ABB Safety Handbook

Machine Safety - Jokab Safety products

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ABB Safety Handbook
Machine Safety - Jokab Safety products
ABB Safety Handbook | 2TLC172001C0202 1/1
Introduction
Directives and Standards, PL, SISTEMA, SIL, Training

Pluto Safety PLC
Pluto, Gateway, Safe Encoder, IDFIX, program examples
Pluto AS-i
Pluto AS-i, Urax
Pluto Manager
Software for programming of Pluto

Vital and Tina safety systems
Vital, Tina, connection examples

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

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

Stop time measurement and machine diagnosis
Smart, Smart Manager

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

Control devices
JSHD4, Safeball, JSTD20

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

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

Fencing systems
Quick-Guard, Quick-Guard Express, SafeCAD, Roller doors
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ABB Safety Handbook | 2TLC172001C0202 1/3
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We develop innovative products and solutions for machine safety 1/4
Safety history 1/6
Directives and Standards 1/8
Working method as specified in ENISO13849-1 1/14
Case studies 1/18
What defines a safety function? 1/24
SISTEMA 1/26
Safety relay, Vital or Pluto? 1/27
Applying EN 62061 1/28
A mechanical switch does not give a safe function! 1/29
We train you on safety requirements 1/30
Introduction
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Mats Linger and Torgny Olsson founded Jokab Safety AB in Sweden in 1988,
together with Gunnar Widell
Standards and regulations
We help to develop standards
Directives and standards are very important to machinery and
safety component manufacturers. We therefore participate in
several international committees that develop standards, for
among other things industrial robots, safety distances and
control system safety features. This is experience that we
absorb so that the standards will present requirements that
benefit production efficiency allied to a high level of safety.
We are happy to share our knowledge of standards with our
customers.
Do you need to learn about the new safety requirements for robots?
If so, please contact us.
Experience
We have great experience of practical application of safe-
ty requirements andstandards from both authorities and
production. We represent Sweden instandardisation or-
ganisations for machine safety and we work daily with the
practical application of safety requirements in combination
with production requirements. You can use our experience for
training and advice.
We develop innovative products and solutions for
machine safety
We make it simple to build safety systems. Developing innovative products and solutions for machine safety has been
our business idea since the company Jokab Safety, now ABB AB, was founded in Sweden in 1988. Our vision is to
become Your partner for machine safety globally and locally.
Many industries around the world, have discovered how much easier it has become to build protection and safety
systems with our components and guidance.
Systems
We deliver everything from a safety solution to complete
safety systems for single machines or entire production lines.
We combine production demands with safety demands for
production-friendly solutions.
Products
We market a complete range of safety products, which makes
it easy to build safety systems. We develop these innovative
products continuously, in cooperation with our customers Our
extensive program of products, safety solutions and our long
experience in machine safety makes us a safe partner.
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Our products revolutionise the market
Our dynamic safety circuits and our comprehensive safety
PLC are probably the most revolutionary ideas that have
happened in the safety field in the control and supervision of
protection, in many respects:
They save on inputs: a dual safety circuit with one conduc-
tor instead of two. In addition, many protection devices
can be connected to the same input while maintaining the
highest level of safety.
Reliability is better. Our electronic sensors have much lon-
ger lives than mechanical switches
They are safer, since our dynamic safety sensors are che-
cked 200 times per second. Traditional switches on a door
can only be checked each time they are used, for example
once per hour or even once a month.
With the All-Master Safety PLC it is easy to connect and
disconnect machinery from a safety viewpoint. Common
emergencystop circuits and sensors can be created as
soon as the buses are interconnected between our safety
PLCs.
We are continuously designing safety systems for difficult
environments and also to create new safety solutions where
practical solutions are missing. New technical improvements
give new possibilities and therefore we continuously develope
new products.
We train both machine builders
and machine operators
Do you construct machinery?
We can provide the training you need to construct machinery
that meets the requirements. Example subjects:
Practical implementation of the requirementsin the new
Machinery Directive2006/42/EC, which is valid for machi-
nes that was delivered/put into service from the 29th of
december2009
Risk analysis in theory and practice
Control systems safety, standards EN ISO 13849-1 and EN
62061
Do you purchase and use machinery?
As a machinery user it is your responsibility to ensure that the
correct requirements are complied with regardless of whe-
ther your machinery is new or old, i.e. CE-labelled or not.
Unfortunately many have purchased CE-labelled machinery
that does not meet the requirements. This must not be used.
Having it brought into compliance by the supplier can take
a long time and be expensive in terms of loss of production,
etc. We can educate you on this and help you to set the right
demands when buying new or even second-hand machinery.
Pluto AS-i
Programmable
Not programmable
Safety relay
Double static inputs that
only test the switches
each time they are used.
Vital
Dynamic "doubled up"
safety signal that tests a
sensor, for example, 200
times per second.
Flexibility
Number of machines/different stops
Traditional safety PLC
Master-Slave with static inputs
Pluto All-Master
Safety PLC with static and dynamic
safety inputs.
Slaves
Master
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Developments of the 70's
Our background in safety started in the seventies when there was a signicant focus on the safety
of manually operated presses, the most dangerous machine in those days. The probability of
loosing a nger or hand while working with these machines was very high. New safety solutions for
both safety devices as well as for the control systems for presses were developed and introduced
on both old and new machines. We were directly involved in this work through the design of Two-
Hand devices, control systems for presses, making safety inspections for the Health and Safety
authorities and writing regulations for safety of these machines. This work provided an excellent
base for our knowledge in machinery safety.
The numbers of accidents involving presses decreased signicantly during these years however
there is still room for new ideas to enable safety equipment become more practical and ergonomic.
Developments of the 80's
During the eighties, industrial robots (Irbs) started to become commonplace in manufacturing
industry. This meant that workers were outside of the dangerous areas during production but had at
certain times to go inside the machine in order to e.g. adjust a product to the correct position, ins-
pect the production cycle, troubleshoot and to programme the Irb. New risks were introduced and
new safety methods required. It was for example hard to distinguish whether production machines
had stopped safely or simply waiting for the next signal, such as a sensor giving a start signal while
a product was being adjusted into the correct position. Mistakes in safety system design resulting
in serious accidents were made, such as the omission of safety devices to stop the Irb, unreliable
connection of safety devices and unreliable safety inputs on the Irb.
In the mid eighties the standards committee for safety in Industrial Robot Systems EN 775/ISO 775
was started. This was the rst international standard for machine safety. In order to give the correct
inputs to the standard, work around Irbs was closely studied in order to meet production integrated
safety requirements. The introduction of a production oriented safety stop function was made, using
for example, software to stop machines smoothly and then safety relays/contactors to disconnect
the power to the machines actuators after the machine had stopped. This technique allows easy
restart of production after a stop situation by the machine safeguards.
There were a lot of discussions as to whether one could have both safety and practical require-
ments in a standard, such as a safe stop function, which allowed an easy restart of the machine.
Three-position enabling devices were also introduced for safety during programming, testing and
trouble shooting of Irbs and other equipment. In the robot standard the three-position enabling
function was rst dened by only allowing for hazardous machinery functions in the mid switch posi-
tion. Releasing or pressing the three-position push button in panic leading to a stop signal.
Developments of the 90's
In Europe, during the nineties, the machinery directive was the start of a tremendous increase
in co-operation across borders to get European standards for safety for machinery and safety
devices. The experience from different European countries has led to a wide range of safety
standards and this has made work in safety much easier. With the integration of Europe it is
now only necessary for a safety company such as ourselves to get one approval for our com-
ponents for all of Europe instead of one per country.
Developments 2000
Internationally the work on safety has now been intensied within ISO. The objective is to have the
same structure of safety requirements and standards within ISO as within EN. ABB JokabSafety
is active both internationally and nationally in different standard working groups. The co-operation
between countries is leading to better safety solutions, making it much easier to create safe working
environments around the world.
We protected
people from
loosing fingers
or/and hands
in dangerous
machines.
Three-position
enabling devices
were also intro-
duced for safety
during program-
ming.
Safety history
European standards for
safety for machinery and
safety devices.
...of the 80's
...of the 70's
...of the 90's
...2000
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Vital 1 Vital 2 Vital 3
Stop time measu-
rement
3-position
devices
Quick-Guard aluminium
fencing system
Safeball - ergonomic
control device
Three-position
switch for robots
SafeCad for
Quick-Guard
Smallest safety relays
JSBT5 and JSBR4
Timer reset and first light beam RT series universal relays
Jokab Safetys first
steel fencing system
Jokab Safetys first
safety relay
Pluto Ma-
nager
+
AS-i
31 AS-i nodes 20 I/O 46 I/O 42 I/O
12 I/O
(A/D)
Pluto All-Master safety PLC
Sensors with inte-
grated AS-i safety
nodes
Safety nodes for
connection of sensors on
the AS-i cable
Vital with dynamic safety circuits
Non-contact sensor Eden, guard locks, Focus light beam, E-stops Inca and Smile, Smart for machine diagnosis and
three-position device with hand detection
Jokab Safetys developments
...of the 80's
...of the 90's
...2000
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EN ISO 12100
EN ISO 13857
EN 349
EN ISO 13849-1
EN ISO 13855
EN ISO 13850
EN 1088
EN 60204-1
EN ISO 10218-1
EN 692
EN 693
Harmonised standards
Harmonised standards give support on how to fulfil the requi-
rements of the Machinery Directive. The relationship between
the Machinery Directive and the harmonised standards is
illustrated by the diagram below.
Within ISO (The International Organization for Standardization)
work is also going on in order to harmonise the safety stan-
dards globally in parallel with the European standardisation
work.
ABB Jokab Safety takes an active part in the working groups
both for the ISO and EN standards.
Directives and standards are of great importance for manufacturers of machines and safety components. EU Directives
giving requirements for the minimum level of health and safety are mandatory for manufacturers to fulfil. In every
member country the Directives are implemented in each countries legislation.
Machines which have been put on the market since december 29, 2009, must comply with the new Machinery Directive
2006/42/EC. Before that, the old Machinery Directive 98/37/EC was valid.
Giving basic concepts, principles for design, and general
aspects that can be applied to all machinery
B1: Standards on particular safety aspects (e.g. safety distan-
ces, surface temperature, noise)
B2: Standards on safeguards,e.g. two-hand controls, interlo-
cking devices, pressure sensitive devices, guards
Dealing with detailed safety requirements for a particular
machine or group of machines
Examples of standards
2006/42/EC
The Machinery
Directive
Directives and Standards
A-standard
B1-standard
B2-standard
C-standard
The objectives of the Machinery Directive, 2006/42/EC, are to
maintain, increase and equalise the safety level of machines
within the members of the European Community. Based on
this, the free movement of machines/products between the
countries in this market can be achieved. The Machinery Di-
rective is developed according to The New Approach 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 fulfil the basic
safety requirements in the Machinery Directive.
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The Machinery Directive; for machines and safety
components
From 2006/42/EC
1 This Directive applies to the following products:
a) machinery;
b) interchangeable equipment;
c) safety components;
d) lifting accessories;
e) chains, ropes and webbing;
f) removable mechanical transmission devices;
g) partly completed machinery.
The Machinery Directive gives the following definition:
a) machinery means:
an assembly, tted with or intended to be tted with a drive
system other than directly applied human or animal effort,
consisting of linked parts or components, at least one of
which moves, and which are joined together for a specic
application,
an assembly referred to in the rst indent, missing only the
components to connect it on site or to sources of energy
and motion,
an assembly referred to in the rst and second indents,
ready to be installed and able to function as it stands only if
mounted on a means of transport, or installed in a building
or a structure,
assemblies of machinery referred to in the rst, second
and third indents or partly completed machinery referred
to in point (g) which, in order to achieve the same end, are
arranged and controlled so that they function as an integral
whole,
an assembly of linked parts or components, at least one of
which moves and which are joined together, intended for
lifting loads and whose only power source is directly applied
human effort;
CE-marking and Declaration of conformity
Machines manufactured or put on the market fro december29,
2009, shall be CE-marked and full the requirements according
to the European Machinery Directive 2006/42/EC. This is also
valid for old machines (manufactured before 1 January 1995) if
they are manufactured in a country outside the EEA and impor-
ted to be used in a country in the EEA.
For machines manufactured and/or released to the market
between january 1, 1995, and december 28, 2009, the old
Machinery Directive (98/37/EC) is valid.
NOTE! The point in time when the Machinery Directive was
implemented in each Member Country varies. Machines have
to be accompanied by a Declaration of Conformity (according
to 2006/42/EC, Annex II 1.A) that states which directive and
standards the machine fulls. It also shows if the product has
gone through EC Type Examination.
Safety components have to be accompanied with a Declaration
of Conformit.
Requirements for the use of machinery
For 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 fulfil. For the use
of machinery there is a Directive, 89/655/EEC (with amend-
ment 96/63/EC and 2001/45/EC).
About CE-marked machinery the Directive gives the following
requirement
From 89/655/EEC (with amendment 96/63/EC and
2001/45/EC)
1. Without prejudice to Article 3, the employer must ob-
tain and/or use:
(a) work equipment which, if provided to workers in the
undertaking and/or establishment for the first time after
31 December 1992, complies with:
(i) the provisions of any relevant Community directive
which is applicable;
(ii) the minimum requirements laid down in Annex I,
to the extent that no other Community directive is
applicable or is so only partially;
This means that when repair/changes are made on the
machine it shall still fulfil the requirements of the Machinery
Directive. This doesnt have to mean that a new CE-marking is
required. (Can be required if the changes are extensive)
NOTE! This means that the buyer of a machine also has to
make sure that a new machine fulfills the requirements in the
directives. If the machine does not fulfill the requirements the
buyer is not allowed to use it.
Old machines
For machines delivered or manufactured in the EEA before 1
January 1995 the following is valid.
(b) work equipment which, if already provided to workers
in the undertaking and/or establishment by 31 December
1992, complies with the minimum requirements laid down
in Annex I no later than four years after that date.
(c) without prejudice to point (a) (i), and notwithstanding
point (a) (ii) and point (b), specific work equipment subject
to the requirements of point 3 of Annex I, which, if already
provided to workers in the undertaking and/or establish-
ment by 5 December 1998, complies with the minimum
requirements laid down in Annex I, no later than four years
after that date.
Annex l contains minimum requirements for health and safety.
There can also be additional national specific requirements for
certain machines. NB The point in time when the Machinery
Directive was implemented in each Member Country varies.
Therefore it is necessary to check with the national authorities
in ones own country, to find out what is considered as old and
respectively new machines.
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"Old" machines "New" machines
1. Machine that is put
on the market or put
into service after 1/1
1995 in the EEA.
Council Directive 89/655/EEC
(with amendment 96/63/EC
and 2001/45/EC)
concerning the minimum safety
and health requirements for
the use of work equipment by
workers at work.
Possible national legislation
on specific machines
Low Voltage Directive
2006/95/EC
Machine that is put on the
market or put into service
before 1995 in the EEA.
2. All machines that
are imported to the
EEA irrespective of
date of origin.
CE-marking +
Declaration of
conformity
The Machinery Directive
98/37/EC
(Jan 1, 1995 - Dec 28, 2009)
2006/42/EC
(from December 29, 2009)
EMC-directive
2004/108/EC
Council Directive 89/655/EEC
(with amendment 96/63/EC
and 2001/45/EC) concerning
the minimum safety and health
requirements for the use of work
equipment by workers at work.
N.B! Not annex 1, instead use
applicable directives.
A well thought-out risk assessment supports manufacturers/
users of machines to develop production friendly safety solu-
tions. One result of this is that the safety components will not
be a hindrance. This minimizes the risk of the safety system
being defeated.
New machines
The following requirement is given by the Machinery Directive
The manufacturer of machinery or his authorised repre-
sentative must ensure that a risk assessment is carried out
in order to determine the health and safety requirements
which apply to the machinery. The machinery must then be
designed and constructed taking into account the results
of the risk assessment.
The standard ENISO12100 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
Risk assessment must be carried out on all machines that are
in use; CE-marked as well as not CE-marked.
To fullfil the requirements from Directive 89/655/EEC
(concerning the minimum safety and health requirements
for the use of work equipment by workers at work) risk
assessment have to be made.
Documentation of risk assessment
The risk assessment shall be documented. In the assess-
ment the actual risks shall be analysed as well as the level of
seriousness.
Risk assessment an important tool both when constructing
a new machine and when assessing risks on older machines
Possibly
more
directives
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2
3
4
5
Example on prioritizing according to the 5-step-method
Priority Example of hazard and safety measure taken
Protection or warning?
How is it possible to choose safety measures that are production friendly and in
every way well balanced? The Machinery Directive gives an order of priority for the
choice of appropriate methods to remove the risks. Here it is further developed in a
five step method.
Prioritize safety measures according to the five step method
1. Eliminate or reduce risks by design and construction
2. Move the work tasks outside the risk area
3. Use guards/safety devices
4. Develop safe working routines/information/education
5. Use warnings as pictograms, light, sound etc.
The further from middle of the circle, the greater the responsibility for the safety is
put onto the user of the machine. If full protection is not effectively achieved in one
step, one has to go to the next step and find complementary measures.
What is possible is dependant on the need for accessibility, the seriousness of the
risk, appropiate safety measures etc.
The possibilities will increase to achieve a well thought-through safety system if each risk is handled
according to the described prioritizing.
Combine the five step method with production friendly thinking.
This can give you e.g.
fast and easy restart of machines after a stop from a safety device
enough space to safely program a robot
places outside the risk area to observe the production
electrically interlocked doors, instead of guards attached with screws, to be able to take the
necessary measures for removing production disturbances
a safety system that is practical for all types of work tasks, even when removing production
disturbances
1. Make machine safe by
design and construction
Hazard: Cuts and wounds from sharp edges and corners on machinery
Safety measure: Round off sharp edges and corners.
2. Move the work tasks
outside the risk area
Hazard: Crushing of fingers from machine movements during inspection of
the production inside the risk area
Safety measure: Installation of a camera.
3. Use guard/safety
devices
Hazard: Crushing injuries because of unintended start during loading of
work pieces in a mechanical press
Safety measure: Install a light curtain to detect operator and provide safe stop of the
machinery.
4. Safe working routines/
information
Hazard: 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. Warnings Hazard: Burns because of hot surfaces in reach
Safety measure: Warning signs
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Examples of regularly used EN/ISO standards
EN ISO 12100
(replaces EN
ISO 12100-1/-
2 and EN ISO
14121-1)
Safety of machinery - General principles
for design - Risk assessment and risk
reduction
Part 1: This standard defines basic terminology and methodology used in achieving safety
of machinery. The provisions stated in this standard are intended for the designer.
Part 2: This standard defines technical principles to help designers in achieving safety in
the design of machinery.
EN ISO 13857
Safety of machinery - Safety distances to
prevent hazard zones being reached by
upper and lower limbs
This standard establishes values for safety distances to prevent danger zones being
reached by the upper limbs. The distances apply when adequate safety can be achieved
by distances alone.
EN 349
(ISO 13854)
Safety of machinery Minimum gaps to
avoid crushing of parts of the human body
The 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 13850
Safety of machinery Emergency stop
Principles for design
This standard specifies design principles for emergency stop equipment for machinery. No
account is taken of the nature of the energy source.
EN 574
Safety of machinery Two-hand control
devices Functional aspects Principles
for design
This 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 characteristics for three
types.
EN 953
Safety of machinery Guards General
requirements for the design and construc-
tion of fixed and movable guards
This standard specifies general requirements for the design and construction of guards
provided primarily to protect persons from mechanical hazards.
EN ISO 13849-1
(replaces EN
954-1)
Safety of machinery Safety related parts
of control systems
Part 1: General principles for design
This standard provides safety requirements and guidance on the principles for the design
(see 3.11 of EN 292-1:1991) of safety-related parts of control systems. For these parts it
specifies categories and describes the characteristics of their safety functions. This inclu-
des 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 13849-2
Safety of machinery. Safety-related parts of
control systems. Validation
This standard specifies the procedures and conditions to be followed for the validation by
analysis and testing of:
the safety functions provided, and
the category achieved of the safety-related parts of the control system in compliance with
EN 954-1 (ISO 13849-1), using the design rationale provided by the designer.
EN 62061
Safety 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 13855
(replaces EN
999)
Safety of machinery - Positioning of
safeguards with respect to the approach
speeds of parts of the human body
This standard provides parameters based on values for hand/arm and approach speeds
and the methodology to determine the minimum distances from specific sensing or actua-
ting devices of protective equipment to a danger zone.
EN 1088
and EN 1088/
A1
Safety of machinery. Interlocking devices
associated with guards. Principles for
design and selection
This standard specifies principles for the design and selection - independent of the nature
of the energy source - of interlocking devices associated with guards. It also provides
requirements specifically intended for electrical interlocking devices. The standard covers
the parts of guards which actuate interlocking devices.
EN 60204-1
Safety of machinery. Electrical equipment
of machines. General requirements
This part of IEC 60204 applies to the application of electrical and electronic equipment and
systems to machines not portable by hand while working, including a group of machines
working together in a co-ordinated manner but excluding higher level systems aspects (i.e.
communications between systems).
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New standards for safety in control systems
Building a protection system that works in practice and provides sufficient safety requires expertise in several
areas. The design of the safety functions in the protection system in order to ensure they provide sufficient
reliability is a key ingredient. As help for this there is, for example, the EN ISO 13849-1 standard. The purpose of
this text is to provide an introduction to the standard and its application in conjunction with our products.
Introducing the new standard
The generation change for standards on safety in control sys-
tems introduces new concepts and calculations for machine
builders and machine users. The EN954-1 standard has been
phased out and is replaced by ENISO13849-1 (PL, Perfor-
mans Level) and EN62061 (SIL, Safety Inegrity 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.
Experience
EN ISO 13849-1 uses categories from EN 954-1 for defining
the system structure, and therefore the step to the new calcu-
lations is not so great if you have previous experience of the
categories. EN 62061 defines the structures slightly differently.
Customer requirements
If the customer comes from an industry that is accustomed to
using SIL (e.g. the process industry), requirements can also
include safety functions for machine safety being SIL rated.
We notice that most of our customers prefer PL as it is tech-
nology-neutral and that they can use their previous knowledge
in the categories. In this document we show some examples
of how to build safety solutions in accordance with EN ISO
13849-1 and calculate the reliability of the safety functions to
be used for a particular machine. The examples in this docu-
ment 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 level the PL system achieves you need
to know the following:
The systems structure (categories B, 1-4)
The Mean Time To dangerous Failure of the component
(MTTF
d
)
The systems Diagnostic Coverage (DC)
You will also need to:
protect the system against a failure that knocks out both
channels (CCF)
protect the system from systematic errors built into the
design
follow certain rules to ensure software can be developed
and validated in the right way
The five PL-levels (a-e) correspond to certain ranges of PFH
D
-
values (probability of dangerous failure per hour). These indi-
cate how likely it is that a dangerous failure could occur over
a period of one hour. In the calculation, it is beneficial to use
PFH
D
-values directly as the PL is a simplification that does not
provide equally accurate results.
What is the easiest way of complying with the standard?
1. Use pre-calculated components.
As far as it is possible, use the components with pre-calcu-
lated PL and PFH
D
-values. You then minimise the number of
calculations to be performed. All ABB JokabSafety products
have pre-calculated PFH
D
-values.
2. Use the calculation tool.
With the freeware application SISTEMA (see page 16) you
avoid making calculations by hand. You also get help to
structure your safety solutions and provide the necessary
documentation.
3. Use Pluto or Vital
Use the Pluto safety PLC or Vital safety controller. Not only
is it easier to make calculations, but above all it is easier to
ensure a higher level of safety.
1/14 2TLC172001C0202 | ABB Safety Handbook
1
Risk assessment and risk minimisation
According to the Machinery Directive, the machine builder
(anyone who builds or modifies a machine) is required to per-
form a risk assessment for the machine design and also inclu-
de an assessment of all the work operations that need to be
performed. The EN ISO 12100 standard (combination of EN
ISO 14121-1 and EN ISO 12100-1/-2) stipulates the require-
ments for the risk assessment of a machine. It is this that EN
ISO 13849-1 is based on, and a completed risk assessment
is a prerequisite for being able to work with the standard.
Step 1 Risk assessment
A risk assessment begins with determining the scope of the
machine. This includes the space that the machine and its
operators need for all of its intended applications, and all ope-
rational stages throughout the machines life cycle.
All risk sources must then be identified for all work operations
throughout the machines life cycle.
A risk estimation is made for each risk source, i.e. indication
of the degree of risk. According to EN ISO 13849-1 the risk
is estimated using three factors: injury severity (S, severity),
frequency of exposure to the risk (F, frequency) and the possi-
bility you have of avoiding or limiting the injury (P, possibility).
For each factor two options are given. Where the boundary
between the two options lies is not specified in the standard,
but the following are common interpretations:
S1 bruises, abrasions, puncture wounds and minor
crushing injuries
S2 skeletal injuries, amputations and death
F1 less frequently than every two weeks
F2 more often than every two weeks
P1 slow machine movements, plenty of space, low
power
P2 quick machine movements, crowded, high power
Is the measure
dependent on the
control system?
Has the risk
been adequately
reduced?
Reduce the risk
(redesign, use protection, information)
Start
End
Are new risks
generated?
Yes
No
Yes
Yes
No
No
R
i
s
k

