13 has an internal current limit of 70 mA, the RT7 will not be overloaded when the mat/contact strip is activated or a short circuit is detected. 

## 4. DUAL CHANNEL, 1 NO from +24V, 1 NO from 0V 

Relay functions as option 2, but a shortcircuit, in this case between inputs S14 

## Reset connections - RT7 A/B 

**==> picture [167 x 60] intentionally omitted <==**

**----- Start of picture text -----**<br>
Manual supervised reset Automatic reset<br>$53 %OxX1 OX4 *connected to S13 for  $53. X41 x4<br>safety mat/contact<br>strip<br>**----- End of picture text -----**<br>


The manual supervised reset contact connected to input X1 must be closed and opened in order to activate the  relay outputs. 

Automatic reset is selected when S53, X1 and X4 are linked. The relay outputs are then activated at the same time as the inputs. 

Contactors, relays and valves can be supervised by connecting ‘test’ contacts between S53 and X1. Both manual supervised and automatic reset can be used. 

Testing external contactor status 

Output connections - RT7 A/B 

## Time delay outputs 

## Relay outputs 

The RT7 has four (4 NO) safety outputs of which two can be delayed, and 1 NC information output. 

In order to protect the RT7 output contacts it is recommended that loads (inductive) are suppressed by fitting correctly chosen VDR’s, diodes etc. Diodes are the best arc suppressors, but will increase the switch off time of the load. 

## Transistor outputs 

The RT7 has three(3) voltage free transistor information outputs. 

The transistor outputs are supplied with voltage to Y13 either from S53 (+24V) or externally from 5 to 30 VDC. Y14, Y24 and Y34 follow the inputs and outputs as follows: 

- Y14 becomes conductive when the relay input conditions are fulfilled. 

- Y24 becomes conductive when both the output relays are activated. 

- Y34 becomes conductive when both the delay output relays are activated. 

Time delays are selected by linking the appropriate T0, T1 and T2 connections. 

When a stop signal is detected a program stop command is first given to the PLC/servo which brakes the dangerous machine operations in a ‘soft’ and controlled way. 

The delayed relay safety outputs will then turn off the power to the motors, i.e. when the machinery has already stopped. It takes usually around 0.5 to 3 seconds for a dangerous action to be stopped softly. 

6/13    2TLC172001C0202 | ABB Safety Handbook 

Technical data - RT7 A/B 

|Technical data - RT7 A/B||
|---|---|
|Article number<br>RT7B<br>24 VDC 3 s<br>24 VAC 3 s<br>115 VAC 3 s<br>230 VAC 3 s<br>RT7A<br>24 VDC 1.5 s<br>24 VAC 1.5 s<br>115 VAC 1.5 s<br>230 VAC 1.5 s|2TLA010028R1000<br>2TLA010028R1200<br>2TLA010028R1400<br>2TLA010028R1500<br>2TLA010028R2000<br>2TLA010028R2200<br>2TLA010028R2400<br>2TLA010028R2500|
|Colour|Black and beige|
|Weight|405 g (24 VDC)<br>550 g (24-230 VAC)|
|Supply<br>Voltage (A1-A2)|24 VDC +15/-20%,<br>115/230 VAC,<br>±15%,50-60 Hz|
|Power consumption<br>DC supply, nominal voltage<br>AC supply,nominal voltage|4.6 W<br>8.8 VA|



Connection S13 Short-circuit protected voltage output, 70 mA ±10% current limitation. Is used for the inputs S14, S34 and S44. Connection S53 Short-circuit protected voltage output, internal automatic fuse, max 270 mA. Is used for the reset and autoreset inputs X1 and X4. Connection S23 0V connection for input S24. 

|Safety inputs<br>S14 (+) input<br>S24 (0V) input<br>S34 (+) input<br>S44 (+) input|20 mA<br>20 mA<br>20 mA<br>25 mA|
|---|---|
|Reset input X1<br>Supply for reset input<br>Reset current<br>Minimum contact closure time for<br>reset|+ 24VDC<br>600 mA current pulse at contact<br>closure, then 30 mA.<br>100 ms|
|Maximum external connection cable<br>resistance at nominal voltage for<br>S14, S24, S34<br>S44,X1|300 Ohm<br>150 Ohm|
|Response time<br>At Power on DC/AC<br>When activating (input-output)<br>When deactivating (input–output)<br>At Power Loss|<90/<140 ms<br><20 ms<br><20 ms<br><80 ms|
|Delay time options<br>RT7A<br>RT7B|0; 0.5; 1.0; 1.5 secs<br>0;1.0;2.0;3.0 secs|
|Relay outputs<br>NO direct (relays 1/2)<br>NO direct or delayed (relays 3/4)<br>NC (relays 1/2)<br>Maximum switching capacity<br>Relays 1/2 Resistive load AC<br>Inductive load AC<br>Resistive load DC<br>Inductive load DC<br>Relays 1/2 total|2<br>2<br>1<br>6A/250 VAC/1500 VA<br>AC15 240 VAC 2A<br>6A/24 VDC/150 W<br>DC13 24 VDC 1A<br>Max 9A distributed on all contacts|
|Relays 3/4 Resistive load AC<br>Inductive load AC<br>Resistive load DC<br>Inductive load DC|6A/230 VAC/1380 VA<br>AC15 230 VAC 4A<br>6A/24 VDC/144W<br>DC13 24 VDC 2A|
|Relays 3/4 total|Max 6A distributed on all contacts|



Contact material AgSnO2+ Au flash Fuses output 1/2 (external) 5A gL/gG Fuses output 3/4 (external) 3A gL/gG Conditional short-circuit current (1 kA), each output 6A gG Mechanical life >10[7] operations Transistor outputs External supply to Y13 +5 to +30 VDC Y14 Indicates that the input conditions are fulfilled Y24 Indicates that the output relays 1/2 are activated Y34 Indicates that the delay output relays 3/4 are activated Maximum load of Y14,Y24, Y34 15 mA /output Maximum voltage drop at maximum load 2.4 V LED indication On Supply voltage OK, the LED is on. 

On Supply voltage OK, the LED is on. Flashing light in case of under-voltage or overload. In1 In2 Indicates that the input conditions are fulfilled. 1 2 Indicates that the output relays 1/2 6 are activated. t Indicates that the delay output relays 3/4 are activated.ys 3/4 are activated.s 3/4 are activated. 

1 2 are activated. t Indicates that the delay output relays 3/4 are activated.ys 3/4 are activated.s 3/4 are activated. Mounting Rail 35 mm DIN rail Connection blocks (detachable) Maximum screw torque 1 Nm Maximum connection area: Solid conductors 1x4 mm[2 ] / 2x1,5 mm[2] /12AWG Conductor with socket contact 1x2.5 mm[2] / 2x1 mm[2] Protection class Enclosure IP40 IEC 60529 Connection blocks IP20 IEC 60529 Operating temperature range 24 VDC -10° C to + 55° C (with no icing or condensation) 24-230 VAC -10° C to + 45° C (with no icing or condensation) Operating humidity range 35% to 85% Impulse withstand Voltage 2.5kV Pollution degree 2 Performance (max.) PL e/Cat. 4 The relays must be cycled at least (EN ISO 13849-1:2008) SIL 3 (EN 62061:2005) once a year. PFHD 1.86 E-08 Conformity 2006/42/EC, 2006/95/EC, 2004/108/EC EN 62061:2005 EN ISO 13849-1:2008 

**==> picture [187 x 75] intentionally omitted <==**

**----- Start of picture text -----**<br>
120<br>Connector blocks are detachable<br>84 (without cables having to be disconnected)<br>45<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   6/14 

6 

## Safety relay RT9 

## Approvals: 

TÜV NORD C€ &. Safety relay for: – Emergency stops – Light curtains – Three position devices – Interlocked gates/hatches – Magnetic switches – Light beams – Safety mats – Contact strips – Foot operated switches _— Features: 

- Five input options 

- Single or dual channel input 

- Manual supervised or automatic reset 

- Test input for supervision of external contactors 

Would you like a small safety relay for all your safety applications? Then choose the compact RT9 universal relay to supervise both your safety devices and the internal safety of your machinery. In addition, you can select the safety level that is required for each installation. All this is possible due to the RT9 offering the most versatile input option arrangement available on the market. The RT9 can therefore replace many other relays. 

Other RT9 options include selection of either  manual supervised or automatic resetting. The manual supervised reset can be used for gates and other safety devices that can be bypassed. Automatic reset can be used for small safety hatches, if deemed acceptable from risk assessment. 

- Width 22.5 mm 

- LED indication of supply, inputs and outputs, shortcircuit and low voltage level 

- 2 NO relay outputs 

- One changeover relay with a  double information output Supply 24 VDC 

- Quick release connector blocks 

In addition, the RT9 has a double information output that will indicate e.g if a gate is open or if the relay needs resetting. 

The RT9 uses the latest component technology and modern assembly techniques to ensure a highly cost effective solution. 

Choose the RT9 to simplify your safety circuits and reduce your costs. 

6/15    2TLC172001C0202 | ABB Safety Handbook 

6 

## RT9 Technical information 

## Inputs 

The RT9 can be configured to operate in either of the following input options: 

**1.** Single channel, 1 NO contact from +24 VDC, category 1, up to PL c 

**2.** Dual channel, 2 NO contacts from +24 VDC, category 3, up to PL d 

**3.** Dual channel, 1 NO, 1 NC contact from +24 VDC, category 4, up to PL e 

**4.** Dual channel, 1 NO contact from 0V and 1 NO contact from +24 VDC, category 4, up to PL e 

**5.** Safety mat/contact strips, 1 ‘contact’ from 0V and 1 ‘contact’ +24 VDC, category 3, up to PL d 

When the input/inputs are activated and the test/supervised reset is complete, relays 1 and 2 are energised. These are de-energised when the input/inputs are de-activated in accordance with the input option chosen or in case of a power failure. 

Relays 1 and 2 must both be de-energized before the RT9 can be reset. 

## Relay output status information 

The RT9 has a changeover contact relay output that can be connected to a PLC, control lamp, computer or similar. The output gives information about the status of the relay. 

In addition, the RT9 can also test (supervise), if for example, contactors and valves etc are de-energised/de-activated before a restart is made. 

## Indication of low voltage 

The ‘On’ LED will flash if the relay supply voltage falls below an acceptable level. This indication will also be given if a monitored safety mat/contact strip is actuated. Please see Connection option 5. 

## Safety level 

The RT9 has internal dual and supervised safety functions. Power failure, an internal faulty component or  external interference will not present a risk to options with the highest safety level. A manual reset requires that the reset input is closed and opened before the safety relay outputs are activated. A short-circuit or a faulty reset button is consequently supervised. 

When the RT9 is configured for dual channel input, both the inputs are supervised for correct operation before the unit can be reset. 

The input options 3 and 4 have the highest safety levels as all short-circuits and power failures are supervised. This in combination with an internal current limitation makes the relay ideal for supervision of safety mats and contact strips. 

## Regulations and standards 

## Reset and testing 

The RT9 has two reset options; manual and automatic. The manual supervised reset can be used when the RT9 is monitoring safety devices that can be bypassed, i.e. to ensure that the outputs of the safety relay do not close just because a gate is closed. The automatic reset option should only be used if appropriate from a risk point of view. 

The RT9 is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

Due to special internal circuits the RT9 can be automatically reset regardless of the operational voltage rise time, this being an important factor when large loads are started up on the same power supplies at the same time. 

## Connection of supply - RT9 

DC supply 

Short circuit protection AtT ~~OO~~ oS S13 | s 14 Automatic fuse 

The RT9 should be supplied with +24 V on A1 and 0 V on A2. 

NOTE! If cable shielding is used this must be connected to an earth rail or an equivalent earth point. 

ABB Safety Handbook | 2TLC172001C0202   6/16 

## Connection of safety devices - RT9 

1. SINGLE CHANNEL, 1 NO from +24V 

The input (contact to S14) must be closed before the outputs can be activated. When the input contact is opened, the relay safety output contacts open. 

2. DUAL CHANNEL, 2 NO from +24V Both input contacts (S14 and S34) must be closed before the relay outputs can be activated. The safety relay contacts will open if one or both of the input contacts are opened. Both the input contacts must be opened and reclosed before the relay can be reset. 6 5[).][hea][hore][saa][ Har] ~~[)]~~[Ys24] 

A short-circuit between inputs S14 and S34 can only be supervised if the device connected to the inputs has short-cir- 

cuit supervised outputs, e.g. ABB Jokab Safety´s Focus light curtains 

3. DUAL CHANNEL, 1 NO, 1 NC from +24V 

One input contact must be closed (S14) and one opened (S44) before the relay outputs can be activated. 

The safety relay contacts will open if one or both of the inputs change state or in case of a short-circuit between S14 and S44. Both inputs must be returned to their initial status before the relay outputs can be reactivated. 

> 4. DUAL CHANNEL, 1 NO from +24V, = es hen im Hr2) Ys24 

4. DUAL CHANNEL, 1 NO from +24V, 1 NO from 0V 

Relay functions as option 2, but a shortcircuit, in this case between inputs S14 

and S24, is supervised (safety outputs are opened). 

5. Safety mat/Contact strip 

Both ‘contact’ inputs from a inactivated safety mat/contact strip must be made in order to allow the RT9 relay outputs to be activated. When the safety mat/ contact strip is activated or a shortcircuit is detected across S14-S23, the relay will de-energize (safety contacts open) and the ‘ON’ LED will flash. As output S13 has an internal current limit of 70 mA, the RT9 will not be overloaded when the mat/contact strip is activated or a short-circuit is detected. IL 

## Reset connections - RT9 

## Manual supervised reset 

The manual supervised reset contact connected to input X1 must be closed and opened in order to activate the relay outputs. 

## Automatic reset 

Automatic reset is selected when A1(+), X1 and X4 are linked. The relay outputs are then activated at the same time as the inputs. 

## Testing external contactor status 

Contactors, relays and valves can be supervised by connecting ‘test’ contacts between A1(+) and X1. Both manual supervised and automatic reset can be used. 

Output connections - RT9 

## Relay outputs 

## Information outputs 

The RT9 has two (2 NO) safety outputs. 

In order to protect the output contacts it is recommended that loads (inductive) are suppressed by fitting correctly chosen VDR’s, diodes etc. Diodes are the best arc suppressors, but will increase the switch off time of the load. 

The RT9 has a single changeover contact information relay output.The relay output Y14 is connected internally to 0V and 24V in the following way: 

- Y14 is internally closed to 0V when the RT9 is not reset. 

- Y14 is internally closed to +24V when the relay is reset. 

6/17    2TLC172001C0202 | ABB Safety Handbook 

Technical data – RT9 

|Technical data – RT9|||||||||
|---|---|---|---|---|---|---|---|---|
|Article number||||LED indication|||||
|RT9 24 VDC|||2TLA010029R0000|On|||Supply voltage OK, the LED is on.||
|Colour|||Grey||||Flashing light in case of under-volta-||
|Weight<br>Supply<br>Voltage (A1-A2)|||210 g<br>24 VDC ±20%|In1<br>In2|||ge, overload or current limiting<br>Indicates that the input conditions<br>are fulfilled.||
|Power consumption<br>Nominal voltage|||2 W|1<br>2|||Indicates that the output relays have<br>been activated.||
|Connection S13|||Short-circuit protected voltage<br>output|Mounting<br>Rail|||35 mm DIN rail||
||||70 mA ± 10% current limitation. Is|Connection blocks|||||
||||used for the inputs S14, S34 and|(detachable)<br>Maximum screw torque|||1 Nm||
||||S44.|Maximum connection area:|||||
|Input currents<br>(at nominal supply voltage)<br>S14 (+) input<br>S24 (0V) input<br>S34 (+) input<br>S44 (+) input<br>Reset input X1<br>Supply for reset input|||30 mA<br>20 mA<br>20 mA<br>25 mA<br>+ 24 VDC|Solid conductors<br>Conductor with socket contact<br>Protection class<br>Enclosure<br>Connection blocks<br>Operating temperature range|||1x4 mm2/ 2x1.5 mm2/ 12AWG<br>1x2.5 mm2/ 2x1 mm2<br>IP40 IEC 60529<br>IP20 IEC 60529<br>-10°C to + 55°C (with no icing or<br>condensation)||
|Reset current|||300 mA current pulse at contact|Operating humidity range|||35% to 85%||
|Minimum contact closure time<br>for reset|||closure, then 30 mA<br>80 ms|Impulse withstand Voltage<br>Pollution degree|||2.5kV<br>2|6|
|Minimum contact closure time||||Performance (max.)|||PL e/Cat. 4||
|(at low limit voltage -20%)|||100 ms|The relays must be cycled at least|The relays must be cycled at least||(EN ISO 13849-1:2008)||
|Maximum external connection||||once a year.|||SIL 3 (EN 62061:2005)PFHD9.55E-09||
|cable resistance at a nominal<br>voltage for<br>S14, S24, S34|||300 Ohm|Conformity|||2006/42/EC, 2006/95/EC,<br>2004/108/EC EN 62061:2005||
|S44, X1|||150 Ohm||||EN ISO 13849-1:2008||
|Response time<br>At Power on<br>When activating (input-output)<br>When deactivating (input–output)<br>At Power Loss|||<100 ms<br><20 ms<br><20 ms<br><80 ms||||||
|Relay outputs|||||||||
|NO|||2||||||
|Maximum switching capacity<br>Resistive load AC<br>Inductive load AC<br>Resistive load DC|:||6A/250 VAC/1500 VA<br>AC15 240 VAC 2A<br>6A/24 VDC/150 W|||is<br>2000||||
|Inductive load DC|||DC13 24 VDC 1A||||||
|Max. total switching capacity:<br>Minimum load<br>Contact material<br>Fuses output (External)|i||8A distributed on all contacts<br>10 mA/10V (if load on contact has<br>not exceeded 100 mA)<br>Ag+Au flash<br>5A gL/gG||||84<br>' poog|||
|Conditional short-circuit current<br>(1 kA)|||6A gG|||225,||||
|Mechanical life<br>Relay information output Y14|||107operations|Connector blocks are detachable<br>(without cables having to be disconnected)|||||
|(Changeover contacts)|||||||||
|-(0V)|||Indicates that RT9 is not reset.||||||
|+(24V)|||Indicates that RT9 is reset.||||||
|Maximum load of Y14|||250 mA||||||
|Short-circuit protection for|||||||||
|information output|||Internal automatic fuse||||||



ABB Safety Handbook | 2TLC172001C0202   6/18 

6 

## Safety relay JSBRT11 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Emergency stops 

- Light curtains 

- Three position devices 

- Interlocked gates/hatches 

- Magnetic switches 

- Light beams 

- Safety mats 

- Foot operated switches 

## Features: 

- Selectable inputs and safety category 

- Manual supervised or automatic reset 

- Width 100 mm 

## A flexible safety relay with many outputs 

The JSBRT11 has been designed to provide the safety system circuit designer with the ability to select from both a range of input connection configurations and either automatic or supervised reset. 

- LED indication for supply, inputs and outputs 

- 7 NO + 2 NC relay outputs 

- – Supply 24 VDC 15 or 230 VAC 

- Quick release connector blocks 

The unit can be hardwire configured to operate in either of the following input configurations: 

- Mode 1: Single Channel (1 NO contact from +24 VDC), category 1 PL c 

- Mode 2: Dual Channel (2 NO contacts from +24 VDC), category 3 PL d 

- Mode 3: Dual Channel (1 NO, 1NC contacts from +24 VDC), category 4 PL e. 

- Mode 4: Dual Channel (1 NO contact from 0 V and 1 NO contact from + 24 VDC), safety category 4. 

In addition the unit can also be used to test that contactors and valves have fallen/returned to their ’reset’ state before a new ’start’ signal is given. 

When wired for supervised reset, should a short circuit appear across the reset input the relay will not automatically reset when the input/inputs are made. Only when the super-vised reset input is made and broken will the relay reset. 

The JSBRT11 provides de tection of contact failure in the inputs when wired in dual channel mode. Both inputs have to be opened and closed in order to enable the reactivation of the relay. The highest safety level of the JSBRT11 is in configuration mode 3 and 4 because all short circuits are supervised  i.e. a short circuit between the inputs leads to a safe state as the outputs drop out. 

## Safety level 

The JSBRT11 has dual and monitored internal safety functions. Power failure, internal component failures or ex ternal interference (with the exception of short circuiting of input contact when used in a single channel input mode) do not result in a dangerous function. 

## Regulations and standards 

The JSBRT11 is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/19    2TLC172001C0202 | ABB Safety Handbook 

Technical description – JSBRT11 

Technical data – JSBRT11 

**==> picture [210 x 73] intentionally omitted <==**

**----- Start of picture text -----**<br>
* K<br>** K<br>***<br>*Supervision circuit       **Test and Automatic reset circuit<br>*** Only for AC-supply<br>Supply<br>**----- End of picture text -----**<br>


**==> picture [32 x 42] intentionally omitted <==**

The supply voltage is connected across A1 and A2. The input connection configuration and type of reset required is set by connecting the unit as shown in the diagrams below 

When the input/inputs and the test/supervised reset are made K1 and K2  energise. K1 and  K2  will de-energize if  the power is disconnected or a stop signal is given in accordance to the configuration mode wired. Both K1 and K2 have to be de-activated before the  outputs of the  JSBRT11 can be closed again. 

## – Configuration mode 1. 

When the single input opens both K1 and K2 relays  are deactivated. 

- Configuration mode 2. 

Both inputs have to be closed in order  to enable  the unit to be activated. A stop signal is given if both or one input is opened. Both inputs have to be opened and reclosed in order to enable the reactivation of the unit. If the possibility of short circuits between the inputs cannot be excluded, configuration mode 3 or 4 should be used in order to reach the highest safety level. 

- Configuration mode 3. 

One  input has to be closed and the other input has to be opened in order to enable the unit to be activated. A stop signal is given if both or one input change state. Both inputs have to change state in order to give a dual stop function and to allow a new start after stop. 

- Configuration mode 4. 

Operation as mode 2 but short circuits between the inputs leads to a safe state i.e. the relays inside the JSBRT11 will drop out. 

- Supervised reset connection. 

The input to X1 (see  diagram below) has to be closed and opened  in order to activate the unit, after input/inputs are made according to the configuration mode selected. This mode is selected when X1 - X4 is open-circuit. 

**==> picture [288 x 554] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSBRT11 24 VDC 2TLA010025R0000<br>JSBRT11 115 VAC 2TLA010025R0400<br>JSBRT11 230 VAC 2TLA010025R0500<br>Colour Grey<br>Power supply A1 - A2 24 VDC ± 15%<br>115, 230 VAC ± 15%, 50-60 Hz<br>Power consumption 3.2 W/7.9 VA<br>Relay Outputs 7 NO and 2 NC<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC  AC15 240 VAC 2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC  DC13 24 VDC 1A<br>Max. total switching capacity 21A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA)<br>Contact material AgSnO2+ Au flash<br>Fuses Output (External) 6A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max. Input wire res. at nom.  200 Ohm (S14,S24,S34,X1,X4); 100<br>voltage Ohm (S44)<br>Response time at deactivation  6<br>(input-output) <20 ms<br>Response time at activation<br>(input-output) <30 ms<br>Terminals (max. screw torque 1 Nm)<br>Single strand: 1x4 mm [2 ] / 2x1.5 mm [2]<br>Conductor with socket contact: 1x2.5 mm [2 ] / 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class<br>enclosure IP40 IEC 60259<br>terminals IP20 IEC 60259<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>Function indication Electrical Supply, Input 1 and 2,<br>Output relays 1 and 2<br>Weight 610 g (24 VDC) 790 g (24-230 VAC)<br>Performance (max.) PL e/Cat. 4<br>Functional test: The relays must  (EN ISO 13849-1:2008)<br>be cycled at least once a year. SIL 3 (EN 62061:2005) PFHD 1.69E-08<br>Conformity 2006/42/EC, 2006/95/EC, 2004/108/<br>EC, EN 62061:2005 EN ISO 13849-<br>1:2008<br>**----- End of picture text -----**<br>


- Automatic reset connection. 

The input has to be closed in order to activate the unit after input/inputs are made according to the configuration mode selected. This mode is selected when a connection between X1 and X4 is made. 

## Electrical connection – JSBRT11 

SINGLE CHANNEL *, 1 NO from +24V DUAL CHANNEL*, 1 NO,  1 NC from +24V 

## – Test. 

Test contacts of contactors can be connected between S53 and X1 for supervision. 

ABB Safety Handbook | 2TLC172001C0202   6/20 

Safety relay JSBR4 

6 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

– Two-hand devices of type IIIc 

- Emergency stop 

- Three position devices 

- Interlocked Gates/Hatches 

- Contact strips 

- Safety mats 

- Foot operated switches 

## Features: 

- Two channel with concurrency requirement of 

   - 0.5 s 

- Supervised reset 

- Test input 

- Width 45 mm 

## A universal relay for two-hand and many other safety devices 

The JSBR4 has two inputs, which both have to be closed to keep the safety output contacts  closed. A short-circuit across the inputs  will cause the output contacts to open. The inputs can however be subjected to a continuous shortcircuit without damaging the safety relay. 

In order to make the safety outputs close the reset input must be closed and opened. In this way an unintentional reset is prevented in the case of a short-circuit in the reset button cable or if the button gets jammed in the actuated position. The reset input can also be used for test/supervision to ensure  that contactors or valves have returned to their initial off/stop position before a new start can be allowed by the safety relay. 

When the JSBR4 is used as a two-hand device relay, both buttons have to be pressed within 0.5 seconds of each other in order to close the outputs. 

When the JSBR4 is used for Safety Mats and Safety Strips the ”stop” condition is given following detection of a shortcircuit between input channels A and B. The safety mat, safety strip or the relay will not be damaged by a continuous short-circuit. This also gives the advantage that if there is a failure between the inputs in the installation, the safety relay will not be damaged. 

- LED indication for supply, inputs and outputs 

- 3 NO/1NC relay outputs 

- Supply 24 VDC, 24, 115 or 230 VAC 

- Quick release connector blocks 

## Safety level 

The JSBR4 has a twin supervised safety function. Component failure, short-circuit or external disturbance (e.g. loss of power supply) will not prevent the safe function of the relay. This is valid both for the inputs A and B as well as for the reset input. The JSBR4 operates at the highest safety level for safety relays (PL e according to EN ISO 13849-1). 

## Regulations and standards 

The JSBR4 is designed and approved in accordance with appropriate directives and standards. See technical data.The JSBR4 complies with the highest safety level for the connection of a two-hand device of type IIIc in accordance with EN 574. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/21    2TLC172001C0202 | ABB Safety Handbook 

Technical description – JSBR4 

## Technical data – JSBR4 

**==> picture [96 x 63] intentionally omitted <==**

**==> picture [156 x 76] intentionally omitted <==**

**----- Start of picture text -----**<br>
Prot.<br>circ. Reset & Supervision circ.<br>*<br>* Only for AC-supply<br>**----- End of picture text -----**<br>


The electrical supply  is connected across A1 and A2. After Voltage reduction and Rectification (AC-versions) or reverse polarity protection (DC-version) there is an overload protection-circuit. 

When the inputs S13-S14 and S23-S24 have closed and the reset is made, the relays K1 and K2 are activated. A dual stop signal is given when K1 and K2 drop, due to short circuiting between the inputs, opening of the inputs or power failure. If one input is opened the other input must also be opened for K1 and K2 to be activated again. 

The monitoring circuit checks K1 and K2 and that the reset circuit to X2 is both closed and opened before K1 and K2 are energized. Both the stop and reset function therefore comply with the requirement that a component fault, short circuit or external interference do not result in a dangerous function. 

The safety outputs consist of contacts from K1 and K2 connected internally in series across terminals 13 - 14, 23 -24 and 33 - 34. These contacts are used to cut the power to components which stop or prevent hazardous movements/ functions. It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

NOTE! Output 41-42 is intended for indication purposes only, e.g. gate opened. No load between S14 and S24 allowed. 

## Electrical connection – JSBR4 

**==> picture [257 x 53] intentionally omitted <==**

Emergency stop with manual resetting. 

Interlocked gate with manual reset. 

**==> picture [288 x 535] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSBR4 24 VDC 2TLA010002R0000<br>JSBR4 24 VAC 2TLA010002R0200<br>JSBR4 115 VAC 2TLA010002R0400<br>JSBR4 230 VAC 2TLA010002R0500<br>Colour Black and beige<br>Power supply 24 VDC ± 15%<br>24/115/230 VAC ± 15%, 50 - 60 Hz<br>Power consumption 1.3 W/3.3 VA<br>Relay outputs 3 NO + 1 NC<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC  AC15 240 VAC 2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC  DC13 24 VDC 1A<br>Max. res. load total switching<br>capacity 12A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA)<br>Contact material Ag + Au flash<br>Fuses output (external) 5A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max. Input wire res. at nom.  300 Ohm (S13 - S14 and S23 - S24) 6<br>voltage<br>Response time at deactivation < 20 ms (145 ms at power loss)<br>Terminals<br>(max. screw torque 1 Nm)<br>Single strand: 1 x 2.5 mm [2 ] / 2 x 1 mm [2] .<br>Conductor with socket contact:  1 x 4 mm [2 ] / 2 x 1.5 mm [2] .<br>Mounting 35 mm DIN-rail<br>Protection class IP40 / IP20 IEC 60529<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Inputs, Outputs<br>Weight 350 g (24 VDC),<br>460 g (24-230 VAC)<br>Values Safety Category 4 according to<br>(With Proof test interval 1 year) EN 954-1, PL e, SIL 3,<br>PFHD 1.35E-08<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC,EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


**==> picture [115 x 53] intentionally omitted <==**

Contact mat/strip with manual reset. 

**==> picture [385 x 56] intentionally omitted <==**

Two hand device with buttons in separate or same  enclosure. Buttons to be pressed in within 0.5 s of each other. Footpedal switches can be connected in the same configuration. 

Enabling device, JSHD4. Stop condition is given in both  top and bottom PB positions. 

Control and supervision of external conductor, relay, valve or ABB Jokab Safety’s expansion relays. 

ABB Safety Handbook | 2TLC172001C0202   6/22 

6 : 

## Safety relay JSBT4 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Emergency stops 

- Three position devices 

- Interlocked Hatches 

- Safety mats 

- Contact strips 

– Foot operated switches Features: – Dual input channels synchronism 0.5 s – Test input – Width 45 mm – LED indications for power on, inputs and outputs – 3 NO/1NC relay outputs – Supply 24 VDC Safety relay with synchronised dual input channels – Quick release connector (within 0.5s) blocks The JSBT4 has two inputs, both of which have to be closed ~~_~~ in order to keep the safety output contacts closed. A short circuit between inputs A and B will cause the output contacts to open. The inputs can be continuously short circuited without damaging the safety relay. due to the fact that a short-circuit between the inputs will For  the outputs to close, the test input must be closed. The directly open the relay's safety outputs. 

For  the outputs to close, the test input must be closed. The test input is intended to monitor that contactors or valves have dropped/returned before a new start is permitted. 

## Regulations and standards 

The JSBT4 is designed and approved in accordance with appropriate directives and standards. See technical data. 

This test input must not be confused with the reset function required for gates that a person can walk through and where there is a high safety requirement (see JSBR4). 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

If the JSBT4 is used for safety Mats and safety Strips, the "stop" condition is given following detection of a short circuit. The safety mat, safety strip or the relay will not be damaged by a continuous short-circuit. This also provides the advantage that if there is a failure between inputs A and B in the installation, the safety relay will not be damaged. 

## Safety level 

The JSBT4 has a twin supervised safety function. Component failure, short-circuit or external disturbance (e.g. loss of power supply) will not prevent the safe function of the relay. Safety category level 3 or 4, depending on use. 

The true two-channel safety function has the advantage that the cabling installation demands for safety can be reduced, 

6/23    2TLC172001C0202 | ABB Safety Handbook 

## Technical description – JSBT4 

**==> picture [224 x 69] intentionally omitted <==**

**----- Start of picture text -----**<br>
Prot.<br>circProt. Reset & Supervision circ.<br>circ.<br>*<br>*Only for AC-supply<br>**----- End of picture text -----**<br>


The electrical supply  is connected across A1 and A2. After Voltage reduction and Rectification (AC-versions) or reverse polarity protection (DC-version) there is an overload protection-circuit. 

When the inputs S13-S14 and S23-S24 are closed within 0.5 seconds of each other the relays K1 and K2 are energized . A dual stop signal is given, K1 and K2 de-energize, when there is a short circuit between or an opening of the inputs or at power loss. If one input is opened the other one also has to be opened in order to activate K1 and K2 again. The test circuit, X1 - X2,has to be closed in order to activate the outputs, thereafter the test circuit can be opened or closed continously. If the test circuit is closed after the inputs there is no requirement to close them within 0.5 seconds of each other. 

The internal supervision circuit monitors the two Inputs and relays K1, K2. The stop function then fulfils the requirement that one failure (short circuit, component, external disturbance) shall not prevent the safe function of the JSBT4. 

The safety outputs consist of contacts from K1 and K2 connected internally in series across terminals 13 - 14, 23 -24 and 33 - 34. These contacts are used to cut the power to components which stop or prevent hazardous movements/ functions. It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

The NC output 41 - 42 should only be used for monitoring purposes e.g. Indication lamp or PLC input etc. The output contacts are closed until the module is reset. 

NOTE! Output 41-42 is intended for indication purposes only, e.g. gate opened. No load between S14 and S24 allowed. 

## Technical data – JSBT4 

**==> picture [288 x 501] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSBT4 24 VDC 2TLA010004R0000<br>JSBT4 24 VAC 2TLJ010004R0200<br>JSBT4 230 VAC 2TLJ010004R0500<br>Colour Grey<br>Power supply 24 VDC ±15%<br>Power consumption BT50 1.4W/BT50T 1.8W<br>Relay outputs 3 NO + 1 NC<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC  AC15 240VAC 2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC  DC13 24VDC 1A<br>Max. res. load total switching<br>capacity 12A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA)<br>Contact material Ag + Au flash<br>Fuses output (external) 5A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max. Input wire res. at nom.  300 Ohm (S13 - S14 and S23 - S24)<br>voltage<br>Response time at deactivation < 20 ms, 145 ms with switched  6<br>supply/power loss<br>Terminals<br>(max. screw torque 1 Nm)<br>Single strand 1x4 mm [2 ] / 2x1.5 mm [2]<br>Conductor with socket contact 1x2.5 mm [2 ] / 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class  IP40 / IP20 IEC 60529<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Inputs, Outputs<br>Weight 350 g (24 VDC), 460 g (24-230 VAC)<br>Values Safety Category 4 according to,<br>(With Proof test interval 1 year) PL e, SIL 3, PFHD 1.51E-08<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC, EN 62061:2005,<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


**==> picture [521 x 172] intentionally omitted <==**

**----- Start of picture text -----**<br>
Electrical connection – JSBT4<br>TEST TEST TEST TEST<br>LOAD<br>Emergency stop with automatic  Interlocked hatch with automatic  Contact mat/strip with automatic  Monitoring to ensure that the Start<br>resetting. resetting. reset button cannot stick in pressed posi-<br>tion. Short circuiting over the closing<br>TEST TEST contact is not monitored. The RT-<br>series  and JSBR4 have built in short<br>circuiting monitored re setting.<br>Control and supervision of external contactor,<br>Enabling device, JSHD4. Stop condition is given<br>in both top and bottom positions. relay, valve or ABB Jokab Safety’s expansion<br>relays.<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   6/24 

6 

## Safety relay/expansion relay BT50(T) 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Emergency stop 

- Interlocked hatch 

- Expansion of Pluto 

## Features: 

- Single and “dual” channel 

- Test/”reset” input 

- Width 22.5 mm 

- LED indication 

- 3 NO/1NC relay outputs 

- Supply 24 VDC 

- Quick release connector blocks 

- BT50 - Additional power terminals 

## Safety relay/expansion relay to Pluto 

The BT50 is designed to connect safety devices, such as emergency stops, directly in the voltage supply circuit to the relay. Despite a maximum built-in width of 22.5 mm the relay is very powerful. 

- BT50T -  One  changeover relay with a double information output (Y14) 

- BT50T -  Delay times 

   - selectable from 0 - 1.5 s 

## Safety level 

With 3NO safety outputs, 1NC output (for monitoring purposes), a test input and complete internal supervision, the BT50 is quite unique. In addition, delayed outputs (BT50T) can be ordered. 

In order for the safety outputs to close, the supply voltage, e.g. by means of an emergency stop button, must be connected to A1 and A2 and the test input closed. After actuation of the relay the test input can be opened again. 

The test input is intended to supervise that contactors or valves have dropped/returned before a new start can be permitted.The test input can also be used for starting and the start button can  be supervised (see the connection example on the next page). 

## More outputs 

BT50 have an internal redundant and monitored safety function. Power failure, internal component faults or external interference cannot result in dangerous functions. 

Input via A1 on its own is not protected from short circuiting, and therefore installation is critical for the safety level to be achieved. To achieve a higher safety level a screened cable can be used and/or connection made to both A1 and A2 (see the example on the next page). 

## Regulations and standards 

The BT50  is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the chapter “Connection examples”. 

By connecting a BT50 to a safety relay/PLC it is easy to increase the number of safe outputs. This means that an unlimited number of dangerous machine operations and functions can be stopped by using just one safety-PLC. 

6/25    2TLC172001C0202 | ABB Safety Handbook 

Technical description – BT50(T) 

**==> picture [238 x 72] intentionally omitted <==**

**----- Start of picture text -----**<br>
K1<br>Supervision circuit<br>K2<br>**----- End of picture text -----**<br>


When supply voltage is connected to A1 and A2, relays K1 and K2 are activated. K1 and K2 drop if the supply voltage is disconnected. Both relays K1 and K2 must drop for them to be activated again. Another requirement is that the test circuit, A1 - X4, must be closed for the outputs to be activated. Thereafter A1 - X4 can either be open or constantly closed. 

The supervising circuit ensures that both K1 and K2 have dropped before they can be reactivated. The stop function complies with the requirement that a component fault or external interference cannot lead to a dangerous function. 

The safety outputs consist of contacts from K1 and K2  connected internally  in series across terminals 13 - 14, 23 - 24, and 33 - 34. These contacts are used to cut the power to components which stop or prevent hazardous movements/ functions. It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

The NC output 41 - 42 should only be used for monitoring purposes e.g. indication lamp for emergency stop pressed. 

BT50T - Info. output BT50T - Delay times 

A2   T1  T2                 A2   T1  T2 0 s 1.0 s 0.5 s 1.5 s 

Max load 250 mA 

Technical data – BT50(T) 

**==> picture [288 x 475] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>BT50 2TLA010033R0000<br>BT50T 2TLA010033R1000<br>Colour Black and beige<br>Operational voltage 24 VDC + 15%/-25%<br>Power consumption BT51 1.4W/BT51T<br>Relay outputs 3 NO + 1 NC<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC  AC15 240 VAC 2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC DC13 24 VDC 1A<br>Max. res. load total switching<br>capacity 12A distributed on all contacts<br>Min. load 10mA/10 V(if load on contact has<br>not exceeded 100 mA)<br>Contact material Ag + Au flash<br>Fuses output (external) 5A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max Input wire res. at nom.<br>voltage 200 Ohms<br>Response time at deactivation  Version B <20 ms or delayed max<br>(input - output) 1500 ms (old version of BT50 <60 ms) 6<br>Terminals (max. screw torque 1 Nm)<br>Single strand 2x1.5 mm [2]<br>Conductor with socket contact 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class enclosure/ter-<br>minals IP40 / IP20 IEC 60529<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Relay and X4<br>Weight 200 g<br>Performance (max.) PL e/Cat. 4 (EN ISO 13849-1:2008)<br>Functional test: The relays must  SIL 3 (EN 62061:2005)<br>be cycled at least once a year. PFHD 1.22E-08<br>**----- End of picture text -----**<br>


Electrical connection – BT50(T) 

**==> picture [241 x 57] intentionally omitted <==**

**----- Start of picture text -----**<br>
*  *<br>**----- End of picture text -----**<br>


Emergency stop with reset when Hatch with automatic reset. emergency button returns. 

**==> picture [109 x 58] intentionally omitted <==**

**----- Start of picture text -----**<br>
*<br>**----- End of picture text -----**<br>


**==> picture [117 x 58] intentionally omitted <==**

BT50 as emergency stop and Emergency stop with dual control relay with Start and Stop connection direct to the supply function. voltage. 

**==> picture [114 x 56] intentionally omitted <==**

**----- Start of picture text -----**<br>
A1     X4<br>**----- End of picture text -----**<br>


Controlled monitoring of external contactor, relay, valve or ABB Jokab Safety’s expansion relays. 

**==> picture [111 x 59] intentionally omitted <==**

**----- Start of picture text -----**<br>
A1     X4<br>**----- End of picture text -----**<br>


Monitoring to ensure that the On button is not stuck in pressed position. A short circuit over the closing contact is not monitored. 

* BT50 has additional power terminals A1 and A2. 

ABB Safety Handbook | 2TLC172001C0202   6/26 

6 

## Safety relay/expansion relay BT51(T) 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Emergency stop 

- Interlocked hatch 

- Expansion of Pluto 

## Features: 

- Single and “dual” channel 

- Test/”reset” input 

- Width 22.5 mm 

- LED indication 

- 4 NO relay outputs 

- Supply 24 VDC 

- Quick release connector blocks 

- BT51 - Additional power terminals 

## Safety relay/expansion relay to Pluto 

The BT51 is designed to connect safety devices, such as emergency stops, directly in the voltage supply circuit to the relay. Despite a maximum built-in width of 22.5 mm the relay is very powerful. 

- BT51T - One changeover relay with a double information output (Y14) 

- BT51T - Delay times selectable from  0 - 1.5 s 

With 4 NO safety outputs, test input and complete internal supervising, the BT51 is quite unique. In addition you can order delayed outputs (BT51T). 

In order for the safety outputs to close, the supply voltage, e.g. by means of an emergency stop button, must be connected to A1 and A2 and the test input closed. After actuation of the relay the test input can be opened again. 

The test input is intended to supervise that contactors or valves have dropped/returned before a new start can be permitted.The test input can also be used for starting and the start button can  be supervised   (see   connection example on next page). 

## More outputs 

Input via A1 only is not protected from short circuiting, and therefore installation is critical for the safety level to be achieved. To achieve a higher safety level a screened cable can be used and/or connection made to both A1 and A2 (see example overleaf). 

## Regulations and standards 

The BT51 is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the chapter “Connection examples”. 

By connecting BT51 to a safety relay/PLC it is easy to increase the number of safe outputs. This means that an unlimited number of dangerous machine operations and functions can be stopped from one safety relay/PLC. 

## Safety level 

BT50 has an internal redundant and monitored safety function. Power failure, internal component faults or external interference cannot result in dangerous functions. 

6/27    2TLC172001C0202 | ABB Safety Handbook 

Technical description – BT51(T) 

## Technical data – BT51(T) 

**==> picture [101 x 55] intentionally omitted <==**

**----- Start of picture text -----**<br>
Supervision circuit<br>**----- End of picture text -----**<br>


**==> picture [61 x 50] intentionally omitted <==**

When supply voltage is connected to A1 and A2, relays K1 and K2 are activated. K1 and K2 drop if the supply voltage is disconnected. Both relays K1 and K2 must drop for them to be activated again. Another requirement is that the test circuit, A1 - X4, must be closed for the outputs to be activated. Thereafter A1 - X4 can either be open or constantly closed. 

The supervising circuit ensures that both K1 and K2 have dropped before they can be reactivated. The stop function complies with the requirement that a component fault or external interference cannot lead to a dangerous function. 

The safety outputs consist of contacts from K1 and K2 connected internally in series across terminals 13 - 14, 23 - 24, 33 - 34 and 43 - 44. These contacts are used to cut the power to components which stop or prevent hazardous movements/functions. It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

BT51T - Info. output BT51T - Delay times 0 s 0.5 s A2   T1  T2                 A2   T1  T2 1.0 s 1.5 s 

Max load 250 mA 

Electrical connection – BT51(T) 

**==> picture [246 x 87] intentionally omitted <==**

**----- Start of picture text -----**<br>
*  *<br>Emergency stop with reset when  Hatch with automatic reset.<br>emergency button returns.<br>**----- End of picture text -----**<br>


**==> picture [251 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
*<br>A1     X4<br>Emergency stop with dual connec- Controlled monitoring of external<br>tion direct to the supply voltage. contactor, relay, valve or ABB Jo-<br>kab Safety’s expansion relays.<br>**----- End of picture text -----**<br>


* BT51 has additional power terminals A1 and A2. 

**==> picture [287 x 510] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>BT51 2TLA010033R2000<br>BT51T 2TLA010033R3000<br>Colour Grey<br>Operational voltage 24 VDC + 15%/-25%<br>Power consumption 1.4 W/1.8 W<br>Relay Outputs 4 NO<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC  AC15 240 VAC 2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC  DC13 24 VDC 1A<br>Max. res. load total switching<br>capacity 12 A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA<br>Contact material Ag + Au flash<br>Fuses Output (External) 5A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max Input Wire res. at nom.<br>voltage 200 Ohms<br>Response time at deactivation <20 ms or delayed max 1500 ms<br>6<br>(BT51T)<br>Terminals (Max. screw torque 1 Nm)<br>Single strand: 2x1.5 mm [2]<br>Conductor with socket contact: 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class enclosure/ter-<br>minals IP40 / IP20 IEC 60529<br>Impulse Withstand Voltage 2.5kV<br>Pollution Degree 2<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Relay and X4<br>Weight 200 g<br>Performance (max.)<br>Functional test: The relays must  PL e/Cat. 4 (EN ISO 13849-1:2008)<br>be cycled at least once a year. SIL 3 (EN 62061:2005) PFHD 1.63E-08<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC, EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


**==> picture [111 x 59] intentionally omitted <==**

**----- Start of picture text -----**<br>
A1     X4<br>**----- End of picture text -----**<br>


**==> picture [117 x 58] intentionally omitted <==**

BT51 as emergency stop and Monitoring to ensure that the On control relay with Start and Stop button is not stuck in pressed function. position. A short circuit over the closing contact is not monitored. 

ABB Safety Handbook | 2TLC172001C0202   6/28 

6 

## Safety relay JSBT5(T) 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Emergency stop 

- Interlocked hatch 

## Features: 

- Single and “dual” channel 

- Test/start input 

- Width 22.5 mm 

- LED indication 

- 3 NO/1NC relay outputs 

- (T) = delayed outputs 0.5 sec. 

- Supply 12 VDC, 24 VDC/AC 

## Single channel safety relay 

The JSBT5 is designed to connect safety devices, such as emergency stops, directly in the voltage supply circuit to the relay. Despite a maximum built-in width of 22.5 mm the relay is very powerful. 

## Regulations and standards 

The JSBT5 is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

With 3 NO safety outputs, 1 NC, test input and complete internal supervising, the JSBT5 is quite unique. In addition you can order delayed outputs (JSBT5T). 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

In order for the safety outputs to close, the supply voltage, e.g. by means of an emergency stop button, must be connected to A1 and A2 and the test input closed. After actuation of the relay the test input can be opened again. 

The test input is intended to supervise that contactors or valves have dropped/returned before a new start can be permitted.The test input can also be used for starting and the start button can  be supervised   (see   connection example on next page). 

## Safety level 

The JSBT5 has a twin and supervised internal safety function. Power failure, internal component faults or external interference cannot result in dangerous functions. 

Input via A1 only is not protected from short circuiting, and therefore installation is critical for the safety level to be achieved. To achieve a higher safety level a screened cable can be used and/or connection made to both A1 and A2 (see example overleaf). 

6/29    2TLC172001C0202 | ABB Safety Handbook 

Technical description – JSBT5(T) 

## Technical data – JSBT5(T) 

**==> picture [93 x 51] intentionally omitted <==**

**==> picture [85 x 55] intentionally omitted <==**

When supply voltage is connected to A1 and A2, relays K1 and K2 are activated. K1 and K2 drop if the supply voltage is disconnected. Both relays K1 and K2 must drop for them to be activated again. Another requirement is that the test circuit, X1 - X2, must be closed for the outputs to be activated. Thereafter X1 - X2 can either be open or constantly closed. The supervising circuit ensures that both K1 and K2 have dropped before they can be reactivated. The stop function complies with the requirement that a component fault or external interference cannot lead to a dangerous function. 

The safety outputs consist of contacts from K1 and K2  connected internally  in series across terminals 13 - 14, 23 - 24, and 33 - 34. These contacts are used to cut the power to components which stop or prevent hazardous movements/ functions. It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

The NC output 41 - 42 should only be used for monitoring purposes e.g. indication lamp for emergency stop pressed. 

Electrical connection – JSBT5(T) 

**==> picture [93 x 45] intentionally omitted <==**

**==> picture [92 x 47] intentionally omitted <==**

Emergency stop with automatic reset when emergency button returns. 

Hatch with automatic reset. 

**==> picture [93 x 46] intentionally omitted <==**

**==> picture [92 x 48] intentionally omitted <==**

Controlled monitoring of external contactor, relay, valve or ABB Jokab safety’s expansion relays. 

Emergency stop with dual connection direct to the supply voltage. 

**==> picture [96 x 48] intentionally omitted <==**

**==> picture [95 x 49] intentionally omitted <==**

Monitoring to ensure that the On button is not stuck in pressed position. A short circuit over the closing contact is not monitored. The JSBR4 has built in short circuit monitored re setting. 

JSBT5 as emergency stop and control relay with Start and Stop function. 

**==> picture [288 x 546] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSBT5 24 VAC/VDC 2TLA010005R0100<br>JSBT5 12 VDC 2TLA010005R0700<br>JSBT5T 24 VAC/VDC 2TLA010005R1100<br>Colour Grey<br>Operational voltage<br>JSBT5: 24 VDC/AC + 15%–25%, 50–60 Hz<br>JSBT5T: 12 VDC, 24 VDC/AC + 15% – 25%,<br>50 - 60 Hz<br>Power consumption 1 W/1.9 VA<br>Relay Outputs 3 NO + 1 NC<br>Max. switching capacity<br>Resistive load AC 6A/250 VAC/1500 VA<br>Inductive load AC AC15 240 VAC  2A<br>Resistive load DC 6A/24 VDC/150 W<br>Inductive load DC DC13 24 VDC 1A<br>Max. res. load total switching<br>capacity: 9A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA)<br>Contact material AgCuNi<br>Fuses Output (External) 5A gL/gG<br>Conditional short-circuit current<br>(1 kA) 6A gG 6<br>Max Input Wire res. at nom.<br>voltage 200 Ohm<br>Response time at deactivation <60 ms or delayed max 500 ms<br>(JSBT5T)<br>Terminals (Max. screw torque 1 Nm)<br>Single strand: 2x1.5 mm [2]<br>Conductor with socket contact: 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class enclosure/ter-<br>minals IP40 / IP20 IEC 60529<br>Impulse Withstand Voltage 2.5kV<br>Pollution Degree 2<br>Operating temperature range -10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>Function indication Electrical Supply<br>Weight 200 g<br>Performance (max.) PL e/Cat. 4<br>Functional test: The relays must  (EN ISO 13849-1:2008)<br>be cycled at least once a year. SIL 3 (EN 62061:2005) PFHD 1.22E-08<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC, EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   6/30 

6 

## Safety timer JSHT1 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Time reset 

- – Time bypassing 

## Features: 

- Hardwire time selection 

   - 5 – 40 s 

- Selectable single or dual channel input 

- Test input 

- Width 45 mm 

- LED indication for supply, inputs and outputs 

- 1+1 NO relay outputs 

- Supply 24 VDC 

- Quick release connector blocks 

The JSHT1A/B closes two independent relay outputs during a guaranteed maximum time when the inputs are opened. 

## Time reset 

Time reset can prevent uni ntentional reset of safety systems when someone is still in the dangerous area of the machine. During a guaranteed maximum time, one or several PB´s for reset must be activated. The reset buttons should be sited in such a way that operatives have a clear overview of the whole area which is guarded. Time reset is made by the combi nation of a safety relay and the timer relay JSHT1A/B. 

## Time bypassing 

The JSHT1 can also be used for time bypass of light beams for e.g. autotruck into a dangerous area. 

## Operation 

When the inputs open the output contacts close. The output contacts open when the inputs close or when the time period has expired. The time period is hardwire selectable on terminals T1, T2 and T3. The time given is the maximum time. One or two channel operation is also hardwire selectable. 

Light beam being bypassed for a maximum pre-set time e.g. 5 sec. by the jsht1 during entrance and exit with the JSHD4 Three Position Enabling device. 

**==> picture [95 x 41] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>ey tot<br>2<br>1 SL A |<br>**----- End of picture text -----**<br>


## Regulations and standards 

The JSHT1A/B is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

Time reset procedure. First push PB1, then exit dangerous area and close the door, then push PB2 (PB1 and PB2 must be pressed within the predetermined time period selected). After this procedure the machine can be safely restarted. 

6/31    2TLC172001C0202 | ABB Safety Handbook 

Technical description  – JSHT1 A/B 

## Technical data – JSHT1 A/B 

**==> picture [231 x 121] intentionally omitted <==**

**----- Start of picture text -----**<br>
Connection<br>and monito- Timer<br>ring circuit<br>**<br>** Only for AC-supply.<br>**----- End of picture text -----**<br>


The electrical supply is connected across A1 and A2. The internal supervising circuit is activated directly when the supply is on. The inputs A and B must both be closed and then opened. Thereafter K1 and K2 are activated and the outputs close. K1 and K2 are activated for the hardwired selected time (set by connections on the terminals T1, T2 and T3). If there is a short circuit between the inputs or the inputs are closed again before the set time period has expired the outputs will open. In order to close the outputs again both the inputs have to be closed and both internal relays K1 and K2 deactivated  (cont rol led by the super vising circuit) and the inputs again opened. 

By external hardwire connections the JSHT1 can be made single or dual channel input. See figure below. 

Electrical connection  – JSHT1 A/B 

Connection for single channel input 

**==> picture [209 x 48] intentionally omitted <==**

Connection for dual channel input 

**==> picture [211 x 84] intentionally omitted <==**

**==> picture [288 x 570] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSHT1A 24 VDC 2TLA010011R0000<br>JSHT1B 24 VDC 2TLA010011R1000<br>Colour Grey<br>Power supply 24 VDC ±15 %<br>Power consumption 1.8 W/3.7 VA<br>Max Input wire res. at nom voltage/ 100/200 Ohm (1 Channel/ 2<br>channel<br>Channel)<br>Response time at activation <30ms<br>Response time at deactivation < 15 ms<br>Selectable time  JSHT1A: 5-10-15-20 sec<br>(± 15 % at nom. V.) JSHT1B: 5-15-30-40 sec<br>Relay outputs 2 x 1 NO<br>Max. switching capacity resistive<br>load AC 4A/250 VAC/1000 VA<br>Inductive load AC  AC15 250 VAC 3A<br>Resistive load DC 4A/24 VDC/100 W<br>Inductive load DC  DC13 24 VDC 2A<br>Max. total switching capacity: 8A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>not exceeded 100 mA)<br>Contact material AgCuNi<br>Fuses output (external) 3A gL/gG or 4A fast 6<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max input wire res. at nom. voltage 100 Ohm<br>Terminals (max. screw torque 1 Nm)<br>Single strand 1x4 mm [2] , 2x1.5 mm [2]<br>Conductor with socket contact 1x2.5 mm [2] , 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class enclosure/termi-<br>nals IP20 / IP40 IEC 60529<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating temperature range –10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Inputs, Outputs<br>Weight 24 VDC: 330 g<br>24/48/115/230 VAC: 430 g<br>Performance (max.)<br>Functional test: The relays must be  PL e/Cat. 4 (EN ISO 13849-1:2008)<br>SIL 3 (EN 62061:2005)<br>cycled at least once a year.<br>PFHD 4.42E-09<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC<br>EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


Selection of time by hardwire links 

**==> picture [151 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
JSHT1A JSHT1B<br>**----- End of picture text -----**<br>


**==> picture [89 x 46] intentionally omitted <==**

**==> picture [87 x 45] intentionally omitted <==**

* It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. In the figure the monitoring of two contactors in the test input is shown. 

ABB Safety Handbook | 2TLC172001C0202   6/32 

6 

## Safety timer JSHT2 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- Time bypassing 

- Inching 

## Features: 

- Hardwire time selection 

- 0.2 – 40 s 

- Selectable single or dual channel input 

- Test input 

- Width 45 mm 

- LED indication for supply, inputs and outputs 

- 1+1 NO relay outputs 

- Supply 24 VDC 

- Quick release connector blocks 

The JSHT2A/B/C closes two independent relay outputs during a guaranteed maximum period of time when the inputs are closed. 

## Time bypassing 

Sensors detect the autocarrier and are connected to the JSHT2 which supervises the sensors and by pas ses the light beam for a maximum predeter mined time. 

