— MAIN CATALOG Safety ProductsABB Jokab Safety—ABB AB Jokab SafetyVarlabergsvägen 11SE-434 39 KungsbackaTel. +46 (0) 21-32 50 00www.abb.com/jokabsafetyCopyright© 2018 ABBAll rights reserved2TLC010001C0202
2637485INTRODUCTIONCONTROL DEVICESSAFETY CONTROLLERSEMERGENCY STOPS AND PILOT DEVICESOPTICAL SAFETY DEVICESPRESSURE SENSITIVE DEVICESSENSORS AND LOCKSCONTACTORS AND MOTOR STARTERS—Safety products catalogABB Jokab Safety1
1SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
—Introduction1–2 Introduction 1–6 Standards and regulations 1INTRODUCTION1– 1
—Introduction Company overviewABB Jokab Safety has been helping machine builders to create production-friendly and safe work environments for operators since 1988.We develop products and solutions for machine safetyWe make it simple to build safety systems. Developing products and solutions for machine safety has been our business idea since the company Jokab Safety, now a part of ABB, was founded in Sweden in 1988. Many industries around the world have discovered how much easier it has become to build protection and safety systems with our components and guidance. Our extensive program of products, safety solutions and our long experience in ma-chine safety makes us a safe partner.Together we create a safe world!11– 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Products and systemsWe deliver machine safety solutions for single machines or entire production lines. Our long experience of helping customers making solutions for demanding environments has made us experts in combining production demands with safety demands for production-friendly solutions.We market a wide range of safety products, which makes it easy to build safety systems. We develop these intelligent products continuously, in cooperation with our customers. Markets and industriesSolutions from ABB Jokab Safety can be found in all types of industries across the globe. But we pride ourselves in having products and solutions that are especially well suited for e.g.: - Robotics - Food and beverage - General machinery (OEM)—Introduction Company overviewOur experience of safety requirements and standardsDirectives and standards are very important to machine builders and safety component manufacturers. We represent Sweden in several international committees that develop standards, for e.g. industrial robots, safety distances and control system safety features. We work daily with the practical application of safety requirements in combination with production requirements. We are happy to share our knowledge of standards with our customers. You can use our experience for training and advice.1INTRODUCTION1– 3
Magne magnetic lockto keep doors and hatches locked during a processSmile emergency stop buttonto safely stop machinery in hazardous situationsSafeball control device for an ergonomic and safe two-hand controlJSHD4 three-position device for safe and ergonomic inspection and troubleshootingGKey safety lockfor safe locking of doorsMKey9 key switchfor safe locking of hatches and doorsInca emergency stop buttonfor compact panel mountingOrion light guardsfor a production friendly safety detectionEden sensorfor reliable non-contact monitoring of doors and hatchesPluto programmable safety controller,Vital safety controller and Sentry safety relaysfor flexible monitoring of safety devicesLineStrong pull wire emergency stop switch for easy access of emergency stop functionOperators and signalling devicesfor control and indicationMats, rails and bumpersto detect the presence of peopleContactors and electroniccompacts starters to control power and motors—Our range of safety products ABB is the only supplier that can deliver complete safety solutions (including output devices such as contactors and frequency converters) together with automation solutions such as robotics, motors, drives and PLCs.11– 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Magne magnetic lockto keep doors and hatches locked during a processSmile emergency stop buttonto safely stop machinery in hazardous situationsSafeball control device for an ergonomic and safe two-hand controlJSHD4 three-position device for safe and ergonomic inspection and troubleshootingGKey safety lockfor safe locking of doorsMKey9 key switchfor safe locking of hatches and doorsInca emergency stop buttonfor compact panel mountingOrion light guardsfor a production friendly safety detectionEden sensorfor reliable non-contact monitoring of doors and hatchesPluto programmable safety controller,Vital safety controller and Sentry safety relaysfor flexible monitoring of safety devicesLineStrong pull wire emergency stop switch for easy access of emergency stop functionOperators and signalling devicesfor control and indicationMats, rails and bumpersto detect the presence of peopleContactors and electroniccompacts starters to control power and motors1INTRODUCTION1– 5
Harmonised standardsHarmonised standards give support on how to fulfill the requirements of the Machinery Directive. The relationship between the Machinery Directive and the harmonised stan-dards is illustrated by the diagram below.Within ISO (The International Organization for Standardiza-tion) work is also going on in order to harmonise the safety standards globally in parallel with the European standardi-sation work. ABB Jokab Safety takes an active part in the working groups both for the ISO and EN standards. Directives and standards are of great importance for manufacturers of machines and safety components. In the Europe-an Union, the EU Directives gives requirements for the minimum level of health and safety, and these are mandatory for manufacturers to fulfill. In every member country the Directives are implemented in national legislation.Machines which have been placed on the market since 2010, must comply with the new Machinery Directive2006/42/EC. Before that, the old Machinery Directive 98/37/EC was valid.Although the requirements in the Directives are specific for Europe, they also apply to machines that are imported to Eu-rope. And the Directives are supported by standards, of which many also are valid internationally. —European Directives and StandardsThe 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 Ap-proach” which is based on the following principles: –The directives give the basic health and safety require-ments, 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 fulfill the basic safety requirements in the Machinery Directive.Giving basic concepts, principles for design, and general aspects that can be applied to all machineryB1: Standards on particular safety aspects (e.g. safety distances, surface temperature, noise)B2: Standards on safeguards (e.g. two-hand controls, interlocking devices, pressure sensi-tive devices, guards)Dealing with detailed safety requirements for a particular machine or group of machinesExamples of standardsA-standardsB1-standardsB2-standardsC-standardsEN ISO 1200EN ISO 13857EN 349EN ISO 13849-1 EN ISO 13855EN ISO 13850EN ISO 14119EN 60204-1EN ISO 10218-1EN 692EN 693The Machinery Directive2006/42/EC11– 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
The Machinery Directive, for machines and safety compo-nentsFrom 2006/42/EC1 § 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 a detailed definition of a machine, which can be simplified as something that has linked parts that are moving, where the energy source is not human effort. Two or more machines that are put together into a production line is also regarded as one machine. CE-marking and Declaration of conformityMachines manufactured or placed on the market from december 29, 2009, shall be CE-marked and fulfil the requirements according to the European Machinery Direc-tive 2006/42/EC. This is also valid for old machines (manu-factured 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 (European Economic Area).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! Machines have to be accompanied by a Declaration of Con-formity (according to 2006/42/EC, Annex II 1.A) that states which directive and standards the machine fulfills. It also shows if the product has gone through EC Type Examina-tion. Safety components have to be accompanied with a Declara-tion of Conformity.Requirements for the use of machineryFor a machine to be safe it is not enough that the manufac-turer has been fulfilling all valid/necessary requirements. The user of the machine also has requirements to fulfill. For the use of machinery there is a Directive 2009/104/EC.It requires that the work equipment that is provided to workers must comply with relevant Community directives.This means that when repair/changes are made on the machine it shall still fulfill the requirements of the Machinery Directive. This doesn’t have to mean that a new CE-marking is required (unless 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 di-rectives. If the machine does not fulfill the requirements the buyer is not allowed to use it.“Old” machinesFor machines delivered or manufactured in the EEA before 1 January 1995 the following is valid.From 2009/104/EC(b) work equipment which, if already provided to workers in the undertaking or establishment by 31 December 1992, complies with the minimum requirements laid down in Annex I no later than 4 years after that date; (c) without prejudice to point (a)(i), and by way of derogation from point (a)(ii) and point (b), spe-cific work equipment subject to the requirements of point 3 of Annex I, which, if already provided to workers in the undertaking or establishment by 5 December 1998, complies with the minimum requirements laid down in Annex I, no later than 4 years after that date. Annex l contains minimum requirements for health and safety. There can also be additional national specific require-ments for certain machines. NOTE! The point in time when the Machinery Directive was imple-mented 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 respec-tively “new” machines.—Machinery DirectiveFrom 2006/42/EC1 § 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.From 2009/104/ECb) work equipment which, if already provided to workers in the undertaking or establishment by 31 December 1992, complies with the minimum requirements laid down in Annex I no later than 4 years after that date;c) without prejudice to point (a)(i), and by way of derogation from point (a)(ii) and point (b), spe- cific work equipment subject to the requirements of point 3 of Annex I, which, if already provided to workers in the undertaking or establishment by 5 December 1998, complies with the minimum requirements laid down in Annex I, no later than 4 years after that date.1INTRODUCTION1– 7
Machinery that is placed on the market or put into service before 1995 in the EEA.—Risk assessment an important tool both when constructing a new machine and when assessing risks on older machines"New" machines1. Machinery that is placed on the market or put into service from 1995 in the EEA.2. All machinery that are imported to the EEA irre-spective of date of origin.Use of work equipment2009/104/ECNote! Not Annex 1 - instead use applicable directives.The Machinery Directive98/37/EC (1995 - 2009)2006/42/EC (from 2010)Possible moredirectivesEMC Directive2014/30/EUCE-marking +Declaration ofconformityLow Voltage Directive2014/35/EU"Old" machinesUse of work equipment2009/104/ECPossible national legislation on specific machines Risk assessmentA well thought-out risk assessment supports manufactur-ers/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 machinesThe following requirement is given by the Machinery Direc-tiveFrom 2006/42/ECThe manufacturer of machinery or his authorised repre-sentative must ensure that a risk assessment is carried out in order to determine the health and safety require-ments which apply to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment.The standard EN ISO 12100 gives guidance on the informa-tion 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. Machines in use A risk assessment must have been carried out on all ma-chines that are in use; CE-marked as well as not CE-marked. A risk assessment must also be performed when making changes on a machine, to determine if the safety measures needs to be adapted.Documentation of risk assessmentThe risk assessment shall be documented. The risk assess-ment should take into consideration the severity of the potential injuries as well as the probability that they occur. 11– 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Example on prioritizing according to the 5-step-methodProtection 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 5-step-method1. Eliminate or reduce risks by design and construction2. Move the work tasks outside the risk area 3. Use guards/safety devices4. Develop safe working routines/information/education5. Use warnings as pictograms, light, sound etc.Combine the 5-step-method with production friendly thinking. This can give you e.g. –fast and easy restart of machines after a safety stop –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 disturbancesPriority Example of hazard and safety measure taken1. Make machine safe by design and constructionHazard:Safety measure:Cuts and wounds from sharp edges and corners on machineryRound off sharp edges and corners.2. Move the work tasks out-side the risk areaHazard: Crushing of fingers from machine movements during inspection of the production inside the risk areaSafety measure: Installation of a camera.3. Use guard/safety devicesHazard: Crushing injuries because of unintended start during loading of work pieces in a mechanical pressSafety measure: Install a light curtain to detect operator and provide safe stop of the machinery.4. Safe working routines/informationHazard: Crushing injuries because the machine can tip during installation 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. WarningHazard: Burns because of hot surfaces in reachSafety measure: Warning signsThe likelihood that the safety solution will be well made, well received and suitable for the application increases if each risk is handled according to the 5-step-method.The further away from the center of the circle, the greater responsibility for the safety is placed 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 severity of the risk, appropiate safety measures etc. 1INTRODUCTION1– 9
EN ISO 12100Safety of machinery - General principles for design - Risk assessment and risk reductionThe primary purpose of this standard is to provide designers with an overall frame-work and guidance for decisions during the development of machinery to enable them to design machines that are safe for their intended use.EN ISO 13857Safety of machinery - Safety distances to prevent hazard zones being reached by up-per and lower limbsThis standard establishes values for safety distances to prevent danger zones being reached by the upper and lower limbs. The distances apply when adequate safety can be achieved by distances alone.EN ISO 13854Safety of machinery – Minimum gaps to avoid crushing of parts of the human bodyThe object of this standard is to enable the user (e.g. standard makers, designers of machinery) to avoid hazards from crushing zones. It specifies minimum gaps relative to parts of the human body and is applicable when adequate safety can be achieved by this method.EN ISO 13850Safety of machinery – Emergency stop – Principles for designThis standard specifies design principles for emergency stop equipment for machin-ery. No account is taken of the nature of the energy source.ISO 13851Safety of machinery – Two-hand control devices – Principles for design and selectionThis standard specifies the safety requirements of a two-hand control device and its logic unit. The standard describes the main characteristics of two-hand control devices for the achievement of safety and sets out combinations of functional charac-teristics for three types. EN ISO 14120Safety of machinery – Guards – General re-quirements for the design and construction of fixed and movable guardsThis standard specifies general requirements for the design and construction of guards provided primarily to protect persons from mechanical hazards.EN ISO 13849-1Safety of machinery – Safety-related parts of control systems – Part 1: General prin-ciples for designThis standard provides safety requirements and guidance on the principles for the design of safety-related parts of control systems. For these parts it specifies categories and describes the characteristics of their safety functions. This includes programmable systems for all machinery and for related protective devices. It applies to all safety-related parts of control systems, regardless of the type of energy used, e.g. electrical, hydraulic, pneumatic, mechanical. It does not specify which safety functions and which categories shall be used in a particular case.EN ISO 13849-2Safety of machinery - Safety-related parts of control systems - Part 2: ValidationThis standard specifies the procedures and conditions to be followed for the valida-tion by analysis and testing of:• the safety functions provided, and• the category achieved of the safety-related parts of the control system in compli-ance with EN 954-1 (ISO 13849-1), using the design rationale provided by the designer.EN 62061Safety of machinery - Functional safety of safety-related electrical, electronic and pro-grammable electronic control systems The standard defines the safety requirements and guiding principles for the design of safety-related electrical/electronic/programmable parts of a control system.EN ISO 13855Safety of machinery - Positioning of safeguards with respect to the approach speeds of parts of the human bodyThis standard provides parameters based on values for hand/arm and approach speeds and the methodology to determine the minimum distances from specific sens-ing or actuating devices of protective equipment to a danger zone.EN ISO 14119Safety of machinery - Interlocking devices associated with guards - Principles for de-sign and selectionThis standard specifies principles for the design and selection — independent of the nature of the energy source — of interlocking devices associated with guards.The standard provides measures to minimize defeat of interlocking devices in a reasonably foreseeable manner.EN 60204-1Safety of machinery - Electrical equipment of machines - Part 1: General requirementsThis part of IEC 60204 provides requirements and recommendations relating to the electrical equipment of machines so as to promote:– safety of persons and property;– consistency of control response;– ease of maintenance.—Examples of regularly used EN/ISO standards11– 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
—Standards for safety in control systemsBuilding 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. Please note that outside of the European Union there are often other standards that are used in place of EN ISO 13849.Introducing the standardThe generation change for standards on safety in control systems introduced 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, Performance Level) and EN 62061 (SIL, Safety Integrity Level).PL or SIL? What should I use?The standard you should use depends on the choice of tech-nology, 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.ExperienceEN ISO 13849-1 uses categories from EN 954-1 for defin-ing the system structure, and therefore the step to the new calculations is not so big if you have previous experience of the categories. EN 62061 defines the structures slightly differently.Customer requirements If you or your end customer comes from an industry that is accustomed to using SIL (e.g. the process industry), require-ments can also include safety functions for machine safety being SIL rated.We notice that most of our customers prefer PL as it is tech-nology-neutral and that they can use their previous knowl-edge in the categories. In this text 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 text are simplified in order to provide an understanding of the principles. The values used in the examples can change. 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. To calculate which PL level the 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)You will also need to:– protect the system against simultaneous failure of 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 wayThe 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 ben-eficial to use PFHD-values directly as the PL is a simplifica-tion that does not provide equally accurate results.What is the easiest way of complying with the standard?1. Use pre-calculated components.As far as it is possible, use components with pre-calculated PL and PFHD-values. You then minimise the number of calcu-lations to be performed. All ABB Jokab Safety products have pre-calculated PFHD-values.2. Use a calculation tool.With the calculation softwares FSDT or SISTEMA you avoid making calculations by hand. You also get help to structure your safety solutions and provide the necessary documenta-tion.3. Use Pluto or Vital Use the Pluto programmable safety controller or Vital safety controller. Not only is it easier to make calculations and changes in the future, but above all it is easier to ensure a higher level of safety.1INTRODUCTION1– 11
Step 1Has the risk been adequately reduced?Step 3Reduce the risk (redesign, use protection, information)Step 2Risk assessmentSTARTAre new risks generated?Is the measure dependent on the control system?Determine the system’s scope (space, usage, time, environment)Identify risk sources (all work operations during the life cycle)Estimate the risk (determine PLr with S, F and P)Evaluate the risk (is action required?)Ye sYe sNoNoYe sNoAre all safety functions executed?Determine PLrIdentify the safety functionsDesign and implement the solution for the safety functionVerify that PL ≥ PLrCalculate PLValidateHave other require ments been met?Ye sYe sNoNoENDRisk analysis11– 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Risk assessment and risk minimisationAccording 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. EN ISO 12100 stipulates the requirements for a risk assessment. 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 assessmentA 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 opera-tions 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), frequency of exposure to the hazard (F) and the possibility you have of avoiding or limiting the injury (P). For each factor two options are given. Where the boundary between the two op-tions lies is not specified in the standard, but the following are common interpretations and our recommendations:S1 bruises, abrasions, puncture wounds and minor crushing injuriesS2 skeletal injuries, amputations and deathF1 less frequent than once per 15 min*F2 once per 15 min or exposure time exceeding 1/20 of the overall operating timeP1 slow machine movements, plenty of space, low powerP2 quick machine movements, crowded, high power* We often recommend to choose a higher value to be on the safe side, e.g. once per day.By selecting S, F and P for the risk, you will get the PLr 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.Risk estimationTo calculate the performance level required (PLr).S Severity of injuryS1 slight (normally reversible injury)S2 serious (normally irreversible injury or death)F Frequency and/or exposure to hazardF1 seldom to less often and/or exposure time is shortF2 frequent to continuous and/or exposure time is longP Possibility of avoiding hazard or limiting harmP1 possible under specific conditionsP2 scarcely possibleStep 3 - Design and calculate the safety functionsTo begin with you need to identify the safety functions on the machine. (Examples of safety functions are emergency stop and monitoring of gate.)For each safety function, a PLr should be established (which has often already been made in the risk assessment). The solution for the safety function is then designed and imple-mented. Once the design is complete, you can calculate the PL the safety function achieves. Check that the calculated PL is at least as high as PLr and then validate the system as per the validation plan. The validation checks that the specification of the system is carried out correctly and that the design complies with the specification.You will also need to verify that 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.Step 2 – Reduce the riskIf 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. (E.g. reduce power, avoid interference in the danger zone.)2. Use protection and/or safety devices. (E.g. fences, light grids or control devices.)3. Provide information about how the machine can be used safely. (E.g. in manuals and on signs.)If risk reduction is performed using safety devices, the control system that monitors these needs to be designed as specified in EN ISO 13849-1.abcdePLrP1P2P1P2P1P2P1P2F1F2F1F2S1S2low riskhigh risk1INTRODUCTION1– 13
PL calculation in Step 3 When you calculate the PL for a safety function, it is easi-est 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 or fewer 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 manufac-turer, so you do not have to calculate yourself. The manu-facturer of switches, sensors and logic devices often have PL and PFHD-values for their components, but for mechani-cal devices (such as key switches or contactors) a PL-value cannot be supplied since it depends on how often the component will be used. You then need to calculate yourself according to EN ISO 13849-1 or use default values from the standard, if provided.To calculate PL or PFHD for a block, you need to know its category, DC and MTTFd. In addition, you need to protect the system against systematic errors and ensure that an error does not knock out both channels, and generate and vali-date any software used correctly. The following text gives a brief explanation of what to do.Safety function (SF)+ + PFHD, InputInputPL/PFHDPFHD, LogicLogicPL/PFHDPFHD, Output OutputPL/PFHDPFHD, Tot al =The relationship between categories, the DCavg, MTTFd for each channel and PL. The table also shows the PFHD-range that corresponds to each PL. PFHDPL10-4a10-5b3x10-6c10-6d10-7e10-8DC noneDC noneDC lowDC mediumDC lowDC mediumDC highCat. BCat. 1Cat. 2Cat. 2Cat. 3Cat. 3Cat. 4MTTFdlowMTTFdmediumMTTFdhigh11– 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
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 positive-guided contacts.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 manufac-turer. 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 calcu-late the MTTFd, you also need to know the average number of cycles per year that the component will execute.Calculation of the average number of cycles is as follows:dop x hop x 3600tcyclenop =B10d0,1 x nopMTTFd =wherenop = Number of cycles per yeardop = Operation days per year hop = Operation hours per daytcycle = Cycle time (seconds)Example: dop= 365 days, hop= 24 hours and tcycle= 1,800 sec-onds (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 ac-cording to the total number of cycles the component will be working. A typical example of this is the contactors that fre-quently 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.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 condi-tions 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 errorsAppendix 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 functionsPL is given in the table on the previous 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 softwareIf you use a safety PLC for implementing safety func-tions, this places requirements 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 Appen-dix J of EN ISO 13849-1 specify requirements for safety related software.The following are examples of requirements for soft-ware 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.1INTRODUCTION1– 15
Step 1 – Risk assessmentFood 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 restart-ed. The packaging machine with conveyor belt only oper-ates when 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. The total access to the danger zone is estimated to be four times per hour (F2), including manual packaging and tending operational disturbances. Unexpected start-ups are not considered to cause serious injury but rather minor heal-able injuries (S1). The operator is considered 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 x (3x8) hours/day x 2 cycles/hour = 17,520 cycles/yearThe 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.Determination of the PLr necessary for the safety function with interlocked door for this example.NOTE! The assessment needs to be made for each safety function.Key switch MKey5Monitors that the door is closed.Safety relay SentryMonitors safety compo-nents.Emergency stop buttonTo stop the machine in case of danger.Step 2 – Reduce the riskAs protection, an interlocked door is selected with the key switch MKey5. Stopping time is short enough for the dan-gerous movement to have ceased before the operator can access it. The emergency stop is placed within easy reach, on both sides of the cell near the doors. —Case study 1 - Safety relay SentryProtection layout for a packaging machine with low risksabcdePLrP1P2P1P2P1P2P1P2F1F2F1F2S1S2low riskhigh risk11– 16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
PFHD, E-stop + PFHD, Sentry + PFHD, Contactors = 4.3x10-8 + 4.9x10-9 + 4.9x10-9 + 2.47x10-8 = 7.75x10-8 PL ePLr=cInputOutputSafety function 3PLr=cSafety function 1B1 MKey5 (PL c)S1 E-stop (PL e)InputLogicPFHD, MKey5 + PFHD, Sentry + PFHD, Contactors = 1.14x10-6 + 4.9x10-9 + 2.47x10-8 = 1.17x10-6 PL cK2Sentry (PL e)Q1/Q2 Contactors (PL e)Q1/Q2 Contactors (PL e)OutputThe reason for not achieving more than PL c with Safety function 1 is that only one key switch is used per door, and a key switch is mechanically a Category 1 device. For e-stop devices though, a fault exclusion for the mechanical parts is allowed according to EN ISO 13849-2 if a maximum number of operations is considered. For this solution to reach a higher PL, EN ISO 14119 and ISO/TR 24119 need to be consulted.Step 3 - Calculate the safety functionsThe output subsystem that is composed of double moni-tored contactors has been calculated at 2.47x10-8. The safety functions are represented by block diagrams.Safety functions 1 and 2 are identical. Therefore, only safety function 1 is shown.Safety functions 3 and 4 are identical. Therefore, only safety function 3 is shown.* Monitoring of contactors with K2How safe is a mechanical switch? Mechanical switches have a tendency to break if misused.Manufacturer instructions must be followed, e.g. no excessive force or dirty environment. For interlocking switches in general EN ISO 14119 must be considered. It handles e.g. the possibility to defeat a switch and require-ments on key switches. Connecting key switches in series gives a significant risk of masking errors, as stated in the technical report ISO/TR 24119, which limits the maximum achievable DC depending on the number of frequently used doors connected in series.S1 E-stopK1Sentry SSR10S2 E-stopB2 Key switchQ1ContactorB1 Key switchK2Sentry SSR10K1Q2ContactorResultResultPL cPL e*LogicK1Sentry (PL e)LogicK2Sentry (PL e)1INTRODUCTION1– 17
Step 1 – Risk assessmentThe workpieces are transported into the robot cell where the robot places them in a test cabinet. Approved workpieces leave the cell on the conveyor belt, while workpieces that fail the tests are placed on the table for manual adjustments. 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/day), unloading from the manual station (about four times an hour), program adjustments (once/week) and cleaning (once/week) (F2). Unexpected start-ups of the robot are considered to cause potentially serious injury (S2). The operator is considered not to have the possibility of avoiding injury as the robot moves quickly (P2). The risk estimation gives PLr=e (S2, F2, P2) for the safety functions required for access to the machine.The standard for robot systems/cells (EN ISO 10218-2) speci-fies that safety functions shall comply with at least PL d, un-less the risk assessment determines otherwise. In this case the risk assessment gives us PLr= e.Step 2 – Reduce the riskAs protection, the door and hatch are interlocked with Eden non-contact sensors. To protect against entering the cell the wrong way, transport of materials in and out is protected with light cur-tains and provided with muting to distinguish between material and people. The emergency stop function is also a safety function that is required. The energy to all hazardous machine functions shall be re-moved by 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 DYNlink loop, with PL e in accordance with EN ISO 13849-1.NOTE! The assessment needs to be made for each safety function.Emergency stop button, Smile TinaTo stop the machine in case of danger.Emergency stop button INCA TinaTo stop the machine in case of danger.Light curtain, Orion Monitors the passages. Safety controller, VitalMonitors safety components in series.Non-contact sensor, EdenMonitors that the doors and hatches are closed.—Case study 2 - Safety controller VitalProtection layout for a robot cell with high risksDetermination of PLr for the safety function with interlocked door.abcdePLrP1P2P1P2P1P2P1P2F1F2F1F2S1S2low riskhigh risk11– 18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Step 3 - Calculate the safety functionsThe PFHD-value of the robot’s safety stop input is 5.79x10-8 (the value applies to ABB industrial robots with IRC5 control-ler). The safety functions are represented by block diagrams.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 in the robot cell.PFHD, Eden + PFHD, Vital + PFHD, Robot = 4.5x10-9 + 2.74x10-8 + 5.79x10-8 = 8.98x10-8 PL ePLr=eB1Eden (PL e)InputK1Vital (PL e)LogicQ1Robot (PL e)OutputResultSafety function 1PL ePFHD, Smile Tina+ PFHD, Vital + PFHD, Robot = 4.66x10-9 + 2.74x10-8 + 5.79x10-8 = 9.0x10-8 PL eSafety function 2PLr=eS2Smile Tina (PL e)InputK1Vital (PL e)LogicQ1Robot (PL e)OutputResultPL ePFHD, Orion + PFHD, Tina 10 + PFHD, Vital + PFHD, Robot = 2.64x10-9 + 4.5x10-9 + 2.74x10-8 + 5.79x10-8 = 9.24x10-8 PL ePLr=eSafety function 3B3Orion with muting (PL e)InputK1Vital (PL e)LogicQ1Robot (PL e)OutputResultTina 10B(PL e)PL eSafety function 3 - muting of light guardsIf the logic of the muting function is included in the light guard, the PFHD-value of the light guard should include the PFHD-values for the muting components. If the logic is external (i.e. safety PLC) the muting sensors should be added as separate blocks in the safety function. B5 EdenK1 VitalS1Inca TinaS2 Smile TinaB2 EdenB4 Orion 2E with OMC1, MuteR2 and Tina 10BB3Orion 2E with OMC1, MuteR2 and Tina 10BQ1Machine stop input for robot, redundant1INTRODUCTION1– 19
—Case study 3 - Programmable safety controller PlutoProtection layout for a production cell with high risksStep 1 – Risk assessmentThe workpieces 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 operator then places the workpiece on the conveyor belt for transfer to station 2. A light curtain prevents the operator from entering station 2 unnoticed. The robot in station 2 places the workpiece 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, e.g. to ad-dress operational disturbances in the press and the robot a few times a week (F1). Unexpected start-ups of the robot are considered to cause serious injury (S2). The operator is considered not to have the possibility of avoiding injury as the robot moves quickly (P2). The risk estimation for the safety function required for access to station 2 is PLr=e (S2, F2, P2). This estimation would still be the same for the press. For the safety function for the risks associated with the con-veyor belt, the estimation S1, F2, P1 is made giving PLr= b.Step 2 – Reduce the riskAs 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 (Orion) and a non-contact sensor at door 4 (Eden) protects the entry. If the door is opened or the light curtain is interrupted, energy to the hazardous functions in station 2 is removed. By opening doors 2 and 3 (also monitored by Eden sensors) the conveyor belt and the pneumatic machin-ing tool will stop safely. Manual reset must always be done after actuation of any safety device.When the protection system requires a number of safety devices and that multiple machines must be stopped, Pluto programmable safety controller is the most effective solu-tion. If the protection system also has to work by zones and in different modes of operation, this is another good reason to use Pluto. With Pluto, PL e can be achieved regardless of the number of connected safety devices.PLr= d for the robot and hydraulic press. PLr=b for the conveyor belt.Programmable safety controller Pluto Monitors safety components.Station 2Station 1Door 4Door 3Door 2Door 1RobotConveyor beltabcdePLrP1P2P1P2P1P2P1P2F1F2F1F2S1S2low riskhigh riskabcdePLrP1P2P1P2P1P2P1P2F1F2F1F2S1S2low riskhigh risk11– 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Step 3 - Calculate the safety functions for the robot cellThe PFHD-value for the robot’s safety stop input is 5.79x10-8 (the value applies to ABB industrial robots with IRC5 control-ler).Only safety functions to help remove energy to the industrial robot are shown below. This is only a subset of the safety functions. When energy is removed to multiple machines in a cell, the safety functions can be defined in different ways depending on the risk assessment. The safety functions are represented by block diagrams.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 in the robot cell.PFHD, Eden + PFHD, Pluto + PFHD, Robot = 4.5x10-9 + 2x10-9 + 5.79x10-8 = 6.44x10-8 PL ePLr=dSafety function 1B1 Eden (PL e)InputK1Pluto, relay outputs (PL e)LogicQ1Robot (PL e)OutputPL eResultPFHD, Smile Tina + PFHD, Pluto+ PFHD, Robot = 4.66x10-9 + 2x10-9 + 5.79x10-8= 6.46x10-8 PL ePLr=dS2 Smile Tina (PL e)InputQ1Robot (PL e)OutputPL eResultSafety function 2K1 Pluto, relay outputs (PL e)LogicPFHD, Orion + PFHD, Tina 10 + PFHD, Pluto + PFHD, Robot = 2.5x10-9 + 4.5x10-9 + 2x10-9 + 5.79x10-8 = 6.69x10-8 PL ePLr=dB5 Orion (PL e)InputQ1Robot (PL e)OutputPL eResultK1Pluto, relay outputs (PL e)LogicTina 10A(PL e)Safety function 3S1Two-hand device, SafeballS2–S4Emergency stop, Smile TinaB1–B3Non-contact sen-sor EdenB4–B5Non-contact sensor Eden/Light curtain Orion with Tina 10AQ3Pneumatic machining toolQ2Hydraulic pressQ1 Machine stop input for robot, redundant1INTRODUCTION1– 21
SF1SF3SF2K1Logic unitS1E-stop buttonF1Light curtainQ1MachineB1Interlocked switchS1E-stop buttonQ3Machine 3B1Interlocked switchF1Light curtainQ1Machine 1Q2Machine 2K1Logic unitMultiple safety functions for a machine Multiple safety devices are often used on a machine in order to provide satisfactory and practical protection for the op-erators. In the following example, a machine is protected by three safety devices connected to a logic device. The follow-ing figure illustrates this interconnection schematically.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 which parts should be included in each safety function?This must be resolved before you start the calculations. To summarise in simple terms you can say that each safety device should be a part of the safety function for each machine that is affected by the safety device in question. Three safety devices that all remove the energy to three machines in a cell is therefore equal to nine safety functions. In the section that follows, we explain the background.Three safety functions (SF) are defined for the machine and are calculated as:SF1: PFHD, F1 + PFHD, K1 + PFHD, Q1= PFHD, SF1SF2: PFHD, B1 + PFHD, K1 + PFHD, Q1= PFHD, SF2SF3: PFHD, S1 + PFHD, K1 + PFHD, Q1= PFHD, SF3Multiple safety functions for multiple machines in a cell It is quite common for several machines in a single cell/zone 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 by 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 e.g. when the operator enters the cell through the door interlocked by B1.—What defines a safety function?11– 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Conclusions –Use the practical approach for multiple machines. –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 re-quired.Sources:http://www.dguv.de/medien/ifa/en/pra/en13849/safe-ty_functions.pdfTheoretical approach for multiple machinesThe theoretical approach to calculate the safety function is as follows:Q3Machine 3B1 Interlocked switchQ1Machine 1Q2Machine 2K1Logic unitFor 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 dis-abled. 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 safe-ty 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.Practical approach for multiple machinesA more practical approach is to divide the safety func-tion into three parts, one for each of the three machines.B1Interlocked switchQ2Machine 2K1Logic unitB1Interlocked switchQ3Machine 3K1Logic unitB1Interlocked switchQ1Machine 1K1Logic unitThis 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 de-signed 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.Practical approach If you use the practical approach the safety functions are as follows:Robot:PFHD, B1 + PFHD, K1 + PFHD, Q1 = 4.5x10-9 + 2•10-9 + 5.79x10-8 = 6.44x10-8 PL eHydraulic press:PFHD, B1 + PFHD, K1 + PFHD, Q2 = 4.5x10-9 + 2•10-9 + 8x10-8 = 8.65x10-8 PL ePneumatic machining tool:PFHD, B1 + PFHD, K1 + PFHD, Q3 = 4.5x10-9 + 2x10-9 + 2x10-7 = 2.07x10-7 PL dThis 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 What would the result be using the theoretical approach? Would the safety function achieve PL e?All machines:PFHD, B1 + PFHD, K1 + PFHD, Q1 + PFHD, Q2 + PFHD, Q3 = 4.5x10-9 + 2x10-9 + 5.79x10-8 + 8x10-8 + 2x10-7 = 3.44x10-7 PL dIn this case, the safety function would not achieve a total PL e, which was required for the risks associated with the robot and hydraulic press. 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 = 4.5x10-9) –Pluto K1 (PFHD, K1 = 2x10-9) –Robot Q1 (PFHD, Q1 = 5.79x10-8) –Hydraulic press Q2 (PFHD, Q2 = 8x10-8) –Pneumatic machining tool Q3 (PFHD, Q3 = 2x10-7).Please note that the examples on these pages are simplified in order to ex-plain the principles. Values of products can also change.1INTRODUCTION1– 23