a
s
s
e
s
s
m
e
n
t
R
i
s
k

a
n
a
l
y
s
i
s
By setting S, F and P for the risk, you will get the PL
r
Perfor-
mance Level (required) that is necessary for the risk source.
Finally, the risk assessment includes a risk evaluation where
you determine if the risk needs to be reduced or if sufficient
safety is ensured.
Step 1
Step 2
Determine the system's scope
(space, usage, time, environment)
Identify risk sources
(all work operations during the life cycle)
Estimate the risk
(determine PL
r
with S, F and P)
Evaluate the risk
(is action required?)
Working method as specified in ENISO13849-1
ABB Safety Handbook | 2TLC172001C0202 1/15
1
a
b
c
d
e
PL
r
F
1
F
2
F
1
F
2
S
1
S
2
P
1
P
2
P
1
P
2
P
1
P
2
P
1
P
2
Risk estimation
To calculate the performance level required (PL
r
).
S Severity of injury
S1 slight (normally reversible injury)
S2 serious (normally irreversible injury or death)
F Frequency and/or exposure to hazard
F1 seldom to less often and/or exposure time is short
F2 frequent to continuous and/or exposure time is long
P Possibility of avoiding hazard or limiting harm
P1 possible under specific conditions
P2 scarcely possible
Step 3 - Design and calculate the safety functions
To 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 PL
r
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 PL
r
and then validate the system as per
the validation plan. The validation checks that the specifica-
tion 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 risk
If you determine that risk reduction is required, you must com-
ply with the priority in the Machinery Directive in the selection
of measures:
1. Avoid the risk already at the design stage.
(For example, reduce power, avoid interference in the danger
zone.)
2. Use protection and/or safety devices.
(For example, fences, light grids or control devices.)
3. Provide information about how the machine can be used-
safely. (For example, 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 ENISO13849-1.
No
No
Yes
A
r
e

a
l
l

s
a
f
e
t
y

f
u
n
c
t
i
o
n
s

e
x
e
c
u
t
e
d
?
Yes
Step 3
low risk
high risk
Verify that
PL PL
r
Identify the safety functions
Determine PL
r
Design and implement the solution
for the safety function
Calculate PL
Validate
Have other require ments
been met?
1/16 2TLC172001C0202 | ABB Safety Handbook
1
PL calculation in Step 3
When you calculate the PL for a safety function, it is easiest to
split it into separate, well defined blocks (also called subsys-
tems). It is often logical to make the breakdown according to
input, logic and output (e.g. switch - safety relay - contac-
tors), but there may be more than three blocks depending
on the connection and the number of components used (an
expansion relay could for example create an additional logic
block) .
For each block, you calculate a PL or PFH
D
-value. It is easiest
if you obtain these values from the component manufacturer,
so you do not have to calculate yourself. The manufacturer of
switches, sensors and logic devices often have PL and PFH
D
-
values for their components, but for output devices (such as
contactors and valves) you do not usually specify a value as it
depends on how often the component will be used. You can
then either calculate yourself according to EN ISO 13849-1 or
use the pre-calculated example solutions such as those from
ABB JokabSafety.
To calculate PL or PFH
D
for a block, you need to know its
category, DC and MTTF
d
. In addition, you need to protect
yourself against systematic errors and ensure that an error
does not knock out both channels, and generate and validate
any software used correctly. The following text gives a brief
explanation of what to do.
Safety function (SF)
+ + PFH
D,

Input
Input
PL/PFH
D
PFH
D, Logic
Logic
PL/PFH
D
PFH
D, Output

Output
PL/PFH
D
PFH
D,

Total
=
The relationship between categories, the DC
avg
, MTTF
d
for each channel and PL. The table also shows the PFH
D
-range that corresponds to each PL.
PFH
D
PL
10
-4
a
10
-5
b
3x10
-6
c
10
-6
d
10
-7
e
10
-8
DC
none
DC
none
DC
low
DC
medium
DC
low
DC
medium
DC
high
Cat. B Cat. 1 Cat. 2 Cat. 3 Cat. 4
MTTF
d
low
MTTF
d
medium
MTTF
d
high
ABB Safety Handbook | 2TLC172001C0202 1/17
1
Category
The structure for the component(s) in the block is assessed to
determine the category (B, 1-4) it corresponds to. For catego-
ry 4, for example, individual failures do not result in any loss of
the safety function.
In order to achieve category 4 with contactors, you need to
have two channels - i.e., two contactors - that can cut the
power to the machine individually. The contactors need to be
monitored by connecting opening contacts to a test input on,
for example a safety relay. For monitoring of this type to work,
the contactors need to have contacts with positive opening
operation.
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 (MTTF
d
)
The MTTF
d
-value should primarily come from the manufactu-
rer. If the manufacturer cannot provide values, they are given
from tables in EN ISO 13849-1 or you have to calculate
MTTF
d
using the B
10d
-value, (average number of cycles until
10% of the components have a dangerous failure). To calcu-
late the MTTF
d
, 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:
d
op
h
op
3600
t
cycle
n
op
=
B
10d
0,1 n
op
MTTF
d
=
where
n
op
= Number of cycles per year
d
op
= Operation days per year
h
op
= Operation hours per day
t
cycle
= Cycle time (seconds)
Example: d
op
= 365 days, hop= 24 hours and t
cycle
= 1,800 se-
conds (2 times/hour) which gives n
op
= 17,520 cycles. With a
B
10d
=2106 this gives a MTTF
d
=1,141 year which corresponds
to MTTF
d
=high.
Note that when you calculate MTTF
d
you have to calculate
according to the total number of cycles the component will be
working. A typical example of this is the contactors that 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 MTTF
d
is calculated from a B
10d
-value, also consider
that if the MTTF
d
-value is less than 200years, the component
needs to be replaced after 10% of the MTTF
d
-value (due to
the T
10d
-value). That is, a component with MTTF
d
= 160 years
needs to be replaced after 16 years in order for the conditions
for achieving PL to continue to be valid. This is because EN
ISO 13849-1 is based on a mission time of 20 years.
Common Cause Failure (CCF)
In Appendix F of EN ISO 13849-1 there is a table of actions to
be taken to protect against CCF, to ensure a failure does not
knock out both channels.
Systematic errors
Appendix G of EN ISO 13849-1 describes a range of actions
that need to be taken to protect against incorporating faults
into your design.
PL for safety functions
PL is given in the table on the facing page. If you want to use
an exact PFH
D
-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
ISO13849-1. This gives a rough estimate of the PL. If you
have calculated PFH
D
for each block instead, you can get a
total of PFH
D
for the safety function by adding together all the
values of the blocks. The safety functions total PFH
D
corres-
ponds to a particular PL in Table 3 of EN ISO 13849-1.
Requirements for safety-related software
If you use a safety PLC for implementing safety functions,
this places demands on how the software is developed
and validated. To avoid error conditions, the software
should be readable, understandable and be possible to
test and maintain.
A software specification must be prepared to ensure that
you can check the functionality of the program. It is also
important to divide the program into modules that can
be tested individually. Paragraph 4.6 and AppendixJ of
EN ISO 13849-1 specify requirements for safety related
software.
The following are examples of requirements for software
from EN ISO 13849-1:
A development life cycle must be produced with valida-
tion 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.
1/18 2TLC172001C0202 | ABB Safety Handbook
1
a
b
c
d
e
F
1
F
2
F
1
F
2
S
1
S
2
P
1
P
2
P
1
P
2
P
1
P
2
P
1
P
2
PL
r
Step 1 Risk assessment
Food to be packaged is loaded into the cell manually through
the rear door. A batch is prepared for the packing conveyor in
the infeed hopper. The cell is reset and restarted. The pa-
ckaging machine with conveyor belt only operates hen both
doors are closed and when the protection system has been
reset.
In the risk assessment it was established that the machine is
to be operated in three shifts (8 hours per shift) 365 days a
year. It is assumed that operational disturbances were resol-
ved in less than one minute in the danger zone. This can be
carried out two times per hour (F2). Unexpected start-ups are
not deemed to cause serious injury but rather minor healable
injuries (S1). The operator is deemed not to have the possibili-
ty of avoiding injury as the machine moves quickly (P2).
The number of cycles for the safety function = 365 days/year
(38) hours/day 2 cycles/hour = 17,520 cycles/year
The assessment for the safety function required for access to
the machine is PL
r
= c (S1, F2, P2). In addition to this safety
function, an emergency stop function is needed. This is also
assessed as PL
r
=c.
CASE STUDY SAFETY RELAY RT9
Assessment of the PL
r
necessary for the safety function with interlo-
cked door for this example.
NOTE! The assessment needs to be made for each safety
function.
low risk
high risk
Protection layout for a packaging machine with low risks.
Key switch MKey8
Monitors that the door is
closed.
Safety relay RT9
Monitors safety components. Emergency stop button
To stop the machine in
case of danger.
Step 2 Reduce the risk
As protection, an interlocked door is selected with the key
switch MKey8. Downtime is short enough for the dangerous
movement to have stopped before the operator can access
it. The emergency stop is placed within easy reach, on both
sides of the cell near the locked doors.
ABB Safety Handbook | 2TLC172001C0202 1/19
1
*
PFH
D, MKey8
+ PFH
D, RT9
+ PFH
D, Q1/Q2
= 1.1410
-6
+ 9.5510
-9
+ 2.4710
-8
= 1.1810
-6
PLc
PFH
D
+ PFH
D, RT9
+ PFH
D, Q1/Q2
= 1.3410
-6
+ 9.5510
-9
+ 2.4710
-8
= 1.3710
-6
PLc
The reason for not achieving more than PL c with this solution is that you use one key switch per door. PL d could be
achieved by using two key switches per door, but further action on the monitoring of each switch will be required as well.
Note: If the risk assessment had shown that a serious injury, S2, could occur, the outcome would have been PL
r
= e. This
would have meant that the above solution was inadequate. For the emergency stop function, PL d can be achieved provi-
ded that certain failure exclusions can be made. These safety functions can be downloaded from our website as a SISTE-
MA project, www.abb.com/jokabsafety.
Step 3 - Calculate the safety functions
The starting block that is composed of double unmonitored
contactors has been calculated at 2.4710
-8
. The safety func-
tions 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 K1
How safe is a mechanical switch?
A mechanical switch must be installed and used according
to its specifications in order to be reliable.
Life expectancy only applies if correctly installed.
The locking head must be fixed so that it will not loosen.
The environment around the lock housing must be kept
clean.
Two mechanical switches on a door can also fail for the
same reason.
K1
RT9
Q1
Contactor
Q2
Contactor
B1
Key switch
B2
Key switch
S2
Emerg. Stop
S1
Emerg. Stop
PL
r
=c
Safety function 1
B1
Key switch MKey8
PLc
Input
K1
Safety relay RT9
PLe
Logic
Q1/Q2
Redundant monitored contactors
PLe
Output
PL
r
=c
S1
E-Stop button
PLc
Input
K1
Safety relay RT9
PLe
Logic
Q1/Q2
Redundant monitored contactors
PLe
Output
Safety function 3
Result
Result
PLc
PLc
1/20 2TLC172001C0202 | ABB Safety Handbook
1
a
b
c
d
e
F
1
F
2
F
1
F
2
S
1
S
2
P
1
P
2
P
1
P
2
P
1
P
2
P
1
P
2
PL
r
Step 1 Risk assessment
The workpieces are fed into the equipment and transported
out again following an error-free test. With the help of a robot
the workpieces are added to a machine for testing. Unautho-
rised workpieces are positioned by the robot for post-machi-
ning in a manual discharge station. The work that needs to be
done in the robot cell is to correct operational disturbances
for the test equipment and the conveyor belt (about once an
hour), post-machining and unloading from the manual station
(about once an hour), program adjustments (once/week) and
cleaning (once/week) (F2). Unexpected start-ups of the robot
are expected to cause serious injury (S2). The operator is
deemed not to have the possibility of avoiding injury as the
robot moves quickly (P2). The assessment for the safety func-
tion required for access to the machine is PL
r
=e (S2, F2, P2).
The coming ISO 10218-2 standard for robot systems/cells
specifies the requirement PL d for the safety functions to be
used (if the risk analysis does not show a different PL). For the
robot safety stop and emergency stop inputs, the requirement
is at least PL d (according to the ENISO10218-1 standard).
However, in this case risk assessment is PL
r
= e.
Step 2 Reduce the risk
As protection, an interlocked door is selected with the Eden
non-contact sensor. To protect against entering the cell the
wrong way, transport of materials in and out is protected and
provided with muting to distinguish between material and
people. The emergency stop is also a safety function that is
required. The power source to all hazardous machinery func-
tions has to be cut using all safety functions.
The solution with Vital makes it possible to implement a robot
application with only one safety controller, which does not
need to be configured or programmed. Vital makes it possible
to connect up to 30 safety functions in a single loop, with PL e
in accordance with EN ISO 13849-1.
Protection layout for a robot cell with high risks.
Assessment of the PL
r
required for the safety function with interlocked
door.
NOTE! The assessment needs to be made for each safety
function.
low risk
high risk
Emergency stop
button, Smile Tina
To stop the machine
in case of danger.
Emergency stop
button INCA Tina
To stop the machine in
case of danger.
Light curtain, Focus (with
integrated muting function)
Prevents passage.
Safety controller, Vital
Monitors safety
components in series.
Non-contact sensor, Eden
Monitors that the door is
closed.
CASE STUDY SAFETY CONTROLLER VITAL
ABB Safety Handbook | 2TLC172001C0202 1/21
1
Step 3 - Calculate the safety functions
The PFH
D
-value of the robots safety stop input is 5.7910
-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 that is represented in the robot cell.
B5
Eden
K1
Vital
S2
Smile Tina
S1
Inca Tina
B4
Focus with Tina 10B
with muting unit MF-T
B1
Focus with Tina 10A
B3
Focus with Tina 10A
with muting unit MF-T
B2
Focus with Tina 10A
PFH
D, Eden
+ PFH
D, Vital
+ PFH
D, Robot
= 4.510
-9
+ 2.7410
-8
+ 5.7910
-8
= 8.9810
-8
PL e
PL
r
=e
B5
Non contact safety
sensor Eden PLe
Input
K1
Safety controller
Vital PLe
Logic
Q1
Machine stop input for
robot, redundant PLe
Output Result Safety function 1
PLe
PFH
D, Smile Tina
+ PFH
D, Vital
+ PFH
D, Robot
= 4.6610
-9
+ 2.7410
-8
+ 5.7910
-8
= 9.010
-8
PL e
PL
r
=e
Safety function 2
S2
E-Stop button
Smile Tina PLe
Input
K1
Safety controller
Vital PLe
Logic
Q1
Machine stop input for
robot, edundant PLe
Output Result
PLe
PFH
D, Focus
+ PFH
D, Tina10
+ PFH
D, Vital
+ PFH
D, Robot
= 2.510
-9
+ 4.510
-9
+ 2.7410
-8
+ 5.7910
-8
= 9.2310
-8
PL e
PL
r
=e
Safety function 3
B4
Light curtain Focus
with muting unit MF-T
PLe
Input
K1
Safety controller
Vital PLe
Logic
Q1
Machine stop input
for robot, redundant
PLe
Output Result
Tina 10B
PLe
PLe
Safety function 3
When calculating the safety function the PFH
D
- values for
both the light curtain and the muting unit shall be inclu-
ded in the same function. See safety function 3 below.
1/22 2TLC172001C0202 | ABB Safety Handbook
1
a
b
c
d
e
F
1
F
2
F
1
F
2
S
1
S
2
P
1
P
2
P
1
P
2
P
1
P
2
P
1
P
2
PL
r
a
b
c
d
e
F
1
F
2
F
1
F
2
S
1
S
2
P
1
P
2
P
1
P
2
P
1
P
2
P
1
P
2
PL
r
Protection layout for a machining tool and
industrial robot with high risks.
Safety system using Pluto
Step 1 Risk assessment
The workpieces to be machined are fed into the cell through a
conveyor belt and positioned by the operator in the pneuma-
tic machining tool in station 1. The operator starts station 1
manually. The pneumatic machining tool performs work on the
workpiece in station 1. The operator then places the machi-
ned workpiece on the conveyor belt for transfer to station 2.
The robot then takes the workpiece that is placed in the hy-
draulic press. The workpiece leaves the cell by transport out
onto the conveyor. The work that needs to be done in station
2 is, for example, to address operational disturbances in the
press and the robot (a few times a week, F2).
Unexpected start-ups of the robot are expected to cause
serious injury (S2). The operator is deemed not to have the
possibility of avoiding injury as the robot moves quickly (P2).
The assessment for the safety function required for access to
station 2 is PL
r
=e (S2, F2, P2). This assessment would still be
the same in respect of the press. For the safety function for
the risks associated with the conveyor belt, the assessment
S1, F2, P1 is made giving PL
r
= b.
Step 2 Reduce the risk
As protection, interlocked doors are selected with the Eden
non-contact sensor. Station1 with the pneumatic machining
tool is operated by a two-hand device. When the two-hand
device is released, the dangerous movement will be stop-
ped safely. Station 2 can be in automatic mode, when a light
curtain (Focus) and a non-contact sensor at door 4 (Eden)
protects the entry. If the door is opened or the light curtain is
breached, station 2 stops in a safe manner. By opening doors
2 and 3 (also monitored by Eden) the conveyor belt and the
pneumatic machining tool will stop safely. Manual reset must
always be done after actuation by any safety device.
When the protection system requires a number of safety
devices and that multiple machines must be checked, safety
PLC Pluto is the most effective solution. If the protection
system also has to work by zones and in different modes of
operation, this is another compelling reason to use Pluto.
With Pluto, PL e can be achieved regardless of the number of
connected safety devices.
PL
r
= e for the robot and hydraulic press and PL
r
=b for the conveyor belt.
Safety PLC Pluto
Monitors safety
components.
Station2
Station1
low
risk
low
risk
high risk high risk
Robot Conveyor belt
Door 4
Door 3
Door 2
Door 1
CASE STUDY SAFETY-PLC PLUTO
ABB Safety Handbook | 2TLC172001C0202 1/23
1
PFH
D, Eden
+ PFH
D, Pluto
+ PFH
D, Robot
= 4.510
-9
+ 210
-9
+ 5.7910
-8
= 6.4410
-8
PL e
PFH
D, Smile Tina
+ PFH
D, Pluto
+ PFH
D, Robot
= 4.6610
-9
+ 210
-9
+ 5.7910
-8
= 6.4610
-8
PL e
PFH
D,Focus
+ PFH
D, Pluto
+ PFH
D, Robot
= 2.510
-9
+ 210
-9
+ 5.7910
-8
= 6.2410
-8
PL e
Step 3 - Calculate the safety functions for the robot cell
The PFH
D
-value for the robots safety stop input is 5.7910
-8
(the value applies to ABB industrial robots with IRC5 control-
ler).
Only safety functions to help cut the power to the industrial
robot are shown below. This is only a subset of the safety
functions. When the power is to be cut to multiple machines
in a cell, the safety functions can be defined in different ways
depending on the risk analysis. The safety functions are repre-
sented 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 that appear in the robot cell.
B1B3
Non-contact sensor
Eden
B4B5
Non-contact sensor
Eden/Light curtain Focus
with Tina 10A
S1
Two-hand device,
Safeball
S2S4
Emergency stop,
Smile Tina
Q2
Hydraulic press
Q3
Pneumatic
machining tool
Q1
Robot
PL
r
=e
Safety function 1
B1
Non contact safety
sensor Eden
PLe
Input
K1
Safety-PLC Pluto
PLe
Logic
Q1
Machine stop input
for robot, redundant
PLe
Output
PLe
Result
PL
r
=e
S2
E-Stop button
Smile Tina
PLe
Input
Q1
Machine stop input
for robot, redundant
PLe
Output
PLe
Result Safety function 2
K1
Safety-PLC Pluto
PLe
Logic
PL
r
=e
B5
Light curtain Focus
PLe
Input
Q1
Machine stop input
for robot, redundant
PLe
Output
PLe
Result
K1
Safety-PLC Pluto
PLe
Logic
Tina 10A
PLe
Safety function 3
1/24 2TLC172001C0202 | ABB Safety Handbook
1
SF1
SF3
SF2
K1
Logic unit
S1
E-Stop button
F1
Light curtain
Q1
Machine
B1
Interlocked switch
S1
E-Stop button
Q3
Machine 3
B1
Interlocked switch
F1
Light curtain
Q1
Machine 1
Q2
Machine 2
K1
Logic unit
Multiple safety functions for a machine
Multiple safety devices are often used on a machine in order
to provide satisfactory and practical protection for the ope-
rators. In the following example, the machine is protected by
three safety devices connected to a logic device. The fol-
lowing figure illustrates this interconnection schematically.
Calculating that you have achieved the PL
r
that is required is not difficult, especially if you use pre-calculated safety
devices and logic units. But what parts should then be included in each safety function?
This must be resolved before you start calculating phase. To summarise in simple terms you can say that each safety
device gives rise to a safety function for each machine that is affected by the safety device in question. Three safety
devices that all cut the power to three machines in a cell is therefore equal to nine safety functions. In the section that
follows, we explain the background.
Three safety functions (SF) are defined for the machine and
are calculated as:
SF1: PFH
D, F1
+PFH
D, K1
+PFH
D, Q1
= PFH
D, SF1
SF2: PFH
D, B1
+PFH
D, K1
+PFH
D, Q1
= PFH
D, SF2
SF3: PFH
D, S1
+PFH
D, K1
+PFH
D, Q1
= PFH
D, SF3
More commonly, several machines in a single cell/zone are to
be protected by multiple safety devices. The following figure
illustrates the interconnection schematically for an example.
Each of the machines Q1 Q3 is shut down separately and
independently of K1.
If the operator enters the cell, he is exposed in this case to
the same type of risk from all three machines. The power to all
three machines must be cut when the operator enters the cell
through the door interlocked by B1.
Multiple safety functions for multiple machines in a cell
What defines a safety function?
ABB Safety Handbook | 2TLC172001C0202 1/25
1
Conclusions
Use the practical approach.
Use safety devices/logic units with high reliability (low PFH
D
) to make it easy to achieve the PL
r
required.
With Vital or Pluto, it is easier to achieve the PL
r
required.
Sources:
www.dguv.de/ifa/de/pub/grl/pdf/2009_249.pdf
www.bg-metall.de/praevention/fachausschuesse/
infoblatt/deutsch.html
(No 047, Date 05/2010)
Theoretical approach for multiple machines
The theoretical approach to calculate the safety function is as
follows:
Q3
Machine 3
B1
Interlocked switch
Q1
Machine 1
Q2
Machine 2
K1
Logic unit
For the full safety function to be performed you require all
the components to be working. Note that if B1 or K1 has a
dangerous malfunction, the entire safety function is disabled.
However, if for example machine Q1 has a dangerous mal-
function, and is not shut down, machines Q2 and Q3 will still
be shut down. One disadvantage in considering the safety
function in this way is that you may have trouble achieving the
PL
r
required. But if you achieve the PL
r
required, you can use
the theoretical approach.
Practical approach for multiple machines
A more practical approach is to divide the safety func-
tion into three parts, one for each of the three machines.
B1
Interlocked switch
Q2
Machine 2
K1
Logic unit
B1
Interlocked switch
Q3
Machine 3
K1
Logic unit
B1
Interlocked switch
Q1
Machine 1
K1
Logic unit
This is an approach that can provide a more accurate way of
looking at the safety functions, especially where a different
PL
r
is required for the safety functions above. If machine Q1
is a robot and machine Q2 is a conveyor which is designed
to have negligible risks, the different PL
r
required to pro-
tect 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
fr Arbeitsschutz der Deutschen Gesetzlichen Unfallversi-
cherung). 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:
PFH
D, B1
+PFH
D, K1
+PFH
D, Q1
= 4.510
-9
+210
-9
+5.7910
-8
= 6.4410
-8
PL e
Hydraulic press:
PFH
D, B1
+PFH
D, K1
+PFH
D, Q2
= 4.510
-9
+210
-9
+810
-8
= 8.6510
-8
PL e
Pneumatic machining tool:
PFH
D, B1
+PFH
D, K1
+PFH
D, Q3
= 4.510
-9
+210
-9
+210
-7
= 2.0710
-7
PL d
This is to be done in a similar way with other safety functions for the cell. For each safety device, you define the machines it
affects, and establish the various safety functions according to this.
Theoretical approach
How would it have worked if you had used the theoretical approach? Would the safety function have achieved PL e?
All machines:
PFH
D, B1
+PFH
D, K1
+PFH
D, Q1
+PFH
D, Q2
+PFH
D, Q3