## Inching 

Inching applications require safety outputs to be closed for a predetermined maximum period of time, allowing the machine to move only a short distance each time the inching control is activated. For each new motion the inching control e.g. PB or pedal must be released and activated again. 

## Operation 

When the inputs close the output contacts close. The output contacts open when the input opens or when the time period has expired. The time is hardwire selectable on the terminals T1, T2 and T3. The time given is the maximum time. Single or dual channel operation is also hardwire selectable. 

Light beam being bypassed only for the time it takes the auto carrier to pass. 

## Regulations and standards 

The JSHT2A/B/C is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

Shaft only turns a small amount each time the PB is pressed. 

6/33    2TLC172001C0202 | ABB Safety Handbook 

Technical description  – JSHT2 A/B/C 

Technical data – JSHT2 A/B/C 

**==> picture [232 x 120] intentionally omitted <==**

**----- Start of picture text -----**<br>
Connection and  Timer<br>monitoring circuit<br>**<br>** Only for AC-supply.<br>**----- End of picture text -----**<br>


The electrical supply is connected across A1 and A2. The internal supervising circuit is activated directly when the supply is on. The inputs A and B must both be opened and then closed. Thereafter K1 and K2 are activated and the outputs close. K1 and K2 are activated for hardwired selected time (set by connections on the terminals T1, T2 and T3). If there is a short circuit between the inputs or the inputs are opened again before the set time period has expired the outputs will open. In order to close the outputs again both the inputs have to be opened and both internal relays K1 and K2 deactivated (controlled by the supervising circuit) and then the inputs closed again. 

By external hardwire connectors the JSHT2 can be made to operate from either single or dual channel inputs. See figure below. 

Electrical connection  – JSHT2 A/B/C 

Connection for single channel input 

**==> picture [193 x 45] intentionally omitted <==**

Selection of time by hardwire links 

JSHT2A JSHT2B JSHT2C 

**==> picture [250 x 38] intentionally omitted <==**

**==> picture [288 x 570] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>JSHT2A  240 VDC 2TLA010012R0000<br>JSHT2B  24 VDC 2TLA010012R1000<br>JSHT2C 24 VDC 2TLA010012R2000<br>Colour Grey<br>Power supply 24 VDC ±15 %<br>Power consumption 1.8 W/3.8 VA<br>Max input wire res. at nom volta- 100/200 Ohm (1 Channel/ 2 Chan-<br>ge/channel<br>nel)<br>Response time at activation < 30 ms<br>Response time at deactivation < 15 ms<br>Selectable time  JSHT2A: 0.2 - 0.5 - 0.7 - 1.0 sec<br>(± 15 % at nom. V.) JSHT2B: 5 - 10 - 15 - 20 sec<br>JSHT2C: 5 - 15 - 30 - 40 sec<br>Relay outputs 2 x 1 NO<br>Max. switching capacity<br>Resistive load AC 4A/250 VAC/1000 VA<br>Inductive load AC AC15 250VAC 3A<br>Resistive load DC 4A/24 VDC/100 W<br>Inductive load DC  DC13 24VDC 2A<br>Max. total switching capacity: 8A distributed on all contacts<br>Min. load 10mA/10 V (if load on contact has<br>6<br>not exceeded 100 mA)<br>Contact material AgCuNi<br>Fuses output (external) 3A gL/gG or 4A fast<br>Max input wire res. at nom.<br>voltage 100 Ohm<br>Terminals (max. screw torque 1 Nm)<br>Single strand: 1x4 mm [2]  or 2x1.5 mm [2]<br>Conductor with socket contact: 1x2.5 mm [2]  or 2x1 mm [2]<br>Mounting 35 mm DIN-rail<br>Protection class  IP20 / IP40 IEC 60529<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating temperature range –10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>LED indication Electrical Supply, Inputs, Outputs<br>Weight 24 VDC: 310 g<br>24/48/115/230 VAC: 410 g.<br>Performance (max.)<br>Functional test: The relays must  PL e/Cat. 4 (EN ISO 13849-1:2008)<br>be cycled at least once a year. SIL 3 (EN 62061:2005) PFHD 4.42E-09<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC<br>EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


Connection for dual channel input 

**==> picture [195 x 72] intentionally omitted <==**

* It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. In the figure the monitoring of two contactors in the test input is shown. 

ABB Safety Handbook | 2TLC172001C0202   6/34 

6 

## Expansion relay E1T 

## Approvals: 

TÜV NORD 

## Safety relay for: 

- More safety outputs 

- Delayed safety outputs 

## Features: 

- Width 22.5 mm 

- Supply 24 VDC 

- LED output indication 

- 4 NO relay outputs 

- Single or dual channel operation option 

- Quick release connector blocks 

## More outputs 

By connecting expansion relays to a safety relay it is easy to increase the number of safe outputs. This means that an unlimited number of dangerous machine operations and functions can be stopped from one safety relay. 

Stop category 1 may also be permitted when it is not possible to gain physical access to the machine before the safe stop is affected e.g: 

- Gates, access time is normally over 1 sec. 

## Safe soft stop 

When a gate is opened a program stop is first given to the machine’s PLC/servo which brakes the dangerous operations in a soft and controlled way. The safety outputs then break the power to the motors, that is, when the machine has already stopped. Normally between 0.5 and 1 second is needed to brake a dangerous machine operation softly. 

Soft stop ensures many advantages: 

- The machine lasts longer. 

- Parts being processed are not damaged. 

– Restart from stopped position is enabled and simplified. A safe soft stop is achieved by means of a safety relay which gives the program stop, and an expansion relay, E1T, which gives safe delayed stop signals. See section ”Connection examples”. The drop time delay on a E1T can as standard be selected from 0 to 3 seconds. By connecting several E1T´s in series even longer times can be achieved. 

## When are delayed safe stops used? 

Delayed safety stop signals can be used for emergency stops according to EN ISO 13850:2008 § 4.1.4. Stop category 1, i.e. a controlled stop with power to the actuator(s) available to achieve the stop and then removal of power  when stop is achieved. 

- Covers and gates which are locked until dangerous  operations and functions have been stopped. 

- Long distances between a safety device and a dangerous machine function. 

## Safety level 

The E1T has twin stop functions, that is, two relays with mechanically operated contacts. A monitored stop function is achieved by con necting the test output (terminals X1 and X2) to the test or reset input on the safety relay which is being expanded. 

One condition for a safe delayed stop is that the delay time cannot increase in the event of a fault. The E1T complies with this requirement. 

## Regulations and standards 

The E1T is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/35    2TLC172001C0202 | ABB Safety Handbook 

6 

## Technical description – E1T 

The E1T has to be connected to a safety relay  in order to fulfill the necessary safety requirements (see connection examples below). The safety relay controls and monitors the E1T (The E1T can be connected for single or dual channel operation - see below). When the inputs S14 and S24 close, relays K1 and K2 are activated. A stop signal is given, K1 and K2 drop, if the inputs are opened or during power failure. K1 and K2 drop either directly or after a delay* (if incorporated). Delay time of module is fixed and shown on front panel of device. The delay circuit is so arranged that the design time cannot be exceeded. 

To check that both the relays K1 and K2 drop during a stop signal they must be monitored. This is achieved by connecting X1 and X2 to the test or reset input on the safety relay which is expanded (see below). K1 and K2 are mechanically operated relays,  therefore, if one of the output contacts should stick closed then the relay’s contact in X1-X2 cannot be closed thus preventing  a new ready signal being given to the safety relay. 

Inductive loads should be equipped with an arc suppressor to protect the output  contacts. 

Diodes are the best arc suppressors but will increase the switch off time of the load. 

## Electrical connection – E1T 

SAFETY RELAY RT6 1 1 SAFETY RELAY RT6 1 r + CD. 1 i, 1 1A $14] A2 S24] x1 x21 '®@ @. “BAB 1 ee ee re, 1A1 S14 AZ S24_X4 X2 ' all|S14. A2 S24 x1 x20 DELAYED SAFETY STOP nd ie Av PL PL Single channel expansion of outputs Dual channel expansion with for a safety relay connected to an delayed safety outputs for a safety emergency stop. relay monitoring a gate. 

## Technical data – E1T 

|Technical data – E1T||
|---|---|
|Article number<br>E1T 0 s 24 VDC<br>E1T 0.5 s 24 VDC<br>E1T 1 s 24 VDC<br>E1T 1.5 s 24 VDC<br>E1T 2 s 24 VDC<br>E1T 3 s 24 VDC<br>||2TLA010030R0000<br>2TLA010030R1000<br>2TLA010030R2000<br>2TLA010030R3000<br>2TLA010030R4000<br>2TLA010030R5000<br>||
|Colour|Grey|
|Operational voltage|24 VDC ± 15%|
|Power consumption|1.5 W|
|Relay Outputs|4 NO|
|Max. switching capacity<br>Resistive load AC<br>Inductive load AC<br>Resistive load DC<br>Inductive load DC|6A/250 VAC/1500VA<br>AC15 240 VAC 2A<br>6A/24 VDC/150W<br>DC13 24 VDC 1A|
|Max. total switchingcapacity|12A distributed on all contacts|
|Min. switching load|10 mA/10 V (if load on contact has<br>not exceeded 100 mA)|
|Contact material|Ag+ Au flash|
|Fuses output (external)|5AgL/gG|
|Conditional short-circuit current<br>(1 kA)|6A gG|
|Maximum external resistance at a<br>nominal voltage|150 Ohm (S14, S24)|
|Response time at deactivation<br>(input - output)|< 0,020 s, 0,5 s, 1 s, 1,5 s, 2 s, 3 s,<br>± 20%|
|Response time at activation<br>(input-output)|<30 ms|
|Terminals (max. screw torque 1 Nm)<br>Single strand:<br>Conductor with socket contact:|1x4 mm2/ 2x1.5 mm2<br>1x2.5 mm2/ 2x1 mm2|
|Mounting|35 mm DIN-rail|
|Protection class<br>enclosure<br>terminals|IP40 IEC 60529<br>IP20 IEC 60529|
|Impulse withstand voltage|2.5kV|
|Pollution degree|2|
|Operating temperature range|-10°C – +55°C (with no icing or<br>condensation)|
|Operatinghumidity range<br>LED indication<br>:|35% to 85%<br>Output status<br>:|
|Weight|220g|
|Performance (max.)<br>Functional test: The relays must<br>be cycled at least once a year.<br>:<br>:<br>:|PL e/Cat. 4<br>(EN ISO 13849-1:2008)<br>SIL 3 (EN 62061:2005)<br>PFHD1.55E-08<br>:<br>:<br>:|
|Conformity<br>:<br>:<br>:|D<br>2006/42/EC, 2006/95/EC,<br>2004/108/EC<br>EN 62061:2005<br>EN ISO 13849-1:2008<br>:<br>:<br>:|



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Connector blocks are detachable (without cables having to be disconnected) 22,5 

ABB Safety Handbook | 2TLC172001C0202   6/36 

## Expansion relay JSR1T 

## Approvals: 

**==> picture [28 x 18] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Safety relay for: 

- More safe outputs 

- Delayed safe outputs 

– Information output Features: – Width 45 mm – Supply 24 VDC – LED function indication – 4 NO/1 NC relay outputs – Single and dual channel – Quick release connector 6 blocks a ~~—~~ More outputs Stop category 1  may also be permitted when it is not possibBy connecting expansion relays to a safety relay it is easy to le to gain physical access to the machine before the safe stop increase the number of safe outputs. This means that an unliis affected e.g: 

By connecting expansion relays to a safety relay it is easy to increase the number of safe outputs. This means that an unlimited number of dangerous machine operations and functions can be stopped from one safety relay. 

- Gates, access time is normally over 1 sec. 

- Covers and gates which are locked until dangerous operations and functions have been stopped. 

## Safe soft stop 

- Long distances between a safety device and a dangerous machine function. 

When a gate is opened a program stop is first given to the machine’s PLC/servo which brakes the dangerous operations in a soft and controlled way. The safety outputs then break the power to the motors, that is, when the machine has already stopped. Normally between 0.5 and 1 second is needed to brake a dangerous machine operation softly. 

## Safety level 

The JSR1T has twin stop functions, that is, two relays with mechanically operated contacts. A monitored stop function is achieved by con necting the test output (terminals X1 and X2) to the test or reset input on the safety relay which is being expanded. 

## Soft stop ensures many advantages: 

- The machine lasts longer. 

- Parts being processed are not damaged. 

– Restart from stopped position is enabled and simplified. A safe soft stop is achieved by means of a safety relay which gives the program stop, and an expansion relay, JSR1T, which gives safe delayed stop signals. See section ”Connection examples”. The drop time delay on a JSR1T can as standard be selected from 0 to 10 seconds. By connecting several JSR1T´s in series even longer times can be achieved. 

One condition for a safe delayed stop is that the delay time cannot increase in the event of a fault. The JSR1T complies with this requirement. 

## Regulations and standards 

The JSR1T is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

## When are delayed safe stops used? 

Delayed safety stop signals can be used for emergency stops according to EN418 § 4.1.4 Stop category 1, i.e. a controlled stop with power to the actuator(s) available to achieve the stop and then removal of power  when stop is achieved. 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/37    2TLC172001C0202 | ABB Safety Handbook 

6 

## Technical description – JSR1T 

The JSR1T has to be connected to a safety relay  in order to fulfill the necessary safety requirements (see connection examples below). The safety relay controls and monitors the JSR1T. (The JSR1T can be connected for single or dual channel operation - see below). When the inputs S14 and S24 close, relays K1 and K2 are activated. A stop signal is given, K1 and K2 drop, if the inputs are opened or during power failure. K1 and K2 drop either directly or after a delay* (If incorporated). Delay time of module is fixed and shown on front panel of device. The delay circuit is so arranged that the design time cannot be exceeded. 

To check that both the relays K1 and K2 drop during a stop signal they must be monitored. This is achieved by connecting X1 and X2 to the test or reset input on the safety relay which is expanded (see below). K1 and K2 are mechanically operated relays,  therefore, if one of the output contacts should stick closed then the relay’s contact in X1-X2 cannot be closed thus preventing a new ready signal being given to the safety relay. 

Inductive loads should be equipped with an arc suppressor to protect the output  contacts. 

Diodes are the best arc suppressors but will increase the switch off time of the load. 

## Electrical connection – JSR1T 

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**----- Start of picture text -----**<br>
SAFETY RELAY RT6 SAFETY RELAY  RT6<br>hen | wT |<br>PROGRAM STOP<br>TAtas JSR1T S14] A2nnS24] PenneX1 x2} SoeAt S14 A2S650S24_X1 X2 i<br>'1At JSR1T 814 AZ $24 x1Q@ x2!oO: \1 JSR1T OV DELAYED SAFETY STOP A PY J A\<br>Expansion of outputs for safety  Dual-channel expansion with<br>relay connected to emergency stop  delayed safety outputs for safety<br>with automatic reset. relay monitoring a gate.<br>**----- End of picture text -----**<br>


## Technical data – JSR1T 

|Technical data – JSR1T||
|---|---|
|Article number<br>JSR1T 0<br>JSR1T 1.5<br>JSR1T 8<br>JSR1T 0.5<br>JSR1T 10s<br>JSR1T 1<br>JSR1T 2<br>JSR1T 3<br>JSR1T 5<br>:<br>:|2TLA010015R0000<br>2TLA010015R0500<br>2TLA010015R0600<br>2TLA010015R1000<br>2TLA010015R2000<br>2TLA010015R3000<br>2TLA010015R4000<br>2TLA010015R5000<br>2TLA010015R6000<br>:<br>:|
|Colour|Grey|
|Power supply|24 VDC ±15%|
|Power consumption|1.2 W|
|Relay outputs|4 NO + 1 NC|
|Max. switching capacity<br>Resistive load AC<br>Inductive load AC<br>Resistive load DC<br>Inductive load DC|6A/250 VAC/1500 VA<br>AC15 240 VAC 2A<br>6A/24 VDC/150 W<br>DC13 24 VDC 1A|
|Max. total switchingcapacity:|16A distributed on all contacts|
|Min. load|10mA/10 V (if load on contact has<br>not exceeded 100 mA)|
|Contact material|Ag+ Au flash|
|Fuses output (external)|5A gL/gG|
|Conditional short-circuit current<br>(1 kA)|6A gG|
|Max. Input wire res. at nom.<br>voltage|150 Ohm (S14, S24)|
|Response time at deactivation<br>(input- output)|< 0.020 s, 0.5 s, 1 s, 1.5 s, 2 s, 3 s,<br>5 s, 8 s, 10 s ± 20 %|
|Terminals (max. screw torque 1 Nm)<br>Single strand:<br>Conductor with socket contact:|1x2.5 mm2/ 2x1 mm2<br>1x4 mm2/ 2x1.5 mm2|
|Mounting|35 mm DIN-rail|
|Protection class enclosure/ter-<br>minals|IP40 / IP20 IEC 60529|
|Impulse withstand voltage|2.5kV|
|Pollution degree<br>Operating temperature range|2<br>-10°C to +55°C (with no icing or|
|Operatinghumidity range|condensation)<br>35% to 85%|
|LED indication|Output Relay Supplies|
|Weight|280g|
|Performance (max.)<br>Functional test: The relays must<br>be cycled at least once a year<br>:|PL e/Cat. 4 (EN ISO 13849-1:2008)<br>SIL 3 (EN 62061:2005)<br>PFH1.55E-08<br>:|
|be cycled at least once a year<br>Conformity<br>:<br>:<br>:|PFHD1.55E-08<br>2006/42/EC, 2006/95/EC,<br>2004/108/EC EN 62061:2005<br>EN ISO 13849-1:2008<br>:<br>:<br>:|



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120<br>ae Rs. S Connector blocks are detachable<br>(without cables having to be disconnected)<br>74<br>|a<br>_—<br>_ |<br>Ca “al<br>45 mm<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   6/38 

6 

## Expansion relay JSR2A 

## Approvals: 

## TÜV NORD 

## Safety relay for: 

- More safe outputs 

- Greater current switching capacity 

- Information output 

## Features: 

- Switching capacity of up to 10 A/250V per output 

- Width 45 mm 

- LED function indication 

- 4 NO/1 NC relay outputs 

- 5 supply versions 

- Supply 24 VDC/VAC, 115 and 230 VAC 

- Quick release connector blocks 

## More outputs 

The JSR2A expansion relay is used to provide increased switching capacity and number of safety outputs to a safety relay. This means that an unlimited number of dangerous machine operations and functions can be stopped from one safety relay. 

## Greater current switching capacity 

The JSR2A Expansion relay enables switching of up to 10 amps per output contact. 

## Safety level 

The JSR2A has twin stop functions, that is, two relays with mechanically positively guided contacts. A monitored stop function is achieved by connecting the test output (terminals X1 and X2) to the test or reset input on the safety relay which is to be expanded. 

## Regulations and standards 

The JSR2A is designed and approved in accordance with appropriate directives and standards. See technical data. 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/39    2TLC172001C0202 | ABB Safety Handbook 

Technical data – JSR2A 

Technical description – JSR2A 

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Test Outputs<br>A2 S24 X1 gaa(13 23 33aa<br>Supply<br>**----- End of picture text -----**<br>


The JSR2A has to be connected to a suitable safety relay in order to fulfill the necessary safety requirements (see chapter “Connection examples”). The Safety Relay controls and monitors the JSR2A unit. (The JSR2A can be connected for single or dual channel operation - see Electrical connection diagrams below). When the inputs to S14 and S24 close, internal relays K1 and K2 are activated. A stop signal is given, K1 and K2 drop, if the inputs are opened or during power failure. 

To check that both the K1 and K2 relays drop during a stop signal they must be monitored. This is achieved by connecting X1 and X2 to the test or reset input on the safety relay which is expanded. K1 and K2 have mechanically positively guided contacts, therefore, if one of the output contacts should stick closed then the relay’s contact in X1-X2 cannot be closed thus preventing a new ready signal being given to the safety relay. 

## Electrical connection – JSR2A 

One channel expansion of RT6 with JSR2A  connected for manual reset. 

oO eos Reset 

Dual channel expansion of RT6 with JSR2A connected for automatic reset. 

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™ Re 120 ~<br>Re<br>Connector blocks are detachable<br>| (without cables having to be disconnected)<br>74<br>45 mm<br>**----- End of picture text -----**<br>


Article number JSR2A 10 A 24 VAC/VDC 2TLA010027R0100 JSR2A 10 A 115 VAC 2TLA010027R0400 JSR2A 10 A 230 VAC 2TLA010027R0500 Colour Grey Supply A1 - A2 24 VDC/AC, 115, 230 VAC + 15%, 50-60 Hz Power consumption 2.7W/2.4–4 VA Relay outputs 4 NO + 1 NC Max. switching capacity Resistive load AC 8A/230 VAC/1840 VA 10A/115VAC/48VAC/24VAC/ 1840 VA Inductive load AC AC15 230 VAC 4A (NO-contact) 1.5A (NC-contact) Resistive load DC 8A/24 VDC/192 W Inductive load DC DC13 24 VDC 1.2A (NO/NC-contact) Max. total switching capacity: 16A distributed on all contacts Min. load 10mA/10V/100mW (if load on contact has not exceeded 100 mA) Contact material AgSnO2 + Au flash Fuses output (External) 6A gL ( 8A fast if short-circuit current >500A ) 6 Conditional short-circuit current (1 kA) 10A gG Max. Input wire res. at nom. 24 VDC/VAC: 100 Ohm voltage 48/115/230 VAC: 200 Ohm Mechanical operational Life >10[7] operations Response time at deactivation (input- output) <25 ms activation (input - output): <15 ms Terminals (removable) Max. screw torque 1 Nm Connection area (max.) Single strand 1x4 mm[2] or 2x1.5 mm[2] / 12AWG Conductor with socket contact : 1x2.5 mm[2] or 2x1 mm[2] Mounting 35 mm DIN-rail Protection class terminals Enclosure IP40 IEC 60529 : Terminals IP20 IEC 60529 LED indication On Supply voltage 1 2 Output relays 1 and 2 ~~secseeeesseeeeeseceesseceeseeeeeeceeeessssssssssssssnsssssnnnavannnssuenniseiefeceesseeeeesessssssssnnsnnnsenesseesetseeeeseenssssssnnsnnnneniesseessteeseeeeety~~ Impulse withstand voltage : 2.5kV Pollution degree 2 Operating temperature range -10°C to +55°C (with no icing or condensation) ~~re~~ Operating humidity range 35% to 85% ~~a~~ Weight 313 g Performance (max.) PL e/Cat. 4 Functional test: The relays must (EN ISO 13849-1:2008) be cycled at least once a year SIL 3 (EN 62061:2005) PFHD 1.55E-08 Conformity 2006/42/EC, 2006/95/EC, 2004/108/EC EN 62061:2005 EN ISO 13849-1:2008 

ABB Safety Handbook | 2TLC172001C0202   6/40 

Approvals: 

6 

## Expansion relay JSR3T 

## TÜV E NORD Safety relay for: – Safe delay of stop signals with selectable value – Delayed safe outputs ~~Oe~~ Features: – Width 22.5 mm 

- Supply 24V AC/DC 

- Output indication 

- 2 x 1 NO relay outputs 

- Hardwire Selectable Delay 0.5 - 10.0 sec by hardwire links and Time trim potentiometer 

## Delayed outputs 

By connecting the JSR3T expansion relay to a compatible Safety relay it is easy to obtain safe "delayed" outputs. 

The JSR3T provides the system designer with the facility to hardwire selected time delays in steps between 0.5 and 10 seconds. 

to the machine control system i.e. via a PLC which applies the necessary braking/stopping of the machine in a controlled way, and to switch  a delayed expansion relay e.g JSR3T. The delayed safety outputs of the JSR3T expansion relay are then used to control the safe disconnection of the power to the actuators/motors etc. of the machine. 

## Safety level 

## Use of delayed outputs 

There are many applications where delayed outputs are necessary and permissible. For example delayed stop signals can be used for emergency stops according to EN ISO 13850:2008 § 4.1.4 Stop Category 1 (a controlled stop with power to the machine actuator(s) available to achieve the stop and then removal of power when stop is achieved). Stop Category 1 may also be  permitted when it is not possible to gain physical access to the  machine before the safe stop is effected e.g. by: 

- Covers and Gates which are locked until  dangerous operations and functions have been stopped. 

- Long distances  between a safety device and dangerous machine functions. 

- Using this technique of stopping a machine provides many advantages i.e.: 

- Machines last longer as they are not subjected to excessive loading etc when requested to stop. 

The JSR3T has twin stop functions, using two positively guided contact relays. 

In order to achieve the level of monitoring required the JSR3T must be used with a suitable Safety Relay e.g. JSBR4, or RT6. The JSR3T test output (terminals X1 and X2) must be connected to the test input of the Safety relay being expanded (see connection examples). 

The JSR3T provides delay times that even in the event of an internal fault condition complies with the requirement that the set delay cannot increase in time. 

## Regulations and standards 

The JSR3T is designed and approved in accordance with appropriate directives and standards. Examples of such are 98/37/EC, EN ISO 12100-1/-2, EN 60204-1, EN 954-1/ EN ISO 13849-1. 

- Parts being processed are not damaged. 

- Restarting machines from stopped position is simplified. 

A safe "Soft" stop is achieved by means of a safety relay giving a programme stop to the machine control system.  e.g. when a gate is opened or emergency stop is activated. The output of the Safety relay is used to provide both a stop signal 

## Connection examples 

For examples of how our safety relays can solve various safety problems, please see the section “Connection examples”. 

6/41    2TLC172001C0202 | ABB Safety Handbook 

Technical data – JSR3T 

## Technical description – JSR3T 

**==> picture [188 x 74] intentionally omitted <==**

When supply voltage is connected to A1 and A2, relays K1 and K2 are activated. When the supply voltage is removed relays K1 and K2 remain energized for a time period determined by the hardwire link configuration chosen (set by connecting links on the terminals Y1, Y2, Y3 and Y4.) and  the setting of the Time Trim potentiometer. 

NOTE 1! Max. time set by hardwire links can only be reduced (up to approx. 30% reduction) by Time Trim potentiometer. 

NOTE 2! Both the output contacts of K1 and K2 (13 - 14 and 23 - 24) must be used. Output contacts must be either connected in series (forming one safety output) or used in parallel circuits in order to obtain necessary redundancy. 

## Electrical connection – JSR3T 

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Article number<br>JSR3T  24 VAC/VDC 2TLA010017R0100<br>Colour Grey<br>Power supply 24 VAC/VDC, 50 - 60 Hz<br>Power consumption 1.3 VA/W<br>Relay outputs 2 x 1 NO (See Connection examples)<br>Max. switching capacity<br>Resistive load AC 4A / 250 VAC/1000 VA<br>Inductive load AC AC15 240 VAC 3A<br>Resistive load DC 4A / 24 VDC /100 W<br>Inductive load DC  DC13 24 VDC 2A<br>Max. res. load total switching<br>capacity: 6A distributed on all contacts<br>Min. load 10mA/10V (if load on contact has<br>not exceeded 100 mA)<br>Contact material AgNi<br>Fuses output (external) 3A gL/gG or 4A fast<br>Conditional short-circuit current<br>(1 kA) 6A gG<br>Max Input wire res. at nom.<br>voltage 100 Ohm<br>Response time at activation <20ms<br>Response time at deactivation <0.5 - 10.0 sec. at nom. voltage.  6<br>Selected delay can be lowered by up<br>to approx. 30% by means of preset<br>potentiometer on front panel.<br>Terminals (max. screw torque 1 Nm) Single strand: 2x1.5 mm [2]<br>Conductor with socket contact:<br>2x1mm [2] .<br>Mounting 35 mm DIN-rail<br>Protection class enclosure/ter-<br>minals IP40 / IP20 IEC 60529<br>Impulse withstand voltage 2.5kV<br>Pollution degree 2<br>Operating temperature range –10°C to +55°C (with no icing or<br>condensation)<br>Operating humidity range 35% to 85%<br>LED indication Outputs<br>Weight 158 g<br>Performance (max.) PL e/Cat. 4<br>Functional test: The relays must  (EN ISO 13849-1:2008)<br>be cycled at least once a year. SIL 3 (EN 62061:2005) PFHD 3.67E-09<br>Conformity 2006/42/EC, 2006/95/EC,<br>2004/108/EC EN 62061:2005<br>EN ISO 13849-1:2008<br>**----- End of picture text -----**<br>


Selection of time delay by hardwire links (Y1, Y2, Y3, Y4). 

Selected delay can be lowered by up to approx. 30% by means of preset potentiometer on front panel. 

It is recommended that all switched loads are adequately suppressed and/or fused in order to provide additional protection for the safety contacts. 

ABB Safety Handbook | 2TLC172001C0202   6/42 

6 

6/43    2TLC172001C0202 | ABB Safety Handbook 

## Connection examples 

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HA5400A Connection examples JSBR4  6/45<br>HA6400A Connection examples JSBT4  6/45<br>HA6500A Connection examples JSBT5  6/46<br>HA6500B Connection examples BT50  6/46<br>HA6501B Connection examples BT50T  6/47<br>HA6500C Connection examples BT51  6/47<br>HA6501C Connection examples BT51T  6/48<br>HA7100A Connection examples JSBRT11  6/48<br>HA7600A Connection examples RT6  6/49<br>HA7600B Principle drawing RT6  6/49<br>HA7672A Enabling device JSHD4 - EX with RT6  6/50<br>HA7700A Connection examples RT7  6/50<br>HA7900A Connection examples RT9  6/51<br>HE3811B Safety Light Beam Spot with time-limited reset  6/51<br>HE3824C-01 Lightbeam with time-limited bypass 0.2–40 s  6/52<br>HE3824E-01 Lightbeams with time-limited bypass 0.2–40 s  6/52<br>HG7636B Focus light grid/curtain with three-position device  6/53<br>HG7611A Interlocked door with RT6 and pre-reset  6/53<br>HG7636A Interlocked door with three-position device  6/54<br>HG7646A Interlocked door with three-position device  6/54<br>HG7654A Interlocked door with RT6 and output expansion JSR1T  6/55<br>HG7658A Interlocked door with RT6 and output expansion JSR2A  6/55<br>HG7673A Interlock switch JSNY8 with RT6  6/56<br>HG7674A Safety interlock switch JSNY9M/MLA with RT6  6/56<br>HG7674B Safety interlock switch JSNY9S/SLA with RT6  6/57<br>HH0000C Three-position device JSHD4 with various safety controllers 6/57<br>HI8552A Connection examples JSHT2 intermittent running 6/58<br>HK7600A Safety mat/Contact strip with RT6  6/58<br>HL7600B Several JSNY7 connected to one RT6 with unique indication 6/59<br>HM0000A Magnetic switch JSNY7 with various safety controllers  6/59<br>HN7660A Delayed outputs RT6 with output expansion JSR3T and RT7 6/60<br>HP7600A Machine control - Isolation of PLC inputs and outputs  6/60<br>HP7600B Machine control-Isolation of PLC outputs  6/61<br>HR7200B Focus light curtain/beam  6/61<br>HR7800B Focus lightbeam/curtain  6/62<br>HT5400A Two-hand device with safety relay JSBR4  6/62<br>HB0008A Focus light curtain/light beam with RT9 and M12-3D  6/63<br>**----- End of picture text -----**<br>


6 

ABB Safety Handbook | 2TLC172001C0202   6/44 

6 

## Connection examples 

HA5400A Connection examples JSBR4 

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HA6400A Connection examples JSBT4 

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## Connection examples 

HA6500A Connection examples JSBT5 

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HA6500B Connection examples BT50 

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ABB Safety Handbook | 2TLC172001C0202   6/46 

6 

## Connection examples 

HA6501B Connection examples BT50T 

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HA6500C Connection examples BT51 

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## Connection examples 

HA6501C Connection examples BT51T 

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HA7100A Connection examples JSBRT11 

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ABB Safety Handbook | 2TLC172001C0202   6/48 

6 

## Connection examples 

HA7600A Connection examples RT6 

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HA7600B Principle drawing RT6 

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## Connection examples 

HA7672A Enabling device JSHD4 - EX with RT6 

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HA7700A Connection examples RT7 

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ABB Safety Handbook | 2TLC172001C0202   6/50 

6 

## Connection examples 

HA7900A Connection examples RT9 

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HE3811B Safety Light Beam Spot with time-limited reset 

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## Connection examples 

HE3824C-01 Lightbeam with time-limited muting 0.2–40 s 

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HE3824E-01 Lightbeams with time-limited muting 0.2–40 s 

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ABB Safety Handbook | 2TLC172001C0202   6/52 

6 

## Connection examples 

HG7636B Focus light grid/curtain with three-position device 

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HG7611A Interlocked door with RT6 and pre-reset 

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## Connection examples 

HG7636A Interlocked door with three-position device 

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HG7646A Interlocked door with three-position device and time-limited entrance/exit 

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ABB Safety Handbook | 2TLC172001C0202   6/54 

6 

## Connection examples 

HG7654A Interlocked door with RT6 and output expansion JSR1T 

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HG7658A Interlocked door with RT6 and output expansion JSR2A 

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## Connection examples 

HG7673A Interlock switch JSNY8 with RT6 

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HG7674A Safety interlock switch JSNY9M/MLA with RT6 

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ABB Safety Handbook | 2TLC172001C0202   6/56 

6 

## Connection examples 

HG7674B Safety interlock switch JSNY9S/SLA with RT6 

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HH0000C Three-position device JSHD4 with various safety controllers 

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## Connection examples 

HI8552A Connection examples JSHT2 intermittent running 

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HK7600A Safety mat/Contact strip with RT6 

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ABB Safety Handbook | 2TLC172001C0202   6/58 

6 

## Connection examples 

HL7600B Several JSNY7 connected to one RT6 with unique indication 

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HM0000A Magnetic switch JSNY7 with various safety controllers 

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## Connection examples 

HN7660A Delayed outputs RT6 with output expansion JSR3T and RT7 

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HP7600A Machine control - Isolation of PLC inputs and outputs 

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6 

## Connection examples 

HP7600B Machine control-Isolation of PLC outputs 

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HR7200B Focus light curtain/beam 

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## Connection examples 

HR7800B Focus lightbeam/curtain 

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HT5400A Two-hand device with safety relay JSBR4 

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6 

## Connection examples 

HB0008A Focus light curtain/light beam connected to an RT9 with the aid of a M12-3D 

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ABB Safety Handbook | 2TLC172001C0202   6/64 

7 

7/1    2TLC172001C0202 | ABB Safety Handbook 

## Light curtains, Light grids and Light beams 

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**----- Start of picture text -----**<br>
Why use light grids and light curtains?  7/3<br>Reset - 3 alternatives  7/5<br>Muting and blanking 7/6<br>Light curtain for short safety distance  7/7<br>Cycle initiation with light curtain  7/8<br>Safety distance  7/9<br>Light curtains, Light grids<br>Focus II  7/11<br>Muting units - MF-T, MF-L  7/16<br>Muting sensors - Mute R  7/18<br>Muting accessories - FMC, FMI  7/20<br>Accessories - MFII mirrors  7/22<br>Light protection stand - Bjorn  7/23<br>Protection against water and dust - WET  7/25<br>Blanking program - BP-1  7/26<br>Connection examples Focus II  7/27<br>Safety Light Beam<br>Spot  7/34 7<br>Connection examples  7/37<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   7/2 

7 - 

## Why use light grids and light curtains? 

Light grids and light curtains are production friendly safety components that causes no physical obstruction for the machine operator. Light barrier protection is also a good safety component to use when goods are to be passed in and out of a hazardous area. 

## How does a light grid/light curtain work? 

Both light grids and light curtains utilise optical transmitter and receiver units. From the transmitters beams of infrared light are sent to the receiver. When a light beam is interrupted a dual stop signal is given to the dangerous machines inside the light grid/curtain protected area. 

## What is the difference between a light curtain and a light grid? 

A light curtain has several beams that are placed closely together whereas a light grid consists of only one, two, three or four light beams. The beams are closest on a light curtain that is used for finger detection. Then the resolution is 14 mm. For light grids the beams are normally placed at a relative distance of 300 to 500 mm. The choice between light grid or light curtain is often a question of available safety distance, reach and price. Light curtains are often chosen for short safe/minimum distances. Light grids are chosen for longer safe/minimum distances, long range up to 40 m and for a low price. 

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7 

Light grids for long distances 

Light curtain for short safe/minimum distances 

Light curtain as area protection 

What safety requirements are there for a light protection device? 

High safety demands are stated in the standard EN 61496-1 which deals with light protection. The main demands are on a safe stopping function and that light from light sources other than the transmitter or other disturbances do not affect the safety function. 

Depending on how the safety function is built up there are safety components of type 2 and 4 to choose between. Type 2 and 4 relates in principle category 2/PL c and category 4/ PL e according to EN ISO 13849-1. 

Light grids with monitored bypassing during material transport 

Light curtain to protect during cycle initiation 

Light curtain for inner area limiting 

Type 2 states that a simple but monitored safety function is required, which means that the safety function shall be monitored through periodic tests which break the output when a fault occurs. Between the testing times there can though be faults which result in the safety component malfunctioning. The test function can either be built into the safety device or an external unit (e.g. the machine´s control system) can initiate a test. Maximum allowed scattering angle for the light is ±5°. 

Light grids and light curtains are included among the products in the machine directive´s appendix 4, which means that an external certifying procedure with an officially recognised institution is called for. 

Type 4 which has the highest safety level, states that a fault is not allowed to affect the safety function and that the fault shall be detected by the outputs falling immediately or that they do not re-connect after being disconnected. Maximum allowed scattering angle for the light is ±2.5°. 

ABB Safety Handbook | 2TLC172001C0202   7/4 

## Reset – 3 alternatives 

## Supervised manual reset 

7 

When a light curtain/grid is interrupted it will give a stop signal to dangerous machines within the hazardous area it protects and a reset-lamp can be lit. For a new start of the machine the light curtain/grid has to be reset. This is done with the reset button which is placed where the whole hazardous area can be supervised and can not be reached from within the area which it protects.. There are high requirements on the reset function - neither a short circuit nor a component fault shall give automatic reset. When the reset button has been set the outputs are activated and the reset-lamp is turned off. 

## Supervised time-reset 

When supervised time-reset (pre-reset) is in use, its purpose is not to allow a reset from outside the protected area without first having confirmed that no-one is out of sight within the area. To reset the light beam (see figure) button 1 must first be pressed and afterwards button 2 within e.g. 5 seconds. This is especially important when one cannot see the entire area that is protected by the light beam. 

Reset button with light indication. 

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1<br>2<br>**----- End of picture text -----**<br>


Button 1 is pressed and afterwards, within a chosen time e.g. 5 seconds, button 2 is pressed for resetting the light beam. 

## Automatic reset 

Automatic reset is used when the light beam is used for area monitoring. When the light beam is actuated this indicates that e.g. a robot is in the area. The robot is stopped if a person enters the same area e.g. through a gate. When the light beam is free again the control unit will be reset automatically. 

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a<br>b<br>A<br>Oe GA VI<br>B<br>A light beam b indicates that the robot is situated in<br>area A. In this position it is possible to walk in through<br>the gate to area B without stopping the robot.<br>**----- End of picture text -----**<br>


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## Muting (bypassing) 

Bypassing may be needed for different reasons. One of the most common reasons for bypassing is during in and out feeding of material on a conveyor, Automated guided vehicle (AGV), etc. Another common application is bypassing while passing with a three-position device to the hazardous area. 

Important aspects for bypassing is that it shall be safe, not be activated by mistake and be difficult to defeat. In other words it shall give a reliable bypassing when a loading carrier enters but not allow a human to pass. To achieve the highest safety level a dual and supervised bypassing system is needed (usually with at least two independent signals). If this is done with sensors, it is recommended they be of different kinds, because of the probability of them both malfunctioning for the same reason e.g. common cause failure. An example of a solution is to use a mechanical limit switch and a photo-cell sensor. 

To avoid deliberate defeating/manipulation of the bypassing sensors/signals a safety relay or a safety-PLC is connected thereby monitoring that the sensors are both activated and deactivated in every bypassing cycle. 

Automatic bypassing of light grid when an Automated guided vehicle passes. 

The number of variations in bypassing systems are almost infinite. This depends on the specific requirements of each plant/machine. For Focus II there are a number of bypassing possibilities prepared. 

## Blanking 

Blanking means permanent switching off of a number of beams in the detection zone of a light curtain. This is a function that is permitted and used when an object that is larger than the resolution of the light curtain is permanently located in the detection zone, without deactivating the safety outputs (OSSD). If the object is removed from the detection zone, the safety outputs are deactivated. 

Blanking function has different tolerance settings that allow movement or vibration of the objects that obscure the detection zone. 

When a “blanking” function is used, it is very important that the light curtain provides protection and can detect objects, as small as a finger or hand, depending on the resolution, anywhere outside the zone that is rendered inactive because the object is there. Blanking may require an additional fixed guard and may require additonal minimum distance to the dangerous movment. 

It must not be possible to select the “blanking function” without using a key, tool or similar unlocking device. 

One tolerance setting can be called ”Floating blanking”, that means that the part of the zone which is intentionally blocked can be moved around in the detection zone while the machinery is operating. Other beams are active and providing normal protection, but often with reduced resolution. 

ABB Safety Handbook | 2TLC172001C0202   7/6 

## Light curtain for short safety distance 

A light curtain can be used in a machine or a production plant in the same way as a hatch. There is a great difference though when it comes to the risk situation. When one has a light curtain installed with a short minimum distance in front of a dangerous machine, there is a high risk for spontaneous engagement into the machine, often called after-grasp. If the dangerous machine movement does not stop during such an engagement, one has a small chance of avoiding injury. 

Therefore it is of great importance that the whole chain in the stopping circuit is dual and supervised. Even valves and contactors which ultimately control dangerous movements normally have to be doubled up and supervised. 

Regulations concerning safety distances are given in specific C-standards such as EN 692 for mechanical presses. If no specific C-standard is available, EN ISO 13855 is used. 

Hand resolution 

## Automatic machines 

For light curtains on automatic machines there shall be a reset 7 function which is active when the machine is set for automatic production whether or not it is a passable protection. After affected a light curtain, one must first use a reset function then the restart of the cycle shall be made with a separate starting device. The same reset applies for machines with semi-automatic drive. 

Operator protection during manually serviced machines Manually operated machines where one or more operators pick in and out parts between every cycle are the most risky light curtain applications. This because of the number of engagements into the machine´s hazardous area is often several times per minute. 

## Light curtains on presses 

Light curtains have traditionally been a common protection method among press applications and there has since long existed detailed information on the usage of light curtains on presses. (see next spread for “Cycle initiation with light curtain“). Only light curtains of type 4 are accepted on presses. 

Finger resolution 

## Reset 

On the servicing side i.e. the side or sides where there is an operator that picks in and out parts, there shall be a separate reset function for the light curtain, usually a button. If there are several light curtains e.g. on the front and back there shall be one for each. If the light curtain is actuated during a dangerous movement the press shall not be able to restart without being reset. During engagement after the end of the cycle no reset is needed. 

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## Cycle initiation with light curtain 

## Cycle initiation 

Cycle initiation is a concept when the machine is designed so that a new cycle initiated by affecting the light curtain. A cycle is defined as the hand being placed in and taken out once. Usually it is possible to choose between one-cycle and two-cycle operation. During one-cycle a new action is started when the light curtain has been actuated once and during two-cycle when the light curtain has been actuated twice. The operator thereby operates the machine by the action of putting parts in and out. 

On presses this “Cycle initiation“ function is very common. But because the press starts without any particular command there are some risks involved and therefore many conditions have to be met before the machine operates. 

Smaller presses which cannot be entered have certain regulations that means some limitations: The table height may not be lower than 750 mm, the stroking length may not be larger than 600 mm and the table depth may not be larger than 1000 mm. The light curtain shall have 30 mm or higher resolution. If the press is not started within approx. 30 seconds after the end of the cycle, a new cycle shall not be accepted without the light curtain being again manually reset. NB. For machines with cycle initiation, the installation of the light curtain must be in accordance with machine parameters and all relevant standards and regulations. 

## Installation of light curtain 

The light curtain must be installed so no-one can reach a trapping/crushing risk without actuating the light curtain. The most important thing is that there are no gaps under, on the sides and over the top during cycle operation. The lower edge of the light curtain must therefore be slightly below the 

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press table edge. Also if it is open above the light curtain the height must be adapted so that it is not possible to reach over the detection zone (see ISO 13855). Physical adjustment possibilities must be limited so that dangerous motions are placed out of reach. 

Between the light curtains detection zone and mechanical parts there shall only be max 75 mm gap to prevent a person from standing there. In practise to achieve this demand and the required safety distance one usually has to complement with e.g. additional mechanical protection or additional horizontally positioned light curtains i.e. step-in light curtain. Another solution could be a lying or an angled light curtain. 

Installation – correct and incorrect during cycle initiation 

Correctly installed. The operator cannot reach into the machine without actuating the light curtain. 

Incorrect installation. Gap below the light curtain. The operator can reach into the machine without actuating the light curtain. 

Incorrect installation. Gap above the light curtain. The operator can reach into the machine without actuating the light curtain. 

Correctly installed. Light curtain complemented with a horizontal light curtain to detect the operator. 

ABB Safety Handbook | 2TLC172001C0202   7/8 

7 H1} . F ~~a~~ 

## Minimum distance for light protection according to EN ISO 13855 

The distance ’S’ is a minimum distance between a light curtain and a hazardous area. The distance shall prevent that a person is not able to reach a hazardous machine part before the machine movement has stopped. This is calculated with the formula from  EN ISO 13855 - Safety of machinery - Positioning of safeguards with respect to the approach speeds of parts of the human body. 

## S = (K x T) + C 

S = minimum distance in mm 

K = body/part of body (e.g. hand) speed in mm/s T = T1 + T2 

where 

T1 = the safety device´s reaction time in seconds 

T2 = the machine´s reaction time in seconds 

C = additional distance in mm based upon the body´s intrusion towards the hazardous area before the safety device has been actuated. 

Resolution for finger (≤14 mm) gives C = 0 

NB If it is possible to reach the hazard zone by reaching over the light beam, an addition is made to the formula. In table 1 in EN ISO 13855 an alternative safety distance addition (Cro) is given to the formula S = (K x T) + C. The greatest value out of C and Cro is to be used to prevent reaching the hazard zone by reaching over the light curtain/grid. 

Minimum distances for vertical and horizontal installed light curtains according to EN ISO 13855 

S =  minimum distance in mm H1 = the lower beam may not be situated higher than 300 mm above the ground 

H2 = the upper beam may not be situated lower than 900 mm above the ground 

For S ≤ 500 mm the minimum distance for vertical installation is calculated with the following formula: 

## S = (2000 x T) + 8 x (d-14) 

S = minimum distanc ~~e~~ in mm H = the light curtain detection zone must be positioned between 0 and 1000 mm above the floor 

The minimum distance for horizontal installation is calculated with the following formula: 

## S = (1600 x T) + (1200 - 0.4 x H) 

where H is the height of the detection zone above the reference plane, e.g. the ground 

where d is the light curtain´s resolution in mm. 

K here is 2000 mm/s which represents the speed of the hand. The expression (8 x (d-14)) may never be less than 0. Minimum distance S is 100 mm. 

(1200 – 0,4 x H) may not be less than 850 mm. Depending on the resolution, d, that the light curtain has, there is a minimum height that the detection zone may be placed.  This is calculated with: 

H = 15 x (d – 50). 

If the minimum distance according to the formula above gets larger than 500 mm one can instead use: 

## S = (1600 x T) + 8 x (d-14) 

H cannot be less than 0. With a resolution d =14 or 30 mm one can therefore install the light curtain from H = 0 and up. The higher it is situated, the shorter the minimum distance gets. The highest permissible height H of the detection zone is 1000 mm. 

K is1600 mm/s which represents the speed of the body. Minimum distance according to this formula is 500 mm. 

When you use a horizontal light curtain as entry protection, the depth of the light curtain shall be at least 750 mm to prevent people from inadvertently stepping over it. The estimated minimum distance is measured from the machine’s hazardous section to the outermost beam of the horizontal light curtain (seen from the machine). 

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Minimum distance for light beams according to EN ISO 13855 

For light beams the minimum distance is calculated from the following: 

## S = (1600  x T) + 850 mm 

|Number of beams|Height over the reference plane, e.g.<br>ground|
|---|---|
|4|300, 600, 900, 1200|
|3|300, 700, 1100|
|2|400, 900|



NOTE! The additional distance will in most cases be more than 850 mm due to the possibility to reach over a light beam. (Cro) 

The formula applies whether one installs 2,3 or 4 beams. It is the risk assessment that decides the number of beams that are to be chosen. The following possibilities must be considered. 

- to crawl under the lowest beam; 

- to reach over the top beam; 

- to reach in between two beams; 

- that the body passes in between two beams. 

To fulfill the requirements the beams shall be installed at the following heights: 

Minimum distances for new and old presses 

## New presses 

For new CE-marked presses there are specific requirements from the standards EN 692 Machine tools – Safety – Mechanical presses – Safety and EN 693 Machine tools – Safety – Hydraulic presses. 

## Old presses 

“NB“  For old presses there are different rules for each country. 

The formula that applies here is: 

The same requirements apply for vertical installation on presses as with vertical installation on other machines with the difference that C is given according to the following: 

|Resolution,<br>d, (mm)|Minimum distance<br>addition, C (mm)|Cycle<br>initiation|
|---|---|---|
|≤ 14|0|Permitted|
|>14 - 20|80||
|>20 - 30|130||
|>30 - 40|240|Not<br>permitted|
|>40|850||



## Other manually serviced machines 

The rules for presses may well be applied to other machines which function in a similar way and that have the same risk situation. There is no other standard which is as detailed on the usage of light curtains. 

For cycle initiation the light curtains resolution, d, must be ≤ 30 mm. This applies to both old and new (CE-marked) presses. 

## S = (2500 x T) + C 

The minimum distance addition C for different resolutions of the light curtain is given in the following table 

|Resolution,<br>d, (mm)|Minimum distance<br>addition, C (mm)|
|---|---|
|<16|0|
|16|70|
|20|110|
|25|130|
|30|140|
|35|240|
|40|270|
|45|300|
|50|330|
|55|360|
|>55|850|



ABB Safety Handbook | 2TLC172001C0202   7/10 

7 _ 

## Safety Light Grids and Safety Light Curtains Focus II 

## Approvals: 

## Application: 

- Optical protection in an opening or around a hazardous area 

## Features: 

- Type 4 according to EN 61496 

- Flexible assembly 

- LED indication 

- High protection class (IP65) 

- Range 0.2-40 m 

- Time reset 

- Fixed / floating blanking 

- Muting 

- Single/Double Break funktion 

- External Device Monitoring (EDM) 

## A light grid/light curtain with many possibilities 

Focus II is a new version of our previous light grid/light curtain Focus. Features such as muting and override are standard in all Focus II light curtains and light grids. For light curtains, blanking and break functions are also standard. The optical sensors on Focus II also have variable coding. The Focus II units are light grids/curtains with safety functions intended for applications where it is of great importance to protect persons from a dangerous machine, robot or other automated systems where it is possible to access to a hazardous area. 

Focus II creates a detection zone with infrared beams. If any beam is interrupted the safety mechanism is triggered and the dangerous machine is stopped. Focus II fulfills the requirements for non-contact safety equipment type 4 according to the international regulation standard EN 61496-1. 

Units are available with safety heights between 150 and 2400 mm. All electronic control and monitoring functions are included in the light curtain profiles. External connection is made via a M12 connection at the end of the profile. Synchronization between transmitter and receiver is achieved optically. No electrical connection between the units is required. Control and monitoring of the beam transmission is carried out by two micro-processors which also give information on the status and alignment of the light curtain via several LEDs. 

- Available with different resolutions 

- Up to PL e according to EN ISO 13849-1 

## Muting and Override included in all Focus II 

The ”Muting” and ”Override” functions are available on all Focus II light grids/curtains and is enabled directly when an indication lamp LMS is connected. Muting implies that one or more segments or the whole light curtain can be bypassed during in and out passage of material. 

In the Focus II with muting enabled there is also an Override function which makes it possible to bypass the light grid/ curtain i.e. activate the outputs if a machine start is necessary even if one or more light beams are interrupted. This is the case when the muting function is chosen and the A and B inputs are activated. If for example during the muting operation a loading pallet has stopped inside the detection zone after a voltage loss, the override function is used to enable the pallet to be driven clear. 

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## Blanking 

It is also possible to obtain the Focus II light curtains with blanking. Floating blanking is a tolerance setting that makes it possible to ’disconnect’ a defined number of beams from the detection zone. The object is then free to move in the detection zone without the safety function being  triggered. Other tolerance settings allows less movment of the interfering object. Blanking may require an additional fixed guard and may require additonal minimum distance to the dangerous movment. 

## Safety outputs OSSD1 and OSSD2 

Focus II has two PNP outputs - OSSD1 and OSSD2. If the load to be switched is alternating current or requires a higher current than 500 mA then one should use a safety relay e.g. RT9, Pluto PLC or the FRM-1 unit (converts the outputs to relay contacts) from ABB Jokab Safety. The FMC-Tina  and Tina 10A/10B/10C converts the outputs to a dynamic signal for connection to Pluto or Vital. Pluto can also work directly with the OSSD-outputs. 

## External Device Monitoring (EDM) 

In all light grids and light curtains an EDM function is available which allows Focus II to test if the external control element responds correctly. A test channel is connected through the respective contactor, in order to detect any faults and thereby prevent a reset. 

## Reset 

On every Focus II there are inputs for reset. The reset option is chosen through dual switches in the Focus II receiver. At delivery, Focus II is set to automatic reset. 

- Automatic reset –  When the detection zone is free the outputs are closed directly. (Setting when delivered). 

- Manual reset – When the light field detection zone is free, the reset button has been actuated before the outputs are activated. 

- Time reset – To reset the Focus II a pre-reset button must first be actuated and afterwards within 8 seconds a reset button outside the hazardous area must be actuated. 

## Single/Double Break function 

This function is used for presses when the operator prepares or picks out a detail. With the Single Break function the light curtain allows operation after entry and withdrawal out of the curtain. Similarly, the Double Break function allows operation after entry and withdrawal twice. 

## Focus II light curtain 

## Standard: 

- Muting (bypassing) partly or completely 

- Supervised output for muting lamp 

- Override 

- Manually supervised or automatic reset 

- Time-reset 

- Blanking 

## Focus II light grid 

## Standard: 

   - Muting (bypassing) of one, two, three or four beams 

   - Supervised output for muting lamp 

   - Override 

   - Manually supervised or automatic reset 

   - Time-reset. 

   - EDM 

- Single/Double Break 

- EDM 

## Option: 

- Light grids for tough environments with parallel beams of light for improved reliability. 

**==> picture [95 x 36] intentionally omitted <==**

**----- Start of picture text -----**<br>
With the  switches at the<br>bottom of Focus II you can<br>choose the function you<br>desire.<br>**----- End of picture text -----**<br>


JSM 66 2TLA022090R1300 JSM 66 Bracket for Focus II 

ABB Safety Handbook | 2TLC172001C0202   7/12 

## Focus ll light curtain/grid, Type 4 (FII-4) Summary 

7 

**==> picture [567 x 618] intentionally omitted <==**

**----- Start of picture text -----**<br>
Model name FII-4-14-zzzz FII-4-30-zzzz FII-4-K4-zzzz FII-4-K3-800 FII-4-K2-500<br>Resolution 14 30<br>Beam distance 300 400 400 500<br>150  150<br>300  300<br>450  450<br>600  600<br>750  750<br>900  900<br>1050  1050<br>1200  1200<br>Height (mm=zzzz) 1350  1350  900 1200 800 500<br>1500  1500<br>1650  1650<br>1800  1800<br>1950  1950<br>2100  2100<br>2250  2250<br>2400 2400<br>Range (m)<br>SR<br>0.2-3  0.2-7  0.5-20  0.5-20 0.5-20<br>LR<br>3-6 7-14 20-40 20-40 20-40<br>Reaction time off (ms) 18-103 14-47 13 13 13<br>Reaction time on (ms) 138-104 141-119 142 142 142<br>Manual reset<br>Automatic reset<br>Pre reset<br>Muting inputs<br>Muting lamp supervision<br>Override<br>Muting T/L/X<br>Blanking 3 types<br>Single/Double break<br>EDM<br>Dyn. Adaption to Vital/Pluto ¤ ¤ ¤ ¤ ¤<br>**----- End of picture text -----**<br>


Standard                 ¤ With Tina 10A/10B/10C or FMC-Tina 

NOTE! For ordering data and article number see the product list. For more information see the manual on our home page. 