—FSDT and SISTEMATools for determining performance level (PL) Tools to simplify the process of safety function designFSDT is an ABB software for determining PL and SIL of safety functions and generating technical documentation. The tool helps simplifying the process of safety function design, verification and documentation. It supports the compliance of the requirements of both EN ISO 13849-1 and IEC 62061 as well as the European Machinery Directive. FSDT is freeware and can be downloaded from the ABB website.Another commonly used software tool for the calculation of PL according to EN ISO 13849-1 is SISTEMA, developed by IFA (The Institute for Occupational Safety and Health) in Ger-many. With SISTEMA it is possible to “build” safety functions, verify them and generate the technical documentation required. The tool is freeware and can be downloaded from the IFA website.To simplify the use of FSDT and SISTEMA with our products we have created a library con-taining all of our safety products. 2TLC172300D020111– 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY
Safety Integrity Level, SILProbability of dangerous Failure per Hour (PFHD)3≥10-8 to <10-72≥10-7 to <10-61≥10-6 to <10-5There is a method in IEC/EN 62061 for assigning the Safety Integrity Level.Severity (Se)Class (Cl)3-45-78-1011-1314-154SIL2SIL2SIL2SIL3SIL33(OM)SIL1SIL2SIL32(OM)SIL1SIL21(OM)SIL1Cl=Fr+Pr+Av OM=Other MeasuresThe severity of injury that can occur is divided into 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 repre-sents 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 fulfill the SIL that has been assigned to it in the risk assess-ment. 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 contac-tors. The sensor is sub-element 1, Pluto is sub-element 2 and the two supervised contactors are sub-element 3. If in the assessment it has been established that SIL2 shall be used, every individual sub-element in the safety function must fulfill the SIL2 requirements. And the safety function must in its entirety fulfill the SIL2 requirements.If the SIL requirements are not fulfilled in any of the sub-elements or by the safety function in its entirety, a re-design must be made. FinallyThis is just a brief introduction to the EN ISO 13849-1 and IEC/EN 62061 standards. You are welcome to contact us for more information and we are happy to guide you in how to apply the standards to our products.The information given in this document is not intended to replace the standards - we strongly encourage you to pur-chase the standards if you are working with machine safety.Definition of protective safety in accordance with IEC/EN 62061"Function of a machine whose failure can result in an immediate increase of the risk(s)"If a safety function is designed in accordance with IEC/EN 62061, the level of reliability is expressed as the Safety Integrity Level, SIL. There are a total of 4 levels, but in the IEC/EN 62061 standard SIL 3 is the highest level. SIL is similar to PL (performance level) and uses the same PFHD (probability of dangerous failure per hour) to express the reliability of components and systems.—Applying IEC/EN 62061INTRODUCTION1– 251
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—Safety controllers2– 2 Introduction and overview 2– 6 Programmable safety controller Pluto2– 16 Safety controller Vital2– 22 Safety relay Sentry SAFETY CONTROLLERS2– 12
—Introduction and overviewSelection guideThe safety controllers from ABB can monitor anything from a single safety function to complete manufacturing lines. PlutoVitalSentryImageTy p eProgrammable safety controllerSafety controllerSafety relayDescriptionA cost-effective, powerful and compact programmable safety controller for all types of safety applications.A configurable safety controller that can monitor all safety devices on smaller machines.Powerful and easy-to-install safety relays suitable for all common types of safety devices.Application(s)Monitoring of multiple safety de-vices and several safety functions, as well as control of machines and/or processes. Many I/Os and pro-grammable logic.Monitoring multiple safety devices with all the advantages of the DYN-link system.Monitoring safety devices with one safety function, as well as expan-sion of safety outputs, with or without time delay.Compatible safety devicesAll types of conventional safety devices and DYNlink devicesDYNlink devicesAll types of conventional safety devicesAdvantages- Easy-to-use while still allowing advanced programming- Free software- Easy system modification- Gateway communication with all main fieldbuses- Monitor up to 30 sensors in series maintaining Cat. 4/PL e- No programming- Easy and fast to install with push-in terminals- Universal models for all common applications- Extensive status information- Advanced timer functions- Multireset of up to 10 safety relays2– 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
Conventional safety devicesBy conventional safety devices, we mean safety devices with one or two channels with contacts (e.g. key switches and emergency stop buttons), devices with OSSD outputs (e.g. light guards and Eden OSSD), safety devices with solid state outputs (e.g. safety magnetic sensors) and pressure sensitive devices (e.g. safety mats, safety edges and bumpers).A safety controller compatible with conventional safety devices can be used with most safety devices on the market, independently of the brand.The DYNlink solutionThe DYNlink solution is a unique ABB Jokab Safety feature allowing to connect safety de-vices in series and still reach category 4/PL e/SIL 3 with only one channel (instead of two with conventional safety devices). This saves cabling and hardware.For a small machine, the Vital safety controller can be a very cost effective solution since up to 30 DYNlink devices can be connected to one Vital and still reach category 4/PL e/SIL 3. With conventional safety devices this would require one safety relay per safety device.When Pluto programmable safety controller is used, only one safety input is necessary for each DYNlink circuit instead of two inputs for a traditional safety device, which means that less I/Os are necessary.Tina adapters allow to use conventional safety devices in a DYNlink solution and transform between DYNlink signals and conventional safety signals, while maintaining the highest level of safety. This means that most conventional safety devices can be used in a DYNlink solu-tion when used together with a suitable Tina adapter.—OverviewSelection orientation Programmable logicQuite often, there is a need for logic between the different safety functions. For instance: IF (“door A” AND “door B” are open) OR (“door C” is open) THEN “Action 1”. A logic like this can be hardwired without using programmable safety controllers, but the cabling becomes much more complicated, modifications are time consuming, errors happen more often and are difficult to find.With a programmable safety controller, the safety devices are simply connected to the safe inputs of the controller and the logic is made in the program of the safety controller. The logic is then easy to modify without changing anything in the cabling. The Pluto Manager programming software allows to test the logic and see on the screen if there are any prob-lems, which means much faster troubleshooting. Pluto also offers many functions that enables it to do much more than supervising safety functions. It can e.g. control the complete manufacturing process of a smaller machine, thus saving the cost of a standard (non-safety) PLC. SAFETY CONTROLLERS2– 32
—Introduction and overviewStandardsStandardsSome of the more important safety standards to follow when designing safety solutions are:EN ISO 12100 - Risk assessmentEN ISO 13849 - Performance LevelEN ISO 62061 - SILISO/TR 23849 - Guidance on the use of the PL and SIL standardsEN 60204 - Electrical equipment2– 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
SAFETY CONTROLLERS2– 52
Pluto is a cost effective, powerful and compact programmable safety controller used in a variety of applications: in large and small systems for process and functional safety.Pluto can control most types of safety devices on the market, as well as ABB Jokab Safety DYNlink safety devices, analog sensors, encoders, con-tactors, valves and many more. Programming is done easily in the complimentary software, Pluto Manager.The models with safety bus communication sim-plify the design of safety systems, thanks to our All-Master concept. A wide range of gateways al-lows communication with other networks and also remote monitoring of a Pluto system.Continuous operationProgramming software free of chargePluto Manager is an easy to use PC based programming software provided free of charge.Easy programmingReady-made TÜV approved function blocks for safety functions make it easy to reach PL e/SIL3. Ladder logic and text programming allow the de-sign of more advanced functions and the control of complete machines.Communication with external net-worksPluto gateways provide a two-way communication between the Pluto safety bus and other field buses.Optimum interfaceEasy modificationEasy and quick replacement of units without any configuration.Flexible monitoringOnline monitoring from any Pluto in the system and remote monitoring and control with an Ethernet gateway. —Programmable safety controllerPlutoGreat flexibilityUp to 32 Pluto units can exchangedata on the same safety bus, and theunique All-Master system allows simplescaling, splitting and modification.Powerful yet compactUnexpected features for its size, likereal programming and speed monitor-ing, enables replacement of more com-plex PLC systems in some applications.More sensors and less cablingThe DYNlink solution allows seriesconnection of up to 10 safetydevices on each input.StatusBus and light button featurealso reduces cabling to a minimum.Speed up installation2-6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
DYNlink solutionThe DYNlink circuit is a unique solution that allows up to 10 DYNlink devices to be connected in series to a Pluto input while still reaching up to Cat. 4/PL e/SIL3. This saves inputs and cabling, since to reach the same level with standard two-channel safety devices, two inputs are necessary and series connection is not possible.The DYNlink solution checks the signal 200 times/second and a fault such as a short circuit will be detected before any safety device is used.Examples of DYNlink devices are Eden and Smile Tina. Most two-channel safety devices can be connected to the DYNlink solution using Tina adapters.StatusBus functionalityThe StatusBus functionality is available with some DYNlink devices and allows to collect the status of each individual safety device, even when connected in series. A single input on Pluto can collect the status of up to 30 safety devices. The devices are connected using standard cable and M12-5 connectors. No specific bus cable or extra communication module is necessary. All Pluto models offer the StatusBus functionality.—FeaturesPlutoSafety bus with All-Master functionThe unique All-Master system allows simple scaling, split-ting and modification of the safety system.In a traditional safety PLC network, there is one Master and additional Slave units. But for Plutos connected to a safety bus, all units are Masters and make their own decisions, while still having the possibility to listen to what is hap-pening to the other Plutos on the safety bus. This enables great flexibility when it comes to modification of the safety system. It also enables very simple replacement of a broken Pluto, since all Plutos have a copy of the application soft-ware of all other Plutos on the safety bus stored locally. If the replacement Pluto is given the same ID as the broken Pluto (using IDFIX), the software is downloaded from the safety bus with a simple button on the front of Pluto.Up to 32 Pluto units can be connected to the Pluto safety bus. The Pluto S20 and S46 are stand-alone models and can-not be connected to the Pluto safety bus. All other models have bus functionality. The Safety bus functionality is neces-sary in order to use a Pluto gateway.I/OsFailsafe inputs (I) are used to connect the safety devices tobe monitored. Some of them can be used as analog inputsand counter inputs. The choice is made in the Pluto programwhen the I/Os are configured. Depending on the model, theanalog inputs can be low resolution 0-27 V or high resolution0-10 V/4-20 mA. The fast counter inputs can handle frequen-cies up to 14 kHz.Failsafe inputs/non-failsafe outputs (IQ) are terminals thatcan be used as failsafe inputs or communication outputs(non-failsafe). The choice is made in the Pluto program whenthe I/Os are configured. A specific configuration is “light button” which means that both the contact and the LED in-dicator of an illuminated push-button are connected to only one IQ, thus saving one I/O. Failsafe outputs (Q) are individually safe and independentlyprogrammable outputs. There are both relay and transistoroutputs. The transistor outputs deliver a negative voltage(-24 VDC) that facilitates the detection of a short circuit with other voltage potentials and increases safety. The tran-sistor outputs are primarily intended for electromechanical components such as contactors and valves.StatusBus logotypeSAFETY CONTROLLERS2-72
Pluto ManagerPluto Manager is the programming software for Pluto, downloaded free of charge from our website http://new.abb.com/low-voltage/products/safety-products/program-mable-safety-controllers/plutoAn update function in Pluto Manager helps you to always have the latest version installed as long as you have an Inter-net connection. Pluto Manager is a user friendly PC software that allows a simple configuration of the Pluto I/Os and programming in ladder logic and with TÜV approved func-tion blocks.Examples of what the available function blocks can handle: - Two-channel safety devices, with or without Reset and Monitoring. - Single channel functions with Reset. - Muting functions - Encoders and counters - Communication with Gateways and StatusBus Examples of ladder logic functions provided: - Boolean instructions, Edge/inverted edge detection, Latch function, Toggle - Timers - Addition, Subtraction, Multiplication, Division - Remanent memories - Registers: 16 and 32 bit - Sequence programming - Option handling - Online monitoringIn Pluto Manager there is a unique Option handling function suitable for series production of machines with different customer options. All versions of a machine type can have the same PLC program. To handle the different customer options, check boxes are used to set memories that activate the different functions of the code.Current monitoringPluto A20 has a special current monitoring function. The function is mainly used to check if the connected muting lamps are working.—FeaturesPlutoRemote monitoring and controlRemote monitoring allows the connection to a remote Plutosystem via the Internet and an Ethernet gateway. Pluto Man-ager is used for the monitoring.This function can be used for:- Support of local maintenance personnel during trouble-shooting- Regular monitoring of the status of the machine or process- Follow-up of operational data like number of cycles/day orruntime. Pluto Manager also offers remote control of a Pluto system using the Internet and an Ethernet gateway.With the remote control function it is possible to:- Download a program from PC to the remote Pluto- Configure addressing of AS-i and StatusBus slaves, write IDFIX codeThe security of the remote control function is guaranteed by use of the K-button on Pluto. A change in a remote Pluto sys-tem cannot be made without a person at the remote Pluto confirming the action by pressing the K-button. Configuration of the gateway itself, e.g. switching remote control on/off, can only be made via the programming port on the gateway and not via the Ethernet port.2-8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—AccessoriesPlutoOperator panelsAn operator panel can be connected to the programming port of Pluto with a specific cable and communicate with Pluto in MODBUS ASCII. We recommend the ABB CP600 series operator panels that offer the appropriate communi-cation driver.An operator panel can also communicate with Pluto via a GATE-MT gateway.Pluto gatewaysPluto gateways provide two-way communication between the Pluto safety bus, i.e. all the Pluto units connected to it, and other field buses. Several models are available for the most common field buses.Ready-made function blocks in Pluto Manager facilitate the communication. A gateway can be located anywhere on the Pluto safety bus.Pluto safe encodersRotary absolute encoders can be used for safe position determination. Our safe encoders are intended to be connected to the Pluto safety bus. They are available in single and multi-turn ver-sions, with shaft or hollow shaft. Up to 16 absolute encoders can be connected to a Pluto safety bus. In Pluto Manager, specific function blocks make it easy to read and evaluate the values of two encoders forming a PL e/SIL3 solution. Apart from position, the speed values are available which means that also zero speed and overspeed can be moni-tored.Examples of applications are gantry robots, industrial ro-bots, and also eccentric shaft presses, where the encoders can replace existing cam mechanisms.SAFETY CONTROLLERS2-92
2TLC010035V0201Pluto S20 v2—Ordering informationPlutoSafety busFailsafe outputs a)Failsafe inputs (max) b)Analog inputs (max) b)Fast counter inputs(max) b)StatusBus inputs (max) b) Non failsafe outputs(max) b)Width mmTy p e Order codeNo4161 c)-4845Pluto S202TLA020070R47006403 c)-41690Pluto S462TLA020070R1800Ye s-221 c)-4845Pluto B22 e)2TLA020070R480024--2245Pluto O2 f)2TLA020070R85004161 c)-4845Pluto A20 g)2TLA020070R4500Pluto B202TLA020070R46004 d) + 1 c)-4845Pluto D202TLA020070R64006403 c)-41690Pluto B462TLA020070R1700398 d)441590Pluto D452TLA020070R6600a)Failsafe outputs2 failsafe outputs: - 2 independent individually safe potential free relay outputs (Q0 and Q1) with 3 contacts each4 failsafe outputs: - 2 independent individually safe potential free relay outputs (Q0 and Q1) - 2 independent individually safe transistor outputs (-24 VDC) (Q2 and Q3)6 failsafe outputs: - 2 independent individually safe potential free relay outputs (Q0 and Q1) - 2 independent individually safe potential free relay outputs with common supply (Q4 and Q5) - 2 independent individually safe transistor outputs (-24 VDC) (Q2 and Q3)b) -The number of failsafe inputs available decreases with the number of used non-failsafe outputs, analog inputs, f ast counter inputs and StatusBus inputs. -The number of analogue inputs available decreases with the number of used fast counter inputs. -The number of non-failsafe outputs available decreases with the number of StatusBus inputs used. Check the Pluto hardware manual for more information.c)0-27 V analog inputsd)0-10 V/4-20 mA (high resolution) analog inputse)Expansion model with failsafe inputs and no failsafe outputs.f)Expansion model with 2 failsafe outputs with 3 contacts each. Also possible to use as stand-alone unit.g)Model with current monitoring Pluto A20 v22TLC010008V0201Pluto D452TLC010029V0201Failsafe inputs / Outputs (not failsafe) / Dynamic outputsIQ10IQ11supplyPower+24VIQ12IQ13Identifier IDFIXIQ15IQ14IQ16I30BInputs, individual failsafeQ0IQ17I31I32I33I34I35I36Q2AI37Pluto B46, S46Pluto busI45I40I41I42I43I44I46I47Inputs, individual failsafeI0I1I2I3I6I5I4I7IQ21IQ20IQ25IQ24IQ23IQ22IQ27IQ26BAAQ1BAQ4BQ5ABQ3BA0V0VIDCHCL1)AIAIAISR46SR45SR414L1L0LSafety outputsDigital/AnalogueInputs, individual failsafeCLI0CHIDPluto O2IQ10Q1BIQ1133A1314+24V 0VCSh232434B333413142324AQ0I1250VAC, 5A24V, 1.5A24V, 1.5A250VAC, 5APower supplySafety Output ModuleSafe inputsNon-safe outpDynamic outpSafe inputsNon-safe outpDynamic outp—Pluto ordering tablePluto is available in different models depending on the needs of your application. Optional features includes bus communication, high resolution analog inputs and current monitoring. 2-10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
IDFIX-PROG 10k2TLC172613F0201IDFIX-PROG 2k52TLC172611F0201—Ordering informationPluto accessoriesDescriptionTy p e Order codePre-programmed unique identification number.IDFIX-R 2TLA020070R2000 Programmable identification number, i.e. the user can choose identification number.IDFIX-RW 2TLA020070R2100 Programmable identification number and storage of AS-i safety codes. IDFIX-DATA 2TLA020070R2300 Storage of the Pluto program, 2.5 Kbyte. Especially useful for stand-alone Pluto.IDFIX-PROG 2k5 2TLA020070R2400 Storage of the Pluto program, 10 Kbyte. Especially useful for stand-alone Pluto.IDFIX-PROG 10k 2TLA020070R2600 DescriptionTy p e Order codePluto programming and on-line monitoring cable. For a PC serial port, 9-pole D-sub connector. Pluto cable serial2TLA020070R5600 Pluto programming and on-line monitoring cable. For a PC USB port.Pluto cable USB2TLA020070R5800 Cable for connecting a HMI-panel to the Pluto programming port. Connector on HMI-side: 15-pole D-sub. On Pluto side: 90 degrees angled Modbus contact.Pluto cable HMI2TLA020070R5700 Cable for connecting HMI-panel ABB CP400 to Pluto programming port. Connector on HMI-side: 9-pole D-sub.Pluto cable CP4002TLA020070R6700 Cable for connecting HMI-panel ABB CP600 to Pluto programming port. Connector on HMI-side: 9-pole D-sub.Pluto cable CP6002TLA020070R6900 Bus cable for Pluto safety bus, 2 x 0.75 mm2. Ordered by meter, cut to size. Minimum order length 10 m.PCABLE-0002TLA020070R6800Bus cable for Pluto safety bus, 2 x 0.75 mm2. 50-meter ring.PCABLE-0502TLA020070R6805Bus cable for Pluto safety bus, 2 x 0.75 mm2. 100-meter ring.PCABLE-1002TLA020070R6810Bus cable for Pluto safety bus, 2 x 0.75 mm2. 500-meter drum.PCABLE-5002TLA020070R6850Bus cable for Pluto safety bus, 2 x 0.75 mm2. Halogen free. Ordered by meter, cut to size. Minimum order length 10 m.PCABLE-000-HF2TLA020070R8600Bus cable for Pluto safety bus, 2 x 0.75 mm2. Halogen free. 50-meter ring.PCABLE-050-HF2TLA020070R8605Bus cable for Pluto safety bus, 2 x 0.75 mm2. Halogen free. 100-meter ring.PCABLE-100-HF2TLA020070R8610Bus cable for Pluto safety bus, 2 x 0.75 mm2. Halogen free. 500-meter drum.PCABLE-500-HF2TLA020070R8650DescriptionTy p e Order codeSet of function blocks for mechanical presses.Pluto press block2TLA020070R4100Smile reset button for light button function with M12-5 connector.Smile 11 RB2TLA030053R0100Handheld terminal for StatusBus. Used for e.g. addressing and test. Connection to PC via USB-micro cable FIXA2TLA020072R2000Terminating resistor for Pluto safety bus. Necessary for each stand-alone Pluto and on the Pluto units at each end of the Pluto safety bus. Should be removed from the other Pluto units.R120 Resistor2TLA020070R2200 DescriptionTy p e Order codeContact block for safety relays and Pluto. 7 poles. Grey.Contact block 7 grey2TLA081200R1500IDFIX-R2TLC172609F0201IDFIX-RW2TLC172765F0201IDFIX-DATA2TLC172607F0201R120 Resistor2TLC172624F0201FIXA—Pluto cables and connection accessories—IDFIX identifiersIDFIX is an identification circuit that is connected to Pluto. It must be used: • when several Pluto are connected to the Pluto Safety bus (IDFIX-R or IDFIX-RW) • to get the possibility to replace a stand-alone Pluto with a new one without the need of a PC (IDFIX-PROG stores the Pluto program)—Other accessories—Pluto spare parts (included when ordering a Pluto)SAFETY CONTROLLERS2-112
Type of safety deviceType of connection to the DYNlink loopDescriptionTy p e Order codeDevices with posi-tively driven force-guided contacts like E-stop buttons and key switchesVia the device connectionMounted directly on the device enclosure to a M20 cable entry.Tina 2A2TLA020054R0100Placed inside the safety device enclosureTina 2B2TLA020054R1100M12-5 male connectorMounted directly on the device enclosure to a M20 cable entry. Tina 3A2TLA020054R0200M12-5 male connector with extra conductor for the supply of the safety deviceTwo circuits and with supply voltage for the safety sensor. Connects to a M20 cable entry.Tina 3Aps2TLA020054R1400Removable terminal blocksMounted on a DIN rail in the electrical cabi-net. Note that the connected safety device(s) must be mounted on the same cabinet. Tina 7A2TLA020054R0700Devices with OSSD outputs like Orion light guardsM12-5 male connectorAdaptation of OSSD to DYNlink. M12-8 con-nector for OSSD and M12-5 for DYNlink.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with possibil-ity to connect a local reset button. M12-8 for OSSD and M12-5 for DYNlink and reset.Tina 10B v22TLA020054R1310Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD and M12-5 for DYNlink and power.Tina 10C v22TLA020054R1610Safety mats, edges and bumpers with short-circuit detectionM12-5 male connectorShort-circuit detection and adaptation to DYNlink.Tina 6A2TLA020054R0600—Ordering informationDYNlink solutionDescriptionTy p e Order codeTina 1A is a blind plug connected to the unused M12 connectors of the connection blocks Tina 4A and Tina 8A.Tina 1A2TLA020054R0000 DescriptionTy p e Order codeConnection block for serial connection of up to 4 DYNlink devices with M12-5 connectorsTina 4A2TLA020054R0300Connection block for serial connection of up to 8 DYNlink devices with M12-5 connectorsTina 8A2TLA020054R0500Connection block for serial connection of 2 DYNlink devices with M12-5 connectorsTina 11A2TLA020054R1700Connection block for serial connection of 2 DYNlink devices with M12-8 connectors, e.g. Magne.Tina 12A2TLA020054R18002TLC172475F0201Tina 10BTina 7A2TLC172469F0201Tina 10A2TLC172473F02012TLC172459F0201Tina 3A2TLC172467F0201Tina 6A2TLC172477F0201Tina 10C2TLC172457F0201Tina 2B2TLC172453F0201Tina 2A—Tina adaptation units to DYNlink The Tina devices adapt the DYNlink signals from Pluto to safety components with mechanicalcontacts, such as E-stops, switches and light beams/curtains with dual outputs. Tina is available in several versions depending on the type of safety component that is connected to theDYNlink solution. Also available is connector blocks and a blind plug.—Connection blocks for serial connection of DYNlink devices (or devices with Tina adapter)—Blind plug to complete the serial connection on a connection block All M12 connectors on Tina 4A or Tina 8A must be connected to a safety device or a Tina 1A. For example, if only 6 devices are connected to a Tina 8A, two Tina 1A are necessary.DescriptionTy p e Order codeM12 Y-connector for series connection of DYNlink devices such as Eden, Smile, Inca and Tina.M12-3A2TLA020055R0000M12 Y-connector for parallel connection of 2 DYNlink devices.M12-3B2TLA020055R0100M12 Y-connector for the connection of 2 DYNlink devices or one DYNlink and one light button to Pluto safety PLC with only one cable.M12-3E2TLA020055R0200M12 Y-connector for series connection of DYNlink devices with the StatusBus function.M12-3S2TLA020055R0600—M12 Y-connectors 2-12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
FunctionShaftShaft diameter (mm)Type of connectionTy p e Order codeSingle-turnSolid10Connector male 12 polesRSA 597 connector 2TLA020070R3600 61.5 m cableRSA 597 1.5 m cable2TLA020070R3300 Hollow122 m cableRHA 597 2 m cable 2TLA020070R3400 10 m cableRHA 597 10 m cable 2TLA020070R5900 Multi-turnSolid6M12 connectorRSA 698 6 mm solid 2TLA020071R7800 10M12 connectorRSA 698 10 mm solid2TLA020070R3700Holow12M12 connectorRHA 698 hollow2TLA020071R7900 For more information, see the manual: Pluto safe encoders 2TLC172006M0206—Ordering informationAccessories DescriptionTy p e Order codeFemale 12 pole connector to be used with absolute encoder “RSA 597 connector”. Con-nector to be mounted on the cable.Connector for abso-lute encoder 2TLA020070R3900 M12 plug with Pluto safety bus termination resistor. To be used when the encoder is at one end of the Pluto safety bus. M12-CANend2TLA020061R0300FieldbusEthernetTy p e Order codeCANopenGATE-C22TLA020071R8100DeviceNet GATE-D22TLA020071R8200PROFIBUS-DPGATE-P22TLA020071R8000EtherCATxGATE-EC2TLA020071R9100Ethernet/IPxGATE-EIP2TLA020071R9000Modbus TCPxGATE-MT2TLA020071R9400PROFINETxGATE-PN2TLA020071R9300SERCOS IIIxGATE-S32TLA020071R9200For more information, see the gateway manuals: Pluto gateways 2TLC172009M0210 Pluto Ethernet gateways 2TLC172285M0203 DescriptionTy p e Order codeOperator panel, 4.3” touch screen, 480 x 272 pixelsCP6041SAP504100R0001For more sizes and version, see: http://new.abb.com/plc/control-panelsGATE-C22TLC172509F0201GATE-EC2TLC172843F0201CP604RSA 698 2TLC172543F0201RSA 5972TLC172331F0201—Pluto gateways With the use of a gateway, Pluto can communicate with other control systems and form a part of a larger network. The gateway models GATE-D2 and C2 can also be used as an extension of the safety bus cable to extend the Pluto network.—Pluto safe encoders The safe encoders can be used together with Pluto to safely determine the position of machine movements.—Pluto safe encoders accessories—Operator panels An operator panel (also called HMI) can be connected to the Pluto programming port (on the Pluto front) with a special cable and communicate with Pluto using MODBUS ASCII. We recommend the ABB CP600 series that offer the appropriate communication driver. An operator panel can also communicate with Pluto via a GATE-MT gateway.SAFETY CONTROLLERS2-132
Technical dataApprovalsConformity2006/42/EC - Machinery2014/30/EU - EMC 2011/65/EU - RoHSEN ISO 13849-1:2015, IEC 62061:2015+Corr.1:2015, EN 61496-1:2013(in extracts), EN 574:1996+A1:2008(in extracts), EN 692, EN 60204-1:2006+A1:2009+AC:2010, EN 50178:1997, EN 61000-6-2, EN 61000-6-4, EN 61000-4-1...6, IEC 61508:2010, IEC 61511-1, EN 50156-1, EN 50156-2:2015, ISO 13851:2002 (in extracts)Functional safety dataPFHD Failsafe relay outputsPFHD Failsafe transistor outputsEN 61508:2010SIL32.00 × 10-91.5 × 10-9EN 62061:2005+A1:2013SILCL32.00 × 10-91.5 × 10-9EN ISO 13849-1:2008PL e/Cat.42.00 × 10-91.5 × 10-9Electrical dataElectrical insulationCategory II in accordance with IEC 61010-1Operating voltage+24 VDC ± 15%Failsafe outputs QTransistor, -24 VDC, 800 mAQ2, Q3Pluto O2Pluto O2Q0, Q1, (Q4, Q5)Relay outputs AC-12: 250 V / 1.5 AVAC-15: 250 V /1.5 A VDC-12: 50 V /1.5 A DC-13: 24 V / 1.5 ARelay outputsAC-12: 250 V / 5 AAC-15: 250 V / 3 ADC-12: 60 V / 5 ADC-13: 24 V / 3 ARelay outputs (33-34)AC-12: 24 V / 1.5 AAC-15: 24 V / 1.5 ADC-12: 24 V / 1.5 ADC-13: 24 V / 1.5 AInstallation35 mm DIN railAmbient temperature–10 ̊C to +50 ̊CPluto safety busMax. number of Pluto units32Cable lengthUp to 600 mMore information For more information, e.g. the complete technical information, see product manual: Pluto hardware manual 2TLC172001M0211Connection diagramsFor Pluto connection diagrams please see https://library.abb.com/—Technical dataPluto2-14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—Dimension drawingsPlutoSingle sizeAll dimensions in mmDouble size45120120908484SAFETY CONTROLLERS2-152
Vital is a configurable safety control-ler that does not require program-ming. It uses the DYNlink system, which allows up to 30 safety devices to be connected in series to the same circuit, while achieving PL e.This enables a single Vital to super-vise all safety functions on many machines that otherwise would have required a programmable safety con-troller or multiple safety relays.Vital is also commonly used to super-vise all emergency stops for larger machine lines.Easy connectionReduced installation and engineer-ing time thanks to simple installa-tion with serial connection using M12 connectors.No programming requiredThe use of only one safety module without any programming simpli-fies engineering, commissioning and replacement.Less componentsSignificantly less components needed to achieve PL e/SIL 3.Speed up your projectsSafety and protectionLED diagnosticsIntegrated LED diagnostics reduces down time when troubleshooting.Detachable connection blocks Detachable connection blocks simplify replacement.Exchange without configuration The configuration is made with jump-ers in the detachable connection blocks. In case of exchange, the new unit automatically gets the correct configuration. Continuous operationEasy to reach highest safety levelThe DYNlink solution makes it possible to maintain the highest level of safety with up to 30 sensors connected in series.Extensive fault detectionThe DYNlink solution enables uniquefault detection features and prevents2-channel faults. —Safety controllerVital2–16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—Applications and featuresVitalDYNlink The DYNlink circuit is a unique solution that uses one single channel to achieve up to Cat. 4/PL e. Vital sends out a square wave signal that is inverted by each safety device. A connection between B1 and S1 sets if Vital should receive a non-inverted signal, i.e. an even number of devices are connected (no shunt indicates an odd number). Vital checks the returning signal 200 times/second and a fault such as a short circuit will be detected before any safety device is used. Vital can only be used with DYNlink safety device, such as Eden DYN, and devices with a Tina adapter.FeaturesApplicationsVital safety controller excels at supervising multiple safety devices on the same machine, since up to 30 safety devices can be connected in series to the same input while achieving up to PL e.Typical applications are machines with multiple doors/hatches or emergency stop buttons.SAFETY CONTROLLERS2–172
—Ordering informationVital2TLC010101V0201Vital 1DYNlink circuitsMaximum DYNlink devicesSafe outputsTy p e Order code1302 NOVital 12TLA020052R1000Type of safety deviceType of connection to the DYNlink loopDescriptionTy p e Order codeDevices with posi-tively driven force-guided contacts like E-stop buttons and key switchesVia the device connectionMounted directly on the device enclosure to a M20 cable entry.Tina 2A2TLA020054R0100Placed inside the safety device enclosureTina 2B2TLA020054R1100M12-5 male connectorMounted directly on the device enclosure to a M20 cable entry. Tina 3A2TLA020054R0200M12-5 male connector with extra conductor for the supply of the safety deviceTwo circuits and with supply voltage for the safety sensor. Connects to a M20 cable entry.Tina 3Aps2TLA020054R1400Removable terminal blocksMounted on a DIN rail in the electrical cabi-net. Note that the connected safety device(s) must be mounted on the same cabinet. Tina 7A2TLA020054R0700Devices with OSSD outputs like Orion light guardsM12-5 male connectorAdaptation of OSSD to DYNlink. One M12-5 and one M12-8 connector.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with pos-sibility to connect a local reset button. M12-8 connector for OSSD. M12-5 connector for DYNlink and reset button.Tina 10B v22TLA020054R1310Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD. M12-5 for DYNlink and power.Tina 10C v22TLA020054R1610Safety mats, edges and bumpers with short-circuit detectionM12-5 male connectorShort-circuit detection and adaptation to DYNlink.Tina 6A2TLA020054R06002TLC172475F0201Tina 10BTina 7A2TLC172469F0201Tina 10A2TLC172473F02012TLC172459F0201Tina 3A2TLC172467F0201Tina 6A2TLC172457F0201Tina 2B2TLC172453F0201Tina 2ADescriptionTy p e Order codeBlind plug connected to unused M12 connectors of the connection blocks Tina 4A and Tina 8A.Tina 1A2TLA020054R0000DescriptionTy p e Order codeConnection block for serial connection of up to 4 DYNlink devices with M12-5 connectorsTina 4A2TLA020054R0300Connection block for serial connection of up to 8 DYNlink devices with M12-5 connectorsTina 8A2TLA020054R0500Connection block for serial connection of 2 DYNlink devices with M12-5 connectorsTina 11A2TLA020054R1700Connection block for serial connection of 2 DYNlink devices with M12-8 connectors, e.g. Magne.Tina 12A2TLA020054R1800—Description—Tina adaptation units to DYNlinkThe Tina devices adapt the DYNlink signals from Pluto to safety components with mechanicalcontacts, such as E-stops, switches and light beams/curtains with dual outputs. Tina is available in several versions depending on the type of safety component that is connected to theDYNlink solution. Also available is connector blocks and a blind plug.—Connection blocks for serial connection of DYNlink devices (or devices with Tina adapter)—Blind plug to complete the serial connection on a connection blockAll M12 connectors on Tina 4A or Tina 8A must be connected to a safety device or a Tina 1A. For example, if only 6 devices are connected to a Tina 8A, two Tina 1A are necessary.DescriptionTy p e Order codeM12 Y-connector for series connection of DYNlink devices such as Eden, Smile, Inca and Tina.M12-3A2TLA020055R0000M12 Y-connector for parallel connection of 2 DYNlink devices.M12-3B2TLA020055R0100M12 Y-connector for the connection of 2 DYNlink devices with only one cable.M12-3E2TLA020055R0200M12 Y-connector for series connection of DYNlink devices with the StatusBus function.M12-3S2TLA020055R0600—M12 Y-connectors 2–18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
Technical dataApprovalsTÜV NORDConformity2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2015, EN 62061:2005+A1:2013, EN 60204-1:2006+A1:2009+Cor.:2010, EN 60664-1:2007, EN 61000-6-2:2016, EN 61000-6-4:2007, EN 61496-1:2013Functional safety dataEN 61508:2010EN 62061:2005+A1:2013EN ISO 13849-1:2008 SIL3SILCL3PL e, Cat. 4PFHD Relay output2.74 × 10-8Electrical dataPower supply+24 VDC ± 15%AC-1250 VAC / 6 A / 1500 VAAC-15240 VAC / 2 ADC-124 VDC / 6 A / 150 WDC-1324 VDC / 1 ANumber of sensorsMax. number of Eden DYN or Tina units per input 30Total max. cable length (depending on the number of Eden/Tina units)1000 mOperating temperature-10 °C to +55 °C—Technical dataVitalMore informationFore more information, e.g. the complete technical information, see product manual for:Vital 1: 2TLC172156M0201Connection diagramsFor Vital connection diagrams please see https://library.abb.com/SAFETY CONTROLLERS2–192
—Dimension drawingsVitalVital 1 1208422.52–20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
SAFETY CONTROLLERS2–212
The Sentry safety relays are powerful and easy to use safety relays, suitable for all common types of safety applications.The Sentry series contains basic models for simple applications and easy output expansion, as well as highly flexible models with extremely accurate timer functions.Sentry safety relays are used in both simple and more advanced safety solutions when safety devices need to be monitored according to the requirements of functional safety standards.Twice as fast to installPush-in terminals are twice as fast compared to regular spring loaded connectors.Handles ferruled and rigid cablesBoth ferruled and rigid cables are easy to just push into the push-in terminals by hand.No tools required for installationNo tools are required for connecting a cable in the push-in terminals. Just use the cable to push into the opening. Speed up your projectsDetachable terminal blocksDetachable terminal blocks speed up connection and replacement.Switch for reset selectionManual or automatic reset easily select-able by switch.Powerful outputs Powerful outputs allow to drive larger contactors and simplify installation by saving the use of an intermediary contactor.Easy to installLEDs and displayLEDs in 3 colours allow for more status messages and simplify troubleshoot-ing. Models with display offer preset configurations and extensive fault information.Advanced timer functionsTimer functions with an accuracy of ± 1% minimize unnecessary downtime.Multi-reset The multi-reset function enables reset of up to 10 Sentry safety relays using just one reset button.Continuous operation—Safety relaySentry2– 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—ApplicationsSentryMonitoring of safety devicesSentry safety relays make it easy to reach the required level of safety when monitoring safety devices like emergency stop buttons, door switches, light guards, etc.Expansion of safety outputsSentry expansion modules are used to increase the number of safety outputs of a safety control module in order to con-trol more machinery. SAFETY CONTROLLERS2– 232