= 4.510
-9
+210
-9
+5.7910-8+810
-8
+210
-7
= 3.4410
-7
PL d
In this case, the safety function would therefore have not achieved a total PL e, which was required for the risks associated
with the robot and hydraulic press.
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 PL
r
for the individual machines. The robot
and the hydraulic press requires PL
r
= e, while the pneumatic
machining tool requires PL
r
= 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 (PFH
D, B1
= 4.510
-9
)
Pluto K1 (PFH
D, K1
= 210
-9
)
Robot Q1 (PFH
D, Q1
= 5.7910
-8
)
Hydraulic press Q2 (PFH
D, Q2
= 810
-8
)
Pneumatic machining tool Q3 (PFH
D, Q3
= 210
-7
).
Please note that the examples on these pages are simplied in order to explain the principles. Values of products can also change.
1/26 2TLC172001C0202 | ABB Safety Handbook
1
EN ISO 13849-1 requires calculations. To do this in a ma-
nageable way a software tool provides excellent help. ABB
JokabSafety has chosen to use SISTEMA, a software tool
developed by BGIA, now called IFA, in Germany. The tool is
freeware and can be downloaded from the IFA website,
www.dguv.de/ifa. With SISTEMA it is possible to build safety
functions, verify them and generate the technical documenta-
tion required.
To work with SISTEMA in a rational way, we have developed
a library of our products for download from our website www.
abb.com/jokabsafety. In order to have access to the latest
version, visit this page periodically to check for updates and
new releases.
To download SISTEMA go to www.dguv.de/ifa/en/pra/softwa/
sistema/index.jsp or search the Internet for sistema.
SISTEMA
A tool for determining performance level (PL) and generating
technical documentation
Screenshot from SISTEMA.
ABB Safety Handbook | 2TLC172001C0202 1/27
1
To achieve PLe using a conventional safety relay, such as
RT9, you need to use both channels on the input side and
only connect a single safety device. Under certain conditions
PL d can be achieved by connecting multiple two-channel
devices to a safety relay, but this is not a generally accepted
method. Vital is a safety controller that allows you to connect
Benefits of Pluto
Pluto is an all-master-system with communications
across a separate safety bus
Greater flexibility facilitates the design of protection
systems
One software for all systems
Easy programming for PLe by using function blocks
(certified by TV)
More than 30 000 Pluto systems have been successfully
installed.
Benefits of Vital
It is possible to connect up to 30 safety components
through a channel in line with PL e
No programming required
The option of combining various safety components
(e.g. emergency stop button and door contact)
Easy configuration of the circuit
Electromechanical switches can also be used (with the
addition of the Tina adaptation device)
More than 70 000 Vital systems have been successfully
installed.
Safety relay, Vital or Pluto?
and monitor a variety of safety components in series, and to
achieve PL e to EN ISO 13849-1. The Vital module is based
on a dynamic single-channel concept and can replace mul-
tiple safety relays. A similar solution, although more flexible,
is safety PLC Pluto. Pluto, like Vital, is able to make use of
dynamic signals to achieve maximum reliability.
Various benefits in comparison to EN ISO 13849-1
Pluto AS-i
Programmable
Not programmable
Safety relay
Double static inputs that
only test the switches
each time they are used.
Vital
Dynamic "doubled up"
safety signal that tests a
sensor, for example, 200
times per second.
Flexibility
Number of machines/different stops
Traditional safety PLC
Master-Slave with static inputs
Pluto All-Master
Safety PLC with static and dynamic
safety inputs.
Slaves
Master
1/28 2TLC172001C0202 | ABB Safety Handbook
1
Safety Integrity Level, SIL Probability of dangerous Failure per Hour (PFH
D
)
3 10
-8
to <10
-7
2 10
-7
to <10
-6
1 10
-6
to <10
-5
There is a method in EN 62061 for assigning the Safety Integrity Level.
Severity (Se) Class (Cl)
3-4 5-7 8-10 11-13 14-15
4 SIL2 SIL2 SIL2 SIL3 SIL3
3 (OM) SIL1 SIL2 SIL3
2 (OM) SIL1 SIL2
1 (OM) SIL1
Cl=Fr+Pr+Av OM=Other Measures
The seriousness of injury that can occur is defined at one of
four levels. Class is the addition of the values of frequency
(Fr, stated as a value between 1 and 5, where 5 represents
the highest frequency), probability that a dangerous event will
occur (Pr, stated as a value between 1 and 5, where 5 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 fulfil
the SIL that has been assigned to it in the analysis. The safety
function consists of a number of sub-elements. Example: a
door is interlocked by a non-contact sensor which is in turn
monitored by a Pluto safety PLC, with outputs that break the
power to two supervised contactors. The sensor is sub-
element 1, Pluto is sub-element 2 and the two supervised
contactors are sub-element 3. If in the analysis it has been
established that SIL2 shall be used, every individual sub-ele-
ment in the safety function must fulfil the SIL2 requirements.
The safety function must then in its entirety fulfil the SIL2
requirements.
If the SIL requirements are not fulfilled in any of the sub-ele-
ments or by the safety function in its entirety, there must be a
re-design.
Finally
This is just a brief introduction to the EN ISO 13849-1 and EN
62061 standards. You are welcome to contact us so that we
can prepare suitable training and guide you in how to apply
the standards to our products.
Definition of protective safety in accordance with
EN62061
"Function of a machine whose failure can result in an
immediate increase of the risk(s)"
If one chooses to design a safety function in accordance with EN 62061, the level of reliability is expressed as the
Safety Integrity Level, SIL. There are a total of 4 levels, but in the EN 62061 standard SIL 3 is the highest level. SIL also
(similar to the Performance Level PL), is expressed as the Probability of Dangerous Failure Per Hour.
Applying EN 62061
ABB Safety Handbook | 2TLC172001C0202 1/29
1
Dynamic
sensors
Door 1 Door 2 Door 3 *Dynamic monitoring,
Vital/Pluto
Up to 30 doors (Eden sensors) can be connected to the
dynamic monitoring maintaining category 4.
**Static monitoring,
e.g. RT6 Interlocked switch
D
o
o
r

1
Maximum 1 door (2 interlocked switches) can be connected
to the static monitoring for category 4 to be maintained for
the entire system.
*
**
A mechanical switch does not give a safe function!
When it comes to mechanically operated interlocked swit-
ches, it has long been accepted a Category 1 switch is
adequate for many installations, which is also supported
by several standards. However some companies have now
re-evaluated this and have instead started to demand two
mechanical switches or non-contact switches/sensors, where
they previously accepted single mechanical switches. Many
reported incidents form the background to this. The require-
ments for switches to provide safe functioning are that they
are mounted correctly and that their positions do not change
during their life-cycle, in other words, ideal conditions. In
many installations the location of hatches or doors changes
over time. This has led to a switch not giving a stopping signal
when an interlocked gate has opened. The reasons for this
are many, but they can be summarized in mechanical deteri-
oration or physical damage to a door/hatch. In turn this has
led to an interlocked switch being affected by higher stress
than the switch manufacturers specifications. To avoid this
type of malfunction it is more appropriate to use non-contact
switches/sensors because mechanical deterioration does not
affect the safety function, i.e. the stop signal is given directly if
the position is wrong.

A non-contact switch/sensor does not have a guided function
and is designed to fulfill the requirements in another way. The
requirements are fulfilled either with dynamic sensors where
the safety signal is monitored all the time and a fault directly
leads to a stop signal or with a magnetic switch which has
two independent contact elements which are monitored every
time a gate opens. From the user's perspective the dynamic
function is preferable because several sensors can be con-
nected to a single safety module and still achieve PLe. Also
the sensors safety function is monitored without having to
open a gate. For a magnetic switch the requirements for PLe
are only fulfilled if one switch per monitoring unit is used and if
the gate is opened regularly.
If PL e is to be achieved with electromechanical switches,
maximum two switches can be connected to one safety relay.
This means that it is only with Eden that several doors can be
supervised with one safety module and achieve PL e.
Since the standard EN 954-1 was written, development has
progressed and the costs to fulfill category 4 have dropped
dramatically. Generally mechanical switches are replaced with
non-contact sensors to increase the reliability of production
equipment. The same goes for the safety side. With electro-
nic non-contact switches, with a transmitter and a receiver,
one avoids the problems of deterioration and excessive stress
which harm the sensor. For that kind of sensor dynamic
monitoring is required to enable a safe function. This means
that its function is constantly being monitored, hundred of
times per second. The reaction time for a safe stop will then
be the same during a malfunction as during the activation of
a stop (e.g. a gate opening). The monitoring frequency will
also be astronomical compared to that of mechanical swit-
ches and magnetic switches, which are only monitored every
time they are used. In the new EN ISO 13849-1, which has
replace 954-1, probability calculations are used together with
different category levels to compare different performance
levels. Even when using EN ISO 13849-1 it can be so that
one achieves reasonably high theoretical reliability with an
electromechanical switch, although this presumes correct
installation, proper use and otherwise ideal conditions. A non-
contact switch instead provides high levels of both theoretical
and practical reliability.
Our conclusion, use dynamic signals!
Our conclusion is that today it is more cost effective, safer
and more reliable to work with dynamic signals to achieve
category 4 for sensors and monitoring units. In that case it is
also possible to fulfill the Machinery Directive, 1.2.7. requi-
rement: A fault in the control circuit logic, or failure of or
damage to the control circuit, must not lead to dangerous
situations. Also one does not have to discuss whether the
correct safety category has been chosen!
A mechanical switch does not give a safe function!
1/30 2TLC172001C0202 | ABB Safety Handbook
1
We train you on safety requirements
What requirements are there today?
For international companies there are many new standards
and regulations with which to comply. There have also been
changes and revisions of existing standards and directives.
As a business and designer one is obliged to know about
and to follow all the regulations. But it can be difficult for each
individual company to keep track of all the new regulations
and how they should be applied.
Your local ABB JokabSafety sales office can help you with
training and analysis during a build-up phase or as a
continuous consulting assignment.
Our course trainers have a extensive experience in machine safety
A distinguishing feature of all the engineers at ABB JokabSafety is that they work daily with practical applications of standards
and regulations. This is true for everything from safety components for individual machines to entire deliveries of safety sys-
tems for larger production lines. Within the company there is also a very good knowledge of machine control and production.
We are also represented in standardisation groups which decide on European and International standards concerning machine
safety. Because ABB JokabSafety is represented globally, we have the knowledge of safety requirements in different countries.
Training in machine safety
Are you building machines for sale or for your own use? Are you a user of machines? Are you working with
automation of production plants or do you make technical evaluations of machines prior to purchase?
Regardless of the purpose, there is a need for knowledge concerning what requirements and regulations exist
in respect of machine safety, and how they should be applied.
Product liability and its consequences
CE-labelling
The Machine Directive and how to apply it
Choice of certification procedure with examination of the
parts which are required in order to be able to CE-label a
machine
Harmonised standards and the applications of these, e.g.
EN ISO 13849-1/-2
EN ISO 12100
EN 60204-1
EN ISO 13850
EN ISO 13857
EN ISO 13855 (previously EN 999)
Machine safety analysis; method and cases
Choice of safety measures/safety devices
Requirements for manufacturers technical documentation
Requirements for manuals
Requirements for old machines
Specific interpretation cases, e.g. re-construction of
machines
Changes in the Machine Directive
We offer company-adapted training in the following fields:
Company-adapted training in machine safety
Contact your local sales office with questions and your current
training needs. Together with you, we will customize the trai-
ning to your specific company requirements.
- enhance your knowledge!
ABB Safety Handbook | 2TLC172001C0202 1/31
1
Product training
Do you need assistance in CE-marking a machine? Do you want a third
party to carry out a risk analysis on a machine line? Do you have the need
of a partner to examine how various regulations effect the safety of your
machines?
Training in risk analysis
We regularly have training courses in our offices. One of these covers risk
analysis and how to choose production adapted measures.
A course in risk analysis contains the following:
Risk analysis - from theory to practice
What durability towards errors shall the safety system have?
Standard EN ISO 13849-1/-2
Safety distances for fencing systems and safety components - how do you choose?
Cases, practice and briefing of risk analysis and choice of actions
Our unique Pluto Safety PLC gives new and great possibilites to build-up a cost
effective and flexible safety system. With this also comes the demands of higher
knowledge. For you as a customer to be able to quickly get started using Plu-
to in the most effective way and to learn about its possibilities, we regularly offer
trainings at our local sales offices. In the training course cost is included a Pluto,
software for Pluto and full documentation. We also offer training on the other ABB
Jokab Safety products such as the Vital solution, safety relays and light beams/
curtains.
Training - Pluto and other ABB JokabSafety products
Contact your local sales office with questions and your current training needs.
Together with you, we will customize the training to your specific company require-
ments.
Consulting - Contact us
Come to us with your needs and we
will plan with you a suitable project
programme. You can also contact us
with short questions which we can solve
directly over the phone or via e-mail.
Stopping time measurement is required in
order to be able to determine the correct safety
distance.
We can offer assistance and support in both short and longer assignments.
Here are a few examples of what we can offer you:
Risk analysis with proposal of measures. We do this together
with the customer and it is often done as a pilot-project so that the
company afterwards themselves can carry out analysis.
Guide the customer business through a CE-marking of machine/plant.
Write/review technical documentation/manuals
Interpret standards and regulations
Stopping time measurement - We can measure the stopping time
on your machines with our Stopping time and motion analyser tool.
Knowledge of the stopping time is a prerequisite to be able to determine the cor-
rect safety distance. EN ISO 13855 (previously EN 999) gives the requirements.
Programming of Pluto Safety-PLC.
Consulting
2/1 2TLC172001C0202 | ABB Safety Handbook
2
ABB Safety Handbook | 2TLC172001C0202 2/2
2
Why should you have Pluto safety PLC? 2/3
Connection examples for Pluto 2/5
Pluto safety PLC
Pluto 2/7
Function Blocks for Analogue inputs Pluto D20 and D45 2/9
Counter inputs 2/10
Input connection 2/11
Output connector expansion 2/12
I/O overview 2/12
Technical data 2/15
Application examples 2/17
Gateway
Gate P2 - Profibus DP 2/23
Gate D2 - DeviceNet 2/25
Gate C2 - CANOpen 2/27
Gate E2 - Profinet, Ethernet/IP, Modbus TCP 2/29
Safe Encoder
Safe Encoder 2/31
IDFIX
IDFIX 2/35
Pluto Safety PLC
With dynamic safety concept
2/3 2TLC172001C0202 | ABB Safety Handbook
2
Why should you have Pluto safety PLC?
Pluto is an All-Master safety PLC concept, that simplifies the design of safety systems and achieves the highest safety level
PLe according to EN ISO 13849-1 and SIL 3 according to EN62061 and EN61508. The key difference between Pluto and
conventional safety PLCs is that there is no "Master-Slave" relationship between the control units connected to the safety bus.
Each Pluto is a Master unit and can see the other Plutos' inputs and outputs, and can thereby make decisions about its own
safety environment.
This concept enables simple communication, programming and changes to the safety system. With the use of a Gateway
device, a Pluto can communicate with other bus systems and thereby form part of a larger network. Gateway units are available
for several different bus systems, such as Profibus, CanOpen, DeviceNet, Profinet, Ethernet/IP and Modbus TCP. With a Pluto
AS-i, both safety slaves and standard slaves can be handled.
Pluto offers an economic solution for both single machines and for major machine systems.
for simplifying the design of and changes to safety systems!
+ +
4 4 4 + +
4
6 4
+
+
+
Pluto AS-i
Pluto All Master
S
a
f
e

b
u
s
12 I/O
46 I/O 20 I/O
31 AS-i
safety nodes
20 I/O 20 I/O 20 I/O
Master
Slaves
Traditional safety PLC
Master
Pluto All-Master
Our solution with All-Master
Pluto All-Master
Pluto All-Master
Pluto All-Master
Pluto All-Master
Pluto All-Master
ABB Safety Handbook | 2TLC172001C0202 2/4
2
to supervise safety devices!
Most safety devices on the market can be connected di-
rectly to Pluto units. By using dynamic signals with sensors
from ABB JokabSafety only one input is needed to achieve
the highest level of safety, compared to two inputs for other
manufacturers' PLCs. It is also possible to connect up to 10
sensors in series to a single input on Pluto and still achieve
the highest level of safety. For example non-contact Eden
sensors, Spot light beams and Tina emergency stop buttons
can all be connected in series to a single Pluto input. Even
mechanical switches can be connected to the dynamic
safety circuit using ABB JokabSafety's various Tina adapters.
Pluto also has IO connections that can be used as both inputs
and outputs.
to save on inputs!
O
n
e

i
n
p
u
t
O
n
e

i
n
p
u
t
O
n
e

c
o
n
n
e
c
t
i
o
n
T
w
o

i
n
p
u
t
s
Pluto has inputs for static and
dynamic sensors. Several sen-
sors can be connected to one
dynamic input in accordance
with PLe.
IO connections
Pluto has IO connections that can be used in three ways:
input
output
both input and output at the same time (e.g. for a reset button
with lamp indication)
Dynamic signals
110 doors with one Eden per door
PLe
Dynamic signals
1-10 sensors
PLe
Static inputs (mechanical switches)
2 for each door = PLe
input/output
Light beams Light grids/curtains 3-position
devices
Sensors/
switches
Two-hand
controls
Emergency
stops
Strips Mats
2/5 2TLC172001C0202 | ABB Safety Handbook
2
Pluto B20
Connection examples for Pluto with safety bus
Connection examples for Pluto without a safety bus
1.Gateway For two-way safe bus communication between
Pluto and other control systems.
2.Absolute encoder 8 single turn or multi turn absolute
encoders can be connected directly to the safety bus.
6.Stand alone Pluto
Same functionality as other Plutos, but without safety
bus connections.
7.IDFIX Identifies Pluto
If IDFIX PROG is used for single-Pluto, there is the option of
copying a PLC program via the identification circuit over to
Pluto without having to connect a computer.
4 independent
failsafe outputs
Safety bus for connection of
up to 32 Pluto units
20 I/O
Gateway
Profibus DP
DeviceNet
CANopen
Ethernet
3
Free software at www.abb.com/jokabsafety,
Ladder with TV-approved function blocks.
2
Pluto S20 Pluto S46
6
Pluto Manager
7
6 6
2
1
ABB Safety Handbook | 2TLC172001C0202 2/6
2
Pluto AS-i Pluto B46
3.Pluto bridge With a Gateway it is possible to:
increase the safety bus length
use different bus speeds for each section
filter information from one section to reduce the load on
the safety bus.
4.HMI An HMI operator panel can communicate with Pluto
in both directions. Connection can be made direct to the front
of the Pluto.
5.Pluto AS-i Can either be AS-i master on the AS-i bus or
work together with an AS-i master as a monitor. It includes
AS-i nodes, analogue and digital outputs, as well as safety
outputs. Also available as Pluto B42 AS-i for more I/O. For
more information see the AS-i safety chapter.
6 independent
failsafe outputs
4 independent
failsafe outputs
46 I/O
12I/O
31 AS-i safety slaves
Safety Monitor/
Master
Safe bus
5
Approvals
EN 61508, SIL 3
EN ISO 13849-1, PL e
4
Overview Pluto Safety-PLC
Model
S
2
0
S
4
6
A
2
0
B
2
2
D
2
0
D
4
5
B
2
0
B
4
6
A
S
-
i
B
4
2

A
S
-
i
Number of I/O 20 46 20 22 20 45 20 46 12 42
Failsafe inputs 8 24 8 14 8 24 8 24 4 20
Failsafe inputs or
non-failsafe outputs
8 16
8 8 8 15 8
16
4 16
Analogue inputs 0-10V/4-20mA - - - - 4 8* - - - -
Counter inputs - - - - - 4* - - - -
Analogue inputs (0-27V) 1 3 1 1 1 3 1 3 4 3
Failsafe relay outputs 2 4 2 - 2 4 2 4 2 4
Failsafe transistor outputs 2 2 2 - 2 2 2 2 2 2
Pluto bus - -
Pluto AS-i bus - - - - - - - -
Current monitoring - - 2 - - - - - - -
Dimensions (b x h x d) mm 45 x 84
x 118
90 x 84
x 118
45 x 84
x 118
45 x 84
x 118
45 x 84
x 118
90 x 84
x 118
45 x 84
x 118
90 x 84
x 118
45 x 84
x 118
90 x 84
x 118
Supply voltage 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC 24VDC
*4 of the analogue inputs can be congured as counter inputs. The total number of analogue inputs + counter inputs = 8.
2/7 2TLC172001C0202 | ABB Safety Handbook
2
Pluto Safety PLC facilitates the design of your safety
systems
Pluto is an All-Master system for dynamic and static safety
circuits where inputs and other information are shared over
the bus. Multiple safety sensors can be connected to a single
input and still achieve the highest level of safety. Pluto has in-
puts suited for every safety product on the market, and each
input function is configured in the accompanying software
Pluto Manager.
Besides failsafe inputs (I) Pluto has a number of failsafe relay
and transistor outputs (Q). On every Pluto unit there is also a
possibility of using a number of terminals as failsafe inputs,
non-failsafe outputs or both in and output simultaneously (IQ).
The characteristics of the terminals are easily configured in
Pluto Manager.
Safety in large and small systems
Pluto models with bus communication can be connected to
the Pluto bus where up to 32 Pluto units can interact and
control large as well as small safety systems. The fact that
Pluto is an All-Master system means that each Pluto unit
controls their outputs locally, while it is as easy to read other
Pluto units inputs as their own. It is also easy to both read
and write to global memory locations available across the
Pluto bus.
Gateways can be connected to the Pluto bus for commu-
nication with other systems. The gateway models GATE D2
and C2 can also be used as an extension of the bus cable to
Safety PLC
Pluto
Approvals:
Control of:
Safety products in dynamic
and static circuits
Electrically controlled actu-
ators such as contactors,
valves, motors
Indicators and buttons
Features:
A Safety-PLC for each system
part
Dispersed constructions of
machines
Great flexibility
Up to 10 sensors in series
connected to one input
Software Pluto Manager free
of charge
Handles conventional circuit
breakers as well as dynamical
sensors
Custom made safety bus
extend the Pluto network. You can also connect speed and
position sensors via the Pluto bus.
Pluto is primarily designed to satisfy the requirements of EU
Machinery Directive (2006/42/EG) regarding safety in control
systems, but the system can also be used in other areas as
in the process industry, boiler plants etc which have similar
requirements.
Single Pluto - Pluto without safety bus
The Pluto models S20 and S46 without bus communication
are stand alone units which are perfectly suited for smaller
systems that do not require communication with other Pluto
units or gateways. In all other ways the S20 has the same
functionality as the B20 model, and the S46 as the
B46 model but without a safety bus connection.
Current monitoring (Pluto A20 only)
Pluto A20 differs from the other models in that it can monitor
the current through the IQ16 and IQ17 outputs. The function
is designed for, but not limited to, ensuring that the muting
lamps are working. The hardware for current monitoring is
not designed with individual redundancy, which means that
the function must be used dynamically if it is to be used in a
TV
Rheinland
ABB Safety Handbook | 2TLC172001C0202 2/8
2
safety function. This means that the current must be read
and evaluated both when the output is enabled and disabled.
Pluto for the AS-i system
Pluto AS-i can either be AS-i master on the AS-i bus or
work together with an AS-i master as a monitor. It includes
AS-i nodes, analogue and digital outputs, as well as safety
outputs. Also available as Pluto B42 AS-i for more I/O. For
more information see the AS-i safety chapter.
Pluto D20 and D45 - with analogue inputs
Pluto D20 is equipped with 4, and Pluto D45 with 8, safe
4-20mA/0-10V analogue inputs. These can be configured as
either ordinary failsafe inputs, as analogue inputs 0-10V or
as analogue inputs 4-20mA. For an application to reach
SIL 3/PL e it is required that two sensors in parallel with one
input each are being used.
Counter inputs Pluto D45
For Pluto D45 four of the analogue inputs can be configured
as counter inputs (pulse counting) which work for frequencies
up to 14000 Hz. As counter inputs IA0 IA3 can be used in
two ways, Up counting or Up/Down counting.
Pluto B22 - expansion module with increased number of
inputs
Pluto B22 is an expansion module without safety outputs. It
is equipped with 14 safe inputs and 8 safe inputs or non-safe
outputs.