7/13    2TLC172001C0202 | ABB Safety Handbook 

7 

**==> picture [566 x 618] intentionally omitted <==**

**----- Start of picture text -----**<br>
FII-4-K4-zzzz D FII-4-K3-800 D FII-4-K2-500 D FII-4-K2C-zzzz FII-4-K2C-800 FII-4-K1C-500<br>300 400 400 500 300 400 400 500<br>900 1200 800 500 900 1200 800 500<br>0.5-20 0.5-20 0.5-20 0.5-7 0.5-8 0.5-12<br>20-40 20-40 20-40<br>13 13 13 13 13 13<br>142 142 142 142 142 142<br>¤ ¤ ¤ ¤ ¤ ¤<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   7/14 

7 

Technical data – Focus ll 

**==> picture [259 x 546] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>Light curtains<br>FII-4-14-150 2TLA022200R0000<br>FII-4-14-300 2TLA022200R1000<br>FII-4-14-450 2TLA022200R2000<br>FII-4-14-600 2TLA022200R3000<br>FII-4-14-750 2TLA022200R4000<br>FII-4-14-900 2TLA022200R5000<br>FII-4-14-1050 2TLA022200R6000<br>FII-4-14-1200 2TLA022200R7000<br>FII-4-14-1350 2TLA022200R8000<br>FII-4-14-1500 2TLA022200R9000<br>FII-4-14-1650 2TLA022201R0000<br>FII-4-14-1800 2TLA022201R1000<br>FII-4-14-1950 2TLA022201R2000<br>FII-4-14-2100 2TLA022201R3000<br>FII-4-14-2250 2TLA022201R4000<br>FII-4-14-2400 2TLA022201R5000<br>FII-4-30-150 2TLA022201R6000<br>FII-4-30-300 2TLA022201R7000<br>FII-4-30-450 2TLA022201R8000<br>FII-4-30-600 2TLA022201R9000<br>FII-4-30-750 2TLA022202R0000<br>FII-4-30-900 2TLA022202R1000<br>FII-4-30-1050 2TLA022202R2000<br>FII-4-30-1200 2TLA022202R3000<br>FII-4-30-1350 2TLA022202R4000<br>FII-4-30-1500 2TLA022202R5000<br>FII-4-30-1650 2TLA022202R6000<br>FII-4-30-1800 2TLA022202R7000<br>FII-4-30-1950 2TLA022202R8000<br>FII-4-30-2100 2TLA022202R9000<br>FII-4-30-2250 2TLA022203R0000<br>FII-4-30-2400 2TLA022203R1000<br>Light grids<br>FII-4-K2-500 2TLA022204R0000<br>FII-4-K3-800 2TLA022204R1000<br>FII-4-K4-900 2TLA022204R2000<br>FII-4-K4-1200 2TLA022204R3000<br>FII-4-K2-500D 2TLA022204R4000<br>FII-4-K3-800 D 2TLA022204R5000<br>FII-4-K4-900 D 2TLA022204R6000<br>FII-4-K4-1200 D 2TLA022204R7000<br>FII-4-K1C-500 2TLA022204R8000<br>FII-4-K2C-800 2TLA022204R9000<br>FII-4-K2C-900 2TLA022205R0000<br>FII-4-K2C-1200 2TLA022205R1000<br>Supply voltage 24 VDC ±20%<br>Power consumption<br>Transmitter 70 mA maximum<br>Receiver 100 mA maximum<br>Protective height Light curtains: 150 mm - 2400 mm<br>Light grids: 500 mm - 1200 mm<br>Object resolution Light curtains: 14 mm and 30 mm<br>**----- End of picture text -----**<br>


**==> picture [260 x 387] intentionally omitted <==**

**----- Start of picture text -----**<br>
PFHD 2.5x10 [-9]<br>Light source Infrared Emitting LEDs, Wavelength<br>880 nm<br>Enclosure Housing: Aluminium painted yellow<br>Front: Polycarbonate<br>Connector: Polyamide<br>End cap: Polyamide<br>Profile dimensions 37 x 48 mm<br>Protection class IP65<br>Operating temperature -10 to +55° C<br>Storage temperature -25 to +70° C<br>Safety outputs (OSSD) Two PNP safety outputs, each sour-<br>cing 500 mA 24 VDC. Short circuit<br>protection.<br>Response time ON to OFF Maximum: 13-103 ms<br>(depending on model)<br>Connection transmitter M12 5-pin male<br>Connection receiver M12 8-pin male<br>Indication LED´s on transmitter and receiver<br>indicating alignment, dirt, power<br>supply and outputs<br>Safety level<br>EN/IEC 61496 Type 4<br>EN ISO 13849-1 PL e/Cat. 4<br>IEC 61508 SIL 3<br>Conformity EN ISO 12100-1:2010, EN ISO<br>13849-1:2008, EN 62061:2005, EN<br>60204-1:2007+A1:2009, EN 61496-1/<br>AC:2010, EN 60664-1:2007, EN<br>61000-6-2:2005, EN 61000-6-4:2007<br>**----- End of picture text -----**<br>


**==> picture [193 x 192] intentionally omitted <==**

**----- Start of picture text -----**<br>
18,50<br>37<br>18<br>Ø<br>48<br>22,30<br>16,70<br>**----- End of picture text -----**<br>


7/15    2TLC172001C0202 | ABB Safety Handbook 

7 

## Focus II Muting (bypassing) 

## Focus II muting types 

- T-muting. Four NO muting sensors are used in two pairs (OR function), allowing bi-directional transport of material. Maximum muting time is 600 s. Muting A and Muting B need an activation time difference of 30 ms. 

- L-muting. Two NO muting sensors works together with the light protection, allowing transport out from the hazardous area. Maximum muting time is 600 s. Muting A and Muting B need a activation time difference of 30 ms. 

- X-muting. One NO and one NC muting sensor is like a cross through the light protection, allowing bi-directional transport of material. An alternative X-muting (only on Focus Light beams) with 2 NO muting sensor is also possible, but then with the condition of a 30 ms activation time difference on the muting sensors.  Both solutions gives an infinite muting time. 

## Built-in muting for Focus II is available in three ways: 

- Pre-made muting units MF-T and MF-L, which have integral 

   - photocells. 

- Connection of muting sensors via a FMC. 

- Separate connection of muting sensors  (Mute R) directly to the Focus II receiver unit. 

## Muting-lamp 

To the Focus II receiver unit it is also possible to directly connect a external muting-lamp. It is also possible to connect the muting-lamp via a FMC. During bypassing the muting-lamp is lit. Bypassing is only possible if the muting-lamp is functioning or a resistor of 220 Ohm is used in its place. 

## Muting with MF-T and MF-L units 

MF-T and MF-L are muting units with integrated photocells built into a aluminum profile. They work with all Focus II light grid and curtain. No additional sensors are required because the muting units contain the required components. MF-T/MF-L is connected between the Focus II and the supervising unit (e.g safety relay, safety PLC). The cable between the Focus II and MF-T/MF-L is included with the muting unit. 

## MF-T 

The muting unit MF-T consist of a transmitter unit and a receiver unit with four photocells A1, B1, B2 and A2. A1 and A2 are connected in parallell and B1 and B2 connected in parallell. In this way the unit is configured for installations where material is transported into and/or out of a hazardous area. 

## MF-L 

**==> picture [200 x 216] intentionally omitted <==**

**----- Start of picture text -----**<br>
MF-T MF-L<br>F F<br>o o<br>c c<br>u u<br>s s<br>ll ll<br>Focus MF-T Focus MF-L<br>out/in from out from<br>hazardous area hazardous area<br>M12 connection between<br>Focus II and MF-T Reflex<br>**----- End of picture text -----**<br>


The muting unit MF-L consist of a transmitter unit and a receiver unit with two photocells A1 and B1. The A1 and B1 sensor are actuated before the material is transported through the light grid/curtain. The light grid is an active part in upholding the muting function once A1 and B1 have been passed by the material. The light grid/curtain is being bypassed just as long as the material exiting. Unit MF-L is primarily intended for material transport out of a hazardous area. 

## MF-T Reflex 

The muting unit MF-T Reflex consist of a transmitter/receiver side and a reflector unit. The active side contains four transmitters/receivers photocells. The MF-T Reflex works as the MF-T with a limited range (6m). These units, together with a light grid with one active and one passive side provides a good solution were electrical connections is only necessary on one side! 

## MF-L Reflex 

The muting unit MF-L Reflex consist of a transmitter/receiver unit and a reflector unit. The active side contains two transmitters/receivers photocells. The MF-L Reflex works as the MF-L with a limited range (6m). These units, together with a light grid with one active and one passive side provides a good solution were electrical connections is only necessary on one side! 

ABB Safety Handbook | 2TLC172001C0202   7/16 

## Focus II Muting with MF-T and MF-L 

A solution with Focus Muting unit MF-T with integrated muting sensors. Possible direction of movement - in/out of hazardous area. 

**==> picture [86 x 10] intentionally omitted <==**

**----- Start of picture text -----**<br>
Hazardous area<br>**----- End of picture text -----**<br>


7 

A solution with Focus Muting unit MF-L with integrated muting sensors This solution shall only be used for movement out from a hazardous area. 

**==> picture [195 x 166] intentionally omitted <==**

**----- Start of picture text -----**<br>
B1  A1<br>'<br>ot '<br>'<br>ot '<br>‘ Hazardous area<br>'<br>'<br>'<br>d2 = 260 mm<br>D = 300 mm<br>**----- End of picture text -----**<br>


NOTE! The muting sensors A and B must be placed so that the sensor A is always activated at least 30 ms before sensor B. 

D: indicates the minimum length of the material that is to actuate the muting sensors that must be maintained during the passage through the light grid/curtain. d2: indicates the measurement between the two/four pre-assembled muting sensors within the MF-L and MF-T. 

7/17    2TLC172001C0202 | ABB Safety Handbook 

7 

## Muting sensors – Mute R Retro-reflective with polarizing filters 

## Approvals: 

## Features: 

- Range adjustable 

- Light reserve warning indictor 

- Transistor output, PNP 

- 1000 Hz switching frequency 

- Short-circuit protection, reverse polarity protection and power-up output suppression 

- Connector M12 

- EMC tested according to IEC 801 and EN50081-1/ EN 50082-2 

   1. Connector M12 

## Technical data 

|Technical data||
|---|---|
|Article number<br>Mute R(FSTR-1)|2TLA022044R0000|
|Output|PNP,dark on|
|Connection<br>:<br>:|Connector M12<br>:<br>:|
|Range adjustment<br>:<br>:|Yes<br>:<br>:|
|Range<br>:<br>~~|~~|0.15... 2.5 m (with reflector FZR 1)<br>0.15...5m(with reflector FZR 2A)<br>:<br>~~|~~|
|Light source<br>~~|~~|Visible-red, 660 nm, pulsed with<br>polarizingfilter<br>~~|~~|
|Supplyvoltage|10...30 VDC|
|Allowable ripple|± 10% of Us|
|Current consumption (without<br>load)|<15 mA|
|Max. load current|100 mA|
|Residual voltage|<1.6 V|
|Max. switchingfrequency|1000 Hz|
|Protection class|IP67|
|Temperature<br>(operating and storage)|-25 to +65° C|
|Weight|approx. 15g|



2.  Range adjustment and function indicator 

3. Plastic housing 

**==> picture [183 x 49] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>2<br>4  Dark-on output<br>4 3 (-) Supply  voltage<br>Rl 3<br>**----- End of picture text -----**<br>


1 (+) Supply voltage 10...30 V 

## Dark-on output 

The output is activated when an object interrupts the light. 

**==> picture [68 x 77] intentionally omitted <==**

**----- Start of picture text -----**<br>
 Connector M12<br>2<br>3 1<br>4<br>**----- End of picture text -----**<br>


10...30 VDC PNP Dark-on output 

FZR 1 2TLA022044R0100 Reflector Ø 80 mm incl.screw MC6S M5 x 14 + Locking nut M5. 

FZR 2A 2TLA022044R0400 Reflector 100 x 100 mm incl. screw MC6S M5 x 14 + Locking nut M5. 

ABB Safety Handbook | 2TLC172001C0202   7/18 

7 

## Muting with Mute R 

A solution with two sensors and one movement direction for material transport: 

**==> picture [384 x 142] intentionally omitted <==**

**----- Start of picture text -----**<br>
Possible direction of movement - IN (Even IN/OUT is possible)<br>Hazardous area<br>d3<br>d4<br>B  S  A  d3 > 500 mm<br>d4 the least possible<br>S = safety light curtain/light grid<br>**----- End of picture text -----**<br>


A solution with four sensors and one movement direction for material transport: 

**==> picture [288 x 200] intentionally omitted <==**

**----- Start of picture text -----**<br>
Possible direction of movement - IN.<br>D<br>Hazardous area<br>B2  A2  B1  A1<br>S  d1 > 200 mm d1 < 200mm<br>d1  d2 > 250 mm<br>d2 > 250mm<br>d2  D = (d1x2)+d2+40<br>D=(d1x2)+d2+40<br>D<br>**----- End of picture text -----**<br>


A solution with four sensors and two movement directions for material transport: 

**==> picture [253 x 162] intentionally omitted <==**

**----- Start of picture text -----**<br>
Possible direction of movement - IN/OUT.<br>D<br>Hazardous<br>area<br>A2  B2  B1  A1<br>S  d1 > 200 mm d1 < 200mm<br>d1 d2 > 250 mm<br>d2 > 250mm<br>D = (d1x2)+d2+40<br>d2  D=(d1x2)+(d2x2)+40<br>D<br>**----- End of picture text -----**<br>


D: indicates the minimum length on the material that is to actuate the muting sensors that must be maintained  during the passage through the light grid/curtain. 

d1 must be as short as possible, and definitely less than 200 mm d2: indicates the distance between A1 and B1 

7/19    2TLC172001C0202 | ABB Safety Handbook 

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## Muting accessories FMC and FMI units 

## Approvals: 

## Application: 

– FMC: Muting connection box 

- FMI: Muting Indicator 

## Features: 

– Small 

– Easy to connect 

Various FMC, FMI, FRM- versions and Tina units The Tina-versions have dynamic safety outputs for Vital/Pluto. 

|Model|Description|
|---|---|
|FMC-1(2)<br>:|with connectors for muting sensors (A+B),<br>reset, power off and muting lamp (R) and<br>muting lamp (M).<br>:|
|FMI-1A<br>~~outside~~|with muting lamp only.<br>~~outside~~|
|FMI-1B<br>~~outside~~<br>:<br>sessusananeseeenssasuatasanseesessussnneeesssusunsseeesasusnassesssniasaneeesasiussnaseeessisnnssetessonnansesssisnt|with reset, power off and muting lamp.<br>~~outside~~<br>:<br>sessusananeseeenssasuatasanseesessussnneeesssusunsseeesasusnassesssniasaneeesasiussnaseeessisnnssetessonnansesssisnt|
|FMI-1C<br>sessusananeseeenssasuatasanseesessussnneeesssusunsseeesasusnassesssniasaneeesasiussnaseeessisnnssetessonnansesssisnt|with reset, power off and muting lamp.<br>with reset and power off.<br>sessusananeseeenssasuatasanseesessussnneeesssusunsseeesasusnassesssniasaneeesasiussnaseeessisnnssetessonnansesssisnt|
|FMI-1D<br>:<br>~~ee~~|with reset, power off and internal resistor for<br>the muting lamp.<br>:<br>~~ee~~|
|FMI-1E<br>~~ee~~<br>:|as pre reset connected to connector A (A2)<br>on FMC-1(2) (Tina).<br>~~ee~~<br>:|
|FMI-1G|with reset, and internal resistor for the muting<br>lamp.|
|FMC-1<br>(2) Tina<br>~~ouinunniwinniiuiiiniiiiniinniniee,~~<br>:|same as FMC-1(2) but connected to Vital or<br>Pluto.<br>~~ouinunniwinniiuiiiniiiiniinniniee,~~<br>:|
|Tina 10A<br>~~ouinunniwinniiuiiiniiiiniinniniee,~~<br>:<br>~~cccusutusuindiuuiiuuwannnaanaanenn,~~|adaptor unit for connecting Focus II to Vital<br>or Pluto.<br>~~ouinunniwinniiuiiiniiiiniinniniee,~~<br>:<br>~~cccusutusuindiuuiiuuwannnaanaanenn,~~|
|Tina 10B<br>Tina 10C<br>~~cccusutusuindiuuiiuuwannnaanaanenn,~~<br>i|simplified FMC-1(2) Tina including only the<br>connector (R).<br>simplified FMC-1(2) Tina including only power<br>~~cccusutusuindiuuiiuuwannnaanaanenn,~~<br>i|
|Tina 10C<br>FRM-1A<br>:|simplified FMC-1(2) Tina including only power<br>supply on con.no.3.<br>translates the two OSSD outputs to relay<br>:|
|FRM-1A<br>:<br>:|translates the two OSSD outputs to relay<br>outputs (and power supply).<br>:<br>:|
|JS SP-1<br>:|outputs (and power supply).<br>protection plug for not used connectors.<br>:|
|JS AP-1<br>:|adaptor for FMC units to use instead of<br>FMI-1B or -1D on the (R) connector including<br>muting resistor.<br>:|



ABB Safety Handbook | 2TLC172001C0202   7/20 

## Muting with FMI and FMC 

Connection of Focus II and muting components as FMC and FMI 

Ex 1. Connection of light curtain with connection block FMC1,  test/reset button and switch for supply voltage placed in (by) the control cabinet. 

Ex 2. Connection of light curtain with connection block FMC1. The Reset unit FMI must be placed out of reach from the hazardous area. 

**==> picture [530 x 184] intentionally omitted <==**

**----- Start of picture text -----**<br>
Cabinet Cabinet<br>Muting lamp<br>Muting lamp<br>Power  FMI Reset<br>”off”<br>Connection  Power<br>unit FMC-1 Test/Reset ”off”<br>Connection<br>unit FMC-1<br>Muting<br>photocells Muting<br>photocells<br>BR a _ a _<br>WARY BY RA IRA RY RY<br>7<br>**----- End of picture text -----**<br>


Connection of Focus II and muting components directly to the control cabinet 

- The TEST /RESET button shall be placed so the operator can see the protected area during reset, testing, and bypassing. It shall not be possible to reach the button from within the hazardous area. 

**==> picture [138 x 83] intentionally omitted <==**

**----- Start of picture text -----**<br>
Muting lamp<br>Cable to<br>Test & reset  lamp<br>buttons rapt Supply<br>cable<br>Muting<br>Protect cable<br>cables FR-cable<br>FT-cable<br>**----- End of picture text -----**<br>


- The LMS lamp for indication of muting and bypassing shall be placed so that it can be seen from all directions from where it is possible to access the hazardous area. 

- If photocells are used as muting sensors then the sensor receivers shall be assembled on the light curtain´s transmitter side to minimise the interference risk. 

- The system is protected against dangerous functions caused by damage on the transmitter cable and/or the receiver cable. However, we recommend that the cables be protected so that physical damage to them can be minimised. 

7/21    2TLC172001C0202 | ABB Safety Handbook 

7 

## Accessories MFII mirrors for light curtain 

## Technical data – Mirrors 

|Type|Article No|Height mirror<br>glass, mm|Height total,<br>mm|
|---|---|---|---|
|MFII-300|2TLA022041R0200|356|361|
|MFII-450|2TLA022041R0300|506|511|
|MFII-600|2TLA022041R0400|653|658|
|MFII-750|2TLA022041R0500|796|801|
|MFII-900|2TLA022041R0700|953|958|
|MFII-1050|2TLA022041R1200|1103|1108|
|MFII-1200|2TLA022041R0800|1253|1258|
|MFII-1350|2TLA022041R1300|1403|1408|
|MFII-1500|2TLA022041R0900|1546|1551|
|MFII-1650|2TLA022041R1000|1703|1708|



Bracket for MFII mirrors. 2 pcs needed for each mirror. 

## Adjustment plate 

JSM 70, 2TLA040001R1500. Plate for easy adjustment on uneven floors. 

**==> picture [185 x 136] intentionally omitted <==**

**----- Start of picture text -----**<br>
~<br>O<br>=<br>10<br>260<br>R5,50 220<br>Ø<br>170<br>20°<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   7/22 

7 

## Light protection stand Bjorn 

## Application: 

- Protects light curtain, light grids and mirror 

## Features: 

– Robust – Adjustable ~~a~~ 

Bjorn is a very stable and flexible stand system in which Focus II safety light grids/ curtains and mirrors are mounted in the stand. The fixings for the mirrors in the stand can be turned to provide either vertical or horizontal angles. The robust material of the Bjorn protects Focus II units from direct collisions, and thus prevents unnecessary material damage and halts in production. 

**==> picture [226 x 165] intentionally omitted <==**

**----- Start of picture text -----**<br>
Receiver<br>M3<br>M4<br>Transmitter<br>Bjorn N2<br>M2<br>M1<br>Bjorn V2<br>vertical<br>Bjorn H2<br>horizontal<br>**----- End of picture text -----**<br>


7/23    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – Bjorn 

**==> picture [526 x 378] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>Bjorn H2 2TLA022041R4000<br>Bjorn V2 2TLA022041R4100<br>Bjorn H3 2TLA022041R4200<br>Bjorn H4-1 2TLA022041R4300<br>Bjorn H4-2 2TLA022041R4400<br>Bjorn N2 2TLA022041R4500<br>Bjorn N3 2TLA022041R4600<br>Bjorn N4-1 2TLA022041R4700<br>Bjorn N4-2 2TLA022041R4800<br>Bjorn N5 2TLA022041R4900<br>H = Horizontal reflection<br>V = Vertical reflection<br>N = For the light guard unit<br>Colour Yellow powder-coated  (RAL 1018)<br>Material 3 mm steel<br>Dimensions<br>Cross section 146 mm x 130 mm<br>Foot 230 mm x 190 mm<br>Weight<br>N2 14 kg/piece<br>H2, V2 15 kg/piece<br>N3  17 kg/piece<br>H3, N4-1 18 kg/piece<br>H4-1 20 kg/piece<br>N4-2: 22 kg/piece<br>H4-2 24 kg/piece<br>N5 27 kg/piece<br>Mirror reduction ~10 % per mirror<br>**----- End of picture text -----**<br>


**==> picture [526 x 321] intentionally omitted <==**

**----- Start of picture text -----**<br>
230<br>181<br>Bjorn N2  Bjorn N3  Bjorn N4-1 Bjorn N4-2  Bjorn N5  Bjorn H2  Bjorn V2  Bjorn H3  Bjorn H4-1 Bjorn H4-2<br>2TLA022041R4500 2TLA022041R4600  2TLA022041R4700 2TLA022041R4700 2TLA022041R4900 2TLA022041R4000  2TLA022041R4100 2TLA022041R4200  2TLA022041R4300 2TLA022041R4400<br>15<br>43<br>190 144<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   7/24 

Protection against water and dust WET 

7 

## Application: 

- Protection in severe environments 

## Features: 

- Adjustable 

- IP68 

## Technical data – WET 

Article number WET-150 FII 2TLA022038R4000 WET-300 FII 2TLA022038R4100 WET-450 FII 2TLA022038R4200 WET-600 FII 2TLA022038R4300 WET-750 FII 2TLA022038R4400 WET-900 FII 2TLA022038R4500 WET-1050 FII 2TLA022038R4600 WET-1200 FII 2TLA022038R4700 WET-1350 FII 2TLA022038R4800 WET-1500 FII 2TLA022038R4900 WET-1650 FII 2TLA022038R5000 WET-1800 FII 2TLA022038R5100 WET-K-500 FII 2TLA022038R5200 WET-K-800 FII 2TLA022038R5300 WET-K-900 FII 2TLA022038R5400 WET-K-1200 FII 2TLA022038R5500 WET-L FII 2TLA022038R5600 WET-T FII 2TLA022038R5700 Colour Transparent plastic Length including lid light curtain/light grid + 54 mm Material Tube PC Lid PEHD-300 Angle bracket Stainless steel Max. ambient temperature +55°C Installation adjustment ± 20° Protection rating IP68 (IP69K) 

WET is used for protection against water (or dust) where extreme washing conditions are encountered. The protective encapsulation rating (IP68) now enables Focus II light curtains and light grids to be used for such applications as the food industry where the use of high pressure washing for cleaning machinery often occurs. 

WET, with Focus II light curtains or light grids, is pre-assembled complete with cabling, on request. During installation on a machine a WET unit can be adjusted by ± 20° with the accompanying angle bracket. 

7/25    2TLC172001C0202 | ABB Safety Handbook 

Blanking programmer BP-1 

7 

## Application: 

- Program blanking 

## Features: 

- Easy to connect 

- Can stay fitted during operation 

Technical data – BP-1 Blanking programmer 

|Article number<br>BP-1 Blanking programmer|2TLA022090R2300|
|---|---|
|Colour|yellow and black|



Programming blanking is made easy by using the Blanking programmer BP-1. The BP-1 is easily connected between the receiver unit of the light curtain and the cable otherwise connected to the receiver. The blanking object is placed in the light curtain detection zone and the button on the BP-1 is then pressed. 11 seconds later blanking is programmed for the object. 

If the object needs to be changed a new programming is needed. 

The unit can stay fitted during operation if required. 

ABB Safety Handbook | 2TLC172001C0202   7/26 

7 

## Connection examples 

HR7000C-01 Focus II - Connection without and with muting function 

**==> picture [375 x 257] intentionally omitted <==**

HR7000E-01 Focus II - Connection with pre-reset function 

**==> picture [370 x 254] intentionally omitted <==**

7/27    2TLC172001C0202 | ABB Safety Handbook 

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## Connection examples 

HR7000F-01 Focus II - Connection with muting to safety relay 

**==> picture [369 x 255] intentionally omitted <==**

HR7000G-01 Focus II - Connection with MF-T/MF-L units 

**==> picture [374 x 258] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   7/28 

## Connection examples HR7000H-01 Focus II - Connection with FMC/Tina Interface 

**==> picture [6 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
7<br>**----- End of picture text -----**<br>


## FMC - Connection possibilities 

7/29    2TLC172001C0202 | ABB Safety Handbook 

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## Connection examples 

HR7000J-01 FMC-1 or FMC-1 Tina with muting sensors and reset unit 

**==> picture [375 x 259] intentionally omitted <==**

HR7000K-01 FMC-1 or FMC-1 Tina connected with Pre-Reset 

**==> picture [375 x 259] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   7/30 

7 

## Connection examples 

HR7000L-01 Tina 10A, 10B and 10C connection example 

**==> picture [370 x 254] intentionally omitted <==**

HR7000M FRM-1 - Changing OSSD outputs to relay contacts 

**==> picture [375 x 254] intentionally omitted <==**

7/31    2TLC172001C0202 | ABB Safety Handbook 

7 

## Connection examples 

HR7000O-01 Connection example FMC/FMI 

**==> picture [365 x 252] intentionally omitted <==**

HR7000P Cable connection example 

**==> picture [369 x 254] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   7/32 

7 

## Connection examples 

HR7000Q Cable connection example 

**==> picture [369 x 255] intentionally omitted <==**

HR7000S Focus II; Muting with the aid of Pluto, FMC and a transfer cable 

**==> picture [375 x 259] intentionally omitted <==**

7/33    2TLC172001C0202 | ABB Safety Handbook 

7 

## Safety Light Beam Spot 

## Approvals: 

## TÜV NORD 

## Application: 

- Photoelectric guarding of an entrance or around a risk area 

## Features: 

- Safety level Type 4 according to EN 61496 

- Versatile mounting 

- LED indication 

- IP67 

- 10 m or 35 m range 

- Bypassing possibility 

- Light beam, emergency stop and Eden in the same safety circuit together with Vital/Pluto achieves PL e according to EN SO 13849-1 

## A light beam for the highest safety level 

The light beam is available in two versions Spot 10 for distances up to 10 m  and Spot 35 for up to 35 m . The light beams can be mounted at different heights and be angled around a machine using our mirrors and brackets. 

supervised which means that if the signal stops pulsating at the correct frequency it is immediately detected. By means of coding, the dynamic signal can pass between up to 6 pairs of transmitters and receivers, with only one pair needing to be electrically connected to a Vital. 

Spot and Vital/Pluto in combination fulfils the requirements for PL e according to EN ISO 13849-1 and  type 4 according to EN 61496. Several light beams, Eden sensors and emergency stops can be connected in series achieving the high safety level for the safety circuit. A number of solutions for bypassing of light beams for material transport are  available. 

For indication there are LED´s on the transmitter and on the receiver which indicate ’contact’ between transmitter and receiver and safety status. The ’contact’ information is available via the light beam receiver connection cables. 

## Function 

The Spot light beam is supervised by the Vital safety controller or by the Pluto safety-PLC. A unique coded signal is sent out from the control unit to the transmitter (Spot T). The signal which comes back from the receiver (Spot R) is then compared in the Vital/Pluto. If the correct coded signal is received the Vital/Pluto switches the necessary safety output contacts to permit dangerous machine movements. Coding guarantees that no output signals can be produced by light from other sources, interference or faults in components in the transmitter or receiver. The light beam is dynamically 

**==> picture [242 x 193] intentionally omitted <==**

**----- Start of picture text -----**<br>
         Transmitter 1         Receiver 1  Transmitter 2            Receiver 2<br>         Spot T       Spot R  Spot T                  Spot R<br>\7t LY — Pp | —<br>10 m 10 m<br>35 m 35 m<br>+p +[-jur f+ |-|n +|-hr<br>* *<br>Coded pulse transmission<br>Coded<br>pulse  *  24VDC  This supply does<br>transmission not need to be the same as<br> connected to the Vital.<br>Coded pulse transmission<br>ie Vital Safety controller can accomodate up to 6 Spot systems.<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   7/34 

## Spot Mounting and alignment 

## Safety distance 

The basic principle is that dangerous machine movements should be stopped before a person reaches the dangerous area, which should be at least 850 mm from the light beams. When determining the correct safety distance the stopping time of the machine and the risk level must be taken into account (see also EN ISO 13855). 

## Accessories and Mounting 

The Spot light beam can be mounted using a variety of  brackets, posts and mirrors. 

**==> picture [6 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
7<br>**----- End of picture text -----**<br>


Different sizes of mirrors, mounting brackets and profiles are available. 

## JSM64 

Pivot M18 bracket for Spot 10 or MUTE R (FSTR1) for example 

NOTE! Every mirror reduces the sensing distance of the beam by approx. 20%. 

## Alignment 

When aligning the light beam, look towards the transmitter. In the lens  will be seen a strong red light. When this light is seen from the receiver (via mirrors if fitted) the light beam is basically aligned. The LED on the receiver is on when the receiver is aligned with the transmitter. By moving the transmitter up/ down and left/right the best alignment can be found. 

When vertically mounting, (as shown in the diagram) the receiver should be mounted above the transmitter as this will simplify the alignment and minimise the risk of extraneous light disturbance. In exceptional light  disturbance environments the received light can be adjusted by a screw on the rear of the Spot 35 receiver. On Spot 10 this adjustment can be made on the transmitter. 

**==> picture [9 x 87] intentionally omitted <==**

**----- Start of picture text -----**<br>
R<br>T<br>**----- End of picture text -----**<br>


7/35    2TLC172001C0202 | ABB Safety Handbook 

7 

Technical data - Spot 

|Technical data - Spot|||||||
|---|---|---|---|---|---|---|
|Article number||||Connections|||
|Spot 10 T/R|||2TLA020009R0600|Transmitter:|||
|Spot 35 T/R|||2TLA020009R0500|Brown (1)||+24 VDC|
|Safety level<br>EN/IEC 61496<br>EN ISO 13849-1<br>PFHD<br>Power supply<br>Current consumption<br>Transmitter<br>Receiver|||Type 4 with Vital/Pluto<br>PL e/Cat. 4<br>1.14x10-8<br>17 – 27 VDC, ripple ±10%<br>< 25 mA<br>< 15 mA|White (2)<br>Blue (3)<br>Receiver:<br>Brown (1)<br>White (2)<br>Blue (3)<br>Black (4)<br>Grey (5)||Dynamic signal in<br>0 VDC<br>+24 VDC<br>0 VDC<br>Dynamic signal out<br>Info output|
|Output currents||||||24 VDC when LED is green or flas-|
|Info. output|||10 mA max.|||hing (tolerance -2 VDC)|
|Dynamic signal out|||30 mA max.|||0 VDC when LED is off (tolerance|
|Light source|||Red visible light, 660 nm, <±2°|||+2 VDC)|
|Optical power||||Conformity||EN ISO 12100:2010, EN ISO|
|Spot 10|||< 0.1 mW|||13849-1:2008, EN 62061:2005,|
|Spot 35|||< 0.2 mW|||EN 61508:2010, EN 60204-|
|LED indication||||||1:2006+A1:2009, EN 61496-|
|Green LED on transmitter (power)|||Power supply OK|||1:2004+A1:2008, EN 60664-1:2007,|
|Green LED on receiver status||||||EN 61000-6-2:2005, EN 61000-6-|
|On|||Alignment OK, safety circuit closed|||4:2007|
|Flashing<br>Off|||Alignment OK, earlier safety<br>circuit open<br>Beam interrupted, safety circuit open|Certifications||TÜV Nord, cCSAus|
|Protection class|||IP67||||
|Range<br>Spot 10<br>Spot 35|||0 - 10 m<br>0 - 35 m||||
|Range adjustment<br>Spot 10<br>Spot 35|||Trim pot. on transmitter<br>Trim pot. on receiver||||
|Installation<br>Spot 10<br>Spot 35|||2xM18 nuts (provided)<br>Either via mounting holes in the<br>casing or with angle bracket JSM63<br>(provided)||||
|Operating temperature range|||-25°C – +65°C||||
|Cable connection|||M12 fixed connector||||
|Casing Material|||||||
|Spot 10<br>Spot 35||||Steel housing with polyacryl lens<br>protection.<br>Polyamide housing with polyacryl<br>lens protection.||KCa om|SN 9}|
|Colour<br>Spot 10<br>Spot 35|:||Steel grey<br>Yellow/black|Spot10T/R||Spot35T/R|
|Weight|||||||
|Spot 10|||2 x 21 g||||
|Spot 35|||2 x 100 g||||



ABB Safety Handbook | 2TLC172001C0202   7/36 

7 

## Connection examples 

HD3800A-01 Connection of Spot T/R to Vital1 

HA3306D Vital 1 with 3 lightbeams Spot 

**==> picture [383 x 260] intentionally omitted <==**

**==> picture [169 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
*For more connection examples see chapters for Vital or Pluto<br>**----- End of picture text -----**<br>


7/37    2TLC172001C0202 | ABB Safety Handbook 

7 

ABB Safety Handbook | 2TLC172001C0202   7/38 

8 

8/1    2TLC172001C0202 | ABB Safety Handbook 

Stopping time and machine diagnosis tool Smart 

8 

**==> picture [258 x 44] intentionally omitted <==**

**----- Start of picture text -----**<br>
|||
|---|---|
|Why measure stopping time?|8/3|
|Smart|8/4|
|Smart Manager|8/5|
|Smart and accessories|8/7|

**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   8/2 

## Stopping time Why measure stopping time? 

— to find out which safety arrangements can be used in a certain area around a machine, and where they should be located. 

## Stopping time 

The safety distance (how far away from the risk area a safety component must be placed) is based upon the machines stopping time. The basic idea is that a safety component should be placed so far from the risk area that it is not possible to enter the area before the machine has stopped. 

The stopping time for manually operated machines is especially important when light beams and light curtains are used as safety components. By reflex action the operator tries to grab or adjust if something has gone wrong in the machine tool, even if the machine has started. It is then imperative that the machine stops before the hand reaches the risk area. A short stopping distance is also of importance for getting good ergonomics. 

Where the safety distance is small, one can for example sit close to the machine and work, as in the picture on the left. If the safety distance is greater, it may be necessary to approach the machine to intervene, and also perhaps use additional protection to prevent starting when someone is within the protected distance. 

Grabbing or adjusting is also common when using automatic machines. Usually this is done to prevent production downtime by quickly adjusting a work piece. The stopping time is also of great  importance if someone trips and falls into the 8 _ machine. 

Stopping time, walking speed (1.6 m/s) and hand speed (2.0 m/s) is used for the calculation of safety distances. Sometimes a fixed minimum distance is also used. See the standard EN ISO 13855 for more details on the calculation of safety distances. 

EN ISO 13855, which deals with the placing of safety devices around a machine based on its stopping time. The standard is general for all types of machinery, although for some, where there is a harmonised C standard, the requirements for minimum distance and stopping time measurement will apply. In the case for example of mechanical press tools there is also a requirement in EN 692 for how stopping time measurements are to be performed, and in the case of hydraulic press tools this is in EN 693. 

## Annual checks 

## Stopping distance 

For safety contact strips it is extra important that the stopping distance is monitored. An incorrect stopping distance could in many cases result in very high risks. The stopping distance is also needed during area limiting e.g. for robots when dividing the working area into sectors. 

Wear in a machine is something that can affect braking and motors, which means that the stopping time of a machine can change with time. Certain other changes in a machine, such as changing the weight of a workpiece or alterations in pneumatic pressure, can also affect the stopping time. For these and other reasons it is important to perform an annual check on the stopping time. 

## How the stopping time affects the choice of protective equipment – an example 

For door sensitive edges, it is important that the stopping distance is shorter than the soft part of the sensitive edge. 

## Regulations and standards 

It is also important to measure the stopping time, to meet the requirements set by the machinery standards, directives and regulations. Here we can help, with our long experience in the practical application of regulations and standards, from the viewpoints of both the authorities and production. In addition we collaborate with the standardisation committees responsible for producing these standards. One example is 

There was a case where we measured the stopping time of the rollers in a textile industry company. The company had planned to place light beams or a light curtain in front of the rollers to prevent the operators from being caught in the material and dragged in. The stopping time measurement showed that it took over one second for the rollers to stop. During this time the material was pulled in by almost two metres. In order to obtain sufficient protection distance, the light beams would have needed to be positioned almost three metres from the machinery, and a light curtain about two metres away. The factory did not have so much space, nor was it realistic. The solution became instead vertical sliding safety barriers. 

8/3    2TLC172001C0202 | ABB Safety Handbook 

8 

- Stopping time and Machine Diagnosis Tool Approvals: 

- Smart Smart shows graphs/ values for: – Stopping time 

- – Stopping distance 

- – Speed 

- – Position of stopping signal 

- W ~~ee~~ Features: – Easy to use 

- – Measurements with or without electrical connection 

- – Ideal for machine performance diagnosis 

- – Calculation of correct safety distances 

- ~~7~~ 

- Smart is ideal for safety supervision and for diagnosis of machine operation Smart has many valuable features for machine diagnosis: 

- Graphic presentation of measurements 

- Easy to analyse stopping characteristics and movement 

- Gives parameters for safety design (e.g. stop time) 

- Calculates minimum allowed safety distance 

- Shows how the stop distance can be optimised 

- Electrical reaction time and mechanical/hydraulic breaking can be identified and analysed 

- Digital in/out signals and analogue inputs 

Smart is perfect for periodic monitoring of safety parameters and other conditions for the maintenance and trouble-shooting of machines. Because Smart can compare old and new graphs, it becomes easy to find out the reasons for machine malfunctions. One can also supervise machines during operation and compare how they perform over time. 

## Stopping units and sensors 

Smart is a further development of our well established JSSM1 Stopping Analyser. All the stopping units and sensors for the JSSM1 can also be used with Smart. The amount of connection possibilities have also increased. Smart has 9 digital I/O, one input for an incremental sensor (for position and speed) and two analogue inputs. This makes it easy to measure sequences in conjunction with motion lapse and other analogue values. 

ABB Safety Handbook | 2TLC172001C0202   8/4 

8 

## Smart Manager 

## Benefts: 

- Simple program structure 

Smart is controlled in real time by a computer using the Smart Manager program. This performs measurements, and the measured data can be saved and analysed. The measurements are saved in an SQL database, with the ability to export data to Microsoft Excel if necessary. The program calculates the stopping time and protective distance, and can print out the results, together with a graph of the event sequence. Smart Manager is available in several languages: English, Swedish, Danish, German, French, Czech and Polish. Translation into other languages can easily be arranged as necessary. The program is free, and is available for downloading from our web site when purchasing equipment to measure stopping times. 

   - Shows the entire stop sequence 

   - Provides a machine movement “fingerprint” 

   - Compares measurements 

   - Calculates stopping time 

   - Saves measurements to a database 

   - Exports measured data to Excel 

   - Prints out a complete measurement report 

- Current values from sensors and the system 

- Start conditions 

- Stop signal conditions 

- Shutdown conditions 

Start menu 

- Measuring settings can be saved 

- Stop time data 

Measuring form 

- Zoom control 

- Own cursors 

Stop signal given 

Measured result Relay contacts Machine Calculations drop out stopped 

- Min., max. and average value and standard deviation from a series of measurements 

- Protective distance can be calculated 

8/5    2TLC172001C0202 | ABB Safety Handbook 

8 

Saving 

- Select measurement series 

- State extra information, e.g. the conditions and special circumstances for the measurements. 

Archiving 

- Search filter 

- Saved measurements 

- Exported measurements 

## Conversion of analogue signals 

Smart can measure and show graphs for two different analogue sensors at the same time, with its inputs for 0/4-20 mA. Conversion of the measured current values can be done automatically by setting minimum and maximum values and the units for the inputs. In this way, for example, the results from an analogue pressure sensor can be shown and calculated as 0-400 bar instead of 4-20 mA, or an analogue load cell as 0-2 kN. This also means that if it is desired for the system to be triggered at a certain force, that force can be defined instead of needing to calculate the equivalent current value. 

## Printout 

Printing out is one of the most important functions of the program. Here is shown all the vital information about the measurements that is needed for such items as annual checking or providing the basis for CE labelling of a machine. Since the entire measuring sequence is shown in graphical format, one can understand why the stopping time has a certain value and also, in some cases, see what needs to be done to minimise the stopping time. The graph also acts as a kind of “fingerprint" of the machine movements, which means that different measurements can be compared with each other to see how the stopping sequence varies from time to time, or from year to year. In this way the effects of e.g. worn brakes or the effect on the machine control system can be seen. In order to get a complete basis from a measurement it is also important to state what assumptions have been made and what conditions applied when deciding when and how the stop signal was given. 

Among other things, the stop signal details the person measuring, the measuring equipment, the machinery, the calculations and the protective distance. The printout also has a replaceable company logo and a field for extra information. 

ABB Safety Handbook | 2TLC172001C0202   8/6 

## Smart and accessories 

||Smart Logger||||
|---|---|---|---|---|
||Article number|2TLA070300R0100|||
||Dimensions|62 x 220 x 80 mm.(wxhxd)|The Smart Logger is the principal unit for data collection. The logger||
||Weight|0.5 kg|has a USB connection to the PC and 8 M12 connections: one for the||
||Protection class|IP67|power supply to the I/O, one connection for an incremental sensor,||
||Supplyvoltage|24 VDC|two connections for analogue sensors and four connections for||
|8<br>other I/O signals.<br>The Logger encapsulation is watertight, with M12 connections to<br>prevent the entry of particles and fluids in the workshop envi-<br>ronment. To prevent the Smart Logger from being damaged by<br>incorrect currents and voltages from external equipment, all inputs<br>and outputs, and external units, are electrically isolated from the<br>processor in the Smart Logger by means of opto-couplers.<br>Response speed<br>max 1 ms<br>Positional accuracy<br>+/- 0.1 mm<br>Digital I/O<br>8 inputs,4 outputs(NPN OC)<br>Analogue inputs<br>2 off, 0/4-20 mA<br>Encoder<br>1 connection for a pulse sensor<br>SM2 Button unit<br>Article number<br>2TLA070300R0200<br>The SM2 is used in conjunction with the Smart Logger for measu-<br>ring with a manual stop impulse, without an electrical connection<br>to the machine. When an SM2 is, for example, pressed against an<br>emergency stop button to stop the machine, the SM2 sends a signal<br>to the Smart Logger to start the measurement. An LED on the SM2<br>lights when the desired stop position is reached. The SM2 is con-<br>nected to the Smart Logger by an M12 connection.<br>Dimensions<br>Size: 50 x 100 x 25 mm.(wxhxd)<br>Weight<br>0.2 kg<br>Application area<br>Two-handed control unit, Emer-<br>gencystop,etc.<br>Supply voltage<br>Fed from the Smart Logger<br>SM3 Relay unit<br>Article number<br>2TLA070300R0300<br>The SM3 is used in conjunction with the Smart Logger for automatic<br>stopping time measurements at the set position, or alternatively a<br>manual stop pulse. When a stop signal comes from the Smart Log-<br>ger a relay switches in the SM3.<br>The SM3 then sends a signal to the Smart Logger to start measu-<br>ring, and also activates the relay outputs to stop the machine. The<br>relay in the SM3 is reset via the software when a new measurement<br>is to be made. The SM3 is connected to the Smart Logger by an<br>M12 connection.<br>Dimensions<br>85 x 72 x 49 mm.(wxhxd)<br>Weight<br>0.2 kg<br>Application area<br>Electrical connection providing a<br>stop pulse.<br>Supplyvoltage<br>Fed from the Smart Logger<br>Relayoutputs<br>2 NO,2 NC,6A/250 VAC.<br>Encoder<br>1 connection for a pulse sensor<br>~~oF~~|||||
||SM11 Flag unit||||
||Article number|2TLA070300R1100|The Smart Logger is used in conjunction with the SM11 for automa-||
||Dimensions<br>Weight<br>Application area<br>Protection class<br>Batteries|145 x 85 x 37 (wxhxd).<br>Shaft ø3 x 45 mm<br>0.6 kg<br>Ligh curtain,light beam<br>IP40<br>10 rechargeable 1.2 V NiMH bat-<br>teries. Total 12 V|tic measurements of the stopping time and stopping distance. The<br>unit is located in a light curtain with the flag parallel to the beam.<br>When the flag is activated, the light beam/light curtain is interrupted,<br>and the machine stops. The SM11 is connected to the Smart Logger<br>by an M12 connection.||
||Power|Max 1200 mAh (approx. 200<br>operations).|||
||Temperature|0 to +45°C.|||
||Installation|On a table or a standard ¼” came-<br>ra tripod|||
||Charger|SM14|||



8/7    2TLC172001C0202 | ABB Safety Handbook 

8 

SM5 1250/2500 Linear sensor 

|Article number<br>SM5/1250 Linear sensor<br>SM5/2500 Linear sensor|2TLA070300R0400<br>2TLA070300R0500|The SM5 is an incremental pulse sensor for connection to a<br>Smart Logger. The sensor is protected by a robust enclosure.<br>The sensor and end of the cable are secured to the machine by<br>powerful magnets. The SM5 is connected to the Smart Logger<br>by an M12 connection.|:<br>te|
|---|---|---|---|
|Dimensions|1250: 106 x 88 x 100 mm (wxhxd)<br>2500: 114 x 125 x 116 mm(wxhxd)|||
|Weight|SM5/1250: 1 kgSM5/2500: 1.4 kg|||
|Application area|Linear movement, e.g. press tools|||
|Supplyvoltage|Fed from the Smart Logger|||
|Max length|1250 or 2500 mm|||
|Max speed|5 m/s|||
|Resolution|0.1 mm|||



SM7 Rotation sensor 

|SM7 Rotation sensor|||
|---|---|---|
|Article number|2TLA070300R0700|The SM7 is an incremental sensor for connection to a Smart Log-|
|Dimensions<br>Weight<br>Application area<br>Supplyvoltage<br>Max speed|Sensor size: 46 x 40 x 59 (wxhxd)<br>Stand size: Extended, approx. 400 x<br>50 x 80(wxhxd)<br>1.7 kgincludingstand<br>Rotatingmotion,e.g. lathes,rollers<br>Fed from the Smart Logger<br>5 m/s|ger. The sensor detects rotational movement via a wheel rolling<br>against a shaft. The stand secures the sensor with the aid of just<br>one knob. The stand itself is secured to the machine by a power-<br>ful magnetic foot. The SM7 is connected to the Smart Logger by<br>an M12 connection.|
|Resolution|0.1 mm||
|Wheel circumference|125 mm||
|SM13 Battery pack|||
|Article number|2TLA070300R2300||
|Dimensions<br>Weight<br>Protection class<br>Connector<br>Current rating<br>Power<br>Batteries|145 x 85 x 37 mm(LxWxH)<br>0.8 kg<br>IP40<br>Negative pole at the centre of the<br>chargingconnector<br>Maximum 0.9A<br>2100 mAh. With normal use lasts<br>about 10-12 hours. (Higher capacity<br>on request.)<br>20 rechargeable 1.2 V NiMH batteries<br>of size AA(R06). Total 24 V|SM13 is a battery pack for the Smart Logger, which makes the<br>Smart a completely mobile measuring tool. With the SM13 you<br>don’t need to connect the Logger to a wall socket for power,<br>and can easily move it from one machine to another when you<br>are measuring. Since the SM13 battery pack is the same physi-<br>cal size as the SM11 flag unit, it fits snugly into the SM9 carrying<br>case. The charger for the SM13 is called the SM14 and provides<br>a charging time of about 3 hours 15 minutes (2100 mAh). The<br>SM14 also acts as afast charger for the SM11.|
|SM9 Carrying case|||
|Article number|2TLA070300R0900|The SM9 is a practical carrying case with pockets to suit the|
|Dimensions<br>Weight|535 x 155 x 430 mm(LxWxH)<br>3.5 kg|various Smart units. Part of the protective foam insert in the lid of<br>the case can be removed to make room for a laptop computer,<br>so that all the equipment required can be carried in a single<br>case.|



||case.|=|
|---|---|---|
|Other accessories|||
|Name|Article number|Description|
|SM6|2TLA070300R0600|AC/DC converter for Smart|
|SM14|2TLA070300R2400|Charger for flagunit SM11 and battery pack SM13.|
|USB cable|2TLA070300R1500|USB cable for communication with computer|
|Extension cables||ABB Jokab Safety's extension cables with 5 conductors ideal<br>for all Smart accessories|



ABB Safety Handbook | 2TLC172001C0202   8/8 

9 a 

9/1    2TLC172001C0202 | ABB Safety Handbook 

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## Sensors/Switches/Locks 

|Whyshouldyou use sensors/switches?|9/3|
|---|---|
|Non-contact safety sensor||
|Eden|9/5|
|Eden AS-i|9/7|
|SafetyMagnetic Switch - Sense7|9/13|
|Magnetic lock||
|Magne|9/15|
|Process lock||
|Dalton|9/21|
|Safety and process lock||
|Knox|9/27|
|Safety Interlock Switch||
|SafetyInterlock Switch - MKey5|9/33|
|SafetyInterlock Switch - MKey8|9/35|
|SafetyInterlock Switch - MKey9|9/39|



ABB Safety Handbook | 2TLC172001C0202   9/2 

## Why should you use sensors/switches? 

## – to supervise doors and hatches around dangerous machines! 

Assurance that a machine stops, when a door or a hatch is opened, can be solved by using different types of switches and sensors,  which are monitored with a safety relay or a safety PLC. Switches and sensors are available both as non-contact (dynamic or magnetic) and various types of interlocking devices. Interlocking devices can be used when it is required, via a signal, to lock a gate during processes that cannot be stopped during certain operations. They are also used with machines that have a long stopping time to prevent someone from entering before the machine has stopped. 

## – to ensure that a position is reached! 

The sensor monitors that the robot is standing still in a monitored position when someone enters the robot´s working area. The robot is then only stopped by the program , not by loss of power. If the robot leaves the position the power will be cut 9 directly. This is used when the robot can not be stoped safely without resolving in restarting problems. 

## – to manage the safety in harsh environments! 

Non-contact dynamic sensors have a long lifetime because they are not physically mechanically operated. They also endure very harsh environments, e.g. cold, heat, high-pressure wash-down which is important in the food industry for example. Because the sensors are small, they are very easy to position and can even be completely concealed in doors and hatches. 

9/3    2TLC172001C0202 | ABB Safety Handbook 

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## **Safety level** 

## Eden – highest safety level and reliability 

Our recommendation is to use the Eden sensor because it is the safest and most reliable solution. The Eden sensor is a non-contact switch and has a dynamic function. Also it is possible to connect up to 30 Eden sensors in series and still achieve PL e according to 13849-1. 

**Eden -** sensor with dynamic signal 

What requirements should one have on sensors/switches? The sensor/switch shall be reliable from both the safety and production point of view. 

- A person must be able to trust that dangerous movements and functions are safely stopped by the sensors/switches. 

- From the production point of view unintentional stops should be avoided. 

- Standard EN ISO 13855 now includes requirements for safety distances for interlocked doors without locking function. 

## Magnetic switch 

Safety Interlock switch 

## **Reliability** 

## How safe is a sensor/switch? 

In order to trust the safety function it is essential to be aware that a safety sensor/switch must be mounted and be used according to the specifications. The certification authorities only test the product according to the appropriate standards and to the specifications from the manufacturer. 

## Mechanical switches 

For mechanical switches, e.g. key operated, this means that a door or a hatch has to constructed to small tolerances in order for the switch, the key or the mounting brackets to last according to the life time specification from the supplier. The screws holding the parts have to be locked in such a way that they cannot be loosened. In order to prevent material from getting into the slot for the key the environment has to be clean. If a door goes outside the design tolerances from wear, the screws loosen or material comes into the slot, this may lead to the interlocked switch not giving a stop signal when the door is opened. Even two mechanical switches on a door could fail to an unsafe state if the door somehow gets outside the tolerances of the switches. To prevent accidents the mechanical switch normally needs continuous checks of both the switch and the installation. 

## Non-contact sensors/switches 

For non contact sensors the risks associated with mechanical switches (see above) do not exist. If screws, brackets or sensors get loose, it will lead to a stop signal. Therefore only one sensor with dual or dynamic function is needed in order to reach the high- 

est safety level. There are two types of non-contact sensors - active and passive. The active sensor, Eden, is constantly communicating via a dynamic signal between the two parts and any failure will directly lead to a stop signal. The passive type, a magnet switch, has two reed contacts which are activated by a coded magnet. Both the passive and the active sensors are checked every time a door is opened. From a safety point of view the active sensor, Eden, is to be preferred because it is checked constantly whereas the passive sensor is only checked when a door opens. 

From the reliability point of view a long detection distance with large tolerances and a well defined on and off position is needed. The active sensor, Eden, fulfils these demands. A magnet switch has smaller tolerances and an intermediate position where only one contact opens. A bad installation or vibrations can lead to an unintentional stop if one contact opens and closes again. The supervision of a two channel system is based on both contacts having to be operated in order to permit a new start. In a dynamic safety circuit there is only one pulsed signal and therefore no intermediate position. 

ABB Safety Handbook | 2TLC172001C0202   9/4 

## Non-contact safety sensor Eden 

## Approvals: 

**==> picture [29 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>NORD<br>**----- End of picture text -----**<br>


## Application: 

- Door and hatches 

- Position control 

- Sector detection 

- Slot detection 

## Features: 

- PL e/Cat. 4 according to EN ISO 13849-1 together with Vital or Pluto 

- Non-contact detecetion, large sensing distance 0 - 15 mm +/- 2 mm 

- Up to 30 sensors in series with the highest level of safety PL e 

A non-contact safety sensor for the highest safety level Eden - Adam and Eva is a non-contact safety sensor for use on interlocked gates, hatches etc. The safety sensor Eden is built on the principle of a dynamic safety signal that can be 9 generated an interpreted by the control device Vital, or Safety PLC Pluto. The maximum sensing distance between Adam and Eva is 15 mm ± 2 mm. 

Up to 30 Edens can be connected in series to Vital and still achieve the same safety level in the safety circuit. It is also possible to connect safety light beams and E-stops in the same safety circuit. 

Adam is available with only a M12 connector or with cable lengths up to 20 m (also with M12 connector).  For harsh environments there is a special version of Eden cast in Polyurethane; Eden E. 

In addition to the safe signal out from Adam, there is also a non-safe status signal (on pin 5) that indicates contact/noncontact between Adam and Eva. 

## LED indication 

The LED on Adam provides a green indication of contact between Adam and Eva, and a red indication indicates a non-contact. A rapid flash indicates that an alignment of the sensor is necessary. If the LED is flashing between red and green the sensor is not receiving a dynamic signal from previous sensor or Vital/Pluto. 