—FeaturesSentryTimer functions with an accuracy of ± 1%Several timer functions are available: On/Off-delay, time bypass and time reset. On/Off-delay are used to postpone the activation/deactiva-tion of the safety outputs with a preset time delay. This is used in e.g. Category 1 stops. Time bypass activates the safety outputs for a maximum predefined time when the safety inputs are closed. Inching is an example of application. Time reset activates the safety outputs for a maximum pre-defined time when the safety inputs are opened. Pre-reset is an example of application. An accuracy of ± 1% allows a very precise time to be set in order to increase safety and minimize unnecessary down-time.Configurable models with displayThe models with display are configurable and the user can choose between preset configurations and a custom con-figuration that can be protected by password. Faster troubleshooting with displayThe display minimizes troubleshooting by giving extensive information about internal faults, I/O faults, system faults, function faults and a log of the last 10 errors.Switch for selection of the reset functionAll models can be used in automatic reset and some models allow to choose manual reset, either by switch or by con-figuration, which simplifies connection. In order to prevent mistakes, it is not possible to change reset function during operation by just flipping the switch.Push-in terminalsAll models are available with push-in terminals, enabling a fast and tool-free installation.Multi-resetThe multi-reset function enables reset of up to 10 Sentry safety relays using just one reset light-button. This simplifies connection, minimizes cabling and unneces-sary downtime. The multi-reset function is available for all +24 VDC Sentry models offering manual reset.Light-button functionThe light-button function is used for the multi-reset func-tion, but can also be used for a standard reset button. The function of the LED in the light-button is the following: on - at least one input is not accepted flashing - all inputs are accepted, reset possible off - all inputs accepted, reset performed, outputs activeNote: if an input is accepted it means that the door is closed, the light curtain is not interrupted, etc.Powerful outputsThe outputs have a switching capacity of up to 6A DC-13. This allows Sentry to drive larger contactors and saves the use of an intermediary contactor.Delayed outputsSome Sentry models have delayed outputs in order to e.g. give a machine time to apply breaking force before power is disconnected. For models with 2 NO + 2 NO outputs, it is only the second pair of NO outputs that is delayed. For models with 3 NO + 1 NC, all outputs are delayed.Single function or universal modelsSentry SSR models are single function safety relays de-signed for a specific application such as 1 and 2 channel devices, OSSD devices or two-hand devices. Sentry USR models are universal safety relays. They are ca-pable of handling most types of applications and safety de-vices, i.e. 1 and 2 channel devices, OSSD-devices, two-hand devices and contact mats/bumpers/edges. This means that only one type of relay is necessary as a spare, which reduces stock and saves warehouse space.2– 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
—Ordering informationSentryBSR10USR10SSR32DescriptionTy p eOrder codeScrew terminal block for Sentry safety relays. One piece.S30A2TLA010099R0000Push-in terminal block for Sentry safety relays. One piece.S30C2TLA010099R0001Coding kit for terminal blocks. One kit for one Sentry relay.S30B2TLA010099R0100S30AS30B—AccessoriesExpan-sionSafety devicesTest/ResetSafety relay outputsTimer functionFea-turePower supplyExpansion of safety controller outputs1 channel2 channels with equivalent contacts2 channels with antivalent contactsOSSD outputs / PNP outputsContact mats, bumpers and safety edges c)Two-hand devicesManual reset (all models have auto reset)Start/Test3 NO + 1 NC4 NO 2 NO + 2 delayed/delayable NO4 NO + 1 NCOff-delay 0.5 sOff-delay 1.5 sAdvanced timer functions 0 – 999 s d)Configuralble with display85-265 VAC / 120-375 VDC+24 VDCTy p eP=push-in terminalsOrder codea)b)BSR10BSR10P2TLA010040R00002TLA010040R0001a)b)BSR11BSR11P2TLA010040R02002TLA010040R0201a)BSR23 e)BSR23P e)2TLA010041R06002TLA010041R0601SSR10SSR10P2TLA010050R00002TLA010050R0001SSR10MSSR10MP2TLA010050R01002TLA010050R0101SSR20SSR20P2TLA010051R00002TLA010051R0001SSR20MSSR20MP2TLA010051R01002TLA010051R0101SSR32SSR32P2TLA010052R04002TLA010052R0401SSR42SSR42P2TLA010053R04002TLA010053R0401TSR10TSR10P2TLA010060R00002TLA010060R0001TSR20TSR20P2TLA010061R00002TLA010061R0001TSR20MTSR20MP2TLA010061R01002TLA010061R0101USR10USR10P2TLA010070R00002TLA010070R0001USR22USR22P2TLA010070R04002TLA010070R0401a) These models can also be used for expansion of Pluto safe transistor outputs (-24 VDC)b) No monitoring of two-channel fault, i.e. max Category 3 without fault exclusion.c) The safety relay detects a short-circuit, not a change in resistance.d) Off-delay, On-delay, Time bypass or Time reset.e) BSR23 must be monitored by another device in order to reach higher than Category 1/PL c according to EN ISO 13849-1, for example a safety relay, a safety PLC or an Orion light guard (EDM function).—Ordering detailsS30CSAFETY CONTROLLERS2– 252
Technical dataApprovalsConformity2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2015, EN 62061:2005+A2:2015, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 61508:2010Functional safety dataBSR10BSR11, BSR23SSR10, SSR10M, SSR20, SSR20M, TSR10, TSR20, TSR20M, USR10SSR32, SSR42, USR22EN/IEC 61508:2010 SIL3, PFHD = 3.0 x 10-9SIL3, PFHD = 4.1 x 10-9SIL3, PFHD = 4.9 x 10-9SIL3, PFHD = 9.3 x 10-9EN/IEC 62061:2005+A1:2013 SILCL3, PFHD = 3.1 x 10-9SILCL3, PFHD = 4.1 x 10-9SILCL3, PFHD = 4.9 x 10-9SILCL3, PFHD = 3.9 x 10-9EN ISO 13849-1:2008 PL e, Cat. 4, PFHD = 3.1 x 10-9PL e, Cat. 4, PFHD = 4.1 x 10-9PL e, Cat. 4, PFHD = 4.9 x 10-9PL e, Cat. 4, PFHD = 3.9 x 10-9Note! The relays must be cycled at least once a year.Electrical dataOperating voltage+24 VDC (19.2-27.6 VDC) PELV / SELVMains models: 85-265 VAC (50 / 60 Hz) or 120-375 VDCResponse time at deactivation20 msMaximum switching capacityDC13, DC1Up to 6 A (except relays with 2 NO + 2 NO outputs that switch 3 A)AC15, AC1Up to 5 A (except relays with 2 NO + 2 NO outputs that switch 3 A)Mechanical dataOperating temperatureBSR10, BSR11, BSR23, SSR10M, SSR20M, TSR20M-25 °C to 55 °CSSR10, SSR20, SSR32, SSR42, TSR10, TSR20, USR10, USR22-25 °C to 65 °CHumidity range10% ... 90%Protection classIP20 (enclosure/electrical cabinet must have at least an IP54)Mounting35 mm DIN rail (DIN 50022)Minimum space between relays in the enclosure0 mm (except for BSR23 which needs 5 mm distance)—Technical dataSentryMore informationFore more information, e.g. the complete technical information, see product manuals: https://library.abb.com/Connection diagramsFor Sentry connection diagrams please see https://library.abb.com/2– 26SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY2
All dimensions in mmDimension drawing—Dimension drawingSentry2SAFETY CONTROLLERS2– 272
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Optical safety devicesOPTICAL SAFETY DEVICES33– 13– 2 Introduction and overview 3– 8 Safety light curtain - Orion1 Base 3– 16 Safety light curtain - Orion1 Extended3– 24 Safety light grid - Orion2 Base3– 32 Safety light grid - Orion2 Extended3– 40 Safety light grid - Orion3 Base3– 48 Safety light grid - Orion3 Extended
Light curtains and light grids that cover most types of applications. Orion1 Orion2Orion3Function Light curtain, Transmitter + Receiver, Slim profileFunctionLight grid, Transmitter + Receiver, Slim profileLight grid, Active + Passive units, Sturdy profileImage ImageTy p eOrion1 BaseOrion1 ExtendedTy p eOrion2 BaseOrion2ExtendedOrion3 BaseOrion3ExtendedType of detection Finger Hand Finger HandType of detection Body BodyResolution14 mm30 mm14 mm30 mmResolution2, 3 or 4 beamsProtected height15-180 cm15-180 cm30-180 cm30-180 cmProtected height50-120 cmApplicationsManually serviced machines with short safety distances.Manually serviced machines with short safety distances. With advanced features like muting, blanking and cascading.ApplicationsPerimeter guarding over long distancesPerimeter guarding over long distances with mutingPerimeter guarding with one-sided con-nectionPerimeter guarding with one-sided connection and mutingFunctionsFunctionsRange6 m19 m7 m20 mRange50 m50 mUp to 8 m Up to 8 mAuto/Manual reset Auto/Manual resetEDMEDMMutingMutingOverrideOverrideIntegrated muting lampIntegrated muting lampBlankingBlankingNo dead zoneNo dead zoneCodingCodingCascadingCascading—Introduction and overviewSelection guide3– 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Orion1 Orion2Orion3Function Light curtain, Transmitter + Receiver, Slim profileFunctionLight grid, Transmitter + Receiver, Slim profileLight grid, Active + Passive units, Sturdy profileImage ImageTy p eOrion1 BaseOrion1 ExtendedTy p eOrion2 BaseOrion2ExtendedOrion3 BaseOrion3ExtendedType of detection Finger Hand Finger HandType of detection Body BodyResolution14 mm30 mm14 mm30 mmResolution2, 3 or 4 beamsProtected height15-180 cm15-180 cm30-180 cm30-180 cmProtected height50-120 cmApplicationsManually serviced machines with short safety distances.Manually serviced machines with short safety distances. With advanced features like muting, blanking and cascading.ApplicationsPerimeter guarding over long distancesPerimeter guarding over long distances with mutingPerimeter guarding with one-sided con-nectionPerimeter guarding with one-sided connection and mutingFunctionsFunctionsRange6 m19 m7 m20 mRange50 m50 mUp to 8 m Up to 8 mAuto/Manual reset Auto/Manual resetEDMEDMMutingMutingOverrideOverrideIntegrated muting lampIntegrated muting lampBlankingBlankingNo dead zoneNo dead zoneCodingCodingCascadingCascadingOPTICAL SAFETY DEVICES3– 33
Finger detectionLight curtains with 14 mm resolution are intended for finger detection when the light guard needs to be very close to the machine in order to give the operator a good view and easy accessibility to the machine. Choose the right resolution for your applicationHand detectionLight curtains with 30 mm resolution are intended for hand detection and area protection and is often a good compro-mise between cost and accessibility to the machine. They offer a better sensing range than finger detection light curtains, but require a slightly greater safety distance.—Introduction and overview Selection orientationBody detectionLight grids have a resolution adapted for detection of the whole body and are intended for perimeter guarding where there is a requirement for high accessibility. They offer a very good sensing range, but require a much greater safety distance than light guards for finger and hand detection.3– 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Introduction and overview StandardsResolution and safety distanceThe optical safety device must be installed so that no-one can reach the hazardous area without first passing through the detection zone of the light guard. The distance from the hazardous area to the detection zone of the optical safety device must be large enough in order for the machine to have time to stop before someone can reach the hazardous area. This distance is called the safety distance, and it shall be calculated using the formula from EN ISO 13855.The safety distance is influenced by the distance between each beam in the light guard. The closer the beams are together, the smaller the safety distance can be, which is why light cur-tains for finger detection can be placed much closer to the hazardous area than light grids for body detection.OPTICAL SAFETY DEVICES3– 53
The distance ’S’ is the minimum distance between a light curtain and a hazardous area. 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 = minimum distance in mmH1 = the lower beam may not be situated higher than 300 mm above the groundH2 = the upper beam may not be situated lower than 900 mm above the groundS = minimum distance in mmH = the light curtain detec-tion zone must be posi-tioned between 0 and 1000 mm above the floorS = minimum distance in mmK = approach speed (of hand or body) in mm/sT = stopping time of the machine (including reaction time of safety devices) in secondsC = additional distance in mm based upon the body ́s intrusion towards the hazardous area before the safety device has been actuated.For S ≤ 500 mm the minimum distance for vertical installation is calculated with the following formula:S = (2000 x T) + 8 x (d-14)where d is the light curtain ́s resolution in mm.K = 2000 mm/s is used to represent the speed of the hand. The expression (8 x (d-14)) may never be less than 0. Mini-mum distance S may never be less than 100 mm.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)K = 1600 mm/s is used to represent the speed of the body. Minimum distance according to this formula is 500 mm.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 refer-ence plane, e.g. the ground(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 mini-mum height where the detection zone may be placed. This is calculated with:H = 15 x (d – 50). 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.When you use a horizontal light curtain as perimeter protec-tion, 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 ma-chine’s hazardous section to the outermost beam of the horizontal light curtain (seen from the machine).Resolution for finger (≤14 mm) gives C = 0NB If it is possible to reach the hazard zone by reaching over the light beam, an adjustment is made to the formula. In table 1 in EN ISO 13855 an alternative safety distance addi-tion (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.—Safety distance according to EN ISO 13855S = (K x T) + C Minimum distances for light curtains installed vertically and horizontally according to EN ISO 138553– 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Minimum distance for light beams according to EN ISO 13855Minimum distance for single beams according to EN ISO 13855For light beams the minimum distance is calculated from the following:S = (1600 x T) + 850 mmNOTE! 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 to light guards with 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:A single beam as only protection is normally not suitable to prevent whole body access. Single beams are mostly used in combination with other safety devices or fixed guards.The risk assessment should determine if a single beam is a suitable protection for the hazard in question.The safety distance is calculated using:S = (1600 x T) + 1200 mmA height of 750 mm from the reference plane has been found suitable to prevent inadvertent access to the danger zone.Number of beamsHeight over the reference plane, e.g. ground4300, 600, 900, 12003300, 700, 11002400, 900OPTICAL SAFETY DEVICES3– 73
Orion1 Base is an easy to use light curtain with compact dimensions and two resolutions for detection of fingers and hands. Light curtains are usually used closed to the hazardous zone when repeated access to the machine is necessary, for example manually serviced machines.Light curtains can also be used to limit work zones inside the hazardous area and be mounted horizontally for area protection.Visible alignment levelSince the alignment level is displayed, the alignment can be improved before the occurrence of an unwanted stop.Extensive error indicationExtensive error indication reduces troubleshooting time.Protection against harsh environ-mentProtective tubes and lens shields protect the devices in harsh environ-ments.Continuous operationEasy to installEasy to align Alignment help and a wide angle within the limits of a Type 4 device facilitate alignment. Rotation brackets also sim-plify alignment.Easy to connectM12 connectors speed up cabling.No more functions than neccessaryOrion1 Base comes with a minimum of advanced functionalities to save cost.Minimized cablingA local reset button can be connected directly to the light curtain. In this way there is no need for a cable between the reset button and the electrical cabinet or for an extra control module.External device monitoringEach light curtain can monitor the actuators without any extra control module (EDM function).Cost effective solution—Safety light curtainOrion1 Base3– 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Vertical mountingWhen using standard vertical mounting the light guard can be placed close to the hazard zone. This is suitable for appli-cations where repeated access to the machine is necessary, e.g. manually serviced machines.—Applications and featuresOrion1 BaseApplicationsHorizontal mountingHorizontal mounting is mainly used for area protection and limitation of work zones.Finger detectionA 14 mm resolution is intended for finger detection when the light guard needs to be very close to the machine in order to give the operator a good view and easy accessibility to the machine. A 14 mm resolution enables a sensing range of 6 m.Hand detectionA 30 mm resolution is intended for hand detection and area protection and is a good compromise between cost and accessibility to the machine. A 30 mm resolution enables a sensing range of 19 m.EDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/PLC inputs and minimizes cabling to the electrical cabinet. Clever accessories makes the connection easier.FeaturesOPTICAL SAFETY DEVICES3– 93
—Safety light curtainOrion1 Base Detection (Resolution mm)Protected heightmmTy p e (Transmitter + receiver)Order codeFinger(14)150Orion1-4-14-015-B2TLA022300R0000300Orion1-4-14-030-B2TLA022300R0100450Orion1-4-14-045-B2TLA022300R0200600Orion1-4-14-060-B2TLA022300R0300750Orion1-4-14-075-B2TLA022300R0400 900Orion1-4-14-090-B2TLA022300R05001050Orion1-4-14-105-B2TLA022300R06001200Orion1-4-14-120-B2TLA022300R07001350Orion1-4-14-135-B2TLA022300R08001500Orion1-4-14-150-B2TLA022300R09001650Orion1-4-14-165-B2TLA022300R10001800Orion1-4-14-180-B2TLA022300R1100Hand(30)150Orion1-4-30-015-B2TLA022302R0000300Orion1-4-30-030-B2TLA022302R0100 450Orion1-4-30-045-B2TLA022302R0200 600Orion1-4-30-060-B2TLA022302R0300 750Orion1-4-30-075-B2TLA022302R0400 900Orion1-4-30-090-B2TLA022302R0500 1050Orion1-4-30-105-B2TLA022302R06001200Orion1-4-30-120-B2TLA022302R07001350Orion1-4-30-135-B2TLA022302R0800 1500Orion1-4-30-150-B2TLA022302R0900 1650Orion1-4-30-165-B2TLA022302R1000 1800Orion1-4-30-180-B2TLA022302R1100 Orion1 Base2TLC172787F0201DescriptionTy p e Order code4 standard brackets for Orion1 & Orion2JSM Orion012TLA022310R0000JSM Orion012TLC172781F0201—Ordering Details—Spare parts (included when ordering Orion)3– 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Mounting accessoriesDescriptionTy p eOrder codeOrion Test Piece 14 mmOrion TP-142TLA022310R5200Orion Test Piece 30 mmOrion TP-302TLA022310R5300Orion Laser pointerOrion Laser2TLA022310R5000JSM M5B special T-nut M5 to be used with M5x12 screw for mounting Orion on Quick-GuardT-nut JSM M5B2TLA040035R0400 4 rotation brackets for Orion1 BaseJSM Orion032TLA022310R0100Kit for mounting of Orion1 & Orion2 in Stand (4 pieces for lengths shorter than 1200 mm) JSM Orion062TLA022310R0400Kit for mounting of Orion1 & Orion2 in Stand (6 pieces for lengths of 1200 mm or more) JSM Orion072TLA022310R0500Kit for mounting of Orion1 Mirror in StandJSM Orion112TLA022310R0900Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror to be mounted in Orion Stand with one kit JSM Orion11Orion1 Mirror*Protective standOrion Stand*Protective tubeOrion WET*Lens shieldOrion Shield*Connection accessoriesSmile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Smile reset button with NO contact for Orion1 BaseSmile 11RO12TLA022316R3000Y-connector for series connection of DYNlink devices with M12-5 connectors, e.g. EdenM12-3A2TLA020055R0000Y-connector for connection of a Smile reset button to OrionM12-3R 2TLA022316R0000Y-connector for easy connection of a transmitterM12-3D2TLA020055R0300Adaptation of OSSD to DYNlink. M12-8 connector for OSSD and M12-5 for DYNlink.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with possibility to connect a local reset button. M12-8connector for OSSD and M12-5 for DYNlink and reset.Tina 10B v22TLA020054R1310Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD and M12-5 for DYNlink and transmitter.Tina 10C v22TLA020054R1610*These accessories are available in different sizes. For more information see:Orion1 Mirror 2TLC172058L0201, Orion Stand 2TLC172059L0201, Orion WET 2TLC172061L0201, Orion Shield 2TLC172071L0201For more information about the connection accessories, please see:Orion connection accessories 2TLC172101L0201—AccessoriesOrion1 Base2TLC172012V0201M12-3RSmile 11 RB2TLC172367F0201Tina 10C2TLC172477F0201JSM Orion032TLC172783F0201 Local or global resetAdaption to DYNlink* Safety controle moduleTy p e Useful connection accessoriesLocal reset button con-nected to the light guard (Orion in manual reset mode)Ye sVital or PlutoSmile 11RO1Tina 10B: OSSD to DYNlink + local reset button M12-3A: Serial connection of DYNlinkNoAny safety control module compatible with light guardSmile 11RO1 M12-3R: Easy connection of a local reset button Global reset button connected to the control module(Orion in automatic reset mode)Ye sVitalSmile 11 RATina 10A: OSSD to DYNlinkTina 10C: OSSD to DYNlink + supply to transmitterPlutoSmile 11 RBTina 10A: OSSD to DYNlink Tina 10C: OSSD to DYNlink + supply to transmitterNoAny safety control module compatible with light guardSmile 11 RA** -* The ABB Jokab Safety DYNlink solution offers the following advantages:- Serial connection of safety devices while maintaining PLe/cat. 4, up to 25 Tina 10 per Vital and up to 5 Tina 10 per Pluto input.- Only one safety input of the Pluto instead of two with the standard OSSD outputs.** Smile 11 RA has one NO contact, which is the most common for reset buttons. Please check what is requested for the chosen safety control module.Orion Laser pointer2TLC172816F0201—Accessories—How to choose correct reset buttonOPTICAL SAFETY DEVICES3– 113
—Cables and connectorsOrion1 Base ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5 Female3 mM12-C31 2TLA020056R0500 (b)6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 (a)0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R0200(c)10 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R2900(d)6 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R6400(e)1 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 M12-8 male + femaleFemale + male0.2 M12-CTO1BA12TLA022315R3000M12-8 male + femaleFemale + male0.2 M12-CTO1BM22TLA022315R3100Letters (a, b, c, d, e, t1, t2) refer to cables in connection examples, e.g:2TLC010002T0001 Connection diagram Orion_cables_Tina10_M12-3A_M12-3D1) M12-CTO1BA (t1) can be used for:- connection of Orion1 Base to Tina 10A/C- replacement of Focus II in automatic reset with Orion in automatic reset. The EDM function should be deactivated in all cases.2) M12-CTO1BM (t2) can be used for:- connection of Orion1 Base to Tina 10B or M12-3R for use of a local reset button, for example Smile 11ROx- replacement of Focus II in manual reset with Orion in manual reset.The EDM function should be deactivated in all cases.M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectors3– 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Connection examplesOrion1 BaseOrion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole maleReset to Orion with M12-3RConnection of a local reset button via M12-3R.With local reset button (a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleReset to Orion with Tina 10BOrion with Tina 10A/C Orion receiver or active partTina 10A/C1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleCableConnection to the ABB Jokab Safety DYNlink signal via Tina 10 A/C. To be used with Vital safety control module or Pluto programmable safety controller.Connection to the ABB Jokab Safety DYNlink signal via Tina 10B. To be used with Vital safety control module or Pluto programmable safety controller.Without local reset button (t1)(t2)(t2)Connection diagramsFor Orion1 Base connection diagrams please see https://library.abb.com/OPTICAL SAFETY DEVICES3– 133
—Technical dataOrion1 BaseTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 2.64 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 2.64 x 10-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 2.64 x 10-9Electrical dataPower supply+24 VDC ± 20%Power consumtion, transmitter1.5 W maxPower consumption, receiver4 W max (without load)Outputs2 PNPShort-circuit protection1.4 A maxOutput current0.5 A max / outputOutput voltage – ONVdd -1 V minOutput voltage – OFF0.2 V maxCapacitive load2.2 μF at +24 VDC maxCable length (for power supply)50 m maxConnectorsM12-4 pole male on transmitter (compatible with M12-5 pole female)M12-8 pole male on receiverOptical dataLight emission (λ)Infrared, LED (950 nm)Resolution14 or 30 mmOperating distance0.2...19 m for 30 mm0.2...6 m for 14 mmAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature0...+ 55 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)Weight1.3 kg / meter for each single unitHousing materialPainted aluminium (yellow RAL 1003)Front glass materialPMMACap materialPC MAKROLONMore informationFor more information, e.g. the complete technical information, please see product manual for:Orion1 Base 2TLC172287M0201 Connection diagramsFor Orion1 Base connection diagrams please see https://library.abb.com/3– 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
All dimensions in mm3850,514L1L212,5M12Ø16Ø16M2 n°336,932,3x2Orion1 Base—Dimension drawingsOrion1 Base Protected heightmmL1mmL2mmTy p e 150 233.3 153.3Orion1-4-xx-015-B300 383.2 303.2Orion1-4-xx-045-B450 533.2 453.3Orion1-4-xx-045-B600 683.3 603.2Orion1-4-xx-060-B750 833.2 753.3Orion1-4-xx-075-B900 983.2 903.2Orion1-4-xx-090-B10501133.21053.2Orion1-4-xx-105-B12001283.21203.3Orion1-4-xx-120-B13501433.21353.2Orion1-4-xx-135-B15001583.31503.3Orion1-4-xx-150-B16501733.31653.3Orion1-4-xx-165-B18001883.31803.3Orion1-4-xx-180-Bxx = Resolution—DimensionOPTICAL SAFETY DEVICES3– 153
Reduced downtimeExtensive error indication reduces troubleshooting time.Interference protectionProtection against mutual interfer-ence with coding.Continuous operationOrion1 Extended is an easy to use light curtain with compact dimensions. It has two resolutions for detection of fingers and hands, and comes with advanced features like cascading, muting and blanking.Light curtains are usually placed closed to the hazardous zone when repeated access to the machine is necessary, for example manually serviced machines.Easy to installEasy to align Alignment help and a wide angle within the limits of a Type 4 device facilitate installation.Easy to connectCables with M12 connectors speeds up connection.Integrated muting functionMuting sensors are connected directly to the light grid, with no need for a remote muting module.No dead zonesThe light beams cover all of the profile length, without the usual dead zones at the ends requiring extra mechanical guards.Easy serial connectionCascading with the standard units:no separate slave or master units.Cost effective solution—Safety light curtainOrion1 Extended3– 16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—FeaturesOrion1 ExtendedCascadingAll Orion1 Extended units can be connected in series (cas-caded) to easily create a suitable light curtain setup with no special units needed.Hand detectionA 30 mm resolution is intended for hand detection and area protection and is a good compromise between cost and accessibility to the machine. A 30 mm resolution enables a sensing range of 20 m.Finger detectionA 14 mm resolution is intended for finger detection when the light guard needs to be very close to the machine in order to give the operator a good view and easy accessibility to the machine. A 14 mm resolution enables a sensing range of 7 m.No dead zonesA special feature of Orion1 Extended is that the light beams cover all of the profile length, without any dead zones. This enables to place it inside openings, instead of having a larg-er light guard in front of an opening.BlankingThe blanking function allows to define a number of beams that can be constantly interrupted without stopping the machine. In this way a fixed material or a cable is allowed in the protected field, but a hand interrupting an extra beam would stop the machine. With floating blanking, the object, for ex. the cable, can move within the protected field.EDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/programmable inputs and minimizes cabling to the electrical cabinet. MutingBy connecting muting sensors to the light guard, it can distinguish material from persons and allow the material to pass through an opening but not persons. OPTICAL SAFETY DEVICES3 – 173
—Ordering informationOrion1 Extended Resolution mmProtected heightmmTy p e (Transmitter + receiver)Order codeFinger(14)300Orion1-4-14-030-E2TLA022301R0100450Orion1-4-14-045-E2TLA022301R0200600Orion1-4-14-060-E2TLA022301R0300750Orion1-4-14-075-E2TLA022301R0400 900Orion1-4-14-090-E2TLA022301R05001050Orion1-4-14-105-E2TLA022301R06001200Orion1-4-14-120-E2TLA022301R07001350Orion1-4-14-135-E2TLA022301R08001500Orion1-4-14-150-E2TLA022301R09001650Orion1-4-14-165-E2TLA022301R10001800Orion1-4-14-180-E2TLA022301R1100Hand(30)300Orion1-4-30-030-E2TLA022303R0100450Orion1-4-30-045-E2TLA022303R0200600Orion1-4-30-060-E2TLA022303R0300750Orion1-4-30-075-E2TLA022303R0400900Orion1-4-30-090-E2TLA022303R05001050Orion1-4-30-105-E2TLA022303R06001200Orion1-4-30-120-E2TLA022303R07001350Orion1-4-30-135-E2TLA022303R08001500Orion1-4-30-150-E2TLA022303R09001650Orion1-4-30-165-E2TLA022303R10001800Orion1-4-30-180-E2TLA022303R1100 DescriptionTy p e Order code4 standard brackets for Orion1 & Orion2JSM Orion012TLA022310R00002TLC172792F0201Orion1 ExtendedJSM Orion012TLC172781F0201—Ordering Details—Spare parts (included when ordering Orion)3– 18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—AccessoriesOrion1 Extended Connection accessoriesDescriptionTy p eOrder codeConnection box for two or four muting sensorsOMC12TLA022316R2000Retroreflex photoelectric sensorMute R22TLA022044R0500Adjustable mounting bracket for M18 sensors (e.g. Mute R2).JSM 642TLA040007R0200Reflector diameter 63 mmReflect 12TLA022044R2000Reflector diameter 82 mmReflect 22TLA022044R3000Smile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Mounting accessoriesOrion Test Piece 14 mmOrion TP-142TLA022310R5200Orion Test Piece 30 mmOrion TP-302TLA022310R5300Orion Laser pointerOrion Laser2TLA022310R5000JSM M5B special T-nut M5 to be used with M5x12 screw for mounting Orion on Quick-GuardT-nut JSM M5B2TLA040035R0400 Kit for mounting of Orion1 & Orion2 in Stand (4 pieces for lengths shorter than 1200 mm) JSM Orion062TLA022310R0400Kit for mounting of Orion1 & Orion2 in Stand (6 pieces for lengths of 1200 mm or more) JSM Orion072TLA022310R0500Kit for mounting of Orion1 Mirror in StandJSM Orion112TLA022310R0900Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror to be mounted in Orion Stand with one kit JSM Orion11Orion1 Mirror*Protective standOrion Stand**These accessories are available in different sizes. For more information see:Orion1 Mirror 2TLC172058L0201Orion Stand 2TLC172059L0201For more information about the connection accessories, please see:Orion connection accessories 2TLC172101L0201OMC12TLC172016V0201Orion Laser pointer2TLC172816F0201JSM 642TLC010032F02011—AccessoriesOPTICAL SAFETY DEVICES3– 193
—CablesOrion1 Extended Muting to be usedNeccessary transmit-ter/receiver cableSuitable cable between transmitter/receiver cable and el-cabinetLengthSpecial featureTy p e Order codeYe sTransmitter M12-C02PT2TM12-5 female single ended, to e.g. el-cabinet (b)3 mM12-C312TLA020056R05006 mM12-C612TLA020056R00006 mHarsh environment, halogen freeM12-C61HE2TLA020056R800010 m M12-C101HE2TLA020056R810010 mM12-C1012TLA020056R100020 mM12-C2012TLA020056R1400Receiver M12-C02PT62RMM12-5 male + female, to e.g. OMC1 (a)0.06 mM12-C006122TLA020056R63000.3M12-C03122TLA020056R58001 mM12-C1122TLA020056R20003 mM12-C3122TLA020056R21006 mM12-C6122TLA020056R220010 mM12-C10122TLA020056R230016 mM12-C16122TLA020056R540020 mM12-C20122TLA020056R2400M12-12 female single ended, to e.g. el-cabinet6 mM12-C652TLA020056R720010 mM12-C1052TLA020056R730020 mM12-C2052TLA020056R7500NoTransmitter M12-C02PT2TM12-5 female single ended, to e.g. el-cabinet (b)6 mM12-C612TLA020056R00006 mHarsh environment, halogen freeM12-C61HE2TLA020056R810010 mM12-C101HE2TLA020056R540010 mM12-C1012TLA020056R100020 mM12-C2012TLA020056R1400Receiver M12-C02PT6RBM12-12 female single ended, to e.g. el-cabinet6 mM12-C652TLA020056R720010 mM12-C1052TLA020056R730020 mM12-C2052TLA020056R7500M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 M12-C61HE2TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201 DescriptionLengthTy p eOrder codeTransmitter cable for Orion1 Extended. M12-5 male connector.0.2 mM12-C02PT2T2TLA022315R0100Receiver cable for Orion1 Extended when no muting. M12-12 male connector.0.2 mM12-C02PT6RB2TLA022315R0200Receiver cable for Orion1 Extended when muting. M12-5 male connector (for muting sensors) and M12-12 male connector.0.2 mM12-C02PT62RM2TLA022315R0300Cascade cable for Orion1 Extended1 mPT-C1PT2TLA022315R1000Cascade cable for Orion1 Extended0.5 mPT-C05PT2TLA022315R1100Cascade cable for Orion1 Extended0.05 mPT-C005PT2TLA022315R1200M12-C02PT2T M12-C20122TLC172935F0201—Cables with connectors—Separate cables and connectors—Special cables for Orion1 Extended3– 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Connection exampleOrion1 ExtendedNB: Cable with M12-5 male + female connectors shall be used between muting sensors and OMC1 inputs A1, B1, A2, B2. Connection of the muting sensors with M12-C02PT62RM and OMC1OMC1A2A1B1B2Orion receiverM12-12 pole male A1, B1, A2, B21. +24 VDC 2. — 3. 0 V 4. Muting input5. —OPTICAL SAFETY DEVICES3– 213
—Technical dataOrion1 ExtendedTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 2.64 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 2.64 x1 0-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 2.64 x 10-9Electrical dataPower supply+24 VDC ± 20%Power consumtion, Transmitter3 W maxPower consumption, Receiver5 W max (without load)Outputs2 PNPShort-circuit protection1.4 A maxOutput current0.5 A max / outputOutput voltage – ONVdd -1 V minOutput voltage – OFF0.2 V maxCapacitive load2.2 μF at +24 VDC maxCurrent for external lamp20 mA min; 200 mA maxCable length (for power supply)50 m maxConnectorsM12-4 pole male on transmitter (compatible with M12-5 pole female)M12-8 pole male on receiverOptical dataLight emission (λ)Infrared, LED (950 nm)Resolution14 or 30 mmOperating distance0.2...20 m for 30 mm0.2...7 m for 14 mmAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature0...+ 50 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)Weight1.35 kg / meter for each single unitHousing materialPainted aluminium (yellow RAL 1003)Front glass materialPMMACap materialPBT Valox 508More informationFor more information, e.g. the complete technical information, see product manual for:Orion1 Extended 2TLC172290M02013– 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Dimension drawingsOrion1 ExtendedAll dimensions in mmOrion1 Extended L1mmL2mmTy p e 300306.3Orion1-4-xx-030-E 450456.3Orion1-4-xx-045-E 600606.3Orion1-4-xx-060-E 750756.3Orion1-4-xx-075-E 900906.3Orion1-4-xx-090-E10501056.3Orion1-4-xx-105-E12001206.3Orion1-4-xx-120-E13501356.3Orion1-4-xx-135-E15001506.3Orion1-4-xx-150-E16501656.3Orion1-4-xx-165-E18001806.3Orion1-4-xx-180-Exx = Resolution (14 or 30 mm)—DimensionOPTICAL SAFETY DEVICES3– 233
Easy to installAlignment help Alignment help and a wide angle within the limits of a Type 4 device facilitate installation.Easy adjustmentRotation brackets makes alignment easy.Fast connectionM12 connectors speed up cabling.Protection in harsh environmentsThe housing is IP65 rated, and protec-tive tubes and lens shields are avail-able to provide further protection for the device in harsh environments.Continuous operationMinimized cablingA local reset button can be connected directly to the light grid, eliminating the need for cable between the reset button and the electrical cabinet or for an extra control module.External device monitoringEach light grid can monitor the actua-tors without any extra control module (EDM function).Cost effective solutionOrion2 Base is a compact light grid for access protection.The light grid has 2-4 beams and is intended for body detection.With an operating distance of 50 m between transmitter and receiver the light grid is suitable for applications with deviating mirrors.—Safety light gridOrion2 Base3– 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Body detection over long distancesWith 2-4 beams and a maximum sensing range of 50 m be-tween transmitter and receiver, the light grid is intended for body detection and can be used with deviating mirrors to form a protective perimeter around a dangerous area.—Applications and featuresOrion2 BaseApplicationEDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/programmable inputs and minimizes cabling to the electrical cabinet. Clever accesso-ries make the connection easier.FeaturesOPTICAL SAFETY DEVICES3– 253
—Ordering informationOrion2 Base Detection Protected heightmmTy p e (Transmitter + receiver)Order codeBody500 (2 beams)Orion2-4-K2-050-B2TLA022304R0000800 (3 beams)Orion2-4-K3-080-B2TLA022304R0100900 (4 beams)Orion2-4-K4-090-B2TLA022304R02001200 (4 beams)Orion2-4-K4-120-B2TLA022304R0300Orion2 Base2TLC172798F0201 DescriptionTy p e Order code4 standard brackets for Orion1 & Orion2JSM Orion012TLA022310R0000JSM Orion012TLC172781F0201—Ordering details—Spare parts (imcluded when ordering Orion)3– 26SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Mounting accessoriesDescriptionTy p eOrder codeOrion Test Piece 14 mmOrion TP-142TLA022310R5200Orion Test Piece 30 mmOrion TP-302TLA022310R5300Orion Laser pointerOrion Laser2TLA022310R5000JSM M5B special T-nut M5 to be used with M5x12 screw for mounting Orion on Quick-GuardT-nut JSM M5B2TLA040035R0400 4 rotation brackets for Orion2JSM Orion042TLA022310R0200Kit for mounting of Orion1 & Orion2 in Stand (4 pieces for lengths shorter than 1200 mm) JSM Orion062TLA022310R0400Kit for mounting of Orion1 & Orion2 in Stand (6 pieces for lengths of 1200 mm or more) JSM Orion072TLA022310R0500Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror in stand for Orion 2 and 3Orion Mirror*Protective standOrion Stand*Protective tubeOrion WET*Lens shieldOrion Shield*Connection accessoriesSmile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Smile reset button with NO contact for Orion1 BaseSmile 11RO12TLA022316R3000Y-connector for series connection of DYNlink devices with M12-5 connectors, e.g. EdenM12-3A2TLA020055R0000Y-connector for connection of a Smile reset button to OrionM12-3R 2TLA022316R0000Y-connector for easy connection of a transmitterM12-3D2TLA020055R0300Adaptation of OSSD to DYNlink. M12-8 connector for OSSD and M12-5 for DYNlink.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with possibility to connect a local reset button. M12-8connector for OSSD and M12-5 for DYNlink and reset button.Tina 10B v22TLA020054R1310Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD and M12-5 for DYNlink and transmitter.Tina 10C v22TLA020054R1610*These accessories are available in different sizes. For more information see:Orion Mirror 2TLC172060L0201, Orion Stand 2TLC172059L0201, Orion WET 2TLC172061L0201, Orion Shield 2TLC172071L0201For more information about the connection accessories, please see:Orion connection accessories 2TLC172101L0201—AccessoriesOrion2 BaseSmile 11 RB2TLC172367F0201Tina 10 C2TLC172477F02012TLC172012V0201M12-3R Local or global resetAdaption to DYNlink*Safety controle moduleTy p e Useful connection accessoriesLocal reset button connected to the light guard (Orion in manual reset mode)Ye sVital or PlutoSmile 11RO2Tina 10B: OSSD to DYNlink + local reset button M12-3A: Serial connection of the DYNlinkNoAny safety control module compatible with light guardSmile 11RO2 M12-3R: Easy connection of a local reset button Global reset button connected to the control module(Orion in automatic reset mode)Ye sVitalSmile 11 RATina 10A: OSSD to DYNlinkTina 10C: OSSD to DYNlink + supply to transmitter PlutoSmile 11 RBTina 10A: OSSD to DYNlinkTina 10C: OSSD to DYNlink + supply to transmitterNoAny safety control module compatible with light guardSmile 11 RA** -* The ABB Jokab Safety DYNlink solution offers the following advantages:- Serial connection of safety devices while maintaining PLe/cat. 4, up to 25 Tina 10 per Vital and up to 5 Tina 10 per Pluto input.- Only one safety input of the Pluto instead of two with the standard OSSD outputs.** Smile 11RA has one NO contact, which is the most common for reset buttons. Please check what is requested for the chosen safety control module.JSM Orion 042TLC172776F0201—How to choose correct reset button—AccessoriesOPTICAL SAFETY DEVICES3– 273
—CablesOrion2 Base ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R0500(b)6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 (a)0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R0200(c)10 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R2900(d)6 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C0063412TLA020056R6400(e)1 mM12-C13412TLA020056R5000 3 mM12-C33412TLA020056R5100 Letters (a, b, c, d, e) refer to cables in connection examples, e.g: 2TLC010002T0001 Connection diagram Orion_cables_Tina10_M12-3A_M12-3D1) Used for the connection to Tina 10, M12-3D and M12-3R. Tina 10 can be connected directly to the light guard without cable, but will form an angle (i.e. not be aligned) with the light guard, which might be a problem if the light guard is mounted close to a wall/aluminum profile. 2TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050M12-C3342TLC172931F02012TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201M12-C61HE—Cable with connectors—Separate Cables and connectorsM12-C613– 28SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Orion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole maleReset to Orion with M12-3RConnection of a local reset button via M12-3R.With local reset button (a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleReset to Orion with Tina 10BOrion with Tina 10A/C Orion receiver or active partTina 10A/C1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleCableConnection to the ABB Jokab Safety DYNlink signal via Tina 10 A/C. To be used with Vital safety control module or Pluto programmable safety controller.Connection to the ABB Jokab Safety DYNlink signal via Tina 10B. To be used with Vital safety control module or Pluto programmable safety controller.Without local reset button (e)(e)(e)—Connection examplesOrion2 BaseConnection diagrams For Orion2 Base connection diagrams please see https://library.abb.com/OPTICAL SAFETY DEVICES3– 293