Technical info - Dynamic signal
+24 V
0 V
A dynamic signal makes it possible to achieve the highest le-
vel of safety with only one conductor. By transmitting a square
wave and then evaluating the signal when it comes back to
the controller you achieve the redundancy required. The signal
is inverted once at each safety sensor (if the protection is
OK) which makes it possible to detect short circuits across a
sensor. When the signal switches between high (+24 V) and
low (0V) it can be evaluated and tested about 200 times per
second.
Pluto can generate three unique dynamic signals; A pulse, B
pulse or C pulse. Short circuits between two different dynamic
signals are detected whenever the signal that is created is
different from the expected signal in Pluto. The kind of signal
Pluto expects at the input terminal is determined in Pluto Ma-
nager (A, B or C pulse and if the signal should be inverted or not).
Technical info - Static signal
Static signals (+24 V or 0 V) can be connected to all inputs on
Pluto. The kind of signal Pluto expects at the input terminal is
determined in Pluto Manager. To achieve a two-channel struc-
ture according to EN ISO 13849-1 you need two inputs.
Technical info - OSSD-signal
+24 V
0 V
There are safety products with internal monitoring of dual
OSSD signals (the device detects its own faults rather than
Pluto doing this). From these devices, at least one of the two
signals is connected to an I-input in Pluto, i.e. both signals
must not be connected to the IQ-terminals. The terminal
blocks are then configured in Pluto Manager to expect static
inputs (OSSD signals are filtered internally in Pluto).
IQ individual failsafe inputs and non-failsafe outputs
The IQ terminals can be used either as individual failsafe input
or non-failsafe output (e.g. for indicator light or status sig-
nal). The terminal blocks can also be used as both input and
output simultaneously, which is useful for example for push
buttons (input) with indicator light (output). This function is
designed primarily for reset buttons to reduce the number of
used terminal blocks on the controller.
Technical info - I - individual failsafe inputs
All inputs are individually failsafe as each input is connected
separately to both processors in Pluto. In order to maintain
the redundancy required for two-channel structure and the
highest level of safety, the dynamic signal must be used.
When using static signals, two inputs must be used to achie-
ve two-channel structure. The expected signal to the termi-
nals blocks is determined in Pluto Manager (static or dynamic
signal).
Technical info - Q - individual failsafe outputs
All Q outputs are individually safe and are independently
programmable. There are both relay outputs and transistor
outputs.
Technical info - Transistor outputs (-24 VDC)
The transistor outputs are just like the relay outputs, that is
individually safe and independently programmable. However,
the transistor outputs are different from the relay outputs as
the internal connection provides the nominal input voltage -24
VDC, which is primarily intended for controlling electromecha-
nical components such as contactors and valves. As -24 VDC
is a unique signal in the majority of electrical cabinets and the
fact that the output is monitored by Pluto, short circuits with
other potentials can be detected right away.
Technical info - Pluto-bus
The Pluto-bus is a CAN-bus with its own safety protocol.
The bus cable can be up to 600 m long at the minimum bus
speed, and up to 150 m at 400 kb/s. The bus can be both
extended and connected to other types of buses through
gateways.
2/9 2TLC172001C0202 | ABB Safety Handbook
2
Function Blocks for Analogue inputs Pluto D20 and D45
IA0.0 and IA0.1 are configured as Analogue input 0-10V, and IA0.2
and IA0.3 are configured as Analogue input 4-20mA.
Configuration in Pluto Manager
The inputs can be configured under I/O Options in Pluto
Manager. As analogue inputs they can be configured either as
0-10V inputs, or as 4-20mA inputs. For Pluto D45 they can
also be configured as Counter inputs.
ReadVoltage and ReadCurrent function blocks
For analogue input 0-10V the function block ReadVoltage
is needed, and for analogue input 4-20mA the function block
ReadCurrent is needed. There are also 32-bit versions of
these function blocks (ReadVoltage_32 and ReadCur-
rent_32) for use with Double Registers. As output from the
blocks there is one output with the absolute value in V or mA,
and one output which can be scaled as desired. The picture
and table below shows the ReadCurrent function block only,
but ReadVoltage works in the same way.
ReadCurrent function block. Description of inputs and outputs:
inp Input connected to the block.
Value 4mA Input value for scaling. At 4mA the output Scaled value will
show this value.
Value 20mA Input value for scaling. At 20mA the output Scaled value will
show this value.
Q OK output. Value is within range.
Current Output with calibrated absolute value in A.
Scaled Value Output with scaled value.
ABB Safety Handbook | 2TLC172001C0202 2/10
2
Example of speed monitoring with incremental encoders leaving
A and B pulses to two inputs, IA0-IA1 or IA2-IA3. The direction is
then possible to measure.
Configuration of counter input
Up count
When the input is configured for Up count Pluto counts the
pulses on the input. Via a function block the user gets the
pulse rate which for example can represent a speed. The
sensor can be anything, like an inductive sensor, photocell or
incremental encoder (HTL, 24V).
R
T
B
IA4 A
B
IA3
IA1
+24V
0V
B
A
A
Pluto
IA0
+24V
0V
B
A
Example of speed monitoring. The sensors can for example be
proximity switches or photocells. Any of the inputs IA0..IA3 can
be used.
B
A
B
A
IA3
B
A
B
IA2
IA1
+24V
0V
A
B
A
Pluto
IA0
0V
+24V
A
B
For Pluto D45 the inputs IA0 IA3 can be configured as coun-
ter inputs (pulse counting). As counter inputs IA0 IA3 can be
used in two ways, Up counting or Up/Down counting.
Sensor types
The upper frequency limit is dependent on the type of senor.
For incremental encoders with HTL output (push pull) the
counter inputs work for frequencies up to 14 kHz.
For photocells, proximity switches, inductive sensors etc.
which normally do not have a push pull output the maxi-
mum frequency might typically be 1 4 kHz, but the limit is
also dependent on the output resistance, the cable length etc.
Function blocks for speed monitoring
For inputs configured as Up count the function block HS_
SpeedCount_Up shall be used.
For inputs configured as Up/Down count the function
block HS_SpeedCount_Dir shall be used.
The function block SpeedMon1 is intended to be used for
redundant speed monitoring, but has also functions for stand
still monitoring and safe low speed. It has two inputs for
speed values. These input registers can take their values from
different sources such as the function blocks for incremental
encoders, absolute encoders, analogue inputs etc. The input
Speed is a primary input for a speed value and Comp-
Speed is a secondary channel for monitoring the correctness
of the primary speed value.
Counter inputs Pluto D45
Up/Down count
With the function Up/Down count it is possible to detect the
direction of the movement. A pair of inputs, IA0/IA1 and/or
IA2/IA3 can be configured as Up/Down counters. In order
to make up/down counting it requires that the sensors can
produce A/B-pulses. A/B-pulses are two square wave signals
that are 90 phase shifted to each other. The sensor is typi-
cally an incremental encoder with HTL (24V) interface.
2/11 2TLC172001C0202 | ABB Safety Handbook
2
Both a lamp and a pushbutton can be connected to the same terminal. This function is for resetting safety devices and to
reduce the number of I/Os used.
Input connection
The system offers solutions for both single and two-channel safety devices. In order to monitor wiring short-circuits it is possib-
le to use up to three different dynamic signals and static voltage (+24 V) to supply the inputs. The inputs are then programmed
to only accept one of the signal types.
In a two-channel system both channels will be measured, using two different signals. The system will thereby be able to detect
a short-circuit between the channels.
In a single channel system the dynamic signal is modified at each sensor. A short-circuit between the input and the output
of the sensor will be detected at the Pluto input. PLe according to EN ISO 13849-1 can thus be achieved by using only one
channel and one input.
Input connection alternative in accordance with PLe EN ISO 13849-1.
Two-channel system Single channel dynamic system
Emergency
stop with
Tina
Emergency
stop with
Tina
Spot light
beam
Eden sensor
Resetting with a lamp
input/output
(Current monitoring)
Reset button that uses the combined input and output facility
ABB Safety Handbook | 2TLC172001C0202 2/12
2
Type: BT50
A1 X4
24VDC
I/O Overview
Current monitored
Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs
IQ10 IQ11
Power
0V +24V
Pluto bus
CL
IQ12 IQ13
input
ID
Identifier
CH
IQ15 IQ14 IQ16
I0
B B
individual failsafe
Transistor output,
Relay output,
individual failsafe
B B
Inputs, individual failsafe
Q0
IQ17
I1 I2
A
I3 I4
Q1
A
I6
Q2
A
I7
Q3
A
Pluto A20, B20, S20
1)
1) Not S-models, S20,...
2)
2) Current monitored only on A20
SR41
AI
I5
Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs
IQ10 IQ11
Power
0V +24V
Pluto bus
CL
IQ12 IQ13
input
ID
Identifier
CH
IQ15 IQ14 IQ16
IA0
B B
individual failsafe
Transistor output,
Relay output,
individual failsafe
B B
Inputs, individual failsafe
Q0
IQ17
IA1 IA2
A
IA3 I4
Q1
A
I6
Q2
A
I7
Q3
A
Pluto D20
0-24V
I5
AI
0-10V/4-20mA
DI
AI
DI
AI
DI
AI
DI
AI
DI DI DI DI
Output connector expansion
Using an expansion relay, such as BT50, the number of safe
outputs in Pluto can be expanded. The connection shall be
made as shown in the figure. Several expansion relays can be
connected to a single Pluto safety output while retaining the
safety level.
2/13 2TLC172001C0202 | ABB Safety Handbook
2
Failsafe inputs / Outputs (not failsafe) / Dynamic outputs
IQ10 IQ11
supply
Power
+24V
IQ12 IQ13
Identifier IDFIX
IQ15 IQ14 IQ16
I30
B
Inputs, individual failsafe
Q0
IQ17
I31 I32 I33 I34 I35 I36
Q2
A
I37
Pluto B46, S46
Pluto bus
I45 I40 I41 I42 I43 I44 I46 I47
Inputs, individual failsafe
I0 I1 I2 I3 I6 I5 I4 I7
IQ21 IQ20 IQ25 IQ24 IQ23 IQ22 IQ27 IQ26
B A
A
Q1
B
A
Q4
B
Q5
A B
Q3
B A
0V
0V
ID
CH
CL
1)
1) Not S46
AI AI AI
SR46 SR45 SR41
4L
1L
0L
Safety outputs
Digital/Analogue
Inputs, individual failsafe
Failsafe inputs / Outputs (not failsafe) / Dynamic outputs
IQ10 IQ11
supply
Power
+24V
IQ12 IQ13
Identifier IDFIX
IQ15 IQ14 IQ16
I30
B
Inputs, individual failsafe
Q0
IQ17
I31 I32 I33 I34 I35 I36
Q2
A
I37
Pluto D45
Pluto bus
I45 I40 I41 I42 I43 I44 I46
Digital inputs, individual failsafe
IQ21 IQ20 IQ25 IQ24 IQ23 IQ22 IQ26
B A
A
Q1
B
A
Q4
B
Q5
A B
Q3
B A
0V
0V
ID
CH
CL
AI
4L
1L
0L
Safety outputs
Analogue inputs 0-10V/4-20mA
Inputs, individual failsafe
DI
IA7
DI AI
IA6
DI AI
IA5
DI AI
IA4
DI AI
IA2
DI AI
IA1
DI AI
IA0
AI DI
IA3
CS (Shield)
Fast counter
I47
Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs
IQ10 IQ11
Power
0V +24V
Pluto bus
CL
IQ12 IQ13
input
ID
Identifier
CH
IQ15 IQ14 IQ16
I0
Inputs, individual failsafe
IQ17
I1 I2 I3 I4 I6 I7
Pluto B22 SR41
AI
I5
I21 I20 I22 I23 I25 I24
ABB Safety Handbook | 2TLC172001C0202 2/14
2
ID: Connection for identifier, which has a unique ID number that can be read by the system.
I.. Safety inputs (24 VDC) that are individually failsafe. This means that the highest level of safety can be achieved with
only one input if ABB JokabSafety dynamic safety components are used.
Otherwise two inputs are required for each safety function.
IQ.. I/O that can be used for safety inputs or signal outputs, e.g. to indicate or control functions that are not safety-rela-
ted. For IQ.. as safety inputs, refer to I..
Q0, Q1: Failsafe relay outputs that are individually failsafe and individually programmable.
Q2, Q3: Failsafe transistor outputs (-24 VDC) that are individually failsafe and individually programmable. Intended for electro-
mechanical components such as contactors and valves.
Q4, Q5 Failsafe relay outputs with common potential that are individually failsafe and individually programmable.
IDFIX
IQ10 IQ11
+24V
IQ12 IQ13 IQ15 IQ14 IQ16
I30
B
Q0
IQ17
I31 I32 I33 I34 I35 I36
Q2
A
I37
Pluto B42 AS-i
I45 I40 I41 I42 I43 I44 I46 I47 ASi+ ASi+ I2 I1 I0 I3
IQ21 IQ20 IQ25 IQ24 IQ23 IQ22 IQ27 IQ26
B A
A
Q1
B
A
Q4
B
Q5
A B
Q3
B A
0V
0V
ID
CH
CL
AI AI AI
SR46 SR45 SR41
4L
1L
0L
CS
Failsafe inputs / Outputs (not failsafe) / Dynamic outputs
Power
Identifier IDFIX
Inputs, individual failsafe
Pluto bus
Inputs, individual failsafe
Safety outputs
Digital/Analogue
Inputs, individual failsafe
supply
AS-Interface
2/15 2TLC172001C0202 | ABB Safety Handbook
2
Technical data -
type-specific

Pluto A20 Pluto B20 Pluto B22 D20 S20 Pluto B46 Pluto D45 Pluto S46 Pluto AS-i Pluto B42 AS-i
20 I/O
Current monitoring
20 I/O 22 I/O 20 I/O
Analogue inputs
20 I/O
Without safety bus
46 I/O 45 I/O
Analogue/counter inputs
46 I/O
Without safety bus
AS-i bus AS-i bus
Article number 2TLA020070R4500 2TLA020070R4600 2TLA020070R4800 2TLA020070R6400 2TLA020070R4700 2TLA020070R1700 2TLA020070R6600 2TLA020070R1800 2TLA020070R1100 2TLA020070R1400
Failsafe inputs 8 (I0..I7) 8 (I0..I7) 14 (I0..I7, I20..I25) 8 (I0..I7) 8 (I0...I7) 24 (I0..I7, I30..I37, I40..I47) 24 (I0..I7, I30..I37, I40..I47) 24 (I0..I7, I30..I37, I40..I47) 4 (I0..I3) 20 (I0..I3, I30..I47)
Failsafe inputs or
non-failsafe outputs
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10...IQ17)
Max total load 2.5 A
16 (IQ10..IQ17, IQ20..IQ27)
Max total load 2A
15 (IQ10..IQ17, IQ20..IQ26)
Max total load 2A
16 (IQ10..IQ17, IQ20..IQ27)
Max total load 2A
4 (IQ10..IQ13)
Max total load 2A
16 (IQ10..IQ27)
Max total load 2A
Analogue inputs
(0-10V/4-20 mA)
4 4*
Counter inputs 8*
Analogue inputs (0-27V) 1 (I5) 1 (I5) 1 (I5) 1 (I5) 1 (I5) 3 (I5..I7) 3 (IQ10..IQ12) 3 (I5..I7) 4 (IQ10..IQ13) 3 (I1..I3)
Failsafe relay outputs 2 (Q0..Q1) 2 (Q0..Q1) 2 (Q0..Q1) 2 (Q0..Q1) 4 (Q0..Q1 & Q4..Q5) 4 (Q0..Q1 & Q4..Q5) 4 (Q0..Q1 & Q4..Q5) 2 (Q0..Q1) 4 (Q0..Q1 & Q4..Q5)
Failsafe transistor outputs 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3)
Current monitoring 2 (IQ16, IQ17)
0-1.0 A 10%

Pluto safety bus
Pluto AS-i bus
Own current consumption 100...300 mA 100...300 mA 100...300 mA 100...300 mA 100...300 mA 100...500 mA 100...500 mA 100...500 mA 100 mA 150 mA
Recommended external
fuse
6A 6A 6A 6A 6A 10A 10A 10A 6A 10A
Dimensions (w x h x d) 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 90 x 84 x 118 mm 90 x 84 x 118 mm 90 x 84 x 118 mm 45 x 84 x 118 mm 90 x 84 x 118 mm
Technical data - general
Colour Grey
Operating voltage 24 VDC 15%
Installation 35 mm DIN rail
Electrical insulation Category II in accordance with IEC
61010-1
Safety level
EN 954-1
ENISO13849-1
EN 61508
EN 62061
Cat. 4
PLe/Cat.4
SIL 3
SIL 3
PFH
D
Relay output
Transistor output:0
2.0010
-9
1.5010
-9
Failsafe inputs I & IQ
I0..7 (I30..37, I40..47)
IQ10..17 (IQ20..27)
Current at 24 V
Max. overvoltage
+24 V (for PNP sensors)
+24 V (for PNP sensors)
IQ also congurable as non-failsafe
outputs.
5.1 mA
27 V continuous
Failsafe outputs Q
Q2, Q3
Output voltage tolerance
Q0, Q1, (Q4, Q5)
Transistor, 24VDC, 800 mA
Supply voltage - 1.5 V at 800 mA
Relay outputs
VAC-12: 250 V/1.5 A
VAC-15: 250 V/1.5 A
VDC-12: 50 V/1.5 A
VDC-13: 24 V/1.5 A
Non-failsafe outputs Q
IQ10..17 (IQ20..27)
Max. current/output
Transistor +24V, PNP "open coll-
ector" also congurable as failsafe
inputs.
800 mA
Indicator
Input/output LED
Display
1 per I/O (green)
7-segments, two characters
Pluto safety bus
Max number of Pluto units on the
databus
Databus type
Databus speeds
Databus cable length
32
CAN
100, 125, 200, 250, 400, 500, 800,
1000 kb/s
Up to 600 m, 150 m at 400 kb/s
ABB Safety Handbook | 2TLC172001C0202 2/16
2
Technical data -
type-specific

Pluto A20 Pluto B20 Pluto B22 D20 S20 Pluto B46 Pluto D45 Pluto S46 Pluto AS-i Pluto B42 AS-i
20 I/O
Current monitoring
20 I/O 22 I/O 20 I/O
Analogue inputs
20 I/O
Without safety bus
46 I/O 45 I/O
Analogue/counter inputs
46 I/O
Without safety bus
AS-i bus AS-i bus
Article number 2TLA020070R0300 2TLA020070R0600 2TLA020070R4800 2TLA020070R6400 2TLA020070R0500 2TLA020070R1700 2TLA020070R6600 2TLA020070R1800 2TLA020070R1100 2TLA020070R1400
Failsafe inputs 8 (I0..I7) 8 (I0..I7) 14 (I0..I7, I20..I25) 8 (I0..I7) 8 (I0...I7) 24 (I0..I7, I30..I37, I40..I47) 24 (I0..I7, I30..I37, I40..I47) 24 (I0..I7, I30..I37, I40..I47) 4 (I0..I3) 20 (I0..I3, I30..I47)
Failsafe inputs or
non-failsafe outputs
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10..IQ17)
Max total load 2.5 A
8 (IQ10...IQ17)
Max total load 2.5 A
16 (IQ10..IQ17, IQ20..IQ27)
Max total load 2A
15 (IQ10..IQ17, IQ20..IQ26)
Max total load 2A
16 (IQ10..IQ17, IQ20..IQ27)
Max total load 2A
4 (IQ10..IQ13)
Max total load 2A
16 (IQ10..IQ27)
Max total load 2A
Analogue inputs
(0-10V/4-20 mA)
4 4*
Counter inputs 8*
Analogue inputs (0-27V) 1 (I5) 1 (I5) 1 (I5) 1 (I5) 1 (I5) 3 (I5..I7) 3 (IQ10..IQ12) 3 (I5..I7) 4 (IQ10..IQ13) 3 (I1..I3)
Failsafe relay outputs 2 (Q0..Q1) 2 (Q0..Q1) 2 (Q0..Q1) 2 (Q0..Q1) 4 (Q0..Q1 & Q4..Q5) 4 (Q0..Q1 & Q4..Q5) 4 (Q0..Q1 & Q4..Q5) 2 (Q0..Q1) 4 (Q0..Q1 & Q4..Q5)
Failsafe transistor outputs 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3) 2 (Q2..Q3)
Current monitoring 2 (IQ16, IQ17)
0-1.0 A 10%