- Versitile mounting, 360° detection 

- Protection class IP67/IP69K 

- The dynamic signal passes through wood and plastic (not metal) 

- Status information with LED on the sensor and in the cable connection, 

- Small hysteresis (< 1mm) 

**==> picture [198 x 139] intentionally omitted <==**

**----- Start of picture text -----**<br>
0-13 ± 2<br>0-15 ± 2<br>0-13 ± 2 Sey mm<br>i i ><br>| h)<br>AP 5<br>| | a<br>5<br>**----- End of picture text -----**<br>


Flexible mounting 

9/5    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – Eden 

**==> picture [525 x 693] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number Material Eden: Macromelt<br>Eva 2TLA020046R0000 Eden E: Polyurethane (PU)<br>Eva E 2TLA020046R0600<br>Adam M12 (with 4 DA1) 2TLA020051R0000 Chemical resistance<br>Adam 3 m (with 4 DA1) 2TLA020051R0200 Macromelt: Cutting oils, vegetable and animal<br>Adam 10 m (with 4 DA1) 2TLA020051R0400<br>oils, hydrogen peroxide, diluted acids<br>Adam 20 m with (4 DA1) 2TLA020051R0500<br>Adam E 10 m 2TLA020051R0600 and bases: good<br>Adam E 0.5 M12 2TLA020051R0700 Alcohol and strong acids: not recom-<br>Adam E 20 m 2TLA020051R0800 mended<br>Level of safety PU (EdenE): Cutting oils, vegetable and animal<br>IEC/EN 61508-1...7 SIL3 oils,hydrogen peroxide, diluted acids<br>EN 62061 SIL3 and bases,<br>EN ISO 13849-1 PL e/Cat. 4 alcohols: good<br>PFHD 4.50×10 [-9] Strong oxidating acids: not<br>Colour Yellow and black  recommended<br>Weight Eva: 26 g  LED on Adam<br>Eva E: 36 g Green: Eva within range, safety circuit<br>Adam M12: 30 g closed (door closed)<br>Adam 3 m: 220 g incl. cable Flashing: Eva within range, earlier safety circuit<br>Adam 10 m: 650 g incl. cable open (door closed)<br>Adam E10 m: 660 g incl. cable Red: Eva out of range, safety circuit open<br>Adam E 0,5 m + M12: 100 g incl. cable (door open)<br>Power supply 24 VDC +15%-25% Rapid flashing: Eva is within 2 mm from maximum<br>sensing distance (door closed)<br>Power consumption Adam:  without info output 45 mA<br>Cable 3, 10 or 20 m, ø 5.7mm, black, PVC<br>with info output max 55 mA<br>5 x 0.34 mm² + screen, UL 2464<br>Max cable length see Vital technical data<br>Connector M12: 5-pin male contact<br>Ambient temperature<br>Connections<br>Eden -25°C … +70°C (operation)<br>Brown (1) +24 VDC<br>-25°C … +70°C (stock)<br>Eden E -40°C … +70°C (operation) White (2) Dynamic signal in<br>Blue (3) 0 VDC<br>-25°C … +70°C (stock)<br>Black (4) Dynamic signal out<br>Protection class<br>Grey (5) Info output, see below<br>Eden IP67<br>Eden E IP67 and IP69K 24 VDC when LED is green or flashing<br>(tolerance -2 VDC), 10 mA max<br>Mounting<br> 0 VDC when LED is red. (tolerance +2 VDC)<br>Installation Eden M4 screw, e.g. safety screw<br>Warning: Incorrect connection may cause permanent damage to Adam<br>2TLA020053R4200. Max. torque<br>devices.<br>2 Nm. Screw to be locked with<br>Loctite or similar. Conformity 2006/42/EG<br>Installation Eden E M4 screw, e.g. safety screw  EN ISO 12100 1/2, EN 60204-1,<br>2TLA020053R4300. Max. torque  EN ISO 13849-1, EN 1088<br>0.8 Nm. Screw to be locked with<br>Loctite or similar.<br>Detection distance max Eden Eden E<br>Adam/Eva 15 ± 2 mm  Flash 2 mm before red position.<br>Adam E/Eva E 12 ± 2 mm Flash 2 mm before red position.<br>Hysteresis approx. 1 mm<br>Metal may have influence on detection distance.<br>This can be prevented by protection plates, DA1.<br>Minimum distance to metal when<br>there is metal on one or more<br>sides.<br>One  More<br>Adam/Eva<br>0 mm  2.5 mm<br>Adam E/Eva E<br>0 mm  0 mm<br>Minimum distance between Eden<br>pairs<br>**----- End of picture text -----**<br>


Metal may have influence on detection distance. This can be prevented by protection plates, DA1. Minimum distance to metal when there is metal on one or more sides. One More Adam/Eva 0 mm 2.5 mm Adam E/Eva E 0 mm 0 mm Minimum distance between Eden pairs 50 mm Mechanical life >10[7] cycles 

ABB Safety Handbook | 2TLC172001C0202   9/6 

## Non-contact safety sensor with integrated AS-i node Eden AS-i 

## Approvals: 

## TÜV NORD 

## Application: 

- Door and hatches 

- Position control 

- Sector detection 

- Slot detection 

## Features: 

- PL e/Cat. 4 according to EN ISO 13849-1 

- Non contact detection 0-15 mm +/- 2 mm 

- Versatile mounting, 360 degrees 

- Protection class IP69K 

- The signal passes through wood and plastic (not metal) 

- Status information LED 

A non-contact safety sensor for the highest safety level Eden AS-i is a non-contact safety sensor for use on interlocked gates, hatches etc. Eden AS-i consists of two complementary parts called Adam and Eva. The sensor is only 9 activated if the gate or hatch is closed e.g. when Adam and Eva are within sensing distance. Eden AS-i is constantly communicating between the two parts and any failure will directly lead to a stop signal. 

- Small hysteresis (1-2 mm) 

- Individually coded 

## A non-contact safety sensor for AS-i 

Eden AS-i has an integrated AS-i node and is connected via an M12 connection directly to the AS-i cable. 

Eden AS-i has a protective encapsulation that enables Eden AS-i to be used in harsh environments. Each Eden AS-i is individually coded which makes it secure against manipulation. 

The advantage of safety within AS-i is that it is very easy to install since connection of the safety devices is just to the buss cable. The function of the safety devices is determined by the software program in the safety monitor/master. Each safety device (node) has its own address and a unique safety code. 

It is simple to add, move and disconnect safety devices on the AS-i cable as well as to extend the AS-i cable.  Traditional safety systems require new cable running from the electrical cabinet for each new protection. Connection with Eden AS-i is simple as all units are connected to the same cable. 

**==> picture [198 x 139] intentionally omitted <==**

**----- Start of picture text -----**<br>
0-13 ± 2<br>0-15 ± 2<br>0-13 ± 2 See mm<br>Lo [ ><br>Us | 5<br>| | a<br>5<br>**----- End of picture text -----**<br>


Flexible mounting 

9/7    2TLC172001C0202 | ABB Safety Handbook 

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## Connection to the AS-i bus 

## AS-i makes safety easy 

Installation is easy as all units are connected to the same yellow AS-i cable/ bus. This thereby minimises the risk of faulty connection. Each safety node has its own address and a unique safety code. 

Eden AS-i has a built-in AS-i safety node and is supplied with 30 VDC from the AS-i bus. 

Connection to the AS-i bus is through a flat cable connector to M12, making it possible to quickly and easily connect Eden AS-i to the AS-i cable. 

Our Pluto is the most flexible AS-i Safety Controller on the market. Pluto can be used as Safety Master, Monitor or I/O and can control and monitor the safety of a machine at the same time. 

## Manual Status LED indication 

|LED|Setting (hex)|Setting (binary)|Description|
|---|---|---|---|
|LED on Adam AS-i|1|0,0,0,1|LED lights red|
||3|0,0,1,0|LED lights green|
||All other|All other|LED OFF|



## Automatic Status LED indication 

|Automatic Status LED indication|Automatic Status LED indication||
|---|---|---|
|LED|Indication|Description|
|LED on Adam AS-i|Green|Eva within sensing distance of Adam|
||Green and/or Red (fast flash) or both lights at the same<br>time|Eva within ~2 mm of maximum sensing distance|
||Red|Eva not within sensing distance of Adam|



## Status LED indication (independent of manual or automatic control) 

|LED||Indication|Description|
|---|---|---|---|
|LED on Adam AS-i||Green-Red (flash)|No contact with AS-i master|
|||Red (flash)|Internal fault. Power cycle, replace if still present|
|AS-i LED and Fault LED in combination|AS-i LED and Fault LED in combination|||
|AS-i (green)||Fault (red)|Description|
|OFF||OFF|AS-i power missing|
|ON||OFF|Normal operation|
|ON||ON|No data exchange with master|
|Flash||ON|No data exchange because address = 0|



## AS-i LED and Fault LED in combination 

ABB Safety Handbook | 2TLC172001C0202   9/8 

9 

Technical data – Eden AS-i 

|Technical data – Eden AS-i||
|---|---|
|Article number<br>Adam AS-i with 4 DA2 B<br>Eva AS-i|2TLA020051R6000<br>2TLA020051R8000|
|AS-i data<br>AS-i profile<br>Slave address at delivery<br>Adressing via<br>Response time over AS-i bus|S-7.B.E<br>0<br>M12-connector<br>10 ms|
|Safety data - annual usage<br>PFHD<br>Proof test interval (life)|6.0*10e-10<br>20 years|
|Power supply, operating voltages|30 VDC, AS-i bus. Tolerance<br>26.5-31.6 VDC|
|Switching distance<br>(target to target)|15 +/- 2 mm|
|Total current consumption|65 mA|
|Assured release distance (Sar)|45 mm|
|Assured operating distance (Sao)|7.5 mm|
|Enclosure protection|IP67 and IP69K|
|Cable type|M12-connector 4-pole male<br>(only pin1 and pin3 used)|
|Ambient temperature|Storage: -40…+85°C<br>Operation: -25…+55°C|
|Weight|~150 g|
|Material|Housing: Polybutylene<br>terephthalate  (PBT)<br>Moulding: Epoxy|
|Colour|Yellow, black text|
|Mounting bolts|SM4|
|EN ISO13849-1|Up to PL e/Cat. 4|
|EN62061|Up to SIL3|
|IEC/EN 61508-1...7<br>||SIL3, PFHD: 9.11x 10-10<br>||
|Approved standards<br>||European Machinery Directive<br>2006/42/EG<br>EN ISO 12100-1:2003+A1:2009,<br>EN ISO 12100-2:2003+A1:2009,<br>EN ISO 13849-1:2008,<br>EN 62061:2005,<br>EN 60204-1:2006+A1:2009,<br>EN 60664-1:2007,<br>EN 61000-6-2:2005,<br>EN 61000-6-4:2007,<br>EN 60947-5-1:2003+A1:2009,<br>EN 1088+A2:2008<br>||



f‘ M12 - connector: (4-pole male) 1)  Brown: AS-i + 2)  White: Not connected 22) 3)  Blue: AS-i - 4)  Black: Not connected 

**Eden AS-i electrical connections** 

## **Dimensions** 

**==> picture [176 x 78] intentionally omitted <==**

**----- Start of picture text -----**<br>
2. 3.<br>1.<br>6.<br>5.<br>4.<br>**----- End of picture text -----**<br>


Accessories: 

1. Protection plate DA1: 2TLA020053R0000 

2. Safety screws, SM4 x 20: 2TLA020053R4200 

3. SBITS: 2TLA020053R5000 

4. DA2B, Mounting spacer: 2TLA020053R0300 

5. M12-C112 1 m cable, 5-pole, 0.34 mm[2] , M12 female + male: 

- 2TLA020056R2000, 

- M12-C312 3 m cable, 5-pole, 0.34 mm[2] , M12 female + male: 

- 2TLA020056R2100 

6. AS-i T-connector with M12, Flat cable connector to M12: 

- 2TLA020073R0000 

9/9    2TLC172001C0202 | ABB Safety Handbook 

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## Eden and Eden AS-i Application examples 

## Eden to detect position 

Adam and Eva can be used to ensure that a safe position is kept/reached. The safety sensor has contact if they are within 15 mm from each other. 

## Eden is used for sector detection 

Additional Eden sensor(s) can be mounted on a machine to detect working place. 

**==> picture [205 x 68] intentionally omitted <==**

**----- Start of picture text -----**<br>
Adam<br>on wall.<br>eK<br>Eva on robot.<br>/e Metal de<br>**----- End of picture text -----**<br>


Eden can communicate through wood and plastic Wood, plastic and other non-metallic materials between Adam and Eva let the communication signal pass. 

## Eden can be hidden in doors and hatches 

Because of the small size, Eden can easily be hidden in frames or guards. 

**==> picture [26 x 11] intentionally omitted <==**

**----- Start of picture text -----**<br>
Wood,<br>plastic etc<br>**----- End of picture text -----**<br>


## Mounting – Eden 

## Installation and maintenance for Eden 

Eva can be turned in a number of different ways relative Adam. Depending on the cable connector used to connect Eden, different protection plates can be necessary in order to avoid damage to Adam. The protection plates (DA1) supplied with Adam M12-models connector are recommended for this, see figure below. Also, the mounting spacers supplied must be used in order to physically protect Eden from damage. 

- Mounting with one protection plate (DA1) for Adam M12 using prewired moulded M12 connector. For M12 connection, a straight contact is recommended. 

- Mounting with two protection plates (DA1) for Adam M12 using M12 connector with glanded cable. 

- Wrong mounting without protection plate may cause permanent damage to sensor. 

Sensing distance between Adam and Eva: 0-15 mm +/- 2 mm Minimum distance between two Eden pairs: 100 mm 

**==> picture [221 x 237] intentionally omitted <==**

**----- Start of picture text -----**<br>
115<br>DA1<br>120<br>DA1 x 2<br>|<br>*<br>| Se: eS ©<br>ge DA2 B<br>DA1,<br>QS<br>protection plate 2.5 mm * Safety screw<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   9/10 

9 

## Adam M12 Dimensions 

Adam M12 

Adam M12 AS-i 

9/11    2TLC172001C0202 | ABB Safety Handbook 

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## Eden Connection examples 

Connection of Eden to Pluto 

**==> picture [288 x 291] intentionally omitted <==**

Connection of Eden to Vital 1 

ABB Safety Handbook | 2TLC172001C0202   9/12 

Safety Magnetic Switch Sense7 

## Approvals: 

## Application: 

– Gates 

- Hatches 

- Position control 

## Features: 

- Small size 

- Up to IP69K 

- LED 

- 2NC + 1NO 

- Solid State outputs 

## Switch operational description 

The coded non-contact switches Sense7 are designed to interlock hinged, sliding or removable guard doors. Its design makes it advantageous to operate in environments that 9 require the highest level of safety. 

The magnetic switch is small in size which makes it easy to position and hide on gates and hatches. Sense7 is resistant to both dirt and water, and has no dust collecting cavities, which make it useful in environments where hygiene is paramount. The magnetic switch has a long working life since no mechanical contact is necessary for operation. Sensing distance of Sense7 is 14 mm and it has a high tolerance to misalignment. Actuator is always delivered with the non-contact switch. 

## Safety level 

The Sense7 has two closing and one opening contact. Two contacts have to be monitored to achieve the highest level of safety regulations, PL e/Cat. 4 according to EN ISO13849-1 together with safety relay or Safety Pluto PLC. 

## Regulations and Standards 

The Sense7 is designed and approved in accordance to relevant standards. Examples of relevant standards are EN1088, IEC/EN 60947-5-3, EN 60204-1, EN ISO 13849-1, EN 62061 and UL 508. 

## Material 

The Sense7 switch is available in UL approved polyester and in stainless steel 316. The stainless steel has a mirror polished finished (Ra4) suitable for CIP cleaning - food splash zones according to EHEDG guidelines. 

Sensing distance 14 mm 

## Protection from unauthorised or incidental access 

To avoid unauthorised operation of the Sense7 switch, it is only possible to actuate the coded magnetic switch with the coded magnet. Other magnets, screwdrivers and tools have no affect on the switch contacts. 

Quick connected version fitted with 250 mm cable and M12. 

NOTE! Sense7 versions have 2NC and 1NO circuits. For all Sense7 switches the NC circuits are closed when the guard is closed and the actuator present. 

9/13    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – Sense7 series 

|Article number<br>Plastic<br>Sense7 - 2 m cable<br>Sense7 - 5 m cable<br>Sense7 - 10 m cable<br>Sense7 - 250 mm cable with M12<br>Stainless steel<br>Sense7Z - 2 m cable<br>Sense7Z - 5 m cable<br>Sense7Z - 10 m cable<br>Sense7Z - 250 mm cable with M12|2TLA050056R4100<br>2TLA050056R5100<br>2TLA050056R6100<br>2TLA050056R2100<br>2TLA050056R4120<br>2TLA050056R5120<br>2TLA050056R6120<br>2TLA050056R2120|
|---|---|
|Level of Safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e/Cat. 4 depending upon<br>system architecture<br>Up to SIL3 depending upon system<br>architecture|
|Safety data<br>PFHD<br>Switching reliability<br>Proof test interval (life)<br>MTTFd|2.52 x 10-8<br>3.3 x 106operations at 100mA load<br>47 years<br>470 years (8 cycles per hour/24<br>hours per day/365 days)|
|Safety channel 1NC|24 VDC 0.2 A max. rating|
|Safety channel 2NC|24 VDC 0.2 A max. rating|
|Safety channel 3NO|24 VDC 0.2 A max. rating|
|Power supply|24 VDC ±10%|
|Minimum switched current|10 VDC 1mA|
|Dielectric withstand|250 VAC|
|Insulation resistance|100 MOhm|
|Recommended setting gap|5 mm|
|Switching distance<br>(target to target)|Sao 10 mm close (on)<br>Sar 20 mm open (off)|
|Tolerance to misalignment|5 mm in any direction from<br>5 mm setting gap|
|Switching frequency|1.0 Hz maximum|
|Approach speed|200 mm/m to 1000 mm/s|
|Vibration resistance|IEC 68-2-6, 10-55 Hz  1 mm|
|Shock resistance|IEC 68-2-27, 11 ms, 30 g|
|Enclosure protection|IP67 and IP69K|
|Cable type|PVC 8 core 6 mm O.D|
|Operating temperature<br>Sense7<br>Sense7Z|-25°C to +80°C<br>-25°C to +105°C|
|Material<br>Sense7<br>Sense7Z|UL approved polyester<br>Stainless steel 316|
|Colour|Red or stainless steel|
|Mounting position|Any|
|Mounting bolts<br>(Tightening torque)|2 x M4<br>(1.0 Nm)|



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88 88<br>78 78<br>4.50<br>Ø5.20<br>7<br>25 25<br>18.50<br>3.50<br>3 3<br>13 13<br>**----- End of picture text -----**<br>


Dimension Sense7 

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**----- Start of picture text -----**<br>
88 88<br>78 78<br>4.60<br>Ø5.40<br>7<br>25 25 18.50<br>3.50<br>3 3<br>14 14<br>**----- End of picture text -----**<br>


Dimension Sense7Z 

## **RED BLUE** 

**==> picture [164 x 129] intentionally omitted <==**

**----- Start of picture text -----**<br>
BLACK NC<br>POWER & Circuit 1<br>WHITE<br>YELLOW NC<br>& Circuit 2<br>GREEN<br>ORANGE NO<br>& Auxillary<br>BROWN Circuit<br>RECEIVER 1 RECEIVER 2<br>ACTUATOR<br>**----- End of picture text -----**<br>


Electrical connection 

## M12 8pol Sense7 - 250 mm cable with M12(Pin view from switch) Colours 

|M12 8pol|Sense7 - 250 mm cable with M12(Pin view from switch)<br>(Pin view from switch)|Colours|
|---|---|---|
|1<br>2<br>3<br>7<br>8<br>4<br>5<br>6|1|White|
||2|Red|
||3|Blue|
||4|Yellow|
||5|Brown|
||6|Green|
||7|Black|
||8|Orange|



**==> picture [167 x 89] intentionally omitted <==**

**----- Start of picture text -----**<br>
NO<br>ORANGE Auxillary<br>BROWN Circuit<br>YELLOW NC<br>GREEN Circuit 2<br>WHITE NC<br>BLACK Circuit 1<br>=— |<br>-BLUE External<br>+RED Supply<br>| 24VDC<br>Cable configuration<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   9/14 

## Magnetic lock Magne 

Approvals: Magne TÜV NORD ~~eo~~ Application: – Electrical locking of doors and hatches for production applications that are sensitive to unintentional/unnecessary interruptions. – For safety supervision the Magne 2 has an integrated Eden. _— Features: – No moving parts – Strong Magnetic holding force: 1500N – Can withstand and operate in harsh environments – Locked/unlocked indication Magnetic lock with indication – Possible to connect in series Magne is a electro-magnetic lock that is designed for industwith Eden sensors – rial applications and that can withstand harsh environments. No current peaks on activaAs it is designed with no moving parts, it is durable and long tion – lasting. The unit is intended for use in preventing unnecessary Magne 2 in combination with process stoppages, i.e. it is not a safety lock. Magne, with a handle profile provides a its electro-magnet, keeps a door locked with a holding force complete door solution up to 1500 N and magnetic material does not attach to the -_ 

9 _ 

Magne is a electro-magnetic lock that is designed for industrial applications and that can withstand harsh environments. As it is designed with no moving parts, it is durable and long 9 lasting. The unit is intended for use in preventing unnecessary process stoppages, i.e. it is not a safety lock. Magne, with its electro-magnet, keeps a door locked with a holding force up to 1500 N and magnetic material does not attach to the magnetic surface when the power is off. 

Use of M12 connectors makes it easy to connect several Magne units and Eden sensors in series enabling control and monitoring by either a Pluto safety PLC or a Vital safety controller. Via the connection cable it is also possible to obtain an indication signal informing if the Magne unit is locked or not. 

## Accessories: 

- Mounting kit for conventional door, with fitting and  screws for assembly on ABB Jokab Safety Quick-Guard fencing system (5-15 mm door gap) 

- Plastic handle 

- Handle profile for mounting on a hinged door with ABB Jokab Safety’s Quick-Guard fencing system (5-15 mm door gap). 

Magne is easy to install, adjust and dismantle in and out of the T-slot of the Quick-Guard fencing system. 

9/15    2TLC172001C0202 | ABB Safety Handbook 

## Magne Models and accessories 

## Models and ordering data 

Magne 1A with installation kit JSM D21B and JSM D27. 

Magne 2A with installation kit JSM D21B, JSM D24 and JSM D27. 

JSM D28 handle profile which cover Magne completely when the door is closed. 

Magne 2A with installation kit JSM D23. 

|Magne 1A v2 1500N|2TLA042022R2100|Electro-magnet with 5-pole M12-contact. Anchor plate. Cell rubber.|
|---|---|---|
|Magne 1B v2 1500N|2TLA042022R2200|Electro-magnet with 5-pole M12-contact. Anchor plate with perma-<br>nent magnet. Cell rubber.|
|Magne 2A v2 Eden<br>incl. EVA, 8-pol M12|2TLA042022R1600|Magnetic lock with indication. Electro-magnet with 8-pole M12-<br>contact. Anchor plate. Cell rubber.<br>Adam (built-in) + Eva (free) door position sensor.|
|Magne 2B v2 Eden<br>incl. EVA, 8-pol M12|2TLA042022R1800|Magnetic lock with indication. Electro-magnet with 8-pole M12-con-<br>tact. Anchor plate with permanent magnet. Cell rubber. Adam<br>(built-in) + Eva (free) door position sensor.|
|Magne 2Ax v2 Eden<br>incl. EVA, 5-pol M12|2TLA042022R1700|Magnetic lock with indication. Electro-magnet with 5-pole M12-<br>contact. Anchor plate. Cell rubber.<br>Adam (built-in) + Eva (free) door position sensor.|
|Magne 2Bx v2 Eden<br>incl. EVA, 5-pol M12|2TLA042022R1900|Magnetic lock with indication. Electro-magnet with 5-pole M12-con-<br>tact. Anchor plate with permanent magnet. Cell rubber. Adam<br>(built-in) + Eva (free) door position sensor.|
|JSMD28|2TLA042023R0100|Aluminum profile used as both door handle and mounting kit for<br>Magne. Completely covers Magne unit when the door is closed.|
|JSM D21B|2TLA042023R0500|Mounting kit for Magne. For conventional door (5-15 mm door<br>gap). Fits all Magne. Note: When used with Magne 2A/B,–2Ax/Bx a<br>mounting kit for Eva is also required (JSM D24).|
|JSM D23|2TLA042023R0200|Mounting kit for Magne. For sliding door. Fits all Magne.|
|JSM D24|2TLA042023R0300|Mounting kit for Eva. For conventional door.|
|JSM D27|2TLA042023R1000|Handle/screw for JSM D21 Magne installation kit.|
|Magne cellular<br>rubber|2TLA042023R3600|Spare part. Cellular rubber t=10 mm|
|Magne Anchor plate<br>32A|2TLA042023R1300|Spare part. Anchor plate A (without permanent magnet). Width 32<br>mm. Included with Magne 1/2|
|Magne Anchor plate<br>34A|2TLA042022R2300|Spare part. Anchor plate A (without permanent magnet). Width 34<br>mm.|
|Magne Anchor plate<br>32B|2TLA042023R0400|Spare part. Anchor plate B (with permanent magnet). Width 32 mm.<br>Included with Magne 1/2|
|Magne Anchor plate<br>34B|2TLA042022R2400|Spare part. Anchor plate B (with permanent magnet). Width 34 mm.|



ABB Safety Handbook | 2TLC172001C0202   9/16 

9 

Technical data – Magne 

**==> picture [527 x 623] intentionally omitted <==**

**----- Start of picture text -----**<br>
Level of safety<br>For interlocking switch Eden. Not valid for<br>locking function.<br>IEC/EN 61508-1...7 SIL3<br>EN 62061 SIL3<br>EN ISO 13849-1 PL e/Cat. 4<br>PFHD 4.50×10 [-9]<br>Power supply Magnet: 24 VDC +/- 15%<br>Eden: 17–27 VDC, ripple max 10%<br>Power consumption Magnet: 7 W (300 mA at 24VDC)<br>Eden: 45–55 mA (see data for Eden)<br>Operating temp. range -20°C to +50°C<br>Protection class IP65<br>Weight Magne 1: 610 g, Magne 2: 700 g, Anchor 32A/B: 290 g, Anchor 34A/B: 308 g<br>Material Anchor plate and magnet: steel<br>Housing: Aluminium<br>Potting: PUR, epoxy<br>Holding force 24 VDC: Min 1500 N<br>0 VDC: 0 N (Magne 1A/2A/2Ax)<br>0 VDC: 30 N (Magne 1B/2B/2Bx)<br>Contacts Reed sensor (not safe)<br>Switch current max 100 mA<br>Mechanical life >10 [7]  switch operations<br>Connector M12 5-pole male connector (Magne 1A/B, 2Ax/Bx)<br>M12 8-pole male connector (Magne 2A/B)<br>Connections Magne 1A/B:<br>(1) Brown: Locking, +24 VDC<br>(2) White: Sensor supply<br>(3) Blue: 0 VDC<br>(4) Black: NO-contact<br>(5) Grey: NC-contact<br>Magne 2A/B:<br>(1) White: Dynamic signal input<br>(2) Brown: +24V DC<br>(3) Green: Locking, +24V DC<br>(4) Yellow: Locking, 0V DC<br>(5)  Grey: Info closed  (max 10 mA)<br>(6) Pink: Dynamic signal output<br>(7) Blue: 0V DC<br>(8)  Red: Info locked (max 100 mA)<br>Magne 2Ax/Bx:<br>(1) Brown: +24 VDC<br>(2) White: Dynamic signal input<br>(3) Blue: 0 VDC<br>(4) Black: Dynamic signal output<br>(5) Grey: Locking<br>Conformity EN ISO 12100-1:2010, EN ISO 13849-1:2008, EN ISO 13849-2:2008, EN 62061:2005,<br>EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007,<br>EN 60947-5-1:2004, EN 1088+A2:2008<br>**----- End of picture text -----**<br>


9/17    2TLC172001C0202 | ABB Safety Handbook 

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## Magne Dimensions 

**==> picture [357 x 105] intentionally omitted <==**

**----- Start of picture text -----**<br>
10,7 DEEP 7(2x)  6,6(2x) M12 5-pole<br> 20,75   123   18,5   23,5<br> 21,65   158<br> 205<br> 35<br>**----- End of picture text -----**<br>


Dimensions Magne 1A/B 

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**----- Start of picture text -----**<br>
11 DEEP 7(2x)  6,6(2x) M12 5/8-pole<br> 20,75   123   18,5   91<br> 21,65   158<br> 260<br> 35<br>**----- End of picture text -----**<br>


Dimensions Magne 2A/B, -2Ax/Bx 

**==> picture [8 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
32/34<br>**----- End of picture text -----**<br>


Dimensions Anchor plate 32A/34 (without permanent magnet) 

Dimensions - cellular rubber 

**==> picture [115 x 135] intentionally omitted <==**

**----- Start of picture text -----**<br>
±3<br>±5<br>**----- End of picture text -----**<br>


Installation tolerance (general) 

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**----- Start of picture text -----**<br>
14<br>130<br>100 ±0,20<br>A A<br>M8(2X)<br>SECTION A-A<br>32/34<br>±0,10<br>9,10<br>5,50<br>+0,10 0<br>4,10<br>**----- End of picture text -----**<br>


Dimensions Anchor plate 32B/34B (with permanent magnet) 

NOTE! All dimensions are in mm 

ABB Safety Handbook | 2TLC172001C0202   9/18 

9 

## Magne Connection examples 

Holding force - Magne 1 and 2 

**Holding force / Hållkraft** 

**==> picture [432 x 223] intentionally omitted <==**

**----- Start of picture text -----**<br>
1600<br>1400<br>1200<br>1000<br>800<br>600<br>400<br>200<br>0<br>0 5 10 15 20 25 30 35<br>Volt<br>Newton<br>**----- End of picture text -----**<br>


Connection example - Magne 1 and 2 

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9/19    2TLC172001C0202 | ABB Safety Handbook 

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## Magne Connection examples 

Connection example - Magne 1 in series 

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Connection example - Magne 2 in series 

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ABB Safety Handbook | 2TLC172001C0202   9/20 

9 

## Process lock Dalton 

## Use: 

- Door and hatches 

## Features: 

- Small and robust 

- Integrated with Eden 

- High enclosure classification IP67 

- Withstands harsh enviroments 

- Low current consumption 

- Status information with LED on the lock housing and in the cable connection. 

## Dalton – the intelligent process lock 

Dalton is a locking unit that is intended for use in preventing unnecessary process stoppages, i.e. it is not a safety lock. It can be used either as a free-standing lock or integrated with Eden as a safety sensor. In the unlocked state the door is held closed by a ball catch and in locked state the balls are mechanically blocked so the lock tongue can not be pulled out. If necessary, the holding force of the ball catch can be adjusted. The device only allows to lock when the ball latch is centred around the lock tongue, and when Eva is with Adam (depending on version). When an input is supplied with voltage, the ball catch is locked. 

Dalton is easily connected with an M12 connector. The Tina junction block can be used for distribution of both the safety and locking functions. The Dalton status is indicated by LEDs and can also be read by a PLC via the information output. 

## Dalton has a modular structure 

The Dalton process lock has a modular structure and can be combined in different ways depending on position, installation and function. You choose the lock housing, lock tongue and fixing plate yourself to create a complete Dalton. 

## Installation 

Dalton offers many different installation possibilities as the lock tongue may enter the ball catch from three directions. In order to ensure that Dalton works without any problems, the ball catch must be resting, i.e. the balls not pressed in by the lock tongue when the door is in closed position. Dalton's brackets are therefore made to ensure easy adjustment of the lock tongue and ball latch positions. 

Dalton is easy to install, adjust and dismantle in the Quick-Guard fence system's T-slots. 

9/21    2TLC172001C0202 | ABB Safety Handbook 

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## Dalton Modular structure 

1. Choose Dalton lock housing according to your preferences: 

- Dalton M11/M31 If you only need to be able to lock your door/hatch (8-pin/5-pin M12) 

- Dalton M12 If you want to lock your door/hatch and also have the interlocking switch Eden installed with one cable, common for both Dalton and Eden. 

- Dalton L00 If you only need to use Dalton to keep the door fixed and closed 

## Dalton M11 

with 8-pin male contact Dalton M12 

with 8-pin male contact, 5 pin female contact for Adam Dalton M31 with 5-pin male contact Dalton L00 as ball latch, no electrical functions. 

## 2. Choose a lock tongue depending on how the door/hatch is closed. 

## Lock tongue A 

Selected when the door closes to the Dalton front Lock tongue B 

Selected when the door closes to Dalton‘s upper or lower side 

Lock from front - Tongue A Lock from lower side - Tongue B Lock from upper side - Tongue B 

For Dalton L00 both lock tongues can be used regardless of the operating direction 

## 3. Choose a fixing kit that fits your installation. 

Fixing kit 1 Fixing kit 2 for Dalton and for Dalton and Adam lock tongue and also for lock tongue and Eva 

Fixing kit 3 Fixing kit 4 for Dalton adfor Dalton and Eden apted to ABB adapted to ABB Jokab Safety Jokab Safety fencing fencing system system 

Fixing kit 5 Fixing kit 6 for Dalton, small for Dalton and Eden, bracket for lock small bracket for lock tongue tongue 

Read the manual for further information about correct installation of Dalton 

## Accessories - Dalton 

## Tina 12A junction block 

Tina 12A can be used to connect two Daltons with Edens with one cable to the apparatus enclosure. The summed information that indicates the states of both the Dalton and Eden also goes to the apparatus enclosure. 

## Transfer cables 

A transfer cable can be used when the Dalton's 8-pole connector is to be connected to the 5-pole M12 connector of Tina 4A or Tina 8A. Note that the info-signals from Dalton and Adam can not be used. 

ABB Safety Handbook | 2TLC172001C0202   9/22 

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## Technical data – Dalton 

**==> picture [526 x 659] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number Connections Connector to connect Dalton (varies<br>Dalton L00  2TLA020038R3000   depending on type)<br>Dalton M11  2TLA020038R3100   8-pole male plug, M12<br>Dalton M12  2TLA020038R3200   5-pole male plug, M12<br>Dalton M31 2TLA020038R3300  Outlet for externally connected<br>Lock tongue A  2TLA020039R0800 Adam female plug M12, 5-pole<br>Lock tongue B  2TLA020039R1000 Colour markings (pins)<br>Fixing kit 1  2TLA020039R0000 Function 8-pole Colour 5-pole Colour<br>Fixing kit 2  2TLA020039R0100 Dynamic input signal, Adam 1 (White)<br>Fixing kit 3 2TLA020039R0200 +24 VDC 2 (Brown) 1 (Brown)<br>Fixing kit 4  2TLA020039R0300 Lock signal 3 (Green) 4 (Black)<br>Fixing kit 5  2TLA020039R0400 Not used 4 (Yellow) 2 (White)<br>Fixing kit 6  2TLA020039R0500 Information Adam 5 (Grey)<br>Accessories Dynamic output signal, Adam 6 (Pink)<br>DA 1  2TLA020053R0000 0 VDC 7 (Blue) 3 (Blue)<br>M12-CT0214  2TLA020060R0100 Information Dalton 8 (Red) 5 (Grey)<br>Tina 12A  2TLA020054R1800  Warning Dalton locks mechanically. If the lock is forced, the Dalton can<br>Level of safety be permanently damaged.<br>For interlocking switch Eden. Not  Conformity (lock only) EN 61000-6-4:2007,<br>valid for locking function. EN 61000-6-2:2005<br>IEC/EN 61508-1...7 SIL3<br>EN 62061 SIL3<br>EN ISO 13849-1 PL e/Cat. 4<br>PFHD<br>For interlocking switch Eden. Not  4.50×10 [-9]<br>valid for locking function.<br>LED indication – Dalton<br>Locking function M - Locked when energised<br>L - Only ball latch LED indication<br>=Red =Green =Paus Information function<br>Colour Black<br>Operating voltage 24 VDC +25/–20% 1 Locked<br>Current consumption 0 Closed but unlocked<br>Unlocked 40 mA 0 Open<br>Locked 130 mA Alarm:<br>1Hz Lock has not entered the<br>Lock input 5 mA<br>unlocked state<br>Information output Max. 10 mA<br>Eden See the data for Adam M12 1Hz Eden or ball catch not in<br>Operating temp. range -10°C to +55°C position = open<br>Enclosure classification IP67 1Hz Open, locking not permitted<br>Holding force 1Hz Lock has not entered the<br>Unlocked 25-100 N<br>locked state<br>Locked 2000 N<br>Material 1Hz Undervoltage - locking not<br>permitted<br>Ball catch, securing plate Anodised aluminium<br>1Hz Overvoltage<br>Enclosure Anodised aluminium 1Hz Overtemperature (> 80°C)<br>Lock tongue, securing plate Stainless steel<br>Chemical resistance<br>Stainless steel Good resistance against most<br>acids except hydrochloric acid and<br>sulphuric acid.<br>Anodised aluminium Very good resistance against<br>corrosion, good resistance to most<br>acids.<br>**----- End of picture text -----**<br>


9/23    2TLC172001C0202 | ABB Safety Handbook 

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## Dalton Dimensions 

**==> picture [208 x 167] intentionally omitted <==**

**----- Start of picture text -----**<br>
63<br>8<br>2<br>33 28<br>9<br>17,5 87<br>115<br>2<br>26<br>6<br>27<br>7<br>101<br>R4<br>**----- End of picture text -----**<br>


Bracket 1 with Dalton 

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Bracket 3 with Dalton 

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**----- Start of picture text -----**<br>
 40<br> 28<br> 37,5<br> 6<br> 8,5<br> 17,5   28   17  26<br> 115   87<br> 101<br> 7<br> 2<br> 26<br> 6<br> 27<br> 2x<br>5,5<br> 8x R4<br>**----- End of picture text -----**<br>


Bracket 5 with Dalton 

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**----- Start of picture text -----**<br>
137<br>7<br>2<br>33<br>9<br>49,5<br>202,5<br>2<br>26<br>6 27<br>7<br>101<br>**----- End of picture text -----**<br>


Bracket 2 with Dalton and Eden 

**==> picture [203 x 206] intentionally omitted <==**

**----- Start of picture text -----**<br>
144<br>32<br>2<br>78<br>10<br>70<br>87<br>8 X R 4<br>**----- End of picture text -----**<br>


Bracket 4 with Dalton and Eden 

**==> picture [36 x 44] intentionally omitted <==**

Bracket 6 with Dalton and Eden 

ABB Safety Handbook | 2TLC172001C0202   9/24 

9 

## Dalton Connection examples 

Connection example – Dalton M11, M31 and M12 

Connection example – Dalton M12 and Vital 

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9/25    2TLC172001C0202 | ABB Safety Handbook 

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## Dalton Connection examples 

Connection example – Dalton M12 and Eden through Tina 4A 

**==> picture [91 x 41] intentionally omitted <==**

Connection example – Dalton M12 and Eden through Urax (AS-i) 

**==> picture [115 x 52] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   9/26 

## Safety and process lock Knox 

## Approvals: 

## Application: 

- Safe locking of door to a cell/ line with long stopping time. 

– Prevents unintentional interrupts of processes Features: – Double locking function as specified in PL e/Cat.4 (EN ISO 13849-1) – Withstands harsh enviroments – Status information with LEDs on the lock and at cable connection. – Controlled in locked and unlocked positions - position power failure. – Knox - Double safety lock as specified in PL e/Cat. 4 Electronic connection only on Knox is a double lock that complies with the highest safety level (two lock cylinders the door frame. – with monitored positions) that can be used both as a safety and process lock. The Robust design locking function is electrically controlled and is bi-stable, i.e. it retains its position (unlocked/locked) in the event of a power failure. Dual signal for unlocking is safe at 7 both short-circuits and cable breaks. The handles operate as they would on a normal door but the exterior handle also have a reset function, why a separate reset button is not necessary and the interior handle that can be used for emergency opening also in locked state. The design and durability of the lock mean that it is ideal for harsh environments as the sensors are non-contact and the lock is manufactured of stainless steel. Knox is available in a number of adaptations such as left-hung door, right-hung door, inward and outward opening, with manual unlocking and for sliding door. Knox is easy to assemble, adjust and dismantle in and out of the T-slot of the Quick-Guard fencing system. 

9 a 

Knox is a double lock that complies with the highest safety level (two lock cylinders with monitored positions) that can be used both as a safety and process lock. The locking function is electrically controlled and is bi-stable, i.e. it retains its position 9 (unlocked/locked) in the event of a power failure. Dual signal for unlocking is safe at both short-circuits and cable breaks. 

9/27    2TLC172001C0202 | ABB Safety Handbook 

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## Knox in 4 different states 

Open 

Reset, openable 

Emergency opened 

Operational mode locked and reset (emergency opening only) 

ABB Safety Handbook | 2TLC172001C0202   9/28 

Models and ordering data 

|Models and ordering data|||
|---|---|---|
|Door part|Right|Left|
|Outward opening without manual unlocking|Knox 1A-R v2<br>2TLA020105R5000|Knox 1A-L v2<br>2TLA020105R5100|
|Outward opening with manual unlocking|Knox 1AX-R v2<br>2TLA020105R5800|Knox 1AX-L v2<br>2TLA020105R5900|
|Inward opening without manual unlocking|Knox 1B-R v2<br>2TLA020105R5200|Knox 1B-L v2<br>2TLA020105R5300|
|Inward opening with manual unlocking|Knox 1BX-R v2<br>2TLA020105R6100|Knox 1BX-L v2<br>2TLA020105R6300|
|Sliding door without manual unlocking|Knox 1F-R v2<br>2TLA020105R6400|Knox 1F-L v2<br>2TLA020105R6500|
|Sliding door with manual unlocking|Knox 1FX-R v2<br>2TLA020105R6400|Knox 1FX-L v2<br>2TLA020105R6500|
|Frame part|||
|Knox safety lock|Knox 2A v2<br>2TLA020105R2200||
|Knox process lock|Knox 2X v2<br>2TLA020105R2300||
|Accessories|||
|PC plate for Knox on mesh door|2TLA020106R0000|When mounting Knox on door with mesh the accessory PC<br>plate for Knox is recommended. This is to avoid emergency<br>opening from the outside.|
|Escutcheon plate for Knox (without emergency<br>release handle)|2TLA020106R0600|When mounting Knox on a low door it is recommended to<br>replace emergency release handle to prevent opening from the<br>outside by reaching over.|



9 pA ~~aaa~~ Knox door part 1A-R Knox door part 1A-L Knox door part 1B-R Knox door part 1B-L Knox door part 1F-R Knox door part 1F-L and frame part 2A and frame part 2A and frame part 2A 

Knox door part 1B-R Knox door part 1B-L Knox door part 1F-R Knox door part 1F-L and frame part 2A and frame part 2A and frame part 2A and frame part 2A 

## Maintenance mode 

If any work is to be carried out inside the hazardous area, a padlock can be put in place in any of the two locking bolts to prevent the door from locking. This can also act as an indication of presence within the hazardous area (only helpful if operators are informed of the use of padlocks). 

NOTE! The use of padlocks is not a part of the safety function and only serves as an additional measure to reduce the risk of entrapment. 

Door part Knox1 

Frame part Knox 2 

NOTE! Cable outlet on frame part must be mounted upwords. 

9/29    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – Knox 

**==> picture [527 x 421] intentionally omitted <==**

**----- Start of picture text -----**<br>
Level of safety<br>EN ISO 13849-1 PL e/Cat. 4<br>PFHD 4.50×10 [-9]<br>Lock function S/M - unlocked and locked with voltage.<br>Operating voltage 24 VDC +/- 10%<br>Operating temperatur +5°C...+55°C<br>Power consumption<br>Electronics 70 mA (in locked position)<br>Lock/lock inverse 135 mA (when locking/unlocking)<br>Total max Knox 2A 160mA, Knox 2x 165mA<br>Information output Max. 10 mA<br>Insulation class IP65<br>Holding strength<br>Unlocked 5000 N (10,000 N ultimate breaking strength)<br>Locked 5000 N (10,000 N ultimate breaking strength)<br>Connection Male plug M12, 8-pole<br>Connections Knox 2A<br>Function 8-pole  Colour<br>Dynamic input signal 1  (White)<br>+24 VDC 2  (Brown)<br>Lock 3  (Green)<br>Lock inverse 4  (Yellow)<br>Information Locked 5  (Grey)<br>Dynamic output signal 6  (Pink)<br>0 VDC 7  (Blue)<br>Information reset 8  (Red)<br>Connections Knox 2X<br>Function 5-pole  Colour<br>+24 VDC 1  (Brown)<br>Dynamic signal input 2  (White)<br>0 VDC 3  (Blue)<br>Dynamic signal output 4  (Black)<br>Lock 5  (Grey)<br>**----- End of picture text -----**<br>


Warning Knox locks mechanically. Forcing the lock may damage Knox permanently. When mounting Knox on door with mesh the accessory PC plate for Knox is recommended. This is to prevent emergency opening from the outside. When mounting Knox on a low door it is recommended to replace emergency release handle with the accessory Escutcheon plate for Knox to prevent opening from the outside by reaching over. Conformity 2006/42/EG EN ISO 12100-1/2:2003,  EN ISO 13849-1:2008, EN 62061:2005, EN 1088 

**==> picture [385 x 186] intentionally omitted <==**

**----- Start of picture text -----**<br>
LED indicator – Knox<br>LED indicator<br>=Red =Green =Paus Function<br>LED1<br>LED 1 LED2<br>Locked (and reset)<br>Locked, no dynamic signal in<br>Unlocked<br>LED 2<br>Reset<br>Not reset<br>Alarm LED 2 Dirt indicator reset sensor<br>Reset<br>Not reset<br>**----- End of picture text -----**<br>


**==> picture [77 x 64] intentionally omitted <==**

ABB Safety Handbook | 2TLC172001C0202   9/30 

9 

## Knox Connection examples 

Connection example - Knox 

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Connection example - Knox with other unlocking 

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9/31    2TLC172001C0202 | ABB Safety Handbook 

9 

## Knox Connection examples 

Connection example - Knox with downtime monitor 

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ABB Safety Handbook | 2TLC172001C0202   9/32 

Safety Interlock Switch MKey5 

## Approvals: 

**==> picture [61 x 23] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>Rheinland<br>(X-versions) =<br>**----- End of picture text -----**<br>


## Application: 

– Gates – Hatches 

## Features: 

- 2NC + 1NO (actuator in) 

- 4 actuating positions 

- Holding force 12 or 40N 

- Up to PL e/Cat.4 

- Plastic, Plastic with stainless steel head or stainless steel 

## Switch operational description 

MKey5 Interlock switches are designed to provide position interlock detection for moving guards. They are designed to fit the leading edge of sliding, hinged or lift off machine guards. 9 The actuator is fitted to the moving part of the guard and is aligned to the switch entry aperture. 

The head can be rotated to provide four given actuator entry positions. When the actuator is inserted into the switch the safety contacts close and allow the machine start circuit to be enabled. MKey5 has two versions regarding holding force, 12N and 40N. MKey5 has several types of actuators as an option. A standard actuator key is always delivered with interlock switches. 

## Positive forced disconnected contacts 

A positive forced contact provides a forced disconnect of the safety contacts at the withdrawal of the actuator. The design of the MKey5 ensures that the contacts will not fail or be held in a normally closed position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. 

## Safety level 

The positive forced disconnect contacts gives a high safety level and the interlock switch has an anti-tamper mechanism. By combining the MKey5 with one of our suitable safety control module, for example a safety relay from the RT-series, Pluto safety-PLC or Vital module, the requirements for both hatch and gate switch supervision can be fulfilled. To obtain the highest level of safety, two switches per gate are required. 

## Material 

Depending on the environment where the switch will be used, different material can be chosen on the Mkey5. The basic version is in a full plastic body (polyester) and in cases where the demands are higher on the interlock switch head, there is a version with a plastic body and with a stainless steel head. Both these types give the MKey5 interlock switch a rating of IP67. 

In harsh applications as for food processing and chemical industry there is a MKey5Z Interlock switch with a total rugged stainless steel 316 body. This version has IP69K enclosure protection (maintained by a double seal lid gasket) and can be high pressure hosed with detergent at high temperature. 

## Explosion Proof version (X) 

MKey5 also exist in versions with certified explosion proof contact block (X-versions). MKey5ZX is in stainless steel and can be used in European Zone 1, 2, 21,22 enviroments (Gas and Dust). Preassembled with 3 meter cable. 

## Regulations and Standards 

The MKey5 is designed and approved in accordance to relevant standards. Examples of relevant standards are EN 1088, IEC/EN 60947-5-1, EN 60204-1, EN ISO 13849-1, EN 62061 and UL 508. 

9/33    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – MKey5 series 

|Article number<br>Standard<br>MKey5 - 12N<br>Mkey5+ - 40N<br>Stainless steel head<br>MKey5 - 12N<br>MKey5+ - 40N<br>Full stainless steel<br>MKey5Z - 12N<br>MKey5+Z - 40N<br>MKey5ZX (EX)<br>||2TLA050003R0100<br>2TLA050003R0101<br>2TLA050003R0110<br>2TLA050003R0111<br>2TLA050003R0120<br>2TLA050003R0121<br>2TLA050003R0125<br>||
|---|---|
|Level of safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e/Cat. 4 depending upon<br>system architecture<br>Up to SIL3 depending upon system<br>architecture|
|Safety data<br>Mechanical reliability B10d<br>Proof test interval (life)<br>MTTFd<br>;<br>:<br>~~sociithiniiiinininaiiiinnainiitinianiitiniainfeininniiinninissinniiistnnninstninnsnnense~~|2.5 x 106operations at 100mA load<br>35 years<br>356 years (8 cycles per hour/24<br>hoursper day/365 days)<br>;<br>:<br>~~sociithiniiiinininaiiiinnainiitinianiitiniainfeininniiinninissinniiistnnninstninnsnnense~~|
|Utilisation category<br>~~sociithiniiiinininaiiiinnainiitinianiitiniainfeininniiinninissinniiistnnninstninnsnnense~~<br>:<br>~~coetettnnnnnnneinnentiti~~<br>~~titinneniinnnnitinsieibeinitstsintihninsishsinsintnintenstnsietannseeseee~~|AC15 A300 3A<br>~~sociithiniiiinininaiiiinnainiitinianiitiniainfeininniiinninissinniiistnnninstninnsnnense~~<br>:<br>~~titinneniinnnnitinsieibeinitstsintihninsishsinsintnintenstnsietannseeseee~~|
|Force/travel for<br>positive opening<br>~~coe tettnnnnnnneinnen titi~~<br>~~titinneniinnnnitinsieibeinitstsintihninsishsinsintnintenstnsietannseeseee~~<br>:|6 mm<br>~~titinneniinnnnitinsieibeinitstsintihninsishsinsintnintenstnsietannseeseee~~<br>:|
|Acuator entry mini. radius<br>:|175 mm Standard Key<br>100 mm Flexible Key<br>:|
|Max. approached/withdrawal<br>speed|600 mm/s|
|Actuator|Stainless steel|
|Mechanical life|1 million switch operations|
|Rated insulation/withstand voltage|500VAC / 2500VAC|
|Vibration resistance<br>~~a~~|IEC 68-2-6, 10-55Hz+1Hz,<br>excursion: 0.35 mm,<br>1 octave/min|
|Contacts<br>(actuator key inserted)<br>~~Luutniiininiinininininininininiininininniiinpaninniniininnnnnnnnnnnnnnn~~|2NC + 1NO<br>(NC are direct opening action)<br>~~Luutniiininiinininininininininiininininniiinpaninniniininnnnnnnnnnnnnnn~~|
|Thermal current (lth)<br>~~Luutniiininiinininininininininiininininniiinpaninniniininnnnnnnnnnnnnnn~~|10A<br>~~Luutniiininiinininininininininiininininniiinpaninniniininnnnnnnnnnnnnnn~~|
|Enclosure protection<br>MKey5<br>MKey5Z(X)<br>:<br>~~ccsossestsesseeseseesssssustoiasiesasioasetosetoesenosnssessetoeestssfiseasiosssiisnetosssstssetisesinsssiinstinsssisesiiesiesetees~~|IP67<br>IP69K and IP67<br>:<br>~~ccsossestsesseeseseesssssustoiasiesasioasetosetoesenosnssessetoeestssfiseasiosssiisnetosssstssetisesinsssiinstinsssisesiiesiesetees~~|
|Operating temperature<br>~~ccsossestsesseeseseesssssustoiasiesasioasetosetoesenosnssessetoeestssfiseasiosssiisnetosssstssetisesinsssiinstinsssisesiiesiesetees~~|-25°C to +80°C<br>~~ccsossestsesseeseseesssssustoiasiesasioasetosetoesenosnssessetoeestssfiseasiosssiisnetosssstssetisesinsssiinstinsssisesiiesiesetees~~|
|Conduit entries<br>:|3 x M20<br>:|
|Material<br>MKey5<br>MKey5Z(X)|Polyester or/and stainless steel 316<br>Stainless steel 316|
|Colour|Red or stainless steel|
|Mounting position|Any|
|Mounting bolts|Body 2 x M5, actuator 2 x M5|
|Explosion Proof version (X)<br>Classification<br>Rated Voltage<br>Rated Current<br>:|Ex d IIC T6<br>(-20°C ≤ Ta ≤ +60°C) Gb<br>Ex tb IIIC T85°C<br>(-20°C ≤ Ta ≤ +60°C) Db<br>250V AC/DC<br>2 pole 4A<br>4 pole 2.5A<br>:|



**==> picture [246 x 81] intentionally omitted <==**

**----- Start of picture text -----**<br>
1 3 4<br>a a Z: {8 5 6<br>2<br>Actuator<br>**----- End of picture text -----**<br>


1. Standard Key for plastic head 

   - 2TLA050040R0201 2TLA050040R0202 2TLA050040R0220 2TLA050040R0221 2TLA050040R0203 2TLA050040R0204 

2. Standard Key for SS head 

3. Flat Key 

4. Flexible Key with plastic housing 

5. Flexible Key with metal housing 

6. Flexible Key with SS housing (Key always in Stainless steel) 

Dimension MKey5 

Dimension MKey5Z 

For all MKey the normally closed (NC) circuits are closed when the guard is closed (actuators inserted). 

|**11/12**|**Open**|**Open**||
|---|---|---|---|
|**21/22**|**Open**|||
|**33/44**||**Open**||



Contact block configuratiContacts at withdrawal of actuator on 2NC, 1NO 

ABB Safety Handbook | 2TLC172001C0202   9/34 

## Safety Interlock Switch MKey8 

## Approvals: 

**==> picture [37 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>Rheinland<br>**----- End of picture text -----**<br>


## Application: 

– Gates 

- Hatches 

## Features: 

- Robust design 

- 8 actuating positions 

- High holding force 

- Up to PL e/Cat.4 

- Painted metal or stainless steel 

- LED status indication 

## Switch operational description 

MKey8 interlock safety switches are design to provide position interlock detection and locking for moving guards.They are designed to fit the leading edge of sliding, hinged or lift off machine guards. The actuator is fitted to the moving part of the guard and 9 is aligned to the switch entry aperture. The possibility to lock the switch in the protective position prevents unwanted access to machinery until dangerous operations have ceased. 

The locking is useful when applications include: 

- processes which cannot be interrupted, such as welding. 

- machinery with a long stopping procedure, such as paper machinery that requires a long braking operation. 

- prevention of unauthorised access to a particular area. 

The head can be set in four positions, thus providing the safety device with eight different operating positions. The leading edges of the actuator key are reinforced and beveled in order to guide it properly into the hole. The MKey8 series have been developed with a high holding force of 2000N. MKey8 has several types of actuators as an option. A standard actuator key is always delivered with interlock switches. 

## Material 

Depending on the environment where the switch will be used, different material can be chosen for the Mkey8. The basic version has a rugged die cast housing with a rating of IP67. In harsh applications as for food processing and chemical industry there is a MKey8 Interlock switch with a total rugged stainless steel 316 body. This version has IP69K enclosure protection (maintained by a double seal lid gasket and seals) and can be high pressure hosed with detergent at high temperature. 

## Two ways to interlock 

The MKey8 is available in two basic versions, either with a spring lock or an electro-magnetic lock. 

In the spring lock version, the locking mechanism moves into the locked position directly when the door is closed and the actuator key is pushed into the switch. The actuator key can only be released and the gate opened by supplying operational voltage to the solenoid (A1-A2). The MKey8 also has an emergency rear release ’unlocking’ facility to enable the actuator key to be released without the energisation of the solenoid (A1-A2). This version is called MKey8ER. 

MKey8M is the electro-magnetic lock version, the locking mechanism is only in the locked position when the solenoid (A1-A2) is supplied with operating voltage. Release of the actuator key is only possible when the operating voltage is removed from the solenoid (A1-A2). The solenoid voltage can be 24 VDC or 230 VAC depending on choice. 

## Safety level 

The MKey8 has double forced disconnection contacts connected to the actuator key and the locking mechanism. The actuator key is designed to protect against unauthorised access; no tools, magnets or similar allow that the MKey8 can be tampered with. To achieve highest safety level in connection with the machine control system, it is recommended that the MKey8 is monitored by an appropriate ABB Jokab Safety safety relay, Pluto safety-PLC or Vital system. To obtain the highest level of safety, two switches per gate are required. 