—Technical dataOrion2 BaseTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 2.64 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 2.64 x 10-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 2.64 x 10-9Electrical dataPower supply+24 VDC ± 20% (SELV/PELV)Power consumtion, Transmitter30 mA max. / 0.9 WPower consumption, Receiver75 mA max. (without load) / 2.2 WCable length (for power supply)50 m max with 50 nF capacitive load and +24 VDCInternal capacitance23 nF (Transmitter) / 120 nF (Receiver)Outputs2 PNPShort-circuit protectionMax 1.4 A at 55 °C, min. 1.1 A at -10 °COutput current0.5 A max / outputLeakage current< 1 mACapacitive load (pure)65 nF max at 25 °CResitive load (pure)56 Ω min at +24 VDCCurrent for external lamp20 mA min, 250 mA maxConnectorsM12-4 pole male on transmitter (compatible with M12-5 pole female)M12-8 pole male on receiverOptical dataLight emission (λ)Infrared, LED (880 nm)Resolution315 - 515 mmOperating distance0.5...50 mAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature10...+ 55 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)Weight1.2 kg max / meter for each single unitHousing materialPainted aluminium (yellow RAL 1003)Front glass materialPMMACap materialPC Lexan 943AMore information For more information, e.g. the complete technical information, see product manual for: Orion2 Base 2TLC172288M0201 Connection diagrams For Orion2 Base connection diagrams please see https://library.abb.com/3– 30SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
All dimensions in mmOrion2 Base—Dimension drawingsOrion2 Base Lr mmL1mmL2mmTy p e 617664538.4Orion2-4-K2-050-B917964838.4Orion2-4-K3-080-B10171064938.4Orion2-4-K4-090-B131713641238.4Orion2-4-K4-120-Bxx = Resolution—DimensionOPTICAL SAFETY DEVICES3– 313
Protection in harsh environmentsThe housing is IP65 rated, and protec-tive tubes and lens shields are avail-able to provide further protection for the device in harsh environments.Continuous operationOrion2 Extended is a compact light grid for access protection in muting applications.The light grid has 2-4 beams and is intended for body detection.Easy to installAlignment helpAlignment help and a wide angle within the limits of a Type 4 device facilitate installation.Easy adjustmentRotation brackets makes alignment easy.Fast connectionM12 connectors speed up cabling.Integrated muting functionMuting sensors are connected directly to the light grid, with no need for a remote muting module.Minimized cablingA local reset button can be connected directly to the light grid, eliminating the need for cable between the reset button and the electrical cabinet.External device monitoring (EDM)Each light grid can monitor the actua-tors without any extra control module.Cost effective solution—Safety light gridOrion2 Extended3– 32SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—FeaturesOrion2 ExtendedEDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/PLC inputs and minimizes cabling to the electrical cabinet. Clever accessories makes the connection easier.MutingOrion2 Extended is intended for muting applications. By connecting muting sensors to the light guard, it can distin-guish material from persons and allow the material to pass through an opening but not persons. Muting sensors and a connection box for muting are available to simplify the muting application.OPTICAL SAFETY DEVICES3– 333
—Ordering informationOrion2 Extended—Ordering detailsResolution (Detection)mmProtected heightmmTy pe (Transmitter + receiver)Order codeBody500 (2 beams)Orion2-4-K2-050-E 2TLA022305R0000800 (3 beams)Orion2-4-K3-080-E2TLA022305R0100900 (4 beams)Orion2-4-K4-090-E2TLA022305R02001200 (4 beams)Orion2-4-K4-120-E2TLA022305R0300—Spare parts (included when ordering Orion)DescriptionTy pe Order code4 standard brackets for Orion1 & Orion2JSM Orion012TLA022310R00002TLC172798F0201Orion2 ExtendedJSM Orion012TLC172781F02013– 34SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—AccessoriesOrion2 Extended DescriptionTy peOrder codeConnection box for two or four muting sensorsOMC12TLA022316R2000Retroreflex photoelectric sensorMute R22TLA022044R0500Adjustable mounting bracket for M18 sensors (e.g. Mute R2).JSM 642TLA040007R0200Reflector diameter 63 mmReflect 12TLA022044R2000Reflector diameter 82 mmReflect 22TLA022044R3000Smile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Smile reset button with NC contact for Orion2 Base/Extended and Orion3 Extended Smile 11RO22TLA022316R3100 Y-connector for series connection of DYNlink devices with M12-5 connectors, e.g. Eden M12-RA2TLA020055R0000 Y-connector for connection of a Smile reset button to OrionM12-3R2TLA022316R0000Y-connector for easy connection of a transmitterM12-3D2TLA020055R0300 Adaptation of OSSD to DYNlink. M12-8 connector for OSSD and M12-5 for DYNlink.Tina 10A v2 2TLA020054R1210Adaptation of OSSD to DYNlink with possibility to connect a local reset button. M12-8 connector for OSSD and M12-5 connector for DYNlink and reset button..Tina 10B v2 2TLA020054R1310 Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD and M12-5 connector for DYNlink and transmitter.Tina 10C v2 2TLA020054R1610 Mounting accessoriesOrion Test Piece 14 mmOrion TP-142TLA022310R5200Orion Test Piece 30 mmOrion TP-302TLA022310R5300Orion Laser pointerOrion Laser2TLA022310R5000JSM M5B special T-nut M5 to be used with M5x12 screw for mounting Orion on Quick-GuardT-nut JSM M5B2TLA040035R0400 4 standard brackets for Orion1 & Orion2 JSM Orion012TLA022310R0000 4 rotation brackets for Orion2JSM Orion042TLA022310R0200Kit for mounting of Orion1 & Orion2 in Stand (4 pieces for lengths shorter than 1200 mm) JSM Orion062TLA022310R0400Kit for mounting of Orion1 & Orion2 in Stand (6 pieces for lengths of 1200 mm or more) JSM Orion072TLA022310R0500Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror in stand for Orion 2 and 3Orion Mirror*Protective standOrion Stand*Protective tube Orion WET* Lens shieldOrion Shield* *These accessories are available in different sizes. For more information see:Orion Mirror 2TLC172060L0201,,Orion Stand 2TLC172059L0201, Orion WET 2TLC172061L0201, Orion Shield 2TLC172071L0201For more information about the connection accessories, please see: Orion connection accessories 2TLC172101L0201OMC12TLC172016V0201JSM 642TLC010032F02011Orion Laser pointer2TLC172816F0201Smile 11 RB2TLC172367F0201Mute R22TLC172091V0201Local or global resetAdaption to DYNlink*Safety controle moduleTy p e Useful connection accessoriesLocal reset button con-nected to the light guard (Orion in manual reset mode)Ye sVital or PlutoSmile 11RO2Tina 10B: OSSD to DYNlink + local reset button M12-3A: Serial connection of DYNlinkNoAny safety control module compatible with light guardSmile 11RO2 M12-3R: Easy connection of a local reset button Global reset button connected to the control module(Orion in automatic reset mode)Ye sVitalSmile 11 RATina 10A: OSSD to DYNlinkTina 10C: OSSD to DYNlink + supply to transmitter PlutoSmile 11 RBTina 10A: OSSD to DYNlinkTina 10C: OSSD to DYNlink + supply to transmitterNoAny safety control module compatible with light guardSmile 11 RA** -* The ABB Jokab Safety DYNlink solution offers the following advantages:- Serial connection of safety devices while maintaining PLe/cat. 4, up to 25 Tina 10 per Vital and up to 5 Tina 10 per Pluto input.- Only one safety input of the Pluto instead of two with the standard OSSD outputs.** Smile 11 RA has one NO contact, which is the most common for reset buttons. Please check what is requested for the chosen safety control module.2TLC172093V0201Reflect 2—Connection Accessories—How to choose correct reset buttonOPTICAL SAFETY DEVICES3– 353
—CablesOrion2 Extended ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R0500(b)6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 (a)0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R0200(c)10 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R2900(d)6 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C0063412TLA020056R6400(e)1 mM12-C13412TLA020056R5000 3 mM12-C3341 2TLA020056R5100 M12-8 female - M12-5 male Female + male1 M12-CYMUTE22TLA022316R0100Letters (a, b, c, d, e) refer to cables in connection examples, e.g: 2TLC010002T0001 Connection diagram Orion_cables_Tina10_M12-3A_M12-3D1) Used for the connection to Tina 10, M12 3D and M12-3R. Tina 10 can be connected directly to the light guard without cable, but will form an angle (i.e. not be aligned) with the light guard, which might be a problem if the light guard is mounted close to a wall/aluminum profile.2) M12-CYMUTE is used to simplify the connection of 2 or 4 muting sensors with the help of the OMC1 connection box.M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectors3– 36SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Separate cables and connectors—Connection examplesOrion2 ExtendedOrion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole maleReset to Orion with M12-3RConnection of a local reset button via M12-3R.With local reset button (a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleReset to Orion with Tina 10BOrion with Tina 10A/C Orion receiver or active partTina 10A/C1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleCableConnection to the ABB Jokab Safety DYNlink signal via Tina 10 A/C. To be used with Vital safety control module or Pluto programmable safety controller.Connection to the ABB Jokab Safety DYNlink signal via Tina 10B. To be used with Vital safety control module or Pluto programmable safety controller.Without local reset button NB: Cable with M12-5 male + female connectors shall be used between muting sensors and OMC1 inputs A1, B1, A2, B2. M12-8 pole male Connection to: - Tina 10A/B/C - M12-3R - Electrical cabinetOrion receiver or active partA1, B1, A2, B2:Muting sensorsOMC1A2A1B1B2A1, B1, A2, B21. +24 VDC 2. — 3. 0 V 4. Muting input5. — Connection of muting sensors with M12-CYMUTE and OMC1(e)(e)(e)Connection diagrams For Orion2 Extended connection diagrams please see https://library.abb.com/ OPTICAL SAFETY DEVICES3– 373
—Technical dataOrion2 ExtendedTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 2.64 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 2.64 x 10-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 2.64 x 10-9Electrical dataInternal capacitance23 nF (Transmitter) / 120 nF (Receiver)Power supply+24 VDC ± 20% (SELV/PELV)Power consumtion, Transmitter0.5 W during normal operationPower consumption, Receiver2 W during normal operationOutputs2 PNPShort-circuit protectionMax 1.4 A at 55 °C, min 1.1 A at -10 °COutput current0.5 A max / outputLeakage current< 1 mACapacitive load (pure)65 nF max at 25 °CResistive load (pure)56 Ω min at +24 VDCCurrent for external lamp20 mA min, 250 mA maxResponse time2 and 3 beams: 14 ms; 4 beams: 16 msConnectorsM12-4 pole male on transmitter (compatible with M12-5 pole female)M12-8 pole male on receiverOptical dataLight emission (λ)Infrared (880 nm)Resolution315 - 515 mmOperating distance0.5...50 mAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature- 10...+ 55 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)Weight1.2 kg max / meter for each single unitHousing materialPC Lexan 943ALens materialPMMACap materialPC MAKROLONMore information For more information, e.g. the complete technical information, see manual for:Orion2 Extended 2TLC172291M0201 Connection diagrams For Orion2 Extended connection diagrams please see https://library.abb.com/ 3– 38SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
All dimensions in mmOrion2 Extended—Dimension drawingsOrion2 Extended LrmmL1mmL2mmTy p e 617664538.4Orion2-4-K2-050-E917964838.4Orion2-4-K3-080-E10171064938.4Orion2-4-K4-090-E131713641238.4Orion2-4-K4-120-E—DimensionOPTICAL SAFETY DEVICES3– 393
Easy to installAlignment help Alignment help and a wide angle within the limits of a Type 4 device facilitate installation.Easy adjustmentRotation brackets makes alignment easy.Fast connectionM12 connectors speed up cabling.Less cablingOnly the active part needs connecting.Orion3 Base is a light grid with a sturdy profile for access protection.Only one of the parts needs power supply, since both transmitter and receiver are in the same active part. The other part is passive with mirrors to reflect the beams.With 2-4 beams and an operating range of up to 8 m, it is intended for body detection.Visible alignment levelSince the alignment level is displayed, the alignment can be improved before the occurrence of an unwanted stop.Extensive error indicationExtensive error indication reduces troubleshooting time.Continuous operationMinimized cablingA local reset button can be connected directly to the light grid, eliminating the need for cable between the reset button and the electrical cabinet or for an extra control module.External device monitoringEach light grid can monitor the actua-tors without any extra control module (EDM function).Cost effective solution—Safety light gridOrion3 Base3– 40SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Sturdy profile for demanding applicationsWith its thicker and sturdier profile Orion3 is suitable for ap-plications with tougher requirements.—FeaturesOrion3 BaseEDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/PLC inputs and minimizes cabling to the electrical cabinet. Clever accessories makes the connection easier.FeaturesPower on one sideBoth transmitter and receiver is in one active part, and the other part is passive containing mirrors. This simplifies installation and saves cables, making it easier to place in ap-plications where cables needs to be avoided.OPTICAL SAFETY DEVICES3– 413
—Ordering informationOrion3 Base Detection Protected heightmmActive or passive partTy p e Order codeBody500 (2 beams)Active partOrion3-4-K1C-050-B2TLA022306R0000Passive partOrion3-4-M1C-0502TLA022306R1000800 (3 beams)Active partOrion3-4-K2C-080-B2TLA022306R0100Passive partOrion3-4-M2C-0802TLA022306R1100900 (4 beams)Active partOrion3-4-K2C-090-B2TLA022306R0200Passive partOrion3-4-M2C-0902TLA022306R13001200 (4 beams)Active partOrion3-4-K2C-120-B2TLA022306R0300Passive partOrion3-4-M2C-1202TLA022306R1400Orion3 Base22TLC172804F0201 DescriptionTy p e Order code4 standard brackets for Orion3JSM Orion022TLA022310R1000JSM Orion022TLC172779F0201—Ordering details—Spare parts (included when ordering Orion)3– 42SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Mounting accessoriesDescriptionTy p eOrder codeOrion Laser pointerOrion Laser2TLA022310R5000JSM M5B special T-nut M5 to be used with M5x12 screw for mounting Orion on Quick-GuardT-nut JSM M5B2TLA040035R04004 standard brackets for Orion3JSM Orion052TLA022310R0300Kit for mounting of Orion3 in Stand (4 pieces for lengths shorter than 1200 mm) JSM Orion082TLA022310R0600Kit for mounting of Orion3 in Stand (6 pieces for lengths of 1200 mm or more) JSM Orion092TLA022310R0700Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror in stand for Orion 2 and 3Orion Mirror*Protective standOrion Stand*Connection accessoriesSmile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Smile reset button with NC contact for Orion3 BaseSmile 11 RO32TLA022316R3200Y-connector for series connection of DYNlink devices with M12-5 connectors, e.g. EdenM12-3A2TLA020055R0000Y-connector for connection of a Smile reset button to OrionM12-3R 2TLA022316R0000Y-connector for easy connection of a transmitterM12-3D2TLA020055R0300Adaptation of OSSD to DYNlink. M12-8 connector for OSSD and M12-5 for DYNlink.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with possibility to connect a local reset button. M12-8connector for OSSD and M12-5 for DYNlink and reset button.Tina 10B v22TLA020054R1310Adaptation of OSSD to DYNlink with possibility to power the transmitter. M12-8 connector for OSSD and M12-5 connector for DYNlink and transmitter.Tina 10C v22TLA020054R1610*These accessories are available in different sizes. For more information see: Orion Mirror 2TLC172060L0201Orion Stand 2TLC172059L0201For more information about the connection accessories, please see:Orion connection accessories 2TLC172101L0201—AccessoriesOrion3 Base2TLC172012V0201M12-3RSmile 11 RB2TLC172367F0201Tina 10C2TLC172477F0201 Local or global resetAdaption to DYNlink*Safety controle moduleTy p e Useful connection accessoriesLocal reset button con-nected to the light guard (Orion in manual reset mode)Ye sVital or PlutoSmile 11 RO3Tina 10B: OSSD to DYNlink solution + local reset button M12-3A: Serial connection of the DYNlink solutionNoAny safety control module compatible with light guardSmile 11 RO3 M12-3R: Easy connection of a local reset button Global reset button connected to the control module(Orion in automatic reset mode)Ye sVitalSmile 11 RATina 10A: OSSD to DYNlink solution Tina 10C: OSSD to DYNlink solution + supply to transmitter/active partPlutoSmile 11 RBTina 10A: OSSD to DYNlink solution Tina 10C: OSSD to DYNlink solution + supply to transmitter/active partNoAny safety control module compatible with light guardSmile 11 RA** -* The ABB Jokab Safety DYNlink solution offers the following advantages:- Serial connection of safety devices while maintaining PLe/cat. 4, up to 25 Tina 10 per Vital and up to 5 Tina 10 per Pluto input.- Only one safety input of the Pluto instead of two with the standard OSSD outputs.** Smile 11 RA has one NO contact, which is the most common for reset buttons. Please check what is requested for the chosen safety control module.2TLC172816F0201Orion Laser pointer—Accessories—How to choose correct reset buttonOPTICAL SAFETY DEVICES3– 433
—CablesOrion3 Base ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R0500(b)6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 (a)0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R0200(c)10 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R2900(d)6 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 0,2 mM12-CTO3B 12TLA022315R3200Letters (a, b, c, d, t2) refer to cables in connection examples, e.g: 2TLC010002T0002 Connection diagram Cables Orion3 to Tina10 1) M12-CTO3B (t2) can be used for: - connection of Orion3 Base to Tina 10A/B/C. - connection of Orion 3 Base to M12-3R. The EDM function is deactivated in all casesM12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050M12-C3342TLC172931F02012TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201M12-C61HE—Cable with connectors—Separate cables and connectors3– 44SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Connection examplesOrion3 BaseOrion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole maleReset to Orion with M12-3RConnection of a local reset button via M12-3R.With local reset button (a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleReset to Orion with Tina 10BOrion with Tina 10A/C Orion receiver or active partTina 10A/C1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleCableConnection to the ABB Jokab Safety DYNlink signal via Tina 10 A/C. To be used with Vital safety control module or Pluto programmable safety controller.Connection to the ABB Jokab Safety DYNlink signal via Tina 10B. To be used with Vital safety control module or Pluto programmable safety controller.Without local reset button (t2)(t2)(t2)Connection diagramsFor Orion3 Base connection diagrams please see https://library.abb.com/OPTICAL SAFETY DEVICES3– 453
—Technical dataOrion3 BaseTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 9.28 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 9.28 x 10-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 9.28 x 10-9Electrical dataPower supply+24 VDC ±20 %Power consumption, Active unit6.5 W max (without load)Cable length (for power supply)70 m maxOutputs2 PNPShort-circuit protection1.4 A maxOutput current0.5 A max / outputOutput voltage – ONPower supply value less 1 V (min)Output voltage – OFF0.2 V maxCapacitive load2.2 μF at +24 VDC maxCable length (for power supply)70 m maxConnectorsM12-8 pole male on receiverOptical dataLight emission (λ)Infrared, LED (950 nm)Resolution319.75 - 519.75 mmOperating distance0.5...8 m except K2C-090: 0.5...6.5 mAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature0...+ 55 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)WeightOrion3-4-K1C-050-B 1.3 kgOrion3-4-K2C-080-B1.8 kgOrion3-4-K2C-090-B2.1 kgOrion3-4-K2C-120-B2.6 kgOrion3-4-M1C-050 (passive)1.2 kgOrion3-4-M2C-080 (passive)1.7 kgOrion3-4-M2C-090 (passive)1.9 kgOrion3-4-M2C-120 (passive)2.5 kgHousing materialPainted aluminium (yellow RAL 1003)Cap materialPBT Valox 508Lens materialPMMAMore InformationFor more information about the connection accessories, see manual for:Orion3 Base 2TLC172289M0201Connection diagramsFor Orion3 Base connection diagrams please see https://library.abb.com/3– 46SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
L1Ø 425256,91036L23030M4 TCEI inox204052Ø 421756,9M4 TCEI inox30M12L1L210,8530153610Orion3 Base—Dimension drawingsOrion3 Base L1mmL2mmTy p e 606.4520.5Orion3-4-K1C-050-B (active part)906.4820.5Orion3-4-K2C-080-B (active part)1006.4920.5Orion3-4-K2C-090-B (active part)1306.41220.5Orion3-4-K2C-120-B (active part)580.5520.5Orion3-4-M1C-050 (passive part)880.5820.5Orion3-4-M2C-080 (passive part)980.5920.5Orion3-4-M2C-090 (passive part)1280.51220.5Orion3-4-M2C-090 (passive part))xx = ResolutionPassive part – All dimensions in mmActive part – All dimensions in mm—DimensionsOPTICAL SAFETY DEVICES3– 473
Visible alignment levelSince the alignment level is displayed, the alignment can be improved before the occurrence of an unwanted stop.Extensive error indicationExtensive error indication reduces troubleshooting time.Continuous operationOrion3 Extended is a sturdy light grid for access protection in muting applications.Only one of the parts needs power supply, since both transmitter and receiver are in the same active part. The other part is passive and contains mirrors to reflect the beams.With 2-4 beams and an operating range of up to 8 m, it is intended for body detection.Easy to installAlignment helpAlignment help and a wide angle within the limits of a Type 4 device facilitate installation.Easy adjustmentRotation brackets makes alignment easy.Fast connectionM12 connectors speed up cabling.Less cablingOnly the active part needs connecting.Integrated muting functionMuting sensors are connected directly to the light grid, with no need for a remote muting module.Minimized cablingA local reset button can be connected directly to the light grid, eliminating the need for cable between the reset button and the electrical cabinet.External device monitoring (EDM)Each light grid can monitor the actua-tors without any extra control module.Cost effective solution—Safety light grid Orion3 Extended3– 48SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Local resetA local reset button is connected directly to the light guard instead of to the safety control module in the electrical cabinet. This saves safety relays/PLC inputs and minimizes cabling to the electrical cabinet. Clever accessories make the connection easier.—Applications and featuresOrion3 ExtendedMutingOrion2 Extended is intended for muting applications. By connecting muting sensors to the light guard, it can distin-guish material from persons and allow the material to pass through an opening but not persons. Muting sensors and a connection box for muting are available to simplify the mut-ing application.EDMExternal Device Monitoring is a feature allowing the light guard to supervise the actuators in simpler applications, eliminating the need for a safety relay or programmable safety controller.ApplicationFeaturesPower on one sideBoth transmitter and receiver are in one active part, and the other part is passive and contains mirrors. This simplifies installation and saves cables, making it easier to place in ap-plications where cables need to be avoided.Sturdy profile for demanding applicationsWith its thicker and sturdier profile Orion3 is suitable for ap-plications with tougher requirements.OPTICAL SAFETY DEVICES3– 493
—Ordering informationOrion3 Extended DetectionProtected heightmmActive or passive partTy p e Order codeBody500 (2 beams)Active partOrion3-4-K1C-050-E 2TLA022307R0000Passive partOrion3-4-M1C-0502TLA022306R1000800 (3 beams)Active partOrion3-4-K2C-080-E2TLA022307R0100Passive partOrion3-4-M2C-0802TLA022306R1100900 (4 beams)Active partOrion3-4-K2C-090-E2TLA022307R0200Passive partOrion3-4-M2C-0902TLA022306R13001200 (4 beams)Active partOrion3-4-K2C-120-E2TLA022307R0300Passive partOrion3-4-M2C-1202TLA022306R1400Please note that active and passive parts are ordered separately and both are necessary for Orion3 Extended to function. DescriptionTy p e Order code4 standard brackets for Orion3JSM Orion022TLA022310R10002TLC172804F0201Orion3 ExtendedJSM Orion022TLC172779F0201—Ordering details—Spare parts (included when ordering Orion3– 50SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—AccessoriesOrion3 Extended Connection accessoriesDescriptionTy p eOrder codeConnection box for two or four muting sensorsOMC12TLA022316R2000Retroreflex photoelectric sensorMute R22TLA022044R0500Adjustable mounting bracket for M18 sensors (e.g. Mute R2).JSM 642TLA040007R0200Reflector diameter 63 mmReflect 12TLA022044R2000Reflector diameter 82 mmReflect 22TLA022044R3000Smile reset button with NO contactSmile 11 RA2TLA030053R0000Smile reset button with NO contact for PlutoSmile 11 RB2TLA030053R0100Smile reset button with NC contact for Orion2 Base/Extended and Orion3 ExtendedSmile 11R022TLA022316R3100Y-connector for series connection of DYNlink devices with M12-5 connectors, e.g. Eden M12-3A2TLA020055R0000Y-connector for connection of a Smile reset button to OrionM12-3R 2TLA022316R0000Adaptation of OSSD to DYNlink. M12-8 connector for OSSD and M12-5 for DYNlink.Tina 10A v22TLA020054R1210Adaptation of OSSD to DYNlink with possibility to connect a local reset button. M12-8connector for OSSD and M12-5 for DYNlink and reset button.Tina 10B v22TLA020054R1310Mounting accessoriesOrion Laser pointerOrion Laser2TLA022310R5000JSM M5B Special T-nut M5 to be used with screw M5x12 screw for mounting Orion on QuickGuardT-nut JSM M5B2TLA040035R0400 4 rotation brackets for Orion3JSM Orion052TLA022310R0300Kit for mounting of Orion3 in Stand (4 pieces)- For a pair Orion3 - 050 / 080 / 090 (active + passive units)JSM Orion082TLA022310R0600For a pair Orion3 - 120 (Orion3-4-K2C-120 + Orion3-4-M2C-120)JSM Orion092TLA022310R0700Orion Plate kit for adjustment of protective standOrion Stand Plate2TLA022312R5000Deviating mirror in stand for Orion 2 and 3Orion Mirror*Protective standOrion Stand*Protective tubeOrion WET*Lens shieldOrion Shield**These accessories are available in different sizes. For more information see:Orion Mirror 2TLC172060L0201, Orion Stand 2TLC172059L0201, Orion WET 2TLC172061L0201, Orion Shield 2TLC172071L0201 For more information about the connection accessories, please see:Orion connection accessories 2TLC172101L0201OMC12TLC172016V0201JSM 642TLC010032F02011Orion Laser pointer2TLC172816F0201Smile 11 RB2TLC172367F0201Mute R22TLC172091V02012TLC172475F0201Tina 10B Local or global resetAdaption to the DYNlink solution*Safety controle moduleTy p eSuitable connection accessoriesLocal reset button connected to the light guard(Orion in manual reset mode) Ye sVital or PlutoSmile 11RO2Tina 10B: OSSD to DYNlink + local reset buttonM12-3A: serial connection of DYNlinkNoAny safety control module compatible with light guardSmile 11RO2M12-3R: Easy connection of a local reset buttonGlobal reset button connected to the control module (Orion in automatic reset mode)Ye sVitalSmile 11 RATina 10A: OSSD to DYNlink Tina 10C: OSSD to DYNlink + supply to transmitterPlutoSmile 11 RBTina 10A: OSSD to DYNlink Tina 10C: OSSD to DYNlink + supply to transmitterNoAny safety control module compatible with light guardSmile 11 RA**-* The ABB Jokab safety DYNlink solution offers the following advantages:- Serial connection of safety devices while maintaining PLe/cat. 4, up to 25 Tina 10 per Vital and up to 5 Tina 10 per Pluto input.- Only one safety input of the Pluto instead of two with the standard OSSD outputs.** Smile 11RA has one NO contact, which is the most common for reset buttons. Please check what is requested for the chosen safety control module.Reflect 22TLC172093V0201—Accessories—How to choose correct reset buttonOPTICAL SAFETY DEVICES3– 513
—CablesOrion3 Extended ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R0500(b)6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 (a)0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R0200(c)10 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R2900(d)6 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C0063412TLA020056R64001 mM12-C13412TLA020056R5000 3 mM12-C3341 2TLA020056R5100 M12-8 female + M12-5 male Female + male1 M12-CYMUTE22TLA022316R0100Letters (a, b, c, d, t2) refer to cables in connection examples, e.g:2TLC010002T0002 Connection diagram Cables Orion3 to Tina10 1) These cables (t2) are used for the connection to Tina 10, M12 3D and M12-3R. Tina 10 can be connected directly to the light guard without cable, but will form an angle (i.e. not be aligned) with the light guard, which might be a problem if the light guard is mounted close to a wall/aluminum profile.2) M12-CYMUTE is used to simplify the connection of 2 or 4 muting sensors with the help of the OMC1 connection box.M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201C5 cable2TLC010038F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectors3– 52SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
—Connection examplesOrion3 ExtendedOrion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole maleReset to Orion with M12-3RConnection of a local reset button via M12-3R.With local reset button (a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleReset to Orion with Tina 10BOrion with Tina 10A/C Orion receiver or active partTina 10A/C1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleCableConnection to the ABB Jokab Safety DYNlink signal via Tina 10 A/C. To be used with Vital safety control module or Pluto programmable safety controller.Connection to the ABB Jokab Safety DYNlink signal via Tina 10B. To be used with Vital safety control module or Pluto programmable safety controller.Without local reset button NB: Cable with M12-5 male + female connectors shall be used between muting sensors and OMC1 inputs A1, B1, A2, B2. M12-8 pole male Connection to: - Tina 10A/B/C - M12-3R - Electrical cabinetOrion receiver or active partA1, B1, A2, B2:Muting sensorsOMC1A2A1B1B2A1, B1, A2, B21. +24 VDC 2. — 3. 0 V 4. Muting input5. — Connection of muting sensors with M12-CYMUTE and OMC1(t2)(t2)(t2)Connection diagramsFor Orion3 Extended connection diagrams please see https://library.abb.com/OPTICAL SAFETY DEVICES3– 533
—Technical dataOrion3 ExtendedTechnical dataApprovalsConformity2006/42/EC - Machinery2004/108/EC - EMCEN ISO 13849-1:2008, EN 62061:2005/A1:2013, EN 61496-1:2013, EN 61496-2, EN 61508-1:2010, EN 61508-2:2010, EN 61508-3:2010, EN 61508-4:2010Functional safety dataEN 61508:2010SIL3, PFHD = 8.57 x 10-9EN 62061:2005+A1:2013SILCL3, PFHD = 8.57 x 10-9EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 8.57 x 10-9Electrical dataPower supply+24 VDC ± 20% Power consumtion, Active unit2.5 W max (without load)Cable length (for power supply)70 m maxOutputs2 PNPShort-circuit protection1.4 A at 55 °COutput current0.5 A max / outputOutput voltage – ONPower supply value less 1 V (min)Output voltage – OFF0.2 V maxCapacitive load2.2 μF at +24 VDC maxCurrent for external lamp20 mA min, 250 mA maxResponse timeK1C-050: 11 ms, others: 12 msConnectorsM12-4 pole male on transmitter (compatible with M12-5 pole female)Optical dataLight emission (λ)Infrared (860 nm)Resolution319.75 - 519.75 mmOperating distance0.5...8 m except K2C-090: 0.5...6.5 mAmbient light rejectionAccording to IEC-61496-2:2013Mechanical dataOperating temperature0...+ 55 °CStorage temperature- 25...+ 70 °CHumidity range15...95% (no condensation)Protection classIP65 (EN 60529:2000)Housing materialPainted aluminiumLens materialPMMACap materialPBT Valox 508WeightOrion3-4-K1C-050-E 1.3 kgOrion3-4-K2C-080-E1.8 kgOrion3-4-K2C-090-E2.1 kgOrion3-4-K2C-120-E2.6 kgOrion3-4-M1C-050 (passive)1.2 kgOrion3-4-M2C-080 (passive)1.7 kgOrion3-4-M2C-090 (passive)1.9 kgOrion3-4-M2C-120 (passive)2.5 kgMore informationFor more information about the connection accessories, see manual for:Orion3 Extended 2TLC172292M0201Connection diagramsFor Orion3 Extended connection diagrams please see https://library.abb.com/3– 54SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY3
Orion3 Extended—Dimension drawingsOrion3 Extended L1mmL2mmTy p e 606.4520.5Orion3-4-K1C-050-E (active part)906.4820.5Orion3-4-K2C-080-E (active part)1006.4920.5Orion3-4-K2C-090-E (active part)1306.41220.5Orion3-4-K2C-120-E (active part)580.5520.5Orion3-4-M1C-050 (passive part)880.5820.5Orion3-4-M2C-080 (passive part)980.5920.5Orion3-4-M2C-090 (passive part)1280.51220.5Orion3-4-M2C-090 (passive part)204052Ø421756,9M4 TCEI inox30M12L1L210,8530153610Active part - All dimensions in mmL1Ø425256,91036L23030M4 TCEI inoxL1Ø425256,91036L23030M4 TCEI inoxPassive part - All dimensions in mm—DimensionsOPTICAL SAFETY DEVICES3– 553
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Sensors and locks4– 2 Introduction and overview 4– 6 Non-contact safety sensor Eden4– 16 Safety magnetic switch Sense4– 20 Safety interlock switch MKey 4– 28 Electromagnetic process lock Magne 4– 34 Safety lock GKey SENSORS AND LOCKS4 – 14
—Introduction and overviewSelection guideABB has a full range of switches for monitoring doors and hatches, both with and without locking function. EdenSenseMKeyMagneGKeyImageImageFunctionInterlockInterlockInterlock and process/safety lockFunctionInterlock and process lockInterlock and safety lockTy p eNon-contact switchMagnetic non-contact switchMechanical switchTy p eElectromagnetic lockMechanical safety lockDescriptionThe original non-contact sen-sor with unique fault-detec-tion capabilities.Coded magnetic switch in stainless steel for harsh environments.A classic and well-tried solution.DescriptionA robust magnetic lock with strong holding force.A robust safety lock with die cast housing.ApplicationsMonitoring doors and hatches. Ideal for use in harsh environments. Also for moni-toring of end positions of e.g. an overhead crane.Monitoring doors and hatches in applications where a stainless steel product is required.Monitoring doors and hatches. Also available with safe locking.ApplicationsLocking doors and hatches to prevent inter-ruption of machines with short stopping time e.g. robotics applications.Safe locking of hinged and sliding doors for ma-chines with a long stopping time.Advantage- Flexible mounting - M12 connectors - IP69K for harsh environ-ments - One switch to reach Cat. 4 - Unique coding to prevent defeat - Local reset minimizes cabling - Non-contact eliminates wear- Stainless steel- IP69K for harsh environ-ments- Extreme temperature range- Coded sensor- Non-contact eliminates wear- Holds the door closed - Possible to lockAdvantage- Robust design- M12 connectors.- Safe locking- Robust design- Room to integrate 22 mm pilot devices- Rear escape release- High level coding- Lockout function- Manual unlocking (auxiliary release)4 – 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
EdenSenseMKeyMagneGKeyImageImageFunctionInterlockInterlockInterlock and process/safety lockFunctionInterlock and process lockInterlock and safety lockTy p eNon-contact switchMagnetic non-contact switchMechanical switchTy p eElectromagnetic lockMechanical safety lockDescriptionThe original non-contact sen-sor with unique fault-detec-tion capabilities.Coded magnetic switch in stainless steel for harsh environments.A classic and well-tried solution.DescriptionA robust magnetic lock with strong holding force.A robust safety lock with die cast housing.ApplicationsMonitoring doors and hatches. Ideal for use in harsh environments. Also for moni-toring of end positions of e.g. an overhead crane.Monitoring doors and hatches in applications where a stainless steel product is required.Monitoring doors and hatches. Also available with safe locking.ApplicationsLocking doors and hatches to prevent inter-ruption of machines with short stopping time e.g. robotics applications.Safe locking of hinged and sliding doors for ma-chines with a long stopping time.Advantage- Flexible mounting - M12 connectors - IP69K for harsh environ-ments - One switch to reach Cat. 4 - Unique coding to prevent defeat - Local reset minimizes cabling - Non-contact eliminates wear- Stainless steel- IP69K for harsh environ-ments- Extreme temperature range- Coded sensor- Non-contact eliminates wear- Holds the door closed - Possible to lockAdvantage- Robust design- M12 connectors.- Safe locking- Robust design- Room to integrate 22 mm pilot devices- Rear escape release- High level coding- Lockout function- Manual unlocking (auxiliary release)SENSORS AND LOCKS4 – 34
The difference between locking and interlocking functionsInterlocking functionAn interlocking function indicates if a door is open or closed. When the door is open the interlocking function also prevents dangerous machine functions, but it does not prevent the door from being opened.Locking functionA locking function prevents the door from being opened until an unlocking signal has been sent.When to use interlocking and locking functionsAn interlocking function is required if the dangerous machine functions needs to be stopped when someone enters the dangerous area.A locking function is required if a user can open a door/hatch and reach the dangerous machine parts before the dangerous machine functions have ceased. It is also required if the process needs to be protected from unwanted stops that would occur if a person could open a door in the middle of a critical stage of the process..All locks of the ABB Jokab Safety range can be used as process locks but only GKey and the models of MKey that uses power to unlock can be used as safety locks. Here is why:A process lock protects the process. One example of an application is a lock on a door giv-ing access to a machine with short stopping time, e.g. a welding machine. The door should not be unlocked before the end of the welding cycle. Should the door be unlocked before the end of the cycle (as a consequence of a fault in the installation like a loss of power or a short-circuit) the door could be opened, which would result in a process stop. It might take a long time to restart the process, but no person would have had time to come close to the danger or get injured. Since the lock only protects the process there is no need for a safe locking signal.A safety lock protects people. One example of an application is a lock on a door giving ac-cess to a dangerous machine with a long stopping time, e.g. a circular saw. The door should never be unlocked before the dangerous movement has stopped, not even as a consequence of a fault in the installation like a loss of power or a short-circuit. Should the door be un-locked before the machine has stopped, a person could open the door and have time to get close to the dangerous movement and get injured. Since the lock is protecting the person, the unlocking signal should be safe.Since a loss of power should not unlock a safety lock, only locks that require power to unlock (e.g. +24 VDC) can be used as safety locks. The difference between a process lock and a safety lock—Introduction and overview Selection orientationInterlocking function e.g. EdenLocking function e.g. MagneProcess lock e.g. MagneSafety lock e.g. GKey4 – 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Interlocking function e.g. EdenLocking function e.g. MagneProcess lock e.g. MagneSafety lock e.g. GKeySENSORS AND LOCKS4 – 54
Eden is a non-contact safety sensorused as interlocking device for e.g. doors and safe position monitoring. Eden consists of two parts: Adam and Eva. Adam senses the presence of Eva without mechanical contact and therefore without any wear. The compact size of Eden and its 360° mounting possibility make it easy to use in most applications.Different models of Eden are available for different types of control modules. All Eden models make it very easy to reach PL e, often using fewer compo-nents than other solutions.All Eden models have an IP67/IP69K sealing.Local reset functionThe integrated reset function reduces the number of cables and PLC inputs.PL e with fewer componentsSeries connection with PL e, local reset and DYNlink signal allow to considerably reduce the number of components needed to reach PL e.Affordable rangeEasy to installLarge mounting toleranceA 360° mounting possibility with gen-erous tolerances facilitates mounting.Fast connectionM12 connectors, local reset and acces-sories speed up installation. Easier troubleshootingExtensive LED indication and status information reduce downtime.Suitable in harsh environments IP67/IP69K and a temperature range of -40 to +70°C offer an excellent resis-tance in demanding environments.No wear, no mechanical breakageNon-contact sensing means no me-chanical wear and the large sensing tolerance gives a better tolerance to vibrations, resulting in fewer unwanted process stops.Continuous operation—Non-contact safety sensor Eden4 – 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Doors and hatchesEden monitors whether the hatch is open or closed. The dangerous movement is stopped as soon as the hatch is opened.—ApplicationsEdenApplicationsPosition controlEden can be used to monitor the position of a machine when someone is in the work area. This can be useful when removing power to the machine causes problems like a long restart time. As long as the machine remains in the safe position moni-tored by Eden, a person can be allowed to enter the hazard-ous area even though the machine is still powered. If the machine leaves the safe position while the person is still in the hazardous area, power is removed from the machine.SENSORS AND LOCKS4 – 74