Pluto safety bus
Pluto AS-i bus
Own current consumption 100...300 mA 100...300 mA 100...300 mA 100...300 mA 100...300 mA 100...500 mA 100...500 mA 100...500 mA 100 mA 150 mA
Recommended external
fuse
6A 6A 6A 6A 6A 10A 10A 10A 6A 10A
Dimensions (w x h x d) 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 45 x 84 x 118 mm 90 x 84 x 118 mm 90 x 84 x 118 mm 90 x 84 x 118 mm 45 x 84 x 118 mm 90 x 84 x 118 mm
*4 of the analogue inputs can be congured as counter inputs. The total number of analogue inputs + counter inputs = 8.
The terminal blocks are detachable without needing to disconnect the
wiring. The units shall be assembled with a gap of at least 5 mm.
Pluto AS-i bus
Master prole
Number of slave units
Bus operation mode
Bus cable length:
M2
31/62*
Master
Safety monitor
Safety monitor, slave and safe I/O
module.
Up to 500 m
100 m between each repeater
Temperature
Ambient temperature
Storage and transport
10C to +50C
25C to +55C
Response times
Dyn. A or static input to relay
output
Dyn. A or static input to
transistor output
Dyn. B or Dyn. C input to
relay output
Dyn. B or Dyn. C input to
transistor output
Software setting "NoFilt"
AS-i bus to relay output
AS-i bus to transistor output
<20.5 ms + program exec. time
<16.5 ms + program exec. time
<23 ms + program exec. time
<19 ms + program exec. time
5 ms shorter response time on
I & IQ inputs
<33 ms + prog. execution time
<29 ms + prog. execution time
Additional Response times
Databus between Pluto units
Databus between Pluto units
at fault condition
10 ms
1040 ms
Enclosure classication
Enclosure
Connection terminals
IP40, IEC 60 529
IP20, IEC 60 529
2/17 2TLC172001C0202 | ABB Safety Handbook
2
Description
The example describes a processing machine served by a
robot. The machine safety system consists of one (Pluto 1) to
which all protection has been connected. The robot has been
equipped with a (Pluto 0) to which the cell protection has
been connected. The Pluto for the machine has been connec-
ted via a databus cable to the robot's Pluto so that common
functions, such as emergency stop, can be used by the whole
cell.
Function
Emergency stop takes priority and will stop both the machine
and the robot. The machine hatch acts as the zone divider,
when the hatch is closed the machine forms one zone and the
robot another zone. When the machine hatch is open, both
the machine and the robot belong to the same zone. If the
door is opened when the machine hatch is open, the machi-
ne and the robot will both stop, but if the machine hatch is
closed, only the robot will be stopped.
After the door has been opened, the system must be reset by
means of the reset button on the outside of the door. Emer-
gency stop is reset when the pressed-in button is pulled out.
NOTE. The cell operating cycle must not however start imme-
diately on resetting the emergency stop or the door.
Robot cell with Pluto
APPLICATION EXAMPLE - Pluto
ABB Safety Handbook | 2TLC172001C0202 2/18
2
Electrical connections
2/19 2TLC172001C0202 | ABB Safety Handbook
2
1
Start
2 Two channel monitoring with automatic reset of emergency stop at the door.
TC1S
Q In1
In2
Start
I0.0
P0_ES1_Ch1
I0.1
P0_ES1_Ch2
GM0.0
P0_ES_OK
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
I0.0=P0_ES1_Ch1 Emergency stop 1 channel 1 - Static
I0.1=P0_ES1_Ch2 Emergency stop 1 channel 2 - Dynamic A non-inverted
3 Emergency stop of robot.
When the emergency stop is actuated the robot will make an emergency stop.
In order to restore safety requires the emergency stop button needs to be reset.
An emergency stop from the machine panel will also emergency stop the robot.
GM0.0
P0_ES_OK
GM1.0
P1_ES_OK
Q0.3
P0_ES
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
GM1.0=P1_ES_OK Emergency stop OK in Pluto 1
Q0.3=P0_ES Robot emergency stop - Expansion BT50 relay
4 Auto stop of robot.
When the door to the robot cell is opened the robot is auto stopped.
To reset the safety the door needs to be closed and the reset button pressed and released.
Note that IQ15 of the Pluto is used both as a button in and to indicate diffirent reset states.
Constant light means reset is not possible, safety not ok.
Flash 0.4 s high, 0.6 s low means reset is possible but not performed.
No light means reset has been performed and the safety is ok.
ResetT
Q In1
Reset
Test
IndReset
I0.2
P0_Eden1
N
I0.15
P0_LB1_In
Q0.15
P0_LB1_Out
Q0.2
P0_AS_OK
I0.15=P0_LB1_In Reset Door - Light button input - Dynamic A
I0.2=P0_Eden1 Door Eden sensor - Dynamic A
Q0.15=P0_LB1_Out Reset Door - Light button output - Static
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
PLC code Pluto 0 Robot cabinet
APPLICATION EXAMPLE - Pluto
ABB Safety Handbook | 2TLC172001C0202 2/20
2
1
Start
2 Two channel monitoring with automatic reset of emergency stop at the door.
TC1S
Q In1
In2
Start
I0.0
P0_ES1_Ch1
I0.1
P0_ES1_Ch2
GM0.0
P0_ES_OK
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
I0.0=P0_ES1_Ch1 Emergency stop 1 channel 1 - Static
I0.1=P0_ES1_Ch2 Emergency stop 1 channel 2 - Dynamic A non-inverted
3 Emergency stop of robot.
When the emergency stop is actuated the robot will make an emergency stop.
In order to restore safety requires the emergency stop button needs to be reset.
An emergency stop from the machine panel will also emergency stop the robot.
GM0.0
P0_ES_OK
GM1.0
P1_ES_OK
Q0.3
P0_ES
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
GM1.0=P1_ES_OK Emergency stop OK in Pluto 1
Q0.3=P0_ES Robot emergency stop - Expansion BT50 relay
4 Auto stop of robot.
When the door to the robot cell is opened the robot is auto stopped.
To reset the safety the door needs to be closed and the reset button pressed and released.
Note that IQ15 of the Pluto is used both as a button in and to indicate diffirent reset states.
Constant light means reset is not possible, safety not ok.
Flash 0.4 s high, 0.6 s low means reset is possible but not performed.
No light means reset has been performed and the safety is ok.
ResetT
Q In1
Reset
Test
IndReset
I0.2
P0_Eden1
N
I0.15
P0_LB1_In
Q0.15
P0_LB1_Out
Q0.2
P0_AS_OK
I0.15=P0_LB1_In Reset Door - Light button input - Dynamic A
I0.2=P0_Eden1 Door Eden sensor - Dynamic A
Q0.15=P0_LB1_Out Reset Door - Light button output - Static
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
5 Alarm 03 - Machine hatch open.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
GM1.1
P1_Hatch_OK
Q0.2
P0_AS_OK
SR0.11=0
SR_ErrorCode=0
SR0.10=203
SR_PlutoDisplay=203
GM1.1=P1_Hatch_OK Hatch closed
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR0.11=SR_ErrorCode Error code
6 Alarm 02 - Door open.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
I0.2
P0_Eden1
SR0.11=0
SR_ErrorCode=0
SR0.10=202
SR_PlutoDisplay=202
I0.2=P0_Eden1 Door Eden sensor - Dynamic A
SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR0.11=SR_ErrorCode Error code
7 Alarm 01 - Emergency stop actuated.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
GM0.0
P0_ES_OK
SR0.11=0
SR_ErrorCode=0
SR0.10=201
SR_PlutoDisplay=201
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
SR0.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR0.11=SR_ErrorCode Error code
2/21 2TLC172001C0202 | ABB Safety Handbook
2
1
Start
2 Two channel monitoring with automatic reset of emergency stop at the machine hatch.
TC1S
Q In1
In2
Start
I1.1
P1_ES1_Ch1
I1.2
P1_ES1_Ch2
GM1.0
P1_ES_OK
GM1.0=P1_ES_OK Emergency stop OK in Pluto 1
I1.1=P1_ES1_Ch1 Emergency stop 1 channel 1- Dynamic A non-inverted
I1.2=P1_ES1_Ch2 Emergency stop 1 channel 2 - Static
3 Two channel monitoring with automatic reset of interlocking switch of the machine hatch.
TC1S
Q In1
In2
Start
I1.3
P1_IS1_Ch1
I1.4
P1_IS1_Ch2
GM1.1
P1_Hatch_OK
GM1.1=P1_Hatch_OK Hatch closed
I1.3=P1_IS1_Ch1 Interlocking switch channel 1 - Dynamic A non-inverted
I1.4=P1_IS1_Ch2 Interlocking switch channel 2 - Static
4 Emergency stop of machine.
When the emergency stop is actuated the machine will make an emergency stop.
In order to restore safety requires the emergency stop button needs to be reset.
An emergency stop from the robot will also emergency stop the machine.
GM1.0
P1_ES_OK
GM0.0
P0_ES_OK
Q1.0
P1_ES
GM0.0=P0_ES_OK Emergency stop OK in Pluto 0
GM1.0=P1_ES_OK Emergency stop OK in Pluto 1
Q1.0=P1_ES Machine Emergency Stop
PLC code Pluto 1 Machine cabinet
5 Monitoring of the hatch.
When the hatch is opened the monitoring of the hatch is inactive.
To reset the safety the hatch needs to be closed and the reset button pressed and released.
Note that IQ15 of the Pluto is used both as a button in and to indicate different reset states.
Constant light means reset is not possible, safety not ok.
Flash 0.4 s high, 0.6 s low means reset is possible but not performed.
No light means reset has been performed and the safety is ok.
ResetT
Q In1
Reset
Test
IndReset
GM1.1
P1_Hatch_OK
N
I1.15
P1_LB1_In
M1.1
HB_Ind_Hatch_OK
M1.0
HB_Hatch_OK
GM1.1=P1_Hatch_OK Hatch closed
I1.15=P1_LB1_In Reset Hatch - Light button input - Dynamic A
M1.0=HB_Hatch_OK Help Bit - Hatch closed
M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch
6 Light button indication of the reset of the hatch.
If the robot cell's door is closed and reset no light indication is needed inside the cell.
M1.1
HB_Ind_Hatch_OK
Q0.2
P0_AS_OK
Q1.15
P1_LB1_Out
M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
Q1.15=P1_LB1_Out Reset Hatch - Light button output - Static
7 Protective stop of the machine.
Either the hatch is closed and reset or the door to the robot cell is closed and reset.
This means the cell can work with the hatch both open or closed as long as the cell's door is closed and reset.
M1.0
HB_Hatch_OK
Q0.2
P0_AS_OK
Q1.1
P1_PS
M1.0=HB_Hatch_OK Help Bit - Hatch closed
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
Q1.1=P1_PS Machine Protective Stop
8 Alarm 03 - Machine hatch open.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
GM1.1
P1_Hatch_OK
Q0.2
P0_AS_OK
SR1.11=0
SR_ErrorCode=0
SR1.10=203
SR_PlutoDisplay=203
GM1.1=P1_Hatch_OK Hatch closed
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
SR1.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR1.11=SR_ErrorCode Error code
APPLICATION EXAMPLE - Pluto
ABB Safety Handbook | 2TLC172001C0202 2/22
2
5 Monitoring of the hatch.
When the hatch is opened the monitoring of the hatch is inactive.
To reset the safety the hatch needs to be closed and the reset button pressed and released.
Note that IQ15 of the Pluto is used both as a button in and to indicate different reset states.
Constant light means reset is not possible, safety not ok.
Flash 0.4 s high, 0.6 s low means reset is possible but not performed.
No light means reset has been performed and the safety is ok.
ResetT
Q In1
Reset
Test
IndReset
GM1.1
P1_Hatch_OK
N
I1.15
P1_LB1_In
M1.1
HB_Ind_Hatch_OK
M1.0
HB_Hatch_OK
GM1.1=P1_Hatch_OK Hatch closed
I1.15=P1_LB1_In Reset Hatch - Light button input - Dynamic A
M1.0=HB_Hatch_OK Help Bit - Hatch closed
M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch
6 Light button indication of the reset of the hatch.
If the robot cell's door is closed and reset no light indication is needed inside the cell.
M1.1
HB_Ind_Hatch_OK
Q0.2
P0_AS_OK
Q1.15
P1_LB1_Out
M1.1=HB_Ind_Hatch_OK Help Bit - Indication Reset Hatch
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
Q1.15=P1_LB1_Out Reset Hatch - Light button output - Static
7 Protective stop of the machine.
Either the hatch is closed and reset or the door to the robot cell is closed and reset.
This means the cell can work with the hatch both open or closed as long as the cell's door is closed and reset.
M1.0
HB_Hatch_OK
Q0.2
P0_AS_OK
Q1.1
P1_PS
M1.0=HB_Hatch_OK Help Bit - Hatch closed
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
Q1.1=P1_PS Machine Protective Stop
8 Alarm 03 - Machine hatch open.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
GM1.1
P1_Hatch_OK
Q0.2
P0_AS_OK
SR1.11=0
SR_ErrorCode=0
SR1.10=203
SR_PlutoDisplay=203
GM1.1=P1_Hatch_OK Hatch closed
Q0.2=P0_AS_OK Robot auto stop - Expansion BT50 relay
SR1.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR1.11=SR_ErrorCode Error code
9 Alarm 02 - Door open.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
I0.2
P0_Eden1
SR1.11=0
SR_ErrorCode=0
SR1.10=202
SR_PlutoDisplay=202
I0.2=P0_Eden1 Door Eden sensor - Dynamic A
SR1.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR1.11=SR_ErrorCode Error code
10 Alarm 01 - Emergency stop actuated.
To generate User Errors (UE) a value of 200 - 299 can be written to the display of the Pluto.
A check of System Register 11 (SR11) in the Pluto prioritises errors from the Pluto itself over User Errors.
GM1.0
P1_ES_OK
SR1.11=0
SR_ErrorCode=0
SR1.10=201
SR_PlutoDisplay=201
GM1.0=P1_ES_OK Emergency stop OK in Pluto 1
SR1.10=SR_PlutoDisplay Pluto display figure. For user error: 200+no
SR1.11=SR_ErrorCode Error code
2/23 2TLC172001C0202 | ABB Safety Handbook
2
Probus DP
DeviceNet
CANopen
Pronet
Ethernet/IP
Modbus TCP
Pluto gateway is a unit providing two-way communication
between a Pluto safety PLC and other field buses.
The Pluto gateway is a compact unit mounted on a DIN rail,
and can be connected anywhere in a Pluto safety bus. The
unit has a common interface with Pluto, i.e. the same cabling,
and the Pluto Manager PC program can be used for servicing
and where necessary programming. Normally, however, all
the settings are made via DIP switches, which means that
programming tools are not required to put the gateway itself
into operation.
For programming Pluto there are ready-made function blocks
which, via a Pluto gateway, send and receive data from the
supervisory system.
Data from Pluto
Via PROFIBUS a supervisory PLC system can have access to
the I/O and other variables in a Pluto safety PLC. Global I/O
in a Pluto safety PLC are accessible via PROFIBUS modules
in the gateway, one module for each Pluto unit. Local data in
Pluto units can be read by a "local data module together with
the PLC codes in the supervisory system.
Data to Pluto
Via PROFIBUS a supervisory PLC system can transmit non-
safety-related information to a Pluto safety PLC. A total of
64 Boolean values and 8 different 16-bit registers can be
transmitted. Function blocks for these functions are available
in Pluto Manager.
PLC function blocks
To simplify the integration of a Pluto gateway PROFIBUS
into the supervisory PLC system, ABB JokabSafety provi-
des ready-made function blocks for several popular brands
of PLC. The function blocks make it easier to receive and
send information to the Pluto system. The function blocks
are supplied as open units with full access for the customer
to change and add functions. These function blocks can be
obtained via www.abb.com/jokabsafety.
Pluto safety bus LED
"K" button
PC port
Profibus LED
Profibus connector
Pluto gateway
GATE-P2
Use:
Bi-directional status
information from the
Pluto safety PLC
For Profibus
Features:
Two-way communication
Built-in filter function, shared
network
Only 22.5 mm wide
Can be located anywhere in
the databus
Common interface with Pluto
Ready-made function blocks
ABB Safety Handbook | 2TLC172001C0202 2/24
2
Gateway block schematic diagram - Pluto Profibus
Technical data - GATE-P2
Article number 2TLA020071R8000
Databuses -Pluto safety bus CAN (isolated)
-PROFIBUS RS485 (isolated)
Pluto safety bus speeds 100, 200, 250, 400, 500, 800 and 1000 kbit/s
(automatic speed detection)
PROFIBUS speed Up to 12 Mbit/s (automatic speed detection)
PROFIBUS address Setting via DIP switches (0-99)
PROFIBUS version DP slave, DP-V0
Connections Top, 3-pole terminal for Pluto safety bus (included)
Front, standard 9-pole PROFIBUS connection.
Bottom, 2-pole terminal for 24 VDC (included)
Status indication Pluto safety bus status indication via LED
PROFIBUS status indication via LED
Operating voltage 24 VDC, -15% till +20%
Current at 24 V < 100 mA (recommended fuse 6 A)
Dimensions (w x h x d) 22.5 x 101 x 119 mm
Installation 35 mm DIN rail
Operating temperature
(ambient) -10C to + 55C
Temperature, transport and
storage -25C to + 55C
Humidity EN 60 204-1 50% at 40C (ambient 90% at 20C)
Enclosure classication Enclosure IP20 - IEC 60 529
Terminals IP20 - IEC 60 529
119 mm
22.5 mm
101 mm
2/25 2TLC172001C0202 | ABB Safety Handbook
2
Probus DP
DeviceNet
CANopen
Pronet
Ethernet/IP
Modbus TCP
Pluto gateway is a unit providing two-way communication
between a Pluto safety PLC and other field buses.
The Pluto gateway is a compact unit mounted on a DIN rail,
and can be connected anywhere in a Pluto safety bus. The
unit has a common interface with Pluto, i.e. the same cabling,
and the Pluto Manager PC program can be used for servicing
and where necessary programming. Normally, however, all
the settings are made via DIP switches, which means that
programming tools are not required to put the gateway itself
into operation.
For programming Pluto there are ready-made function blocks
which, via a Pluto gateway, send and receive data from the
supervisory system.
Data from Pluto
Via DeviceNet a supervisory PLC system can have access to
the I/O and other variables in a Pluto safety PLC. Global I/Os
in a Pluto safety PLC are accessible via DeviceNet implicit
messages. Local data in Pluto units can be read via Device-
Net explicit messages.
Data to Pluto
Via DeviceNet a supervisory PLC system can transmit non-
safety-related information to a Pluto safety PLC. A total of
64 Boolean values and 8 different 16-bit registers can be
transmitted (via DeviceNet implicit or explicit messages).
Function blocks for these commands are available in Pluto
Manager.
Pluto bridge
A GATE-D2 can also be used to advantage as a CAN bridge
when it is required to divide a Pluto safety bus into several
sections. This is particularly useful when long databus cables
are needed.
There is also a built-in filter function which makes it possible
to block any data that is not required for use on the other side
of the bridge, which reduces the databus loading in the other
sections and thereby permits longer databus cables.
ABB Robotics IRC5
PLUTO GATE-D2 has support for integration into an ABB
Robotics IRC5-system. The documentation that describes this
integration can be obtained via www.abb.com/jokabsafety.
Pluto safety bus LED
"K" button
PC port
DeviceNet LED
DeviceNet connector
Pluto gateway
GATE-D2
Use:
Bi-directional status
information from the
Pluto safety PLC
For DeviceNet and
Pluto bridge
Features:
Two-way communication
Built-in filter function, shared
network
Only 22.5 mm wide
Can be located anywhere in
the databus
Common interface with Pluto
Ready-made function blocks
ABB Safety Handbook | 2TLC172001C0202 2/26
2
Gateway block schematic diagram - Pluto DeviceNet
Technical data - GATE-D2
Article number 2TLA020071R8200
Databuses -Pluto safety bus CAN (isolated)
-DeviceNet CAN (isolated)
Pluto safety bus speeds 100, 200, 250, 400, 500, 800 and 1000 kbit/s
(automatic speed detection)
DeviceNet speed 125, 250 and 500 kbit/s (set via DIP switch)
DeviceNet address Setting via DIP switches (1-63)
DeviceNet Version ODVA version 2.0
Connections Top, 3-pole terminal for Pluto safety bus (included)
Front, 5-pole terminal for DeviceNet (included)
Bottom, 2-pole terminal for 24 VDC (included)
Status indications Pluto safety bus status indication via LED
DeviceNet MNS status indication via LED
Operating voltage 24 VDC, -15% till +20%
Current at 24 V < 100 mA (recommended fuse 6 A)
Dimensions (w x h x d) 22.5 x 101 x 119 mm
Installation 35 mm DIN rail
Operating temperature (ambient) -10C to + 55C
Temperature,
transport and storage -25C to + 55C
Humidity EN 60 204-1 50% at 40C (ambient 90% at 20C)
Enclosure classication Enclosure IP20 - IEC 60 529
Terminals IP20 - IEC 60 529
119 mm
22.5 mm
101 mm
2/27 2TLC172001C0202 | ABB Safety Handbook
2
Probus DP
DeviceNet
CANopen
Pronet
Ethernet/IP
Modbus TCP
Pluto gateway is a unit providing two-way communication
between a Pluto safety PLC and other field buses.
The Pluto gateway is a compact unit mounted on a DIN rail,
and can be connected anywhere in a Pluto safety bus. The
unit has a common interface with Pluto, i.e. the same cabling,
and the Pluto Manager PC program can be used for servicing
and where necessary programming. Normally, however, all
the settings are made via DIP switches, which means that
programming tools are not required to put the gateway itself
into operation.
For programming Pluto there are ready-made function blocks
which, via a Pluto gateway, send and receive data from the
supervisory system.
Data from Pluto
Via CANopen a supervisory PLC system can have access to
the I/O and other variables in a Pluto safety PLC. Global I/
Os in a Pluto safety PLC are accessible via CANopen PDO
messages. Local data in Pluto units can be read via CANopen
SDO messages together with the PLC codes in the superviso-
ry system.
Data to Pluto
Via CANopen a supervisory PLC system can send non-safety-
related information to a Pluto safety PLC. A total of 64 Boo-
lean values and 8 different 16-bit registers can be transmitted
(CANopen PDO or SDO messages). Function blocks for these
commands are available in Pluto Manager.
Pluto bridge
A GATE-C2 can also be used to advantage as a CAN bridge
when it is required to divide a Pluto safety bus into several
sections. This is particularly useful when long databus cables
are needed.
There is also a built-in filter function which makes it possible
to block any data that is not required for use on the other side
of the bridge, which reduces the databus loading in the other
sections and thereby permits longer databus cables.
Pluto safety bus LED
"K" button
PC port
CANopen LED
CANopen connector
Pluto gateway
GATE-C2
Use:
Bi-directional status
information from the
Pluto safety PLC
For CANopen and
Pluto-bridge
Features:
Two-way communication
Built-in filter function, shared
network
Only 22.5 mm wide
Can be located anywhere in
the databus
Common interface with Pluto
Ready-made function blocks
ABB Safety Handbook | 2TLC172001C0202 2/28
2
Gateway block schematic diagram - Pluto CANopen
Technical data - GATE-C2
Article number 2TLA020071R8100
Databuses -Pluto safety bus CAN (isolated)
-CANopen CAN (isolated)
Pluto safety bus speeds 100, 200, 250, 400, 500, 800 and 1000 kbit/s
(automatic speed detection)
CANopen speeds 125, 250 and 500 kbit/s (set via DIP switch)
10, 20, 50, 100, 125, 250, 500, 800 and 1000 kbit/s (via software)
CANopen address Setting via DIP switches or software (1-63)
CANopen version Version 4.02 of the CiA Draft Standard 301
Connections Top, 3-pole terminal for Pluto safety bus (included)
Front, 5-pole terminal for CANopen (included)
Bottom, 2-pole terminal for 24 VDC (included)
Status indications Pluto safety bus status indication via LED
CANopen status indication via LED
Operating voltage 24 VDC, -15% till +20%
Current at 24 V: < 100 mA (recommended fuse 6 A)
Dimensions (w x h x d) 22.5 x 101 x 119 mm
Installation 35 mm DIN rail
Operating temperature (ambient) -10C to + 55C
Temperature, transport and
storage -25C to + 55C
Humidity EN 60 204-1 50% at 40C (ambient 90% at 20C)
Enclosure classication Enclosure IP20 - IEC 60 529
Terminals IP20 - IEC 60 529
119 mm
22.5 mm
101 mm
2/29 2TLC172001C0202 | ABB Safety Handbook
2
Probus DP
DeviceNet
CANopen
Pronet
Ethernet/IP
Modbus TCP
Pluto gateway is a unit providing two-way communication
between a Pluto safety PLC and other field buses.
The Pluto gateway is a compact unit mounted on a DIN rail,
and can be connected anywhere in a Pluto safety bus. The
unit has a common interface with Pluto, i.e. the same cabling,
and the Pluto Manager PC program can be used for servicing
and where necessary programming. Normally, however, all
the settings are made via DIP switches, which means that
programming tools are not required to put the gateway itself
into operation.
For programming Pluto there are ready-made function blocks
which, via a Pluto gateway, send and receive data from the
supervisory system.
Protocol
PLUTO Gateway GATE-E2 handles the status from and to
Pluto safety PLCs via Ethernet protocols EtherNet/IP, PRO-
FINET, Modbus TCP and a simple binary protocol that uses
TCP/IP.
For IP-address configuration, etc. there is a simple web server
and a terminal server.
Data from Pluto
Via one of the Ethernet protocols a supervisory PLC system
can have access to the I/O and other variables in a Pluto
safety PLC. Global I/Os in a Pluto safety PLC are accessible
via the usual I/O transfer in the respective protocol. Local data
in Pluto units can be read by special commands together with
the PLC codes in the supervisory system.
Data to Pluto
Via the Ethernet protocol a supervisory PLC system can
transmit non-safety-related information to a Pluto safety PLC.
A total of 64 Boolean values and 8 different 16-bit registers
can be transmitted. Function blocks for these functions are
available in Pluto Manager.
Pluto safety bus LED
"K" button
PC port
Ethernet LED
Ethernet connector
Pluto gateway
GATE-E2
Use:
Bi-directional status
information from the
Pluto safety PLC
Profinet, Ethernet/IP,
Modbus TCP
Features:
Two-way communication
Built-in filter function, shared
network
Can be located anywhere in
the databus
Common interface with Pluto
Ready-made function blocks
ABB Safety Handbook | 2TLC172001C0202 2/30
2
119 mm
101 mm
35 mm
Gateway
Ethernet, non safety
PLC
Pluto Pluto Pluto
Q1 Q0 IQ16 IQ14 IQ12
IQ13 IQ15 IQ17 0V ID +24V
I4 I0 C L I2
C H I1 I3
I5 I7 IQ11 Q3
IQ10 I6 Q2
Q1 Q0 IQ16 IQ14 IQ12
IQ13 IQ15 IQ17 0V ID +24V
I4 I0 C L I2
C H I1 I3
I5 I7 IQ11 Q3
IQ10 I6 Q2
Q1 Q0 IQ16 IQ14 IQ12
IQ13 IQ15 IQ17 0V ID +24V
I4 I0 C L I2
C H I1 I3
I5 I7 IQ11 Q3
IQ10 I6 Q2
Pluto CAN bus, safety
M
odbus TCP
PRO
FINET
EtherNet/IP
BUS
PLUTO
GATE-E1
PR
K
Status
Net
Status
Mod
Gateway block schematic diagram - Pluto Ethernet
Technical data - GATE-E2
Article number 2TLA020071R8300
Buses Pluto-bus CAN (isolated)
Pronet (isolated)
Ethernet/IP (isolated)
Modbus TCP (isolated)
Pluto safety bus speeds 100, 200, 250, 400, 500, 800 and
1000 kbit/s
(automatic speed detection)
Ethernet 10/100 Mbit/s
Half and full duplex
Ethernet protocol Status from and to Pluto safety PLC
- EtherNet/IP
- PROFINET
- Modbus TCP
- Binary server (TCP/IP)
Note that certain combinations of
server protocols cannot be used
simultaneously.
Gateway status and IP address
conguration
- Web server
- Terminal server (TCP/IP)
EtherNet/IP According to ODVA CIP Edition 3.2
and EtherNet/IP Adaption of CIP
Edition 1.3.
Minimum RPI of 50 ms
PROFINET PROFINET
Modbus TCP According to the Modbus orga-
nisation, version 1.0b (approx. 20
messages per second).
Binary server (TCP/IP) Simple TCP/IP protocol to send
status from/to the Pluto system.
Web server For simple sharing of IP
addresses.
Terminal server (TCP/IP) Simple server with the same com-
mands as via the serial programming
port in the unit.
IP address Static sharing via web server or via
programming port.
Gateway conguration Takes place via EtherNet/IP, PROFI-
NET, Modbus TCP or
via the binary TCP/IP server.
Connections Top, 3-pole terminal for Pluto safety
bus (included)
Front, Ethernet connection via RJ-45
(screened cable cat. 5e FTP)
Bottom, 2-pole terminal for 24 VDC
(included)
Status indications Pluto safety bus status indication via
LED (Pluto safety bus)
Ethernet module status indication via
LED (Mod Status)
Ethernet network status indication
via LED (Net Status)
Operating voltage 24 VDC, -15 % till +20 %
Current at 24 V < 150 mA (recommended fuse 6 A)
Dimensions (w x h x d) 35 x 101 x 120 mm
Installation 35 mm DIN rail
Operating temperature (ambient) -10C to + 55C
Temperature, transport and storage -25C to + 55C
Humidity EN 60 204-1 50 % at 40C (ambient
90 % at 20C)
Enclosure classication Enclosure IP20 - IEC 60 529
Terminals IP20 - IEC 60 529
2/31 2TLC172001C0202 | ABB Safety Handbook
2
Rotational absolute value sensor for safe positioning
Together with a Pluto safety PLC, this rotational absolute
encoder can be used for safe position determination. This
is particularly useful with equipment such as gantry robots,
industrial robots, etc. Also in eccentric shaft presses, existing
cam mechanisms can be replaced by absolute value positi-
on sensors for safe positioning. The sensors are available in
single and multi-turn versions.