9/35    2TLC172001C0202 | ABB Safety Handbook 

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## MKey8, MKey8M and MKey8Z 

MKey8 -Standard version with spring lock 

The version of MKey8 with die cast housing and spring lock. The switch has a contact block configuration of 2NC + 2NC with positive force disconnection contacts. One pair closes when the actuator key is pushed into the head (2NC). The other pair closes when the locking mechanism is in the locked position (2NC). There are two NO auxiliary circuits, 1NO circuit with indication of guard open and on another 1NO circuit indication of lock status. 

## MKey8Z - Stainless Steel version with spring lock 

The version of MKey8 with rugged stainless steel housing and spring lock. The switch has a contact block configuration of 2NC + 2NC with positive force disconnection contacts. One pair closes when the actuator key is pushed into the head (2NC). The other pair closes when the locking mechanism is in the locked position (2NC). There are two NO auxiliary circuits, 1NO circuit with indication of guard open and on another 1NO circuit indication of lock status. 

MKey8 MKey8M MKey8Z 

## MKey8M - Power to lock version with magnetic lock 

The version of MKey8 with die cast housing and magnetic lock. The switch has a contact block configuration of 2NC + 1 (NC + NO) with positive force disconnection contacts. One pair closes when the actuator key is pushed into the head (1NC + 1NO). The other pair closes when the locking mechanism is in the locked position (2NC). A 1NO/1NC circuit gives an indication of actuator status. 

**==> picture [193 x 78] intentionally omitted <==**

**----- Start of picture text -----**<br>
MKey8/8Z MKey8M<br>a<br>ese a<br>a8 esos ne en ow<br>a i 20 eecrrcece 11) aan 2e—<br>SOLENOID<br>GUARD  DE-ENERGISED<br>OPEN GUARD OPEN<br>**----- End of picture text -----**<br>


Schematic circuit: LED1 status of solenoid, LED2 status of lock (Terminals 33 - 34 are selectable to be used either as power feed to LED2 or as a voltage free auxiliary circuit to indicate lock status). 

**==> picture [194 x 52] intentionally omitted <==**

**----- Start of picture text -----**<br>
6.0 5.0 0 mm<br>11/12 Open<br>21/22 Open<br>33/44 Open<br>43/44 Open<br>**----- End of picture text -----**<br>


MKey8/8Z, Contacts at withdrawal of actuator. 

**==> picture [191 x 54] intentionally omitted <==**

**----- Start of picture text -----**<br>
6.0 5.0 0 mm<br>11/12 Open Solenoid energised<br>21/22 Open Solenoid energised<br>33/34 Open Tongue Inserted<br>43/44 Open               Tongue Inserted<br>**----- End of picture text -----**<br>


MKey8M, Contacts at withdrawal of actuator. 

Dimensions MKey8, MKey8M and MKey8Z 

ABB Safety Handbook | 2TLC172001C0202   9/36 

9 7 

## MKey8ER 

## MKey8ER - Standard version with escape release 

The version of MKey8 with die cast housing and spring lock with escape release. The switch has a contact block configuration of 2NC + 2NC with positive force disconnection contacts. One pair closes when the actuator key is pushed into the head (2NC). The other pair closes when the locking mechanism is in the locked position (2NC). There are two NO auxiliary circuits, 1NO circuit that indicates guard open and 1NO circuit that indicates lock status. 

## Features 

The MKey8ER has manual release button at the rear of the housing. This can be used where the risk assessment for the application permit, a non latching manual escape of the switch lock in case of emergency. The switch must be mounted so that the release button is reachable from inside the active guard area. Press and holding the red button will release the lock mechanism and lock monitoring contacts while the guard can be pushed open. 

**==> picture [43 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
2. Open the<br>guard door<br>**----- End of picture text -----**<br>


LED1 status of solenoid LED2 status of lock (terminals 33-34 are selectable to be used either as power feed to LED2 or as a voltage free auxiliary circuit to indicate lock status). 

1. Press and hold 

**==> picture [228 x 180] intentionally omitted <==**

**----- Start of picture text -----**<br>
124 32 FRONT ENTRY<br>TC 186 s /8 E 1<br>Fixing Holes  aml 5 9.50<br>for M5 Screws END ENTRY<br>176 21<br>[ro] Lif<br>23.50 (Li) [1<br>70<br>| || LLJ<br>£3 a3<br>67 ra 25<br>46 30 21 30 40<br>47 41.50 5<br>28.50 16<br>9.50<br>**----- End of picture text -----**<br>


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**----- Start of picture text -----**<br>
Dimensions MKey8ER<br>**----- End of picture text -----**<br>


9/37    2TLC172001C0202 | ABB Safety Handbook 

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## Technical data – MKey8 series 

|Article number<br>MKey8 - Standard<br>MKey8 - 24 VDC<br>MKey8 - 230 VAC<br>MKey8M - Power to Lock<br>MKey8M - 24 VDC<br>MKey8M - 230 VAC<br>MKey8ER - Escape release<br>MKey8ER - 24 VDC<br>MKey8ER - 230 VAC<br>MKey8Z - Stainless Steel<br>MKey8Z - 24 VDC<br>MKey8Z - 230 VAC|2TLA050011R0132<br>2TLA050011R0134<br>2TLA050013R0132<br>2TLA050013R0134<br>2TLA050015R0132<br>2TLA050015R0134<br>2TLA050011R0122<br>2TLA050011R0124|
|---|---|
|Level of safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e/Cat. 4 depending upon<br>system architecture<br>Up to SIL3 depending upon system<br>architecture|
|Safety data<br>Mechanical reliability B10d<br>Proof test interval (life)<br>MTTFd|2.5 x 106operations at 100mA load<br>35 years<br>356 years (8 cycles per hour/24<br>hours per day/365 days)|
|Utilisation category|AC15 A300 3A|
|Solenoid voltage (by part number)|24 VDC or 230 VAC, +/- 10%|
|Solenoid power consumption|12 W (MKey8M inrush 50 W)|
|LED 2 supply voltage|24 VDC, +/- 10%<br>(MKey8, MKey8ER, MKey8Z)|
|Travel for positive opening|10 mm|
|Actuator entry mini. radius|175 mm Standard Key<br>100 mm Flexible Key|
|Max. approached/withdrawal<br>speed|600 mm/s|
|Rated insulation/withstand voltages|600VAC / 2500VAC|
|Vibration resistance|IEC 68-2-6, 10-55 Hz+ 1 Hz<br>excursion: 0.35 mm<br>1 octave/min.|
|Thermal current (lth)|5A|
|Enclosure protection<br>MKey8/M/ER<br>MKey8Z|IP67<br>IP69K and IP67|
|Operating temperature<br>MKey8<br>MKey8M<br>MKey8ER<br>MKey8Z|-25°C to +55°C<br>-25°C to +40°C<br>-25°C to +55°C<br>-25°C to +55°C|
|Conduit entries|3 x M20|
|Material<br>MKey8/M/ER<br>MKey8Z|Die cast painted red<br>Stainless steel 316|
|Colour|Red or stainless steel|
|Mounting position|Any|
|Mounting bolts|4 x M5|



## Regulations and Standards 

The MKey8 is designed and approved in accordance to relevant standards. Examples of relevant standards are EN 1088, IEC/EN 60947-5-1, EN 60204-1, EN ISO 13849-1, EN 62061 and UL 508. 

**==> picture [215 x 127] intentionally omitted <==**

**----- Start of picture text -----**<br>
2<br>3<br>1<br>4<br>Actuator<br>1. Standard Key for SS head  2TLA050040R0202<br>2. Flat Key  2TLA050040R0220<br>3. Flexible Key with metal housing  2TLA050040R0203<br>4. Flexible Key with SS housing  2TLA050040R0204<br>(Key always in Stainless steel)<br>**----- End of picture text -----**<br>


**==> picture [83 x 28] intentionally omitted <==**

**----- Start of picture text -----**<br>
Top or side<br>manual release<br>points (not on MKey8M)<br>**----- End of picture text -----**<br>


**==> picture [221 x 26] intentionally omitted <==**

**----- Start of picture text -----**<br>
Manual release key  8 actuators entry positions<br>for MKey8Z  rotatable head<br>2TLA050040R0400<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   9/38 

## Safety Interlock Switch MKey9 

## Approvals: 

**==> picture [37 x 17] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>Rheinland<br>**----- End of picture text -----**<br>


Application: – Gates – Hatches ~~—~~ 

## Features: 

- Compact and robust 

- 8 actuating positions 

- High holding force 

- Up to PL e/Cat.4 

- LED status indication 

## Switch operational description 

The MKey9 interlock safety switches are design to provide position interlock detection and locking for moving guards. They are designed to fit the leading edge of sliding, hinged 9 or lift off machine guards. The actuator is fitted to the moving part of the guard and is aligned to the switch entry aperture. The possibility to lock the switch in the protective position prevents unwanted access to machinery until dangerous operations have ceased. 

The locking is useful when applications include: 

- processes which cannot be interrupted, such as welding. 

- machinery with a long stopping procedure, such as paper machinery, that requires a long braking operation. 

- prevention of unauthorised access to a particular area. 

The head can be set in four positions, thus providing the safety device with eight different operating positions. The leading edges of the actuator key are reinforced and bevelled in order to guide it properly into the hole. The safety switch is design to have a high holding force of 2000N. MKey9 has several types of actuators as an option. A standard actuator key is always delivered with interlock switches. 

## Material 

The MKey9 is made in a rugged polyester housing with a stainless steel head which give the switch a rating of IP67. 

## Two versions 

In the spring lock version, the locking mechanism moves into the locked position directly when the door is closed and the actuator key is pushed into the switch. The actuator key can only be released and the gate opened by supplying operational voltage to the solenoid (A1-A2). 

MKey9M is the electro-magnetic lock version, the locking mechanism is in the locked position when the solenoid (A1-A2) is supplied with operating voltage. Release of the actuator key is only possible when the operating voltage is removed from the solenoid (A1-A2). The solenoid voltage is 24VDC. 

## Safety level 

The MKey9 has double forced disconnection contacts to the actuator key and the locking mechanism. The actuator key is designed to protect against unauthorised access; no tools, magnets or similar allow that the MKey9 can be tampered with. To achieve maximum safety level in connection with the machine control system, it is recommended that the MKey9 is monitored by an appropriate ABB Jokab Safety safety relay, Pluto safety-PLC or Vital system. To obtain the highest level of safety, two switches per gate are required. 

## Regulations and Standards 

The MKey9 is designed and approved in accordance to relevant standards. Examples of relevant standards are EN 1088, IEC/EN 60947-5-1, EN 60204-1, EN ISO 13849-1, EN 62061 and UL 508. 

The MKey9 is available in two basic versions, either with a spring lock or an electro-magnetic lock. 

9/39    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – MKey9 series 

|Article number<br>MKey9 - 24VDC<br>MKey9M - 24VDC (power to lock)|2TLA050007R0112<br>2TLA050009R0112|
|---|---|
|Level of Safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e/Cat. 4  depending upon<br>system architecture<br>Up to SIL3 depending upon system<br>architecture|
|Safety data<br>Mechanical reliability B10d<br>Proof test interval (life)<br>MTTFd|2,5 x 106operations at 100mA load<br>35 years<br>356 years (8 cycles per hour/24<br>hours per day/365 days)|
|Utilisation category|AC15 A300 3A|
|Solenoid voltage|24 VDC or 230 VAC, +/- 10%|
|Solenoid power consumption<br>MKey9<br>MKey9M|12 W<br>12 W (Inrush 50W)|
|LED 2 supply voltage|24 VDC, +/- 10%|
|Travel for positive opening|10 mm|
|Actuator entry mini. radius<br>:<br>~~:~~|175 mm Standard Key<br>100 mm Flexible Key<br>:<br>~~:~~|
|Max. approached/withdrawal<br>speed<br>:|600 mm/s<br>:|
|Rated insulation/withstand voltages|600VAC / 2500VAC|
|Vibration resistance<br>:|IEC 68-2-6, 10-55 Hz+ 1 Hz<br>excursion: 0.35 mm<br>1 octave/min.<br>:|
|Thermal current (lth)|5A|
|Conduit entry|1 x M20|
|Enclosure classification|IP67|
|Operating temperature<br>MKey9<br>MKey9M|-25°C to +55°C<br>-25°C to +40°C|
|Head/body material|Stainless steel 316/polyester|
|Colour|Red|
|Mounting position|Any|
|Mounting bolts<br>:<br>~~A~~|4 x M5<br>:<br>~~A~~|



**==> picture [166 x 23] intentionally omitted <==**

**----- Start of picture text -----**<br>
2<br>3<br>1<br>4<br>**----- End of picture text -----**<br>


Actuator 1. Standard Key for SS head 2TLA050040R0202 2. Flat Key 2TLA050040R0220 3. Flexible Key with metal housing 2TLA050040R0203 4. Flexible Key with SS housing 2TLA050040R0204 (Key always in Stainless steel) 

**==> picture [194 x 199] intentionally omitted <==**

**----- Start of picture text -----**<br>
Top or side<br>manual release points<br>(not on MKey9M)<br>8 actuator entry positions<br>rotatable head<br>i,AS pele | AD<br>MKey9 MKey9M<br>: MKey9 <n Mitten 7 e— en<br>ety SeromcuT 1 &— #12 a<br>SOLENOID<br>GUARD  DE-ENERGISED<br>OPEN GUARD OPEN<br>1 ww &<br>**----- End of picture text -----**<br>


Schematic circuit MKey9 LED1 status of solenoid LED2 status of lock (Terminals 33 - 34 are selectable to be used either as power feed to LED2 or as a voltage free auxiliary circuit to indicate lock status). 

Dimensions MKey9 and MKey9M 

**==> picture [190 x 56] intentionally omitted <==**

**----- Start of picture text -----**<br>
6.0  5.0 0 mm<br>11/12 Open<br>21/22 Open<br>33/34 Open<br>43/44 Open<br>**----- End of picture text -----**<br>


MKey9, Contacts at withdrawal of actuator. 

**==> picture [190 x 56] intentionally omitted <==**

**----- Start of picture text -----**<br>
6.0 5.0 0 mm<br>11/12 Open Solenoid energised<br>21/22 Open Solenoid energised<br>33/34 Open Tongue Inserted<br>43/44 Open               Tongue Inserted<br>**----- End of picture text -----**<br>


MKey9M, Contacts at withdrawal of actuator. 

ABB Safety Handbook | 2TLC172001C0202   9/40 

10 

10/1    2TLC172001C0202 | ABB Safety Handbook 

10 

## Control devices 

|Whyshould control devices be used?|10/3|
|---|---|
|Three-position devices||
|JSHD4|10/5|
|Safeball||
|One- and two-hand devices - Safeball|10/15|
|Two-hand control station JSTD25|10/19|
|Two-hand device||
|JSTD20|10/23|



ABB Safety Handbook | 2TLC172001C0202   10/2 

10 

## Why should Control Devices be used? 

-for the machine operator to be able to directly start and stop dangerous machine movement. 

Ergonomic three-position device, JSHD4 with double three-position button that gives a stop signal when released or fully pressed in. 

In an emergency situation the operator can either press harder or release the three-position device to stop the machine. 

## Three-position device 

Three-position devices, hold-to-run devices and enabling devices are used during trouble-shooting, programming and test running when no other safety components are possible or suitable. The device is held in the hand and the operator can in an emergency situation either press harder or entirely release the device to stop the machine. 

Three-position devices in different versions 

Three-position device fitted to a machine control unit. 

Panel assembly of JSHD4H2 on a programming unit for robots. 

10/3    2TLC172001C0202 | ABB Safety Handbook 

10 

## Two-hand control device 

A two-hand control device is used when it is necessary to ensure that the operator's hands will be kept outside the risk area. If there is a risk that someone else other than the operator can reach into the machine without the operator seeing it, the safety device must be supplemented by something more, e.g. a light beam. 

To be able to operate the machine with the two-hand device, all the buttons on the device have to be operated within 0.5 seconds of each other. This is called concurrence. All the buttons also have to be returned to their initial position before one can start again. If any button is released during the machine movement the machine will be stopped. Using the stopping time one can calculate the necessary safety distance. A safety distance of less than 100 mm must not be used. 

The highest safety level is assured by connecting the buttons of the two-hand device to a safety relay. The safety relay checks for concurrence and that all the buttons have returned to their initial position before a new start can be made. The safety relay also gives a stop signal if any of the buttons are released. 

Two-channel all the way out to the hand Safeball is an ergonomic two-hand control device with four built-in buttons. 

The two-hand device protects against "after-grasp"; if the operator by reflex tries to enter or reach into a machine during the dangerous machine movement. 

## Foot operated switches 

A foot operated switch is used when the operator has to hold the material during processing. The pedal must have a safety cover to prevent unintentional start. For seated work one must also have a foot support to facilitate the operator holding his foot in the pedal´s off position. 

The highest safety level is secured by monitoring the pedal with a safety relay. 

The foot operated switch is used when the operator has to hold the material with both hands during processing. 

Safety foot operated switch with three-position function. 

ABB Safety Handbook | 2TLC172001C0202   10/4 

## Three position device JSHD4 

## Approvals: 

## TÜV NORD (AS-i versions) 

## Use: 

- Troubleshooting 

- Test running 

- Programming 

## Features: 

– Ergonomic 

- LED information 

- Adaptable 

- Cheat Safe (option) 

- Available for AS-i 

## The safest solution during trouble shooting, programming and testing 

## The three-position device is designed to be ergonomic 

## Why three-positions? 

An operator who is under pressure must be able to give a stop signal, whether in panic he/she pushes harder on the button or just lets go of it. 10 

Three-position devices, hold-in and acceptance devices can be used for trouble shooting, programming and test running in situations where no other protection is available or feasible. If the operator has to enter a risk area to trouble shoot or run a test, it is extremely important that he/she is able to stop the machinery without having to rely on someone else to stand by a stop button that is further away. In addition, no-one else should be able to start the machinery from the outside after it has been stopped by use of the three-position device. 

## Hold to run device or Acceptance device, what is the difference? 

Hold to run device: The start signal is given when the button is pressed. The stop signal is given when the button is released or pushed fully in. 

Acceptance device: The start signal for separate starting is given when the button is pressed. The stop signal is given when the button is released or pushed fully in. “Separate start” means, for example, that a program start signal is sent to the robot via a separate button in the acceptance device. 

The device is ergonomic, both in respect of its shape, fitting to the hand, and the way the buttons are operated. It is easy to operate the three-position device using just the fingers, and the middle position provides a secure resting position. The device has LED indications that show the operational status, i.e. stop or ready signal. The two additional buttons can be used, for example, for start/stop, up/down or forward/ back. Internally the device is duplicated. The three-position function itself is built up of two completely independent threeposition buttons which are felt by the user to be one button. 

Cheat Safe three-position device with hand recognition The three-position device JSHD4 has sensors which ensure that it is a human hand holding it. By using this, the safety level is increased, and the risk of manipulation or bypass of the safety function is reduced. It is no longer possible to expose the operator to danger by trying to lock the three-position device in run mode. 

## Three-position device adapted for AS-i 

The three-position device JSHD4 also comes in a version adapted for direct attachment to the AS-i bus. 

10/5    2TLC172001C0202 | ABB Safety Handbook 

10 

## Highest safety level whether the button is pushed or released 

When the three-position button is released you will obtain a dual stop. It is essential that the machine stops when you put aside the three-position device, for example during adjustment. 

When the three position button is pushed all the way in you will obtain a dual stop. It is essential that the machine stops in an emergency situation. 

## How does a a three-position device work? 

## Safety level 

A safe Enabling or “Hold to Run“ device should function as follows: 

**==> picture [63 x 8] intentionally omitted <==**

**----- Start of picture text -----**<br>
Released position<br>**----- End of picture text -----**<br>


1.The Stop signal in released (top) and bottom position shall have the same safety level. 

2. Provide a ‘Start’ or ‘Ready’ signal in a distinct middle position. 

3. After a ‘Stop’ in the bottom position, a ‘Start’ signal or ‘Ready’ signal is not permitted until the three position pushbuttons have been totally released and again pressed to the middle position. This function is achieved mechanically within the three position push-buttons in the device. 

4. A Short or Open circuit in the connection cables  shall not lead to a dangerous function e.g. ‘Start’ or  ‘Ready’ signal. 

In order to meet the above conditions, the three-position switch must be connected to a suitable safety relay with a two channel function, or Safety PLC, which can monitor that both three-position buttons are working and that there is no short or open circuit in the connection cable or the switch. 

**==> picture [233 x 7] intentionally omitted <==**

**----- Start of picture text -----**<br>
Middle position Bottom position<br>**----- End of picture text -----**<br>


## Regulations and standards 

The JSHD4 is designed and approved in accordance with appropriate directives and standards. See technical data. 

ABB Safety Handbook | 2TLC172001C0202   10/6 

10 

## Design a three-position device for your needs 

## 1. Choose between five different top units 

**JSHD4-1 JSHD4-2 JSHD4-3 JSHD4-4** 2TLA020006R2100 2TLA020006R2200 2TLA020006R2300 2TLA020006R2400 – LEDs – LEDs – LEDs – Front button – Front button – Top button 

**JSHD4-5** 

2TLA020006R2500 – LEDs 

**==> picture [57 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
–<br>Top button<br>**----- End of picture text -----**<br>


2. Choose a bottom part suitable for your assembly 

**AA** 2TLA020005R1000 with cable gland **AH** 2TLA020005R1700 with cable gland and PCB with 10 screw connections **AJ** 2TLA020005R1800 with cable gland and PCB with 16 screw connections 

**AB** 2TLA020005R1100 with Cannon connection 

**AC** 2TLA020005R1200 with M12 connection (5 poles) **AD** 2TLA020005R1300 with M12 connection (8 poles) **AE** 2TLA020005R1400 with M12 connection (8 poles) and emergency stop **AF** 2TLA020005R1500 with M12 connection (4 poles) and 2 AS-i nodes (for front and top button) **AG** 2TLA020005R1600 with M12 connection (4 poles) and 1 AS-i node (without front and top button) 

3. Choose hand recognition for making your three position device cheat protected (option) 

**Anti-tamper PCB** 

2TLA020005R0900 

10/7    2TLC172001C0202 | ABB Safety Handbook 

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## 4. Check the table if your combination is available 

|||JSHD4-1|JSHD4-2|JSHD4-3|JSHD4-4|JSHD4-5|
|---|---|---|---|---|---|---|
|AA without Cheat Safe|AA without Cheat Safe|JSHD4-1-AA|–|–|–|–|
|AA with Cheat Safe|AA with Cheat Safe|–|–|–|–|–|
|AB without Cheat Safe|AB without Cheat Safe|–|JSHD4-2-AB|JSHD4-3-AB|JSHD4-4-AB|JSHD4-5-AB|
|AB with Cheat Safe|AB with Cheat Safe|–|JSHD4-2-AB-A|JSHD4-3-AB-A|JSHD4-4-AB-A|JSHD4-5-AB-A|
|AC without Cheat Safe|AC without Cheat Safe|JSHD4-1-AC|–|–|–|–|
|AC with Cheat Safe|AC with Cheat Safe|–|–|–|–|–|
|AD without Cheat Safe|AD without Cheat Safe|–|JSHD4-2-AD|JSHD4-3-AD|JSHD4-4-AD|JSHD4-5-AD|
|AD with Cheat Safe|AD with Cheat Safe|–|JSHD4-2-AD-A|JSHD4-3-AD-A|JSHD4-4-AD-A|JSHD4-5-AD-A|
|AE without Cheat Safe|AE without Cheat Safe|–|–|JSHD4-3-AE|–|–|
|AE with Cheat Safe|AE with Cheat Safe|–|–|–|–|–|
|AF without Cheat Safe|AF without Cheat Safe|–|JSHD4-2-AF|JSHD4-3-AF|JSHD4-4-AF|JSHD4-5-AF|
|AF with Cheat Safe|AF with Cheat Safe|–|JSHD4-2-AF-A|JSHD4-3-AF-A|JSHD4-4-AF-A|JSHD4-5-AF-A|
|AG without Cheat Safe|AG without Cheat Safe|–|–|JSHD4-3-AG|–|–|
|AG with Cheat Safe|AG with Cheat Safe|–|–|–|–|–|
|AH without Cheat Safe|AH without Cheat Safe|–|JSHD4-2-AH|JSHD4-3-AH|JSHD4-4-AH|JSHD4-5-AH|
|AH with Cheat Safe|AH with Cheat Safe|–|JSHD4-2-AH-A|JSHD4-3-AH-A|JSHD4-4-AH-A|JSHD4-5-AH-A|
|AJ without Cheat Safe|AJ without Cheat Safe|–|JSHD4-2-AJ|JSHD4-3-AJ|JSHD4-4-AJ|JSHD4-5-AJ|
|AJ with Cheat Safe|AJ with Cheat Safe|–|JSHD4-2-AJ-A|JSHD4-3-AJ-A|JSHD4-4-AJ-A|JSHD4-5-AJ-A|



## 5. Choose a bottom plate (option) 

**JSM50G, bottom plate for  Safety Interlock switch MKey5/JSNY5** 2TLA020205R6300 

**JSM50H, bottom plate for non-contact sensor Eden (Eva)** 2TLA020205R6400 

ABB Safety Handbook | 2TLC172001C0202   10/8 

10 

## Technical data - JSHD4 

|Technical data - JSHD4||
|---|---|
|Level of safety<br>EN ISO 13849-1|PL e/Cat. 4|
|Electrical rating<br>Three-position button<br>Extra button|Maximum 30 VDC, 20mA<br>(Minimum 10 VDC, 8mA)<br>Maximum 50 VAC/VDC 0.2A|
|Protection class|IP65|
|Operatingtemperature|-10 to +50° C|
|Function indication<br>Three-position buttons ready signal|Yes´, green LED<br>No´,red LED|
|Material<br>Handle<br>Rubber|Polyamide and Noryl<br>Neoprene|
|Operation force|Approx. 15 N for three-position buttons (ON)<br>Approx. 45 N for three-position buttons (OFF)<br>Approx. 25 N for top/frontpush button|
|Mechanical life|1 000 000 cycles to middleposition|
|Conformity|EN ISO 1200-1:2010,EN ISO 13849-1:2008,EN 60204-1:2006+A1:2009|



|Cabel with Cannon connector|Cabel with Cannon connector|Cabel with M12 connector|Cabel with M12 connector|Cabel with M12 connector|
|---|---|---|---|---|
|Pin|12  conductors|Pin|8 conductors|5 conductors|
|A|White|1|White|Brown|
|B|Brown|2|Brown|White|
|C|Green|3|Green|Blue|
|D|Yellow|4|Yellow|Black|
|D<br>E|Yellow<br>Grey|4<br>5|Yellow<br>Grey|Black<br>Grey|
|F|Pink|6|Pink|-|
|G|Blue|7|Blue|-|
|H|Red|8|Red|-|
|J|Black||||
|K|Purple||||
|L|Grey and Pink||||
|M|Red and Blue||||



Accessories 

Cable, available in different lengths. 

JSM5B Wall bracket for interlock switches and threeposition device. 

Spiral cable, available in different JSHK0 12 pole lengths. connector for JSHD4. JSHD4 protection coat JSM55 Wall bracket for three“tk position device. Cable drum 

JSHD4 protection coat 

10/9    2TLC172001C0202 | ABB Safety Handbook 

## JSHD4 Models and accessories 

## Three position devices - JSHD4 

## Accessories 

**==> picture [527 x 454] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number Article number<br>JSHD4-1-AA 2TLA019995R0000 Connectors:<br>JSHD4-1-AC 2TLA019995R0100<br>M12-C01 M12 5-pole female, straight 2TLA020055R1000<br>JSHD4-2-AB 2TLA019995R0200 M12-C03 M12 8-pole female, straight 2TLA020055R1600<br>JSHD4-2-AB-A 2TLA019995R0300 JSHK0 12-pole cannon female connector for JSHD4 2TLA020003R0300<br>JSHD4-2-AD 2TLA019995R0400 Cable with 5 conductors:<br>JSHD4-2-AD-A 2TLA019995R0500<br>C5 Cable 5 x 0.34 cut to length (meters) 2TLA020057R0000<br>JSHD4-2-AF 2TLA019995R0600 M12-C101 10 m cable and M12 female connector 2TLA020056R1000<br>JSHD4-2-AF-A 2TLA019995R0700 M12-C201 20 m cable and cannon female connector 2TLA020056R1400<br>JSHD4-2-AH 2TLA019995R0800<br>JSHD4-2-AH-A 2TLA019995R0900 Cable with 8 conductors:<br>JSHD4-2-AJ 2TLA019995R1000 C8 Cable 8 x 0.34 cut to length (meters) 2TLA020057R1000<br>JSHD4-2-AJ-A 2TLA019995R1100 M12-C103 10 m cable and M12 female connector 2TLA020056R4000<br>M12-C203 20 m cable and M12 female connector 2TLA020056R4100<br>JSHD4-3-AB 2TLA019995R1200<br>Cable with 12 conductors:<br>JSHD4-3-AB-A 2TLA019995R1300<br>HKC12 Cable 12 x 0.25 cut to length (meters) 2TLA020003R5500<br>JSHD4-3-AD 2TLA019995R1400<br>HK5 Cable 5 m and cannon female connector 2TLA020003R4700<br>JSHD4-3-AD-A 2TLA019995R1500<br>HK10 Cable 10 m and connector 2TLA020003R4800<br>JSHD4-3-AE 2TLA019995R1600<br>HK20 Cable 20 m and connector 2TLA020003R4900<br>JSHD4-3-AF 2TLA019995R1700<br>HK16S4 spiral cable 1.6 m and cannon female                2TLA020003R5000<br>JSHD4-3-AF-A 2TLA019995R1800<br>connector<br>JSHD4-3-AG 2TLA019995R1900<br>JSHD4-3-AH 2TLA019995R2000 HK20S4 spiral cable 2.0 m and cannon female  2TLA020003R5100<br>JSHD4-3-AH-A 2TLA019995R2100 connector<br>JSHD4-3-AJ 2TLA019995R2200 HK32S4 spiral cable 3.2 m and cannon female  2TLA020003R5200<br>JSHD4-3-AJ-A 2TLA019995R2300 connector<br>HK40S4 spiral cable 4.0 m and cannon female  2TLA020003R3500<br>JSHD4-4-AB 2TLA019995R2400 connector<br>JSHD4-4-AB-A 2TLA019995R2500<br>HK60S4 spiral cable 6.0 m and cannon female  2TLA020003R3600<br>JSHD4-4-AD 2TLA019995R2600<br>connector<br>JSHD4-4-AD-A 2TLA019995R2700<br>HK80S4 spiral cable 8.0 m and cannon female  2TLA020003R5300<br>JSHD4-4-AF 2TLA019995R2800<br>connector<br>JSHD4-4-AF-A 2TLA019995R2900<br>HK-T2 Cable drum and connector 2TLA020003R5400<br>JSHD4-4-AH 2TLA019995R3000<br>JSHD4-4-AH-A 2TLA019995R3100 Brackets:<br>JSHD4-4-AJ 2TLA019995R3200 JSM55 Wall bracket for three position device 2TLA040005R0500<br>JSHD4-4-AJ-A 2TLA019995R3300 JSM5B Wall bracket for 2 MKey5/JSNY5  2TLA040005R0700<br>JSHD4-5-AB 2TLA019995R3400 Others:<br>JSHD4-5-AB-A 2TLA019995R3500 JSHD4 protection coat  2TLA020200R4600<br>JSHD4-5-AD 2TLA019995R3600<br>JSHD4-5-AD-A 2TLA019995R3700<br>JSHD4-5-AF 2TLA019995R3800<br>JSHD4-5-AF-A 2TLA019995R3900<br>JSHD4-5-AH 2TLA019995R4000<br>JSHD4-5-AH-A 2TLA019995R4100<br>JSHD4-5-AJ 2TLA019995R4200<br>JSHD4-5-AJ-A 2TLA019995R4300<br>**----- End of picture text -----**<br>


10 

ABB Safety Handbook | 2TLC172001C0202   10/10 

10 

## Three-position devices for different types of assembly 

## Three-position push button JSHD2C 

The button is the main component in a safe three-position solution. To achieve the highest safety level two buttons are used in a two-channel system. 

## Panel assembly JSHD4H2 

A panel assembly suitable for building into programming units or similar control boxes. Provides simultanous activation of both of the three-position buttons. 

## External assembly JSHD4H2A 

The external assembly is similar to the panel assembly unit, although it is a ‘handle’ design making it suitable for assembly on the outside of a control box. 

**==> picture [322 x 377] intentionally omitted <==**

**----- Start of picture text -----**<br>
16<br>= toe a<br>5,1<br>Ht mm e e<br>M5<br>mm<br>1,4<br>ø2,8 (2x)<br>17,3<br>26,55<br>60<br>80<br>65<br>106<br>13,5<br>21<br>10,3<br>34<br>39<br>8,5<br>14,3<br>20,7<br>3,4<br>12 22<br>18<br>52<br>**----- End of picture text -----**<br>


## Standard versions 

|Standard versions|||
|---|---|---|
|Article number||Model|
|2TLA020002R0200||JSHD4H2A Three-position device for external panel assembly|
|2TLA020002R3100||JSHD4H2 Three-position device for internal panel assembly|
|2TLA020001R1000||JSHD2C type E Three-position button|
|2TLA020001R1300||JSHD2C type K Three-position button|
|Complete JSHD4 with standard options are available to order separately|||



10/11    2TLC172001C0202 | ABB Safety Handbook 

10 

## JSHD4 Connection examples 

## JSHD4 to Pluto 

## Time-limited entrance/exit 

After lifting the three-position device out of it‘s holder the door can be opened and shut for entrance to the safety zone within X seconds. To exit zone press S3. The time is set in the Pluto programme. The device detects the operators hand and prohibits tampering. 

JSHD4 with various safety controllers 

**==> picture [295 x 238] intentionally omitted <==**

**----- Start of picture text -----**<br>
**Only for AC supply<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   10/12 

Connection with bottom parts AB 

10 

**==> picture [109 x 23] intentionally omitted <==**

**----- Start of picture text -----**<br>
15) 16 __ Molex contact | BOTTOM PART<br>**----- End of picture text -----**<br>


Connection with bottom parts AC 

**==> picture [49 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
Screw terminal<br>**----- End of picture text -----**<br>


Connection with bottom parts AD 

**==> picture [421 x 137] intentionally omitted <==**

**----- Start of picture text -----**<br>
7<br>*<br>|TRELAGES / THREE POS. LEDS TOP FRONT = ANTI“TAMPER |TopJSHD4—2parT<br>|<br>|ws |<br>. > /\7% & CA + - | _<br>| |<br>L _ _ _ — —|— —<br>[ 1) 3) 7] _ 2} 4 8 gt 9] a} tol |ts | ta] 15] tol Molex contact | BOTTOM PART<br>**----- End of picture text -----**<br>


*A jump must be placed over pins 14-16 on the 2x8 Molex connector if an anti-tamper PCB is not used. 

10/13    2TLC172001C0202 | ABB Safety Handbook 

Connection with bottom parts AE 

Connection with bottom parts AH 

Connection with bottom parts AJ 

**==> picture [290 x 515] intentionally omitted <==**

**----- Start of picture text -----**<br>
15, __ _14 __16 _ Molex contact a BOTTOM PART ,|<br>_| AE<br>7 6 8<br>FRONT —ANTI-TAMPER | TOP PART<br>JSHD4-—2<br>+ - | 1 | _<br>| JSHD4—2—AH-—A<br>_}__ _ _|<br>un) 13° | 14] 15] 16 __ Molex contact | BOTTOM PART<br>| AH<br>10<br>8 9 10<br>FRONT ~—ANTI- TAMPER | TOP PART<br>JSHD4-—2<br>+ - | y |<br>| JSHD4—2—AJ—A<br>_}__ _ _l<br>hh __ 13 14] 15) 16 __ Molex contact | BOTTOM PART<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   10/14 

## One- and two-hand devices Safeball™ 

## Approvals: 

## Safeball for: 

- Presses 

- Punches 

- Fixtures 

- Shearing machines 

A two-hand device which is comfortable and easy to use. 

## Features: 

– Ergonomic 

- Low activation force 

- Flexible mounting 

- Several grip possibilities 

- Highest safety level 

- Two channel switching in each hand 

- Available for AS-i 

## Safeball™ Unique World Wide Two-hand device 

Safeball™ consists of a spherical ball containing two embedded pushbutton switches, one on each side of the ball. By using this pushbutton configuration, the risk of unintentional activation is minimised and the device is simple and ergono10 _ mic to use. 

Safeball™ can be utilised for either One-hand (one Safeball™) or Two-hand (two Safeballs™) applications. In either application, and in order to meet the required level of safety, the Safeball™ switches are monitored by specified/certified ABB Jokab Safety Safety relays (see electrical connection). 

## When can a Two-hand or One-hand control be used? 

A Two-hand control can be used when it is necessary to ensure that the operator is outside and must be prevented from reaching into the hazardous area. If the operator decides, after the start signal has been given to the machine, to make an ‘after-grasp’ i.e. try to adjust the part that has been placed into the machine, then a dual stop signal is given to the machine. 

An One-hand control device can be used when the operator cannot reach the hazardous area with his/her free hand or on less dangerous machines. 

In the case where Two-hand control is used, both Safeballs™ i.e. all four pushbuttons have to be activated within 0.5 seconds. If one or more pushbuttons are released a Stop signal is given to the machine. In order to provide the highest level of safety the Safeball™ design provides the operator with a dual switching function and short-circuit supervision in each hand. 

## Highest Safety Level 

The Safeball™ is certified by Inspecta in Sweden for use as a Two-hand control device, when used with a JSBR4 ABB Jokab Safety Safety relay or Pluto Safety-PLC, in accordance with the highest safety level in standard EN 574 (type IIIc). 

## Safeball adapted for AS-i 

Each Safeball™ is ergonomically designed and has both its cover and actuator made of environmentally-friendly polypropylene. The design allows for comfort of use for all hand sizes and operation from numerous gripping positions. Mounting of the Safeball™ is also very flexible allowing the device to be mounted in the most ergonomic position for the operator. 

Safeball also comes in a version adapted for direct attachmenent to the AS-i bus. For using the safeball AS-i as a Two-hand device the AS-i safety monitor needs to be able to handle simultaneous monitoring otf the channels. 

10/15    2TLC172001C0202 | ABB Safety Handbook 

## Safeball Function 

## Two-hand control device 

The Two-hand control device is implemented by using two Safeballs™, each having two internal pushbuttons. The Safeballs™ must be mounted a minimum distance between each other (see Mounting description). 

By utilising two pushbuttons in each device a double safety function is provided in each hand. 

The highest safety level is achieved by connecting all four pushbuttons to the ABB Jokab Safety JSBR4 safety relay or Pluto Safety-PLC. The safety relay gives a dual and supervised safety function and requires input activation within 0.5 seconds in order to start the machine. It also checks that all four pushbuttons have returned to their deactivated positions before a new start is allowed. The JSBR4 safety relay also provides a stop signal if one or more pushbuttons are released. 

## One-hand control device 

Safeball™ is also a very practical method of providing a one-hand control device as it is very easy to find and activate by the machine operator. One-hand devices should only be used when the operator cannot reach into the hazardous area with his/her free hand or on less dangerous machines. Before fitting the necessary risk assessment must be made to determine suitability of this type of control. To achieve the highest safety level for One-hand control the Safeball™ must be connected to a safety control system (E.g. safety relay or safety PLC). 

## Technical data - Safeball 

|Technical data - Safeball||
|---|---|
|Article number<br>JSTD1-A<br>JSTD1-B<br>JSTD1-C<br>JSTD1-E<br>JSTD1-G AS-i|2TLA020007R3000<br>2TLA020007R3100<br>2TLA020007R3200<br>2TLA020007R3400<br>2TLA020007R3900|
|Material|Polypropylene|
|Colour|Yellow and black|
|Size|Height: approx. 71 mm<br>Diameter, min.: 68 mm<br>Diameter, max.: 72 mm<br>Diameter,base: 42 mm|
|Weight|0.2 kg with 2 m cable<br>0.7 kg with 10 m cable<br>0.1 kgwith 4x0.2 m wires|
|Level of Safety<br>EN ISO 13849-1|Upto PL e/Cat. 4|
|Ambient temperature|-25°C to +50°C(operating)|
|Protection class|IP67. Not intended for use under<br>water|
|Operatingforce|Approx. 2 N|
|Actuator travel|1.3 +/- 0.6 mm|
|Max switchingload|30 V 2A DC,resistive load|
|Max current (resistive load)|2 A at 30 VDC (max)<br>20 mA at 24 VDC(recommended)|
|Min switchingload|6V 10mA DC,resistive load|
|Contact resistance|100 mohm|
|Life,mechanical|> 1x106operations at max. 1 Hz|
|Life, electrical|Dependant upon electrical load<br>characteristics|
|Connection cable<br>JSTD1-A<br>JSTD1-B, JSTD1-E<br>JSTD1-C<br>JSTD1-G AS-i|2 m PVC-cable, 4 x 0.75mm2<br>4 x 0.75 mm2wires, approx. 0.2 m<br>10 m PVC-cable, 4 x 0.75 mm2<br>2 x 0.75 mm2wires,approx. 0.25 m|
|Conformity|EN ISO 12100:2010<br>EN 574+A1:2008|



## Versions 

Safeball is available in several versions to meet different mounting requirements. 

JSTD1-A - Safeball 1 NO + 1 NC with 2 m cable JSTD1-B - Safeball 1 NO + 1 NC with 0.2 m cable JSTD1-C - Safeball 1 NO + 1 NC with 10 m cable JSTD1-E - Safeball 2 NO 0.2 m cable JSTD1-G - AS-i Safeball 

**==> picture [212 x 145] intentionally omitted <==**

**----- Start of picture text -----**<br>
Activation of a pushbutton.<br>ae<br>A top cover is not needed as activation switches are<br>fitted on each side of the Safeball™.<br> KB<br>**----- End of picture text -----**<br>


|Chemical resistance at 20°C||
|---|---|
|Chemical|Resistance|
|Alcohols|good|
|Paraffin oil|good|
|Milk|good|
|Silicon oil|good|
|Acetone|good|
|Please contact us for more information.||



**==> picture [86 x 121] intentionally omitted <==**

**----- Start of picture text -----**<br>
72<br>68<br>23 23<br>U)<br>Ø4,5 (4x) mm<br>71<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   10/16 

10 

## Safeball Mounting 

The Safeballs™ can be mounted in many different ways. They can be mounted on a table, a machine, on a support or wherever suitable for ergonomic reasons. The Safeball™ can be mounted in a fixed position or on a tilting and/or rotating support. This flexibility of mounting permits the Safeball™ to be fitted in the best ergonomic position for the ease of operation by the operator. The distance requirement between two Safeballs™ or between a Safeball™ and a wall or edge of a table depends on how the Safeball™ is mounted. Safeball™ can be mounted with four M5 screws or ST4.8 self-tapping screws. 

NOTE! When Safeballs™ are mounted in such a way that the distance between them can be adjusted to less than the specified minimum, the mounting screws must be locked to ensure any changes in the distance between the two balls cannot be made. 

## Alternative mounting methods 

**==> picture [191 x 73] intentionally omitted <==**

**----- Start of picture text -----**<br>
Mounting on a table. Example of alternative<br>mounting.<br>Mounting with ball joint, which<br>can be rotated and angled.<br>Sy)<br>**----- End of picture text -----**<br>


## Approved Two-hand device 

To be an approved Two-hand device, both Safeballs™ must be mounted a minimum distance apart in order to prevent operation of both balls with one hand. Safeballs™ must be fitted a minimum distance from the edges of tables or a wall. It is essential that Safeballs™ are correctly installed in order to prevent unintended activation of the devices with part of the body in combination for example with a wall. 

## Mounting distance -Safety distance -  Safeball 

## Mounting distance 

Table mounting of two Safeballs™. 

In order to prevent cheating the distan- 

ces shown are the minimum allowed. 

**==> picture [116 x 94] intentionally omitted <==**

**----- Start of picture text -----**<br>
mm<br>y<br>dinna<br>180 120<br>120<br>**----- End of picture text -----**<br>


## Safety distance 

The Safety distance is the distance between the Safeballs™ and the dangerous machine movement. The safety distance requirement can be calculated using the following formula for Safeball™ in accordance with the approving authority and EN ISO 13855: S= KxT+C 

**==> picture [6 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
S<br>**----- End of picture text -----**<br>


## Where 

S = safety distance in mm 

- K = hand speed, 1600 mm/s 

- T = total stopping time for the dangerous movement (including the response time of the safety relays in seconds) 

The safety distance is the distance between the Safeballs™ and the dangerous machine movement. Note that S must never be less than 100 mm. 

- C = Constant = 0 mm for Safeball. 

10/17    2TLC172001C0202 | ABB Safety Handbook 

## Safeball Electrical connection 

## Two–hand device 

**==> picture [179 x 273] intentionally omitted <==**

**----- Start of picture text -----**<br>
red black grey<br>blue red black grey blue<br>**----- End of picture text -----**<br>


**==> picture [60 x 183] intentionally omitted <==**

**----- Start of picture text -----**<br>
black (2) red<br>black (1) white<br>**----- End of picture text -----**<br>


Safeballs™ are designed to be connected to a ABB Jokab Safety JSBR4 Safety relay or Safety PLC to achieve the highest safety requirements for a Two-hand device. 

Example of two devices connected to a ABB Jokab Safety JSBR4 safety relay. Response time on receiving a stop signal from JSTD1  < 15 ms. 

## One-hand device 

When used as a One-hand device the Safeball™ is designed to be connected to a ABB Jokab Safety RT6, RT7 or RT9 Safety relay in order to achieve the highest possible safety level for this type of control. 

Example of a single Safeball™ connected to a ABB Jokab Safety relay RT9. The response time at ‘stop’ is < 20 ms. 

10 

ABB Safety Handbook | 2TLC172001C0202   10/18 

## Two-hand control station JSTD25 with Safeball 

The JSTD25 replaces the traditional two-hand device. With the JSTD25 control station you have a prepared two-hand unit that is easy to install, while utilizing the good ergonomics of the Safeball. There are several versions to meet differing needs, all versions meet EN 574 and EN ISO 13849-1. 

For mobile or fixed installation 

## JSTD25F/JSTD25H 

Article number - 2TLA020007R6000/2TLA020007R6300 An ergonomic two-hand control unit with two Safeballs mounted on the ends of an aluminum profile. Both Safeball are protected with shields for unintended press of the Safeball buttons. The device can be easily mounted with the aid of grooves in the aluminum profile and an quick connection is made to the M12 connector underneath the device. For mobile applications with repositioning of the two hand device this unit is very suitable because of its low weight. 

JSTD25F is equipped with a 5-pole M12 male connector and the JSHD25H is equipped with an 8-pole M12 male connec10 tor. 

## JSTD25K 

Article number - 2TLA020007R6900 

The JSTD25K is a fully equiped two-hand control device that is very similar and has all the advantages from the JSTD25F/ JSTD25H. 

JSTD25K has just as JSTD25F/H, two Safeballs mounted on the ends of an aluminum profile and the same length. The additional equipment is double protection shields protecting for unintended press from several directions and a Smile 10 EA emergency stop placed on the middle of the profile. Connection is made easily with a 8-pole M12 male connector underneath the device. 

Both units can be equipped with an external emergency stop (Smile) and an Eden sensor for position control (ordered separately and assembled by the customer). 

For mobile installation with a built-in Eden sensor 

JSTD25P-1 

Article number - 2TLA020007R6500 

Two-hand control unit, portable. Two Safeballs mounted on the ends of an aluminium profile, shielded by over hand guards. With built-in Eva sensor for position control. Developed as a portable two-hand device, where the response of the 

machine to operation can vary at different operating stations, since each station can be connected separately. Connection via an 8+1 Zylin connector. 

10/19    2TLC172001C0202 | ABB Safety Handbook 

10 

## Accessories 

**==> picture [64 x 57] intentionally omitted <==**

**----- Start of picture text -----**<br>
ø43<br>23<br>23<br>32<br>**----- End of picture text -----**<br>


## JSM C5 

Article number - 2TLA020007R0900 Angled ball joint for installation of a Safeball on a table or a steel housing. 

## JSM C7 

Article number - 2TLA020007R1200 Suspension shelf for JSTD25F/H/G/K 

## JSM C14 

Article number - 2TLA020007R8000 Suspension shelf for JSTD25P-1 

## JSTK25S 

Article number - 2TLA020007R6700 2.5 m long spiral cable for JSTD25P-1 

## JSTK50S 

Article number - 2TLA020007R6800 8 m long spiral cable for JSTD25P-1 

## JSTK0-A 

Article number - 2TLA020007R6600 Female connector for JSTD25P-1 

## Safeball protection coat 

Article number - 2TLA020007R1900 Extra protection coat for Safeball. 

ABB Safety Handbook | 2TLC172001C0202   10/20 

10 

## Connection examples 

JSTD25F 

**==> picture [95 x 63] intentionally omitted <==**

**==> picture [68 x 49] intentionally omitted <==**

**==> picture [127 x 77] intentionally omitted <==**

JSTD25H 

**==> picture [91 x 86] intentionally omitted <==**

**==> picture [82 x 55] intentionally omitted <==**

**==> picture [81 x 55] intentionally omitted <==**

10/21    2TLC172001C0202 | ABB Safety Handbook 

10 

## Connection examples 

JSTD25P-1 

**==> picture [160 x 71] intentionally omitted <==**

**==> picture [127 x 45] intentionally omitted <==**

**==> picture [93 x 63] intentionally omitted <==**

## Dimensions 

JSTD25 

**==> picture [300 x 105] intentionally omitted <==**

**----- Start of picture text -----**<br>
JSTD25F<br>370 ±1 90.5 ±0.5<br>M12, 5-pole male<br>220±0.5<br>356 ±2<br>4<br>±2<br>129<br>95<br>**----- End of picture text -----**<br>


JSTD25P-1 

ABB Safety Handbook | 2TLC172001C0202   10/22 

## Two-hand device JSTD20 

## Approvals: 

## Use: 

- Presses 

- Punching machines 

- Cutting machines 

- Fixtures 

## Features: 

- Durable material 

- With or without emergency stop pushbutton 

- Fulfils requirements of EN 574 

- Highest level of safety 

## Conventional Two-hand device 

The conventional JSTD20 Two-hand device utilises a welded steel housing. Two operating pushbuttons are protected by over hand guards. Between these pushbuttons there is space for a emergency pushbutton and two extra controls or indica10 _ tion lamps. Below each of the operating pushbuttons is one normally open and one normally closed contact. To start and run the machine both pushbuttons must be activated within 0.5 seconds. If one or both pushbuttons are released a stop signal is given to the machine, and all contacts must return to their deactivated positions before a new start is allowed. 

The design is robust and can withstand harsh environments and long use. The pushbuttons and contact blocks are simple to assemble for quick and easy installation. The device can be mounted directly on the machine, on the ABB Jokab Safety fencing system or on the JSTS30 floor mount. For use with portable Two-hand devices the JSTS31 floor mount, which is provided with a spacer ring to fulfil the requirements of EN 574, is recommended. The JSTD20 is available with or without an emergency stop pushbutton. 

## Highest level of safety 

Correct connection to a ABB Jokab Safety JSBR4 safety relay or Pluto Safety PLC ensures the highest level of safety with dual and supervised safety function and requires input activation of both operating pushbuttons within 0.5 seconds (two hand device type III C in accordance with EN 574). If the emergency pushbutton is installed it should be provided with 

two normally closed contacts and be connected to a separate safety relay, e.g. from the RT series or Pluto. 

## Why use a Two-hand device? 

A Two-hand device can be used when it is necessary to ensure that the operator is outside and must be prevented from reaching into the hazardous area. If the operator decides, after the start signal has been given to the machine, to make an ’after grasp’ i.e. try to adjust the part that has been placed inside the machine, then a dual stop signal is given to the machine. 

The JSTD20 is equipped with a type of large over hand guards in accordance with EN 574. These prevent unintended activation by for instance a knee or elbow. 

A Two-hand device only protects the operator using it. Large machines operated by several operators can be equipped with one control for each operator. 

To calculate the correct safety distance, which depends on the machine’s stopping time including the response time of the relay, the use of the ABB Jokab Safety Smart Stopping analyser is recommended. 

10/23    2TLC172001C0202 | ABB Safety Handbook 

10 

Technical data -  JSTD20 

|Technical data -  JSTD20|||||||
|---|---|---|---|---|---|---|
|Article number<br>JSTD20A|2TLA020007R2000|Utilisation categories|||AC 15 240V 3A<br>DC 13 240V 0.27A||
|JSTD20B<br>JSTD20C|2TLA020007R2100<br>2TLA020007R2200|Cabling|||screw clamp terminals, 1 or 2 wires<br>with max. cross-section 2.5 mm2.||
|Weight|6.4 Kg|Contact material|||silver alloyon brass||
|Colour|Black housing, Black pushbuttons,|Protection class|||IP65||
|Temperature|Black floor stand.<br>-10°C…+70°C (Operating)|Accessories<br>JSTS30 floor stand|||2TLA020007R4000||
||-20°C to +70°C(storage)|JSTS31 floor stand + distance ring|||2TLA020007R4100||
|Level of Safety||JSTS32 distance ring|||2TLA020007R4200||
|EN ISO 13849-1|Upto PL e/Cat. 4|Conformity|||EN ISO 13850, EN IEC 60947-5-5,|EN ISO 13850, EN IEC 60947-5-5,|
|Material|Housing: 3mm Steel||||EN 574+A1:2008, EN 12100:2010,||
||Gasket: Rubber||||EN ISO 13849-1, EN 60947-1,||
||Pushbuttons: Plastic||||EN 60947-5-1,EN ISO 12855||
|Operating pushbuttons<br>Diameter<br>Operating force<br>Operating distance<br>Mechanical life|60 mm<br>Approx. 9N<br>3.5±1mm<br>106operations|mm|||||
|Emergency pushbutton<br>(JSTD20B only)||170<br>| Ohne!|||Vo||
|Diameter<br>Operating force<br>Mechanical life<br>Contacts|40 mm<br>40N<br>3 x 105operations<br>Mechanically separated contact<br>blocks|145|490||||
|Operating pushbuttons<br>Emergency pushbuttons<br>Isolation voltage<br>Contact resistance|1 NO + 1 NC /button<br>2 x NC<br>690V rms<br>20 mohm|JSTD20A – Two-hand device, without emergency stop<br>JSTD20B – Two-hand device, with emergency stop<br>JSTD20C – Only housing, no buttons|||||
|Rated current|10A||||||



## Connection example - JSTD20 

The Two-hand device is intended for use with ABB Jokab Safety’s JSBR4 safety relay (or Pluto Safety PLC ) to ensure the highest level of safety. The JSBR4 ensures that all contacts have returned to their deactivated positions before a new start is allowed. The safety relay also requires that all contacts are activated within 0.5 seconds. The JSBR4 gives a stop signal if one or both of the pushbuttons are released. 

**==> picture [111 x 38] intentionally omitted <==**

**----- Start of picture text -----**<br>
JSTD20A Two-hand device<br>without emergency stop<br>JSTD20B Two-hand device with<br>emergency stop<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   10/24 

11 

11/1    2TLC172001C0202 | ABB Safety Handbook 

11 

## Emergency stops and Safety stops 

|Whydoyou need an Emergencystop?|11/3|
|---|---|
|Emergency stop||
|For enclosure installation - INCA 1|11/4|
|For enclosure installation - INCA 1 Tina|11/5|
|With indication - Smile|11/7|
|With indication - Smile TIna|11/11|
|With indication - Smile AS-i|11/15|
|Compact|11/17|
|EStrongZ|11/19|
|Other buttons||
|Safetystop- INCA,Smile and Compact|11/21|
|Reset button - Smile 11 R|11/22|
|Emergency Stop Grab Wire||
|EmergencyStopGrab Wire SafetySwitches|11/23|
|LineStrong1|11/25|
|LineStrong2|11/27|
|LineStrong3|11/29|
|Accessories|11/33|



ABB Safety Handbook | 2TLC172001C0202   11/2 

11 

## Why do you need an Emergency stop? 

— so that anyone shall be able to stop a machine during a machine break-down or if someone is in danger. 

## How do I recognise an E-stop? 

E-stop buttons shall according to relevant standards be red with a yellow background. An emergency stop grab wire shall be red for high visibility. A sign that indicates the location of the E-stop shall be green with a white picture and possibly with text in the local country's language. 

## How shall an E-stop stop the machine? 

An E-stop shall stop the machine as quickly as possible. To obtain a quick stop one either removes the power directly or one lets a frequency converter 'run down' and afterwards after a little delay, remove the power. An E-stop shall not create other hazards. Therefore a risk analysis must be made for the E-stop to be correctly connected. 