—FeaturesEdenEasy PL e with Eden safety sensor- Eden sensors can be connected in series while maintaining Cat. 4.- Only one Eden per guard is necessary to reach PL e (in-stead of two key switches).- Eden reaches PL e without any need for periodic checks (see ISO/TR 24119). FeaturesLow or high level coded sensorEva is available with General code or Unique code. If a new Adam is paired with an Eva general code at start up, Adam will accept all Eva with general code as a valid actuator. Eden will then classify as a low level coded sensor. If a new Adam is paired with an Eva Unique code at startup, Adam will only accept this specific Eva as a valid actuator. In this case Eden is classified as a high level coded sensor. A high level coded sensor should be used when the motiva-tion to defeat a sensor cannot be eliminated (see EN ISO 14119:2013).Simple status information with StatusBusStatusBus is a simple and cost effective way to collect the status information of safety sensors. The StatusBus func-tionality is available with some DYNlink devices and allows to collect the status of each individual safety device, even when connected in series. A single input on Pluto safety PLC can collect the status of up to 30 safety devices. The devices are connected using standard cable and M12-5 connectors. No specific bus cable or extra communication module is neces-sary. Info signal and extensive indication facilitate troubleshootingAll Eden models offer extensive LED indication to help trou-bleshooting and localizing which doors/hatches are opened. The LED on Adam lights in green or red depending on status:green - valid Eva within rangered - valid Eva out of rangeflashing red/green - valid Eva within range, but no valid safety signal received (loop broken “upstream”)Local reset buttonA local reset button with integrated LED can be connected directly to Adam Reset instead of to the safety control mod-ule. In this way, each Eden can easily have its own reset but-ton, which saves cable length and safety relays/PLC inputs. Adam Reset monitors the reset function and manages the LED in the reset button in the following way:on - Adam and Eva are not in contactflashing - Adam and Eva in contact, waiting for resetoff - Adam and Eva in contact and reset360° mounting possibilityEden offers 360° mounting possibility with generous toler-ances.4 – 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Eden DYNEden DYN consists of an Adam DYN and an Eva (general or unique code).Adam DYN uses the ABB Jokab Safety DYNlink signal that al-lows to connect several safety products in series while main-taining PL e using only one channel. DYNlink signals must be used with Vital safety controller or Pluto safety PLC. Up to 30 Adam DYN can be connected in series to Vital and up to 10 Adam DYN can be connected in series to one input of Pluto.All products using the DYNlink signal can easily be connected in series and mixed in the same loop with a maintained PL e. Tina adapters allow to use other products in a DYNlink loop, and a wide range of connection accessories simplifies the cabling.Eden OSSDEden OSSD consists of an Adam OSSD and an Eva (general or unique code). Adam OSSD can be used with all safety relays and safety PLCs compatible with OSSD signals (commonly used for light guards). Up to 30 Adam OSSD can be connected in se-ries, and since OSSD devices monitor their own outputs for short circuits, a Cat. 4/PL e can still be reached. Models—ModelsEdenEden DYNEden OSSDSENSORS AND LOCKS4 – 94
—Ordering informationEden2TLC010045V0201Adam DYN-Info M12-5 Type of safety controllerStatusBus Info signalLocal resetSeries connectionConnector maleTy p e Order codePlutoxx 1)xM12-5Adam DYN-Status M12-52TLA020051R5200Pluto or VitalxxM12-5Adam DYN-Info M12-52TLA020051R5100xxM12-5Adam DYN-Reset M12-52TLA020051R5300OSSD compatible (incl. Pluto and Sentry)xM12-5Adam OSSD-Info M12-52TLA020051R5400 xxM12-8Adam OSSD-Info M12-82TLA020051R5700 xM12-5Adam OSSD-Reset M12-52TLA020051R5600 xxxM12-8Adam OSSD-Reset M12-82TLA020051R5900 1)Pin 5 can be used as a standard info signal or StatusBus. Code descriptionCode levelTy p e Order codeGeneral code. (Eva is interchangeable)Low levelEva General code 2TLA020046R0800 Unique code. (Prevents defeat/fraud)High levelEva Unique code 2TLA020046R0900 DescriptionTy p eOrder codeDistance plate in yellow PBT (4 pcs).DA 1B 2TLA020053R0700Black distance rings to be mounted in Adam and Eva mounting holes (4 pcs).DA 2B 2TLA020053R0300Distance plate2TLC172727F0201Eva General code2TLC010061V0201 DescriptionTy p e Order codeMounting plate for conventional door/hatch and folding door. Two pieces are needed for a complete set. JSM D4H2TLA040033R3600Mounting plate for folding doors. Used together with one piece of JSM D4H. JSM D4J2TLA042020R4000Sliding lock for Eden on conventional doors. (Eden is not included.)JSM D202TLA020302R1000Mounting converting plate from Eden E to Eden OSSD or Eden DYNDA 3A 2TLA020053R0600Heat shrinking tubes for M12 connectors. Protects M12 connectors in harsh environments and provides extra protection against tampering.M12 Safety seal2TLA020053R0800Wrench for tightening of M12 connectors according to specified torque: 0.6 Nm.M12 Torque wrench2TLA020053R0900Handheld terminal for addressing, configuration and testing of StatusBus devices, DYN-link devices and conventional PNP devices.FIXA2TLA020072R2000JSM D20 Eden slide lock2TLC010040F0201FIXA2TLC010040F0201 DescriptionTy p e Order codeReset button for Adam with 5 pinsSmile 12RF 2TLA030053R2600Reset button for Adam with 8 pinsSmile 12RG 2TLA030053R27002TLC172575F0201Smile 12RG Reset button —Adam—Eva—Accessories—Spare parts (included with main product on delivery)—Reset buttons for local reset4 – 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Cables and connectorsEden ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R05006 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 Angled female connectorM12-C1012V22TLA020056R670016 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C5 cable2TLC010038F0201M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectorsSENSORS AND LOCKS4 – 114
DescriptionTy p e Order codeY-connector for series connection of DYNlink devices with M12-5 connectors, e.g. Eden.M12-3A2TLA020055R0000Y-connector for series connection of DYNlink devices with the StatusBus function. M12-3S2TLA020055R0600Y-connector for series connection of Adam OSSD M12-8 with M12-8 cablesM12-3G 2TLA020055R0700Y-connector for series connection of Adam OSSD M12-8 with M12-5 cablesM12-3H2TLA020055R0800Termination plug M12-5. For Adam OSSD with M12-3H. Connects pin 1 with pin 2 and 4.JSOP-1 Terminator2TLA020053R7000Termination plug M12-8. For Adam OSSD with M12-3G. Connects pin 2 with pin 3 and 4.JSOP-2 Terminator2TLA020053R7100JSOP-2 Terminator 2TLC010008F0201—Connection accessories—Connection AccessoriesEden4 – 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Eden DYN, Eden OSSDApprovals Conformity 2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2015,EN 62061:2005/A2:2015, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 60947-5-3:2013, EN ISO 14119:2013, EN 61508:2010Functional safety data EN/IEC 61508:2010SIL3, PFHD = 4.5 x 10-9 EN/IEC 62061:2005+A1:2013SILCL3, PFHD = 4.5 x 10-9 EN ISO 13849-1:2008PL e, Cat. 4, PFHD = 4.5 x 10-9Electrical data+24 VDC Tolerance: +14.4...+27.6 VDCMechanical dataOperating temperature-40 °C...+70 °C (storage/operation)Protection classIP67 and IP69KHumidity range35 to 85% (no icing, no condensation)MaterialHousingPolybutylene terephthalate (PBT)MouldingEpoxyWeightEva: 70 g, Adam: 80 gAssured release distance (Sar)25 mmAssured operating distance (Sao)10 mmRated operating distance (Sn)15 ± 2mmRecommended distance between Adam and Eva7 mmMin distance between two Eden100 mm—Technical dataEdenMore informationFor more information, e.g. the complete technical information, see product manual for:Eden DYN 2TLC172271M0201Eden OSSD 2TLC172272M0201Connection diagramsFor Eden connection diagrams please see https://library.abb.com/—Technical dataSENSORS AND LOCKS4 – 134
Dimension drawings All dimensions in mmAdam M12-5 male connector.(Note that some models have 8 pins instead.)—Dimension drawingsEden4 – 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
SENSORS AND LOCKS4 – 154
Sense7 is a coded magnetic non-con-tact switch for interlocking gates and hatches.Sense7 has a stainless steel housing that is designed for harsh environ-ments and extreme temperatures. Sense7 offers and interlocking func-tion reaching PL e/SIL3 with low level coding.High safety levelSense7 has two closing and one open-ing solid state contacts. Two of these needs to be monitored to achieve PL e/SIL3.LED indication An integrated LED shows the status of the sensor.Safety and protectionReliable in extreme conditionsCompact sizeSense7 is compact in size to make it easy to position and hide on gates and hatches.Large sensing distanceWith a large sensing distance and a high tolerance for misalignment Sense7 is easy to install.Easy to installStainless steelWith a stainless steel 316 body and a IP67/IP69K rating, Sense7 is resistant to harsh environments with both dirt and water.Hygienic designSense7 has no dust collecting cav-ities, and the stainless steel has a mirror polished finish (Ra4) suitable for CIP cleaning - food splash zones acording to EHEDG guidelines.High temperaturesSense7 can be used at temperatures from -25 °C up to 105 °C.—Safety magnetic switchSense74-16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Sense7Z 2MSense7Z Key SS—Ordering detailsDescriptionConnectorCable length (m)ContactsTy p eOrder codeSafety magnetic switchM12-8 male0,252NC+1NOSense7Z M122TLA050056R2120Safety magnetic switch-22NC+1NOSense7Z 2M2TLA050056R4120Safety magnetic switch-52NC+1NOSense7Z 5M2TLA050056R5120Safety magnetic switch-102NC+1NOSense7Z 10M 2TLA050056R6120Sense7 is always delivered with both switch and actuator.—Spare part Type of handleTy p eOrder codeActuator to safety magnetic switch Sense7Z, stainless steel.Sense7Z Key SS2TLA050040R0212—Ordering detailsSense7SENSORS AND LOCKS4-174
Approvals Conformity2006/42/EC2014/30/EU2011/65/EUEN ISO 12100:2010, EN ISO 14119:2013, EN ISO 13849-1:2008+AC:2009, EN 60947-5-3:1999+A1:2005, EN 60947-5-2:1998+A1:1999+A2:2004Functional safety dataEN/IEC 61508:2010Up to SIL3 (depending on system architecture)PFHD = 2.52 x 10-8 EN/IEC 62061:2005+A1:2013Up to SILCL3 (depending on system architecture)PFHD = 2.52 x 10-8 Proof test interval T1 = 47 aMTTFd = 470 a (8 cycles per hour/24 hours per day/365 days)B10d = 3 300 000 operations at 100 mA loadEN ISO 13849-1:2008Up to PL e, Cat 4 (depending on system architecture)PFHD = 2.52 x 10-8If the product usage differs from these assumptions (different load, operating frequency, etc.) the values must be adjusted accordingly.Electrical dataOperating voltage+24 VDC ± 10%Minimum switched current10 VDC 1 mASafety channel output (NC/NO)24 VDC 0.2 A max. ratingMechanical dataMaterialStainless steel 316Protection classIP67 and IP69KOperating temperature-25 °C ... + 105 °CCable typePVC 8 core 6 mmMounting bolts (tightening torque)2 x M4 (1.0 Nm)Assured release distance (Sar)10 mmAssured operating distance (Sor)20 mmRecommended distance5 mm—Technical dataMore informationFor more information, e.g. the complete technical information,see product manual:Sense 2TLC172249M0201—Technical dataSense74-18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Dimension drawingsSense7Dimensions - Sense7ZAll dimensions in mmSENSORS AND LOCKS4-194
MKey are mechanical safety switch-es used for monitoring doors and hatches. The switch is mounted on the frame and the actuator key on the moving part of the guard. All MKey models have a safe interlock-ing function. Some MKey models can be locked and depending on the lock-ing signal they can be used either as process locks or safety locks (with a safe unlocking function).MKey switches are available in differ-ent material and sizes in order to meet the requirements of different applica-tions. Easy to installEasy mounting with rotating head The head of the switch can be mount-ed in up to 8 actuating positions to allow different mounting positions.Flexible keysFlexible keys are available to minimize mechanical wear and allow a smaller movement radius and use in reduced spaces.Safety and protectionHighest level of safetyPL e/SIL3 can be reached when using two switches on a door.Safety lockModels that use power to unlock can be used as safety locks.Emergency escape button Using MKey8ER with an integrated emergency escape button, it is always possible to open the door from inside the dangerous zone.Strong holding forceA holding force of up to 2000 N pre-vents unwanted process stops. Robust designModels are available with full stainless steel housing with IP69K, suitable for most applications in food processing and chemical industries.Status informationAuxiliary contacts give status informa-tion.Continous operation—Safety interlock switchMKey4 – 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Applications MKeyDoors and hatchesMKey is used to monitor the position of doors and hatches. The models with locking function are usually used for:– Processes which should not be interrupted, such as welding.– Machinery with a long stopping procedure, such as paper machinery that requires a long braking operation.– Prevention of unauthorized access to a particular area.Please note that all safety key switches (including MKey) normally need two switches per door/hatch in order to reach PL e/SIL3. (See EN ISO 13849 and EN ISO 14119.)Locking and interlockingAn interlocking function indicates if a door is open or closed and prevents movement when the door is open, but it does not prevent the door from being opened. A locking function makes sure the door is kept closed.Process lock with safe interlockingAll MKey models offer a safe interlocking function that will stop the process if the door/hatch is opened. All lockable models of MKey can also be used as a process lock to pre-vent the process from being interrupted.An example of an application where a process lock could be used is a welding robot where the stopping time is short, but the welding should not be interrupted once it has started.Safety lock with safe interlocking and safe unlockingThe MKey models that uses power to unlock can be used as safety locks. They have a safe unlocking function, which means that the loss of power for these locks will not result in the release of the locking element, and the door will re-main locked even during a power failure.An example of an application where a safety lock should be used is a circular saw that would have a long stopping time after a power failure.SENSORS AND LOCKS4 – 214
Different modelsMKey5 are simple mechanical interlocks while MKey8 and MKey9 also have locking functions.– MKey5: plastic body with plastic or stainless steel head, or full stainless steel body and head.Holding force 12 N or 40 N.– MKey8: robust design in die cast metal or stainless steel body and head. Holding force of 2000 N.– MKey9: plastic body with stainless steel head. Holding force of 1800 N.Power to lock or power to unlockTwo different types of locking function are available:– Spring lock (power to unlock) models are automatically locked when closing the door. An active signal (+24 VDC) must be supplied to unlock the switch, which makes these models suitable as safe locks.– Electro-magnetic lock (power to lock) models are locked when an active signal (+24 VDC) is supplied, which makes these models suitable only as process locks.Rotatable headDepending on model, the head of MKey can be set in two or four directions with two entrance holes each, thus provid-ing four or eight different mounting positions. The leading edges of the actuator key are reinforced and beveled in order to guide it properly into the hole.Different materials and protection classesThe housing and head of the key switches are available in different material in order to meet the requirements of different applications. Metal heads are more resistant to mechanical wear. The choice between plastic, die cast or stainless steel depends on the environment and the chemi-cals used. Models ending with -Z are completely made of stainless steel 316 and offers an IP69K protection class. They can be high pressure hosed with detergent at high tempera-ture and can be used in harsh applications, e.g. the food pro-cessing and chemical industries. All other models offer IP67.Emergency escape buttonMKey8ER has a manual release button at the rear of the housing. It is used for emergency exit by a person locked inside the dangerous zone by mistake. It is a non-latching manual escape, and can be used when the risk assessment requires it. The switch must be mounted so that the release button is reachable from inside the dangerous zone, but not reachable from outside. Pressing and holding the button will release the locking mechanism allowing to open the door/guard.Constructed for safetyAll MKey switches have double positively operated forced-guided contacts controlled by the actuator key. This means that the contacts that are closed when the actuator key is in the switch will be forced to open, and the ones that are opened will be forced to close, when the actuator key is re-moved. It also means that it is not possible to have, e.g. NO and NC contacts opened at the same time due to a fault like one welded contact.The actuator key is designed to prevent tampering with the safety switch using a tool, a magnet or any similar object.The lockable models also have forced-guided contacts con-trolled by the locking mechanism. MKey8 and MKey9 have auxiliary contacts giving status information (not MKey5, MKey8M or MKey9M).Manual release button—FeaturesMKey4 – 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Locking functionMaterial housingMaterial headHolding forceSpecial featureTy p eOrder code —PlasticPlastic12 NMKey52TLA050003R010040 NMKey5+2TLA050003R0101Stainless steel12 NMKey5 SSH2TLA050003R011040 NMKey5+ SSH2TLA050003R0111Stainless steelStainless steel12 NIP69KMKey5Z2TLA050003R012040 NIP69KMKey5+Z2TLA050003R0121Process lock(power to lock)PlasticStainless steel1800 NMKey9M 24VDC2TLA050009R0112Die castDie cast2000 NMKey8M 24VDC2TLA050013R0132Safety lock(power to unlock)PlasticStainless steel1800 NMKey9 24VDC2TLA050007R0112No key suppliedMKey9 24VDC, No Key2TLA050007R0012Die castDie cast2000 NMKey8 24VDC2TLA050011R0132With escape release buttonMKey8ER 24VDC2TLA050015R0132Stainless steelStainless steel2000 NIP69KMKey8Z 24VDC2TLA050011R0122—Ordering informationMKey2TLC172403F0201MKey52TLC172421F0201MKey92TLC172409F0201MKey5 SSH2TLC172503F0201MKey5Z2TLC172417F0201MKey8ER2TLC172415F0201MKey8Z—MKey ordering informationSENSORS AND LOCKS4 – 234
—AccessoriesMKeyMKey Key 42TLC172628F0201MKey Key 22TLC172627F0201MKey Key 6 Type of keyCompatible MKey modelsKey housingDescriptionTy p eOrder codeStandard keyMKey5MKey5+NoneStandard key for MKey safety switches with plastic head. Stainless steel key.MKey Key 12TLA050040R0201MKey5 SSHMKey5+ SSHMKey5ZMKey5+ZAll MKey8All MKey9NoneStandard key for MKey safety switches with metal head. Stainless steel key.MKey Key 22TLA050040R0202Flat keyAllPlastic shroudFlat key for MKey safety switches. Stain-less steel key with plastic shroud.MKey Key 32TLA050040R0220Flexible keyAll MKey5PlasticFlexible key for MKey5 safety switches. Stainless steel key with plastic housing.MKey Key 42TLA050040R0221AllDie castFlexible key for MKey safety switches. Stainless steel key with black die cast metal housing.MKey Key 52TLA050040R0203AllStainless steelFlexible key for MKey safety switches. Stain-less steel key with stainless steel housing.MKey Key 62TLA050040R0204 DescriptionTy p eOrder codeBit for manual unlocking of MKey8Z. Stainless steel.MKey8Z Manual release2TLA050040R0400Maintenance lockout actuator key. Compatible with all MKey switches.MKey Lockout key2TLA050040R0401Slide Lock for MKey8 and MKey9, left. MKey slide lock left2TLA050040R0500Slide Lock for MKey8 and MKey9, right.MKey slide lock right2TLA050040R0501Fitting in stainless steel for mounting MKey5 on a Quick-Guard conventional door.JSM D29A2TLA040033R6000Fitting in stainless steel for mounting MKey5 on a Guick-Guard sliding door.JSM D29B2TLA040033R6100Fitting in stainless steel for mounting Mkey8 and Mkey9 on a Quick-Guard conventional door.JSM D29C2TLA040033R6200Fitting in stainless steel for mounting Mkey8 and MKey9 on a Quick-Guard sliding door.JSM D29D2TLA040033R6300Spacer in stainless steel for flexible keys. Required when using JSM D29A and JSM D29C.JSM D29E2TLA040033R6400Rear handle for sliding doors.RHS GKey MKey2TLA050040R0510Spring loaded catch for sliding doors.SCS GKey MKey2TLA050040R0511 MKey Key 32TLC172631F0201MKey slide lock leftMKey slide lock right—Actuator keys All MKey safety switches are supplied with the appropriate standard key, except MKey9 24VDC, No key. Choose standard key or flat key depending on suitable mounting direction, e.g. standard door or sliding door. Flexible keys are suitable for doors/hatches with a smaller opening radius (i.e. 100-175 mm). —Other accessories4 – 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
MKey5 MKey8MKey9Approvals Conformity 2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 14119:2013, EN 60204-1:2006:+A1:2009, EN 60947-1:2007:+A1:2011, EN 60947-5-1:2004:+A1:2009 Functional safety data B10d 2,500,000 operations at 100 mA load EN/IEC 62061Up to SILCL3 (depending on system architecture) 1) EN ISO 13849-1 Up to PL e (depending on system architecture) 1)Electrical dataContact block configuration with guard open and unlocked For actuator key2 NO + 1 NC MKey8, Mkey8Z, MKey8ER: 2 NO + 1 NC MKey8M: 1 NO + 1 NCMKey9: 2 NO + 1 NC 2) 1 NO + 1 NCFor solenoid/locking-MKey8, Mkey8Z, MKey8ER: 2NO + 1NC MKey8M: 2 NOMKey9: 2 NO + 1 NC 2) MKey9M: 2 NOSolenoid voltage-+24 VDC ± 10%+24 VDC ± 10%DC-13+24 VDC / 3 AAC-15 230 VAC / 3 AMechanical dataTravel for positive opening6 mm10 mm10 mmActuator key entry minimum radius175 mm Standard Key, 100 mm Flexible KeyMaterialBody: Polyester or stainless steel 316Head: Polyester or stainless steel 316MKey8, MKey8M, MKey8ER: Die cast painted redMKey8Z: Stainless steel 316Body: Glass filled polyester Head: Stainless steel 316Conduit entries3 x M20 x 1.5 3 x M20 x 1.5 1 x M20 x 1.5Operating temperature-25...+80 °C-25...+40 °C -25...+40 °CProtection classMKey5, MKey5+, MKey5 SSH, MKey5+ SSH: IP67MKey5Z, MKey5+Z: IP67, IP69KMKey8, MKey8M, MKey8ER: IP67MKey8Z: IP67, IP69KIP671) Please see EN/IEC 62061, EN ISO 13849, EN ISO 14119 and ISO/TR 24119 to see how fault exclusions and serial connection impacts the reliability of the safety related parts of control systems.2) For MKey9, the pair of contacts for the actuator key and the pair of contacts for the locking cannot be used independently of each other. See the manual for moreinformation.—Technical dataMKeyMore informationFor more information, e.g. the complete technical information, see product manual:MKey5 2TLC172244M0201MKey8 2TLC172245M0201MKey9 2TLC172246M0201Connection diagramsFor MKey connection diagrams please see https://library.abb.com/—Technical dataSENSORS AND LOCKS4 – 254
—Dimension drawingsMKeyAll dimensions in mm21540469.50303212430Fixing Holes for M5 ScrewsFRONT ENTRY41.50176471623.5028.507067219.50525END ENTRYMKey5MKey8 and MKey8MMKey8ERMKey9 and MKey9MMKey5Z4 – 26SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
SENSORS AND LOCKS4 – 274
Magne is an electromagnetic process lock intended for locking doors and hatches. Magne is usually used to prevent unwanted process interruptions, e.g. during a welding operation.Magne models with inte grated Adam safety sensor make it easy to achieve the highest safety level for the inter-locking function. Sealed aluminium housingIP67 sealing gives Magne good protection.Robust designThe electromagnetic lock without mechanical moving parts is a robust design with fewer parts that are sub-ject to wear.Reliable in extreme conditionsContinuous operationM12 connectorsQuick and easy cabling with M12 con-nectors.Magnets simplify installationElectromagnets offer larger mounting tolerances than mechanical locks. Easy to installLED diagnosticsIntegrated LED diagnostics that are easy to see reduce down time when troubleshooting.Strong holding forceA holding force of up to 1500 N pre-vents unwanted process stops.—Electromagnetic process lockMagne4 – 28SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
Locking and interlockingAn interlocking function indicates if a door is open or closed and prevents movement when the door is open. But it does not prevent the door from being opened. A locking function makes sure the door is kept closed.—Applications and featuresMagnePL e in a simple and cost effective wayMagne 4 has an integrated Adam sensor wich provides the interlocking function when it is associated with an Eva actuator: when the door is opened, a safety signal is sent to the safety control unit. Magne 4 makes it easy to reach PL e/SIL3 for the interlock-ing function. The Eva actuator is ordered and installed separately. Eva is available with a general or a unique code. Magne 4 is available with integrated Adam DYN (DYNlink signal) or Adam OSSD (OSSD signal). Both enable serial connection of several Magne 4 locks using only one input for Magne DYN and two for Magne OSSD.Protect the processMagne 4 associated with an Eva actuator is a process lock with a safe interlocking function. This means that the inter-locking function reaches PL e/SIL3 but the unlocking signal is not a safe signal. Magne 3 is a simple lock without any interlocking function/safety function.ApplicationsFeaturesM12 connectorsWith Magne 4, only one cable is necessary for both the lock-ing and the interlocking.The M12 connectors speed up connection and reduce therisk of connection errors.Several Y-connectors and connection accessories are avail-able to facilitate connection in series.Status indicationMost models offer an info signal indicating whether Magne is locked or not, which simplifies troubleshooting and im-proves user friendliness. This signal should not be used for safety.Optional permanent magnetAnchor plates for Magne are ordered separately and are available with or without permanent magnet. A permanent magnet holds the door closed when Magne is unlocked, or if there is a power loss. Without the permanent magnet, Magne has no magnetic field when unlocked, which avoids the accumulation of metallic particles on the magnet.A typical application for Magne 4 is to prevent unintention-al/unnecessary interruptions of a sensitive process when the dangerous movement has a very short stop time.SENSORS AND LOCKS4 – 294
JSM D28—Ordering informationMagne Safe interlocking with integrated AdamSafety signalExtra functionConnectorTy p e Order codeNo-- M12-5 maleMagne 3X M12-52TLA042022R2700Ye sDYNlink-M12-5 maleMagne 4X DYN M12-52TLA042022R3000One combined "locked and closed" information outputM12-8 maleMagne 4 DYN-Info2TLA042022R3400Two separate “locked” and “closed” information outputsM12-8 maleMagne 4 DYN-2Info2TLA042022R3410OSSDOne combined "locked and closed" information outputM12-8 maleMagne 4 OSSD-Info2TLA042022R4600 DescriptionTy p e Order codeAluminium profile for door handle that completely covers a Magne unit when the door is closed. For conventional door (5–15 mm door gap)JSM D282TLA042023R0100Mounting kit for Magne. For conventional door (5 -15 mm door gap) *JSM D21C2TLA042023R0510Mounting kit for Magne. For sliding door *JSM D23C2TLA042023R0210Mounting kit for Eva. For conventional door*JSM D242TLA042023R0300Door handle for JSM D21CJSM D272TLA042023R1000Connection block for serial connection of two Magne (M12-8)Tina 12A2TLA020054R1800Cellular rubber, 10 mm thick. Spare part for Magne Anchor plate.Magne rubber 1B2TLA042023R3610* All mounting kits include the bolts and nuts necessary to mount Magne on ABB Quick-Guard® fencing systemMagne 3JSM D27JSM D24Magne 4Magne Anchor 32EJSM D23CTina 12A DescriptionTy p e Order codeAnchor plate with permanent magnet. Delivered with Magne rubber.Magne Anchor 32E2TLA042023R0420Anchor plate without permanent magnet. Delivered with Magne rubber.Magne Anchor 32D2TLA042023R0410 Compatible AdamCode descriptionCode levelTy p e Order codeAdam DYN and OSSDGeneral code. (Eva is interchangeable)Low levelEva General code 2TLA020046R0800 Unique code. (Prevents defeat/fraud)High levelEva Unique code 2TLA020046R0900 Magne rubber 1BJSM D21C4 – 30SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4—Ordering details For a complete Magne lock both door part and frame parts are necessary. Magne 4 also requires a separate Eva sensor.—Accessories—Door part—Eva sensor for Magne 4 models
—Cables and connectorsMagne DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C5 cable2TLC010038F0201M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201M12-C01 2TLC172657F0201 ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R05006 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 Angled female connectorM12-C1012V22TLA020056R670016 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 M12-C612TLC172951F0201SENSORS AND LOCKS4 – 314—Cable with connectors—Separate cables and connectors
Magne 3Magne 4ApprovalsConformity 2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHS2015/863 - RoHS3EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 60947-5-2:2007+A1:2012, EN 60947-5-3:20132006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHS2015/863 - RoHS3EN ISO 12100:2010, EN ISO 13849-1:2015, EN ISO 13849-2:2012, EN 62061:2005+A1:2012+A2:2015, EN 61508:2010,EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 60947-5-2:2007+A1:2012, EN 60947-5-3:2013Functional safety dataEN 61508:2010Interlocking function: SIL3, PFHD = 4.50 x 10-9EN 62061:2005Interlocking function: SILCL3, PFHD = 4.50 x 10-9EN ISO 13849-1:2015Interlocking function: PL e, Cat. 4, PFHD= 4.50 x 10-9Electrical dataOperating voltage+24 VDC ± 15%Holding force+24 VDCUp to 1500 N0 V, Anchor plate 32D0 N0 V, Anchor plate 32E30 NAssured release distance (Sar)25 mmAssured operating distance (Sao)10 mmMechanical dataOperating temperature-20...+50 °CHumidity range35 to 85% (with no icing or condensation)Protection classIP67Weight700 g700 gAnchor plate 32D/E290 gMaterialAnchor plateIron with nickel coatingElectromagnetIron with zinc coatingHousingAnodized aluminum with parts in polycarbonatePottingPUR, epoxy—Technical dataMagneMore informationFor more information, e.g. the complete technical information, see product manual for:Magne 2TLC172315M02014 – 32SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4—Technical data
Magne All dimensions in mm—Dimension drawingsMagneAnchor plate 32DAnchor plate 32ESENSORS AND LOCKS4 – 334
GKey is a robust safety lock with a die cast housing for hinged and sliding doors.GKey offers an interlocking function reaching PL e/SIL 3 with high level coding. Power is needed to unlock GKey which makes GKey a safety lock.GKey is fitted with a rear escape release button and manual unlocking (auxiliary release).GKey offers four positions for 22 mm pilot devices.Escape releaseThe door can always be opened from inside the danger zone using the escape release button.High level coding A standard mechanical interlock com-bined with RFID coding offers high level coding.Lockout functionGKey can be padlocked off for safe working.Safety and protectionReliable in extreme conditionsIntegrated buttonsThere are four positions in the key housing that can be used for inte-grating push buttons, switches or pilot lights.Easy to installRobust designMade of die cast aluminum alloy with a robust construction, GKey is ideal for use in mechanically demanding environments.—Safety lockGKey4-34SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Ordering DetailsGKey4 RURHS GKey MKeySCS GKey MKeyFHS GKey4CE3P-10R-02C2SS1-10B-20CP1-11C-10MA1-8130KA1-8120 Material (body)Positions for pilot devicesManual unlockTy p eOrder codeDie cast4Ye sGKey4 RU2TLA050304R0002—SwitchesFor a complete safety lock, a switch and a mounting plate with front handle must be ordered separately. Rear handle, spring catch, pilot devices and blanking plugs for the unused positions are available and also ordered separately.DescriptionContactsIlluminatedVoltageTy p eOrder codeEmergency stop button2NCNo24 V AC/DCCE3P-10R-021SFA619501R1051Selector switch2NONo24 V AC/DCC2SS1-10B-201SFA619200R1026Push button Green1NOYe s24 V AC/DCCP1-11G-101SFA619100R1112Push button Yellow1NOYe s24 V AC/DCCP1-11Y-10 1SFA619100R1113Push button Blue1NOYe s24 V AC/DCCP1-11L-10 1SFA619100R1114Push button White/Clear1NOYe s24 V AC/DCCP1-11C-10 1SFA619100R1118Push button Black1NONo24 V AC/DCCP2-10B-10 1SFA619101R1016Blanking plug BlackMA1-81301SFA611920R8130Legend plate holder (without insert)KA1-81201SFA616920R8120—Accessories - Pilot devicesAll models are fitted with an escape release button and delivered with a high level coded RFID actuator.—Mounting plate with front handleThe handle can be mounted on hinged doors and sliding doors, on the left or on the right.Note that door and frame must be aligned when the door is closed.Each order code includes a mounting plate for the switch and a front handle. Type of handleMaterial (mounting plates and sliding bolt)Ty p eOrder codeSlidingDie castFHS GKey42TLA050310R0032—Accessories - Rear handle and spring loaded catchThe spring loaded catch prevents from closing the door by mistake. When the sliding handle is in open position, the catch must be pulled in order to be able to push back the handle to closed position. Type of handleMaterialDescriptionTy p eOrder codeSlidingDie castRear handleRHS GKey MKey2TLA050040R0510Spring catchSCS GKey MKey2TLA050040R0511 More informationFor more optional pilot devices, pre-printed legend plate inserts and other accessories, please see the Compact range of ABB pilot devices: http://new.abb.com/low-voltage/products/pilot-devicesPilot devices and blanking plugs must be ordered separately. Make sure that the total amount is 4, so that all holes in GKey4 are covered. DescriptionTy p e Order codeCable gland M20 x 1.5Gland M20x1.52TLA050040R0002Conduit plug M20 x 1.5Cond.Plug M20x1.52TLA050040R0004—Accessories for cable holes—Ordering detailsGKeySENSORS AND LOCKS4-354
ApprovalsConformity2006/42/EC – Machinery2014/53/EU – RED2011/65/EU – RoHS22015/863 – RoHS3EN ISO 12100:2010, EN ISO 14119:2013, EN ISO 13849-1:2015, IEC 62061:2005+A2:2015, IEC 60947-5-3:2013, IEC 60947-1:2014, EN 60204-1:2018, EN 301 489-1 V2.1.1, EN 301 489-3 V1.6.1Functional safety dataEN 62061:2005+A1:2013SIL3PFH = 4.77 x 10-10 (corresponds to 4.8% of SIL3),PFD = 4.18 x 10-5 (corresponds to 4.2% of SIL3)Proof test interval T1 = 20 aEN ISO 13849-1:2008PL e (if both channels are used in conjunction with a SIL3/PL e control device),Category 4, MTTFd = 1100 a, DC highAssumptionsdop = 365d, hop = 24hIf the product usage differs from these assumptions (different load, operating frequency, etc.) the values must be adjusted accordingly.Electrical dataOperating voltage+24 VDC ± 10%Holding force3000 NMechanical dataConnectionM20 (x3)Operating temperature-25 °C ... +40 °CProtection classIP65.—Technical dataMore informationFor more information, e.g. the complete technical information,see product manual:GKey 2TLC010048M0201Connection diagramsFor GKey connection diagrams please see https://library.abb.com/Actuator must be in place and RFID coding verified for the safety contacts to close.Electrical connection—Technical dataGKey4-36SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY4
—Dimension drawingsGKeyDimensions - GKey4 switch and actuatorDimensions - FHS GKey4 with rear handle and spring loaded catch All dimensions in mmSENSORS AND LOCKS4-374
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
5– 2 Introduction and overview 5– 4 One- and two-hand devices Safeball™ 5– 10 Three-position device JSHD45– 20 Three-position device HD5CONTROL DEVICES5 – 15— Control devices
—Introduction and overviewSelection guideABB offers ergonomic control devices that allow operators to safely control dangerous machinery.SafeballJSHD4HD5ImageTy p eOne or two-hand control deviceTree-position deviceTree-position deviceDescriptionErgonomic and unique machine controlErgonomic hold-to-run device with extra control buttonsErgonomic hold-to-run device for food and beverage applicationsApplicationMainly used in pairs as a two-hand control in applications where it must be ensured that the operator has his hands out-side the hazardous area, e.g. for starting a press cycle.Used during e.g. troubleshooting, test running and programming, in order to allow the operator to be inside the hazardous area without stopping the machine, while ensuring limited movement and stop in case of danger.Advantages- Ergonomic design- Several grip possibilities- Flexible mounting- Two opposing buttons mini-mize thepossibility to defeat- Ergonomic shape and operation- Hand recognition prevents defeat- Easy connection with M12 con-nectors- Several models to suit multiple applications- Extra buttons for e.g. machine control- Adapted and approved for use in food and beverage applications- Ergonomic shape and operation- Flashlight for inspection - Integrated emergency stop- Extra buttons for e.g. machine control5 – 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
Different types of control devicesWhen to use a two-hand or one-hand control device A two-hand control device is often used for machines with manual loading or unloading. The operator uses the two-hand control device to safely start a machine cycle. A two-hand control must be used with a safety control device that supervises that both buttons are pressed simultaneously, i.e. both hands are on the control and therefore outside the dangerous zone, in order to start the dangerous movement. An one-hand control device can be used in applications when the operator cannot reach the hazardous area with his/her free hand, or on less dangerous machines.When to use a three-position deviceA three-position device (or hold-to-run device) is used to allow a limited movement of the machine when the opera-tor needs to be in the dangerous area without stopping the dangerous machine, for example during troubleshooting, test running or programming.The operator pushes the larger black button to a middle position in order to allow a movement. In case of danger, the operator will either release the button or squeeze it to its bottom position and the machine will stop.StandardsThe safety distance of two-hand control devices should be calculated using EN ISO 13855. When constructing a two-hand station for a machine, the standard EN 574 about functional aspects and principles for design needs to be followed.—Introduction and overview Selection orientationCONTROL DEVICES5 – 35
Safeball™ is an ergonomic control device used for safe start and stop of machine cycles. Usually two Safeball™ are used to-gether to form a two-hand control.Safeball™ consists of a spherical ball con-taining two embedded push button switch-es, one on each side of the ball. Both buttons must be pressed in order to start and oper-ate the machine. The risk of unintentional ac-tivation is thereby minimized and the device is simple and ergonomic to use. When two Safeball™ are used in a two-hand device application, the operator must press all four push buttons simultaneously in order to operate the machine. If one or more of the buttons are released, a stop signal is given to the machine.Unique designThe unique design of SafeballTM com-bines the highest level of safety with the best ergonomics.Highest safety levelSafeballTM provides the operator with a dual switching function and short-circuit supervision in each hand.Safety and protectionErgonomic designThe design of Safeball™ allows for comfort of use for all hand sizes and a great variety in gripping positions. And there is no need for shrouding top covers to prevent defeat, as there is for two-hand devices with standard push buttons. Flexible mountingWith the JSM C5 mounting bracket, Safeball™ can be orientated in the most ergonomic position for the op-erator.Optimum interface—One- and two-hand devicesSafeball™5 – 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