Up to 16 absolute encoders can be connected to a Pluto CAN
databus. A Pluto on the databus reads the sensor values,
which are evaluated. With a special function block in the PLC
code, it is possible to design two-channel solutions with the
sensors. The user can obtain safe values for position and
speed from these values. This enables supervision of stationa-
ry and overspeed conditions.
The absolute value sensors are standard sensors with modi-
fied software to meet the safety requirements.
Example of an application where 2 sensors provide safe position determination in a gantry robot.
Pluto
Safe Encoder
Use:
Safe position and
speed determination of
machine movements.
Features:
High resolution
Selectable resolution
Connected directly to the
Pluto safety bus
Ready-made function blocks
ABB Safety Handbook | 2TLC172001C0202 2/32
2
Technical data Safe Encoder RSA 597/RHA 597
Article number 2TLA020070R3600
2TLA020070R3300
2TLA020070R3400
2TLA020070R5900
Ambient temperature -40C .. +70C
Temperature, transport and
storage -30C .. +70C
Ingress protection class IP-67 in accordance with IEC 60529
At shaft inlet IP-66 in accordance with IEC 60529
Vibration (55 to 2000 Hz) < 300 m/s
2
in accordance with IEC 60068-2-6
Shock (6ms) < 2000 m/s
2
in accordance with IEC 60068-2-27
Material, enclosure Aluminium
Surface treatment Painted and chromed or anodised
Weight Approx. 300 g
Accuracy and resolution
Resolution 13 bits, 8192 positions per rotation
Accuracy LSB (Least Signicant Bit)
Operating voltage 9-36 VDC
Polarity-protected Yes
Short-circuit protected Yes
Databus speed 5 kbit/s - 1 Mbit/s, preset at 500kbit/s
Address input Active low
Code type Binary
Programmable functions

Resolution, 0 position
Direction, Databus speed
Current consumption 50 mA at 24 VDC
Max current consumption 100 mA
Ordering details
Shaft Conncection Type Order code
10 mm with face 12-pole connector RSA 597 2TLA020070R3600
6 mm with face 1.5 m cable RSA 579
RSA 597
2TLA020070R3300*
Hollow shaft 12 mm 2 m cable RHA 597 2TLA020070R3400*
Hollow shaft 12 mm 10 m cable RHA 597 2TLA020070R5900*
*Ordering product
2/33 2TLC172001C0202 | ABB Safety Handbook
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Technical data Safe Encoder RSA 698/RHA 698
Article number 2TLA020070R3700
2TLA020070R7800
2TLA020070R7900
Ambient temperature -40C .. +70C
Temperature, transport and storage -30C .. +70C
Ingress protection class IP67 in accordance with IEC 60529
At shaft inlet IP66 in accordance with IEC 60529
Vibration (55 to 2000 Hz) < 100 m/s
2
in accordance with IEC 60068-2-6
Shock (6ms) < 2000 m/s
2
in accordance with IEC 60068-2-27
Material, enclosure Aluminium
Surface treatment Anodised
Weight Approx. 400g
Accuracy and resolution
Resolution, total 25 bit
13 bits, 8192 positions per rotation
12 bits, 4096 rotations
Accuracy 1 LSB (Least Signicant Bit)
Operating voltage 9-36 VDC
Polarity-protected Yes
Short-circuit protected Yes
Databus speed 10 kbit/s - 1 Mbit/s
Code type Binary
Programmable functions Resolution, 0 position
Current consumption 50 mA at 24 VDC
Max current consumption 100 mA
Ordering details
Shaft Conncection Type Order code
10 mm round M12 5-pole connector RSA 698 2TLA020070R3700
6 mm round M12 5-pole connector RSA 698 2TLA020071R7800*
Hollow shaft 12 mm M12 5-pole connector RHA 698 2TLA020071R7900*
*Ordering product
ABB Safety Handbook | 2TLC172001C0202 2/34
2
Encoder Cam
Function block for electronic cam gear.
Function
Output Q is activated if the value of the
input register 'PosReg' is within the
limits for MinPos and MaxPos.
NOTE! It is possible to specify a value
that defines the sensor's zero position.
Position <0 is not permitted.
Example: If MinPos = 3000 and
MaxPos = 200, Q is activated when
the position is greater than 2999 or less
than 201.
Safe Encoder
Function block for two single-turn
encoders that generates safe position
and speed values.
Function
The block reads and evaluates two absolute
encoders. The position value is sent to
the 'Position' output. The 'Speed' out-
put is the average value for the speed,
at the rate of pulses/10 ms. If an error
occurs, the 'OK' output is set to zero. In
certain applications the values of 'Positi-
on' and 'Speed' are used in conjunction
with the 'OK' output.
Safe Encoder Multiturn
Function block for two multi-turn
encoders that generates safe position
and speed values.
Function
The block reads and evaluates two ab-
solute encoders. The average value for
the two sensors is calculated and sent
to the 'Position' output. The 'Speed'
output is the average value for the
speed, at the rate of pulses/10 ms. The
block monitors that the encoder position
values do not differ by more than the
input value set by 'MaxDiff'. If an error
occurs, the 'OK' output is set to zero. In
certain applications the values of 'Positi-
on' and 'Speed' are used in conjunction
with the 'OK' output.
Descriptions of inputs and outputs
PosReg: Input for the position value
MinPos: Minimum limit value
MaxPos: Maximum limit value
Descriptions of inputs and outputs
- AdrEncoderA: Encoder A node address
- AdrEncoderB: Encoder B node address
- MaxDiff: Max allowed deviation between the encoders
(max 2% of Range)
- Range: Number of increments per revolution
- OK: Set when encoders are working OK and
the position values are within the margin set by 'MaxDiff'
- Position: Position value
- Speed: Speed value as increments/10ms
- A: Encoder A position. Must not be used in PLC program!
- B: Encoder B position. Must not be used in PLC program!
NOTE! Position values from single encoders are only available for adjustment pur-
poses and must NOT be used for safety.
NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and the OK output will
be reset.
Descriptions of inputs and outputs
AdrEncoderA: Encoder A node address
AdrEncoderB: Encoder B node address
MaxDiff: Max allowed deviation between the encoders
(max 2% of IncrPerRev)
IncrPerRev: Number of increments per revolution
OK: Set when encoders are working OK and
the position values are within the margin set by 'MaxDiff'
Position: Position value
Speed: Speed value as increments/10ms
A: Encoder A position. Must not be used in PLC program!
B: Encoder B position. Must not be used in PLC program!
NOTE! Position values from single encoders are only available
for adjustment purposes and must NOT be used for safety.
NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and the OK output will
be reset.
2/35 2TLC172001C0202 | ABB Safety Handbook
2
Pluto identifier
IDFIX
Use:
Gives each Pluto unit
an identity on the bus
For storage of the PLC
program
For storage of the AS-i
safety codes
IDFIX is an identifier circuit which gives each Pluto an address
on the bus. It contains an identification code which can be
read by the system. The identification code is declared in the
PLC program so that the correct part of the PLC program is
executed by each specific Pluto. The use of IDFIX is mandato-
ry in a multi-Pluto project, but voluntary if a unit works alone.
If one Pluto in a multi-Pluto project needs to be replaced it is
possible to let the new Pluto self load the PLC program from
another Pluto on the bus. The IDFIX will ensure that the new
Pluto has the correct address on the bus.
Five different versions of IDFIX
R is preprogrammed.
RW is programmable.
DATA is programmable and can also store the AS-i safety
codes.
PROG 2k5 is for single-Pluto projects only, and has a 2.3
kbyte memory for storage of the PLC program. It can also
store the AS-i safety codes in the same way as IDFIX-
DATA.
PROG 10k works in the same way as PROG 2k5, but it
has a larger memory (10 kbyte).
IDFIX is connected between the input terminals ID and 0V.
IDFIXDATA
IDFIX-DATA is for Pluto AS-i and B42 AS-i, and contains a
memory for storage of the AS-i safety codes.
IDFIXPROG
IDFIX-PROG contains a memory for storage of the PLC pro-
gram for single-Pluto projects. When a program is downloa-
ded to Pluto the IDFIX-PROG will automatically be updated.
If the Pluto unit needs to be replaced, the new Pluto can self
load the PLC program from IDFIX-PROG by pressing the K
button (in the same way as a Pluto can self load the program
over the CAN bus). Only one Pluto is allowed in the project
and the IDFIX code is always EEEEEEEEEEE0. IDFIX-PROG
can also store the AS-i safety codes in the same way as
IDFIX-DATA.
NOTE! Single-Pluto project means that the PLC program
only contains one Pluto. It is still possible to connect several
Single-Pluto projects, each with its own program and IDFIX-
PROG, together via the Pluto bus.
ABB Safety Handbook | 2TLC172001C0202 2/36
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3/1 2TLC172001C0202 | ABB Safety Handbook
3
ABB Safety Handbook | 2TLC172001C0202 3/2
3
Why should I use the bus system at component level? 3/3
Pluto AS-i Safety Safety is now simple! 3/5
A Pluto AS-i can be used in three ways 3/7
Sensors with built in AS-i safety nodes 3/8
Safety node Urax
Urax-A1/A1R 3/9
Urax-B1R 3/11
Urax-C1/C1R 3/13
Urax-D1R 3/15
Urax-E1 3/17
AS-i Safety
Two-wire bus system
3/3 2TLC172001C0202 | ABB Safety Handbook
3
provides simplicity in the construction of systems
The AS-i system provides benefits both when the system is
planned and installed. A single network can, for example, be
divided into monitoring and control of different work zones.
The zones can be dependent on each other or not, even
though they are controlled and are connected to the same
general process.
in order to easily expand the system
The systems construction allows, where necessary, the easy
extension or expansion of the network. Cable is added which
thereby extends the production line without any additional
controllers being installed.
Why should I use the bus system at component level?
to save installation time
Components designed for the AS-i bus system can easily
connect to the network wherever this is required. The required
function is then selected in the control system.
as it provides a flexible system
You can use the AS-i cable to move, replace or add new safe-
ty products anywhere as needed. Additional monitors such as
Pluto AS-i can also be connected in the same way.
ABB Safety Handbook | 2TLC172001C0202 3/4
3
The AS-interface makes it easy to connect and remove products
to and from the AS-i bus.
Why is the AS-i Safety so good from a safety perspective?
The simple connection to a cable also applies to safety com-
ponents. The risk of incorrect wiring is thereby minimised.
Each safety node, i.e. safety product, has its own address on
the AS-i bus along with a unique safety code.
The additional requirement for an AS-i system to cope with
safety products is that there must be extra safe monitoring.
The control ("Master") does not need to be safe, but is com-
plemented with a safety Monitor (however, safety PLC Pluto
AS-i can act as both Master and/or Monitor).
The advantage of safety within AS-i is that it is easy to intro-
duce changes without significant costs compared to traditi-
onal safety systems that require new cable running from the
electrical cabinet for each new protection. Moreover, experi-
ence shows that most safety systems need to be retrofitted to
adapt the protection to suit the changes to production.
How does the bus system AS-Interface work?
The AS-i system is distinguished by its special yellow profile
cable. The cable connects all sensors, transducers and actua-
tors on the network to a master system. The component parts
of a system can include both non-safe and safe products.
This means that both operational and safety related products
can be mixed in a network. The bus system drives a Master-
Slave (node) configuration where each I/O module corres-
ponds to a common master.
Communication takes place through the yellow cable which
also provides the nodes with supply voltage. The installation
of the cable is usually done along a production line or cen-
trally around the AS-i system's I/O products. After commissio-
ning the system can always be expanded by adding branches
or extensions to the cable. In a similar way, more products
can be added, moved or replaced. The changes are easily
made in the software to the controller. With the AS-i concept,
decentralised systems can be designed with all products,
non-safe and safe monitored by a device. This advantage
means that the system can be handled as zones where one
zone can be down, another can be in operation and a third
manually operated. Without degrading operation and safety or
influencing each other's zones.
Voltage and communications
The AS-i network is maintained by a special AS-i power sup-
ply unit that generates a regulated DC output voltage bet-
ween 29.5 and 31.6 V. This supplies voltage to the network
nodes at the same time as communications are transmitted in
a superimposed manner.
Nodes
Safety nodes (maximum 31) and A / B-nodes (maximum 62)
are connected to the AS-i for both inputs and outputs.
Two-wire cable
The AS-i cable is a two-wire cable (2x1.5mm
2
) that is not
shielded. Connection is made using piercing technology, whe-
re the cable housing is self-restoring if a connection is moved.
The cable retains enclosure protection class IP67 in this way.
Adaptation devices
For the AS-i cable it is possible to connect the adaptation
devices that act as a link between a component and the AS-i
system. These adaptation devices are available as both safety
nodes and nodes for non-safe products.
Sensors with integrated safety nodes
Some AS-i adapted components have nodes directly built
into the product, for example, there is one safety node in the
customised Smile Emergency Stop.
3/5 2TLC172001C0202 | ABB Safety Handbook
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Gateway
Probus DP
DeviceNet
CANopen
Ethernet
Pluto AS-i
Safety is now simple!
The AS-i system
The AS-i cable can be connected to the safety products se-
parately or through the adaptation device Urax. Some compo-
nents have an integrated AS-i node and are connected via an
M12 connection directly to the yellow AS-i cable. Traditional
products without an integrated AS-i node need to be connec-
ted via the safety node Urax.
In both cases, the highest level of safety is maintained. The
AS-i cable is powered by 30VDC power supply and connec-
ted to a special AS-i power supply unit. Some components
have power requirements that are higher than the AS-i cable
is able to supply. Therefore, there is also a black cable (AUX
24VDC) with secondary supply voltage that is able to supply
more current.
Possible connections for a complete system:
all our sensors for AS-i via Urax
all Pluto PLCs, gateways and absolute encoders through
Plutos safety bus to the Pluto AS-i
operator panel via the programming port on Pluto
expansion relay for multiple outputs
Adaptation device Urax with integrated safety node
Urax is an adaptation device for safety components that can-
not be directly connected to the AS-i bus. You can connect
safety components, local reset, and non-safe controls, such
as process locks to Urax. Urax is available in several versions,
adapted to suit specific safety products.
Safety level
Pluto, Urax and products with integrated safety nodes achieve
safety level PL e/Cat. 4 in compliance with EN ISO 13849-1.
Pluto AS-i is a version of Pluto with AS-i bus connection.
It can either be a master on the AS-i bus or work together
with another AS-i master as a monitor. It has digital and
analogue inputs and safe outputs. Pluto AS-i can also
operate as a safe I/O module for the AS-i bus.
ABB Safety Handbook | 2TLC172001C0202 3/6
3
Sensors with integrated AS-i safety nodes
Some of our products can be ordered with integrated AS-i
node.
These are connected to the yellow cable with a M12 contact
directly to the yellow AS-i cable via a screw terminal which is
clamped to the cable. More information can be found under
each product.
AS-interface - an intelligent cable running system
The field bus system AS-interface came to light in the 90s.
The system was the result of a collaboration between several
component manufacturers for machine control. The idea was
a bus system at a component level where the goal was simp-
licity and flexibility. Since the system was launched, many new
and innovative ideas have been added.
AS-International Association
In 1991, the AS-International Association for organisational
cohesion and marketing was founded. The AS-i association
works in both an advisory and auditing capacity to ensure the
AS-i standard is maintained.
The goal of the AS-i Association is that the AS-interface is to
become a world standard for easy communication for compo-
nents within the automation industry.
The distinguishing feature of the AS-interface is that data
communication is mixed with the power supply. This is done in
a simple two-wire cable. In 2001 safety was integrated in the
AS-interface via the work group Safety at Work, which also
includes ABB JokabSafety.
Simple connections to the AS-i cable
Adaptation devices are clamped directly to the AS-i cable.
Transition from the AS-i cable to M12 units is made via a T
connector on the AS-i cable. Cable branches or extensions of
the AS-i cable are made using a splitter box.
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Probus DP
DeviceNet
Ethernet
CANopen
AS-i Master
AS-i Master
AS-i Master AS-i Monitor AS-i Monitor AS-i Monitor
AS-i I/O
Pluto without AS-i
Gateway
Gateways allow you to communicate
easily with other bus systems.
Bus connection
Pluto AS-i can be connected with other
Pluto units both via the AS-i bus and
through the Pluto safety bus.
How large can you build the system?
From a technical aspect there are no constraints on the size of
the system you can build. A Pluto PLC can, in addition to pro-
cessing a complete AS-i bus, communicate with another Pluto
either through a Pluto safety bus or through the AS-i bus.
Through Pluto's safety bus, each Pluto can be a party to the
I/Os of others and a total of 32 Plutos can be linked in this
way. If two Plutos are connected to each other via the AS-i
bus, each Pluto can be connected to 31 other Plutos.
Using Gateways the system can be expanded further to other
bus systems for information exchange.
1. Pluto as Safety Master*
The master distributes and controls communication on the
AS-i bus and acts simultaneously as Safety Monitor.
2. Pluto as Safety Monitor*
The monitor listens to what is happening on the AS-i bus and
controls the safe outputs.
Pluto AS-i
A Pluto AS-i can be used in three ways - as Safety
Master, Safety Monitor or as Safety I/O
3. Pluto as Safety I/O*
Multiple safe inputs and/or outputs are controlled and com-
municate with a safe master or monitor across the AS-i bus.
*Whether Pluto is used as a Master, Monitor or I/O it can
simultaneously control and monitor the safety of a machine.
ABB Safety Handbook | 2TLC172001C0202 3/8
3
Model Urax A
1
A
1
R
B
1
R
C
1
C
1
R
D
1
R
E
1
Dynamic sensor (Eden, Tina) 3 3 10
Two-channel sensors
Sensors with OSSD Signals
Two-hand station
Local reset function
External power source
Non-safe outputs 1 1 3 3 3
The Urax safety node has safety inputs for sensors and reset buttons, and
outputs such as process locks.
Sensors with built-in AS-i safety nodes