## From 2006/42/EC, clause 1.2.4.3 

## ... 

## This device must: 

- have clearly identifiable, clearly visible and quickly accessible control devices, 

- stop the hazardous process as quickly as possible, without creating additional risks, 

- where necessary, trigger or permit the triggering of certain safeguard movements. 

- ... 

## Requirements for E-stops are stated in the following standards and regulations 

## 2006/42/EC The Machinery Directive 

Clause 1.2.4.3 in Annex 1 gives requirements for the emergency stop function for new machines). See also clause 1.2.2 Control devices. (see chapter “Standard and Regulations”) 

## EN ISO 13850 Safety of machinery – Emergency stop — Principles for design 

A harmonized standard that gives technical specifications for the requirements in the Machinery Directive. Could also be used for older machinery. 

## Council Directive 89/655/EEC (with amendments) 

concerning the minimum safety and health requirements for the use of work equipment by workers at work Clause 2.4 gives the requirements for the emergency stop function for older machines. See also clause 2.1. (see chapter “Standard and Regulations”) 

EN 60204-1 Safety of Machinery - Electrical equipment of machines – Part 1: General requirements. 

Harmonized standard that gives requirements for the electrical equipment of machinery including the emergency stop actuator/function. Se clauses 9.2.2 and 9.2.5.4.2. 

11/3    2TLC172001C0202 | ABB Safety Handbook 

11 

## Emergency stop for enclosure installation INCA 1 

## Approvals: 

## Application: 

- To stop a machine or a process 

## Features: 

- Terminal blocks 

- Emergency push button up to PL e/Cat. 4 acc. to EN ISO 13849-1 

- Only 53 mm construction depth 

- With LED info in push button 

- Push button IP65, connector IP20 

- Available as safety stop (black push button) 

## Description 

INCA 1 is an emergency stop designed for installation in 22.5 mm holes on cabinets. INCA 1 has potential free contacts for connection to safety relays. The connection is made in cabinets via a removable terminal which also have excellent measuring points. Inca 1 is also available with a black pushbutton and used as a safety stop. See section on Safety stops. 

In the emergency stop button there is a LED that displays current status on: 

- Green = everything ok 

- Red = this emergency push button has been pressed 

- Off = a unit earlier in the circuit is affected 

**==> picture [214 x 127] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto RT6 INCA 1<br>A<br>+24V (+) S13<br>S34 1<br>IQ 10 (A2) S23<br>2<br>A pulse<br>0V<br>0V A2<br>3<br>I1 S24<br>4<br>I0 S14<br>5<br>**----- End of picture text -----**<br>


INCA 1S. See more information on section - Safety stop. 

ABB Safety Handbook | 2TLC172001C0202   11/4 

11 _ 

## Emergency stop for enclosure installation INCA 1 Tina 

## Approvals: 

## TÜV NORD 

## Application: 

- To stop a machine or a process 

## Features: 

- Terminal blocks 

- Emergency push button up to PL e/Cat. 4 acc. to EN ISO 13849-1 

- Only 53 construction depth 

- With LED info in push button 

- Info output (INCA 1 Tina) 

- Push button IP65, connector IP20 

- Available as safety stop 

   - (black push button) 

## Description 

INCA 1 Tina is an emergency stop designed for installation in 22.5 mm holes in equipment cabinets. In addition to the INCA 1 version, INCA 1 Tina is adjusted to work in dynamic safety cirucits for connection to the safety relay Vital and safety PLC Pluto units. The connection is made in equipment cabinets via a removable terminal block which also has marked measuring points. Inca 1 Tina is also available with black push button and is used in this case as a safety stop. See section on safety stops. 

The emergency stop button has a LED that displays the current status: 

- Green = everything is OK 

- Red = this emergency stop has been pressed. 

- Flashing red/green = a protection device earlier in the circuit has been actuated. 

**==> picture [475 x 137] intentionally omitted <==**

**----- Start of picture text -----**<br>
Pluto Vital INCA 1 Tina<br>+24V B1 A<br>1<br>IQ 10 T1<br>2<br>A pulse<br>0V B2 0V INCA 1S Tina. See more information on section - Safety stop.<br>3<br>I0 R1<br>4<br>5<br>re<br>Info PLC<br>**----- End of picture text -----**<br>


11/5    2TLC172001C0202 | ABB Safety Handbook 

Technical data - INCA 1/INCA 1 Tina 

|Article number|||Current consumption (LED)||INCA 1: 15 mA|
|---|---|---|---|---|---|
|INCA 1||2TLA030054R0100|||INCA 1 Tina: 47 mA|
|INCA 1 Tina||2TLA030054R0000|Actuating force||22 ± 4 N|
|Impact resistance||Max. 150m/s², pulse width 11 ms,|Operating movement||Approx. 4 mm to locked position|
|(half sinusoidal)||3-axis, acc. to EN IEC 60068-2-27|Contact material||Gold-plated silver alloy|
|Vibration resistance||Max. 50 m/s² at 10 Hz…500 Hz,|Minimum current||INCA 1: 10 mA, 10 VDC/10 VAC|
|(sinusoidal)||10 cycles, 3 axis, acc. to EN IEC<br>60068-2-6|Maximum current||INCA 1 Tina: —<br>INCA 1: 2 A 24 VDC|
|Climate resistance<br>Damp heat, cyclical<br>Damp heat, sustained<br>Dry heat<br>Cooling<br>Salt mist||96 hours, +25 °C / 97%, +55 °C / 93<br>% relative humidity, as per<br>EN IEC 60068-2-30<br>56 days, +40 °C / 93 % relative<br>humidity, as per<br>EN IEC 60068-2-78<br>96 hours, +70 °C, as per<br>EN IEC 60068-2-2<br>96 hours, -40 °C, as per<br>EN IEC 60068-2-1<br>96 hours, +35 °C in a chemical<br>solution with NaCl as per<br>EN IEC 60068-2-11|Mechanical life<br>Accessories<br>Front ring yellow for INCA<br>Emergency Stop Sign S DK FIN,<br>22.5 mm<br>Emergency Stop Sign EN F D,<br>22.5 mm<br>Emergency Stop Sign (blank)<br>22.5 mm<br>Conformity||INCA 1 Tina: —<br>> 50 000 operations<br>Emergency Stop Sign S DK FIN,<br>2TLA030054R0400<br>2TLA030054R0500<br>2TLA030054R0600<br>2TLA030054R0900<br>EN ISO 12100:2010<br>EN ISO 13849-1:2008<br>EN 62061:2005<br>EN 60204-1:2006+A1:2009|
|Level of safety|||||IEC 60664-1:2007|
|EN ISO 13849-1||Up to PL e/Cat. 4 depending upon|||EN 61000-6-2:2005|
|||system architecture|||EN 61000-6-4:2007|
|EN 62061||SIL 3 depending upon system|||EN 60947-5-5:2005|
|IEC/EN 61508-1...7||architecture<br>SIL 3|||EN ISO 13850:2006|
|PFHD<br>INCA 1<br>INCA 1 Tina||PFHD: 1.60×10-10<br>PFHD: 4.66×10-9||||
|Colour||Yellow, red and black||||
|Weight||Approx. 45 grams||||
|Size||See drawing||||
|Material|Polyamide PA66, Macromelt,<br>Polybutylenterephthalate PBT<br>UL 94 V0<br>~~|~~<br>,<br>a<br>x<br>2<br>—|||||
|Temperature||-10°C to +55°C (operation), -30°C to||||
|||+70°C (storage)|Yellow front ring and emergency stop signs for emergency stop.|||
|Protection class||Button: IP65, Connector: IP20||||
|Installation||22.5 mm||||
|Emergency stop LEDs|INCA 1:<br>Green: Safety device OK.<br>Not lit:  A unit earlier in the circuit is<br>affected.<br>Red: This emergency stop has been<br>pressed.<br>INCA 1 Tina:<br>Green: Safety device OK, safety<br>|<br>‘SS<br>22,5mm|||||
|||circuit OK<br>Flashing: Safety device OK, safety<br>circuit previously interrupted.<br>Red: This button is pressed in, and<br>the safety circuit is interrupted.|7<br>nace|1<br>\<br>NN<br>“nw we<br>INCATina||
|Operating voltage (LED)||INCA 1: 24 VDC<br>INCA 1 Tina: 24 VDC +15% -25%||||



11 

ABB Safety Handbook | 2TLC172001C0202   11/6 

11 

## Emergency stop with indication Smile 

## Approvals: 

## Application: 

- To stop a machine or a process 

## Features: 

- Emergency push button up to PL e/Cat. 4 acc. to EN ISO 13849-1 

- With LED info in push button 

- Robust 

- IP65 

- Available as safety stop (black push button) 

- Available for AS-i 

## Smile - small and cost effective E-stop 

In order to fulfill the need for a small and easy to install E-stop, Smile has been developed. The size of the device makes it possible to be installed wherever you want. With M12 connection/s or cable and centralised mounting holes Smile is very easy to install, especially on aluminium extrusions. Smile is available for E-stops in both dynamic and static safety circuits i.e. for interfacing to Vital/Pluto and Safety relays. Each version is available with either one or two M12 connections or cable. At the top of Smile, a LED shows the current status as: green = protection OK, red = this emergency stop has been pressed and if the LED is off, an emergency stop earlier in the circuit has been actuated. Smile is also available with black push button and is used as a safety stop. See section on safety stops. 

## Smile emergency stop comes in five different versions: 

1. Smile 10 EA has a 1 m cable connected through the base of the unit. 

2. Smile 10 EK has four 1 m connecting leads through the base of the unit. No LED. 

3. Smile 11 EA has a 5-pole M12 connector on one end of the unit. 

4. Smile 12 EA has two 5-pole M12 connectors, one on each end of the unit. 

5.  Smile 11 EAR has one 5-pole M12 connector at one end of the unit. 

## Smile 11 EA adapted for AS-i 

The Smile 11 EA also comes in a version adapted for direct attachment to the AS-i bus. 

**==> picture [107 x 186] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>4<br>2<br>5<br>3<br>**----- End of picture text -----**<br>


11/7    2TLC172001C0202 | ABB Safety Handbook 

11 

## Smile Connection examples 

Smile 10 EA connected to either Pluto or a safety relay with LED indication. The connection cable exits from underneath. 

**==> picture [211 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
A<br>+24V (+) S13 1<br>2<br>Pluto  Safety<br>safety  relay<br>PLC E.g. RT6,<br>0V RT9 A2 0V 3<br>S34 4<br>I0 S14 5<br>Smile 10 EA<br>**----- End of picture text -----**<br>


**==> picture [211 x 100] intentionally omitted <==**

**----- Start of picture text -----**<br>
A<br>+24V (+) S13 1<br>S34<br>IQ 10 A-pulse (A2) S23 2<br>Pluto  Safety<br>safety  relay<br>PLC 0V E.g. RT6,  A2 0V 3<br>RT9<br>I0 S24 4<br>I1 S14 5<br>Smile 10 EA<br>**----- End of picture text -----**<br>


Single channel - Safety category 1. 

Dual channel - Safety category 4. 

Smile 11 EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connector. 

**==> picture [477 x 97] intentionally omitted <==**

**----- Start of picture text -----**<br>
A A<br>+24V (+) S13 1 +24V (+) S13 1<br>S34<br>Pluto  Safety  2 IQ 10 A-pulse (A2) S23 2<br>safety  relay Pluto  Safety<br>PLC E.g. RT6,  safety  relay<br>0V RT9 A2 0V 3 PLC 0V E.g. RT6,  A2 0V 3<br>4 RT9 4<br>S34 I0 S24<br>I0 S14 5 I1 S14 5<br>Smile 11 EA Smile 11 EA<br>**----- End of picture text -----**<br>


Single channel - Safety category 1. 

Dual channel - Safety category 4. 

Smile 12 EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connector + termination. 

**==> picture [484 x 90] intentionally omitted <==**

**----- Start of picture text -----**<br>
A JST2 A JST2<br>+24V (+) S13 1 1 +24V (+) S13 1 1<br>S34<br>2 2 2 2<br>IQ 10 A-pulse (A2) S23<br>Pluto  Safety  Pluto  Safety<br>safety PLC 0V relayE.g. RT6,  A2 0V 3 3 safety PLC 0V relayE.g. RT6,  A2 0V 3 3<br>RT9 S34 4 4 I0 RT9 S24 4 4<br>I0 S14 5 5 I1 S14 5 5<br>Smile 12 EA Smile 12 EA<br>**----- End of picture text -----**<br>


Single channel - Safety category 1. 

Dual channel - Safety category 4. 

Smile 10 EA / 11 EA / 12 EA connected to either Pluto or a safety relay without LED indication. 

**==> picture [223 x 107] intentionally omitted <==**

**----- Start of picture text -----**<br>
+24V Output 1 1<br>2<br>IQ 10 A-pulse<br>Safety<br>Pluto<br>relay<br>safety PLC 0V E.g. RT6,  3<br>I0 RT9 4<br>I1 Input 1 5<br>Smile 11 EA<br>**----- End of picture text -----**<br>


**==> picture [223 x 107] intentionally omitted <==**

**----- Start of picture text -----**<br>
+24V Output 1 1<br>IQ 10 A-pulse Output 2 2<br>Safety<br>Pluto  relay<br>safety  E.g.<br>PLC 0V RT6,  3<br>I0 RT9 Input 2 4<br>I1 Input 1 5<br>Smile 11 EA<br>**----- End of picture text -----**<br>


Single channel - Safety category 1. 

Dual channel - Safety category 4. 

ABB Safety Handbook | 2TLC172001C0202   11/8 

## Smile Connection examples 

Smile 12 EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connectors. Reconnection to the Pluto/safety relay is made via a separate cable. You can also use JST2 as a termination device after Smile12EA (C). 

**==> picture [348 x 87] intentionally omitted <==**

**----- Start of picture text -----**<br>
A B C<br>+24V Safety  (+) S13S34 1 1 1 1 1 1<br>2 2 2 2 2 2<br>IQ 10 A-pulse relay (A2) S23<br>Pluto  E.g.<br>safety  RT6,<br>PLC 0V RT9 A2 0V 3 3 3 3 3 3<br>I0 S24 4 Smile 12 EA 4 4 Smile 12 EA 4 4 Smile 12 EA 4<br>I1 S14 5 5 5 5 5 5<br>**----- End of picture text -----**<br>


Dual channel series connection - Safety category 3. 

Smile 12 EA and 11 EA connected to either Pluto or safety relay with LED indication. Connection via M12 connectors. Note that there is no termination connector as the Smile 11EA (C) completes the circuit without the need for a termination connector (JST2) or return cable. 

**==> picture [344 x 90] intentionally omitted <==**

**----- Start of picture text -----**<br>
A B C<br>1 1 1 1 1<br>+24V (+) S13<br>Pluto  Safety  S34 2 2 2 2 2<br>safety  IQ 10 A-pulse relay (A2) S23<br>PLC E.g. RT6,<br>0V RT9 A2 0V 3 3 3 3 3<br>I0 S24 4 Smile 12 EA 4 4 Smile 12 EA 4 4 Smile 11 EA<br>I1 S14 5 5 5 5 5<br>**----- End of picture text -----**<br>


Dual channel series connection - Safety category 3. 

11 

|1. Input 1<br>2. Input 2<br>3. 0 VDC (if use of LED)<br>4. Output 2, feedback<br>5. Output 1, feedback<br>Brown<br>White<br>Blue<br>Black<br>Grey<br>Smile 12 EA<br>**1**<br>**2**<br>**3**<br>**4**<br>**5**<br>Brown<br>White<br>Blue<br>Black<br>Grey<br>Smile 10 EA<br>**1**<br>**2**<br>**3**<br>**4**<br>**5**<br>Brown<br>White<br>Blue<br>Black<br>Grey<br>Smile 11 EA (R)<br>**1**<br>**2**<br>**3**<br>**4**<br>**5**<br>Smile 10 EK<br>E-Stop Button status<br>LED Indication<br>A<br>B<br>C<br>A<br>B<br>C<br>R<br>R<br>R<br>G<br>G<br>G<br>R<br>R<br>P<br>G<br>G<br>Rd<br>R<br>P<br>R<br>G<br>Rd<br>B<br>R<br>P<br>P<br>G<br>Rd<br>B<br>P<br>R<br>R<br>Rd<br>B<br>B<br>P<br>R<br>P<br>Rd<br>B<br>B<br>P<br>P<br>R<br>Rd<br>B<br>B<br>P<br>P<br>P<br>Rd<br>B<br>B<br>Brown<br>White<br>Black<br>Grey<br>1<br>2<br>4<br>5<br>LED Indicationfor the connection example above, where two<br>Smile 12 EA and one Smile 11 EA are connected in series, is<br>showed in the following table (applies for all Smile).<br>A = Smile 12EA<br>R = Released<br>B = Smile 12EA<br>P = Pressed<br>C = Smile 11EA<br>G = Green light<br>Rd = Red light<br>B = Blank, no light|Smile 10 EA<br>Smile 11 EA (R)<br>Smile 10 EK|Smile 10 EA<br>Smile 11 EA (R)<br>Smile 10 EK|1. Input 1<br>2. Input 2<br>3. 0 VDC (if use of LED)<br>4. Output 2<br>5. Output 1<br>1. Output 1<br>2. Output 2<br>3. 0 VDC<br>4. Input 2, feedback<br>5. Input 1, feedback<br>Brown<br>White<br>Blue<br>Black<br>Grey<br>**1**<br>**2**<br>**3**<br>**4**<br>**5**<br>1. Input 1<br>2. Input 2<br>3. 0 VDC (if use of LED)<br>4. Output 2<br>5. Output 1<br>1. Input 1<br>2. Input 2<br>4. Output 2<br>5. Output 1|
|---|---|---|---|
|||||
|||||
||Smile 12 EA|||
|||||
|||||



11/9    2TLC172001C0202 | ABB Safety Handbook 

11 

## Technical data – Smile 

|Technical data – Smile||
|---|---|
|Article number<br>Smile 10 EA<br>Smile 10 EK<br>Smile 11 EA<br>Smile 12 EA<br>Smile 11 EAR<br>Smile 11 EA AS-i<br>Note.There are other versions for<br>dynamic technology (with Tina).|2TLA030051R0400<br>2TLA030051R0600<br>2TLA030051R0000<br>2TLA030051R0200<br>2TLA030051R0100<br>2TLA030052R0000|
|Impact resistance<br>(half sinusoidal)|max. 150 m/s2, pulse width 11 ms,<br>3-axis, as per<br>EN IEC 60068-2-27|
|Vibration resistance (sinusoidal)|max. 50 m/s2at 10 Hz,<br>10 cycles, 3-axis, as per<br>EN IEC 60068-2-6|
|Climate resistance<br>Damp heat, cyclical<br>Damp heat, sustained<br>Dry heat<br>Cooling<br>Salt mist|96 hours, +25 °C / 97%, +55 °C / 93<br>% relative humidity, as per EN IEC<br>60068-2-30<br>56 days, +40 °C / 93 % relative<br>humidity, as per<br>EN IEC 60068-2-78<br>96 hours, +70 °C, as per<br>EN IEC 60068-2-2<br>96 hours, -40 °C, as per<br>EN IEC 60068-2-1<br>96 hours, +35 °C in a chemical<br>solution with NaCl as per<br>EN IEC 60068-2-11|
|Level of safety<br>EN ISO 13849-1<br>EN 62061<br>IEC/EN 61508-1...7|Up to PL e/Cat. 4 depending upon<br>system architecture<br>SIL 3 depending upon system<br>architecture<br>SIL 3|
|PFHD|1.60E-10|
|Colour|Yellow, red and black|
|Weight|Approx. 65 grams|
|Size|Length: 84 mm + M12 contact(s)<br>(12.5 mm each)<br>Width: 40 mm<br>Height: 52 mm|
|Material|Polyamide PA66, Macromelt,<br>Polybutylentere phthalate PBT,<br>Polypropylene PP, UL 94 V0|
|Ambient temperature|-10°C to +55°C (operation),<br>-30°C to +70°C (stock)|
|Protection class|IP65|
|Actuating force|22 ± 4 N|
|Actuator travel|Approx. 4 mm to latch|
|Mechanical life|> 50 000 operations|
|Mounting|Two M5 recessed hexagon head<br>screws, L ≥25 mm.<br>Hole cc: 44 mm|



LED on E-Stop Green: Safety device OK, Safety circuit OK Off: Safety circuit is previously interrupted. (When an E-Stop is depressed all following units in the circuit lose the LED function). Red: This button is pressed, and the safety circuit is interrupted. Operating voltage (LED) 17-27 VDC ripple ±10% (LED supply voltage) Current consumption (LED) 15 mA Material, contacts Silver alloy gold plated Min current 10 mA 10 VDC/ 10 VAC Max current 2 A 24 VDC Accessories Emergency Stop Sign S DK FIN, 2TLA030054R0700 32.5 mm Emergency Stop Sign EN F D, 2TLA030054R0800 32.5 mm Emergency Stop Sign (blank) 2TLA030054R1000 32.5 mm JST2 termination for Smile 12 2TLA030051R1300 Smile side shield 2TLA030054R1100 Conformity EN ISO 12100:2010, 

2TLA030051R1300 2TLA030054R1100 EN ISO 12100:2010, EN ISO 13849-1:2008, EN 62061:2005, IEC 60664-1:2007 EN 60204-1:2006+A1:2009, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 60947-5-5:2005, EN ISO 13850:2006 

Smile side shield 

Sign for emergency stop 

Termination device JST2 

ABB Safety Handbook | 2TLC172001C0202   11/10 

11 

## Emergency stop with indication Smile Tina 

## Approvals: 

## TÜV NORD 

## Application: 

- To stop a machine or a process 

## Features: 

- Emergency push button up to PL e/Cat. 4 acc. to EN ISO 13849-1 

- Light grids, emergency stop and Eden in the same safety circuit together with Vital or Pluto gives PL e/Cat. 4 acc. to EN ISO 13849-1 

- With LED indication on push button 

- Robust 

- Info-signal from each emergency stop 

## Smile Tina - small and cost effective E-stop 

In order to fulfill the need for a small and easy to install E-stop, Smile has been developed. The size of the device makes it possible to be installed wherever you want. With M12 connections or cable and centralised mounting holes Smile is very easy to install, especially on aluminium extrusions. Smile is available for E-stops in both dynamic and static safety circuits i.e. for interfacing to Vital system/Pluto safety PLC and Safety relays. Each version is available with either one or two M12 connections or cable. Two M12 connectors are used to enable the connection of E-stops in series, which is often used with dynamic safety circuits fulfilling safety category 4. In the top of the Smile Tina E-stop unit, LEDs show the actual status according to the dynamic system: 

- IP65 

- Available as safety stop 

   - (black push button) 

Green = everything is OK 

Red = E-stop activated. 

Flashing Red/Green = Stop activated from another preceding device. 

Smile is also available with black push button and used as a safety stop. See section on safety stops. 

## The Smile Tina emergency stop is available in four versions: 

1. Smile 10 EA Tina has a 1 m cable connected via the base of the unit. 

2. Smile 11 EA Tina has a 5-pole M12 connector on the end of the unit. 

**==> picture [115 x 111] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>3<br>2<br>4<br>**----- End of picture text -----**<br>


3. Smile 12 EA Tina has two 5-pole M12 connectors, one on each end of the unit. 

4.  Smile 11 EAR Tina has one 5-pole M12 connector at one end of the unit. 

11/11    2TLC172001C0202 | ABB Safety Handbook 

11 

## Smile Tina Connection examples 

Smile 10 EA Tina connected to either a Pluto or Vital system with LED indication/information. The connection cable exits from underneath the unit. Safety circuit category 4. 

**==> picture [222 x 34] intentionally omitted <==**

**----- Start of picture text -----**<br>
IQ10 T<br>Pluto I0 Vital R<br>Smile 10 EA Tina<br>**----- End of picture text -----**<br>


Smile 11 EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 11 EA Tina units connected via M12 connectors in a serie via connection terminals in the electrical cabinet. Safety circuit category 4. 

**==> picture [224 x 110] intentionally omitted <==**

**----- Start of picture text -----**<br>
Electrical cabinet Smile 11 EA Tina<br>IQ10 T A<br>Pluto I0 Vital R<br>Smile 11 EA Tina<br>B<br>Smile 11 EA Tina<br>Connection termination C<br>**----- End of picture text -----**<br>


Smile 11 EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 11 EA Tina units and one Eden connected via M12 connectors in a serie via a Tina 4A connection block. Safety circuit category 4. 

**==> picture [286 x 121] intentionally omitted <==**

**----- Start of picture text -----**<br>
Smile 11 EA Tina<br>A<br>IQ10 T 1 3<br>Pluto Vital Tina 4A Smile 11 EA Tina<br>I0 R 2 4<br>B<br>Smile 11 EA Tina<br>C<br>Eden = Adam & Eva<br>**----- End of picture text -----**<br>


Smile 12 EA Tina connected to either a Pluto or Vital system with LED indication/information. Two Smile 12 EA Tina’s, one Eden sensor and one Focus Light Curtain connected via M12 connectors in a serie. Safety circuit category 4. 

**==> picture [408 x 96] intentionally omitted <==**

**----- Start of picture text -----**<br>
Focus<br>Eden = Adam & Eva<br>M12-3A M12-3A<br>IQ10 T<br>Pluto Vital<br>I0 R Smile 12 EA Tina Smile 12 EA Tina<br>M12-3B Tina 10A<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/12 

## Smile Tina Connection examples 

Smile 12 EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 12 EA Tina units connected via M12 connectors in a serie. Reconnection to the Pluto/safety relay is made via a separate cable. Safety circuit category 4. 

**==> picture [385 x 57] intentionally omitted <==**

**----- Start of picture text -----**<br>
A B C<br>IQ10 T<br>Pluto Vital<br>I0 R Smile 12 EA Tina Smile 12 EA Tina Smile 12 EA Tina<br>**----- End of picture text -----**<br>


|E-Stop Button status|E-Stop Button status|E-Stop Button status|E-Stop Button status|LED Indication|LED Indication|LED Indication|
|---|---|---|---|---|---|---|
|A|B|C||A|B|C|
|R|R|R||G|G|G|
|R|R|P||G|G|Rd|
|R|P|R||G|Rd|F|
|R|P|P||G|Rd|Rd|
|P|R|R||Rd|F|F|
|P|R|P||Rd|F|Rd|
|P|P|R||Rd|Rd|F|
|P|P|P||Rd|Rd|Rd|



LED Indication for the connection example above, where three Smile 12 EA Tina units are connected in series, is showed in the following table (applies for all Smile Tina). 

A = Smile 12 EA Tina R = Released B = Smile 12 EA  Tina P = Pressed C = Smile 12 EA Tina G = Green light Rd = Red light 

F =   Flashes, changing between red and green light. 

||E-Stop Button status|E-Stop Button status|E-Stop Button status|E-Stop Button status|Information|Information|Information||
|---|---|---|---|---|---|---|---|---|
||||||output signal||||
||A|B|C||A|B||C|
||R|R|R||H|H||H|
||R|R|P||H|H||L|
||R|P|R||H|L||H|
||R|P|P||H|L||L|
||P|R|R||L|H||H|
||P|R|P||L|H||L|
|11|P<br>P|P<br>P|R<br>P||L<br>L|L<br>L||H<br>L|
||||||||||



Information output signal for the connection example above, where three Smile 12 EA Tina units are connected in series, is showed in the following table (applies for all Smile Tina). The status information signal can be connected to e.g. PLC input. Note. The information signal must not be used as a safety signal. The signal should only be used to indicate the status of connected devices. 

A = Smile 12 EA Tina B = Smile 12 EA  Tina C = Smile 12 EA Tina 

R = Released P = Pressed H = High (i.e. supply voltage) L = Low (= 0 VDC) 

**==> picture [179 x 129] intentionally omitted <==**

**----- Start of picture text -----**<br>
Smile 10 EA Tina<br>Brown 1 +<br>White 2<br>Blue 3 -<br>Black 4<br>Grey 5<br>Smile 11 EA Tina<br>Brown 1 +<br>White 2<br>Blue 3 -<br>Black 4<br>Grey 5<br>**----- End of picture text -----**<br>


1. Input voltage,17-27 VDC ripple+/- 10% 2. Dynamic input signal 

3. 0 VDC 4. Dynamic output signal 

5. Information output 

1. Input voltage,17-27 VDC ripple+/- 10% 

2. Dynamic input signal 

3. 0 VDC 

4. Dynamic output signal 

5. Information output 

Smile 12 EA Tina 

1. Output voltage to next unit 

1. Input voltage,17-27 VDC 

**==> picture [464 x 50] intentionally omitted <==**

**----- Start of picture text -----**<br>
    ripple+/- 10% Brown 1 + + 1 Brown 2. Dynamic output signal (To next<br>White 2 2 White<br>2. Dynamic input signal Blue 3 - - 3 Blue     Smile or to Pluto or Vital system)<br>3. 0 VDC  Black 4 4 Black 3. 0 VDC<br>4. Not used 5 5 4. Not used<br>Grey Grey<br>5. Not used 5. Information output<br>**----- End of picture text -----**<br>


5. Information output 

11/13    2TLC172001C0202 | ABB Safety Handbook 

11 

## Technical data – Smile Tina 

|Technical data – Smile Tina||
|---|---|
|Article number<br>Smile 10 EA Tina<br>Smile 11 EA Tina<br>Smile 12 EA Tina<br>Smile 11 EAR Tina<br>Note.There are versions for use<br>with relay technology (without Tina).|2TLA030050R0400<br>2TLA030050R0000<br>2TLA030050R0200<br>2TLA030050R0100|
|Impact resistance<br>(half sinusoidal)|max. 150 m/s2, pulse width 11 ms,<br>3-axis, as per<br>EN IEC 60068-2-27|
|Vibration resistance (sinusoidal)|max. 50 m/s2at 10 Hz, 10 cycles,<br>3-axis, as per<br>EN IEC 60068-2-6|
|Climate resistance<br>Damp heat, cyclical<br>Damp heat, sustained<br>Dry heat<br>Cooling<br>Salt mist|96 hours, +25 °C / 97%, +55 °C / 93<br>% relative humidity, as per EN IEC<br>60068-2-30<br>56 days, +40 °C / 93 %<br>relative humidity, as per<br>EN IEC 60068-2-78<br>96 hours, +70 °C, as per<br>EN IEC 60068-2-2<br>96 hours, -40 °C, as per<br>EN IEC 60068-2-1<br>96 hours, +35 °C in a chemical solu-<br>tion with NaCl as per<br>EN IEC 60068-2-11|
|Level of safety<br>EN ISO 13849-1<br>EN 62061<br>IEC/EN 61508-1...7|Up to PL e/Cat. 4 depending upon<br>system architecture<br>SIL 3 depending upon system<br>architecture<br>SIL 3|
|PFHD|4.66E-09|
|Colour|Yellow, red and black|
|Weight|Approx. 65 grams|
|Size<br>~~|~~|Length: 84 mm + M12 contact(s)<br>(12.5 mm each)<br>Width: 40 mm Height: 52 mm<br>~~|~~|
|Material|Polyamid PA66, Macromelt, Polybu-<br>tylenterephthalate PBT, Polypropylen<br>PP, UL 94 V0|
|Ambient temperature|-10°C to +55°C (operation) -30°C to<br>+70°C (stock)|
|Protection class|IP65|
|Mounting<br>i|Two M5 hexagon socket screws, L<br>≥25 mm.<br>Hole centres: 44 mm<br>i|
|LED on E-Stop<br>:<br>:<br>:<br>:|Green: Safety device OK, Safety<br>circuit OK<br>Flashing: Safety device OK, safety<br>circuit previously interrupted<br>Red: This button is pressed, and the<br>safety circuit is interrupted<br>:<br>:<br>:<br>:|
|Time delay|1:1.5 (Two Smile units are equal to<br>three Edens in time delay)|
|Operating voltage|17-27 VDC ripple ±10%|



|Current consumption|47 mA (57mA with max. current from<br>information output)|
|---|---|
|Current from information output|10 mA max|
|Actuating force|22±4 N|
|Actuator travel|Approx. 4 mm to latch|
|Material, contacts|Silver alloy gold plated|
|Mechanical life|> 50 000 operations|
|Accessories<br>Emergency Stop Sign S DK FIN,<br>32.5 mm<br>Emergency Stop Sign EN F D,<br>32.5 mm<br>Smile side shield|2TLA030054R0700<br>2TLA030054R0800<br>2TLA030054R1100|
|Conformity|EN ISO 12100:2010<br>EN ISO 13849-1:2008<br>EN 62061:2005,<br>EN 60204-1:2006+A1:2009<br>IEC 60664-1:2007<br>EN 61000-6-2:2005<br>EN 61000-6-4:2007<br>EN 60947-5-5:2005<br>EN ISO 13850:2006|



Smile side shield 

**==> picture [85 x 8] intentionally omitted <==**

**----- Start of picture text -----**<br>
Sign for emergency stop<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/14 

11 

## Emergency stop with indication Smile AS-i 

## Approvals: 

## TÜV NORD 

## Application: 

- To stop a machine or a process 

- Safe input node in AS-i systems 

## Features: 

- Emergency push button up to PL e/Cat. 4 acc. to EN ISO 13849-1 

- Simple connection to AS-i bus 

- With LED indication on push button and AS-i status indication 

- Robust 

- IP65 

Smile 11 EA AS-i is an emergency stop with a built-in dual channel safe AS-i input node. The AS-i bus and the safety around it is specified by the two organisations “AS-International Association” and “AS-Interface Safety at Work”, and is described in publications such as “AS-Interface The Automatic Solution”. 

- Available as safety stop (black push button) 

Smile 11 EA AS-i is supplied with 30 VDC from the AS-i bus. The recommended connection to the AS-i bus is made via a flat cable terminal to M12 (see Figure), which makes it possible to quickly and easily connect the device to the yellow AS-i cable. 

Smile 11 EA AS-i can also be connected directly to the AS-i bus using only two conductors (pins 1 and 3 on the unit's M12 contact). Smile is also available with black push button and is used in this case as a safety stop. See section on safety stops. 

The possibility with LED indication is also avalible on the Smile 11 EA AS-i, with the difference that the AS-i version has programable LEDs. This gives the customer full flexibility for making own indication. 

11/15    2TLC172001C0202 | ABB Safety Handbook 

11 

Technical data – Smile AS-i 

**==> picture [527 x 335] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>Smile 11 EA AS-i 2TLA030052R0000<br>AS-i data<br>AS-i profile S-7.B.0<br>Addressing M12-contact<br>Node address on delivery 0<br>Response time across the AS-i bus 5 ms (+ response time for safety monitor)<br>Pin configuration<br>(1) AS-i +<br>(2) Not used<br>(3) AS-i –<br>(4) Not used<br>(5) Not used<br>Operating voltage 30 VDC from the AS-i bus. Tolerance 26.5 – 31.6 VDC.<br>Total current consumption  < 60 mA<br>Protection class IP65<br>Ambient temperature  -25…+50°C<br>Dimensions 52 x 40 x 84 (+12,5 mm M12 contact) (H x W x L)<br>Colour Yellow, red and black<br>Actuating force 22 ±4 N<br>Actuating travel Approx. 4 mm to latch<br>Mechanical life > 50 000 operations<br>PFHD  6.95 x 10 [-9]<br>Level of safety<br>EN ISO 13849-1 Up to PL e/Cat. 4 depending upon system architecture MTTFd: high<br>EN 62061 SIL 3 depending upon system architecture<br>IEC/EN 61508-1...7 SIL 3, PFDavr: 2.95 x 10 [-5] , PFHD: 6.95*10 [-9]<br>Conformity EN ISO 12100:2010, EN ISO 13849-1:2008/AC:2009, EN ISO 13849-2:2008, EN 60204-1:2007+A1,<br>EN ISO 13850:2006<br>**----- End of picture text -----**<br>


## LED in emergency stop button 

LED is individually programmed in the PLC program as shown below. 

**==> picture [527 x 93] intentionally omitted <==**

**----- Start of picture text -----**<br>
LED in push button Indicator Description<br>Red ON Output bit 1 ON<br>OFF Output bit 1 OFF or<br>Output bit 1 & 2 ON<br>Green ON Output bit 2 ON<br>OFF Output bit 2 OFF or<br>Output bit 1 & 2 ON<br>**----- End of picture text -----**<br>


## AS-i LED and Fault LED 

in combination LED pair at the M12 contact. 

**==> picture [527 x 69] intentionally omitted <==**

**----- Start of picture text -----**<br>
AS-i (Green)  Fault (Red) Description<br>OFF OFF AS-i voltage missing<br>ON OFF Normal operation<br>ON ON No data exchange with master<br>Flash ON No data exchange due to address = 0<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/16 

11 _ 

Emergency stop Approvals: Compact Application: – To stop a machine or a process Features: – Assembled compact emergency stop – Emergency push button up to PL e/Cat. 4 acc. to _ ~~_~~ EN ISO 13849-1 – Robust – IP67 and IP69K – Available as safety stop (black push button) The Compact emergency stop with an enclosure The emergency stop comes from the Compact range of ABB:s Pilot Devices. The Compact is an “All-in-one design“ solution, with button and contact block in one unit. It has a building hight of 42 mm. 

- Robust 

- – IP67 and IP69K – Available as safety stop (black push button) 

The emergency stop complemented with a robust enclosure gives a high IP rating that fulfills the demands in severe and moist environments, such as food and beverage industry. This unit is also available with a black push button and a grey enclosure and is then used as a safety stop. See section on safety stops. 

## Adjustment for dynamic circuits 

If the emergency stops are used with Pluto or Vital, a Tina adaptation product can be used. Tina 2A, Tina 2B and Tina 3A all work with the Compact emergency stop and its enclosure. 

. 

Compact as a machine stop. See more infor- 

mation on section - Safety stop. 

11/17    2TLC172001C0202 | ABB Safety Handbook 

Technical data – Compact 

11 

|Technical data – Compact||
|---|---|
|Article number<br>Emergency stop and enclosure<br>(CEPY1-1002)<br>Emergency stop with enclosure and shroud<br>(CEPY1-2002)|1SFA619821R1002<br>1SFA619821R2002|
|Reset action|Pull release|
|Contact material|Silver|
|Termination Clamp|Up to 1.5 mm2conductors|
|Torque settings<br>Cable terminals<br>Nut (M22)|0.8 Nm<br>Min. 2 Nm, Max. 2.3 Nm|
|Conduit entries|2 x M20|
|Rated insulation/withstand voltages|300 V|
|Thermal current (lth)|5 A|
|Utilisation category|AC-15; 1 A (240 V), 1.5 A (120 V)<br>DC-13; 0.3 A (24 V), 0.2 A (125 V)|
|Short circuit overload protection|Max. fuse 16 A|
|Level of safety<br>B10d|50 000|
|Colour|Yellow, red, black and grey|
|Weight|135 g (with Shroud)<br>118 g|
|Size|Length: 65 mm<br>Width: 65 mm<br>Height: 78.1 mm (with Shroud 79.6 mm)|
|Ambient temperature|-25°C to +70°C (operation)<br>-30°C to +85°C (stock)|
|Protection class|IP66, IP67 and IP69K|
|Mounting|2 x M4|
|Mechanical life|50 000 operations|
|Accessories<br>Shroud Yellow (CA1-8053)<br>Shroud Grey (CA1-8054)<br>Tina 2A<br>Tina 2B<br>Tina 3A|1SFA619920R8053<br>1SFA619920R8054<br>2TLA020054R0100<br>2TLA020054R1100<br>2TLA020054R0200|
|Conformity|EN 60947-1:2007,  EN 60947-5-1:2004, EN 60947-5-5:1997+A1:2005|



Adaptation units: Tina 2A and Tina 3A 

ABB Safety Handbook | 2TLC172001C0202   11/18 

Emergency stop EStrongZ 

11 _ 

## Approvals: 

**==> picture [37 x 18] intentionally omitted <==**

**----- Start of picture text -----**<br>
TÜV<br>Rheinland<br>**----- End of picture text -----**<br>


**==> picture [22 x 5] intentionally omitted <==**

**----- Start of picture text -----**<br>
(X-versions)<br>**----- End of picture text -----**<br>


## Application: 

- To stop a machine or a process 

## Features: 

- Compact and robust 

- Universal installation 

- Stainless steel 

- LED status indication (optional) 

- 2NO + 2NC 

- EX version 

## Switch operational description 

The EStrongZ is an emergency stop designed to provide a robust unit in exposed and severe environments. Perfect for industries that have special demands. 

The contact block configuration is a 2NC and 2NO and the emergency stop is mounted with 4 x M4 screws from the inside. 

The EStrongZ has a special lid that is mechanical linked to the emergency stop safety mechanism. This means that the safety contacts will open if the lid is removed. An optional feature gives the EStrongZ a two colour LED that can be seen easily from a distance. 

## Material 

The EStrongZ is available in a total rugged stainless steel 316 body, developed for applications such as food processing and chemical industry. With a double seal lid gasket and seals, the EStrongZ has an IP69K enclosure protection and therefore can be high pressure hosed with detergent at high temperature. 

## Explosion Proof version (X) 

EStrongZ also exist in versions with certified explosion proof contact block (X-versions). EStrongZX have a stainless steel body and can be used in European Zone 1, 2, 21, 22 enviroments (Gas and Dust). Preassembled with 3 meter cable. 

## Regulations and Standards 

The EStrongZ is designed and approved in accordance to relevant standards. Examples of relevant standards are IEC/EN 60947-5-1, IEC/EN 60947-5-5, EN 62061, UL 508, EN ISO 13850 and EN ISO 13849-1. 

11/19    2TLC172001C0202 | ABB Safety Handbook 

11 

## Technical data – EStrongZ series 

|Technical data – EStrongZ seriesgZ seriesZ series||
|---|---|
|Article number<br>EStrongZ<br>EStrongZ (LED)<br>EStrongZX|2TLA050220R0020<br>2TLA050220R0222<br>2TLA050220R0025|
|Level of Safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e/Cat. 4 depending upon system architecture<br>Up to SIL3 depending upon system architecture|
|Safety data<br>Mechanical reliability B10d<br>Proof test interval (life) MTTFd|1.5 x 106operations at 100mA load 21 years<br>214 years (8 cycles per hour/24 hours per day/365 days|
|Torque settings|Mounting M5 4.0Nm, Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm|
|Termination|Clamp up to 2.5 mm2conductors|
|Short circuit overload protection|Fuse externally 10A (FF)|
|Rated insulation/withstand voltages|500VAC / 2500VAC|
|Utilisation category|AC15 A300 3A|
|Shock resistance|15 g 11 ms|
|Thermal current (lth)|10A|
|Conduit entries|3 x M20|
|Enclosure classification|IP67 and IP69K|
|Operating temperature|-25°C to +80°C|
|Weight|820 g|
|Contact type|IEC/EN 60947-5-1 double break typ Zb snap action|
|Contact material|Silver|
|Enclosure / Cover|Stainless steel 316|
|Mounting position|Any|
|Mounting bolts|4 x M4|
|Explosion Proof version (X)<br>Classification Ex d IIC T6<br>Rated Voltage<br>Rated Current|(-20°C ≤ Ta ≤ +60°C) Gb Ex tb IIIC T85°C (-20°C ≤ Ta ≤ +60°C) Db<br>250V AC/DC<br>2 pole 4A<br>4 pole 2.5A|



EStrongZ (LED) 

EStrongZ 

Dimensions EStrongZ (LED) 

ABB Safety Handbook | 2TLC172001C0202   11/20 

## Safety stop INCA, Smile and Compact 

## Approvals: 

## Application: 

- To make a safe stop of a machine or a process 

## Features: 

- Safe machine stop with black push button 

- With LED info in push button 

- Up to IP69K 

- Info output (Tina) 

## When should I use the safety stop? 

Safety stops are used to stop the operation of a machine in a safe manner. It must not be used as an emergency stop, but only as a stop for an individual hazardous motion. This is indicated by black push button. Likewise, an emergency stop push button with red push button must not be used as a safety stop. 

## INCA machine stop for panel mounting 

The INCA series is available with black push button and is 11 called INCA 1S/INCA 1S Tina. The safety stop is identical to the corresponding emergency stop apart from the black push button. For technical data see the INCA emergency stop. 

## Smile machine stop with indication 

The Smile emergency stop series is also available with black push button as safety stops. These stops are identical to the corresponding emergency stops apart from the button. The Smile with the black push button has a similar designation apart from an S in the name instead of E. For technical data see the Smile emergency stop. 

|Model|Article number|
|---|---|
|Smile 11 SA|2TLA030051R0900|
|Smile 12 SA|2TLA030051R1000|
|Smile 11 SAR|2TLA030051R1100|
|Smile 11 SA Tina|2TLA030050R0500|
|Smile 12 SA Tina|2TLA030050R0600|
|Smile 11 SAR Tina|2TLA030050R0700|
|Smile 12 SAR Tina|2TLA030050R0800|
|Smile 11 SA AS-i|2TLA030052R0100|
|||
|Model|Article number|
|INCA 1S|2TLA030054R0300|
|INCA 1S Tina|2TLA030054R0200|
|||
|Model|Article number|
|Machine stop and enclosure<br>(CEP1-1002)|1SFA619811R1002|
|Machine stop with enclosure and<br>shroud (CEP1-2002)|1SFA619811R2002|



## The Compact Machine stop with an enclosure 

This machine stop comes from the Compact range of ABB:s Pilot Devices, built on the ”All-in-one design”. The black machine stop complemented with a robust enclosure gives a high IP rating the fulfills the demands in severe and moist environments. The machine stop has one normal open and one normally closed contact (1NO+1NC). For technical data see the Compact emergency stop. 

11/21    2TLC172001C0202 | ABB Safety Handbook 

11 

## Reset button Approvals: Smile 11 R ~~—~~ Application: – Reset push button =. Features: – With LED info in push button – IP65 – Adapted version for the Pluto feature “light button” ar ~~e~~ Smile push button box with a blue button are intended to be a Technical data – Smile 11 RA/B reset button to safety circuits. Article number 

## Approvals: ~~—~~ 

|Article number<br>Smile 11 RA<br>Smile 11 RB|2TLA030053R0000<br>2TLA030053R0100|
|---|---|
|Color<br>Base<br>Pushbutton|yellow<br>blue|
|Material<br>Housing<br>Pushbutton contact|Polyprobylene PP<br>Au|
|Power Supply<br>LED operating voltage<br>LED current consumption<br>Pushbutton operating voltage<br>Pushbutton current consumption<br>Pushbutton rated power|24 VDC (maximum 33 VDC)<br>20 mA at 24 VDC<br>30 mA at 33 VDC<br>Min: 5 V, max: 35 V<br>Min: 1 MA, max 100 mA<br>Max: 250 mW|
|Ambient temperature|-25...+55°C|
|Humidity range|35 to 85% (with no icing or conden-<br>sation)|
|Protection class|IP65|
|Connectors|5-pole male M12 connector|
|Size|84 x 40 x 36 (LxWxH) + 12 mm for<br>M12 connector (L)|
|Weight|Approx. 60 g|
|Mechanical life|1.000.000 operations at<br>10 mA/24 VDC|
|Switching reliability|10 x 10-6at 5 mA/24 VDC|



## Smile 11 RA 

The Smile 11 RA is an ”open” reset push button box with one circuit for connections though a normally open contact and one circuit for connection of the indication LED in the push button. 

## Smile 11 RB 

The Smile 11 RB is a reset push button box adapted to be use together with the Safety PLC Pluto. 

The Safety PLC Pluto has a function called “Light button” which is used in order to reduce the numbers of terminals on the Pluto. With this function, one terminal can be used both as an input for the reset as well as output for controlling the LED. This function demands special connection for the reset button and its light indication, which the Smile 11 RB offers. 

ABB Safety Handbook | 2TLC172001C0202   11/22 

## Emergency Stop Grab Wire Safety Switches 

## Application 

ABB Jokab Safety Emergency stop grab wire safety switches are designed to be mounted on machines and sections of conveyors which can not be protected by guards. In contrast to traditional mushroom head type Emergency stop buttons, Emergency stop grab wire safety switches can initiate the emergency command from any point along the installed wire length, and thereby provide robust emergency stop protection for exposed conveyors and machines. 

The switches have a positive mechanical linkage between the switch contacts and the wire rope. The switches also include wire-breakage monitoring. This means, on pulling or breakage (tension loss) of the wire, the safety contacts are positively opened and the auxiliary contacts are closed. The switches are mechanically latched and can then only be returned to the operational condition by pressing the reset button as required according to EN ISO 13850 (EN 418). 

## System set up 

Wire support eyebolts must be fitted at 2.5-3 meters intervals along the hole wire length and the wire must be supported no more than 500 mm from the switch eyebolt or Safety Spring (if used). It is important that the first 500 mm not are used as part of the active protection coverage. When using one switch, the wire must be anchored at the other end using a Safety spring. When using a Safety spring, a maximum of one corner pulley may be used, to ensure that the complete length of the wire is visible to either the switch or the spring anchorage. The emergency stop switches are brought into the operational condition by pre-tensioning the wire by using a tensioner / gripper device which clamps the wire and then 11 hooks to the switch eyebolts. Correct tension can be observed by viewing the tension indicator on the switch housing. Once tensioned, the switch contact blocks can be set to the operational condition (safety contacts closed, auxiliary contacts open) by pressing a blue reset button on the switch cover. 

## Safety level 

All ABB Jokab Safety Emergency stop grab wire safety switches conform to European Standard EN ISO 13850 (EN 418) and IEC/EN 60947-5-5. They have a positive mechanical linkage between the switch contacts and the wire rope as per IEC/EN 60947-5-1. 

In combination with a dual channel safety monitoring relay (or safety PLC) an Emergency stop grab wire system can be used as emergency stop device monitored for up to PL e, Cat 4 according to EN ISO 13849-1. 

**==> picture [145 x 117] intentionally omitted <==**

**----- Start of picture text -----**<br>
3<br>2<br>1<br>4<br>**----- End of picture text -----**<br>


1. Tension indicator -Ensures the system is easy to set up and maintain the correct wire tension. 

2. Reset button -The blue button must be pushed to reset the switch following activation by pulling or slackening of the wire. 

3. Indicator LED -Can be wired to flash red in the event of the wire being pulled-switch activated, or illuminate steady green to indicate a reset switch in machine 'Run' state. Visible from long distances. 

4. Mushroom type Emergency stop button -Can be installed or repositioned left or right after installation. 

Wiring diagram for LED 

**==> picture [459 x 82] intentionally omitted <==**

**----- Start of picture text -----**<br>
Inactive zone Inactive zone<br>Zone of protection<br>(500 mm)  (500 mm)<br>Eyebolt<br>Wire<br>1@ 2 [Same a + — $< ree<br>Slack Pull<br>Tensioner / Gripper Pull v Quick Link Safety Spring<br>**----- End of picture text -----**<br>


11/23    2TLC172001C0202 | ABB Safety Handbook 

11 

## Reliable connectivity 

When setting up an Emergency stop grab wire system from ABB Jokab Safety it is recommended to do the tensioning of the wire by using of ABB Jokab Safety Tensioner / Gripper accessory. Traditional grab wire systems normally need turnbuckle and clamps, which are difficult to tension and adjust, and also normally require frequent re-tensioning. 

For greater reliability and ease, of installation the Tensioner / Gripper accessory significantly reduces the installation time. This by offering an eyehook, tensioner thimble and wire strength gripper in one assembly which enables rapid connection to the switch eyebolts and fast and accurate tensioning of the wire. Thanks to the switch viewing window, systems can be accurately and quickly tensioned. The double clamp mechanism prevents wire slippage and significantly reduces machine 'down time' which can occur which traditional turnbuckle systems. 

**==> picture [105 x 77] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>= 7<br>2<br>3<br>**----- End of picture text -----**<br>


Wire Tensioner / Gripper, Stainless Steel article no: 2TLA050210R4020, Wire Tensioner / Gripper, Galvanized article no: 2TLA050210R4030. 

## Tensioner / Gripper installation 

The end of the safety wire is fed through a central hole in a cone shaped guide which protrudes from the main housing. After being fed through the guide hole, the wire enters the main housing by going through a feed hole and then is looped back through 180 degrees and is fed through a second feed hole on the opposite side of the mechanism. The wire is then pulled for maximum tension and is locked in position by a locking bar inside the main housing which is moved by turning an Allen type locking bolt. 

## Navigating Corners 

Because of the added friction on the eyebolts and wire when navigating corners, a corner pulley can be used to navigate inside or outside corners without causing damage to the wire. They are stainless steel and can be rigidly mounted. 

1. Tension to mid position as indicated by the green arrows in the viewing window of each switch. 

2. The tensioner thimble allows immediate accurate and final tensioning of the wire, whilst viewing the tension marker through the viewing window on the switch. 

3. For systems up to 50 meter Quick Link termination is provided for easy connection to either a Safety spring or Switch eyebolt. (Note for systems above 50 meter a Tensioner / Gripper is required each side). 

**==> picture [303 x 115] intentionally omitted <==**

**----- Start of picture text -----**<br>
Machine<br>.a<br>a-_— —<br>Outside<br>Inside Corners Machine<br>Corners<br>Machine<br>Examples of using the corner pulley<br>Machine<br>**----- End of picture text -----**<br>


**==> picture [87 x 16] intentionally omitted <==**

**----- Start of picture text -----**<br>
Outside<br>Machine<br>Corners<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/24 

## Emergency Stop Grab Wire Safety Switch LineStrong1 

## Approvals: 

## Application: 

– Machines 

- Transportation lines 

## Features: 

- Easily accessible 

- Forced contacts 

- Double switching in both directions of travel 

- Up to 50 m Wire length 

- IP67 

- 2NO + 2NC 

## Switch operational description 

LineStrong1 is an emergency stop grab wire safety switch used for easy reach of an emergency stop along machines, conveyors and processes. LineStrong1 is a compact and small, yet robust switch that can handle wires up to 30 meters on a single switch (up to 50 meters on two switches). 

A grab wire emergency stop is easier to install than a system of several emergency stop buttons along a carriage path. 11 _ LineStrong1 can be used as protection, for example along a conveyors with low risks where the wire can be installed at waist height in front of the conveyor, which provides an emergency stop if someone walks or falls towards the conveyor. LineStrong1 has double switching in both directions of the wire. So if someone pulls the wire or if the wire is broken, the switch goes to a safe state, e.g. the machine is emergencystopped. After a safe state the LineStrong1 needs to be reset to be able to run again and this is made on the local reset button. LineStrong1 is equipped with an indication of how taut the wire is, which make the installation or adjustment easy. 

not fail or be held in a normally closed position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong1 switch has 2NC and 2NO contacts. 

## Safety level 

The forced disconnected contacts provide a high level of safety. To achieve a maximum safety level in connection with the machine control system, it is recommended that the LineStrong1 is monitored by an appropriate ABB Jokab Safety safety relay, Pluto safety-PLC or a Vital system. 

## Regulations and Standards 

The LineStrong1 is designed and approved in accordance to relevant standards. Examples of relevant standards are IEC/EN 60947-5-1, IEC/EN 60947-5-5, EN 62061, UL 508, EN ISO 13850 and EN ISO 13849-1. 

## Material 

The LineStrong1 is made a rugged die cast housing with a rating of IP67. 

## Positive forced disconnected contacts 

A positive forced contact provides a forced disconnect of the safety contacts when the wire is being pulled or broken. The design of the LineStrong1 ensures that the contacts will 

Emergency stop grab wire easily accessible during normal work operation along a machine. 