One-hand control deviceOne Safeball™ can be used as an ergonomic “hold to run” button, i.e. the movement is allowed as long as both push buttons on Safeball™ are pressed, usually when the opera-tor cannot reach the hazardous area with his/her free hand, or on less dangerous machines. SafeballTM is a very practical one-hand control device since it is very easy to locate and activate.—Applications and featuresSafeball™ApplicationsTwo-hand control deviceA two-hand control device is often used for machines withmanual loading or unloading. The operator uses the two-handcontrol device to safely start a machine cycle. A two-hand control must be used with a safety control device that makes sure that both buttons are pressed simultaneously, i.e. both hands are on the control and therefore outside the dangerous zone, in order to start the dangerous movement. Using two SafeballTM, it is easy to realize a custom two-hand device. FeaturesMounting methodsSafeball™ can be mounted in many different ways. It can be mounted on a table, on the machine, on a support or wherever suitable for ergonomic reasons. Safeball™ can be mounted in a fixed position or on a tilting and/or rotating support when used with a JSM C5. This flexibility in mount-ing enhances ergonomics and minimizes work-related mus-culoskeletal disorders.When two Safeball™ are used as a two-hand device, no shrouding top cover is necessary to prevent defeat, as it is for two-hand devices with push buttons, since it is very dif-ficult to push all 4 push buttons of the two Safeball™ with e.g. a hand and an elbow. Highest level of safetyWhen used as a two-hand control device, a safety control-ler for two-hand devices must be used, like an appropriate Sentry safety relay or a Pluto programmable safety control-ler. The safety controller monitors that all four push buttons (i.e. on each side of both Safeball™) are pressed within 0.5 second, in order to detect e.g. a short circuit or fraud, like a rubber band around one device. Safeball™ is certified to comply with type III C according to EN 574+A1:2008.JSTD25The JSTD25 control stations are pre-built two-hand devices utilizing the good ergonomics of Safeball™. They can be used as fixed devices that are easy to install, or as mobile devices. All models are equipped with shields to protect the buttons from accidental operation, and also protect from damage if the device is dropped on the floor when used as mobile device. All versions meet EN 574 and EN ISO 13849-1. CONTROL DEVICES5 – 55
—Ordering informationSafeball™2TLC010041F0201Safeball™Types of switchesCable lengthTy p e Order code1 NO + 1 NC2 mJSTD1-A2TLA020007R30000.2 mJSTD1-B2TLA020007R310010 mJSTD1-C2TLA020007R32002 NO0.2 mJSTD1-E2TLA020007R3400Extra featureConnector maleTy p e Order codeNoneM12-5JSTD25F2TLA020007R6000M12-8JSTD25H2TLA020007R6300Pre-mounted Smile 10 EK emergency stop button M12-8JSTD25K2TLA020007R6900JSMC52TLC172194F0201JSMC72TLC172195F0201JSTD25F2TLC172086F02012TLC172681F0201JSTD25KDescriptionTy p e Order codeMounting bracket for JSTD1 with orientation possibility (ball joint)JSM C52TLA020007R0900Suspension shelf for JSTD25F/H/K JSM C72TLA020007R1200Protection coat for SafeballSafeball coat2TLA020007R1900—Safeball™ JSTD1—Two-hand control devices JSTD25—Accessories5 – 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Cables and connectorsSafeball™ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R05006 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 Angled female connectorM12-C1012V22TLA020056R670016 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 M12-C612TLC172951F0201DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C5 cable2TLC010038F0201M12-C3342TLC172931F0201M12-C61HE2TLC010003F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectorsCONTROL DEVICES5 – 75
Technical dataApprovals Conformity 2006/42/EC - MachineryEN ISO 12100:2010, EN 574+A1:2008Functional safety dataEN/IEC 61508:2010Up to SIL3, depending on system architectureEN/IEC 62061:2005+A1:2013Up to SILCL3, depending on system architectureEN ISO 13849-1:2008Up to Cat. 4, PL e, depending on systemMechanical dataOperating forceApprox. 2NLife, mechanical> 1 x 106 operations at max 1 HzConnection cableJSTD1-APVC-cable, 4 x 0.75 mm2, L = 2 m JSTD1-B, JSTD1-EWires, 4 x 0.75 mm2, L = approx. 0.2 mJSTD1-CPVC-cable, 4 x 0.75 mm2, L = 10 mProtection classIP67. Not intended for use under waterAmbient temperature-25 °C to +50 °C (operating)Material JSTD1PolypropyleneWeight JSTD1With 2 m cable0.2 kgWith 10 m cable0.7 kgWith 4 x 0.2 m wires0.1 kg—Technical dataSafeball™More informationFore more information, e.g. the complete technical information, see product manual for:Safeball 2TLC172182M0201 Connection diagramsFor Safeball connection diagrams please see https://library.abb.com/5 – 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Dimension drawingsSafeball™Safeball™ JSTD25F All dimensions in mmCONTROL DEVICES5 – 95
JSHD4 is a three-position device used to allow a limited movement of the machine when the operator is in the dangerous area, for example during troubleshooting, test running and programming.The operator pushes the larger black button to a middle position in order to allow a movement. In case of danger, the operator will either release the button or squeeze it to its bottom position and the machine will stop.JSHD4 is available with different types of connectors for an optimal adaptation to the application. Some models offer additional top and front button to control a non-safe signal, for ex. move forward and/or backward.Cheat-safe hand recognitionAll JSHD4 models comply with PL e/Cat 4. Some models offer an “anti-tamper” function: an extra signal indicate if the JSHD4 is held in the middle position by a human hand. A machine movement will be authorized only in presence of this signal and not if the device is held in run position by any other (fraudulent) mean.Safety and protectionContinuous operationErgonomic shape and operation JSHD4 is ergonomic, both in respect of its shape, fitting to the hand, and the way the buttons are operated. JSHD4 is easy to operate using just the fingers (even with gloves), and the middle position provides a safe resting position.Optimum interfaceSafely inspect a running machineJSHD4 allows the operators to safely inspect the manufacturing process without completely stopping the ma-chine.—Three-position device JSHD45 – 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
Safe troubleshooting, programming and testingIf the operator has to enter a risk area for troubleshooting or test running, it is extremely important that he/she is able to stop the machinery without having to rely on someone else pushing a stop button. In addition, no-one else should be able to start the machinery after it has been stopped by the operator. An operator who is under pressure must also be able to give a stop signal, whether in panic he/she pushes harder on the button or just releases it.—Applications and featuresJSHD4ApplicationsJSHD4 three-position control device can be used for trou-bleshooting, programming and test running in situations where no other protection is available or feasible. JSHD4 allows the operator to safely inspect the process without completely stopping the machine. The big black button has 3 distinct positions: released, pressed gently and pressed hard. The middle position allows the machine to run with limited speed or range, but when released or pressed hard the machine stops.Hand recognition for protection against tamperingAn optional “anti-tamper” function sends an extra signal to indicate if the JSHD4 is held by a human hand or not. By us-ing this, the safety level is increased, and the risk of manipu-lation 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 control device in run mode.Ergonomic designJSHD4 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 device by using just the fingers (even with gloves), and the middle position provides a secure resting position.FeaturesAdditional top and front buttons for non-safe signals The two additional buttons can be used for e.g. start/stop, up/down or forward/ back. These buttons should not be used for safety related functions.CONTROL DEVICES5 – 115
—Ordering informationJSHD4To p pa r tBottom partAnti-Buttons and LEDsFeatureIDConnectiontamperTy p eOrder codeJSHD4-1Use your own cableAACable gland and 5 screw connectionsJSHD4-1-AA2TLA019995R0000No LEDs No buttonsCost effective and quick connectionACM12-5 maleJSHD4-1-AC2TLA019995R0100Holder for Eva (used with JSM54)ALCable gland and 10 screw connectionsJSHD4-1-ALOrder separate partsJSHD4-2Cost effective and robustABCannon 12 male pinsJSHD4-2-AB2TLA019995R0200LEDs Front button Top buttonJSHD4-2-AB-AOrder separate partsCost effective and quick connectionADM12-8 maleJSHD4-2-AD2TLA019995R0400JSHD4-2-AD-AOrder separate parts Use your own cable, simplified connectionAHCable gland and 10 screw connectionsJSHD4-2-AH2TLA019995R0800JSHD4-2-AH-AOrder separate partsUse your own cable, full pin connectionAJCable gland and 16 screw connectionsJSHD4-2-AJOrder separate partsJSHD4-2-AJ-AOrder separate partsReplacement of old units*AKCannon 12 male pinsJSHD4-2-AK2TLA019995R4800Holder for Eva (used with JSM54)ALCable gland and 10 screw connectionsJSHD4-2-ALOrder separate partsJSHD4-2-AL-AOrder separate partsJSHD4-3Cost effective and robustABCannon 12 male pinsJSHD4-3-ABOrder separate partsLEDs No buttonsJSHD4-3-AB-AOrder separate partsCost effective and quick connectionADM12-8 maleJSHD4-3-ADOrder separate partsJSHD4-3-AD-AOrder separate partsE-stopAEM12-8 maleJSHD4-3-AEOrder separate partsUse your own cable, simplified connectionAHCable gland and 10 screw connectionsJSHD4-3-AH2TLA019995R2000JSHD4-3-AH-AOrder separate partsUse your own cable, full pin connectionAJCable gland and 16 screw connectionsJSHD4-3-AJOrder separate partsJSHD4-3-AJ-AOrder separate partsReplacement of old units*AKCannon 12 male pinsJSHD4-3-AKOrder separate partsHolder for Eva (used with JSM54)ALCable gland and 10 screw connectionsJSHD4-3-ALOrder separate partsJSHD4-3-AL-AOrder separate partsJSHD4-4Cost effective and robustABCannon 12 male pinsJSHD4-4-ABOrder separate partsLEDs Front buttonJSHD4-4-AB-AOrder separate partsCost effective and quick connectionADM12-8 maleJSHD4-4-ADOrder separate partsJSHD4-4-AD-AOrder separate partsUse your own cable, simplified connectionAHCable gland and 10 screw connectionsJSHD4-4-AHOrder separate partsJSHD4-4-AH-AOrder separate partsUse your own cable, full pin connectionAJCable gland and 16 screw connectionsJSHD4-4-AJOrder separate partsJSHD4-4-AJ-AOrder separate partsReplacement of old units*AKCannon 12 male pinsJSHD4-4-AKOrder separate partsHolder for Eva (used with JSM54)ALCable gland and 10 screw connectionsJSHD4-4-ALOrder separate partsJSHD4-4-AL-AOrder separate partsJSHD4-5Cost effective and robustABCannon 12 male pinsJSHD4-5-ABOrder separate partsLEDs Top buttonJSHD4-5-AB-AOrder separate partsCost effective and quick connectionADM12-8 maleJSHD4-5-ADOrder separate partsJSHD4-5-AD-AOrder separate partsUse your own cable, simplified connectionAHCable gland and 10 screw connectionsJSHD4-5-AHOrder separate partsJSHD4-5-AH-AOrder separate partsUse your own cable, full pin connectionAJCable gland and 16 screw connectionsJSHD4-5-AJOrder separate partsJSHD4-5-AJ-AOrder separate partsReplacement of old units*AKCannon 12 male pinsJSHD4-5-AKOrder separate partsHolder for Eva (used with JSM54) ALCable gland and 10 screw connectionsJSHD4-5-ALOrder separate partsJSHD4-5-AL-AOrder separate parts* See document 2TLC010007L0201 for information about replacementJSHD4-1-AC2TLC010005V0201JSHD4-2-AB2TLC010014F0201JSHD4-2-AH 2TLC010013F0201JSHD4-2-AD2TLC010015F0201Top partBottom part—Complete list of JSHD4 modelsThis list shows the possible combination of features. Some combinations can be ordered pre-assembled with a single order code. Other combinations need to be ordered in separate parts (see next page).5 – 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Ordering informationJSHD4DescriptionTy p eOrder codeTop partsTop part with no LEDs, no buttonsJSHD4-1 Top part2TLA020006R2100Top part with LEDs, front and top buttonsJSHD4-2 Top part2TLA020006R2200 Top part with LEDs, no buttonsJSHD4-3 Top part2TLA020006R2300Top part with LEDs, front buttonJSHD4-4 Top part2TLA020006R2400Top part with LEDs, top buttonJSHD4-5 Top part2TLA020006R2500Bottom partsBottom part with cable glandJSHD4 AA 2TLA020005R1000Bottom part with Cannon connectorJSHD4 AB 2TLA020005R1100 Bottom part with M12-5 connectorJSHD4 AC 2TLA020005R1200 Bottom part with M12-8 connectorJSHD4 AD 2TLA020005R1300 Bottom part with M12-8 connector and E-stop buttonJSHD4 AE 2TLA020005R1400 Bottom part with cable gland and PCB with 10 screw terminalsJSHD4 AH2TLA020005R1700Bottom part with cable gland and PCB with 16 screw terminalsJSHD4 AJ2TLA020005R1800Bottom part with cannon connector (replacement of former JSHD4)JSHD4 AK2TLA020005R1900Bottom part with cable gland and holder for EvaJSHD4 AL2TLA020005R2000Anti tamperAnti-tamper PCBJSHD4 Anti-tamper2TLA020005R0900—Top parts, bottom parts and anti-tamperTo order a complete JSHD4, a top part and a bottom part must be included. Don’t forget the anti-tamper PCB if required.For example, if you want to order a JSHD4-3-AB-A, please order• JSHD4-3 top part• JSHD4 AB bottom part• Anti-tamper PCB (the “-A” at the end of the designation stands for Anti-tamper)Please note that all combinations are not compatible. See previous page for possible combinations.AA, AH, AJ - Cable gland2TLC172156F0201AB, AK - Cannon connection2TLC172157F0201AE - M12 with E-stop2TLC172159F0202AL - Cable gland and holder for Eva (used with JSM54) 2TLC172047V0201AC, AD - M12 connection2TLC172158F0201Anti-tamper PCB2TLC172161F0201JSHD4-2 Top partCONTROL DEVICES5 – 135
DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R170012-pole female cannon connector for JSHD4JSHK02TLA020003R0300Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C5 cableM12-C01 —Separate cables and connectors2TLC010038F02012TLC172657F0201—Cables and connectorsJSHD4ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R0500 6 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 16 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 CannonFemale5 mHK52TLA020003R470010 mHK102TLA020003R480020 mHK202TLA020003R49001.6 mSpiral cableHK16S42TLA020003R50002 mSpiral cableHK20S42TLA020003R51003.2 mSpiral cableHK32S42TLA020003R52004 mSpiral cableHK40S42TLA020003R35006 mSpiral cableHK60S42TLA020003R36008 mSpiral cableHK80S42TLA020003R5300M12-C612TLC172951F0201M12-C3342TLC172931F0201M12-C61HEHK20S4 —Cable with connectors5 – 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
JSM 50G bracket for key switches and JSM 5B wall bracket for 2 pcs MKey5JSM 50G JSM 5B —AccessoriesJSHD4JSHD4 protection coatJSM 54A wall bracket for Adam (and AL bottom part that has a holder for Eva)JSM 54A JSM 55 JSM 55 wall bracket and JSM 50H bracket for EdenJSM 50H DescriptionTy p eOrder codeBrackets and bottom platesJSM 55 Wall bracket for three position deviceJSM 552TLA040005R0500JSM 5B Wall bracket for 2 pcs MKey5 interlock switchesJSM 5B2TLA040005R0700JSM 54A Wall bracket for Adam. Used with AL bottom part that has a holder for EvaJSM 54A2TLA020205R2800JSM 50G Bracket for key switchesJSM 50G2TLA020205R6300JSM 50H Bracket for Eden sensorJSM 50H2TLA020205R6400OthersJSHD4 protection coatJSHD4 Coat2TLA020200R46002TLC172351F0201—AccessoriesCONTROL DEVICES5 – 155
—AccessoriesJSHD4JSHD4H2AMountingLeadsHandTy p eOrder codeExternal mounting6 x 150 mmLeftJSHD4H2A2TLA020002R0200RightJSHD4H2B2TLA020002R0210Internal panel mounting6 x 150 mm-JSHD4H2 0.15 m2TLA020002R31006 x 1200 mm-JSHD4H2 1.2 m2TLA020002R4500—JSHD4H2The three-position button of JSHD4 is available as a separate part for either external mounting or panel mounting.JSHD4H2A/B are intended for mounting on the back side of a handheld teaching pendant or similar.JSHD4H2 can be mounted in a panel hole.JSHD4H2BJSHD4H25 – 16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Electrical wiring diagramsExamples with JSHD4-1 and JSHD4-2 modelsJSHD4-2-AD-A, M12-8JSHD4-2-AK, Cannon 12 pinsJSHD4-2-AB-A, Cannon 12 pinsJSHD4-1-AA, cable gland and 5 screw connections on JSHD4-1CONTROL DEVICES5 – 175
—Electrical wiring diagramsExamples with JSHD4-2 modelsJSHD4-2-AJ-A, cable gland and 16 screw connectionJSHD4-2-AL-A, cable gland and 10 screw connectionJSHD4-2-AB-A, Cannon 12 pinsJSHD4-2-AH-A, cable gland and 10 screw connection5 – 18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Technical data and dimension drawingsJSHD4Technical dataApprovalsConformity2006/42/EC - Machines2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100-1:2010, EN ISO 13849-1:2015, EN ISO 13849-2:2012, EN 60204-1:2006+A1:2009, EN 61000-6-2:2005, EN 61000-6-3:2007Functional safety dataEN ISO 13849-1:2016Up to PL e (depending on number of operations per year)B10d: 2 000 000 to middle position, 968 000 to bottom positionElectrical dataCurrent allowed, three-position buttonPer channel: Maximum +30 VDC, 20 mA, (Minimum +10 VDC, 8 mA) Current allowed, extra buttonMaximum 500 mAOperation forceApprox. 15 N for three-position buttons (ON)Approx. 45 N for three-position buttons (OFF)Approx. 2.5 N for top/front push buttonMechanical dataOperating temperature- 10 ...+50 °CProtection classIP65Mechanical life1 000 000 cycles to middle positionWeightApprox. 0.2 kg without cableDimension drawingsAll dimensions in mm 142 235 78 111 JSHD4-2-ADJSHD4-2-AL 142 235 78 111 More informationFore more information, e.g. the complete technical information, see product manual for:JSHD4 2TLC172072M0201CONTROL DEVICES5 – 195
HD5 is a three-position device developed to meet most demands of the Food and Beverage industry.A three-position device is used to allow a limited movement of the machine when the operator is in the dangerous area, for example during troubleshooting, test running and programming. The operator pushes the larger black button to a middle position in order to allow a movement. In case of danger, the operator will either release the button or squeeze it to its bottom position and the machine will stop.The housing of the HD5 is made of PPh, that not only is approved for contact with foodstuff, but also resists the most commonly used chemicals during cleaning in the Food and Beverage industry. Without sharp edges, there are no places where dirt and bacteria can be accumulated. The construction of the HD5 prevents condensation inside the product when subject to temperature changes in a wet environment. The PPh used is fiberglass reinforced to prevent breakage and minimize risk of small broken bits falling in the foodstuff.Safe inspectionUp to PL e/Cat 4, with TÜV and cULus approval. Home position sensor to detect when the device is out of its holder.Safety and protectionContinuous operationErgonomic, flexible and suitable for Food and Beverage HD5 is easy to operate with additional buttons, integrated emergency stop button and flash-light.Housing material minimizes risk of breakage and is approved for contact with foodstuff.No places where dirt and bacteria can be accumulated.Optimum interfaceAvoid unnecessary process stopsHD5 allows the operators to safely in-spect the manufacturing process with-out completely stopping the machine.Resistant to most cleaning fluids and chemicals in Food and Beverage.—Three-position device HD55 – 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
Safe troubleshooting, programming and testingIf the operator has to enter a risk area for troubleshooting or test running, it is extremely important that he/she is able to stop the machinery without having to rely on someone else pushing a stop button. In addition, no-one else should be able to start the machinery after it has been stopped by the operator. An operator who is under pressure must also be able to give a stop signal, whether in panic he/she pushes harder on the button or just releases it.—Applications and featuresHD5ApplicationsHD5 three-position control device can be used for trouble-shooting, programming and test running in situations where no other protection is available or feasible. HD5 allows the operator to safely inspect the process without completely stopping the machine. The big black button has 3 distinct positions: released, pressed gently and pressed hard. The middle position allows the machine to run with limited speed or range, but when released or pressed hard the ma-chine stops.Indication LEDs Green and a red high intensity LEDs are integrated in the top of the houding. Their function is user-defined and they can be used, e.g. to indicate whether the three-position device is in the middle position or not. Front button and top buttonsThe function of the additional buttons is user-defined. They can be used, e.g. for a start/stop function for individual movements etc.FlashlightAn integrated flashlight can be used to help e.g. trouble-shooting in dark spaces. Home position sensor Used with an active holder, this sensor detects whether the HD5 is in place in its holder. FeaturesEmergency stop button with integrated LED in housingSome models are fitted with an emergency stop button and two rows of LEDs are integrated into the housing of the HD5, below the emergency stop button, one green and one red. Adapted to food and beverageHD5 is specifically developed with focus on the require-ments in food and beverage applications. • It has an hygienic design with rounded edges and lean-ing surfaces to prevent collection of water and dirt. • The operating surfaces of the buttons are directly in-jected in the housing. • The plastics used are approved for food and beverage industry (PHH G30). • The markings are laser permanent in order not to con-taminate any food. • An anti-condensation membrane prevents moist from building up inside.CONTROL DEVICES5 – 215
—Ordering informationHD5AS-i interfaceEmergency stop with LEDHome position sensorMotion sensorLED flashlightConnectorTwo top buttonsTy p eOrder codeNoNoNoNoNoM23-12NoHD5-S-1022TLA023001R0000Ye sHD5-S-1042TLA023001R0200 Ye sYe sYe sYe sM23-19Ye sHD5-S-1112TLA023001R0100Ye sYe sYe sYe sYe sM12-5Ye sHD5-B-1012TLA920502R0003NoYe sYe sYe sM12-5Ye sHD5-B-1022TLA920502R0004—HD5 ordering informationHD5-S-104HD5-M-001HD5-S-102DescriptionSuitable forTy p eOrder codeActive holder (for home position sensor)All modelsHD5-M-0012TLA920509R0001Passive holderAll modelsHD5-M-0022TLA920509R00025 m cable with M23-12 female connectorHD5-S-102/104JSD-TK5-122TLA930050R000010 m cable with M23-12 female connectorHD5-S-102/104JSD-TK10-122TLA930051R000010 m spiral cable with M23-12 female connectorHD5-S-102/104JSD-TK100S-122TLA930034R00005 m cable with M23-19 female connectorHD5-S-111JSD-TK5-192TLA930057R000010 m cable with M23-19 female connectorHD5-S-111JSD-TK10-192TLA930058R00005 m unshielded cable with M12-5 female connectorHD5-B-101/102M12-C51-ASi2TLA910093R00002.5 m unshielded spiral cable with M12-5 female connectorHD5-B-101/102M12-C251S-ASi2TLA910094R0000—HD5 accessoriesHD5-S-1115 – 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
—Technical dataHD5Technical dataApprovalsConformity2006/42/EC - Machines2014/30/EU - EMC2011/65/EU - RoHS 22015/863/EU - RoHS 3EN ISO 12100-1:2010, EN ISO 13849-1:2015, EN 62061:2015, EN 60204-1:2006+A1:2009Functional safety dataThree-position switchesUp to PL e, category 4, SILCL3Three-position switchesB10d: 2 000 000 released to middle to released positionB10d: 968 000 middle to end to middle positionEmergency stop buttonB10d: 250 000Electrical dataOperational voltage HD5-S HD5-B24 VDC, tolerance 20.4 - 27.6 VDC 30 VDC, AS-i bus, tolerance 26 - 31,6 VDCOverall power consumption< 150 mAConnection HD5-S HD5-BM23 male connector, 12 or 19 pinM12 male connector, 5 pinsActuating force Three-position buttonApprox. 20 N from release to middle positionApprox. 45 N from middle to end position Additional buttonsApprox. 3 N for front buttonApprox. 7 N for top buttonMechanical dataOperating temperature- 10 ...+50 °C (no icing, no direct sunlight)Protection classIP65WeightApprox. 0.2 kg without connection cableMaterialHousingFiberglass reinforced plastic, PPh + 30% glass fibreHoldersFiberglass reinforced plastic, PPh + 30% glass fibreOperating buttonsTPEMore informationFore more information, e.g. the complete technical information, see product manual for:HD5-S 2TLC010052M0201HD5-B 2CDC172107D0201CONTROL DEVICES5 – 235
—Dimension drawingsHD5Dimension drawingsAll dimensions in mmHD5-S-1115 – 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY5
CONTROL DEVICES5 – 255
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Emergency stops and pilot devices6– 2 Introduction and overview 6– 6 Emergency stop buttons Smile, INCA, EStrong and Compact 6– 16 Safety stop buttons Smile, INCA, and Compact6– 24 Pull wire emergency stop switch LineStrong6– 34 Push-button box Smile 416– 40 Reset button Smile6– 46 Pilot devices Modular and Compact rangeEMERGENCY STOPS AND PILOT DEVICES6 – 16
—Introduction and overviewSelection guideABB offers a full range of buttons and pull wires for emergency stop functions, as well as pilot devices for e.g. reset functions. Emergency stop buttonsSafety stop buttonsReset buttonsPull wire emergency stop switchesPush button boxesPilot devicesNameSmile, Inca, EStrong, CompactSmile, Inca, CompactSmileNameLineStrongSmile 41Modular range, compact rangeImageImageDescriptionEmergency stop buttons for external mounting and panel mounting in different sizes and materialSafety stop buttons for external mounting and panel mountingSmall and easy to install reset buttonDescriptionEmergency stop switches in robust enclosures for pull wires of various lengths.Gathers up to four push but-tons, including emergency stop, in a single compact devicePush buttons, selector switch-es, pilot lights, joysticks and signal towers in a compact and robust designApplicationsSafely stop dangerous machine functionsSafely stop a limited part of a dangerous machinePushbutton for resetting safety devicesApplicationsEmergency stop line to safely stop conveyor belts and long transporta-tion lines.Emergency stop and pushbuttons in one deviceFor control and indication of ma-chines and processesAdvantagesModels with:- Compact size- Robust enclosure for harsh environments- Quick installation with M12 connectors- LED indicationModels with:- Compact size- Robust enclosure for harsh environments- Quick installation with M12 connectors- LED indication- Compact size- Quick installation- M12 connector- LED indicationAdvantages- Up to 200 m wire with one switch- Reliable mechanical connection- Robust construction- Compact size- Quick installation- M12 connector- LED indication- Highly adaptable with several button colors- Compact size- Up to IP69K- Long life-time thanks to self-cleaning contacts- Quick snap-on design for simple installation without tools6 – 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
Emergency stop buttonsSafety stop buttonsReset buttonsPull wire emergency stop switchesPush button boxesPilot devicesNameSmile, Inca, EStrong, CompactSmile, Inca, CompactSmileNameLineStrongSmile 41Modular range, compact rangeImageImageDescriptionEmergency stop buttons for external mounting and panel mounting in different sizes and materialSafety stop buttons for external mounting and panel mountingSmall and easy to install reset buttonDescriptionEmergency stop switches in robust enclosures for pull wires of various lengths.Gathers up to four push but-tons, including emergency stop, in a single compact devicePush buttons, selector switch-es, pilot lights, joysticks and signal towers in a compact and robust designApplicationsSafely stop dangerous machine functionsSafely stop a limited part of a dangerous machinePushbutton for resetting safety devicesApplicationsEmergency stop line to safely stop conveyor belts and long transporta-tion lines.Emergency stop and pushbuttons in one deviceFor control and indication of ma-chines and processesAdvantagesModels with:- Compact size- Robust enclosure for harsh environments- Quick installation with M12 connectors- LED indicationModels with:- Compact size- Robust enclosure for harsh environments- Quick installation with M12 connectors- LED indication- Compact size- Quick installation- M12 connector- LED indicationAdvantages- Up to 200 m wire with one switch- Reliable mechanical connection- Robust construction- Compact size- Quick installation- M12 connector- LED indication- Highly adaptable with several button colors- Compact size- Up to IP69K- Long life-time thanks to self-cleaning contacts- Quick snap-on design for simple installation without toolsEMERGENCY STOPS AND PILOT DEVICES6 – 36
Why an emergency stop is necessaryIf a machine breaks down or if someone is in danger, anyone should be able to stop the ma-chine, regardless of their knowledge of the specific application.When a safety stop could be usedA safety stop (also called machine stop) should be used to safely stop a part of the machine, e.g. as a stop for an individual hazardous motion. It should not be used as an emergency stop and stop the complete machine. Likewise, an emergency stop with red push button must not be used as a safety stop.In order to separate the safety stop function from the emergency stop function, the safety stop buttons should be colored black.When a pull wire emergency stop could be usedA pull wire emergency stop is easier to install than a system of several emergency stop buttons along a carriage path which makes it ideal for installations over long distances. LineStrong can handle wires up to 200 m on one single switch and the emergency command can be initiated from any point along the installed wire length. —Introduction and overviewSelection orientation6 – 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Introduction and overviewStandardsText and symbolsNeither the emergency stop nor its background should be labelled with text or symbols. It has previously been common with white arrows indicating the direction of unlatching, but this is not allowed anymore.Location and signsThe risk assessment should determine the locations of the emergency stop buttons, but they should in general be placed at operator stations, at locations where man/machine interaction is required and at entry/exit points. Signs to mark the location of emergency stops are not required, but if used they should be green with white markings.Important standards to follow when implementing emergency stop functions are e.g. EN ISO 13850 and EN ISO 60204-1.Stop categoriesThe following stop categories are defined in the standards:Stop Category 0stopping by immediate removal of power to the machine actuatorsStop Category 1a controlled stop with power available to the machine actuators to achieve the stop and then removal of power when the stop is achievedStop Category 2a controlled stop with power left available to the actuatorsNote that these categories should not be confused with the categories used to describe the architecture when calculating PL in EN ISO 13849. The risk assessment should determine which stop category to use, but stop category 2 is normally considered not to be suitable for emergency stops.EMERGENCY STOPS AND PILOT DEVICES6 – 56
Easy to installCompact sizeModels with a compact and appealing housing saves space and makes it easy to place.Quick installationQuick and easy installation of models with features such as centered mount-ing holes, removable terminal blocks and M12 connectors.Serial connectionTina models save cable length and in-stallation time with serial connection.Emergency stop buttons are used to safely stop dangerous machine func-tions.ABB offers a wide range of emergency stop buttons for external mounting or panel mounting, with plastic or metal housing and for different types of connections.Highly adaptableSeveral models to choose between depending on position, installation and function.Reliable in extreme conditionsRobust models and models in stainless steel for use in demanding environ-ments.Optimum interfaceLED diagnosticsModels with integrated LED diagnos-tics reduce downtime when trouble-shooting.Continuous operation—Emergency stop buttonsSmile, INCA, EStrong and Compact6 – 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Models and applicationEmergency stop buttonsSmileSmile is a small and easy to install emergency stop button. Its size allows mounting in reduced spaces, and its cen-tered mounting holes makes it especially easy to mount on aluminum extrusions (e.g. Quick-Guard fencing system). Smile is available with M12 connectors or cable.Smile has an integrated LED in the button that shows the status and simplifies error tracking.The standard models of Smile have 2 contacts and can be used with safety controllers from all brands. Smile Tina models belong to the ABB DYNlink solution, with the ad-vantages of serial connection using only one channel and still reaching Cat. 4/PL e.Models for external mountingEmergency stop buttons are used to safely stop a danger-ous machine function in order to prevent an accident, or minimize the consequences of an accident. An emergency stop should be a complement to other safety devices, and not a replacement for them. ApplicationEStrongEStrong is an emergency stop button designed to provide a robust unit in exposed and severe environments. The unit has a stainless steel enclosure with IP69K rating that with-stands high pressure and high temperature wash-down. It is therefore ideally suited for industries with special demands, such as food processing or chemical industry. CompactCompact emergency stop buttons offer a robust enclosure with a high IP rating that fulfill the demands in severe and humid environments, such as food and beverage industry. Compact can be fitted with a Tina adapter for use in a DYN-link solution (Tina 2A, Tina 2B or Tina 3A).Models for panel mountingINCAINCA is an emergency stop button for panel mounting, designed for installation in 22.5 mm holes. Its removable terminal block facilitates connection and exchange. INCA has an integrated LED in the button that shows the status and simplifies error tracking. The standard model of INCA has 2 contacts and can be used with safety controllers from all brands. INCA Tina models belongs to the ABB DYNlink solution, with the advantages of serial connection using only one channel and still reaching Cat. 4/PL e.Smile ReverseSmile Reverse is identical to the regular Smile emergency stop button besides from being reversed in order to be mounted on the back side of a panel. Smile Reverse has an IP65 housing that makes it suitable in panels where mois-ture and dust may occur. Smile Reverse has an integrated LED in the button that shows the status and simplifies error tracking. The standard model of Smile Reverse has 2 contacts and can be used with safety controllers from all brands. The Smile Reverse Tina model belongs to the ABB DYNlink solution, with the advantages of serial connection using only one channel and still reaching Cat. 4/PL e.EMERGENCY STOPS AND PILOT DEVICES6 – 76
—FeaturesEmergency stop buttonsDYNlinkEmergency stop buttons with Tina in their name belong to the DYNlink solution, which enables serial connection using only one channel and still reaching Cat. 4/PL e. DYNlink devices must be used with Vital safety controller or Pluto programmable safety controller. Up to 30 DYNlink devices can be connected in series to Vital and up to 10 can be con-nected to each input on Pluto.Communication featuresStatusBusStatusBus is a simple and cost effective way to collect the status information of emergency stops and safety sen-sors. The StatusBus functionality is available with some DYNlink devices and allows to collect the status of each individual safety device, even when connected in series. A Pluto programmable safety controller must be used to read the StatusBus information, and a single input on Pluto can collect the status of up to 30 safety devices. The devices are connected using standard cable and M12-5 connectors. No specific bus cable or extra communication module is necessary.6 – 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Ordering informationEmergency stop buttons2TLC172863F0201Smile 10 EA Tina2TLC172857F0201Smile 11 EC Tina2TLC172187F0201Smile 12 EA2TLC172689F0201EStrongZ and EStrongZ LED DescriptionType of safety signalConnection typeFeatureTy p e Order codeCompact sizePlastic housingIP65DYNlink1 m cable from bottomStatus LEDSmile 10 EA Tina2TLA030050R04001 x M12-5 maleStatus LEDSmile 11 EA Tina2TLA030050R00001 x M12-5 maleStatus LED, StatusBusSmile 11 EC Tina2TLA030050R09002 x M12-5 maleStatus LEDSmile 12 EA Tina2TLA030050R02002 NC1 m cable from bottomStatus LEDSmile 10 EA2TLA030051R04001 m leads from bottom-Smile 10 EK2TLA030051R06001 x M12-5 maleStatus LEDSmile 11 EA2TLA030051R00002 x M12-5 maleStatus LEDSmile 12 EA2TLA030051R0200Plastic housingIP66, IP67 and IP69K2 NC*2 x M20 conduits-CEPY1-1002 (Compact)1SFA619821R1002With shroudCEPY1-2002 (Compact)1SFA619821R2002Metal housingIP67 and IP69K2 NO + 2 NC3 x M20 conduitsStatus LEDEStrongZ LED2TLA050220R0222-EStrongZ2TLA050220R0020* Can be adapted to DYNlink with Tina IP ratingDepthConnection typeType of safety signalFeatureTy p e Order codeIP6526 mm1 x M12-5 maleDYNlink Status LEDSmile 11 EAR Tina2TLA030050R01002 NCStatus LEDSmile 11 EAR2TLA030051R0100Button IP65, connector IP2053 mmRemovable termi-nal blockDYNlinkStatus LEDINCA 1 Tina 2TLA030054R0000Status LED,StatusBusINCA 1 EC Tina2TLA030054R14002 NCStatus LEDINCA 12TLA030054R01002TLC172861F0201Smile 11 EAR 2TLC172363F0201INCA 1ABB Compact emergency stop shroud—External mounting—Panel mountingEMERGENCY STOPS AND PILOT DEVICES6 – 96
—AccessoriesEmergency stop buttons2TLC172034V0201M12-3S2TLC172471F0201Tina 8A2TLC172906F0201E-sign 22.5 DescriptionTy p eOrder codeConnection accessoriesM12 Y-connector for serial connection of device with StatusBus functionality.M12-3S2TLA020055R0600M12 Y-connector for serial connection of devices without StatusBus functionality.M12-3A2TLA020055R0000Connection block for the serial connection of up to 4 DYNlink devices with 12-5 connectors.Tina 4A2TLA020054R0300Connection block for the serial connection of up to 8 DYNlink devices with 12-5 connectors.Tina 8A2TLA020054R0500Adaptation unit for DYNlink solution with M20 fitting. For e.g. Compact.Tina 2A*2TLA020054R0100Adaptation unit for DYNlink solution, internal assembly. For e.g. Compact.Tina 2B*2TLA020054R1100Adaptation unit for DYNlink solution with M20 fitting and M12 connector. For e.g. con-necting Compact to Pluto/Vital.Tina 3A*2TLA020054R0200Termination for Smile 12JST22TLA030051R1300AccessoriesEmergency stop sign, yellow, no text, for INCA (22.5mm)E-Sign 22.52TLA030054R0900Emergency stop sign, yellow, no text, for Smile (32.5mm)E-Sign 32.52TLA030054R1000Yellow surround for IncaSurround for Inca2TLA030054R0400Yellow shroud for CompactCA1-80531SFA619920R8053Stainless steel cable gland, for EStrongGland M20x1.52TLA050040R0002 Stainless steel conduit plug, for EStrongConduit Plug M20x1.52TLA050040R0004 LED Green/Red 230 VAC, for EStrongLED 2302TLA050211R0003* For more information about Tina adapter units, please see Pluto and Vital chapters. ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R05006 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 Angled female connectorM12-C1012V22TLA020056R670016 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-C612TLC172951F0201M12-C61HE2TLC010003F0201—Connection accessories—Cable with connectors6 – 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 C5 cable2TLC010038F0201M12-C01 2TLC172657F0201—Separate cables and connectorsEMERGENCY STOPS AND PILOT DEVICES6 – 116
—Technical dataEmergency stop buttonsTechnical dataApprovalsSmile, INCA Smile Tina, INCA TinaTÜV NORD EStrong Compact ConformitySmile, INCA2006/42/EC – Machinery2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2008/AC:2009, EN 60204-1:2006+A1:2008, EN ISO 13850:2008Smile Tina, INCA Tina 2006/42/EC - Machinery2004/108/EC - EMCEN ISO 12100:2010, EN ISO 13849-1:2008, EN 62061:2005, EN 60204-1:2006+A1:2009, IEC 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 60947-5-5:2005, EN ISO 13850:2006EStrong2006/42/EG – Machinery2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13850:2015, EN 60204-1:2006:+A1:2009+AC:2010, EN 60947-5-5:1997:+A1:2017, EN 60947-5-1:2004:+A1:2009Compact2006/42/EC - Machinery2014/30/EU - EMCEN 60947-1:2007/A1:2011/A2:2014, EN 60947-5-1:2004/A1:2009, EN 60947-5-5:1997/A1:2005/A11:2013, EN ISO 13850:2008Functional safety dataEN 61508:2010Up to SIL3, depending on system architectureEN 62061:2005Up to SILCL3, depending on system architectureEN ISO 13849-1:2008Up to Cat. 4, PL e, depending on system architectureSmile, INCAB10d = 100 000Smile Tina, INCA TinaPFHD = 4.66 x 10-9EStrongB10d = 1 500 000CompactB10d = 250 0006 – 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Technical dataEmergency stop buttonsTechnical dataElectrical dataOperating voltage Smile, INCA17-27 VDC ± 10%Smile Tina, INCA Tina+24 VDC +15% -25%EStrong230 VAC / +24 VDC (the LED is +24 VDC originally, but can be replaced with a 230 VAC accessory)Compact230 VAC / +24 VDCMechanical dataMechanical life>50 000 operationsOperating temperatureSmile, INCA -10...+55 °CEStrong -25...+80 °CCompact -25...+70 °CProtection classSmile, INCAIP65EStrongIP67, IP69KCompactIP66, IP67, IP69KWeightSmile65 gINCA45 gEStrong820 gCompact108 g, 124 g (with shroud)MaterialSmile Polyamide PA66, Macromelt, polybutylenterephthalate PBT, Polypropene PP, UL 94 V0INCAPolyamide PA66, Macromelt, polybutylenterephthalate PBT, Polypropene PP, UL 94 V0EStrongStainless steel 316 housingCompactPolycarbonateMore informationFore more information, e.g. the complete technical information, see product manual for:Smile 2TLC172097M0201INCA 2TLC172163M0201EStrong 2TLC172247M0201Compact 1SFC151005C0201Connection diagramsFor connection diagrams of emergency stop buttons please see https://library.abb.com/EMERGENCY STOPS AND PILOT DEVICES6 – 136