Urax safety node is available in several versions, and is designed for a variety of
safety components. Urax has the capability to connect multiple sensors in
series to the highest level of safety PL e in compliance with EN ISO 13849-1.
Safeball, a control device with a built-in AS-i node
Our globally-unique control device with ergonomic design fits all hands and offers
many grip options. Safeball has double safety for each hand, i.e. two buttons on
each ball need to pressed. It can be used for either one or two hand operation.
Smile, a small and robust emergency stop with built in AS-i node
Smile has a width of 40 mm and its centered mounting holes make installation easy
especially in aluminium profiles that are often used for machine construction and
machine protection. Smile also has LED indication.
Three-position device with built in AS-i node
The three-position device JSHD4 with sensors that ensure that it is a human hand
thats grips the device (fraud-proof) is available with a built in AS-i node. The device
is usted for settings, fault tracking and test running when no other protection is
possible or feasible.
Eden, a non-contact safety sensor with built in AS-i node
Eden is a non-contact safety sensor for use on interlocked gates, hatches etc.
Eden consists of two complementary parts called Adam and Eva. The sensor is
only activated if the gate or hatch is closed, when Adam and Eva are within sensing
distance. Eden is constantly communicating between the two parts and any failure
will directly lead to a stop signal
3/9 2TLC172001C0202 | ABB Safety Handbook
3
0V 24V
Urax-A1 Urax-A1R
Reset
Adaptation device for dynamic sensors for AS-i.
Urax-A1/A1R is a safety node for the AS-i bus, where it is possible to connect up
to three dynamic sensors, such as Eden, in series in compliance with PL e EN ISO
13849-1.
Switches adapted to dynamic sensors such as Smile Tina can also be connected to
the safety circuit.
Urax-A1/A1R also has an output for non-safe control, where it is possible to control
non-safety critical equipment such as process locks. Urax-A1R has an additional
feature that provides local reset button (R) with LED indicator.
The dynamic safety sensors are controlled by Urax over one hundred times per
second which gives a high level of safety.
Urax-A1/A1R has LED indication for the dynamic loop and can be addressed on the
bus via the ADDR contact.
Safety node
Urax-A1/A1R
Approvals:
Application:
Adapts dynamic sensors to
the AS-i bus
Features:
Enables dynamic sensors on
the AS-i bus
Multiple sensors in series with
maintained safety level
Possibility of local reset
Outputs of non-safe control,
e.g. process locks
TV Rheinland
ABB Safety Handbook | 2TLC172001C0202 3/10
3
Technical data Urax-A1/A1R
Article number
Urax-A1 2TLA020072R0000
Urax-A1R 2TLA020072R0100
Colour Yellow and black
Weight 155 g
AS-i data
AS-i prole Urax-A1/A1R S-7.B.E
Addressing Jack plug
Slave address upon delivery 0
Voltage supply
Voltage AS-i yellow cable, 30 VDC.
Tolerance 26.5 31.6 VDC.
Insulation 0 V is common with AS-i and must
not be connected to the protective
earth. (The AS-i voltage is oating.)
Total current consumption <260 mA (Own consumption, sensor
and outputs)
Current limit for the outputs in total 180 mA (Sensors, outputs and reset
indicator)
Output (non-safe)
Output voltage 24-28 VDC at nominal AS-i voltage,
30V.
Current Depending on load.
See total current consumption
Reaction time
Reaction time (off)* 12 ms (excluding sensors and other
peripheral components)
Reaction time including Eden
sensor (Normal) <20 ms
Reaction time including Eden
sensor (Worst case) <34 ms
Sensor info
Number of Eden sensors (max) 3
Cable to sensor, total length <30 m
Enclosure
Enclosure protection class IP67
Ambient temperature 25+65C
Enclosure dimensions 96x60x25 (HxWxD)
Safety/Harmonised standards
IEC/EN 61508-1..7 SIL3, PFD
avr
: 1.5x10
-4
,
PFH: 1.7x10
-9
, Share of SIL3: 15 %
EN 62061 SIL3
EN ISO 13849-1 PL e/Cat. 4
EN 954-1 MTTF
d
: high
Certication Cat. 4
The concept of dynamic signal
The concept is a safety circuit that is based on a single-
channel dynamic signal. The dynamic signal along with the
adapted sensor makes it possible to build large systems with
sensors in series while maintaining the highest level of safety.
The safety principle is based on each sensor inverting the si-
gnal, making it possible to detect faults such as short circuits
and defective sensors.
Odd or even number of sensors on Urax
The dynamic signal is generated in Urax and goes out to
the sensors and then back again. The fact that the number
of sensors may vary and that each sensor inverts the signal
make it necessary for Urax-A1/A1R to be configured so that
it takes into account whether it is an odd or even number of
sensors that are connected to the safety loop. This is done
via the AS-i node parameter settings.
Non-safe outputs
Connections for
Urax-A1 and A1R
Urax-A1/A1R is fitted with a non-safe output. This can be
used for diverse control or indicators and is controlled directly
from the AS-i master.
The output is located on the same contact as the safety sen-
sor, i.e. on contact 1 and controlled on pin 5. For example,
you can connect a Dalton or Knox to this contact.
Reset
Urax-A1R has an input for local reset on contact 2 that can
be configured using parameter settings for either automatic or
manual reset.
Auto reset
If auto reset has been selected, pins 1-4 on contact 2 must
be bridged.
Manual reset
If manual reset has been selected, the reset input must be
switched on and off within 2 seconds in order for Urax to be
enabled (generate safety code).
*NOTE: The above reaction time refers only to the Urax device. In calculating the total
reaction time, all the component parts in the safety chain must be taken into account.
9
6
60
ADDR
25
8
ASI
AUX
12 36
30
4
.
5
7
3
URAX-
Safety
I
Q1
FAULT AS-i COn
ADDR
5
2
3
4
1
0V
Dyn outp
+24V
Inp
Out1 (AS-i)
Dyn. sensor
Connector 1
-A1
4
3 2
5
1
1
URAX-A1
Safety
I
Q1 R.Ind
Reset
FAULT AS-i COn
ADDR
1
2
3
4
5
2
3
4
1
0V
Dyn outp
+24V
Inp
Out1 (AS-i)
Dyn. sensor
Connector 1
Connector 2
-A1R
Inp
Reset ind.
Ind. outp.
Dyn outp
0V
Reset
Auto reset
5
4
3 2
5
1
1 2
URAX-A1R
Safety
3/11 2TLC172001C0202 | ABB Safety Handbook
3
Urax-B1R
0V 24V
Reset
Adaptation device for dynamic sensors for AS-i.
Urax-B1R is a safety node for the AS-i bus, where it is possible to connect up
to ten dynamic sensors, such as Eden, in series in compliance with PL e EN ISO
13849-1.
Switches designed for dynamic safety circuit, such as Smile Tina, can also be con-
nected.
Urax-B1R also has three outputs for non-safe control. Through these it is possible
to control non-safety critical equipment such as the process lock Magne.
Urax-B1R will be supplied with an auxiliary power supply (AUX), which means that
more power-consuming equipment can be connected to the node.
An additional feature is that it is possible to connect a local reset button (R) with
LED indicator.
The dynamic safety sensors are controlled by Urax over one hundred times per
second which gives a high level of safety.
Urax-B1R has LED indication for the dynamic loop and can be addressed on the
bus via the ADDR contact.
Safety node
Urax-B1R
Approvals:
Application:
Adapts dynamic sensors with
higher current requirements to
the AS-i bus
Features:
Enables dynamic sensors on
the AS-i bus
Up to 10 sensors connected
in series while maintaining the
highest level of safety
Possibility of local reset
Outputs of non-safe control,
e.g. process locks
TV Rheinland
ABB Safety Handbook | 2TLC172001C0202 3/12
3
The concept of dynamic signal
The concept is a safety circuit that is based on a single-
channel dynamic signal. The dynamic signal along with the
adapted sensor makes it possible to build large systems with
sensors in series while maintaining the highest level of safety.
The safety principle is based on each sensor inverting the si-
gnal, making it possible to detect faults such as short circuits
and defective sensors.
Odd or even number of sensors on Urax
The dynamic signal is generated in Urax and goes out to
the sensors and then back again. The fact that the number
of sensors may vary and that each sensor inverts the signal
make it necessary for Urax-B1R to be configured so that it
takes into account whether it is an odd or even number of
sensors that are connected to the safety loop. This is done
via the AS-i node parameter settings.
Non-safe outputs
Urax-B1R is fitted with three non-safe outputs.
These can be used for diverse controls or indicators and are
controlled directly from the AS-i master.
Output 1 is located on the same contact as the safety sensor,
i.e. contact 1 and controlled on pin 5. For example, you can
then connect a Dalton or Knox to this contact. Outputs 2 and
3 have non-safe control on pin 4 of contact 3 and 4 respec-
tively.
Reset
Urax-B1R has an input for local reset on contact 2 that, with
parameter settings, can be configured for either automatic or
manual reset.
Auto reset
If auto reset has been selected, pins 1-4 on contact 2must
be bridged.
Manual reset
If manual reset has been selected, the reset input must be
switched on and off within 2 seconds in order for Urax to be
enabled (generate safety code).
Technical data Urax-B1R
Article number
Urax-B1R 2TLA020072R0200
Colour Yellow and black
Weight 155 g
AS-i data
AS-i prole Urax-B1R S-7.B.E
Addressing Jack plug
Slave address upon delivery 0
Voltage supply
Voltage AS-i (Yellow cable) 30 VDC. Tolerance 26.5 31.6VDC.
Voltage AUX (Black cable) 24 VDC (15 %)
Insulation
Current limit (+24 V)
Total current consumption AS-i
0V is common with AUX which shall
be connected to protective earth at
power supply.
700 mA
<30mA
Output (non-safe)
Output voltage 24 VDC (AUX)
Current 700
Reaction time
Reaction time (off)* 12 ms (excluding sensors and other
peripheral components)
Reaction time including Eden
sensor (Normal) <20 ms
Reaction time including Eden
sensor (Worst case) <34 ms
Sensor info
Number of Eden sensors (max) 10
Cable to sensor, total length <30 m
Enclosure
Enclosure protection class IP67
Ambient temperature 25+65C
Enclosure dimensions 96x60x25 (HxWxD)
Safety/Harmonised standards
IEC/EN 61508-1..7 SIL3, PFD
avr
: 1.5x10
-4
,
PFH: 1.7x10
-9
, Share of SIL3: 15 %
EN 62061 SIL3
EN ISO 13849-1 PLe/Cat. 4
EN 954-1 MTTF
d
: high
Certication Cat. 4
Connections for Urax-B1R
Q2
Q1 R.Ind
Reset I
Q3
FAULT AUX AS-i COn
ADDR
Out2 (AS-i)
0V 3
4
2
1
1
4
2
3
Out1 (AS-i) 5
4
3
Inp
0V
Dyn outp
1
2
+24V Dyn. sensor
Connector 1
Connector 2
Connector 3
-B1R
5
Inp
0V
Ind. outp.
Dyn outp
Reset
Reset ind.
Auto reset
5
5
Connector 4
1
2
4
3 0V
Out3 (AS-i)
+24V
+24V 4
3 2
5
1
1
3
2
4
URAX-B1R
Safety
*NOTE: The above reaction time refers only to the Urax device. In calculating the total
reaction time, all the component parts in the safety chain must be taken into account.
9
6
60
ADDR
25
8
ASI
AUX
12 36
30
4
.
5
7
3
URAX-
Safety
3/13 2TLC172001C0202 | ABB Safety Handbook
3
Urax-C1
Urax-C1R
Adaptation device for sensors with two-channel structure on AS-i
Urax-C1/C1R is a safety node for the AS-i bus that enable the connection of swit-
ches or emergency stops. Connections can be made so that Urax-C1/C1R together
with the switch comply with PL e EN ISO 13849-1.
Urax-C1/C1R is configurable depending on the switch you prefer to use. The safety
node's two-channel structure works with both NO+NO and NO+NC contacts.
Urax-C1R has an additional feature that allows the connection of a local reset but-
ton (R) with LED indicator.
The safety switches' contacts are controlled by Urax each time they are actuated,
for example when a door is opened and closed.
Urax-C1/C1R has LED indicators for all channels and can be addressed on the bus
via the ADDR contact.
Safety node
Urax-C1/C1R
Approvals:
Application:
Adapts switches/E-stop with
two-channel structure to the
AS-i bus
Features:
Suitable for both normally
open (NO) and normally
closed (NC) contacts
Possibility of local reset
TV Rheinland
ABB Safety Handbook | 2TLC172001C0202 3/14
3
Two-channel input
Urax-C1 is designed for safety components with two-channel
switches. The channels are supplied with individual dynamic
signals which enables the detection of short circuits between
channels. It is possible to either connect a two-channel com-
ponent exclusively to contact 1, or to connect two separate
single-channel components to contact 1 and contact 3.
Contact function, NO+NO/NO+NC
Urax-C1/C1R can work in either of the two operating modes
NO + NO, with two closing contacts, or NO+NC with one
closing and one opening contact. This selection is made using
parameter settings.
Filtration of contact bounce
Urax-C1R has a function to filter contact bounce ("debounce")
which is active irrespective of the parameter settings. After
both channels (I1 and I2) have been enabled, it is accepted
for 1 second that they turn off/on. In other words, the chan-
nel monitoring is disabled during the first second after being
enabled.
Concurrency requirements
Urax-C1R also has the capability of monitoring concurrency
requirements. Both channels must then change status within
2 seconds. This setting is made via the node's parametrisa-
tion.
Technical data Urax-C1 and C1R
Article number
Urax-C1 2TLA020072R0300
Urax-C1R 2TLA020072R0400
Colour Yellow and black
Weight 150 g
AS-i data
AS-i prole Urax-C1/C1R S-0.B.0
Addressing Jack plug
Slave address upon delivery 0
Voltage supply
Voltage AS-i yellow cable, 30 VDC (26.5 31.6)
Total current consumption AS-i <150 mA
Reaction time
Reaction time (off)* 12 ms (excluding sensors and other
peripheral components)
Enclosure
Enclosure protection class IP67
Ambient temperature 25+65C
Enclosure dimensions 96x60x25 (HxWxD)
Safety/Harmonised standards
IEC/EN 61508-1..7 SIL3, PFD
avr
: 1.5x10
-4
,
PFH: 1.7x10
-9
, Share of SIL3: 15 %
EN 62061 SIL3
EN ISO 13849-1 PLe/Cat. 4
EN 954-1 MTTF
d
: high
Certication Cat. 4
I1
FAULT AS-i COn
I2
ADDR
5
4
1
2
3
Input 1
Dyn outp 1
Input 2
Dyn outp 2
4
5
Input 2
Dyn outp 2
3
2
1
Alt 1
Alt 2
Connector 1
Connector 3
-C1
5
4
1
2
3
Input 2
Dyn output
Input 1
Connector 1
Change over contact mode (Drawing shows OFF position)
4
3 2
5
1
1
3
URAX-C1
Safety
I1
FAULT AS-i COn
I2
ADDR
R.Ind
Reset
2
3
4
1
5
4
1
2
3
Input 1
Dyn outp 1
Input 2
Dyn outp 2
4
5
Input 2
Dyn outp 2
3
2
1
Alt 1
Alt 2
Connector 1
Connector 3
Connector 2
-C1R
5
Inp
0V
Ind. outp.
Dyn outp 1
Reset
Reset ind.
Auto reset
5
4
1
2
3
Input 2
Dyn output
Input 1
Connector 1
Change over contact mode (Drawing shows OFF position)
4
3 2
5
1
1
3
2
URAX-C1R
Safety
Connections for
Urax-C1 and C1R
*NOTE: The above reaction time refers only to the Urax device. In calculating the total
reaction time, all the component parts in the safety chain must be taken into account.
9
6
60
ADDR
25
8
ASI
AUX
12 36
30
4
.
5
7
3
URAX-
Safety
Reset
Urax-C1R has an input for local reset on contact 2 that can
be configured using parameter settings for either automatic
or manual reset.
Auto reset
If auto reset has been selected, pins 1-4 on contact 2 must
be bridged.
Manual reset
If manual reset has been selected, the reset input switch
must be switched on and off within 2 seconds in order for
Urax to be enabled (generate safety code).
3/15 2TLC172001C0202 | ABB Safety Handbook
3
Urax-D1R
Adaptation device for sensors with transistor outputs (OSSD) for the AS-i bus
Urax-D1R is a two-channel safety input slave for the AS-i bus that enables the con-
nection of different protection with OSSD outputs. Examples of components of this
type are light curtains, light grids and scanners. Connections can be made so that
the safety node together with the sensor comply with PL e EN ISO 13849-1.
The safety node is also fitted with three non-safe outputs.
Urax-D1R has an additional feature that allows the connection of a local reset but-
ton (R) with LED indicator.
Urax-D1R has LED indicators for all OSSD outputs and can be addressed on the
bus via the ADDR contact.
Safety node
Urax-D1R
Approvals:
Application:
Adapts safety products with
transistor outputs (OSSD) to
the AS-i bus
Features:
Handles safety products with
transistor outputs (OSSD)
Monitors test pulses
Possibility of local reset
Outputs of non-safe control
TV Rheinland
ABB Safety Handbook | 2TLC172001C0202 3/16
3
Technical data Urax-D1R
Article number
Urax-D1R 2TLA020072R0500
Colour Yellow and black
Weight 150 g
AS-i data
AS-i prole Urax-C1/C1R S-0.B.0
Addressing Jack plug
Slave address upon delivery 0
Voltage supply
Voltage AS-i (Yellow cable)
Voltage AUX (Black cable)
Insulation
Current limit (+24 V)
Total current consumption AS-i
30 VDC. Tolerance 26.5 - 31.6 VDC.
24 VDC (15%)
0V is common with AUX which shall
be connected to protective earth at
power supply.
700 mA
<30 mA
Output (non-safe)
Output voltage 24 VDC (AUX)
Current 700
Reaction time
Reaction time (off)* 12 ms (excluding sensors and other
peripheral components)
Enclosure
Enclosure protection class IP67
Ambient temperature 25+65C
Enclosure dimensions 96x60x25 (HxWxD)
Safety/Harmonised standards
IEC/EN 61508-1..7 SIL3, PFD
avr
: 1.5x10
-4
, PFH: 1.7x10
-9
,
Share of SIL3: 15 %
EN 62061 SIL3
EN ISO 13849-1 PLe/Cat. 4
EN 954-1 MTTF
d
: high
Monitoring of short circuits (test pulses)
The safety device that connects to Urax-D1R must be capa-
ble of detecting both short circuits between the channels and
short circuits to the supply voltage. These types of faults are
not detected by Urax! The most common way for the safe-
ty device to detect this is by transmitting test pulses on the
outputs (OSSD).
Detection of test pulses
You can configure Urax-D1R to detect whether the test pulses
are transmitted from the connected device or not (see Table,
"Parameter settings and safety codes"). If Test Pulse Detec-
tion is selected, Urax will be disabled if these test pulses are
missing. This feature is a safeguard against fraud.
Non-safe outputs
Urax-B1R is fitted with 3 non-safe outputs.
These can be used for diverse controls or indicators and are
controlled directly from the AS-i master.
Output 1 is located on the same contact as the safety sensor,
i.e. contact 1 and controlled on pin 5. For example, you can
then connect a Dalton or Knox to this contact. Outputs 2 and
3 have non-safe control on pin 4 of contact 3 and 4 respec-
tively.
Reset
Urax-D1R has an input for local reset on contact 2 that, with
parameter settings, can be configured for either automatic
or manual reset. (See table, parameter settings and safety
codes.)
Auto reset
If auto reset has been selected, pins 1-4 on contact 2 must
be strapped.
Manual reset
If manual reset has been selected, the reset input must be
switched on and off within 2 seconds in order for Urax to be
enabled (generate safety code).
Connections for Urax-D1R
FAULT AS-i
Q2
R.Ind
Reset I1
Q3
COn
Q1
ADDR
I2
AUX
Out2 (AS-i)
0V 3
4
2
1
1
4
2
3
5
4
3
Inp 1
0V
Inp 2
1
2
+24V
Connector 1
Connector 2
Connector 3
-D1R
5
Inp
0V
Ind. outp.
Dyn outp 1
Reset
Reset ind.
Auto reset
5
5
Connector 4
1
2
4
3 0V
Out3 (AS-i)
+24V
+24V
Receiver
OSSD1
OSSD2
Transmitter
Out1 (AS-i)
4
3 2
5
1
1
3
2
4
URAX-D1R
Safety
*NOTE: The above reaction time refers only to the Urax device. In calculating the total
reaction time, all the component parts in the safety chain must be taken into account.
9
6
60
ADDR
25
8
ASI
AUX
12 36
30
4
.
5
7
3
URAX-
Safety
3/17 2TLC172001C0202 | ABB Safety Handbook
3
Urax-E1
Adaptation device for two-hand stations for the AS-i bus
Urax-E1 is a dual channel safety input slave to the AS-i bus, which is designed to
connect the two-hand station in compliance with EN 574 model IIIC. Connections
can be made so that the safety node with two-hand station complies with PL e EN
ISO 13849-1.
Urax-E1 has LED indicators for all channels and can be addressed on the bus via
the ADDR contact.
Safety node
Urax-E1
Approvals:
Application:
Adapts two-hand devices to
the AS-i bus
Features:
Handles two-hand devices
with two channels
Simultaneity requirement
TV Rheinland
ABB Safety Handbook | 2TLC172001C0202 3/18
3
Technical data Urax-E1
Article number
Urax-E1 2TLA020072R0600
Colour Yellow and black
Weight 150 g
AS-i data
AS-i prole Urax-C1/C1R S-0.B.0
Addressing Jack contact
Slave address upon delivery 0
Voltage supply
Voltage AS-i yellow cable, 30 V DC (26.5 31.6)
Total current consumption AS-i <150 mA
Output (non-safe)
Output voltage 24V DC (AUX)
Current 700
Reaction time
Reaction time (off)* 12 ms (excluding sensors and other
peripheral components)
Enclosure
Enclosure protection class IP67
Ambient temperature 25+65C
Enclosure dimensions 96x60x25 (HxWxD)
Safety/Harmonised standards
IEC/EN 61508-1..7 SIL3, PFD
avr
: 1.5x10
-4
, PFH: 1.7x10
-9
,
Share of SIL3: 15 %
EN 62061 SIL3
EN ISO 13849-1 PLe/Cat. 4
EN 954-1 MTTF
d
: high
Certication Cat. 4
Inputs for two-hand stations
Urax-E1 has two inputs for each hand, one for closing and
one for opening contact. For safe activation (generating safety
code), all four inputs are required to be enabled within 0.5 se-
conds. All inputs are monitored, and if Urax is disabled (stops
generating safety code) this requires that all four inputs are
disabled before a restart is possible. ("Open" condition for a
opening (NC) contact is closed contact, and "Open" condition
for a closing (NO) contact is open contact.)
Connections for Urax-E1
.
NC
NO
FAULT AS-i
NC
NO
COn
ADDR
5
4
1
2
3
Inp channel 1, NC
Dyn outp 1
Inp channel 1, NO
4
5
Dyn outp 2
3
2
1
Connector 1
Connector 3
-E1
Left hand
Right hand
Inp channel 2, NC
Inp channel 2, NO
4
3 2
5
1
1
3
URAX-E1
Safety
*NOTE: The above reaction time refers only to the Urax device. In calculating the total
reaction time, all the component parts in the safety chain must be taken into account.
9
6
60
ADDR
25
8
ASI
AUX
12 36
30
4
.
5
7
3
URAX-
Safety
4/1 2TLC172001C0202 | ABB Safety Handbook
4
ABB Safety Handbook | 2TLC172001C0202 4/2
4
Pluto Manager 4/3
Pluto Manager
4/3 2TLC172001C0202 | ABB Safety Handbook
4
A programming tool for your safety functions
Pluto Manager is a software tailored for the safety PLC Pluto.
Programming is done in ladder and together with the function
block creates the structure of your safety functions. The soft-
ware comes with predefined function blocks approved by TV
to facilitate the work on designing the safety functions. Pluto
Manager offers the possibility to split the program into different
program blocks in order to separate various program functions
from each other, and it gives you a structured overview of Plu-
tos, gateways and peripheral components in large and small
projects. It gives you an overview and control of the sensors
and actuators, and the reactions between them. Pluto Mana-
ger also contains manuals for the software and hardware that
are connected and needs to be handled through the program.
The interface gives the option to connect to one of the Plutos
in the net, and go online and view the status for Plutos two
bus options, AS-i and Pluto bus. There are also diagnostic
functions and the option to export data.
Systematic working method through project management
Step 1 - Configuration of I/O
In every started project, each Pluto is defined individually. Its
inputs and outputs are configured as desired and depending
on what they connect to. Plutos IQ ports are also configured
here as inputs or outputs, dynamic or static signals.
Step 2 - Naming of variables
After configuration the systems variables are determined.
Inputs (I), outputs (Q), remanent memories (M), global auxiliary
memories for bus communication (GM) and registers (R) are
given names that can be used in place of the actual variable
designation in the PLC program.
Step 3 - Ladder programming
The program is built using the named variables connected
to inputs and outputs. The programming language has a full
range of instructions, similar to standard PLCs on the market,
with timers, arithmetic, sequence programming etc.
The project is then downloaded to Pluto via a programming
cable. This program is distributed simultaneously through bus
communication to the other Plutos in the project. In this way,
you need only access a single Pluto where each Pluto gets
the right information specified in your project.
Pluto Manager is included when purchasing the safety PLC
Pluto. The software is Windows based and can be downloa-
ded free from www.abb.com/jokabsafety.
Programming tool
Pluto Manager
Use:
Gates
Hatches
Features:
Free software
Downloaded from
www.abb.com/jokabsafety
Ready to use function blocks
for your safety components
Contains TV-approved func-
tion blocks
Provides an overview of the
current projects and your
Plutos
Easy programming through
ladder language
ABB Safety Handbook | 2TLC172001C0202 4/4
4
Twohand1
Q Right_NO
Right_NC
Left_NO
Left_NC
Test
List of standard and special function blocks for Pluto Manager
The safety designer has complete freedom to program the safety functions or to use TV-approved pre-defined
safety function blocks.
Example: Function block Twohand1
Two-hand control for actuators with NO/NC + NO/NC
contacts.
Right_NO is right hand NO contact
Right_NC is right hand NC con-
tact, etc.
Test is an input condition that must
be on before any of the other inputs
changes from the initial position
and can be used for monitoring of
external components.
Function:
In initial position shall:
Right_NO be off,
Right_NC be on,
Left_NO be off and
Left_NC be on
To start the output (Q), these four
inputs must change state in 0.5
seconds and remain in that position. After stop, all inputs
must come to the initial position to enable restart.
Block for division.
Block for monitoring of selector switch.
2 blocks for validation of exported register value sent over
bus. (For register or for double registers.)
Library AS-i01:
Blocks for Pluto AS-i and B42 AS-i. (Control of, and rea-
ding of AS-i slaves, AS-i locks etc.)
Library Ext01:
Blocks for communication with external devices (gateways,
HMI etc.)
Library Analog01:
Blocks for reading of analogue inputs. (Pluto D20 and D45
only.)
Library Counter01:
Blocks for speed monitoring via counter inputs. (Pluto D45
only.)
Library Encoder01:
Blocks for absolute encoders.
Special function blocks:
Program library with blocks for eccentric shaft presses.
Standard library func05:
6 different blocks for two-channel function. (With or without
start input, test input, reset input, output for two-channel
fault, monitoring of simultaneous operation.)
3 different blocks for single-channel function. (With output
for reset button indication, with or without start input, test
input.)
2 different blocks two-channel function with time limitation.
Block for single-channel prereset.
Block for two-channel prereset.
4 different blocks for muting (bypass).
Block for two-hand control.
2 Counter blocks (up-count and down-count).
4 different blocks for muting lamp. (Pluto A20 only.)
Block for off-delay function.
2 Blocks for light curtains.
Block for multiplication.
In1 and In2 are safety inputs, to which
the safety device outputs are connec-
ted.
Test is an input condition which must
be true at the start up moment and
can be used for monitoring of external
components. Test must switch on be-
fore In1 and In2, i.e. the function block
cannot be initiated by Test.
Reset is a monitored reset input which
must switch on-off (reset on negative
edge) after all other inputs, in order to
switch on the output of the function
block.
Example: Function block TC2RTI
Two-channel function with test, reset inputs
and reset indication.
IndReset is an output for indication which is ON when
the function block is switched off and In1, In2 or Test
is off, and flashes when the function block is ready for
activation with reset.
TCfault is on at two-channel fault, i.e. when the function
block is on, and only one of In1 or In2 switches off and
on again.
Description
The function block works as a conventional safety relay
with redundant and monitored inputs (In1, In2).
5/1 2TLC172001C0202 | ABB Safety Handbook
5
ABB Safety Handbook | 2TLC172001C0202 5/2
5
Safety system - Dynamic safety circuit - Vital-Tina 5/3
Safety Controller - Vital
Why should you use the Vital safety system? 5/5
How does a dynamic circuit of Vital work? 5/6
Safety Controller - Vital 5/7
Adaptation unit - Tina
Why should you use the Tina adaptation units? 5/21
Tina is available in several versions 5/22
Tina 1A 5/23
Tina 2A/B 5/24
Tina 3A/APS 5/25
Tina 4A 5/26
Tina 5A 5/27
Tina 6A 5/29
Tina 7A 5/30
Tina 8A 5/31
Tina 10A/B/C 5/33
Tina 11A 5/35
Tina 12A 5/36
Accessories 5/37
Example of safety sensors connections based on Y branch 5/38
Connection examples 5/40
Safety system - Vital
Supervision of dynamic safety signals
5/3 2TLC172001C0202 | ABB Safety Handbook
5
Safety system
Dynamic safety circuit Vital and Tina
Vital
0V 24V
Patented
solution
Active safety sensors for dynamic safety circuits
Sensors with static or OSSD outputs that are
connected via Tina units
Tina units that convert static/OSSD to dynamic signals
Safety circuit category up to PL e
according to EN ISO 13849-1
Dynamic safety
Dynamic safety signal
that tests a sensor 200
times per second.
Vital is a safety controller with a dynamic safety circuit that can monitor up to 30 sensors, such as Eden, in accordance with the
highest safety level. Vital has selectable manual or automatic resetting and dual outputs. (The Pluto safety PLC has many inputs
for dynamic safety circuits.)
Each active sensor and Tina unit has LEDs that indicate OK (green), broken safety circuit (red) or flashing if the loop has been
broken by another earlier sensor.
ABB Safety Handbook | 2TLC172001C0202 5/4
5
Dynamic
circuit 1
Vital 1
Up to 30 sensors can be connected to the same dynamic
safety circuit
Dynamic
circuit 2
Dynamic
circuit 1
Vital 2
Two safety circuits are monitored by one module
Simple system with extensive functionality
Up to 10 sensors can be connected to each dynamic
safety circuit
Output group 2 can be set for time delay
Three different modes of operation
Dynamic
circuit 2
Contact
circuit 1
Vital 3
Two safety circuits are monitored by one module
Devices with two-channel, opening contacts can be
connected to one circuit
Simple system with extensive functionality
Output group 2 can be set for time delay
Three different modes of operation
This example shows a cell that consists of dynamic protection
sensors connected to a Vital with the following functions:
Two charging stations
At each charging station a light curtain checks for anyone
putting their hand into a risk area, and an Eden sensor checks
whether a robot is inside the same risk area. This means that
a stop is only ordered if a robot and a person are in the same
area. When the station is clear, the person presses the reset
button connected to the light curtain.
Fence with Eden-interlocked door
If the door is opened, the robot stops. To reset the robot sys-
tem, the door must be closed and a supervisory reset button
operated.
Three emergency stops with Tina units
If any of the emergency stop buttons is pressed, the robot
performs an immediate emergency stop.
One Vital supervises the entire robot cell!
Vital is available in three versions
Smile 11EA Tina Eden Focus Reset
FMI
Reset
FMI
Focus Eden Eden Smile 11EA Tina Smile 11EA Tina
Transmitter Receiver Transmitter Receiver
Tina 1A
M12-3M
Tina 10B
M12-3B
Tina 8A
Pluto Vital
2 3
1
22 33
1 1
2 3
1
2 2
11
33
M12-3M
Tina 10B
M12-3B
2 3
1
22 33
1 1
2 3
1
2 2
11
33
Smile 11EA Tina Eden Focus Reset
FMI
Reset
FMI
Focus Eden Eden Smile 11EA Tina Smile 11EA Tina
Transmitter Receiver Transmitter Receiver
Tina 1A
M12-3M
Tina 10B
M12-3B
Tina 8A
Pluto Vital
2 3
1
22 33
1 1
2 3
1
2 2
11
33
M12-3M
Tina 10B
M12-3B
2 3
1
22 33
1 1
2 3
1
2 2
11
33
A
B
5/5 2TLC172001C0202 | ABB Safety Handbook
5
to be able to connect several safety components in
series (up to PL e, cat. 4) and supervise them with only
one safety controller!
Vital is the heart of a solution which makes it possible to
install/connect many different types of safety device in
the same safety circuit and still achieve PL e according to
EN ISO 13849-1. The Vital module is based upon a dyna-
mic single-channel concept as opposed to conventional
dual-channel safety relays. Up to 30 dynamic sensors can
be connected directly in the safety circuit and be supervised
by only one Vital module.The Vital therefore replaces several
safety relays. Safety components with output contacts can be
connected to the Vital via low cost Tina adaptors.
The Vital also has automatically or manually supervised reset
selection, dual safety outputs, and an information output for
reset indication and status information for PLCs.
to supervise safety components!
Most safety components on the market can be connected
to the Vital module. Dynamic sensors enable safety PL e to
be achieved in a single-channel system. For example ABB
JokabSafetys dynamic non-contact Eden sensor, Spot light
beam and emergency stops (via Tina adaptors) can be used.
Even mechanical switches can be connected to Vital with the
aid of ABB JokabSafetys Tina adaptors.
for easy installation and assembly of a safety system!
Vital is a small electronic safety controller that dynamically
supervises a number of safety components. Vitals detachable
connector blocks simplify the connection, trouble-shooting
and exchange of modules. The Vital and other safety compo-
nents can be connected together using standard cables and
with cables having M12 connections.
Why should you use the Vital safety system?
Reasons to choose Vital
PLe, according to ENISO13849-1 dynamic safety circuit
Can accommodate long cable lengths
Manually supervised or automatic reset
Two NO safety outputs
Detachable connector blocks
LED indication of: power supply, dynamic signal and outputs
Information output with two functions
Cost-effective cable routing/connections
ABB Safety Handbook | 2TLC172001C0202 5/6
5
The dynamic signal consists of a square wave that is
transmitted through the safety circuit. The signal is
inverted at each safety component and is monitored 200
times per second by Vital or Pluto.
The dynamic signal is transmitted as single channel throug-
hout all the protection in the same safety circuit between
input terminals T1 and R1. If a protection breaks, the dyna-
mic signal is not transmitted which is detected by Vital which
breaks its safe outputs. Even short circuits across a protection
are detected when the signal is inverted in each sensor (the
protection is then OK), while Vital expects a correctly inver-
ted signal at the right time. In this case, an even number of
sensors are connected to the safety loop which means that
the dynamic signal will be inverted an even number of times
when it is evaluated by Vital. This is determined by the ter-
minal inputs S1 and B1 being connected together. If an odd
number of sensors have been connected, connection of S1 is
not required. As the signal is evaluated by Vital at each pulse,
i.e. more than 200 times per second, faults and short circuits
are detected within a few milliseconds.
How does a dynamic circuit of Vital work?
Light Curtain Focus
Prevents passage with
integrated muting function
Smile Tina
emergency stop
to stop machinery
when there is a hazard
The Eden sensor
monitors that doors
are closed
Emergency stop INCA Tina
To stop the machine in case of
danger
Safety module Vital
monitors the safety sensors
in series according to PL e
ENISO13849-1.
5/7 2TLC172001C0202 | ABB Safety Handbook
5
TV Nord Vital 1
TV Rheinland Vital 2 and 3
Vital is based on a single channel safety concept where multiple safety sensors can
be connected in series and monitored with a single safety controller. A dynamic
signal is sent from Vital through all connected sensors, and then returned to Vital
which then evaluates the received signal. As each safety sensor inverts the signal,
it is possible to detect short circuits or faults in any of the sensors. Vital is designed
for use with ABB Jokab Safety Eden sensors, Tina components and Spot light grids
or similar products. Vital 2 and 3 are both safety controllers with two safe input
functions and two output groups, the only difference between the two models being
in the input configuration.
Safety controller
Vital
Approvals:
Application:
Entire safety system based on
the dynamic safety circuit.
Features:
Easy installation
Flexible
Cost effective
Display for troubleshooting
(Vital 2 and 3)
A wide range of safety sen-
sors can be connected into
the circuit
Several safe outputs
Information output
Outputs with time delay
(Vital 2 and 3)
ABB Safety Handbook | 2TLC172001C0202 5/8
5
Dynamic
circuit 2
Dynamic
circuit 1
Dynamic
circuit 2
Contact
circuit 1
Vital 1 Safety controller
Up to 30 sensors can be connected
to the same dynamic safety circuit
Vital 2 Safety controller
Two safety circuits are monitored by
one module
Simple system with extensive
functionality
Up to 10 sensors can be connected
to each dynamic safety circuit
Output group 2 can be set for time
delay
Three different modes of operation
Vital 3 Safety controller
Two safety circuits are monitored by
one module
Devices with two-channel, opening
contacts can be connected to one
circuit
Simple system with extensive
functionality
Output group 2 can be set for time
delay
Three different modes of operation
Dynamic
circuit 1
5/9 2TLC172001C0202 | ABB Safety Handbook
5
Output connections Vital 1
The Vital 1 has two (2 NO) safety
outputs. In order to protect the output
contacts it is recommended that loads
(inductive) are suppressed by fitting cor-
rectly chosen VDRs, diodes etc. Diodes
are the best arc suppressors, but will
increase the switch-off time of the load.
Relay outputs Information outputs
Reset connections Vital 1
The manually supervised reset contact
connected to input X1 must be closed
and opened in order to activate the
relay outputs.
Automatic reset is selected when B1,
X1 and X4 are connected. The relay
outputs are then activated at the same
time as the inputs.
Contactors, relays and valves can be
supervised by connecting test con-
tacts between B1 and X1. Both manu-
ally supervised and automatic reset can
be used.
B1
Vital 1 has a switching relay output for
information. The function is determined
by a DIP switch.