11/25    2TLC172001C0202 | ABB Safety Handbook 

11 

Technical data – LineStrong1 series 

|Technical data – LineStrong1 series||
|---|---|
|Article number<br>LineStrong1|2TLA050200R0030|
|Level of Safety<br>EN ISO 13849-1<br>EN 62061|Up to PL e /Cat. 4 depending upon system architecture<br>Up to SIL3 depending upon system architecture|
|Safety data<br>Mechanical reliability B10d<br>Proof test interval (life) MTTFd|1.5 x 106operations at 100mA load 21 years<br>214 years (8 cycles per hour/24 hours per day/365 days)|
|Wire span|up to 50 m|
|Wire tension device|Tensioner / Gripper- Quick Fixing|
|Wire type|PVC sheath steel wire 4.0 mm outside diameter|
|Torque settings|Mounting M5 4.0Nm,  Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm|
|Termination|Clamp up to 2.5 mm2conductors|
|Tension force (typical mid setting)|130N|
|Tension operating force (wire pulled)|< 125N < 300 mm deflection|
|Short circuit overload protection|Fuse externally 10 A (FF)|
|Rated insulation/withstand voltages|500 VAC / 2500 VAC|
|Utilisation category|AC15 A300 3A|
|Vibration resistance|10-500 Hz 0.35 mm|
|Shock resistance|15 g 11 ms|
|Thermal current (lth)|10A|
|Contact type|IEC/EN 60947-5-1 double break Typ Zb snap action|
|Contact material|Silver|
|Conduit entries|3 x M20 x 1.5|
|Enclosure classification|IP67|
|Ambient temperature|-25°C to +80°C|
|Enclosure material/cover|Die cast painted yellow|
|Mounting position|Any|
|Mounting bolts|4 x M5|



Dimension LineStrong1 

up to 50 meter 500 mm every 3 meter every 3 meter 500 mm —| eyebolt 7 / {_1i T 1 me up to 30 meter 500 mm every 3 meter every 3 meter 500 mm ee eyebolt Safety Spring oe | 

ABB Safety Handbook | 2TLC172001C0202   11/26 

## Emergency Stop Grab Wire Safety Switch LineStrong2 

## Approvals: 

**==> picture [22 x 5] intentionally omitted <==**

**----- Start of picture text -----**<br>
(X-versions)<br>**----- End of picture text -----**<br>


## Application: 

– Machines 

- Transportation lines 

## Features: 

- Duplicate extraction in two directions 

- Up to 100 m length 

- Up to IP69K 

- Integrated emergency stop button 

- 2NO + 2NC 

- EX version 

## Switch operational description 

LineStrong2 is an emergency stop grab wire safety switch used for easy reach of an emergency stop along machines, conveyors and processes. LineStrong2 is a robust switch that can handle wires up to 80 meters on a single switch (up to 100 meters on two switches). A grab wire emergency stop is easier to install than a system of several emergency stop buttons along a carriage path. LineStrong2 can be used as protection, for example along conveyors with low risks, where the wire can be installed at waist height in front of the conveyor, which provides an emergency stop if someone 11 _ walks or falls towards the conveyor. LineStrong2 has double switching in both directions of the wire. If someone pulls the wire or if the wire is broken, the switch goes to a safe state, e.g. the machine is emergency-stopped.  After a safe state the LineStrong2 needs to be reset to be able to run again and this is made with the local reset button. Additional features on the LineStrong2 are a "normal" emergency stop that is fitted on the side of the grab wire safety switch and also a two coloured LED for indication. LineStrong2 is equipped with an indication of how taut the wire is, which make the installation and adjustment easy. 

## Material 

Depending on the environment where the switch will be used, different material can be chosen for the LineStrong2. The basic version has a rugged yellow die cast housing with a rating of IP67. In severe applications as for food processing and chemical industry there is a LineStrong2Z with a total rugged stainless steel 316 body. This version has IP69K enclosure protection (maintained by a double seal lid gasket and seals) 

and can be high pressure hosed with detergent at high temperature. 

## Positive forced disconnected contacts 

A positive forced contact provides a forced disconnect of the safety contacts when the wire is being pulled or broken. The design of the LineStrong2 ensures that the contacts will not fail or be held in a normally closed position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong2 switch has 2NC and 2NO contacts. 

## Safety level 

The forced disconnected contacts provide a high level of safety. To achieve a maximum safety level in the connection with the machine control system, it is recommended that the LineStrong2 is monitored by an appropriate ABB Jokab Safety safety relay, Pluto safety-PLC or a Vital system. 

## Explosion Proof version (X) 

LineStrong2 also exist in versions with certified explosion proof contact block (X-versions). LineStrong2ZX have a stainless steel body and can be used in European Zone 1, 2, 21, 22 enviroments (Gas and Dust). Preassembled with 3 meter cable. 

## Regulations and Standards 

The LineStrong2 is designed and approved in accordance to relevant standards. Examples of relevant standards are IEC/EN 60947-5-1, IEC/EN 60947-5-5, EN 62061, UL 508, EN ISO 13850 and EN ISO 13849-1. 

11/27    2TLC172001C0202 | ABB Safety Handbook 

11 

Technical data – LineStrong2 series 

|Article number<br>LineStrong2|2TLA050202R0332|Contact type|IEC/EN 60947-5-1 double break<br>Typ Zb snap action|
|---|---|---|---|
|LineStrong2Z|2TLA050202R0322|Contact material|Silver|
|LineStrong2ZX (EX)|2TLA050202R7125|Conduit entries|3 x M20 x 1.5|
|Level of Safety<br>EN ISO 13849-1|Up to PL e/Cat. 4 depending<br>upon system architecture|Enclosure classification<br>LineStrong2<br>LineStrong2Z(X)|IP67<br>IP69K and IP67|
|EN 62061|Up to SIL3 depending upon<br>system architecture|Ambient temperature:<br>LineStrong2|-25°C to +80°C|
|Safety data||LineStrong2Z(X)|-25°C to +80°C (100°C cleaning)|
|Mechanical Reliability B10d<br>Proof test interval (life)|1.5 x 106operations at 100mA<br>load<br>21 years|Enclosure material/cover<br>LineStrong2<br>LineStrong2Z(X)|Die cast painted yellow<br>Stainless steel 316|
|MTTFd<br>Wire span<br>LineStrong2<br>LineStrong2Z(X)<br>Wire tension device<br>Wire type<br>Torque settings|214 years (8 cycles per hour/24<br>hoursper day/365 days)<br>Up to 80 m<br>Up to 100 m<br>Tensioner / Gripper- Quick<br>Fixing<br>PVC sheath steel wire 4.0 mm<br>outside diameter<br>Mounting M5 4.0Nm|Mounting position<br>Mounting bolts<br>Explosion Proof version (X)<br>Classification<br>Rated Voltage<br>Rated Current|Any<br>4 x M5<br>Ex d IIC T6<br>(-20°C ≤ Ta ≤ +60°C) Gb<br>Ex tb IIIC T85°C<br>(-20°C ≤ Ta ≤ +60°C) Db<br>250V AC/DC<br>2 pole 4A<br>4 pole 2.5A|
||lid T20 Torx M4 1.5Nm<br>terminals 1.0Nm|||
|Termination|Clamp up to 2.5 mm2conduc-<br>tors|||
|Tension force (typical mid setting)|130N|||
|Tension operating force (wire pulled)|< 125N < 300 mm deflection|||
|Short circuit overload protection|Fuse extenally 10A (FF)|||
|Rated insulation/withstand voltages|500VAC / 2500VAC|||
|Utilisation category|AC15 A300 3A|||
|Vibration resistance|10-500Hz 0.35 mm|||
|Shock resistance|15 g 11 ms|||
|Thermal current (lth)|10A|||
|LED|24 VDC|||



**Dimensions LineStrong2 and LineStrong2Z** 

**==> picture [434 x 170] intentionally omitted <==**

**----- Start of picture text -----**<br>
up to 80 meter<br> LineStrong2<br>up to 100 meter<br>LineStrong2Z<br>500 mm every 3 meter every 3 meter 500 mm<br>eyebolt<br>up to 60 meter<br>LineStrong2<br>up to 80 meter<br>LineStrong2Z<br>500 mm every 3 meter every 3 meter 500 mm<br>be-—-—_.TT eyebolt —______+_//| 7 cr|_____1_ Safety Spring T =i<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/28 

## Emergency Stop Grab Wire Safety Switch LineStrong3 

## Approvals: 

**==> picture [22 x 5] intentionally omitted <==**

**----- Start of picture text -----**<br>
(X-versions)<br>**----- End of picture text -----**<br>


## Application: 

- Machines 

- Transportation lines 

## Features: 

- Duplicate extraction in two directions 

- Up to 250 m length 

- Up to IP69K 

- Intergrated emergency stop button 

- 4NC + 2NO 

- EX version 

## Switch operational description 

LineStrong3 is an emergency stop grab wire safety switch used for easy reach of an emergency stop along machines, conveyors and processes. LineStrong3 is a quite robust switch that can handle long wires, up to 250 meters on a single switch. A grab wire emergency stop is easier to install than a system of several emergency stop buttons along a carriage path. LineStrong3 can be used as protection, for example along conveyors, with low risks where the wire can be installed at waist height in front of the conveyor, which provides an emergency stop if someone walks or falls towards 11 the conveyor. 

rugged stainless steel 316 body. This version has IP69K enclosure protection (maintained by a double seal lid gasket and seals) and can be high pressure hosed with detergent at high temperature. 

## Positive forced disconnected contacts 

A positive forced contact provides a forced disconnect of the safety contacts when the wire is being pulled or broken. The design of the LineStrong3 ensures that the contacts will not fail or be held in a normally closed position, due to failure of the spring mechanism or that welding/sticking of the contacts can occur. The LineStrong3 switch has 4NC and 2NO. 

LineStrong3 has double switching in both directions of the wire. If someone pulls the wire or if the wire is broken, the switch goes to a safe state, e.g. the machine is stopped. 

After a safe state the LineStrong3 needs to be reset to be able to run again and this is made on the local reset button. Additonal features on the LineStrong3 is a "normal" emergency stop fitted on the top of the grab wire safety switch and also a two coloured LED for indication. 

LineStrong3 is equipped with an indication of how taut the wire is, which make the installation and adjustment easy. 

## Safety level 

The forced disconnected contacts provide a high level of safety. To achieve a maximum safety level in the connection with the machine control system, it is recommended that the LineStrong3 is monitored by an appropriate ABB Jokab Safety safety relay, Pluto safety-PLC or a Vital system. 

## Explosion Proof version (X) 

LineStrong3 also exist in versions with certified explosion proof contact block (X-versions). LineStrong3LZX/RZX/DZX have a stainless steel body and can be used in European Zone 1, 2, 21, 22 enviroments (Gas and Dust). Preassembled with 3 meter cable. 

## Material 

Depending on the environment where the switch will be used, different materials can be chosen for the LineStrong3. The basic version has a rugged yellow die cast housing with a rating of IP67. In severe applications as for food processing and chemical industry, there is a LineStrong3Z with a total 

## Regulations and Standards 

The LineStrong3 is designed and approved in accordance to relevant standards. Examples of relevant standards are IEC/EN 60947-5-1, IEC/EN 60947-5-5, EN 62061, UL 508, EN ISO 13850 and EN ISO 13849-1. 

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## Single Wire LineStrong3L/3R and LineStrong3LZ/3RZ 

## LineStrong3L/3R - Standard version 

**==> picture [253 x 8] intentionally omitted <==**

**----- Start of picture text -----**<br>
Left hand  Right hand<br>**----- End of picture text -----**<br>


The Linestrong3L/3R are two different versions depending on installation. 

L - "Left hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the left in the installation. 

R - "Right hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the right in the installation. 

Both versions have die-cast housings and are robust to severe indoor or outdoor use. LineStrong3L/3R are designed to protect a length up to 100 meters on a single switch. If two switches are used together, up to 125 meters. A two colour LED ensures switch status can be seen easily from a distance. They have 4NC and 2NO contacts to ensure flexibility with all modern control application. 

## LineStrong3LZ/3RZ - Stainless steel version 

The Linestrong3LZ/3RZ are two stainless steel switches with different installations possibilites. 

L - "Left hand" - is the version of LineStrong3Z where the placement of the grab wire switch is to the left in the installation. 

R - "Right hand" - is the version of LineStrong3Z where the placement of the grab wire switch is to the right in the installation. 

Both versions are in stainless steel 316 housings and are designed specifically to withstand the tough environments found in the food and pharmaceutical industries. LineStrong3LZ/3RZ are designed to protect a length up to 100 meters on a single switch. If two switches are used together, up to 125 meters. A two colour LED ensures switch status can be seen easily from a distance. They have 4NC and 2NO contacts to ensure flexibility with all modern control application. 

Dimensions LineStrong3L/R and LineStrong3LZ/RZ 

**==> picture [527 x 137] intentionally omitted <==**

**----- Start of picture text -----**<br>
up to 125 meter<br>Left hand  Right hand<br>side 500 mm every 3 meter every 3 meter 500 mm side<br>eyebolt<br>up to 100 meter<br>TT 500 mm every 3 meter e every 3 meter e 500 mm<br>ee<br>eyebolt Safety Spring<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202   11/30 

11 

## Double Wire LineStrong3D and LineStrong3DZ 

## LineStrong3D - Standard version 

The Linestrong3D is a third version of the Linstrong3. With wire entries from both sides of the grab wire switch, LineStrong3D can be used for a long protection length. The LineStrong3D has a die-cast housing and is robust to manage severe indoor or outdoor use. LineStrong3D is designed to protect a length up to 200 meters on a single switch. If several switches are used together, it will be possible with a length up to 125 meters between the switches. A two colour LED ensures switch status can be seen easily from a distance. LineStrong3D have 4NC and 2NO contacts to ensure flexibility with all modern control application. 

## LineStrong3DZ - Stainless steel version 

The Linestrong3DZ is a third version of the Linstrong3Z. As a stainless steel version with wire entries on both sides of the grab wire switch, LineStrong3DZ can be used for a long protection length. 

The LineStrong3DZ has stainless steel 316 housing and is designed specifically to withstand the tough environments found in the food and pharmaceutical industries. LineStrong3DZ is designed to protect a length up to 200 meters on a single switch. If several switches are used together it will be possible with a length up to 125 meters between the switches. A two colour LED ensures switch status can be seen easily from a distance. LineStrong3DZ have 4NC and 2NO contacts to ensure flexibility with all modern control application. 

**Dimensions LineStrong3D and LineStrong3DZ** 

**==> picture [481 x 148] intentionally omitted <==**

**----- Start of picture text -----**<br>
up to 125 meter up to 125 meter<br>500 mm every 3 meter 500 mm 500 mm every 3 meter 500 mm 500 mm<br>eyebolt<br>up to 100 meter up to 100 meter<br>500 mm CL every 3 meter —r 500 mm rT 500 mm every 3 meter + 500 mm<br>Safety Spring eyebolt Safety Spring<br>**----- End of picture text -----**<br>


11/31    2TLC172001C0202 | ABB Safety Handbook 

Technical data – LineStrong3 series 

**==> picture [528 x 660] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>LineStrong3L 2TLA050206R0332<br>LineStrong3R 2TLA050208R0332<br>LineStrong3LZ 2TLA050206R0322<br>LineStrong3RZ 2TLA050208R0322<br>LineStrong3LZX (EX) 2TLA050204R7125<br>LineStrong3RZX (EX) 2TLA050206R7125<br>LineStrong3D 2TLA050204R0332<br>LineStrong3DZ 2TLA050204R0322<br>LineStrong3DZX (EX) 2TLA050208R7125<br>Level of Safety<br>EN ISO 13849-1 Up to PL e, Cat. 4 depending upon system architecture<br>EN 62061 Up to SIL3 depending upon system architecture<br>Safety data<br>Mechanical reliability B10d 1.5 x 10 [6]  operations at 100mA load 21 years<br>Proof test interval (life) MTTFd 214 years (8 cycles per hour/24 hours per day/365 days)<br>Wire span<br>LineStrong3L/R/LZ(X)/RZ(X) Up to 125 m<br>LIneStrong3D/DZ(X) Up to 250 m<br>Wire tension device Tensioner / Gripper- Quick Fixing<br>Wire type PVC sheath steel wire 4.0 mm outside diameter<br>Torque settings Mounting M5 4.0Nm, Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm<br>Termination Clamp up to 2.5 mm2 conductors<br>Tension force (typical mid setting) 130N<br>Tension operating force (wire pulled) < 125N < 300 mm deflection<br>Short circuit overload Protection Fuse extenally 10A (FF)<br>Rated insulation/withstand voltages 500VAC / 2500VAC<br>Utilisation category AC15 A300 3A<br>Vibration resistance 10-500Hz 0.35 mm<br>Shock resistance 15 g 11 ms<br>Thermal current (lth) 10A<br>LED 24 VDC<br>Contact type IEC/EN 60947-5-1 double break Typ Zb snap action<br>Contact material Silver<br>Conduit entries 4 x M20 x 1.5<br>Enclosure classification<br>LineStrong3D/L/R IP67<br>LineStrong3LZ(X)/RZ(X)/DZ(X) IP69K and IP67<br>Ambient temperature:<br>LineStrong3L/R/D -25°C to +80°C<br>LineStrong3LZ(X)/RZ(X)/DZ(X) -25°C to +80°C (100°C cleaning)<br>Enclosure material/cover:<br>LineStrong3L/R/D Die cast painted yellow<br>LineStrong3LZ(X)/RZ(X)/DZ(X) stainless steel 316<br>Mounting position Any<br>Mounting bolts 4 x M5<br>Explosion Proof version (X)<br>Classification Ex d IIC T6  (-20°C ≤ Ta ≤ +60°C) Gb Ex tb IIIC T85°C  (-20°C ≤ Ta ≤ +60°C) Db<br>Rated Voltage 250V AC/DC<br>Rated Current 2 pole 4A<br>4 pole 2.5A<br>**----- End of picture text -----**<br>


11 

ABB Safety Handbook | 2TLC172001C0202   11/32 

11 a 

## Emergency Stop Grab Wire Safety Switch Accessories 

## Accessories 

|Accessories||
|---|---|
|Type|Article number|
|Wire pull kit includes:<br>Wire, Eyebolts, Tensioner /Gripper, Allen key<br>Galvanized wire pull kits<br>10 m wire kit<br>20 m  wire kit<br>80 m wire kit<br>100 m wire kit||
||2TLA050210R0130|
||2TLA050210R0330|
||2TLA050210R0630|
||2TLA050210R0730|
|Stainless steel wire pull kits<br>50 m wire kit<br>100 m wire kit|2TLA050210R0520|
||2TLA050210R0720|
|Wire only<br>10 m wire<br>80 m wire<br>100 m wire<br>1 m wire (order by length)|2TLA050210R2120|
||2TLA050210R2520|
||2TLA050210R2620|
||2TLA020034R0500|
|Wire Tensioner / Gripper<br>Tensioner / Gripper, galvanized<br>Tensioner / Gripper, stainless steel|2TLA050210R4030|
||2TLA050210R4020|
|Corner pulley<br>Corner pulley, galvanized<br>Corner pulley, stainless steel|2TLA050210R6030|
||2TLA050210R6020|
|Eyebolt<br>Eyebolt, M8 x 1.25, galvanized<br>Eyebolt, M8 x 1.25, stainless steel|2TLA050210R8030|
||2TLA050210R8020|
|General wire pull accessories<br>Safety spring, 220 mm long, stainless steel<br>Screw driver, Anti-Tamper, Torx T20|2TLA050211R0004|
||2TLA050211R0006|
|Gland and plug<br>M20 x 1.5 gland<br>M20 x 1.5 conduit plug|2TLA050040R0002|
||2TLA050040R0004|



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ABB Safety Handbook | 2TLC172001C0202   11/34 

12 _ 

12/1    2TLC172001C0202 | ABB Safety Handbook 

12 

## Contact edges, Bumpers and Safety mats 

**==> picture [258 x 57] intentionally omitted <==**

**----- Start of picture text -----**<br>
|||
|---|---|
|When shall I use Contact edges, Bumpers and Safety mats?|12/3|
|Safety contact edges|12/4|
|Safety bumpers|12/7|
|Safety mats|12/9|
|Electrical connections|12/12|

**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202 12/2 

12 

## When shall I use Safety contact edges, Safety bumpers and Safety mats? 

## Contact edges and Bumpers 

Contact edges are used as protection against squeezing accidents, i.e. on moving machine parts and automatic doors and hatches. The strips come in customised lengths and various cross sections. 

Bumpers are used as safety buffers to protect against remote control transport vehicles and other dangerous moving objects that require long stopping distances. 

## § 

Standard: EN 1760-2 Safety of machinery - Pressure sensitive protective devices - Part 2: General principles for the design and testing of pressure sensitive edges and pressure sensitive bars 

## Safety mats 

Safety mats are used for protection around hazardous machinery. They are well suited for monitoring an area used for loading and unloading of material to a machine. 

## § 

Standard: EN 1760-1 Safety of machinery - Pressure sensitive protective devices - Part 1: General principles for the design and testing of pressure sensitive mats and pressure sensitive floors 

## Fields of Application 

12/3    2TLC172001C0202 | ABB Safety Handbook 

12 

## Safety contact edges 

## Approvals: ~~ee~~ 

## Application: 

- Protection against squeezing accidents on moving machine parts and automatic doors. 

## Features: 

- Can be connected to a safety relay, Vital or Pluto 

- Supplied in customized lengths 

- IP65 

- Simple assembly on site 

- Lengths up to 25 m. 

## General 

Safety contact edges are employed to guard closing edges at possible crushing or shearing points. They are used in gates, machines and handling facilities to protect people and equipment. They consist of an aluminium support profile, the contactor profile and the safety contact edge. 

## Contact edges with cast-in contact strips 

The safety contact edges GE series consist of a rubber profile with a cast-in contact strip. In the ends there are special connection plugs and terminal caps (End caps) adapted according to the rubber profile. The end components are glued together with a certain two component glue. The contact edge is mounted on an aluminium C-profile. The easy to handle subcomponents allows customer assemble of the GE contact edges, good for stock handling, but of course a preassembled contact edge can also be ordered. The GE series is available in EPDM design and can be supplied in lengths up to 25 m. 

## Material 

EPDM design that has a good resistance to ozone and weather, especially against chemicals. 

NBR has good resistance to oil and petrol. 

## Supervision 

The Safety Contact edge must be connected to a suitable two input channel Safety Relay. e.g. ABB Jokab Safety type RT6/RT7/RT9 which provides all necessary monitoring of the contact edges activation and detection of cable faults. The twin cable connection makes it possible to connect several contact edges in series. 

## Contact edges with contact strips SKS 18 

The safety contact edges GP series consists of a rubber profile with a separate safety contact strip (SKS 18) inside. The contact edge is mounted on an aluminium C-profile. The special design of profiles in EPDM or NBR rubber, protect the inner contact strip in the best way possible against damage and allows actuating angles to exceed 90°. GP series is normally supplied in lengths up to 6 m and is allways delivered preassembled. 

**==> picture [30 x 6] intentionally omitted <==**

**----- Start of picture text -----**<br>
Contact!<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202 12/4 

12 

## Contact edges GP - General 

The safety contact edges GP series consist of a contact strip, SKS 18. This is the actual contactor that is located inside the safety contact edge. The safety contact strip consist of a homogeneous highly insulating outer EPDM material and has two internal conducting contact surfaces. The conducting elastomer contains two copper wires that provide low-resistance detection even in lengths exceeding 100 m. Because of the contact points, the safety contact edge has approximate 20 mm of inactive length at each end. 

To provide protection against damage and to enable its proper use, the safety contact strip is inserted into the switching chamber of the rubber profile. The rubber profiles (EDPM or NBR) are then permanently sealed with a special elastic adhesive and end caps to make them watertight. The rubber profile is then mounted on the aluminium profile. The contact strip together with the rubber profile makes the GP safety contact edge. 

**==> picture [131 x 139] intentionally omitted <==**

**----- Start of picture text -----**<br>
Safety contact edge,<br> construction<br> Rubber profile<br>SKS 18 EE<br>Aluminium profile,<br>C-profile<br>**----- End of picture text -----**<br>


Safety contact strip SKS 18 

## Technical data - SKS 18 

|Technical data - SKS 18||
|---|---|
|Outer material<br>EPDM|EPDM,electrical insulation >30 Mohm|
|Inner material<br>EPDM|EPDM,electrical elastomer with reinforce copper wire|
|Conductivity<br>60 ohm / 100 meters|60 ohm / 100 meters|
|Contact resistance<br>a|approx. 50 ohm|
|Max. electrical load<br>24 V / 100 mA|24 V / 100 mA|
|Max. appliedpressure<br>6.5 N/cm2|6.5 N/cm2|
|Dimensions<br>18 x 6 mm|18 x 6 mm|



## Contact edges GE - General 

Inside the GE contact edge there is a cast-in contact strip that consists of two conductive alternating surfaces on the inside and a highly-effective insulating shell. There are two conductive wires in the contact surfaces that allow for low ohm measurements even when the contact edge has an extended length. The cast-in contact strip is protected against damage by the surrounding chamber. The cast end plugs ensure a permanent contact from the conductive surfaces in the contact strip. A special flexible adhesive is used to make the connector ring watertight. 

**==> picture [143 x 74] intentionally omitted <==**

**----- Start of picture text -----**<br>
Conductive<br>contact surface<br>Highly insu-<br>lated outer<br>material<br>Copper wire<br>**----- End of picture text -----**<br>


**==> picture [159 x 110] intentionally omitted <==**

**----- Start of picture text -----**<br>
Aluminium profile<br>Connection<br>plug<br>Connection<br>plug<br>Rubber profile with<br>n Terminal ail<br>integrated contact<br>cap strip<br>**----- End of picture text -----**<br>


## Technical data - Rubber profiles 

|Type<br>€|GP 25-25<br>€|GP 25-25<br>25<br>25<br>GP 25-40<br>25<br>€~~G1ee~~|GP 25-40<br>40<br>25<br>~~G1ee~~|GE 25-25<br>25<br>25<br>~~G1ee~~|GE 25-45<br>25<br>45<br>~~G1ee~~|
|---|---|---|---|---|---|
|FixingProfile|AL 25-14|AL 25-14<br>AL 25-14|AL 25-14|Al 25-14|Al 25-14|
|Material|EPDM/NBR|EPDM/NBR<br>EPDM/NBR|EPDM/NBR|EPDM|EPDM|
|Length max (m)|(1)<br>6(10)|6(10)<br>6(10)|6(10)|25|25|
|Weight (g/m)|370|370<br>480|480|510|770|
|Weight incl. C-Profile (g/m)|690|690<br>800|800|820|1080|
|Activation force (N)|(2)<br>34/37|34/37<br>39/52|39/52|64,1|69,1|
|Actuating distance (mm)|(3)<br>8.0/7.5|8.0/7.5<br>9.4/9.7|9.4/9.7|4,7|6,73|
|Braking distance (mm)|(3)<br>7.2/5.9|7.2/5.9<br>10.2/9.5|10.2/9.5|6.48|20.73|
|Max. actuating ( º )|(4)<br>2x 45º|2x 45º<br>2x 60º|2x 60º|2x20˚|2x20˚|



- (1)  10 m lengths of GP edges on request 

- (2)  Measured with ( Ø 80 mm test specimen),10 mm/s 

- (3)  Measuring speed 10 mm/s 

- (4)  Not including DIN 31006-2 

   - (GS - BE - 17) 

The selected contact profile should be mounted using a suitable aluminium C profile. 

NOTE! Contact us for other profile sizes. 

12/5    2TLC172001C0202 | ABB Safety Handbook 

Technical data - Contact edges Ordering Contact edges Article number GP – Contact edges including GP aluminium profile GP 25-25 EPDM per meter 2TLA076025R2500 When ordering a Contact edge GP it‘s made out of two parts. GP 25-25 NBR per meter 2TLA076125R2500 One article with production cost and cables and one article GP 25-40 EPDM per meter 2TLA076025R4000 with type of Contact edge in meter. Always specify length of GP 25-40 NBR per meter 2TLA076125R4000 safety edge. Cable, production cost 2+2 m cable 2TLA076009R0100 Example (complete and assembled): 5+5 m cable 2TLA076009R0500 1 pcs GP 25-25 EPDM, length 0.25 m, 5+5 m cable = – 7+7 m cable 2TLA076009R0800 0.25 m of 2TLA076025R2500 (Contact edges+alu.profile) – 10+10 m cable 2TLA076009R1000 1 pcs of 2TLA076009R0500 (cables and assemble) Contact us for more options Article number GE GE – Contact edges When ordering a Contact edge GE it‘s necessary to orGE 25-25 EPDM per meter 2TLA076005R0200 der every part specifically. Type of contact edge (in meter), GE 25-45 EPDM per meter 2TLA076005R0400 aluminium profile (in meter), connection plugs (one for each Connection plug with: end) and end caps (one for each end). If desired it can be 2.5 m cable 2TLA076005R4400 assemble by ABB Jokab Safety, for a production cost. Always 5 m cable 2TLA076005R4500 specify length of safety edge. Accessories for GE is ordered 10 m cable 2TLA076005R4600 separately. resistor 8.2kΩ 2TLA076005R4700 End cap End cap for GE 25-25 2TLA076005R6200 Example (complete and assembled): End cap for GE 25-45 2TLA076005R6100 1 pcs GE 25-45 EPDM, length 1.35 m, 2.5+5 m cable =– 1.35 m of 2TLA076005R0400 (Contact edges)[1] Others – Al 25-14 aluminum profile 2TLA076002R0200 1.35 m of 2TLA076002R0200 (Aluminum profile)[2] – Prod. cost GE (when ready made) 2TLA076008R0000 1 pcs of 2TLA076005R4400 (2.5 m cable)[3] – Accessories 1 pcs of 2TLA076005R4500 (5 m cable)[4] – Glueing set small 5 gr/5 ml 2TLA076005R7600 2 pcs of 2TLA076005R6100 (End cap)[5] – Glueing set large 20 gr/10 ml 2TLA076005R7700 1 pcs of 2TLA076008R0000 (Prod. cost GE) Scissor 2TLA076005R8500 Plug insert too 2TLA076005R8600 Mechanical load max[ 1] 500 N 2 Actuating angle (DIN)[1] 2x 20º 3 Mechanical life[1] 10[5] Max. operate temp. range[2] -20Cº to +55ºC Max. temperature range -25ºC to +70ºC Protection classification IP65 5 Max. electrical load 24 VDC 100mA 4 Resistance 0.6  Ohm/m Conductors GP: 2x 0.38 mm[2] 1 GE: 2x 0.34 mm[2] 5 12 Conductors insulation material GP: PVC GE: PUR matte black According to DIN 31006-2 (GS - BE - 17) Not including DIN 31006-2 (GS - BE - 17) ABB Safety Handbook | 2TLC172001C0202 12/6 ~~=~~ 

- 1 According to DIN 31006-2 (GS - BE - 17) 

- 2 Not including DIN 31006-2 (GS - BE - 17) 

## Safety bumpers 

## Approvals: 

## Application: 

- Protection against squeezing accidents on moving machine parts and automatic doors. 

## Features: 

- Can be connected to a safety relay, Vital or Pluto 

- Customized lengths 

- Customized shape 

- IP65 

- Lengths up to 3 m 

## Safety bumpers 

Safety bumpers are safety equipment on transport vehicles, FTS vehicles, highreach forklifts, freely moving systems, and everywhere where the safety systems require larger form alterations. When running against an obstacle, the short response time of the bumper initiates an immediate controller stop, while the bumper’s soft foam core provides a long braking and run out path. This provides optimum protection for individuals and materials. The exterior surface is available as PU or NBR rubber. Standard colours for the PU exterior are either black or black with yellow stripes. The NBR rubber exterior is black on which yellow stripes can be applied. 

1. Polyurethane exterior 

2. Foam core 

## The principle 

The contact function of the ABB Jokab Safety bumper consists of the safety contact strip SKS 18 being actuated by a special mechanical construction. This construction, which is protected by a large foam cushion, is inserted and  glued  to the 12 _ carrier aluminum profile. The foam rubber is covered with a polyurethane or NBR skin. By utilising this construction the bumper gives a stop signal when impacted from all directions with soft sides. The bumpers are delivered mounted to the carrier profile in ordered lengths (0.2 m – 3 m). 

## Supervision 

The Safety bumper must be connected to a suitable two input channel Safety Relay. e.g. ABB Jokab Safety type RT6/RT7/RT9 which provides all necessary monitoring of the bumpers activation and detection of cable faults. The twin cable connection makes it possible to connect several bumpers in series. 

3. Carrier profile 

4. Mounting profile 

5. Sensing element 

**==> picture [103 x 201] intentionally omitted <==**

**----- Start of picture text -----**<br>
1<br>2<br>3<br>4<br>5<br>**----- End of picture text -----**<br>


12/7    2TLC172001C0202 | ABB Safety Handbook 

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Technical data - Bumpers ASB 

|Article number<br>Bumper base price<br>53/100 black<br>100/200 black<br>150/300 black<br>200/400 black<br>53/100 black/yellow<br>100/200 black/yellow<br>150/300 black/yellow<br>200/400 black/yellow<br>53/100 NBR black<br>100/200 NBR black<br>150/300 NBR black<br>200/400 NBR black<br>100/200 NBR black/yellow<br>Contact us for more options|2TLA076200R0000<br>2TLA076200R0100<br>2TLA076200R0200<br>2TLA076200R0300<br>2TLA076200R0400<br>2TLA076200R0500<br>2TLA076200R0600<br>2TLA076200R0700<br>2TLA076200R0800<br>2TLA076200R0900<br>2TLA076200R1000<br>2TLA076200R1100<br>2TLA076200R1200<br>2TLA076200R1500|
|---|---|
|Dimensions|in accordance with the illustration, or special dimensions|
|Actuating distance|~20% of height|
|Braking distance|>50% of height|
|Actuating force [N]|<150 N with round body 80 mm<br><300 N with test object 45 x 400 mm|
|Mechanical life|>105|
|Protection class|IP65|
|Ambient temperature|0º to +60º|
|Chemical resistance<br>Oil, grease<br>10% acid<br>10% alkaline (caustic) solutions|good<br>resistant<br>resistant|
|Connection|20 cm with M8 male connector on one side<br>20 cm with M8 female connector on one side|
|Cable (included)|1 x 5 m with M8 male connector; 2 x 0.25 mm2PU covered<br>1 x 5 m with M8 female connector; 2 x 0.25 mm2PU covered|



## Ordering Safety bumpers 

When ordering a Safety contact bumper it‘s made out of two parts. One article with production cost (base price) and one article with type of bumper in meter. Always specify length of the Safety contact bumper. Bumpers can be supplied in lengths of up to 3000 mm. 

## Lengths and Connection 

The ASB Safety bumper is available in lengths up to 3,000 mm. Wiring outputs are located at each end of the bumper. Special designs available on request. 

## Example (complete and assembled): 

- 1 pcs 150/300, black/yellow, length 2.1 m = 

- 2.1 m of 2TLA076200R0700 (bumper+alu.profile) 

- 1 pcs of 2TLA076200R0000 (base price) 

## Dimensions/Shapes 

**==> picture [195 x 7] intentionally omitted <==**

**----- Start of picture text -----**<br>
X = Bumper hight, Y = Bumper width, Z = Bumper length<br>**----- End of picture text -----**<br>


**==> picture [168 x 7] intentionally omitted <==**

**----- Start of picture text -----**<br>
Special designs and special available on request<br>**----- End of picture text -----**<br>


ABB Safety Handbook | 2TLC172001C0202 12/8 

## Safety mats 

## Approvals: 

## Safety mats for 

- Personal protection within the dangerous areas around presses, robots, production lines, machines etc. 

## Features: 

- Can be connected to a safety relay, Vital or Pluto 

- Very durable 

- IP65 

## Personal protection within dangerous areas 

The ASK Safety mat is used for safeguarding sections within the dangerous areas around presses, robots, production lines, machines and other types of active equipment. When connected to a suitable monitoring system, stepping on the Safety Mat will immediately be detected causing dangerous machine movements to be stopped. This is made possible by the detection of electrical contacts closing within the sandwich construction of the mat. The safety mats offered by ABB Jokab Safety are available in two version, with our without a cast-in moulded ramp rail. Custom made size or shapes of the Safety mats can also be offered. Mounting to the floor can be realized with optional aluminum ramp rails 12 RS14 or BS14 (for mats without moulded ramp rail). 

## Mat construction 

The basic construction of the Safety mat  is made up of a sandwich construction. The pressure contact switch consist of two conducting plates which are separated  from each other by a proprietary isolating layer. The internal switching plates are cast into a durable polyurethane material to protect against moisture, and are  then covered with a top layer of slip-free rubber. This surface provides excellent resistance against oil, water and grease. Optional surfaces in aluminum or stainless steel can be placed on the mat surface in areas where high mechanical demand. Two cable exits are provided, that consist of one M8 male plug and one M8 female plug in the standard construction (Optional cable exits are available upon request). 

**==> picture [344 x 77] intentionally omitted <==**

**----- Start of picture text -----**<br>
Slip-free Surface<br>Polyurethane-<br>Upper Surface Contact!<br>Contact Surface 1<br>Isolating Layer<br>Contact Surface 2<br>**----- End of picture text -----**<br>


12/9    2TLC172001C0202 | ABB Safety Handbook 

12 

## Safety distance - Safety mat as per EN ISO 13855 

If a safety mat is used as entry protection, the smallest permitted safety distance between the hazardous area and the outer edge of the mat (seen from the hazard) is calculated using the formula from EN ISO 13855. 

S = smallest permitted safety distance in mm 

K = body speed (velocity of propagation 1600 mm/s) C = additional distance in mm based on the intrusion of the body into the risk zone before the protection device is actuated (1200 mm applies for safety mats). 

## S = (K * T) + C 

i.e. 

## S = (1600 * T) + 1200 

## Surface layer - Safety mats 

Safety mats are normally supplied with a dotted polyurethane non-slip surface layer that withstands tough conditions very well (oil, acid or caustic substances) and has anti-slip properties. If required, other patterns can be supplied, or for special requirements even other materials, such as NBR rubber or chequer plating in aluminium or stainless steel. Safety mats can also be supplied without a surface layer, to have a full coverage rubber sheet glued on during installation. Please contact us for more information about these alternatives. 

## Edge Trim - Safety mats 

**==> picture [446 x 257] intentionally omitted <==**

**----- Start of picture text -----**<br>
Area for safeguard + 70 mm<br>J Area for safeguard<br>!<br>a| BS 14 RS 14<br>\ 40 \ 67<br>i 4<br>Cee<br>| Mold<br>Connection cable<br>Channel for connection cable<br>Connection<br>cable !<br>al f<br>i<br>ASK-1T4.4-NP - Completely moulded mat<br>with moulded ramp rail.  Surface protection<br>Fixing profile<br>LOS EEE<br>SEL 4<br>t 4 7; A ><br>; — Angle fixing profile ; e }  ~ 4<br>Base unit Corner connection<br>Area for safeguard<br>Area for safeguard + 70 mm<br>**----- End of picture text -----**<br>


ASK-1U4.4-NP - Completely moulded mat without moulded ramp rail. Ramp rail in aluminum profile (RS14). 

## Edge trim RS14 

Eliminates vertical edges and attaches the Safety mat to the floor. Also provides protection and channel for connection cables. Profile BS14 

Best for use on the side nearest the machine. Permits a shorter distance from, for example a wall. Corner trim 

Can be used between two RS 14 profiles as an alternative to mitre cutting of profiles. 

ABB Safety Handbook | 2TLC172001C0202 12/10 

12 

Technical Data - Safety mats 

**==> picture [527 x 544] intentionally omitted <==**

**----- Start of picture text -----**<br>
Article number<br>ASK-1U4.4-NP standard no ramp<br>rail**<br>1000 x 750 mm* 2TLA076310R0500<br>1000 x 1000 mm* 2TLA076310R0600<br>1000 x 1500 mm* 2TLA076310R0700<br>ASK-1U4.4-NP custom made no<br>ramp rail**<br>Base price 2TLA076301R0000<br>Cut to size (m [2] ) * 2TLA076301R0500<br>ASK-1T4.4-NP standard with mol-<br>ded ramp rail**<br>1000 x 750 mm* 2TLA076310R1000<br>1000 x 1000 mm* 2TLA076310R1100<br>1000 x 1500 mm* 2TLA076310R1200<br>ASK-1T4.4-NP custom made with<br>molded ramp rail**<br>Base price 2TLA076301R0200<br>Cut to size (m [2] )*  2TLA076301R0600<br>Accessories<br>Cable 2.5 m M8 Male + M8 Female 2TLA076900R3200<br>Cable 5 m M8 Male + M8 Female 2TLA076900R3300<br>Edge trim RS14 2TLA076300R0500<br>Profile BS14 2TLA076300R0800<br>Corner trim 2TLA076300R0900<br>Cutting cost BS14 and RS14 2TLA076300R0800<br>Maximum area One mat = 2350 x 1350 mm (relation max 3:1) Several mats = 10 m [2]<br>Minimum size 100 x 100 mm<br>Height max 14.5 mm with slip-free surface<br>Inactive area Nominally 10 mm from Mat edge<br>Switching force 150N (Round body 80 mm)<br>Maximum pressure 2000 N over ø 80 mm<br>Material Black polyurethane, other colours on request<br>Protection class IP65<br>Ambient air temperature 0°C to +60°C<br>Chemical resistance<br>Oil, grease good<br>10% acid resistant<br>10% alkaline (caustic) solutions resistant<br>Connection  20 cm with M8 male connector on one corner<br>20 cm with M8 female connector on one corner<br>Cable (included) 1 x 5 m with M8 male connector; 2 x 0.25 mm [2]  PU covered<br>1 x 5 m with M8 female connector; 2 x 0.25 mm [2]  PU covered<br>Mechanical life > 1.5x10 [6]  load shifting<br>**----- End of picture text -----**<br>


* Incl 5 + 5 m cables 

**Size applies for safeguarded area 

## Ordering custom made Safety mats 

When ordering a custom made mat, two articles need to be ordered. A base price and a square meter price. When ordering, the size of the mat need to be specified (X meter x Y meter). 

## Example: 

- 1 pcs 0.450x1.15 m, normal surface with molded ramp rail= 

- 0.518 m[2] of 2TLA076301R0600 (ASK-1T4.4-NP custom made) 

- 1 pcs of 2TLA076301R0200 (base price) 

12/11    2TLC172001C0202 | ABB Safety Handbook 

12 

## Electrical connections Safety contact edges, Safety bumpers and Safety mats 

Contact edge, bumper or safety mat should be used with a suitable monitoring unit (e.g. ABB Jokab Safety safety relays RT6, RT7A/B, RT9, Vital with Tina 6A or Pluto safety-PLC). 

The monitoring unit monitors the functionality of the contact protection and detects any breaks or short-circuits in the lines. Several crush protection units can be connected in series while still retaining the same level of safety. 

NOTE! If alternative units are used rather than the recommended ABB Jokab Safety relays, it is essential that the user checks their suitability with ABB Jokab Safety before use. Failure to do so may result in incorrect operation and/or damage to the safety bumpers and invalidate warranty. 

When pressure is applied, the active surface of the contact area in the contact protection is closed and the safety output on the monitoring unit trips. A stop signal will be sent to the machine's safety circuits preventing any dangerous movements. 

HK7601A – Connection contact protection for safety relay RT6 

ABB Safety Handbook | 2TLC172001C0202 12/12 

12 

HK3310A – Connection contact protection for safety controller Vital 1 

HK0001A – Connection contact protection for safety PLC Pluto 

12/13    2TLC172001C0202 | ABB Safety Handbook 

12 

ABB Safety Handbook | 2TLC172001C0202 12/14 

# AMEE 13 

13/1    2TLC172001C0202 | ABB Safety Handbook 

13 

## Fencing system Quick-Guard and Safety Roller Door 

|Quick-Guard®fencingsystem|13/3|
|---|---|
|Quick-Guard®is supplied in three ways|13/6|
|Quick-Guard®Express|13/7|
|Quick-Guard®Express - can be ordered in sections|13/8|
|Quick-Guard®standard and SafeCAD|13/11|
|AssemblyusingNL2 and NL3 Net-locks on welded mesh|13/13|
|Dimensions for aluminiumprofile lengths andpanels|13/14|
|Components||
|Aluminiumprofiles|13/15|
|Fittings|13/18|
|Door Components|13/20|
|Fittingfor Switches|13/28|
|Terminal Caps and Strips|13/30|
|Accessories|13/31|
|Infill materials|13/32|
|Safety Roller Door||
|SafetyRoller Door|13/34|



ABB Safety Handbook | 2TLC172001C0202   13/2 

13 

## Quick-Guard[®] Fencing system 

Quick-Guard Standard assembled with mesh. 

Quick-Guard Standard with black and transparent Polycarbonate in-fill panels as used for medical applications. 

Quick-Guard Express with few components and easy to angle at up to 45°. 

## Adaption and Modification 

Quick-Guard is a very flexible fencing system consisting of a minimum of different components, e.g. aluminium profiles, patented brackets, net-locks, mesh, solid or noise reduction panels. Using these components there are almost no limitations as to what can be built. Quick-Guard fencing costs little to assemble and modify. 

## Assembly 

Due to our patented screw-lock system, we can supply all brackets pre-mounted with fixing screws and nuts. No holes need to be drilled in the profiles and all cutting is straight. This makes assembly and modification very easy. 

## Proposal and ordering 

By utilising our AutoCAD-based SafeCAD application we are able to make system designs in 3D very quickly. Drawings, cutting lists, etc. are generated from SafeCAD and the drawings can also be used for installation purposes. 

Our policy - To create systems that are environmentally friendly and provide ergonomic working conditions Quick-Guard is environmentally friendly. All components in the Fencing System can easily be disassembled and reused. All materials in the Fencing System are 100% recyclable. Quick-Guard can also provide a pleasing ergonomic working environment. 

## Two versions of Quick-Guard 

The Quick-Guard fencing system is available in two versions, Quick-Guard (Standard) and Quick-Guard Express which also can be combined. The fencing systems are also easy to adjust when production equipment is modified and/or moved. 

13/3    2TLC172001C0202 | ABB Safety Handbook 

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## A flexible and stable fencing system which is easy to install 

Fixings with pre-assembled screws and nuts mean easy assembly 

Width, length and height adapted and easily changed according to needs 

Choose from a large selection of hatches and doors 

Sound Mesh Plastic Glass Plate absorbing 

ABB Safety Handbook | 2TLC172001C0202   13/4 

13 

## What does the standard say? 

EN ISO 13857 applies as safety distance for the risk zones. The standard includes the dimensions that apply for safety distances in various risk situations. The adjacent figure shows examples of dimensions for safety distances for two different fence heights where the risk of injury is relatively small when you reach in. 

With respect to mesh, you specify a minimum distance of 200 mm (for people 14 and above) for opening size 40 x 40 mm. For shorter distances and for noise reduction we use solid panels. When the fence is to protect a robot cell, for example, the fence protection should be placed at a minimum distance of 500 mm between the fence protection and the moving machine part that reaches furthest out (as per EN 349). When test running or programming there must be a space between the fencing and any moving parts to ensure the operator does not become wedged between them. 

**==> picture [165 x 74] intentionally omitted <==**

**----- Start of picture text -----**<br>
mm 0 200 500        900    mm               0 350<br>250 0 250 0<br>200 0<br>160 0<br>**----- End of picture text -----**<br>


Safety distance for 1600 mm guarding with standard mesh. Safety distance for 2000 mm guarding with solid screens 

Safety distance for 1600 mm guarding with standard mesh. Safety distance for 2000 mm guarding with solid screens (e.g. polycarbonate sheet). 

(e.g. polycarbonate sheet). 

For protection that needs to be mounted and removed again, for example for maintenance, the Machinery Directive requires that fasteners remain in place on the protection. We normally deal with this using interlocked doors/gates for faster and safer access. 

Feel free to consult us about the requirements in regulations and standards. 

## Patented assembly function 

The ABB Jokab Safety patented guide and locking method makes it simple to assemble and dismantle the fencing system. The nut has several advantages, it can easily be located into the profile and automatically positions itself when the screw is turned 90 degrees clockwise. When in this position the bracket being fixed can be adjusted as required and locked by turning the screw further clockwise. To remove the bracket the fixing screw is turned anti-clockwise until the nut is in line with the profile slot. 

**==> picture [203 x 57] intentionally omitted <==**

**----- Start of picture text -----**<br>
Centralising and<br>turning limitations<br>Locking  ——— S55 patented<br>perpendicular  <5)Sy Centring<br>to profile slot washer<br>**----- End of picture text -----**<br>


All fittings are supplied pre-assembled. Fittings that do not have a cast-in tab can be provided with a centring washer. 

Mount the fixtures by first slackening the screw 3/4 turn anticlockwise. Then tighten the screw clockwise in the usual way. The nut will then automatically mechanically lock the fixture into the profile. 

Easy to adjust the position of fittings 

The T-slot and patented nut makes it easy to attach fittings to the fencing profiles 

13/5    2TLC172001C0202 | ABB Safety Handbook 

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## Quick-Guard[®] 

## Supplied in three ways 

## 1. To be designed on site 

You only order sections consisting of a few components. Then the fencing system is built on site. A manual mesh clipping tool, for easy cutting of the mesh, is provided with the delivery if needed. 

To be designed on site. 

## 2.  Cut to size according to drawing 

You give us a simple sketch or a AutoCAD® file of how you want the fencing system to look. We input this information into SafeCAD and design the fence in 3D. From this drawing, cutting and component lists and a quotation are generated automatically. 

- Cut to size according to drawing. 

## 3. Pre-mounted or assembled on site 

We can deliver full/partially pre-assembled fencing systems or we can assemble them on site. 

Pre-mounted or assembled on site. 

ABB Safety Handbook | 2TLC172001C0202   13/6 

13 

## Quick-Guard[®] Express - design directly on site 

Quick-Guard E is installed quickly and cost effectively because it only consists of  patented net-locks, welded mesh, panels of polycarbonate, u-profiles and fence posts (profiles with floorbrackets). All parts for Quick-Guard and pre-assembled doors are delivered immediately from stock. The few components of the fencing system make it easy for you to custom build and install the fencing system yourselves. 

The strength of the fencing system originates from the fact that the welded mesh and/or panels of polycarbonate are ‘locked’ into the profile. The outer wire of the mesh is locked by uniquely designed ‘netlocks’ into the profile making the fixing virtually as strong as being welded. The polycarbonate panels are locked in with specially designed infill-locks which, according to our tests, have been as strong as the mesh netlock system. If you want more stable fencing posts, you can choose a sturdier profile measuring 44 x 88 mm instead of the standard 44 x 44 mm profile. 

It is always easy to combine Quick-Guard E with Quick-Guard standard to achieve a complete system. It is also easy to adjust and modify the guarding system when production equipment is modified and/or moved. 

**==> picture [102 x 18] intentionally omitted <==**

**----- Start of picture text -----**<br>
Quick-Guard E is easy to<br>assemble and to angle 45°.<br>**----- End of picture text -----**<br>


## Assembly of Quick-Guard Express 

1. 

Premount floor fixtures on vertical posts. Mount fixtures by first slackening the screw anti-clockwise. Then tighten the screw clockwise in the usual way, the nut will then automatically locate into the correct position and mechanically lock the fixture into the profile. Make sure that the nut has turned correctly. 

**==> picture [255 x 85] intentionally omitted <==**

**----- Start of picture text -----**<br>
2.<br>U-profile<br>Spacer<br>screw Pe i Net-lock NL2 /<br>JSM 37<br> 1. Mount a spacer screw 180 mm from the floor in the posts.<br>**----- End of picture text -----**<br>


2.  Attach the lower U-profile and mesh lock JSM NL2 to the mesh. 

3.  Push the mesh into the profile and fix the mesh with NL2 netlocks. 

4.  Fix top u-profile in place either before or after inserting the mesh. 

4. 

Assemble the next section. The distance between the posts can be adjusted some mm after the mesh is locked in with the Net-locks. The mesh can be angled up to 45° without using hinges (JSM 35-K). 

Lock the top of the mesh using NL3 netlocks; this way the mesh is secured, stabilised and electrically grounded. Grounding is needed when electrical devices or cables are assembled on the mesh. 

3. 

13/7    2TLC172001C0202 | ABB Safety Handbook 

## Quick-Guard[®] Express - can be ordered in sections 

Quick-Guard Express can be ordered in different sections consisting of a few components. By adding the different sections, one person can easily install a Quick-Guard fencing system. 

One person can easily assemble the Express sections. It is also possible to angle these sections up to 45 degrees angle. The mesh can easily be cut to the desired size with a simple clipping tool. 

Measure the number of metres of fencing that are required and determine the number of doors. Our two standard sections have a cc width of 1100 mm and 1500 mm. The cc for the door is 1100 mm and fits anywhere the cc is 1100 mm between the posts. 

If dimensions other than the standard dimensions are needed, just cut the mesh /\ er to the correct size with a bolt cutter. 

## The same fencing sections can be erected in several ways. 

– 4 pcs 1500 sections – 5 pcs 1100 sections – 1 pc door ii _—lL st oe 

13 

ABB Safety Handbook | 2TLC172001C0202   13/8 

13 

Designation explanation 

JSM E11-N/PC20H8 H, X, Y, Z, G, S and Express X = Section type 11 = c-c 1100 mm N = Mesh 20 = Height 2000 mm 8 = 44x88 mm Profile 15 = c-c 1500 mm PC = polycarbonate 22 = Height 2200 mm 4 = 44x44 mm Profile 

**==> picture [335 x 171] intentionally omitted <==**

One person can easily assemble the Express sections. It is also possible to angle these sections up to 45 degrees angle. The mesh can easily be cut to the desired size with a simple clipping tool. 

13/9    2TLC172001C0202 | ABB Safety Handbook 

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|Image|Designation|Article number|Description|
|---|---|---|---|
|Section X|JSM E11-N14X4<br>JSM E11-N20X4<br>JSM E11-N20X8<br>JSM E11-N22X4<br>JSM E11-N22X8<br>JSM E11-N/PC20X8<br>JSM E11-N/PC22X8<br>JSM E11-PC20X8<br>JSM E11-PC22X8<br>JSM E15-N14X4<br>JSM E15-N20X8<br>JSM E15-N22X8|2TLA040106R0200<br>2TLA040101R0200<br>2TLA040101R0300<br>2TLA040102R0200<br>2TLA040102R0300<br>2TLA040104R0100<br>2TLA040105R0100<br>2TLA040101R5300<br>2TLA040102R5300<br>2TLA040106R1000<br>2TLA040101R0900<br>2TLA040102R0800|Components for an additional section with only one post.<br>The height can be varied between 1400 mm or 2200 mm.<br>The section is supplied unassembled.<br>Included parts: Floorbracket, netlocks/panel locks,<br>support screws, edge protection, Aluminum profile and<br>welded steel mesh/panel sheet.|
|Section Y|JSM E11-14Y4<br>JSM E11-20Y8<br>JSM E11-22Y8|2TLA040106R8000<br>2TLA040103R2100<br>2TLA040103R4100|Components for a complete post with floor bracket to<br>finalize the additional sections. The height can be varied<br>between 1400 mm or 2200 mm. The section is supplied<br>unassembled.<br>Included parts: Floorbracket, support screw, and Alumi-<br>num profile.|
|Section Z|JSM E11-N14Z<br>JSM E11-N20Z<br>JSM E11-N22Z<br>JSM E11-N/PC20Z<br>JSM E11-N/PC22Z<br>JSM E11-PC14Z<br>JSM E11-PC20Z<br>JSM E11-PC22Z<br>JSM E15-N14Z<br>JSM E15-N20Z<br>JSM E15-N22Z|2TLA040106R0400<br>2TLA040101R0400<br>2TLA040102R0400<br>2TLA040104R0200<br>2TLA040105R0200<br>2TLA040106R5400<br>2TLA040101R5400<br>2TLA040102R5400<br>2TLA040106R0800<br>2TLA040101R1000<br>2TLA040102R0900|Components for a complete section without fence posts<br>and floor brackets. The height can be varied between<br>1400 mm or 2200 mm. The section is supplied unassem-<br>bled.<br>Included parts: Netlocks/panel locks, edge protection and<br>welded steel mesh/panel sheet.|
|Section G|JSM E11-N14G<br>JSM E11-N20G*<br>JSM E11-N22G*<br>JSM E11-N/PC20G<br>JSM E11-N/PC22G<br>JSM E11-PC14G<br>JSM E11-PC20G<br>JSM E11-PC22G<br>*  The door leaf is<br>supplied pre-mounted.|2TLA040106R0500<br>2TLA040101R0500<br>2TLA040102R0500<br>2TLA040104R0300<br>2TLA040105R0300<br>2TLA040106R5500<br>2TLA040101R5500<br>2TLA040102R5500|Components for complete conventional door with outer<br>profile 44x88 mm. The height can be varied between<br>1400 mm or 2200 mm. The section is supplied unassem-<br>bled. The size of the door can easily be adjusted on site.<br>Included parts: L-brackets, floorbrackets, netlocks/panel<br>locks, handle, hinges, door stop, crossbar, aluminum<br>profiles and welded steel mesh/panel sheet.|
|Section S|JSM E11-N20S<br>JSM E11-N22S<br>JSM E11-N/PC20S<br>JSM E11-N/PC22S<br>JSM E11-PC20S<br>JSM E11-PC22S<br>JSM E15-N20S<br>JSM E15-N22S|2TLA040101R0600<br>2TLA040102R0600<br>2TLA040104R0400<br>2TLA040105R0400<br>2TLA040101R5700<br>2TLA040102R5600<br>2TLA040101R1100<br>2TLA040102R1000|Components for a complete sliding door with outer profile<br>44x88 mm. The height can be varied between 2000 mm or<br>2200 mm. The section is supplied unassembled. The size<br>of the door can easily be adjusted on location.<br>Included parts: L-brackets, T-brackets, floorbrackets,<br>netlocks/panel locks, handle, suspension wheels, guiding<br>components, door stop, crossbar, endcaps, aluminum<br>profiles and welded steelmesh/panel sheet.|



ABB Safety Handbook | 2TLC172001C0202   13/10 

13 

## Quick-Guard[®] standard and SafeCAD[®] 

## Order cut to length in accordance with drawing, pre-assembled or fitted on site. 

Quick-Guard consists of a minimum of different components, such as aluminum profiles, patented assembly parts, netlocks, mesh, solid or noise reduction panels. Furthermore the cost for assembly and modification of the system is low. Thanks to our patented screwlock system, we can supply all brackets pre-mounted with fixing screws and nuts. No holes need to be drilled in the profiles and all cuts are made straight. Assembly and modification is therefore very easy. 

used as the program input. The positions of doors and hatches, choice of mesh, polycarbonate, aluminum/steel sheet or noise reduction panels are typed in.  The program automatically generates 3D drawings along with component and cutting lists. These drawings are also used as the basis for assembly/ installation. 