Smile—Dimension drawingsEmergency stop buttonsINCAAll dimensions in mmEStrongCompact (housing only)Ty p eL1mmL2mmINCA 1 EC Tina 75.549.5 ± 0.5INCA 18054 ± 0.5INCA 1 Tina8054 ± 0.56 – 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
EMERGENCY STOPS AND PILOT DEVICES6 – 156
Easy to installCompact sizeModels with a compact and appealing housing saves space and makes it easy to place.Quick installationQuick and easy installation of models with features such as centered mount-ing holes, removable terminal blocks and M12 connectors.Serial connectionTina models save cable length and in-stallation time with serial connection.Safety stop buttons are used to safely stop a certain part of a dangerous machine. ABB offers safety stop buttons to suit different needs of connection and communication. Models are available for e.g. external mounting or panel mounting, in compact size or robust design, adapted for the DYNlink solu-tion or with 2 NC contacts.Highly adaptableSeveral models to choose between depending on position, installation and function.Reliable in extreme conditionsRobust models for use in demanding environments.Optimum interfaceLED diagnosticsModels with integrated LED diagnos-tics reduce downtime when trouble-shooting.Continuous operation—Safety stop buttonsSmile, INCA and Compact6 – 16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Applications and featuresSafety stop buttonsApplicationsA safety stop (also called machine stop) can be used to safely stop a part of the machine, e.g. as a stop for an individual hazardous machine function. It may not be used as an emer-gency stop and stop the complete machine or production line. Likewise, an emergency stop with red push button should not be used as a safety stop. In order to separate the safety stop function from the emergency stop function, the safety stop buttons should be colored black.FeaturesDYNlinkSafety stop buttons with Tina in their name belong to the DYN-link solution, which enables serial connection using only one channel and still reaching Cat. 4/PL e. DYNlink devices must be used with Vital safety controller or Pluto programmable safety controller. Up to 30 DYNlink devices can be connected in series to Vital and up to 10 can be connected to each input on Pluto.EMERGENCY STOPS AND PILOT DEVICES6 – 176
—Models Safety stop buttonsSmileSmile is a small and easy to install safety stop button. Its size allows mounting in reduced spaces, and its centered mounting holes makes it especially easy to mount on alu-minum extrusions (e.g. Quick-Guard fencing system). Smile has an integrated LED in the button that shows the status and simplifies error tracking.The standard model of Smile has 2 contacts and can be used with safety controllers from all brands. The Smile Tina model belongs to the ABB DYNlink solution, with the advantages of serial connection using only one channel and still reaching Cat. 4/PL e.Smile safety stops are identical to the corresponding Smile emergency stops apart from the color of the button.Safety stop buttons for external mountingCompactThe Compact safety stop button offers a robust enclosure with a high IP rating that fulfills the demands in severe and humid environments, such as food and beverage industry. Compact can be fitted with a Tina adapter for use in a DYN-link solution (Tina 2A, Tina 2B or Tina 3A). Compact safety stop is identical to Compact emergency stop apart from the color of the button.INCAINCA is a safety stop button for panel mounting, designed for installation in 22.5 mm holes. Its removable terminal block facilitates connection and exchange. INCA has an integrated LED in the button that shows the status and simplifies error tracking.The standard model of INCA has 2 contacts and can be used with safety controllers from all brands. INCA Tina belongs to the ABB DYNlink solution, with the advantages of serial con-nection using only one channel and still reaching Cat. 4/PL e.INCA safety stop is identical to INCA emergency stop apart from the color of the button.Safety stops for panel mounting6 – 18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Ordering informationSafety stop buttons2TLC172198F0201Smile 11 SA TinaCEP1-10022TLC172365F0201INCA 1S MountingType of safety signalConnection typeFeatureTy p e Order codeExternalDYNlink1 m cable from bottomStatus LEDSmile 11 SA Tina2TLA030050R05002 NC1 x M12-5Status LEDSmile 11 SA2TLA030051R09001 NO + 1 NC*2 x M20 conduits-CEP1-1002 (Compact)1SFA619811R1002With shroudCEP1-2002 (Compact)1SFA619811R2002PanelDYNlink5 pole terminal blockStatus LEDINCA 1S Tina 2TLA030054R02002 NC5 pole terminal blockStatus LEDINCA 1S2TLA030054R0300* Can be adapted to DYNlink with Tina DescriptionTy p e Order codeM12 Y-connector for serial connection of devices without StatusBus functionality.M12-3A2TLA020055R0000Connection block for the serial connection of up to 4 DYNlink devices with 12-5 connectors.Tina 4A2TLA020054R0300Connection block for the serial connection of up to 8 DYNlink devices with 12-5 connectors.Tina 8A2TLA020054R0500Grey shroud for CompactCA1-80541SFA619920R8054Adaptation unit for DYNlink solution with M20 fitting. For e.g. Compact.Tina 2A *2TLA020054R0100Adaptation unit for DYNlink solution, internal assembly. For e.g. Compact.Tina 2B *2TLA020054R1100Adaptation unit for DYNlink solution with M20 fitting and M12 connector. For e.g. connect-ing Compact to Pluto/Vital.Tina 3A *2TLA020054R0200* For more information about Tina adapter units, please see Pluto and Vital chapters.2TLC172471F0201Tina 8A—Accessories—Safety stop buttonsEMERGENCY STOPS AND PILOT DEVICES6 – 196
—Cable and connectorsSafety stop buttons ConnectorFemale/maleLengthSpecial featureTy p e Order codeM12-5Female3 mM12-C312TLA020056R05006 mM12-C61 2TLA020056R0000 Harsh environment, halogen freeM12-C61HE2TLA020056R800010 mM12-C101 2TLA020056R1000 Harsh environment, halogen freeM12-C101HE2TLA020056R810020 mM12-C201 2TLA020056R1400 Female + male0.3 mM12-C03122TLA020056R5800 0.06 mM12-C006122TLA020056R6300 1 mM12-C112 2TLA020056R2000 3 mM12-C312 2TLA020056R2100 6 mM12-C612 2TLA020056R2200 10 mM12-C1012 2TLA020056R2300 Angled female connectorM12-C1012V22TLA020056R670016 mM12-C16122TLA020056R540020 mM12-C2012 2TLA020056R2400 Male6 mM12-C622TLA020056R020010 mM12-C1022TLA020056R1200M12-C612TLC172951F0201 DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 C5 cable2TLC010038F0201M12-C61HE2TLC010003F0201M12-C01 2TLC172657F0201—Cable with connectors—Separate cables and connectors6 – 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Technical data Safety stop buttonsTechnical dataApprovalsSmile, INCA Smile Tina, INCA TinaTÜV NORD Compact ConformitySmile, INCA2006/42/EC – Machinery2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2008/AC:2009, EN 60204-1:2006+A1:2008, EN ISO 13850:2008Smile Tina, INCA Tina2006/42/EC - Machinery2004/108/EC - EMCEN ISO 12100:2010, EN ISO 13849-1:2008, EN 62061:2005, EN 60204-1:2006+A1:2009, IEC 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 60947-5-5:2005, EN ISO 13850:2006Compact2006/42/EC - Machinery2014/30/EU - EMCEN 60947-1:2007/A1:2011/A2:2014, EN 60947-5-1:2004/A1:2009, EN 60947-5-5:1997/A1:2005/A11:2013, EN ISO 13850:2008Functional safety dataEN 61508:2010Up to SIL3, depending on system architectureEN 62061:2005Up to SILCL3, depending on system architectureEN ISO 13849-1:2008Up to Cat. 4, PL e, depending on system architectureSmile, INCAB10d = 100 000Smile Tina, INCA TinaPFHD = 4.66 x 10-9CompactB10d = 50 000Electrical dataOperating voltage Smile, INCA17-27 VDC ± 10%Smile Tina, INCA Tina+24 VDC +15% -25%Compact230 VAC / +24 VDCMechanical dataMechanical life>50 000 operationsOperating temperatureSmile, INCA -10...+55 °CCompact -25...+70 °CProtection classSmile, INCAIP65CompactIP66, IP67, IP69KWeightSmile65 gINCA45 gCompact108 g, 124 g (with shroud)MaterialSmile Polyamide PA66, Macromelt, polybutylenterephthalate PBT, Polypropene PP, UL 94 V0INCAPolyamide PA66, Macromelt, polybutylenterephthalate PBT, Polypropene PP, UL 94 V0CompactPolycarbonateMore informationFore more information, e.g. the complete technical information, see product manual for:Smile 2TLC172097M0201INCA 2TLC172163M0201Compact 1SFC151005C0201EMERGENCY STOPS AND PILOT DEVICES6 – 216
Smile—Dimension drawings Safety stop buttonsINCAAll dimensions in mmCompact (housing only)6 – 22SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
EMERGENCY STOPS AND PILOT DEVICES6 – 236
Easily accessibleEasy reach of the emergency stop function along machines, conveyors and processes.High level of safetyThe positive forced disconnect con-tacts provide a high level of safety and are double switching, i.e. triggers emergency stop in both directions of the wire.Safety and protectionEasy to installQuick installationA pull wire emergency stop switch is easier to install than a system of sev-eral emergency stop buttons along a carriage path.Highly adaptableSeveral models to choose between gives a variety of mounting possibili-ties and features.Long wire lengthCan handle wires up to 200 m on a single switch.LineStrong is a pull wire emergency stop switch, used for easy reach of the emergency stop function along machines and sections of conveyors. A pull wire emergency stop switch allows to initiate the emergency stop command from any point along the in-stalled wire length by pulling the wire. It replaces a series of emergency stop buttons and is easier to install.LineStrong is also available in differ-ent models for different lengths of wires, with different housing material as well as an explosion proof version.Reliable in extreme conditionsRobust construction makes LineStrong ideal for use in demanding environ-ments.LED diagnosticsIntegrated LED diagnostics ensures status can be seen easily from a dis-tance.Continuous operation—Pull wire emergency stop switchLineStrong6 – 24SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—ApplicationsLineStrongInstead of multiple emergency stopsA pull wire emergency stop switch is often placed along conveyor belts or carriage paths where access to the stop function must be possible along the whole line. It is often easier to install a pull wire emergency stop switch than to place multiple emergency stop buttons if the distance is longer.LineStrong can handle wires up to 200 m on one single switch and since the emergency stop command can be initiated from any point along the wire, this gives better ac-cess to the emergency stop function than using emergency stop buttons.As protective device in low risk applicationsLineStrong 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 the con-veyor, hence pulling the wire.One, two or several switchesThe maximum length of the wire attached to LineStrong de-pends on if there is a LineStrong unit attached to both ends of the wire or if one end is attached to a wall/fixed object. In the image below LineStrong2 is used as an example.Two unitsOne unitUp to 80 mUp to 60 mEMERGENCY STOPS AND PILOT DEVICES6 – 256
—FeaturesLineStrongWire breakage monitoringThe contacts are double switching which means that the emergency stop command is given both when someone pulls the wire and if the wire should break. Indication of wire tensionAll models are equipped with an indicator of the tension of the wire which simplifies installation and adjustment.Positive forced disconnected contactsThe contacts in LineStrong are positive force disconnected, which ensures that the contacts will not be held in a normal-ly closed position due to a failure of the spring mechanism or the welding/sticking of the contacts.Reset buttonAll models of LineStrong have an integrated reset button that needs to be pressed in order to reset the emergency stop if the emergency stop function has been triggered. Emergency stop buttonMost LineStrong models have an integrated emergency stop button on the housing of the switch. Since the first half me-ter of the wire is not intended to pull in order to trigger the emergency stop function, the integrated emergency stop button provides quick and simple access to the emergency stop function if you are standing right in front of LineStrong. The emergency stop button of LineStrong 2 can be moved to either side of LineStrong to enable best access depending on position and height of LineStrong.Integrated LEDLineStrong2 and LineStrong3 have an integrated 2-color LED that shows if the emergency stop function has been trig-gered or not. The LED is also available as spare part. MaterialLineStrong is available with a housing in yellow die cast aluminum alloy or with a housing in stainless steel 316 which is recommended for severe applications in e.g. the food pro-cessing and the chemical industries.Left hand, right hand or both sidesLineStrong1 and LineStrong2 can be mounted in any direc-tion. Linestrong3 is available in different models depending on installation. L (left hand) should be used if the placement of the grab wire switch is to the left in the installation. R (right hand) should be used if the grab wire switch is to the right in the installation. D (double wire) has wire entries from both sides of the grab wire switch. LeftDoubleDoubleRightUp to 125 mUp to 125 m6 – 26SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
Easier installation with tensioner/gripper The tensioner/gripper accessory significantly reduces the installation time. Traditional grab wire systems normally need turnbuckle and clamps, which are difficult to tension and adjust, and normally require frequent re-tensioning. The tensioner gripper integrates an eyehook, a tensioner thimble and a 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 tension indicator, it is easy to ad-just the system accurately and quickly. The double clamp mechanism prevents wire slippage and significantly reduces machine downtime which can occur which traditional turn-buckle systems.For systems longer than 50 m, the tensioner/gripper is nec-essary on both sides.—FeaturesLineStrong2132Quick-link terminationA quick-link termination is available as an accessory in the wire pull kit, for easy connection to the safety spring or the switch eyebolt for systems up to 50 m.Mounting accessories The wire pull kits contains the suitable accessories for the included wire length. - When using one switch, the wire must be anchored at the other end using a safety spring. - The first eyeball support must be placed no more than 500 mm from the switch eyebolt or safety spring.- The part of the wire from the wire end to the first eyebolt support shall not be used as part of the active protection cover-age. - Wire support eyebolts must be fitted at 2.5 - 3 meters intervals along the complete wire length.- The tensioner/gripper is used to adjust the correct tensionTensioner / GripperPullQuick linkSafety springZone of protectionInactive zone (500mm)Inactive zone (500mm)EyeboltWireCorner pulleyA corner pulley can be used to navigate inside or outside corners without causing damage to the wire. They are in stainless steel and can be rigidly mounted.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 from either the switch or the spring anchorage.MachineMachineMachineOutside cornersMachineOutside cornersMachineInside cornersExamples of using the corner pulley1. Tension to mid position as indicated by the green arrows in the viwing window of each switch2. The tensioner thimble allows immediate accurate and final ten-sioning of the wire, whilst viewing the tension marker through the viewing window on the switch.3. Quick Link termination.Corner pulleyEMERGENCY STOPS AND PILOT DEVICES6 – 276
—Ordering informationLineStrong2TLC172377F0201LineStrong12TLC172385F0201LineStrong3R IP ratingMaterialE-stop but-tonContactsMax. wire length (m)FeatureTy p e Order code1 unit2 unitsIP67Yellow die cast alumi-num alloyNo2 NO + 2 NC3050-LineStrong12TLA050200R0030Ye s2 NO + 2 NC6080-LineStrong22TLA050202R03322 NO + 4 NC100125Left handLineStrong3L2TLA050206R0332Right handLineStrong3R2TLA050208R0332200325Both sidesLineStrong3D2TLA050204R0332IP67, IP69KStainless steel 316Ye s2 NO + 2 NC80100-LineStrong2Z2TLA050202R03222 NO + 4 NC100125Left handLineStrong3LZ2TLA050206R0322Right handLineStrong3RZ2TLA050208R0322200325Both sidesLineStrong3DZ2TLA050204R03222TLC172501F0201LineStrong2Z2TLC172383F0201LineStrong3D2TLC172387F0201LineStrong3LLineStrong22TLC172379F0201—LineStrong6 – 28SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
DescriptionMaterialLengthTy p e Order codeWire pull kit including wire, eyebolts, tensioner/gripper, quick-link termination and Allen key in right quantity for the included wire length.Galvanized10 m wire10 m wire kit, gal2TLA050210R013020 m wire20 m wire kit, gal2TLA050210R033080 m wire80 m wire kit, gal2TLA050210R0630100 m wire100 m wire kit, gal2TLA050210R0730Stainless steel50 m wire50 m wire kit, SS2TLA050210R0520100 m wire100 m wire kit, SS2TLA050210R0720Wire tensioner/gripperGalvanizedWire tensioner, gal2TLA050210R4030Stainless steelWire tensioner, SS2TLA050210R4020Corner pulleyGalvanizedCorner pulley, gal2TLA050210R6030Stainless steelCorner pulley, SS2TLA050210R6020Eyebolt M8 x 1.258 pcsGalvanizedEyebolt M8x1.25, gal2TLA050210R8030Stainless steelEyebolt M8x1.25, SS2TLA050210R8020Safety spring, 220mmStainless steelSpring 220 mm, SS2TLA050211R0004—AccessoriesLineStrong DescriptionTy p e Order codeLineStrong LED Green/Red +24 VDCLineStrong LED 242TLA050211R0001LineStrong LED Green/Red 230 VACLineStrong LED 2302TLA050211R0003LineStrong2 and LineStrong3 Emergency stop button.LineStrong E-Stop2TLA050211R0005 DescriptionTy p e Order codeScrewdriver, anti-tamper, Torx T20Screwdriver T202TLA050211R0006Gland M20 x 1.5Gland M20x1.52TLA050040R0002Conduit plug M20 x 1.5Cond.Plug M20x1.52TLA050040R00042TLC172577F0201Wire pull kit2TLC172215F0201LineStrong ScrewdriverLineStrong LED 2302TLC172902F0201Wire tensioner2TLC172220F02012TLC172219F02012TLC172221F02012TLC172581F0201Corner pulleyEyeboltSafety springGlandConduit plug2TLC172217F02012TLC172218F0201LineStrong LED 230—Mounting Accessories—Other accessories—Spare partsEMERGENCY STOPS AND PILOT DEVICES6 – 296
—CablesLineStrong DescriptionTy p eOrder codeConnectorsM12-5 pole female, straightM12-C012TLA020055R1000M12-5 pole male, straightM12-C022TLA020055R1100 M12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 5 conductors10 m cable with 5 x 0.34 shielded conductors C5 cable 10 m 2TLA020057R000150 m cable with 5 x 0.34 shielded conductors C5 cable 50 m 2TLA020057R0005 100 m cable with 5 x 0.34 shielded conductors C5 cable 100 m 2TLA020057R0010 200 m cable with 5 x 0.34 shielded conductors C5 cable 200 m 2TLA020057R0020 500 m cable with 5 x 0.34 shielded conductors C5 cable 500 m 2TLA020057R0050 Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C5 cable2TLC010038F0201M12-C01 2TLC172657F0201—LineStrong6 – 30SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Technical dataLineStrongTechnical dataApprovalsLineStrong ConformityLineStrong2006/42/EC - MachineryEN ISO 12100:2010, EN ISO 13850:2008, EN 60204-1:2006+A1:2009, EN 60947-1:2007+A1:2011, EN 60947-5-1:2004+A1:2009, EN 60947-5-5:1997+A1:2005Functional safety dataEN ISO 13849-1:2008Up to Cat. 4, PL e, depending on system architecture. EN/IEC 62061:2005Up to SILCL3, depending on system architecture.IEC 61508Up to SIL3, depending on system architecture. B10d1 500 000Electrical dataUtilization category240 VAC / 3 A+24 VDC / 2.5 ALED+24 VDCMechanical dataOperating temperature -25...+80 °CProtection classLineStrong1, LineStrong2, LineStrong3IP67LineStrong2Z, LineStrong3ZIP66, IP67, IP69KWeightLineStrong1675 gLineStrong2880 gLineStrong2Z1635 gLineStrong3L/R1100 gLineStrong3LZ/RZ2000 gLineStrong3D1320 gLineStrong3DZ2200 gMaterialLineStrong1, LineStrong2, LineStrong3D/L/RDie cast painted yellowLineStrong2Z, LineStrong3LZ/RZ/DZStainless steel 316Wire typePVC sheath steel wire 4.0 mm outside diameterConduit entriesLineStrong1/23 x M20 x 1.5LineStrong34 x M20 x 1.5More informationFore more information, e.g. the complete technical information, see product manual for:LineStrong 2TLC172248M0201EMERGENCY STOPS AND PILOT DEVICES6 – 316
LineStrong1—Dimension drawingsLineStrongLineStrong2All dimensions in mmLIneStrong3L-R6 – 32SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
EMERGENCY STOPS AND PILOT DEVICES6 – 336
Smile 41 is a push-button box that gathers push buttons and an emer-gency stop button in a single compact device with only one M12 connector for all functions.Smile 41 push-button box is intended for use with Pluto programmable safety controller.A kit of colored filters is supplied and the color of each button can be cho-sen after delivery and changed later. Compact housingA compact and appealing housing saves space and makes it easy to place.Space savingEasy to installEasy to attach to profilesThe centered mounting holes makes Smile 41 easy to attach to e.g. alumi-num extrusions profiles like Quick-Guard.Quick installationThe four buttons are connected with only one M12 connector which speeds up the connection. A maximum of 8 wires need to be connected for the complete push-button box with LEDs.LED indicationAll push-buttons and emergency stop buttons are illuminated. The light-ing of the push-buttons can easily be managed by the Pluto programmable safety controller, allowing a greater adaptation to the needs.Several button colorsThe color of each button can be chosen after delivery and changed later.Optimum interface—Push-button box Smile 416 – 34SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
Smile 41 is a convenient way to gather several buttons at the same place while reducing cabling and installation. For example, an emergency stop button, a push button used to request the unlocking of the door, a push button used as reset button, and a push button used as start button.—Applications and features Smile 41ApplicationsKit of colored filtersA kit of colored filters is supplied with all models and the color of each push button can be chosen after delivery and changed later.Centered mounting holesCentered mounting holes facilitate the mounting of Smile 41 on aluminum profiles like Quick-Guard.With Pluto programmable safety controller Smile 41 has been developed for use with Pluto programma-ble safety controller and allow to get all the advantages of the Pluto “light-button function”: only one I/O (IQ) is neces-sary for both a push-button and its LEDs and the lighting of the reset buttons can be handled by Pluto without any extra programming. The emergency stop button satisfies the highest level of safety, and although only one cable is used for the signals of the four buttons, a possible short-circuit can be detected by Pluto and the highest level of safety can be reached.FeaturesEMERGENCY STOPS AND PILOT DEVICES6 – 356
—Ordering informationSmile 41 Smile 41 push-button box is delivered with a kit of filtersSafety controllerEmergency stop buttonOther buttonsConnectorTy p eOrder codePluto programmable safety controller13 push-buttonsM12-8 maleSmile 41 EWWWP2TLA030057R0100 DescriptionTy p e Order codeKit of colored filtersColored filters2TLA030059R2600Smile 41 EWWWP2TLC172717F02016 – 36SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6—Smile 41 push button box—Spare parts
—Cables and connectorsSmile 41 ConnectorFemale/maleLengthTy p e Order codeM12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C103 2TLA020056R4000 20 mM12-C203 2TLA020056R4100 Female + male0.06 mM12-C006342TLA020056R64001 mM12-C134 2TLA020056R5000 3 mM12-C334 2TLA020056R5100 M12-C632TLC172951F0201 DescriptionTy p eOrder codeM12-8 connectorsM12-8 pole female, straightM12-C032TLA020055R1600M12-8 pole male, straightM12-C042TLA020055R1700Cable with 8 conductors50 m cable with 8 x 0.34 shielded conductors C8 cable 50 m 2TLA020057R1005 100 m cable with 8 x 0.34 shielded conductors C8 cable 100 m2TLA020057R1010200 m cable with 8 x 0.34 shielded conductors C8 cable 200 m2TLA020057R1020500 m cable with 8 x 0.34 shielded conductorsC8 cable 500 m2TLA020057R1050C8 cable2TLC010038F0201M12-C3342TLC172931F0201M12-C03 2TLC172659F0201—Cable with connectors—Separate cables and connectorsEMERGENCY STOPS AND PILOT DEVICES6 – 376
Technical dataSmile 41Approvals TÜV NORDConformity 2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13849-1:2008/AC:200962061:2005+A2:2015, EN 60204-1:2006+A1:2009, IEC 60664-1:2007,EN 61000-6-2:2005, EN 61000-6-4:2011, EN ISO 13850:2015Functional safety data IEC 61508:2010Up to SIL3, depending on system architecture EN/IEC 62061:2005Up to SILCL3, depending on system architecture EN ISO 13849-1:2008Up to Cat. 4/PL e, depending on system architecture B10d65 000Electrical data Operating voltage+24 VDC ± 15%Mechanical dataMechanical lifeEmergency stop button> 50 000 operationsIlluminated push button1 000 000 operationsOperating temperature-25... +50 °CProtection classIP65Weight190 g—Technical dataSmile 41More informationFore more information, e.g. the complete technical information, see product manual for:Smile 41 2TLC172280M02016 – 38SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
Smile 41—Dimension drawingsSmile 41All dimensions in mmEMERGENCY STOPS AND PILOT DEVICES6 – 396
Smile reset buttons have compact housings with M12 connectors for easy connection. The reset button contains an integrated white LED, and all buttons are delivered with a kit of colored filters to snap on the top of the button. In this way the color of the button can be chosen after delivery and is also possible to changed later. The different models also allow a choice of: - local reset connected directly to the sensor, or - global reset connected to the safety control module.Compact housingA compact and appealing housing saves space and makes it easy to place.Space savingEasy to installEasy to attach to profilesThe centered mounting holes make Smile easy to attach to e.g. aluminum extrusions profiles. Speed up installationn The housing requires no assembly and the M12 connectors speed up installa-tion and reduce the risk of connection error.Local resetLocal reset allows to have the reset button close to the safety device while reducing cabling.Several button colorsAll reset buttons are illuminated with a white LED and the color of each but-ton can be chosen after delivery and changed later using colored snap-on filters.Optimum interface—Reset buttonSmile6 – 40SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Ordering information Smile reset buttons Type of contactIntended useConnectorsTy p eOrder code1 NOMost reset applicationsM12-5 maleSmile 11 RA2TLA030053R00001 NOPluto Safety PLC light button function*M12-5 maleSmile 11 RB2TLA030053R01001 NOLocal reset of Orion1 BaseM12-5 maleSmile 11RO12TLA022316R30001 NCLocal reset of Orion2 Base and Extended, and Orion3 Extended M12-5 maleSmile 11RO22TLA022316R31001 NCLocal reset of Orion3 Base M12-5 maleSmile 11RO32TLA022316R32001 NOLocal reset of Eden DYN-Reset M12-5 and Eden OSSD-Reset M12-5M12-5 male + female Smile 12 RF2TLA030053R26001 NOLocal reset of Eden OSSD-Reset M12-8 M12-8 male + femaleSmile 12 RG2TLA030053R2700* See Pluto hardware manual for more information about the light button function DescriptionTy p eOrder codeY-connector for series connection of DYNlink devices with M12-5 connectors, e.g. Eden.M12-3A2TLA020055R0000Y-connector for series connection of Adam OSSD M12-8 with M12-5 cablesM12-3H2TLA020055R0800Y-connector for series connection of Adam OSSD M12-8 with M12-8 cablesM12-3G2TLA020055R0700Y-connector for connection of Smile reset button to Orion. M12-3R2TLA022316R0000Adaptation unit of OSSD outputs to DYNlink signals for use with Vital control module or Pluto Safety PLC. Tina 10B has an extra M12 connector for connection of a reset button.Tina 10B v22TLA020054R1310Tina 10B M12-3x2TLC172623F02012TLC172475F0201Smile 11 RO12TLC172018V0201 DescriptionTy p eOrder codeKit of colored filters (yellow, green, white, blue, red)Colored filters2TLA030059R26002TLC172725F0201Colored filters —Ordering details—Accessories—Spare partsEMERGENCY STOPS AND PILOT DEVICES6 – 416
Eden Reset M12-5 to Smile 12 RFSmile 12 RF to M12-3AM12-3A to M12 3AEl-cabinet to M12-3AM12-3A to el-cabinet DescriptionFemale/maleLengthTy p eOrder codeM12-5Female6 mM12-C612TLA020056R0000 10 mM12-C1012TLA020056R1000 20 mM12-C2012TLA020056R1400 Female + male1 mM12-C1122TLA020056R2000 3 mM12-C3122TLA020056R2100 6 mM12-C6122TLA020056R2200 10 mM12-C10122TLA020056R2300 20 mM12-C20122TLA020056R2400 Male6 mM12-C622TLA020056R0200 10 mM12-C1022TLA020056R1200 —Cables Smile reset buttons Eden Reset M12-8 to Smile 12 RGSmile 12 RG to M12-3G or M12-3HM12-3G to M12-3GEl-cabinet to M12-3GM12-3G to el-cabinetM12-3H to M12-3HEl-cabinet to M12-3HM12-3H to el-cabinet ConnectorFemale/maleLengthTy p eOrder codeM12-5Female6 mM12-C612TLA020056R0000 10 mM12-C1012TLA020056R1000 20 mM12-C2012TLA020056R1400 Female + male1 mM12-C1122TLA020056R2000 3 mM12-C3122TLA020056R2100 6 mM12-C6122TLA020056R2200 10 mM12-C10122TLA020056R2300 20 mM12-C20122TLA020056R2400 Male6 mM12-C622TLA020056R0200 10 mM12-C1022TLA020056R1200 M12-8Female3 mM12-C332TLA020056R29006 mM12-C632TLA020056R3000 10 mM12-C1032TLA020056R4000 20 mM12-C2032TLA020056R4100 Female + male1 mM12-C1342TLA020056R5000 3 mM12-C3342TLA020056R5100 MaleBy meterM12-C042TLA020055R1700 Smile11 Rx to another M12Smile 11 Rx to el-cabinetSmile 11 ROx to Tina 10BTina 10B to el-cabinetSmile 11 ROx to M12-3RM12-3R to el-cabinetTina 10B to M12-3AM12-3A to M12 3AEl-cabinet to M12-3AM12-3A to el-cabinet ConnectorFemale/maleLengthTy p eOrder codeM12-5Female6 mM12-C612TLA020056R0000 10 mM12-C1012TLA020056R1000 20 mM12-C2012TLA020056R1400 Female + male1 mM12-C1122TLA020056R2000 3 mM12-C3122TLA020056R2100 6 mM12-C6122TLA020056R2200 10 mM12-C10122TLA020056R2300 20 mM12-C20122TLA020056R2400 Male6 mM12-C622TLA020056R0200 10 mM12-C1022TLA020056R1200 —Cables for Smile 12 RF (with Eden DYN/OSSD Reset M12-5)—Cables for Smile 12 RG (with Eden DYN/OSSD Reset M12-8)—Cables for Smile 11 RX and ROx 6 – 42SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Connection examplesSmile reset buttonsOrion receiver or active partSmile reset(a)M12-3R1. + 24 VDC 2. OSSD13. 0 V 4. OSSD2 5. -M12 5-pole male(a)Orion receiver or active partTina 10BSmile reset1. + 24 VDC 2. In3. 0 V 4. Out5. InfoM12 5-pole maleLocal reset to Orion with Tina 10A/CLocal reset to Orion with Tina 10BLocal reset to EdenConnection of Smile 11 ROx to Orion through M12-3R. For connection to any control module compatible with OSSD outputs.Serial connection of Eden with local Smile reset buttons:- Adam OSSD-Reset M12-8 with Smile 12 RG and M12-3G or M12-3H- Adam DYN-Reset with Smile 12 RF and M12-3AConnection of Smile 11 ROx to Orion through Tina 10B.For connection to Vital control module or Pluto Safety PLC.Global vs local resetA global reset is connected directly to the control cabinet with separate cables. The safety controller in the control cabinet supervises the reset and decides the function and actions.A local reset is connected directly to the safety device, and requires no communication with the control cabinet. The safety device supervises the reset and decides the actions. A local reset simplifies installation and minimizes cabling.EMERGENCY STOPS AND PILOT DEVICES6 – 436
—Technical dataSmile reset buttonsApprovalsPower supplyLED operating voltage+24 VDC (maximum +33 VDC)LED current consumption20 mA at +24 VDC, 30 mA at +33 VDCPush button operating voltageMin: +5 V, max: +35 VPush button currentMin: 1 mA, max: 100 mAPush button rated powerMax: 250 mWMechanical dataColor - EnclosureYellowColor - Push buttonWhiteMaterial - HousingPolyprobylene PPMaterial - ContactAuWeightApprox. 60 gProtection classIP65Mechanical life1 000 000 operations at 10 mA / +24 VDCSwitching reliability10 x 10-6 at 5 mA / +24 VDCEnvironmental dataAmbient temperature-25...+55 °CHumidity range35 to 85% (with no icing or condensation)More informationFore more information, e.g. the complete technical information, see product manual for:Smile reset buttons 2TLC172097M02016 – 44SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
—Dimension drawingsSmile reset buttonsSmile 11 RSmile 12 RAll dimensions in mmEMERGENCY STOPS AND PILOT DEVICES6 – 456
—Pilot devicesReliable products, easy to select and installABB pilot devices are engineered for total reliability. Our products are tested to extremes and proven in the toughest environments. Their innovative designs simplify the entire process, from selection to installation. Enclosures, signal towers and signal beacons complete the portfolio. Continuous operationGlobal availabilityEasy to installEngineered for tough environmentsABB pilot devices are designed with protection degree of up to IP69K and 4X, guaranteeing reliability in extreme environments – making ABB pilot devices ideal for use in demanding industries such as construction and food and beverage. An innovative de-sign that automatically cleans contacts ensures high reliability for all products.Simple selection and stock managementABB’s core offering includes the pilot devices most in demand, so product selection is easier, stock management is simpler and product availability is higher. Support for exporters is world-class, thanks to ABB’s standardized global range, certified to comply with all ma-jor international standards.Save time and spaceThe unique design of ABB’s modular range enables tool-free installation that is quick and simple. It provides high flexibility for last-minute changes. With its all-in-one construction, the compact range reduces installation space and saves time. 6 – 46SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
JoysticksSelectorswitchesKey-operated selector switchesToggle switchesPilot lightsPotentiometersA versatile selection of operators with high levels of flexibility and a broad choice of electrical ratings. Find the perfect solution for almost every application.More flexibility:Last-minute changes made easyUp to 6 contact blocks, NO and NCSave up to 30% installation time with unique tool-free snap on componentsChoice of 3- and 5-position holdersSimple solutions nuts require no toolsEvery requirement covered with a wide choice of operators and bezels High AC-15 electrical ratings 6 A at 230 V. The flexible solution that simplifies your stock management.Emergency stop pushbuttonsMachine stop pushbuttonsHeavy duty pushbuttonsPushbuttonsDouble pushbuttonsReset pushbuttonsMushroom pushbuttons—Modular plastic rangeFlexible configurationEMERGENCY STOPS AND PILOT DEVICES6 – 476
ABB’s modular metal range combines ultimate reliability with the total flexibility of a modular range. For mining, construction and heavy industry applications, find the right solution here. Installation time savingsTool-free, snap-on components make mounting and dismounting quick and easySnap on holder for 3 or 5 contact blocksAssured robustness for demanding environments• Full satin chrome metal body and nut• High friction nut and metal stops make sure the operator stays in place• IP66 high dust and water protection ratingPushbuttonsMushroom pushbuttonsSelector switchesSelectorpushbuttonsKey-operated selector switchesToggle switchesJoysticksPilot lights IP66 aluminium metal enclosures are available to accompany this range.—Modular metal rangeDesigned for demanding applications6 – 48SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY6
Compact:Just 42 mm built in depthImprove reliability: Higher protection levels with IP66, IP67 and IP69K classification and 4X (NEMA)Fewer order codes make selection easy and save time. All-in-one design makes installation fast.The most efficient solution available, reducing installation time and cost. The compact range have the highest level of dust and water resistance on the market. BuzzersEmergency stop pushbuttonsMachine stop pushbuttonsPushbuttonsPilot lightsHeavy duty pushbuttonsSelector switchesMushroom pushbuttonshttp://new.abb.com/low-voltage/products/pilot-devicesFor more models, ordering information and tech-nical data, please see web:—Compact rangeAll-in-one solutionEMERGENCY STOPS AND PILOT DEVICES6 – 496
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY77
PRESSURE SENSITIVE DEVICES7-17— Pressure sensitive devices7– 2 Introduction and overview 7– 4 Safety edges7– 8 Safety bumpers 7– 12 Safety mats
—Introduction and overviewSelection guideABB has different types of pressure sensitive devices to cover the needs in various applications. Safety edgesSafety bumpersSafety matsImageTy p ePressure sensitive safety edgePressure sensitive safety bumperPressure sensitive safety matOvertravel distance15-22.7 mm60-240 mm-Application(s)Sliding doors, gates, roller doors and moving platforms.Larger sliding doors/hangar doors and automated guided vehicles.Personal protection within the dangerous area.Advantages- Preassembled- Easy to install- Compact- Up to 25 m long- Preassembled- Easy to install- Very durable- Easy to install- Custom measurements7-2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
S = minimum distance in mmK = approach speed (of hand or body) in mm/sT = stopping time of the machine (including reaction time of safe-ty devices) in secondsC = additional distance in mm based upon the body ́s intrusion towards the hazardous area before the safety device has been actuated.Pressure sensitive edges and bumpersEdges and bumpers have an overtravel distance, which is the distance from the compression point where they react until they are maximum compressed. The overtravel distance should be stated in the product information for edges and bum-pers. Make sure to select an edge or bumper with a larger overtravel than the stopping distance of the moving part it should be placed on. A minimum safety factor of 1.2 should be used, i.e. the overtravel distance should be 120% of the stopping distance.Pressures sensitive matsMats should only be used as perimeter detection devices if the risk assessment indicates it is a suitable protective device. This could e.g. be in environments with lots of debris and particles from the process that would disturb a light curtain. The width of a safety mat used as perimeter detection should be at least 75 cm to prevent unintentional stepping over.The minimum safety distance from the outer edge of the safety mat to the dangerous area is calculated using the formula from EN ISO 13855:—Overview Standards Where H is the height of the safety mat above the floor (which is usually 0).S = (K x T) + CS = 1600 x T + (1200 – 0.4 H)For safety mats the following should be used:PRESSURE SENSITIVE DEVICES7-37
Safety edges are pressure sensitive devices that are used on leading edges of doors or moving machine parts to prevent crushing injuries.The contact edges from ABB are avail-able in two sizes and custom lengths. They are supplied together with an aluminum profile for simple mountingContinuous operationMaterialThe contact edges are made in TPE that has a good resistance to ozone, weather and especially against chemi-cals.—Safety edgesTTEasy to installPreassembled Ordered in custom lengths, preassem-bled - no gluing required, supplied with matching aluminum support profile.Serial connectionThe twin cable connection makes it easy to connect several safety edges in series.7-4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
—Applications and featuresSafety edgesSliding doorsSafety edges are placed on the leading edge of sliding doors, gates and roller doors. When the door hits a person or an object, the safety edge sends a signal to the safety controller to stop the motion. The soft parts of the edge should be big enough to allow compression until the motion has ceased.Safety controllersThe safety edge must be connected to a suitable two-input-channel safety controller that provides all necessary monitoring of the contact edges activation and detection of cable faults. Suitable ABB controllers are Sentry USR safety relays, Pluto programmable safety controllers or Vital safety controllers. When using Vital, a Tina 6 must also be used for short circuit detection. Moving machine partsSafety edges can also be placed on moving machine parts, such as the edges of horizontally moving tables and the underside of a scissor lift table.Internal contactsInside the safety 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. When pressure is applied the two contact surfaces are short circuited, resulting in a stopping signal. The cast-in contact strip is protected against damage by the surrounding chamber. The cast end plugs ensure a perma-nent contact from the conductive surfaces in the contact strip. ApplicationsFeaturesPRESSURE SENSITIVE DEVICES7-57
Ordering detailsWhen ordering a safety edge there are two parts that need to be ordered. One order code for production cost and cables, and one order code for the length of the safety edge. Length should be specified in meters.Example:One piece of 45 mm high safety edge (plus 14 mm high aluminum rail), 0.73 m long with a 5 meter cable in each end =- 0.73 m of 2TLA076025R4510- 1 pcs of 2TLA076010R0500Overtravela)mmDescriptionMaterialTy p e Order code15 30 mm high safety edge with 25-14 aluminum rail. Length in m needs to be specified on order.TPESafety edge TT 25-30 TPE2TLA076025R301022.745 mm high safety edge with 25-14 aluminum rail. Length in m needs to be specified on order.TPESafety edge TT 25-45 TPE2TLA076025R4510a)At 100 mm/s to 400 NLength of cablesmDescriptionTy p e Order code2.5Production cost with a 2,5 m cable in each end.Safety edge production cost 2,5m cable2TLA076010R01005Production cost with a 5 m cable in each end.Safety edge production cost 5,0m cable2TLA076010R050010Production cost with a 10 m cable in each end.Safety edge production cost 10,0m cable2TLA076010R10002TLC010120V0201Safety edge TT 35-30 TPE—Ordering informationSafety edgesSafety edge TT 25-45 TPE2TLC010008V0201—Production cost and cables—Safety edge TT7- 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