It is always easy to combine Quick-Guard Express with Quick-Guard to achieve a complete system. It is also easy to adjust and modify when the production equipment is modified and/or moved. 

Brackets are delivered pre-assembled with screws and nuts. 

To be able to quickly and easily custom design practical safety solutions, we have developed a computer programme, SafeCAD. This is a ‘plug-in’ program for AutoCAD®. A simple sketch of the guarding system that is required is 

With SafeCAD[®] we can easily tailor your protection solution together 

**==> picture [291 x 123] intentionally omitted <==**

**----- Start of picture text -----**<br>
Example of component and cutting list print-outs from SafeCad.<br>Quote<br>Article no  Description  Qty  Unit<br>40-030-06  JSM 30B-K Floorbrack et 26,00  pcs<br>40-030-07  JSM 32B-K L-bracket  72,00  pcs<br>40-030-08  JSM 33B-K T-bracket  18,00  pcs<br>4040-033-31 40-030-10  -037-28  Cutlist Polycarbonate 40-039-10 Article no  JSM A12 Edge protection prof JSM 37 Suport screw for Economy JSM 36-K2 Floorbracket in steel JSM YPC5A1 Pc sheet 5mm uncoloured  2020x864 Description  le for welded mesh  Qty 1  Length 864  1,06  6,00 2,00 Width 2020  Sum 1,75  m [2] mppcscs<br>40-039-12  JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size  1  532  1020  0,54<br>40-039-12  JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size  1  756  504  0,38<br>40-039-12  JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size  1  810  804  0,65<br>Cutlist Welded Mesh<br>Article no  Description  Qty  Length  Width  Sum m [2]<br>40-040-13  JSM YN40W1 Welded steelmesh 40x40x3,5 black, 2020x864  1  864  2020  1,75<br>40-040-14  JSM YN40W2 Welded steelmesh 40x40x3,5 black, 1074x1816  2  1820  1074  3,91<br>40-040-16  JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size  2  864  354  0,61<br>40-040-16  JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size  1  864  804  0,69<br>40-040-16  JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size  1  864  920  0,79<br>40-040-16  JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size  2  864  932  1,61<br>**----- End of picture text -----**<br>


13/11    2TLC172001C0202 | ABB Safety Handbook 

## Quick-Guard[®] Assembly - standard version 

Assembly of the Quick-Guard® system is very easy. All components are very light in weight and ergonomic in design. This enables, in most cases, one person to be able to assemble both simple and complex structures with ease using very few different types of fixing components. All fixtures can be 

1. 

Premount floor fixtures by first slackening the screw anticlockwise. Then tighten the screw clockwise in the usual way. The nut will then automatically locate into the correct position and mechanically lock the fixture into the profile. 

3. 

mounted easily from “outside” by using the specially designed ”locking nut” which can be located anywhere in the extrusion channel. The fixture components, by means of integral locating keys, ensure that correct angles are achieved and enable the number of bolts/nuts to be reduced to half the number that would otherwise be required. 

2. 

Attach lower horizontal extrusion between vertical posts. Use a spacer block to ensure the correct distance from the floor. 

4. 

13 

Insert infill panel and fix middle horizontal profile. The distance between the profiles is the width of the infill minus 20 mm. 

5. 

**==> picture [106 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
Fix the poles to the floor.<br>**----- End of picture text -----**<br>


Insert top infill panel. Fix top profile with fittings on the top on both sides. 

6. 

Secure infill sheet with  plastic strip or Net-lock fixings. Easy, fast and quick. See more under Assembly of netlocks. If there is a risk of the robot striking the polycarbonate, JSM PL3 panel locks must be used. 

ABB Safety Handbook | 2TLC172001C0202   13/12 

## Assembly using NL2 and NL3 Net-locks on welded mesh 

**==> picture [218 x 160] intentionally omitted <==**

**----- Start of picture text -----**<br>
 NL2 Net-lock<br>The outer mesh wire is<br>a” 6 locked into the profile.<br>max 2 mm<br>**----- End of picture text -----**<br>


When assembling the Net-lock NL2 it is first put into the profile as the drawing shows. Then the Net-lock is turned 90°. When cutting the welded mesh the wire ends should not be longer than two (2) mm. 

**==> picture [234 x 180] intentionally omitted <==**

**----- Start of picture text -----**<br>
NL3 Net-lock<br>Mesh with outer wire. Mesh without outer wire.<br>min 15 mm<br>max 2 mm<br>The outer mesh wire is locked  The Net-lock locks the mesh<br>into the profile. against the profile.<br>**----- End of picture text -----**<br>


When assembling the Net-lock NL3 it is first put into the profile with the tabs on each side of the mesh wire. The screw is then tightened. When cutting the welded mesh the wire ends should be at least 15 mm to fit into the profile. NL3 must be used to lock the mesh into the slot. 

Number of Net-locks Quick-Guard standard version On Quick-Guard standard version NL3 is recommended as it can be used for mesh with or without an outer wire. 

about 400 mm 

## Number of Net-locks Quick-Guard Express 

On Quick-Guard Express both Net-lock NL2 and NL3 can be used. For mesh edges without outer wire NL3 must be used instead of NL2. 

**==> picture [557 x 197] intentionally omitted <==**

**----- Start of picture text -----**<br>
90 mm<br>NL3 is used in order to me-<br>chanically lock the mesh<br>and to electrically ground<br>the mesh.<br>approx. 350 mm NL2 or NL3<br>=<br>NL2 or NL3<br>NL2 or NL3<br>13 90 mm NL2 or NL3<br>_  f eat _<br>NOTE! On welded mesh without an outer wire NL3 must be used.<br>NOTE!  On both Quick-Guard Standard and Quick-Guard E at least two NL3 should be used in order to mechanically lock the mesh and to electrically ground the mesh. NL3 should<br>only be used on doors.<br>**----- End of picture text -----**<br>


Fixing posts to the floor when mesh is required to be fitted at a later date. 

**==> picture [155 x 9] intentionally omitted <==**

**----- Start of picture text -----**<br>
Right Wrong<br>**----- End of picture text -----**<br>


Temporarily mount at least two middle profiles before drilling and fixing posts to the floor. This method is used when infill mesh or panels are to be fitted at a later date. 

Note! Never attempt to fix the posts to the floor without first connecting at least two middle profiles to ensure the posts are parallel to each other and vertical. 

13/13    2TLC172001C0202 | ABB Safety Handbook 

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## Dimensions 

## Aluminum profile lengths and infill materials 

**==> picture [488 x 455] intentionally omitted <==**

**----- Start of picture text -----**<br>
A*<br>**----- End of picture text -----**<br>


*A=13 (JSM D1A), A=1 (JSM D1C) 

Material Width Height Polycarbonate X+20 mm Y+20 mm Welded mesh X+20 mm Y+20 mm Steel panel X+20 mm Y+20 mm Sound absorbing panel 25 mm X-37 mm Y-37 mm Sound absorbing 50 mm X-37 mm Y-37 mm Laminated glass X+15 mm Y+15mm Double Pc 2 pcs. X-7 2 pcs. Y-7 JSM AS1 Profile for 25 mm sound absorbing panel 2 pcs. L=X 2 pcs. L=Y-73 JSM AS3 Profile for 50 mm sound absorbing panel 2 pcs. L=X (mitred 2 x 45 degrees) 2 pcs. L=Y (mitred 2 x 45 degrees) JSM AS2 Profile for 2x5 mm pc sheet 2 pcs. L=X 2 pcs. L=Y-33 

ABB Safety Handbook | 2TLC172001C0202   13/14 

13 

## Aluminum profiles 

A wide range of aluminium profiles are available and include, fencing profile, guide rails, and cable ducting. The cable ducting is available in three sizes, and can be delivered with or without mounting holes. The cable ducting is easy to open and can be provided with end caps. Cover strips of plastic are also available, including fencing profiles making the entire groove cross section utilisable as ‘installation conduit’ for cables. The Aluminium profiles have integral "V" grooves to aid in centring any drilling that may be necessary. Alloy: 6063 and 6060F22. Natural anodized aluminium 10µm 

|Fencing Profile|||
|---|---|---|
|Designation<br>Article numbers<br>Material<br>Dimensions<br>sessustntisninnistisniansnstissianatisnsanaie’|JSM A4416<br>2TLA040037R7000 (cut to size)<br>2TLA040037R7400 (L=6000)<br>Natural anodized aluminium<br>16.5 x 44 mm<br>’~~a~~|44<br>20,25<br>11<br>16,5<br>32<br>11,5<br>3,3<br>Ø 5,6 (2x)|
|Designation<br>Article numbers<br>Material<br>Dimensions<br>sessustntisninnistisniansnstissianatisnsanaie ’|JSM A4426<br>2TLA040037R7000 (cut to size)<br>2TLA040037R7400 (L=6000)<br>Natural anodized aluminium<br>44 x 26 mm<br>’~~a~~|10,2|
|Designation<br>Article numbers<br>Material<br>Dimensions<br>Order Unit<br>|<br>||JSM A44A<br>2TLA040037R3500 (cut to size)<br>2TLA040037R3600 (L=1100)<br>2TLA040037R9800 (L=1400)<br>2TLA040037R3700 (L=2000)<br>2TLA040037R3800 (L=2200)<br>2TLA040037R3900 (L=2400)<br>2TLA040037R4000 (L=2500)<br>2TLA040037R4100 (L=6000)<br>Natural anodized aluminium<br>44 x 44 mm<br>10 pcs/box<br>|<br>||11,5<br>v<br>v<br>v<br>v<br>11<br>20,25<br>3,3<br>44<br>sabe<br>160720<br>as|
|Designation<br>Article numbers<br>Material<br>Dimensions<br>Order Unit|JSM A4488A<br>2TLA040037R4200 (cut to size)<br>2TLA040037R4300 (L=2000)<br>2TLA040037R4400 (L=2200)<br>2TLA040037R4500 (L=6000)<br>Natural anodized aluminium<br>44 x 88 mm<br>5 pcs/box|88<br>44<br>44<br>11<br>20,25<br>11,5<br>v<br>v<br>v<br>v<br>v<br>v<br>v<br>v<br>3,3|
|Designation<br>Article numbers<br>Material<br>Dimensions|JSM A8888<br>2TLA040037R7500 (cut to size)<br>2TLA040037R7900 (L=6000)<br>Natural anodized aluminium<br>88 x 88 mm|v<br>v<br>75,4<br>55,8<br>44<br>88<br>20,25<br>11<br>11,5<br>3,3<br>88<br>v<br>v<br>v<br>v<br>v<br>v<br>v<br>v<br>Ø 8 (4x)<br>Ø 5,6 (4x)<br>|<br>Ss Z<br>CEE|



13/15    2TLC172001C0202 | ABB Safety Handbook 

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Technical data – fencing profile 

|||Angular moment|Angular moment|Flexural resistance|Flexural resistance|
|---|---|---|---|---|---|
|Typ|Vikt (kg/m)|lx (mm4x104)|ly (mm4x104)|Wx (mm3x103)|Wy (mm3x103)|
|JSM A4416|1.040|1.1|7.6|1.19|3.43|
|JSM A4426|1.023|3.2|7.4|2.47|3.36|
|JSM A44A|1.504|12.4|12.4|5.64|5.64|
|JSM A4488A|2.379|79.6|21.6|18.1|9.8|
|JSM A8888|3.632|143.0|143.0|32.5|32.5|



|U-Profile||||
|---|---|---|---|
|Designation<br>Article numbers<br>Material<br>Weight|JSM A12<br>2TLA040037R2800 (cut to size, max 2.0 m)<br>2TLA040037R2700 (L=1076)<br>2TLA040037R4600 (L=1476)<br>2TLA040037R4700 (L=2000)<br>Natural anodized aluminium<br>0.230 kg/m|23|10,4<br>~~i~~|
|H-profile||||
|Designation<br>Article numbers<br>Material<br>Weight|JSM A13<br>2TLA040037R5000 (cut to size)<br>2TLA040037R5100 (L=1076)<br>2TLA040037R5200 (L=1476)<br>2TLA040037R5300 (L=2020)<br>Natural anodized aluminium<br>0.452 kg/m|10,4<br>44<br>3<br>6,7<br>i!||
|Guiding Rails||||
|Designation<br>Article number<br>Material<br>Holes<br>Standard Length<br>Weight|JSM A3130C<br>2TLA040037R9900 (cut to size)<br>Natural anodized aluminium<br>C/c = 240 mm, ø = 5.6 mm<br>6.1 m (max)<br>0.578 kg/m|||
|Designation|JSM A56|||
|Article number|2TLA040037R4900 (Cut to size incl. screws)||56|
|Delivered with<br>Material<br>Holes<br>Standard Length<br>Weight<br>2TLA040037R0800 (L=2000, incl.screws)<br>2TLA040037R4800 (L=6000, incl.screws)<br>Screw JSM S8E<br>Nut JSM M8B<br>Natural anodized aluminium<br>C/c = 450 mm, ø = 8.5 mm<br>2.0; 6.0 m<br>1.585 kg/m<br>79<br>v<br>17<br>al<br>~~he~~||||



ABB Safety Handbook | 2TLC172001C0202   13/16 

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|Cable Ducting||||||||
|---|---|---|---|---|---|---|---|
|Designation<br>Article numbers<br>Material|JSM A25_<br>2TLA040037R1300 (JSM A25A)<br>2TLA040037R1400 (JSM A25B)<br>Natural anodized aluminium|||44||||
|Dimensions<br>Standard Length<br>JSM A25A<br>JSM A25B<br>Order Unit<br>Weight|44 x 25 mm<br>2.0 m<br>with holes C/c= 500 mm ø= 5 mm<br>without holes<br>10 pcs/box<br>0.545 kg/m JSMA25A<br>0.567 kg/m JSMA25B|25||v<br>v<br>v|v|||
|Designation<br>Article numbers<br>Material<br>Dimensions<br>Standard Length<br>JSM A60A<br>JSM A60B<br>Order Unit<br>Weight|JSM A60_<br>2TLA040037R1500 (JSM A60A)<br>2TLA040037R1600 (JSM A60B)<br>Natural anodized aluminium<br>44 x 60 mm<br>2.0 m<br>with holes C/c = 500 mm ø = 5 mm<br>without holes<br>10 pcs/box<br>0.923 kg/m JSMA60A<br>0.950 kg/m JSMA60B|60||44<br>v<br>v<br>v<br>v|v<br>v|||
|Designation<br>Article number<br>Material<br>Dimensions<br>Standard Length<br>Weight|JSM A88<br>2TLA040037R3300<br>Natural anodized aluminium<br>88x68 mm<br>2.0 m<br>1.844 kg/m|88<br>v<br>v<br>v<br>v<br>v<br>68<br>~~(To ~~||||v<br>v<br>|~~Le~~|
|Cable tie||||||||
|Designation<br>Article number<br>Pre-assembled with<br>Order Unit<br>Material|JSM X1<br>2TLA040033R4300<br>Screws and Nuts<br>10 pcs/box<br>Nylon 6/6 black|||||||
|Profiles for installation of sound absorbing panels|Profiles for installation of sound absorbing panels|||||||
|Profile for 25 mm sound absorbing panel, JSM YLA25A_||||||||
|Designation<br>Article numbers<br>Material<br>Dimensions<br>Weight|JSM AS1<br>2TLA040037R9500 (cut to size)<br>2TLA040037R0900 (L=2000)<br>Natural anodized aluminium<br>29 x 43 mm<br>0.545 kg/m||20|23,7<br>29,1<br>36,5|43,4||2|
|Profile for 50 mm sound absorbing panel, JSM YLA50A||||||||
|Designation<br>Article numbers<br>Material<br>Dimensions<br>Weight|JSM AS3<br>2TLA042021R8000  (cut to size)<br>2TLA042021R8100 (L=6000)<br>Natural anodized aluminium<br>43 x 56<br>0.694 kg/m|||51<br>55<br>44<br>22<br>43,3<br>36,5<br>20<br>wl||||



Profiles for installation of sound absorbing panels 

13/17    2TLC172001C0202 | ABB Safety Handbook 

13 

|Profile for double 5mm Polycarbonate panel, JSM YPC5_|Profile for double 5mm Polycarbonate panel, JSM YPC5_|Profile for double 5mm Polycarbonate panel, JSM YPC5_||||
|---|---|---|---|---|---|
|Designation||JSM AS2||4,9||
|Article numbers||2TLA040037R9600 (cut to length)||||
|Material||2TLA040037R1000 (L=2000)<br>Natural anodized aluminium|16,3||23,2|
|Dimensions||40 x 23 mm||||
|Weight||0.510 kg/m||40||



## Fittings 

ABB Jokab Safety’s fencing system is put together with various types of fitting. Uprights are anchored to the floor with floor angle fittings. With a small angle fitting it is possible to hang an electrical enclosure and strengthen the corners of free-standing walls. Corners and joints are constructed with the aid of T, L and I fittings. If angles different to 90° between the fence sections are required, a JSM D1C angle fitting can be used. This hinge has a distance between centres of 45 mm, which means that the gap between uprights will always be less than 20 mm. According to EN ISO 13857, the minimum permitted protection distance is 120 mm for a gap narrower than 20 mm. 

|Floor/Angle fitting||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|Designation<br>Article numbers<br>Pre-assembled with<br>Material<br>Order unit||JSM 39-K<br>2TLA040030R1400<br>Screw JSM S8C (x 2), Washer 9 x 18 x 1.5 (x 2),<br>Nuts JSM M8B (x 2)<br>Aluminium<br>10 pcs/box||||||||||||||
|Designation<br>Article number<br>Pre-assembled with<br>Material<br>Order Unit||JSM 30B-K<br>2TLA040030R0600<br>Screw JSM S8C (x 2), Washer 9 x 18 1.5 (x 2)<br>Nut JSM M8B (x2)<br>Aluminium<br>10 pcs/box||||||||||||||
|Designation||JSM 30B-K1||||||||||||||
|Article numbers||2TLA040030R1100||||||||||||||
|Pre-assembled with||Screws JSM S8C (x 4), Washers 9 x 18 x 1.5 (x 4)||||||||||||||
|Material||Nuts JSM M8B (x 4), Washers JSM B8B (x 2)<br>Aluminium||||||||||||||
|Order unit||10 pcs/box||||||||||||||
|Small Angle fitting, e.g. Electrical cabinet fitting|Small Angle fitting, e.g. Electrical cabinet fitting|||||||||||||||
|Designation||JSM 31B-K , Two counter sunk holes||||||||||||||
|Article number||JSM 31A1-K, One counter sunk hole<br>2TLA040030R1300 (JSM 31B-K)||||||||||||||
|Pre-assembled with||2TLA040030R0400 (JSM 31A1-K)<br>Screw JSM M8C, Nut JSM M8B||||||||||||||
|Material||Aluminium||||||||||||||
|Order unit||10 pcs/box||||||||||||||
|L-bracket||||||||||||||||
|Designation||JSM 32B-K||||||||||||||
|Article number||2TLA040030R0700|||||105|||||||||
|Pre-assembled with<br>Material<br>Order Unit||Screw JSM S8A, Nut JSM M8B<br>Aluminium<br>10 pcs/box||105|||||,|||||6||
|||||||||41||||||||



ABB Safety Handbook | 2TLC172001C0202   13/18 

13 

Designation JSM 42 Article number 2TLA042020R3200 Pre-assembled with Screw K6S M8x16 Steel, zinc-plated (2TLJ041017R0100) Nut JSM M8B (2TLA040035R0600) Material Aluminium Order Unit 1 pcs T-bracket Designation JSM 33B-K Article number 2TLA040030R0800 Pre-assembled with Screw JSM S8A, Nut JSM M8B Material Aluminium Order Unit 10 pcs/box 

**==> picture [68 x 71] intentionally omitted <==**

**----- Start of picture text -----**<br>
169<br>6<br>41<br>105<br>**----- End of picture text -----**<br>


I-bracket Designation JSM 34B-K 85 Article number 2TLA040030R1500 Pre-assembled with Screw JSM S8A, Nut JSM M8B 6 Material Aluminium Order Unit 10 pcs/box | | 6 44 zs U-bracket Designation JSM 43 Article number 2TLA042020R3100 Pre-assembled with Screw K6S M8 x 16 Steel, zinc-plated (2TLJ041017R0100) Nut JSM M8B (2TLA040035R0600) Material Aluminium Order Unit 1 pcs Distance screw Designation JSM 37 Article number 2TLA040033R3100 Material Zinc-plated steel Order unit 100 pcs/box Angle bracket Designation JSM 40 Article number 2TLA042021R5600 Pre-assembled with Screw K6S M8x16 Steel, zinc-plated (2TLJ041017R0100) | Nut JSM M8B (2TLA040035R0600) ® 6) Material Steel, zinc-plated Order unit 1 pcs Designation JSM D1C Hinge Article number 2TLA040033R4800 Pre-assembled with JSM M8B, JSM B8C, JSM S8A Material Polyamide, glass fibre reinforced Colour Black Order unit 2 pcs/bag, 10 pcs/box Designation JSM 35-K Article number 2TLA040033R1400 Pre-assembled with Screw JSM S6A, Nut JSM M6B Material Zinc-plated steel Hole C/c =47 mm Order unit 2 pcs/box | 3 os 47 75 

NOTE! The JSM 35-K must only be used for making fence angles. 

13/19    2TLC172001C0202 | ABB Safety Handbook 

13 

## Door components 

To mount conventional doors a hinge is available which permits an opening angle of 180°. For mounting a sliding door, guide rails and suspension wheels are utilised. Other sliding elements make it possible to build different types of hatches. Guide rollers, for wide and heavy doors, door closers, fittings for sensors/switches etc are also available. 

**==> picture [75 x 7] intentionally omitted <==**

**----- Start of picture text -----**<br>
Conventional Door<br>**----- End of picture text -----**<br>


Sliding Door 

Hatch 

Double Hatch 

Folding Hatch 

Sliding Hatch 

ABB Safety Handbook | 2TLC172001C0202   13/20 

13 

Hinge kit Designation JSM D1C Hinge Article number 2TLA040033R4800 Pre-assembled with JSM M8B, JSM B8C, JSM S8A Material Polyamide, glass fibre reinforced | Colour Black Order unit 2 pcs/bag, 10pcs/box ‘(LIers ~~ee ee~~ Designation JSM D1A Hinge Article number 2TLA040033R1500 Pre-assembled with Screw JSM S6A,Nut JSM M6B Material Zinc-plated steel Fixing Holes C/c = 62 mm se Order Unit 2 pcs/box Hi] NOTE! JSM D1A must not be used as a fencing angle fitting | 3 62 Hf 6 because its gap can exceed 95 20 mm. Designation JSM D1B Spring hinge 22 Article numbers 2TLA042020R4700 Material Zinc-plated steel Pre-assembled with Spacer plate, screws and nuts 28 NOTE! The door gap will be 28 mm when installed. 76 Handle Designation JSM D2 Handle 26 Article number 2TLA040033R0100 Pre-assembled with Screw JSM S8D, Nut JSM M8B Material Thermoplastic, black 44 

Designation JSM D18 Handle Article number 2TLA042020R5000 Material Handle: Thermoplastic, black Fittings: Aluminum Pre-assembled with Screws and Nuts Suitable for sliding door on the inside of the fence. 

**==> picture [61 x 125] intentionally omitted <==**

**----- Start of picture text -----**<br>
40<br>22<br>70<br>5 26<br>119<br>150<br>**----- End of picture text -----**<br>


13/21    2TLC172001C0202 | ABB Safety Handbook 

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Door closer 

Designation JSM D3 (conventional door) Article number 2TLA040033R0200 Pre-assembled with Screws and Nuts Material Door closer: Steel Bracket: Aluminium Designation JSM D19 (sliding door) Article number 2TLA042020R5600 Material Zinc-plated steel Pre-assembled with Screws and Nuts 

Gas spring 

Designation JSM D22 Gas spring with fittings Article number 2TLA042024R1000 Stroke (SL) 300 mm Pre-assembled with Screws and Nuts Material Steel 

Designation JSM D22A Gas spring with fittings Article number 2TLA042024R1100 Stroke (SL) 350 mm Pre-assembled with Screws and Nuts Material Steel Fittings included Bracket with ballcup (2TLA042021R2700) U-bracket with ball joint (2TLA042021R2800) 

NOTE! Specify required force (100-1200N) when ordering. 

Bracket for padlock 

Designation JSM D17 Bracket for Padlock 3 Article number 2TLA040020R2200 Pre-assembled with Screws and Nuts Material Zinc-plated steel NOTE! Two pieces are required for one complete unit. 35 62 

ABB Safety Handbook | 2TLC172001C0202   13/22 

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**==> picture [395 x 562] intentionally omitted <==**

**----- Start of picture text -----**<br>
|||||
|---|---|---|---|
|Ball Catch|
|Designation|JSM D11B (conventional door)|40|
|Article number|2TLA040033R4100|40|5|
|Pre-assembled with|Screws and Nuts|
|Material|Brackets: Aluminium|
|Ball Catch: Nickel-plated brass|
|20|
|Designation|JSM D11C (sliding door)|40|
|40|
|Article number|2TLA040033R4200|5|
|Pre-assembled with|Screws and Nuts|
|Material|Aluminium|
|Brackets: Aluminium|
|10|
|Ball catch: Nickel-plated brass|
|20|
|Designation|JSM D11D (folding door)|60|
|Article number|2TLA042020R5200|
|Pre-assembled with|Screws and Nuts|
|Material|Aluminium|
|Brackets: Aluminium|
|||5|
|Ball catch: Nickel-plated brass|
|25|
|70|
|Upper Door bolt|
|Designation|JSM D10A|80|60|
|Article number|2TLA040033R2100|
|Pre-assembled with|Screws and Nuts|
|Material|Rod: Stainless steel|
|5|
|Brackets: Zinc-plated steel|
|90|
|30|
|10|
|40|
|35|

**----- End of picture text -----**<br>


13/23    2TLC172001C0202 | ABB Safety Handbook 

Lower Door bolt Designation JSM D10 Article number 2TLA040033R2000 Pre-assembled with Screws and Nuts 40 Material Rod: Stainless steel Brackets: Zinc-plated steel 10 8 18 

**==> picture [511 x 283] intentionally omitted <==**

**----- Start of picture text -----**<br>
Lower Door bolt<br>Designation JSM D10B<br>Article number 2TLA040033R3800<br>Pre-assembled with Screws and Nuts<br>Material Rod: Stainless steel<br>Brackets: Zinc-plated steel 40<br>6<br>30<br>25<br>10<br>18<br>100<br>995<br>390<br>40 4<br>180<br>25<br>**----- End of picture text -----**<br>


Cam lock Designation JSM D15 Article number 2TLA040033R3900 Pre-assembled with Screws and Nuts Material Lock unit: Polyamide, black Brackets: Aluminium NOTE! Delivered without key. Key to cam lock Designation JSM D16 Article number 2TLA040033R4400 Material Zinc, black 

13 

ABB Safety Handbook | 2TLC172001C0202   13/24 

13 _ 

|Sliding bolt for Eden||||||
|---|---|---|---|---|---|
|Designation<br>Article numbers|JSM D20 (for hinged door)<br>2TLA020302R1000|||110|110|
|Material|Steel, painted yellow||||72|
|Note! Supplied without Eden<br>For installation on hinged doors|||14||130|
|||180||40|60|
|Door stop||||||
|Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D13A<br>2TLA040033R2600<br>Screws and Nuts<br>Natural anodized aluminium|||3|40<br>60<br>25|
|Designation<br>Article number<br>Pre-assembled with<br>Material<br>NOTE! For mounting on vertical<br>profiles.|JSM D13<br>2TLA040033R2500<br>Screws, Nuts and vibration damper<br>Zinc-plated steel|||60<br>60<br>5|60|
|Designation<br>Article number<br>Pre-assembled with<br>Material<br>NOTE! For mounting on horizontal<br>profiles.|JSM D13B<br>2TLA040033R2700<br>Screws, Nuts and vibration damper<br>Zinc-plated steel||40|60<br>75<br>5<br>fea||



13/25    2TLC172001C0202 | ABB Safety Handbook 

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|Suspension wheels|||||||
|---|---|---|---|---|---|---|
|Designation<br>Article number<br>For aluminium guiding rails JSM<br>A3130C and JSM A56|JSM D5<br>2TLA040033R0400||||||
|Sliding elements|||||||
|Sliding element, (rectangular)<br>Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D6<br>2TLA040033R0500<br>Screw and Nut<br>Polyamid, white||40|||19<br>8|
|Sliding element, (round)<br>Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D7<br>2TLA040033R0600<br>Screw and Nut<br>Polyamid, white||40|||19<br>8|
|Sliding element, (guide)<br>Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D8<br>2TLA040033R0700<br>Screw and Nut<br>Polyamid, white|||40|9,6|8<br>19|
|Sliding element, (guide)|||||||
|Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D26<br>2TLA042020R3700<br>Screw and Nut<br>Robalon, black||||OT]<br>4<br> |<br>aE|||
|Guide Components for Sliding Door|||||||
|Designation<br>Article number<br>Pre-assembled with<br>Material<br>NOTE! For mounting on vertical profiles.|JSM D12<br>2TLA040033R2200<br>Screws and Nuts<br>Aluminium and PA6-6||||30<br>65<br>50<br>Cl|5|
|Designation|JSM D12A (Bracket)||||||
|Article number<br>Pre-assembled with|2TLA040033R2300<br>Screws and Nuts||||60|5|
|Material<br>NOTE! For mounting on horizontal<br>profiles.|Aluminium and PA6-6|||40|50<br>kp||



ABB Safety Handbook | 2TLC172001C0202   13/26 

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Designation JSM D12B Article number 2TLA040033R2400 Pre-assembled with Screws and Nuts Material Aluminium 

**==> picture [38 x 110] intentionally omitted <==**

**----- Start of picture text -----**<br>
40<br>5<br>120<br>**----- End of picture text -----**<br>


## Guide roller 

Swivel castor with total lock Designation JSM D9-K Pre-assembled with angle bracket Article number 2TLA040033R1100 Wheel diameter 75 mm Max. load 60 kg 

Fixed castor Designation JSM D9A-K Article number 2TLA040033R1300 Pre-assembled with angle bracket Wheel diameter 75 mm Max. load 70 kg 

**==> picture [95 x 224] intentionally omitted <==**

**----- Start of picture text -----**<br>
JSM D9-K<br>JSM D9A-K<br>|<br>97<br>95<br>**----- End of picture text -----**<br>


Diagonal bar for door 

JSM D14 

Designation JSM D14 Article number 2TLA040033R2800 Length 1160 mm Pre-assembled with Screws and Nuts Material Natural anodized aluminium 

Designation JSM D14A Article numbers 2TLA042021R7300 Length 400 mm Pre-assembled with Screws and Nuts Material Natural anodized aluminium 

**==> picture [37 x 144] intentionally omitted <==**

**----- Start of picture text -----**<br>
20<br>5<br>400/1160<br>**----- End of picture text -----**<br>


13/27    2TLC172001C0202 | ABB Safety Handbook 

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Fittings for switches 

|Fittings for switches|||||||||
|---|---|---|---|---|---|---|---|---|
|Fittings for Eden|||||||||
|Fitting for conventional- and sliding<br>door.<br>Designation<br>Article number<br>Pre-assembled with<br>Material<br>NOTE! Two fittings are needed for a com-<br>plete Eden.|:||JSM D4H<br>2TLA040033R3600<br>Screws and Nuts<br>Aluminium|:||40<br>100|4||
|Fitting for sliding door flush with fence|||||||||
|Designation|||JSM D4J|||60|||
|Article number<br>Pre-assembled with<br>Material<br>NOTE! One JSM D4H and one JSM D4J are|:<br>:||2TLA042020R4000<br>Screws and Nuts<br>Aluminium|:<br>i||4<br>67<br>51<br>Ki<br>|@<br>a||80|
|needed for a complete unit.|||||||||
|Fittings for JSNY5 Interlock Switches|||||||||
|Fitting for conventional door/hatch<br>Designation<br>Article number<br>Pre-assembled with<br>Material|JSM D4A<br>2TLA040033R0900<br>Screws and Nuts<br>Zinc-plated steel<br>50<br>50<br>12<br>4<br>:<br>:<br>U<br>:<br>A<br>Gi<br>fl<br>ie||||||20<br>55<br>:<br>U<br>:|:<br>U<br>:|
|Fitting for conventional door/hatch<br>Designation<br>Article number<br>Pre-assembled with<br>Material|||JSM D4AA<br>2TLA040033R3400<br>Screws and Nuts<br>Zinc-plated steel|||70<br>50<br>40<br>40|5<br>50|5|
|Fitting for sliding door|||||||||
|Designation|||JSM D4B|||127||45|
|Article number|||2TLA040033R1000||||||
|Pre-assembled with|||Screws and Nuts|||||60|
|Material|||Zinc-plated steel|||5<br>65|40||
|||||||5<br>60|||



ABB Safety Handbook | 2TLC172001C0202   13/28 

13 - 

|Fittings for JSNY7 Switches||||||||||
|---|---|---|---|---|---|---|---|---|---|
|Fitting for conventional door/hatch<br>Designation<br>Article number<br>Pre-assembled with<br>Material<br>NOTE! Two fittings are needed for a complete<br>JSNY7.||JSM D4E<br>2TLA040033R1800<br>Screws and Nuts<br>Aluminium|||90||3<br>35|||
|Fitting for sliding door<br>Designation<br>Article number|JSM D4G<br>2TLA040033R3300<br>5<br>~~te~~||||||8|||
|Pre-assembled with||Screws and Nuts||||||||
|Material||Aluminium|||90|40|40|90||
|Fittings for JSNY8/9 Switches||||||||||
|Fitting for JSNY8, sliding door<br>Designation<br>Article numbers<br>Pre-assembled with<br>Material||JSM D4D<br>2TLA040033R1700<br>Screws and Nuts<br>Zinc-plated steel|||||138<br>90<br>tei||5<br>4<br>40<br>o|50<br>Mi|
|Fitting for JSNY8/9, conventional door/hatch<br>Designation<br>Article number<br>Pre-assembled with<br>Material||JSM D4C<br>2TLA040033R1600<br>Screws and Nuts<br>Zinc-plated steel|||35<br>60|42<br>4|154<br>94|55<br>5<br>40||
|Fitting for JSNY9, sliding door<br>Designation<br>Article number<br>Pre-assembled with||JSM D4F<br>2TLA040033R3000<br>Screws and Nuts|||||96<br>Ke||40<br>40<br>60<br>5<br>5||
|Material||Zinc-plated steel|||134|60<br>“("|||40|



13/29    2TLC172001C0202 | ABB Safety Handbook 

13 

## Terminal caps and strips 

Terminal caps are available to cover profile ends, thus eliminating sharp edges. Strips are also available, both narrow and wide, to cover the slot of the fencing profile. 

|Terminal Caps||||||
|---|---|---|---|---|---|
|Terminal Cap for JSM A44A<br>Designation<br>Article numbers<br>Material<br>Dimensions|JSM L1A (yellow)<br>JSM L1B (grey)<br>2TLA040034R0000 (JSM L1A)<br>2TLA040034R0300 (JSM L1B)<br>Polyamide<br>44x44 mm|44<br>5||44||
|Terminal Cap for JSM A4488A<br>Designation<br>Article numbers<br>Material<br>Dimensions|JSM L4A (yellow)<br>JSM L4B (grey)<br>2TLA040034R0400 (JSM L4A )<br>2TLA040034R0500 (JSM L4B)<br>Polyamide<br>44x88 mm||5|88|44|
|Terminal Cap for JSM A25<br>Designation<br>Article number<br>Material<br>Dimensions|JSM L2<br>2TLA040034R0100<br>Polyamide, grey<br>44x25 mm|25||44<br>5||
|Terminal Cap for JSM A60||||44||
|Designation<br>Article number<br>Material<br>Dimensions|JSM L3<br>2TLA040034R0200<br>Polyamide, grey<br>44x60 mm||60|5||
|Cover Strip||||||
|Narrow Cover Strip, for Alt. 1:<br>JSM A4416, -A4426, -A44A, -A4488A and -A8888<br>Alt.2: For fencing profiles with 11 mm slot<br>Designation<br>Article numbers<br>Material<br>Dimensions<br>Order Unit<br>NOTE! Other colours available upon request|JSM T3A (yellow) JSM T3B (grey)<br>2TLA040037R3100 (JSM T3A)<br>2TLA040037R3200 (JSM T3B)<br>ABS<br>16 mm<br>2 m|||2,5<br>16||
|Wide Cover Strip, Alt. 1:||||||
|JSM A4416, -A4426, -A44A, -A4488A and -A8888<br>Alt.2: For fencing profiles with 11mm slot<br>Designation|JSM T2A|||40||
|Article number<br>Material<br>Dimensions<br>Order Unit<br>NOTE! Other colours available upon request|2TLA040037R1900<br>PVC, yellow, soft material<br>40 mm<br>25 m/coil|||2,5||



ABB Safety Handbook | 2TLC172001C0202   13/30 

## Accessories 

All fittings and door components are delivered pre-assembled with screws, washers and nuts. For cable ducting the screws, S5B, and nuts, M5B, have to be ordered separately (4 pcs/2m). 

|Designation|Image|Article number|Description|Dimension|Material|Order Unit|
|---|---|---|---|---|---|---|
|JSM S5B||2TLA041039R0100|Screw to cable ducting|M5x12|Zinc Plated Steel|100 pcs/box|
|JSM S6A||2TLA041039R0200|Screw for hinge cross-slotted Z<br>(pozidrive)|M6x12|Zinc Plated Steel|100 pcs/box|
|JSM S8A||2TLA041019R0000|Fixing screw<br>countersunk.|M8x16|Zinc Plated, Dacrolit|100 pcs/box|
|JSM S8C||2TLA041014R0200|Fixing screw for floor fitting and<br>small angle|M8x20|Zinc Plated Steel|100 pcs/box|
|JSM S8D||2TLA041014R0100|Fixing screw|M8x16|Zinc Plated Steel|100 pcs/box|
|JSM S8E||2TLA041019R0100|Fixing screw for Guide rail JSM<br>A56|M8x12|Zinc Plated Steel|100 pcs/box|
|JSM M4B||2TLA040035R0700|Locking nut|M4|Zinc Plated Steel|100 pcs/box|
|JSM M5B||2TLA040035R0400|Locking nut|M5|Zinc Plated Steel|100 pcs/box|
|JSM M6B||2TLA040035R0500|Locking nut|M6|Zinc Plated Steel|100 pcs/box|
|JSM M8B||2TLA040035R0600|Locking nut|M8|Zinc Plated Steel|100 pcs/box|
|JSM M10A||2TLA041069R0000|M10 Thread insert for<br>JSM A44A|M10x21,<br>Ø18.5/25|Steel, zinc-plated|1 pcs|
|JSM X1||2TLA040033R4300|Cable tie|2.5–7.8 mm|Nylon black UV-<br>resistant|10 pcs/box|
|JSM X2||2TLA041900R4300|Expansion-shell bolt|M10x68|Zinc Plated Steel|50 pcs/box|
|JSM X3||2TLA041910R0000|Window cleaning fluid (Antistatic) for<br>polycarbonate  sheets. Actuator head 0.5 L.|||per can|
|JSM X4||2TLA041911R0100|Mesh clipping tool|L=300||each|
|JSM X5A||2TLA041810R0200|ABB Safety Products sign|220x40x1.5mm|Aluminium, Natural<br>anodized|1 pcs|
|JSM X5B||2TLA041810R0300|ABB Safety Products sign,<br>pre-assembled with screws<br>~~et~~|220x40x1.5mm<br>~~ee~~|Aluminium, Natural<br>anodized<br>~~a~~|1 pcs<br>~~a~~|
|JSM B4C||2TLA040035R5000|Centring washer steel<br>~~et~~|Ø4.2<br>~~ee~~|Zinc Plated Steel<br>~~a~~|100 pcs/box<br>~~a~~|
|JSM B5C|~~Sop~~|2TLA040035R5100<br>~~Sop~~|Centring washer steel<br>~~et~~|Ø5.2<br>~~ee~~|Zinc Plated Steel<br>~~a~~|100 pcs/box<br>~~a~~|
|JSM B6C|~~Sop~~|2TLA040035R5200<br>~~Sop~~|Centring washer steel|Ø6.2|Zinc Plated Steel|100 pcs/box|
|JSM B8C|oP|2TLA040035R5300|Centring washer steel|Ø8.2|Zinc Plated Steel|100 pcs/box|



13/31    2TLC172001C0202 | ABB Safety Handbook 

13 

## Infill materials 

The choice of net and surfaces depends, among other things, on the protection distance. In the case of netting, a minimum distance of 200 mm (for anyone aged 14 or older) with a mesh size of 40x40 mm in accordance with EN ISO 13857. For closer protection distances and for noise reduction, solid panels are used. Panels are available in different materials. For protection of welding cells, polycarbonate welding transparencies are used. 

|Welded mesh|||Designation|||JSM YN40W_/WE _|||
|---|---|---|---|---|---|---|---|---|
||||Square opening|||40 x 40 mm|||
|LJ<br>i ttf |<br>[pot<br>| fy<br>coo<br>LJ<br>i itt ||:<br>:||Thread|:<br>|||ø 3.5 mm|||
|Article number|||Designation|||Material|Dimensions|Type|
|2TLA040040R1300|||JSM YN40W1|||Steel, black RAL 9005 powder coated|2020 x 864 mm|Welded|
|2TLA040040R1400|||JSM YN40W2|||Steel, black RAL 9005 powder coated|1074 x 1816 mm|Welded|
|2TLA040040R1500|||JSM YN40W3|||Steel, black RAL 9005 powder coated|1074 x 2016 mm|Welded|
|2TLA040040R2000|||JSM YN40W4|||Steel, black RAL 9005 powder coated|1474 x 2016 mm|Welded|
|2TLA040040R2100|||JSM YN40W5|||Steel, black RAL 9005 powder coated|1474 x 1816 mm|Welded|
|2TLA040040R2600|||JSM YN40W6|||Steel, black RAL 9005 powder coated|2020 x 754 mm|Welded|
|2TLA040040R2700|||JSM YN40W7|||Steel, black RAL 9005 powder coated|2020 x 1174 mm|Welded|
|2TLA040040R1600|||JSM YN40W9|||Steel, black RAL 9005 powder coated|Cut to size|Welded|
|2TLA040040R2800|||JSM YN40W10|||Steel, black RAL 9005 powder coated|1474 x 1216 mm|Welded|
|2TLA040040R2900|||JSM YN40W11|||Steel, black RAL 9005 powder coated|1074 x 1216 mm|Welded|
|2TLA040040R2500|||JSM YN40WE1|||Stainless steel, SS 2333|2020 x 864 mm|Welded|
|2TLA040040R1800|||JSM YN40WE2|||Stainless steel, SS 2333|1074 x 1816 mm|Welded|
|2TLA040040R1900|||JSM YN40WE9|||Stainless steel, SS 2333|Cut to size|Welded|
|Other colours, hot-dip galvanized mesh or woven wire mesh netting supplied on request.|||||||||
|Net lock for welded mesh with outer wire||Net lock for welded mesh with outer wire|Net lock for welded mesh with outer wire||||||
|Designation|||JSM NL2||||||
|Article numbers|||2TLA040031R0600||||||
|Material|||PA/ABS||||||
|Colour|||Grey||||||
|Order unit|||100 pcs/box||||||
|Net lock for welded or woven mesh|||||||||
|Designation|||JSM NL3||||||
|Article numbers|||2TLA040031R0800||||||
|Pre-assembled with|||Screw||||||
|Material|||Zinc||||||
|Order unit|||100 pcs/box||||||
|Shockproof panelling|||||||||
||||Plastic panels||||||
||||name: JSM Y_||||||
||||Other materials can be supplied on request.||||||
|Plastic panel name: JSM Y_|||||||||
|Article number|||Designation|||Material|Thickness|Dimensions|
|2TLA040039R1000|||JSM YPC5A1|||Polycarbonate, uncoloured|5 mm|2020 x 864|
|2TLA040039R1100|||JSM YPC5A2|||Polycarbonate, uncoloured|5 mm|2020 x 1174|
|2TLA040039R1200|||JSM YPC5A9|||Polycarbonate, uncoloured|5 mm|Cut to size|
|2TLA040039R2400|||JSM YPC3AC9|||Polycarbonate, dark tint, weld-protected|3 mm|Cut to size|
|2TLA040039R2500|||JSM YPC3AC1|||Polycarbonate, dark tint, weld-protected|3 mm|2050 x 3000|
|2TLA042150R0600|||JSM YG6A9|||Laminated glass|6.4 mm|Cut to size|



ABB Safety Handbook | 2TLC172001C0202   13/32 

13 

X-reinforced steel panel Other materials are available on request. 

8-12 

Steel panel 

|Steel panel||||||||||||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
|Article number|||Designation||Material||||||||||||||Thickness||||||||Dimensions|||||||
|2TLA040039R0700|||JSM YGP1A9||Galvanised sheet metal|||Galvanised sheet metal|||||||||||1 mm||||||||Cut to size|||||||
|2TLA040039R0900|||JSM YGP2A9||Galvanised  sheet metal||||||||||||||1.5 mm||||||||Cut to size|||||||
|Painted sheet metal can be supplied on request.|Painted sheet metal can be supplied on request.||Painted sheet metal can be supplied on request.|||||||||||||||||||||||||||||||
|Panel fixings||||||||||||||||||||||||||||||||||
|Designation:|||JSM PL1_(for 5 mm panels)|||||||||Article number||||Article number|||Designation||||||||Length|||||||
||||JSM PL2_(for 4 mm panels)|||||||||2TLA040038R0100|||||||JSM PL1A||||||||842 mm|||||||
|Material:||||||||||||2TLA040038R0200|||||||JSM PL1B||||||||1152 mm|||||||
|JSM PL1:|||PVC, black|||||||||2TLA040038R0300|||||||JSM PL1C||||||||2000 mm|||||||
|JSM PL2:|||PVC, black|||||||||2TLA040038R0400|||||||JSM PL1D||||||||732 mm|||||||
|Standard package:|||50 pcs/package|||||||||2TLA040038R0700|||||||JSM PL2A||||||||842 mm|||||||
||||||fl|Ss|as|||||2TLA040038R0800|||||||JSM PL2B||||||||1152 mm|||||||
|||||||||||||2TLA040038R0900|||||||JSM PL2C||||||||2000 mm|||||||
|||||||||||||2TLA040038R1000|||||||JSM PL2D||||||||732 mm|||||||
|Cellular rubber - To be used with e.g. 1.0 mm steel panel||||||||||||||||||||||||||||||||||
|Designation:<br>Article numbers:||||JSM G2<br>2TLA040038R0600||||5<br>~~LZZz~~<br>~~L~~<br>~~Wh~~|||||||||||||||||||||||||||
|Material:|||Cellular rubber,|||||||||||20||||||||||||||||||||
|Dimension:<br>Standard package:|||self-adhesive<br>5 x 20 mm<br>10 m/roll|||||||||||||||||**1**<br>**2**<br>**3**<br>a ~~5~~<br>|<br>~~jm~~<br>4Z~~a~~<br>Lo~~t~~<br>iO)||||||||||||||
|U-rubberstrip - To be used with e.g. 6.4 mm laminated glass||U-rubberstrip - To be used with e.g. 6.4 mm laminated glass||||||||||||||||||||||||||||||||
|Designation:|||JSM G3|||||||||||10|||||||||||a|||||||||
|Article numbers:|||2TLA041930R0600|||||||||||6||||||||||||||||||||
|Material:|||EPDM|||||||||||||||||||||||||||||||
|Standard package:|i||50 m/roll||||||12|||||||||||||**1**<br>**2**<br>Z<br>EB Zz|||||:<br>~~i~~nt|||||||
|Panel lock||||||||||||||||||||||||||||||||||
|Designation:|||JSM PL3|||||||||||||||||||||||||||||||
|Article numbers:|||2TLA040038R1100|||||||||||||||||||||||||||||||
|Pre-assembled with:|||Screw|||||||||||||||||||||||||||||||
|Material:|||Zinc||||||||||||||||||||||ge||ge|||||||
|Sound absorbing||||||||||||||||||||||||||||||||||
|Article number|||Designation||Material|||||||||||||Thickness|Dimensions||||||||Weight (kg/m|||Weight (kg/m|Weight (kg/m2)|||
|2TLA040037R1100|||JSM YLA25A9||Core|||||||||||||25 mm|Cut to size||||||||13.8|||||||
||||||Rock wool|||||||||||||||||||||||||||||
|2TLA040039R2600|||JSM YLA25A1||Solid surface|||||||||||||||||||||||||||||
||||||PVC coated steel plate, White|||PVC coated steel plate, White|||PVC coated steel plate, White|||||||25 mm|1963 x 1200||||||||13.8|||||||
|2TLA042150R2300|||JSM YLA50A9||Perforated surface|||||||||||||||||||||||||||||
||||||Hot dipped galvanized Steel sheet||||||||Hot dipped galvanized Steel sheet|||||50 mm|Cut to size||||||||21.0|||||||



## Cut to size – max dimension 2000 x 1200 

NOTE! Use mounting profile JSM AS1 for JSM YLA25A_ Use mounting profile JSM AS3 for JSM YLA50A_ 

13/33    2TLC172001C0202 | ABB Safety Handbook 

13 

## Safety Roller Door 

## Approvals: 

- Application: – Allowing access to risk areas 

- – Protection from ejected particles, e.g chips and welding splash 

- ~~7~~ Features: – Highest safety level according to EN ISO 13849-1 

   - Prevents unintentional start 

   - Withstands harsh environments 

   - Quick operation 

   - High reliability 

   - Noise absorbing 

Roller door for short safety distances and narrow spaces Safety Roller Doors make it possible to have a short safety distance to the machine.  The noise absorbing roller door is compact and it can therefore be placed in narrow spaces. It is easy and quick to access the machine or gain access for servicing with the Safety Roller Door. 

It demands a minimum of maintenance and offers reliable operation. To be able to start the machine/plant the door has to be completely closed. The closed position is monitored by the Eden non-contact sensor from ABB Jokab Safety. As soon as the door begins to open the Eden sends a signal to the machine/plant via the Pluto Safety-PLC from ABB Jokab Safety. The roller door fulfills safety category 4 together with Eden and Pluto. 

## Customized roller door 

This door design is easy to customize. The largest possible opening width is 4000 mm and the largest possible opening height is 3500 mm. The maximum size of the door fabric is 10 m[2] . If a larger door fabric is desired, contact ABB Jokab Safety. The door is supplied as standard with a light-grey door fabric. Other colours can also be supplied. The roller door can be supplied with a viewing window in full width and at an optional height. The viewing window can also be made in a special material that protects against welding splash. 

## Protects against welding splash 

The roller door protects against ejected particles, such as chips and welding splash. The roller door fabric is also resistant towards a great number of chemicals, which permits it to be installed in harsh environments. 

## Simple assembly 

The Safety Roller Door is simple to assemble because it consists of few components and it is supplied partly preassembled. It can be integrated into the Quick-Guard fencing system from ABB Jokab Safety as well as in other types of fencing systems. It can also be installed on the machine or other permanent construction. 

ABB Safety Handbook | 2TLC172001C0202   13/34 

Function 

13 

Highest protection in accordance with EN ISO 13849-1 The monitoring of the door´s position by two Eden sensors together with with a Pluto monitoring unit fulfills Cat. 4/PL e enligt EN ISO 13849-1. These units are certified by TÜV. 

## Functions 

The door protects against access to moving parts in the machine/plant. The production process can begin when the door is fully closed. The closed position is monitored by an Eden sensor on both sides of the door. Because the door is monitored by Eden sensors at both sides of the door it is impossible to lift one side of the door and reach into the risk area without the machine/plant stopping. When the door has moved a maximum of 10 mm upwards a stop signal is sent to the protected machine/plant. The Eden sensors are monitored by a Pluto Safety-PLC which has failsafe outputs for stopping the machine/plant in the risk area and to control the door. 

The door also protects from particles ejected by the production process, e.g. chips and welding splash. It has a good sound absorbing ability. Because the door operates quickly, at 0.8-1.0 m/s, the operator has a good access to the machine area. The door is equipped with a safety contact strip in the bottom preventing it from causing personal injury on any person. When the safety contact strip is affected the door is is 

compressed, the door movement reverses to move upwards. The opening and closing of the door can be controlled via the buttons or via the signals from the control system of the machine. 

## Prevents an unintentional start 

When the door is located in front of the machine/plant, where the operator can enter the area with his entire body, safe interlocking of the door´s downward movement is needed. This is to prevent the machine from being started from the outside when somebody is inside the roller door. 

One way to solve this is to use a horizontal light curtain which covers the area which the operator can occupy within the risk area. Another solution is to place double light beams in the opening, combined with a reset facility. Yet another solution is to use time-reset. A time-reset button is placed inside the risk area and a button is placed outside the risk area. First, the button in the risk area should be pressed and thereafter (within a certain amount of time, e.g. 5 seconds) the button outside should be pressed. After this the door can be manoeuvred downwards. 

## Safety distances and standards 

## Minimum safety distance 

For the roller door to be able to provide good protection it has to be installed a sufficient distance away from moving machine parts. 

## Useful standards 

EN ISO 13857 Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs. EN ISO 13855 Safety of machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body. 

NOTE! The roller door has good protection against welding splash and smaller ejected particles from the the production area. The roller door is not intended to act as collision protection. The installer of the roller door has the responsibility of ensuring that sufficient safety distance against moving machine parts is provided. 

13/35    2TLC172001C0202 | ABB Safety Handbook 

13 

Technical data – Safety Roller Door 

|Colour|Frame - aluminium, door cloth - grey. Other colours available on request.|
|---|---|
|Ordering data|Safety Roller door + viewing window. Viewing window with weld splash protection.<br>Daylight height & Daylight width.|
|Maximum size, door cloth|10 m². If a larger size is needed, contact ABB Jokab Safety AB.|
|Maximum width|4000 mm|
|Maximum height|3500 mm|
|Driving unit|Three-phase motor 200-415 VAC 50-60 Hz|
|Speed, roller door|0.8 – 1.0 m/s up/down|
|Max. number of cycles/minute|3 (during continous operation 24 hours a day)|
|Door fabric material|Multi-layer polyester fabric cloth with PVC, 2 mm thick or transparent PVC. The viewing window can also be sup-<br>plied with protection against welding flash light. (Removes 99% of the UV-transmision from the welding process)|
|Door fabric colour|Grey (RAL 7038), can be supplied with recessed window (only in full width). Other colours are available.|
|Material frames|Aluminum extrusion|
|Material upper bracket|4 mm steel painted black|
|Sound absorption|approx. 10 dB|
|Ambient temperature|0˚C to +55˚. When operating in temperatures below -5˚C, the oil in the gear-box should be replaced with an oil<br>suitable to withstand cold temperatures.|
|Safety level|Category 4/PL e, in accordance with EN ISO 13849-1|
|Durability towards chemicals|Ammoniac, sodium hydrate, phosphoric acid, tartaric acid, oxalic acid, hydrochloric acid, citric acid, acetic acid,<br>oil, detergent, calcium chloride (contact ABB Jokab Safety for more specifications)|
|Control monitoring unit for roller door|ABB Jokab Safety´s Safety-PLC, Pluto|
|Outputs|4 safe outputs for connection to machine/plant.|
|Monitoring of position of the roller door|2 Eden sensors one on each side of the door.|
|Contact strip|Mounted on the bottom frame of the door fabric. The door motion is reversed if the contact strip is compressed.|



|A|260|DB||
|---|---|---|---|
|B|270|DH||
|C|400|F|80|
|D|200|G|250|
|E|120|H|320|
|F|80|I|150|
|P|Optional|J|100|
|R|Optional|K|500|
|||L|500|
|||M|450|



ABB Safety Handbook | 2TLC172001C0202   13/36 

Notes 

Notes 

Notes 

Notes 

Notes 

Contact us 

## ABB AB 

Jokab Safety Tel. +46 21-32 50 00 www.abb.com/jokabsafety 

Note: We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB AB, Jokab Safety does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. 

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB AB, Jokab Safety. 

Copyright © 2013 ABB All rights reserved