Technical dataApprovalsConformity2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13856-2:2013, EN ISO 13849-1:2015, EN 62061:2005+A2:2015, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 61508:2010Functional safety data 62061:2005+A1:2013 EN ISO 13849-1:2015SILCL2PL d/Cat 4 (According to EN ISO 13849-2:2012, Table D.8, a fault exclusion for that the contacts in a pressure sensitive device will not close, can be made. This fault exclusion is limited up to PL d.) Electrical dataElectrical capacity24 V, 10 mAMechanical dataSwitching cycles10 000Protection classIP65Operating temperature-10 °C to 50 °C Weight TT 25-45 TT 25-300.34 kg/m0.44 kg/mMaterialRubberTPESupportive profileAluminiumMax Delivery length25 mInactive end region30 mmConnection cablesLIY11Y 2 x 0.34 mmCable materialPUR flat blackMore information For more information, e.g. the complete technical information, see product manual for:Safety Edges 2TLC010046M0201.Connection diagramsFor safety edge connection diagrams please see https://library.abb.com/Dimension drawings—Technical dataSafety edgesTÜV NORDAll dimensions in mmPRESSURE SENSITIVE DEVICES7-77
Safety bumpers are pressure sensi-tive devices used to prevent crushing injuries. They are mounted on lead-ing edges of large doors or moving machinery such as automated guided vehicles.The bumpers are available in four different sizes, and the internal foam construction allows for long deforma-tion zones to provide optimum pro-tection for individuals and material.—Safety bumperASBContinuous operationMaterialThe outer material of the safety bum-pers is an artificial leather that pro-vides excellent resistance against most liquids, oils and chemicals.Easy to installPreassembled Ordered in custom lengths and preas-sembled to a carrier profile. Serial connectionThe twin cable connection makes it easy to connect several safety bum-pers in series.7– 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
—Applications and featuresSafety bumperLarge sliding doorsSafety bumpers are placed on the leading edge of large sliding doors, gates and vertical roller doors. When the door hits a person or an object, the safety bumper sends a signal to the safety controller to stop the motion. The soft parts of the bumper should be big enough to allow compression until the motion has ceased. Safety controllersThe safety bumper must be connected to a suitable two-input-channel safety controller that provides all necessary monitoring of the activation of the safety bumpers and detection of cable faults. Suitable ABB controllers are Sentry USR safety relays and Pluto programmable safety control-lers.Moving vehiclesSafety bumpers can also be placed on moving vehicles, such as AGVs (automated guided vehicles) or high reach fork lifts to detect when a person or an object is hit. Internal contact stripInside the safety bumper there is a cast-in contact strip that consists of two conductive alternating surfaces on the inside and a highly-effective insulating shell. When pressure is applied the large foam cushion presses the two contact surfaces against each other so that they are short circuited, which the safety controller will detect. ApplicationsFeaturesPRESSURE SENSITIVE DEVICES7– 97
—Ordering informationSafety bumper2TLC010122V0201ASB7– 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7Ordering detailsWhen ordering a safety bumper there are two parts that need to be ordered. One order code for production cost and cables, and one order code for the type of bumper and length. Length should be specified in meters. Minimum length is 0.15 m and maximum length is 3 m.Bumpers are delivered with two 0,2 m cables with M8 connectors attached. Two 5 m cables with M8 connectors are also included.Example:One piece of 150x300 mm safety bumper (including aluminum rail), 2.1 m long =- 2.1 m of 2TLA076200R0700- 1 pcs of 2TLA076200R0000Overtravela)mmDescriptionMaterialTy p e Order code6060x100 mm bumper. Length in m needs to be speci-fied on order.Imitation leatherBumper ASB 60-100 black/yellow2TLA076200R0500120100x200 mm bumper. Length in m needs to be speci-fied on order.Imitation leatherBumper ASB 100-200 black/yellow2TLA076200R0600180150x300 mm bumper. Length in m needs to be speci-fied on order.Imitation leatherBumper ASB 150-300 black/yellow2TLA076200R0700240200x400 mm bumper. Length in m needs to be specified on order.Imitation leatherBumper ASB 200-400 black/yellow2TLA076200R0800a)60% of bumper height at 10 mm/sDescriptionTy p e Order codeBumpers production cost, including aluminum rail and cablesBumper production cost2TLA076200R0000—Production cost and cables—Safety bumper ASB
PRESSURE SENSITIVE DEVICES7– 117Technical dataApprovals TÜV NORDConformity2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13856-3:2013, EN ISO 13849-1:2015, EN 62061:2005+A2:2015, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 61508:2010Functional safety data 62061:2005+A1:2013 EN ISO 13849-1:2015SILCL2PL d/Cat 4 (According to EN ISO 13849-2:2012, Table D.8, a fault exclusion for that the contacts in a pressure sensitive device will not close, can be made. This fault exclusion is limited up to PL d.) Electrical dataElectrical capacity24 V, 10 mAMechanical dataActuating force< 150 N by test specimen Ø80 mm (according to EN ISO 13856-3) < 400 N by test specimen 45x400 mm (according to EN ISO 13856-3)Inactive edge region0 mmSwitching cycles> 10 000 Protection classIP54Temperature range0 °C to + 50 °C Connection cablePluggable 2 x 0.34 mm² (PUR black) with M8 connector 0.12mMaterialArtificial leatherChemical resistanceGood chemical resistance, except for Ethyl acetate and Acetone.Dimensioning of bumper height Actuating distance Overtravel distance Maximum compression15% of bumper height60% of bumper height75% of bumper heightMore information For more information, e.g. the complete technical information, see product manual for:Safety Bumpers 2TLC010045M0201.Connection diagramsFor safety bumpers connection diagrams please see https://library.abb.com/Dimension drawings—Technical dataSafety bumpersAll dimensions in mm
Safety mats are pressure sensitive devices placed on the floor to detect if someone is standing on them. They are mostly used inside hazard zones around e.g. presses, robots and production lines to prevent the machine from running when someone is in the hazard zone.—Safety matsASKContinuous operationMaterialThe surface material of the safety mat is a slip-free rubber with excellent re-sistance against oil, water and grease.Easy to installPreassembled Ordered in standard or custom sizes with molded ramp and preassembled with two cables (M8 male and female connector).Serial connectionThe twin cable connection makes it easy to connect several safety mats in series. Extension cables exist to fur-ther simplify connection.7– 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
—Applications and featuresSafety matsPersonal protection within hazard zonesSafety mats are mostly used inside hazard zones around e.g. presses, robots and production lines to prevent the machine from running when someone is in the hazard zone. Safety controllersThe safety mat must be connected to a suitable two-input-channel safety controller that provides all necessary moni-toring of the activation of the safety map and detection of cable faults. Suitable ABB controllers are Sentry USR safety relays, Pluto programmable safety controllers or Vital safety controllers. When using Vital, a Tina 6 must also be used for short circuit detection. Mat constructionThe safety mat is made of a sandwich construction. When stepped upon, two internal conducting plates connect and result in a short circuit that the safety controller detects.Perimeter guardSafety mats can also be used as a perimeter guard e.g. to replace a light curtain in applications where there is a lot of debris or particles in the air that would trigger the light curtain. Ramp railAt the edges of the safety mat there is a molded ramp rail. The ramp rail is 35 mm wide and is not included in the mea-surement of the ramp (i.e. the actual dimensions of a 1000 x 1000 mm safety mat is 1070 x 1070 mm). The purpose of the ramp rail is to minimize the tripping risk and for fastening of the safety mat, since screws can be drilled through the ramp rail. The ramp rail can be cut off using a knife if the safety mat is to be placed close to a wall or next to another safety mat.ApplicationsFeaturesPRESSURE SENSITIVE DEVICES7– 137
Ordering detailsWhen ordering a safety mat you can either select one of the standard sizes or a custom size. For standard sizes only one order code is necessary. For custom sizes two parts need to be ordered. One order code for base price, and one order code for the size in m2. Width x length also needs to be specified in text on the order in mm. Maximum dimensions are 2350 x 1350 mm and minimum dimensions 100 x 100 mm.Example:One piece of 450 x 1150 mm safety mat =- 1 pcs of 2TLA076301R0200- 0.5175 m2 of 2TLA076301R0600- Dimensions 450 x 1150 mmSizemmDescriptionConnectorsTy p e Order code750x1000 750x1000 safety mat with molded ramp rail and two 5 m cables1x M8 male1x M8 femaleSafety mat ASK T4 750x1000mm2TLA076310R10001000x10001000x1000 safety mat with molded ramp rail and two 5 m cables 1x M8 male1x M8 femaleSafety mat ASK T4 1000x1000mm2TLA076310R11001000x15001000x1500 safety mat with molded ramp rail and two 5 m cables1x M8 male1x M8 femaleSafety mat ASK T4 1000x1500mm2TLA076310R1200DescriptionConnectorsTy p e Order codeBase price for custom made safety mat with molded ramp rail-Safety mat ASK CM T4, base price2TLA076301R0200Order code for size (m2) and two 5 m cables. Specify dimensions (width x length in mm) in text.1x M8 male1x M8 femaleSafety mat ASK CM T42TLA076301R0600DescriptionLengthmConnectorsTy p e Order codeExtension cable2.51x M8 male1x M8 femaleSafety mat extension cable 2.5 m2TLA076900R3200Extension cable5.01x M8 male1x M8 femaleSafety mat extension cable 5.0 m2TLA076900R33002TLC010035V0201ASK—Ordering informationSafety mats—Safety mat ASK – standard sizes—Safety mat ASK – custom sizes—Accessories7– 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY7
Technical dataApprovalsConformity2006/42/EC - Machinery2014/30/EU - EMC2011/65/EU - RoHSEN ISO 12100:2010, EN ISO 13856-1:2013, EN ISO 13849-1:2015, EN 62061:2005+A2:2015, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 61508:2010Functional safety data 62061:2005+A1:2013 EN ISO 13849-1:2015SILCL2PL d/Cat 4B10D: 2 000 000(According to EN ISO 13849-2:2012, Table D.8, a fault exclusion for that the contacts in a pressure sensitive device will not close, can be made. This fault exclusion is limited up to PL d.) Electrical dataElectrical capacity24 V, 100 mAResponse time Including Sentry Including Pluto (single Pluto) Including Pluto incl. Pluto bus With function block “BigMat”< 20 ms< 30 msNormal condition: < 40 msAt fault condition: < 70 msAdd 30 msMechanical dataMax. areaEntire safety mat = 2350 x 1350 mm, 10 m2, (divided safety mat) Rec. relation max 3:1, Min 100 x 100 mmHeight14 mmWeight26 Kg/m2MaterialBlack polyurethaneProtection classIP65Ambient air temperature0° C to + 60° CCable2 x 5 m; 2 x 0.34 mm2PU sheathedMechanical life>1.0 x 106 Load shiftingMore information For more information, e.g. the complete technical information, see product manual for:Safety Mats 2TLC010047M0201.Connection diagramsFor safety mats connection diagrams please see https://library.abb.com/—Technical dataSafety matsPRESSURE SENSITIVE DEVICES7– 157
SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
— Contactors and motor starters8– 2 Introduction and overview 8– 4 Safety contactors8– 10 Electronic compact startersCONTACTORS AND MOTOR STARTERS8 – 18
AFSHFImageTy p eSafety contactorElectronic compact startersDescriptionA simple and reliable unit for monitoring and controlling circuits.A compact and space saving alternative to con-tactors, using a combination of semiconductor technology and electromechanical relays. Moni-toring and control of circuits with numerous additional features.ApplicationsRemoving control power to dangerous ma-chinery up to 400 W/400 V.Removing control power to dangerous ma-chinery up to 3 kW/400 V, as well as direct and reversed start of motors.Advantage- Easy to use- Fast switching- High switching capacity- Space saving up to 90% with only 22.5 mm in control cabinets- Extended equipment life time and decreased maintenance cost- Reduced wiring time- Safety variants comply with SIL3, PL e and are ATEX certifiedABB offers a wide range of output devices for safely removing power to dangerous machinery. Apart from contactors and electronic compact starters, we also have frequency converters with safe torque off (STO) and industrial robots with safety stop inputs.—Introduction and overviewSelection guide8 – 2SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
CONTACTORS AND MOTOR STARTERS8 – 38
Designed for machine safety applications, AFS contactors now complete ABB’s safety component portfolio. With a range stretching from 9 A up to 750 A for motor starting applications and with a design complying with the latest safety standard, the AFS range of contactors is the given choice for any application that puts the users safety first.Secure uptimeThe AFS contactor secures system uptime. Featuring ABB’s tested and proven AF technology, AFS contactors are reliable in any network. Direct control by safety PLCs or safety relays ensures the required safety performance.Simplify designAFS design makes integration easier. With energy efficient coils smaller transformers can be used and panel space more efficiently used. Wide voltage range coils and easily available safety data simplifies product selection. In addition, all the safety data for the AFS contactors is available using common safety design tools.Speed up your projectsContinuous operationSafety in all things ABB’s AFS contactors can be easily integrated in machine manufacturer’s systems complying with main standards EN ISO 13849 and EN 62061 - guaranteeing the safe use of your machinery and equipment. An easily identifiable yellow low energy auxiliary contact block ensures the status feedback circuits required in machine safety applications. Safety and protection—AFS 3-pole contactorsDedicated for safety applications8 – 4SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
—AFS 3-pole contactorsDedicated for safety applicationsSimplify calculation of your installation safety levelAFS contactor safety data is available in safety design tools Sistema and FSDT, dedicated software for determining the Performance Level (PL) and Safety Integrity Level (SIL) of safety functions and generating technical documentations.Prevent unexpected operationsFactory fitted auxiliary contact blocks that are permanently fixed protects devices against accidental operation and misuse. A factory-fitted transparent cover on contactors up to 96 A shields the contactor status indicator, providing additional protection from misuse.Guaranteed contactor statusABB’s permanently fixed auxiliary contact blocks guarantee the correct contactor status at all times. Mechanically linked and mirror contacts provide the performance re-quired in feedback circuits. This prevents any unexpected state changes of auxiliary contact if main contacts become welded or stuck and ensures an accurate depiction of the safety system status displayed at all times. Mechanically linked and mirror contact symbols are marked on the yellow auxiliary block.Fast response for increased safetyIn safety applications speed is essential to protect operators. AFS contactors feature fast opening times, down to 20 ms for certain PLC controlled contactors, en-suring that when a dangerous failure is detected the opera-tor is kept out of harms way.CONTACTORS AND MOTOR STARTERS8 – 58
—AFS 3-pole contactors Dedicated for safety applicationsEasy safety chain identificationThe yellow housing of ABB’s AFS contactors makes identify-ing the safety product in your panel quicker. During routine maintenance work, ABB’s intuitive design saves valuable time.Control by safety PLCs or safety relaysABB’s AFS contactors can be controlled directly by safety PLCs or safety relays, or by a power relay depending on size. AFS contactors is part of the ABB safety family, and se-lected sizes are tested together with ABB's Pluto safety PLC and the Sentry safety relay. For full coordination please ad-vise ABB. The auxiliary contacts only require a minimum switching capacity of 3 V / 1 mA. They guarantee system sta-tus feedback, making the system safe and reliable. Panel size reductionUtilizing AF technology, AFS coils needs up to 60% less energy than conventional contactor coils. This allows for smaller transformers to be used for contactor control, which in turn allows for more efficient use of panel space. Using AFS contactors saves money and precious space.Built-in surge suppressionUnlike conventional contactors, ABB's AFS contactors have built-in surge suppression, preventing surges from ever reaching the control circuit. With no need for the usual external surge suppressor add-ons, ABB’s solution means one less device to install and one less complication to man-age. Sentry safety relayPluto safety PLC8 – 6SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
—AFS 3-pole contactorsDedicated for safety applications AFS16-30-221SBC101536V0014 1SBC101539V0014IECUL/CSARated control circuit voltage Uc min. ... Uc max.AuxiliarycontactsfittedTy pe Order codeWeightRated operational3-phase GeneralpowerCurrent θ ≤ 40 °Cmotor ratinguse rating400 VAC-3AC-1480 V600 V ACkWAhpAV 50/60 HzV DCkg425525-24 2 2AFS09Z-30-22-301SBL136082R30220.49024...6020...60 (1)2 2AFS09-30-22-111SBL137082R11220.320100...250100..2502 2AFS09-30-22-131SBL137082R13220.3205.5287.528-24 2 2AFS12Z-30-22-301SBL156082R30220.49024...6020...60 (1)2 2AFS12-30-22-111SBL157082R11220.320100...250100..2502 2AFS12-30-22-131SBL157082R13220.3207.5301030-24 2 2AFS16Z-30-22-301SBL176082R30220.49024...6020...60 (1)2 2AFS16-30-22-111SBL177082R11220.320100...250100..2502 2AFS16-30-22-131SBL177082R13220.32011451545-24 2 2AFS26Z-30-22-301SBL236082R30220.54024...6020...60 (1)2 2AFS26-30-22-111SBL237082R11220.360100...250100..2502 2AFS26-30-22-131SBL237082R13220.36015502050-24 2 2AFS30Z-30-22-301SBL276082R30220.54024...6020...60 (1)2 2AFS30-30-22-111SBL277082R11220.360100...250100..2502 2AFS30-30-22-131SBL277082R13220.36018.5502050-242 2AFS38Z-30-22-301SBL296082R30220.54024...6020...60 (1)2 2AFS38-30-22-111SBL297082R11220.360100...250100..2502 2AFS38-30-22-131SBL297082R13220.36018.570306024...6020...60 (1)2 2AFS40-30-22-111SBL347082R11221.020100...250100..2502 2AFS40-30-22-131SBL347082R13221.00022100408024...6020...60 (1)2 2AFS52-30-22-111SBL367082R11221.020100...250100..2502 2AFS52-30-22-131SBL367082R13221.00030105509024...6020...60 (1)2 2AFS65-30-22-111SBL387082R11221.020100...250100..2502 2AFS65-30-22-131SBL387082R13221.000371256010524...6020...60 (1)2 2AFS80-30-22-111SBL397082R11221.270100...250100..2502 2AFS80-30-22-131SBL397082R13221.220451306011524...6020...60 (1)2 2AFS96-30-22-111SBL407082R11221.270100...250100..2502 2AFS96-30-22-131SBL407082R13221.220For connection with built-in cable clamps551607516024...6020...601 2AFS116-30-12-111SFL427081R11121.75048...13048...1301 2AFS116-30-12-121SFL427081R12121.750100...250100...2501 2AFS116-30-12-131SFL427081R13121.7501 2AFS116-30-12-33 (2)1SFL427081R33121.750250...500250...5001 2AFS116-30-12-141SFL427081R14121.7501 2AFS116-30-12-34 (2)1SFL427081R34121.7507522510020024...6020...601 2AFS146-30-12-111SFL467081R11121.75048...13048...1301 2AFS146-30-12-121SFL467081R12121.750100...250100...2501 2AFS146-30-12-131SFL467081R13121.7501 2AFS146-30-12-33 (2)1SFL467081R33121.750250...500250...5001 2AFS146-30-12-141SFL467081R14121.7501 2AFS146-30-12-34 (2)1SFL467081R34121.750With bar connections551607516024...6020...601 2AFS116-30-12B-111SFL427082R11121.50048...13048...1301 2AFS116-30-12B-121SFL427082R12121.500100...250100...2501 2AFS116-30-12B-131SFL427082R13121.5001 2AFS116-30-12B-33 (2)1SFL427082R33121.500250...500250...5001 2AFS116-30-12B-141SFL427082R14121.5001 2AFS116-30-12B-34 (2)1SFL427082R34121.5007522510020024...6020...601 2AFS146-30-12B-111SFL467082R11121.50048...13048...1301 2AFS146-30-12B-121SFL467082R12121.500100...250100...2501 2AFS146-30-12B-131SFL467082R13121.500250...500250...5001 2AFS146-30-12B-141SFL467082R14121.500 AFS65-30-221SBC101542V0014 AFS96-30-221SBC101544V0014AFS146-30-12AFS146-30-12B1SFC101246V00011SFC101244V0001AFS38-30-22CONTACTORS AND MOTOR STARTERS8 – 78
—AFS 3-pole contactorsDedicated for safety applicationsIECUL/CSARated control circuit voltage Uc min. ... Uc max.AuxiliarycontactsfittedTy pe Order codeWeightRated operational3-phase GeneralpowerCurrent θ ≤ 40 °Cmotor ratinguse rating400 VAC-3AC-1480 V600 V ACkWAhpAV 50/60 HzV DCkg9027512525024...6020...601 2AFS190-30-12-111SFL427082R11123.00048...13048...1301 2AFS190-30-12-121SFL427081R12123.000100...250100...2501 2AFS190-30-12-131SFL427081R13123.000100...250100...2501 2AFS190-30-12-33 (2)1SFL427081R33123.000250...500250...5001 2AFS190-30-12-141SFL427081R14123.000250...500250...5001 2AFS190-30-12-34 (2)1SFL427081R34123.00011035015030024...6020...601 2AFS205-30-12-111SFL527082R11123.00048...13048...1301 2AFS205-30-12-121SFL527082R12123.000100...250100...2501 2AFS205-30-12-131SFL527082R13123.000100...250100...2501 2AFS205-30-12-33 (2)1SFL527082R33123.000250...500250...5001 2AFS205-30-12-141SFL527082R14123.000250...500250...5001 2AFS205-30-12-34 (2)1SFL527082R34123.00013240020035024...6020...601 2AFS265-30-12-111SFL547082R11124.67548...13048...1301 2AFS265-30-12-121SFL547082R12124.675100...250100...2501 2AFS265-30-12-131SFL547082R13124.675100...250100...2501 2AFS265-30-12-33 (2)1SFL547082R33124.675250...500250...50012AFS265-30-12-141SFL547082R14124.675250...500250...5001 2AFS265-30-12-34 (2)1SFL547082R34124.67516050025040024...6020...601 2AFS305-30-12-111SFL587082R11124.67548...13048...1301 2AFS305-30-12-121SFL587082R12124.675100...250100...2501 2AFS305-30-12-131SFL587082R13124.675100...250100...2501 2AFS305-30-12-33 (2)1SFL587082R33124.675250...500250...5001 2AFS305-30-12-141SFL587082R14124.675250...500250...5001 2AFS305-30-12-34 (2)1SFL587082R34124.67520060030052024...6020...601 2AFS370-30-12-111SFL607082R11124.67548...13048...1301 2AFS370-30-12-121SFL607082R12124.675100...250100...2501 2AFS370-30-12-131SFL607082R13124.675100...250100...2501 2AFS370-30-12-33 (2)1SFL607082R33124.675250...500250...5001 2AFS370-30-12-141SFL607082R14124.675250...500250...5001 2AFS370-30-12-34 (2)1SFL607082R34124.675200600350550-24...601 2AFS400-30-12-681SFL577081R6812 (3)4.67548...13048...1301 2AFS400-30-12-691SFL577081R691212.000100...250100...2501 2AFS400-30-12-701SFL577081R701212.000250...500250...5001 2AFS400-30-12-711SFL577081R711212.000250700400650-24...601 2AFS460-30-12-681SFL597081R6812 (3)12.00048...13048...1301 2AFS460-30-12-691SFL597081R691212.000100...250100...2501 2AFS460-30-12-701SFL597081R701212.000250...500250...5001 2AFS460-30-12-711SFL597081R711212.000315800500750-24...601 2AFS580-30-12-681SFL617081R6812 (3)12.00048...13048...1301 2AFS580-30-12-691SFL617081R691212.000100...250100...2501 2AFS580-30-12-701SFL617081R701212.000250...500250...5001 2AFS580-30-12-711SFL617081R711212.0004001050600900-24...601 2AFS750-30-12-681SFL637081R6812 (3)12.00048...13048...1301 2AFS750-30-12-691SFL637081R691212.000100...250100...2501 2AFS750-30-12-701SFL637081R701212.000250...500250...5001 2AFS750-30-12-711SFL637081R711212.000(1) AFS..-30-..-11 for control by transistor outputs of safety PLCs and safety relays use interface relay RA4 1SBN060100R1000.(2) With built-in PLC interface (coil 33 and 34)(3) The connection polarities indicated close to the coil terminals must be respected: A1 for the positive pole and A2 for the negative pole.Note : Accessories available. Please consult the AFS contactors for safety application catalog.AFS205-30-12AFS370-30-121SFC101230V00011SFC101233V0001Products safety data for machine manufacturers following harmonized EN standards: -EN ISO 13849 -EN 62061B10d - Calculated for 50% of the rated current value Ie at AC-3 / 400 VAFS09 ... AFS370 : 1.3 million operating cyclesAFS400 ... AFS750 : 0.68 million operating cyclesAFS460-30-12AFS750-30-121SFC101228V00011SFC101226V00018 – 8SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
CONTACTORS AND MOTOR STARTERS8 – 98
ABB’s electronic compact starter packs more functions into less space. The compact unit is just 22.5 mm wide and is suitable for three-phase motor loads up to 3 kW - 400 V AC. Direct-on-line and reversed starter with overload protection and emergency stop versions are available, making the range a perfect fit for high frequent and reliable long life switching of e.g. paper machines, conveyors, pumps, compressors and machine tools.Up to 90% less space required ABB’s electronic compact starter saves cabinet space, and is especially effective for group mounting. The starter is just 22.5 mm wide and yet still provides motor starting functionalities with motor protection and safety embedded.Integrated safety function Protect your personnel with emergency stop version complying with SIL3, PL e safety standards. Extend equipment life time and decrease maintenance cost as our starters service life is 10 times higher than electromechanical solutions.Up to 75% reduced time in wiring Wiring time during installation is cut to a minimum with motor protection, re-versing function and emergency stop already integrated in the product. With just one component to install, the risk of wiring errors is lower. Separate overload protection is no longer need-ed.Saving spaceSafety and protectionEasy to install—Electronic compact starters: HF rangeA compact solution with great functionality8 – 10SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
Overload protectionABB offers three variants with wide setting ranges, using an electronic relay to protect the motor from overload. Pro-tection against phase asymmetry and phase failure is also integrated.Emergency stopABB’s HF safety range supports safety applications comply-ing to SIL3 and PL e safety level in combination with modular safety relays such as ABB’s Sentry SSR10.Direct-on-lineABB's direct-on-line starter comes with a function that runs the motor in a forward direction. An integrated electronic overload relay also helps protect the motor.Reversing capabilityReversing functionality is already integrated in our hybrid starter. This results in avoiding wiring faults and additionally saving time and space.Direct-on-line and reversing function in only one product—Electronic compact startersAll-in-one: four functions in one starterCONTACTORS AND MOTOR STARTERS8 – 118
Space-savingUsing an HF electronic compact starter saves space – espe-cially when group-mounting units. With a width of just 22.5 mm and high function density, the unit fits any control cabi-net. Smaller footprints for more compact systems are also possible. Less wiringThe control circuit is connected on the upper side of the device with the main circuit on the underside. The all-in-one functionality reduces wiring, saving time and money – and reducing faults. Longer working lifeABB’s hybrid technology improves durability and reduces power losses. Semiconductors switch on and off the unit and the relays remain active while the motor is running. With a lifespan of 30 million cycles now achievable, maintenance costs are reduced.Reset functionAfter the overload function has tripped, the electronic com-pact starter can be reset automatically, manually or remotely. The LEDs on the device are visualizing that an error has oc-curred. Additionally, a feedback relay will be activated.22.5 mm—Electronic compact startersFeatures and benefits8 – 12SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
DescriptionThe HF-DOL-range is used for the direct-on-line start of motors and the switching of non-resistive loads. With contactor and overload relay functionalities integrated into one device, the results are faster wiring times and fewer faults. The range covers 0.6 A, 2.4 A and up to 9 A - for motors up to 3 kW – 500 V AC. The integrated electronic overload protection has a wide setting range that enables just three models to cover all requirements. The control supply voltage is 24 V DC. For the control and main connection points ABB offers screw connections. ABB also offers a HF-DOLE safety range with emergency stop function. This offers Safety Integrity Level 3, in accordance with functional safety standard IEC 61508-1 and Performance Level 'e' in accordance with ISO 13849-1. The safety range is ATEX-certified.Rated operational current AC-53aRated operational powerAC-53aRated op-erational current AC-51Setting rangeFull load amps motor useType Order codeWeight(1 pce)AkWAAAkgDirect-on-line starter with overload protection0.60.18 (400V)0.60.075 ... 0.60.6HF0.6-DOL-24VDC1SAT112000R10110.2052.4 0.75 (400V)2.40.18 ... 2.4 2.4HF2.4-DOL-24VDC1SAT122000R10110.2186.53.00 (400V)9.01.5 ... 9.06.5HF9-DOL-24VDC1SAT142000R10110.206Direct-on-line starter with overload protection and emergency stop0.60.18 (400V)0.60.075 ... 0.60.6HF0.6-DOLE-24VDC1SAT113000R10110.2052.4 0.75 (400V)2.40.18 ... 2.4 2.4HF2.4-DOLE-24VDC1SAT123000R10110.2186.53.00 (400V)9.01.5 ... 9.06.5HF9-DOLE-24VDC1SAT143000R10110.2062CDC241007V0016HF0.6-DOL-24VDC2CDC241010V0016HF0.6-DOLE-24VDCMain dimensions mm, inches2CDC242003F0017HF0.6, HF2.4, HF9—HF0.6, HF2.4, HF9 electronic compact startersDirect-on-line starter—Ordering detailsCONTACTORS AND MOTOR STARTERS8 – 138
DescriptionThe HF-ROL-range is used for forward and reverse running motors, as well as for switching non resistive loads. With contactor and overload relay functionalities integrated into one device, the results are faster wiring times and fewer faults. The range covers 0.6 A, 2.4 A and up to 9 A - for motors up to 3 kW – 500 V AC. The integrated electronic overload protection has a wide setting range that enables just three models to cover all requirements.The control supply voltage is 24 V DC. For the control and main connection points ABB offers screw connections. ABB also offers a HF-ROLE safety range with emergency stop function. This offers Safety Integrity Level 3, in accordance with functional safety standard IEC 61508-1 and Performance Level 'e' in accordance with ISO 13849-1. The safety range is ATEX-certified. Rated operational current AC-53aRated operational powerAC-53aRated operational current AC-51Setting rangeFull load amps motor useType Order codeWeight(1 pce)AkWAAAkgReversing starter6.53.00 (400V)9.0-6.5HF9-R-24VDC1SAT144000R10110.174Reversing starter with overload protection0.60.18 (400V)0.60.075 ... 0.60.6HF0.6-ROL-24VDC1SAT115000R10110.2172.40.75 (400V)2.40.18 ... 2.4 2.4HF2.4-ROL-24VDC1SAT125000R10110.2196.53.00 (400V)9.01.5 ... 9.06.5HF9-ROL-24VDC1SAT145000R10110.218Reversing starter with overload protection and emergency stop0.60.18 (400V)0.60.075 ... 0.60.6HF0.6-ROLE-24VDC1SAT116000R10110.2182.40.75 (400V)2.40.18 ... 2.4 2.4HF2.4-ROLE-24VDC1SAT126000R10110.2706.53.00 (400V)9.01.5 ... 9.06.5HF9-ROLE-24VDC1SAT146000R10110.289Main dimensions mm, inches2CDC242003F0017HF0.6, HF2.4, HF92CDC241004V0016HF0.6-ROL-24VDC2CDC241001V0016HF0.6-ROLE-24VDC2CDC241013V0016HF9-R-24VDC—HF0.6, HF2.4, HF9 electronic compact startersReversing starter—Ordering details8 – 14SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
—HF0.6, HF2.4, HF9 electronic compact startersTechnical dataMain circuit – Utilization characteristics according to IEC/ENTy peHF-DOL/ROLHF-DOLE/ROLEHF-RStandardsIEC/EN 60947-1, IEC/EN 60947-4-2IEC/EN 60947-1, IEC/EN 60947-4-2, IEC/EN 61508, IS0 13849IEC/EN 60947-1, IEC/EN 60947-4-2Rated operational voltage Ue500 V ACOperational voltageMinimum42 V AC, Maximum550 V ACSetting rangesee ordering detailsRated frequency50/60 HzTrip class10ANumber of poles3Number of protected poles3Mechanical durability10000 cyclesElectrical durability30 Mio. cyclesRated impulse withstand voltage Uimp6 kVRated insulation voltage Ui500 VRated operational current Ie AC-51see ordering detailsRated operational current Ie AC-53asee ordering detailsRated uninterrupted current Iusee ordering details, Rated operational current IeOvervoltage categoryIIIDelay timeOff, minimum, switched off with pushbutton1 s1 s-Off, maximum, switched off with pushbutton3 s3 s-Off, typical, switched off via control input voltage30 ms30 ms30 msOff, maximum, switched off via control input voltage-HF0.6, HF2.4: 60 msHF9: 80 ms-Off, typical, switched off via supply voltage25 ms25 ms25 msOff, maximum, switched off via supply voltage-500 ms-Switch off timeBy phase failure1.8 s1.8 s-By phase asymmetry at 33%120 s120 s-By phase asymmetry at 67%1.8 s1.8 s-Overspeed trippingOperating thresholdHF9-DOL/ROL/DOLE/ROLE: >45 AResponse timeHF9-DOL/ROL/DOLE/ROLE: 2 sPower loss Minimum1.1 WMaximumHF0.6: 1.5 WHF2.4: 3.3 WHF9: 14.6 WSwitching frequency≤ 2 Hz; 120 starts/min; 7200 starts/hOvervoltage categoryIIIShort circuit protection with MO132 for single mounting, IEC Type 1, 500 V AC, 35 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2Rated motor powerRated motor currentSta r te r Ty peProtection typeHF-StarterCurrent setting range of HF-StarterMax. allowed setting current for AC-53a kWAAA0.180.48DOL, ROL, DOLE, ROLE (1)MO132-0.63HF0.60.075 - 0.60.61.12.2DOL, ROL, DOLE, ROLE (1)MO132-2.5HF2.40.18 - 2.42.43.05.2DOL, ROL, DOLE, ROLE, R (1)MO132-6.3HF91.5 - 9 (1)6.5(1) HF9 is able to switch 9A in AC-51, 6.5A in AC-53a.Short circuit protection with MO132 for single mounting, IEC Type 1, 415 V AC, 70 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2Rated motor powerRated motor currentSta r te r Ty peProtection typeHF-StarterCurrent setting range of HF-StarterMax. allowed setting current for AC-53a kWAAA0.180.58DOL, ROL, DOLE, ROLE (1)MO132-0.63HF0.60.075 - 0.60.60.751.8DOL, ROL, DOLE, ROLE (1)MO132-2.5HF2.40.18 - 2.42.43.06.3DOL, ROL, DOLE, ROLE, R (1)MO132-6.3HF91.5 - 9 (1)6.5(1) HF9 is able to switch 9A in AC-51, 6.5A in AC-53aCONTACTORS AND MOTOR STARTERS8 – 158
—HF0.6, HF2.4, HF9 electronic compact startersTechnical dataShort circuit protection with MO132 for group mounting, IEC Type 1, 500 V AC, EN/IEC 60947-4-2Max. sum of current of HF-Starter in groupIqHF-Starter TypeSCPDkAA6.535DOL, ROL, DOLE, ROLE, R (1)MO132-6.3103MO132-10123MO132-12163MO132-16203MO132-20253MO132-25323MO132-32(1) HF9 is able to switch 9A in AC-51, 6.5A in AC-53aShort circuit protection with MO132 for group mounting, IEC Type 1, 415 V AC, EN/IEC 60947-4-2Max. sum of current of HF-Starter in groupIqHF-Starter TypeSCPDkAA6.570DOL, ROL, DOLE, ROLE, R (1)MO132-6.31035MO132-10123MO132-12163MO132-16203MO132-20253MO132-25323MO132-32(1) HF9 is able to switch 9A in AC-51, 6.5A in AC-53aSingle mounting fused design, IEC Type 1, 500 V AC, 35 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2Rated motor powerRated motor currentSta r te r Ty peProtection typeHF-StarterCurrent setting range of HF-StarterMax. allowed setting current for AC-53a kWAAA0.180.48DOL, ROL, DOLE, ROLE (1)Fuse 25A gGHF0.60.075 - 0.60.61.12.2DOL, ROL, DOLE, ROLE (1)Fuse 25A gGHF2.40.18 - 2.42.43.05.2DOL, ROL, DOLE, ROLE, R (1)Fuse 25A gGHF91.5 - 91)6.5(1) HF9 variants can switch 6.5A in utilization category AC-53a and 9A in AC-51.Single mounting fused design, IEC Type 1, 415 V AC, 50 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2Rated motor powerRated motor currentSta r te r Ty peProtection typeHF-StarterCurrent setting range of HF-StarterMax. allowed setting current for AC-53a kWAAA0.180.58DOL, ROL, DOLE, ROLE (1)Fuse 25A gGHF0.60.075 - 0.60.60.751.8DOL, ROL, DOLE, ROLE (1)Fuse 25A gGHF2.40.18 - 2.42.43.06.3DOL, ROL, DOLE, ROLE, R (1)Fuse 25A gGHF91.5 - 91)6.5(1) HF9 variants can switch 6.5A in utilization category AC-53a and 9A in AC-51.Group mounting fused design, IEC Type 1, 500 V AC, 35 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2IqSCPDMax. sum of current of used devicesHF-StarterkAA35Fuse 25A gG25HF0.635Fuse 25A gG25HF2.435Fuse 25A gG25HF9Group mounting fused design, IEC Type 1, 415 V AC, 50 kA, 50 Hz, AC-53a, EN/IEC 60947-4-2IqSCPDMax. sum of current of used devicesHF-StarterkAA50Fuse 25A gG25HF0.650Fuse 25A gG25HF2.450Fuse 25A gG25HF98 – 16SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
—HF0.6, HF2.4, HF9 electronic compact startersTechnical dataMain circuit – Utilization characteristics according to UL/CSATy peHFStandardsUL 60947-1; UL 60947-4-2 Rated operational voltage500 V ACOperational voltageMinimum42 V ACMaximum550 V ACAmpere Rating UL/CSAsee ordering details, Full load amps motor useHorse power rating Nominal switching performance full load (power factor = 0.4)HF0.6: 0.4 hpHF2.4: 1.2 hpHF9: 3.0 hpNominal switching performance full load (power factor = 0.8)HF0.6: 0.6 hpHF2.4: 2.2 hpHF9: 6.1 hpFull loads Amps (FLA)see ordering detailsShort-circuit current rating (SCCR) (500 V AC, 30 A Class J or CC)100 kAGeneral technical dataTy peHFUtilization categoryAC51, AC53aPollution degree2Phase loss sensitiveYesAmbient air temperatureOperation-25 ... + 70 °COperation compensated-40 ... + 80 °CMounting positionPosition 1, load side bottomMounting in DIN RailTH35-15 (35 x 15 mm Mounting Rail) acc. to IEC 60715,TH35-7.5 (35 x 7.5 mm Mounting Rail) acc. to IEC 60715Degree of protectionHousingIP20Main circuit terminalsIP20Control circuitTy peHFRated control circuit voltage Uc24 V DCInput voltage UinSwitching Threshold at Signal <0>-3 ... 9.6 VSwitching Threshold at Signal <1>19.2 ... 30 VInput current Ic3 mASupply circuitTy peHFRated control supply voltage Us24 V DCControl supply voltage19.2 ... 30 V DCRated control supply current Is0.04 ASingle and group mounting HF-Starter, Type 1 coordination with fuse class J or CC according to UL60947-1/-4-1 HF-StarterFLAIqSCPDMax. current Max. VoltageA / V ACkAAV ACHF0.60.6 / 500100Fuse class J or CC30480HF2.42.4 / 500100Fuse class J or CC30480HF96.5 / 500100Fuse class J or CC30480Single and group mounting HF-Starter, Type 1 coordination with fuse RK 5 according to UL60947-1/-4-1 HF-StarterFLAIqSCPDMax. current Max. VoltageA / V ACkAAV ACHF0.60.6 / 5005Fuse RK 520480HF2.42.4 / 5005Fuse RK 520480HF96.5 / 5005Fuse RK 520480CONTACTORS AND MOTOR STARTERS8 – 178
Safety related dataTypeHF-DOLE/ROLEStandardsIEC/EN 60947-1, IEC/EN 60947-4-2, IEC/EN 61508, IS0 13849 Safe shut downfor ambient temperature 40°C ... 60°CSafety integrity level acc. to IEC 61508-1SIL 3Performance level Up to eMean time to failure (MTTF) acc. to IEC60050-191-12-07DOLE: 43 yearsROLE: 39.3 yearsMean time to dangerous failure, motor protection447 yearsMean time to dangerous failure, safe shutdownDOLE: 518 yearsROLE: 517 yearsFailure in timeSafe, detectabled λsdDOLE: 543 FITROLE: 664 FITSafe, undetectable λsuDOLE: 852 FITROLE: 968 FITDangerous, detectable λdd218 FITDangerous, undetectable λduDOLE: 2.4 FITROLE: 2.67 FITSafe failure fraction (SFF)DOLE: 99.85%ROLE: 99.86%Diagnostic coverage (DC)DOLE: 98.91%ROLE: 98.79%Probability of dangerous failure per hour (PFH)DOLE: 2.4ROLE: 2.67Motor overload protectionfor ambient temperature 40°C ... 60°CSafety integrity level acc. to IEC 61508-1SIL 3Performance level Up to eMean time to failure (MTTF) acc. to IEC60050-191-12-07DOLE: 43 yearsROLE: 39.3 yearsMean time to dangerous failure, safe shutdownDOLE: 518 yearsROLE: 517 yearsFailure in timeSafe, detectabledDOLE: 517 FIT ROLE: 637 FITSafe, undetectableDOLE: 809 FIT ROLE: 870 FITDangerous, detectable239 FITDangerous, undetectable17 FITSafe failure fraction (SFF)DOLE: 98.92% ROLE: 99.03%Diagnostic coverageDOLE: 98.91wROLE: 98.79%—HF0.6, HF2.4, HF9 electronic compact startersTechnical data8 – 18SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
—HF0.6, HF2.4, HF9 electronic compact startersTechnical dataMain circuitTypeHFConnecting capacityRigid 1 x2 ... 2.5 mm²Flexible1 x2 ... 2.5 mm²Flexible with ferrule1 x2 ... 2.5 mm²Connecting capacity acc. to UL/CSARigid1 x24 ... 14 AWGFlexible1 x24 ... 14 AWGFlexible with ferrule1 x24 ... 14 AWGStripping length8 mmTightening torque0.5 ... 0.6 N·mTightening torque UL/CSA5 ... 7 in·lbTerminal typeScrew terminalsRecommended screw driverM3Control circuitTypeHFConnecting capacityRigid 1 x2 ... 2.5 mm²Flexible1 x2 ... 2.5 mm²Flexible with ferrule1 x2 ... 2.5 mm²Connecting capacity acc. to UL/CSARigid1 x24 ... 14 AWGFlexible1 x24 ... 14 AWGFlexible with ferrule1 x24 ... 14 AWGStripping length8 mmTightening torque0.5 ... 0.6 N·mTightening torque UL/CSA5 ... 7 in·lbTerminal typeScrew terminalsRecommended screw driverM3—Connecting characteristicsCONTACTORS AND MOTOR STARTERS8 – 198
—HF0.6, HF2.4, HF9 electronic compact startersTechnical diagramsDerating curvePlease consider the derating curves for group mounting with and without ≥22.5 mm distance and the overload protection for tripping class 10A. Side by sideWith 22.5 mm distanceHF9HF2.4HF0.6HF90123456789010203040506070Load current (A)Ambient temperature (°C)Derating curve HF range - electronic compact startersTripping characteristicsClass10 AClass10 A +20 %Class10 A -20 %0.101.0010.00100.001000.0010000.0012345678910Tripping time (s) Overcurrent factorTripping characteristics class 10A HF range - electronic compact starters8 – 20SAFETY PRODUCTS CATALOG ABB JOKAB SAFETY8
CONTACTORS AND MOTOR STARTERS8 – 218
NoteWe 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 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.
—ABB Electrification Sweden ABSE-721 32 VästeråsTel. +46 (0) 21-32 50 00abb.com/lowvoltageCopyright© 2021 ABB Electrification Sweden ABAll rights reserved2TLC010001C0202 revH November 2021