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

Y14 is closed to 0V (B2) internally
when Vital 1 has not been reset.
Y14 is closed to +24 V (B1) when
Vital 1 has been reset.
In DIP switch position 2 (the purpose
of the function is to start/restart block,
RES) the information output Y14 is
internally connected to 0V and +24 V
as per:

Y14 is internally closed to 0V (B2)
when the dynamic safety loop is open
or when the dynamic safety loop is
closed and Vital 1 has been reset.
Y14 is internally closed to +24 V
(B1) when the dynamic safety loop is
closed but Vital 1 has not been reset
(RES).
Vital 1
Y14
B1
B2
0V
+24V
0V
Vital 1
Y14
B1
B2
0V 0V
+24V
0V
Connection of S1
Even number of units in series
(Eden+Spot+Tina) requires a connection
between B1 and S1. S1 is not connec-
ted at odd number of units.
See drawing below figure A and other
examples in the book
Manually supervised reset Automatic reset Testing external contactor status
ABB Safety Handbook | 2TLC172001C0202 5/10
5
Technical data Vital 1
Article number
Vital 1 2TLA020052R0000
Level of safety
ENISO13849-1
EN62061
IEC/EN61508-17
PLe/Cat. 4
SIL3
SIL3
PFH
D
2.7410
-8
Colour Grey
Weight 220 g
Power supply
Vital, A1-A2
From Vital to sensors/units, B1-B2
24 VDC 15%
24 VDC
Fuse
An external fuse should be tted in
the supply to A1 3 AT
Max line resistance
at nominal voltage to X1 150 Ohm
Power consumption
DC supply, nominal voltage (wit-
hout load)
DC supply, nominal voltage (with
max load)
3 W
48 W
Dynamic safety circuit
T 1
R 1
Output signal
Input signal
Reset input X1
Supply for reset input
Reset current
Minimum contact closure time for
reset
+24VDC
30 mA max. (inrush current 300 mA
during contact closure)
150 ms
Connection of S1
Even numbers of sensors (Eden + Spot T/R + Tina) require a connection
between B1 and S1. S1 is not connected for odd numbers of sensors.
Odd number, no connection between B1 and S1.
Number of sensors
Max. number of Eden/Tina to
Vital 1
Total max. cable length to Eden/
Tina
Max. number of Spot T/R to Vital
Total max. cable length to Spot
T/R
30
1000 m
Up to 6 pairs
600 m
Maximum number of units varies depending on the installation and cable
size. For more information, see the examples in this chapter.
Response time
At Power on
When activating (input-output)
When deactivating (input-output)
At Power loss
< 65 ms
< 40 ms
< 48 ms
< 55 ms
Relay outputs
NO
Max switching capacity, resistive
load
Minimum load
Contact material
Mechanical life
External fuse (EN 60947-5-1)
2
6A/250 VAC/1500 VA/150W
10 mA/10V
AgCdO
>10
7
operations
6.3A or 4A slow
Relay information output (chan-
geover contact)
Y14 (0V)
+(24V)
Max. load on Y14
Indicates Vital is not reset
Indicates Vital is reset
200 mA (Internal automatic fuse)
LED indication
On
T R
1 2
Fixed light: supply voltage OK,
Flashing light: under-voltage or
overload.
T: Signal out OK. R: Signal in OK.
Indicates that the output relays
have been activated
Mounting
DIN rail
Operating temperature range
35 mm DIN rail
-10C to + 55C
Connection blocks (detachable)
Max screw torque
Max connection area:
Solid conductors
Conductor with socket contact
Air and creep distance
1 Nm
1x4 mm
2
/ 2x1,5 mm
2
/ 12AWG
1x2,5 mm
2
/ 2x1 mm
2
4kV/2 DIN VDE 0110
Protection class
Enclosure
Connection blocks
IP40 IEC 60529
IP20 IEC 60529
Conformity EN ISO 12100-1, -2, EN 954-1, EN
ISO 13849-1, EN 62061, EN 60204-1,
IEC 60664-1, EN61000-6-2,
EN 61000-6-4 EN 60947-5-1,
EN 1088, EN61496-1,
IEC/EN 61508-17
Connector blocks are detachable
(without cables having to be disconnected)
5/11 2TLC172001C0202 | ABB Safety Handbook
5
Connection of units and cable lengths to Vital 1
Connection examples of safety devices to Vital 1
ABB Safety Handbook | 2TLC172001C0202 5/12
5
Three connection alternatives
According to PLe (ENISO13849-1), connection of sensors/
adaptor units in the Vital safety circuit must be made as the
connection examples.
Example
Use separate connection cables from each sensor/adaptor
unit to the Vital safety controller. Interconnections to be made
via suitable terminals in the control cabinet.
Example
Use Tina4A/Tina8A connector blocks to simplify the connec-
tion of externally mounted sensors/adaptor units. Only Tina4A/
Tina8A connector blocks may be used. Use of any other con-
nector blocks will not meet the safety circuit requirements.
Example
Use M12-3A and M12-3B Y connectors to connect sensors
in series/parallel.
Cable lengths and number of sensor/adaptor units for the
three connection examples.
In order to determine the number of sensor/adaptor units that
can be connected to a Vital 1 unit it must be remembered that
1 (one) Spot T/R is equivalent to 5 (five) Eden or Tina units.
Units in parallel are equal to one unit. The following examples
provide guidance as to possible configurations and cable
lengths using suitable cables.
Example
Up to 1000 metres (0.75 mm
2
or 0.34 mm
2
conductors) in
total can be connected to the sensors/units in this example.
The connection is equivalent to 9 Eden or Tina units.
A maximum of 30 Eden or Tina units can be connected to
the Vital 1 unit on a maximum cable length of 500 metres
(0.75 mm
2
conductors) or 300 metres (0.34 mm
2
conductors).
Example
Up to 600 metres (0.75 mm
2
conductors) to Tina 8A and
10 metre cables type M12-C1012 (0.34 mm
2
) to each sensor/
unit connected to the Tina 8A. This connection example is
equivalent to 17 Eden or Tina units.
A maximum of 3 Tina 8A units, equivalent to 27 Eden/Tina
units (= 3 x 8 connected to Tina 8A + 3 Tina 8A) can be con-
nected to one Vital 1 with a total cable length of 600 metres
(0.75 mm
2
). Up to 6 Tina 4A units can be connected to one
Vital 1 (equivalent to 30 Eden/Tina units) with a total cable
length of 600 metres (0.75 mm
2
) to Tina 4A.
Example
Either 2 x 500 metre cables (0.75 mm
2
) from the control
cabinet and 10 metre cables (0.34 mm
2
) to each sensor/unit
or 2 x 10 metre cables (0.75 mm
2
) from the control cabinet
and 200 metre cables (0.75 mm
2
) to each sensor/unit. The
connection is equivalent to 16 Eden or Tina units.
A Total of 30 Eden/Tina units can be connected using a
maximum cable length of 1000 metres (0.75 mm
2
) or 400me-
tres (0.34 mm
2
). If the power supply is only fed from one
direction (from one end of the network) the total cable length
is reduced to approx 300 metres (0.75 mm
2
) and 100 metres
(0.34 mm
2
).
Connection advice for dynamic sensors to Pluto and Vital.
Sensors can be connected in many different ways. Here is
some advice that can make connection better and more stab-
le. The advice is general, but particularly applicable to the use
of Tina 4A and Tina 8A units.
Never have more than the recommended number of sen-
sors in the loop.
If possible use a switched mains power supply that can
deliver a stable 24 VDC.
In the sensor system, use as short cables as possible.
When connecting a Tina 4A or Tina 8A unit, the supply
voltage at the terminal (out at the unit) must not be less
than 20 Volts.
Use screened cable, preferably 0.75 mm
2
or thicker, from
the apparatus enclosure and ground it at one end, for ex-
ample at the apparatus enclosure, not at both ends.
Do not route the signal wiring close to heavy current
cabling or close to equipment that gives off a lot of interfe-
rence, such as frequency converters for electric motors.
Never connect spare conductors.
If M12-3B are used for connection of a parallel loop, with
supply to the sensors from two directions, the loop must
be as short as possible. This is because the conductors
that are not being used are also connected, which incre-
ases the capacitive load and reduces the stability of the
system.
5/13 2TLC172001C0202 | ABB Safety Handbook
5
Vital 2 is a safety controller that combines functionality with the quick and easy
installation of safety sensors. With two safe input functions and two different output
groups, Vital 2 offers the capability to exclusively control smaller machine safety sys-
tems that would otherwise have required a programmable controller or multiple safety
relays. How the two output groups are controlled by the input functions depends on
which of the three operating modes is selected (see Selection of operating mode).
Input function 1
A dynamic safety circuit where ABB JokabSafety's safety sensors such as Eden,
Tina and Spot can easily be connected in series. Up to 10 Eden or Tina devices can
be connected in series per input function.
Input function 2
The same function as input function 1.
Output group 1
A safe relay output in a duplicated series and a safe transistor output with output
voltage of -24 VDC.
Output group 2
A safe relay output in a duplicated series and a safe transistor output with output
voltage of -24 VDC. In addition, output group 2 contains a non-safe transistor out-
put with output voltage of +24 VDC, intended for information. The output group can
have time delay from 0 to 1.5 s.
Selection of operating modes
Vital 2 can be configured to operate in one of three operating modes M1, M2 or M3.
The selection of operating modes is done by connecting one of the terminals M1,
M2 or M3 to +24 V.
Vital 2
ABB Safety Handbook | 2TLC172001C0202 5/14
5
Operating mode M1 - Separate
function Vital 2
Input function 1 controls output group 1, and input function 2
controls output group 2.
Operating mode M2 - Input 1,
master function Vital 2
Input function 1 stops all outputs, and input function 2 stops
output group 2.
Operating mode M3 - Parallel
function Vital 2
Input function 1 and input function 2 operate in parallel and
control all outputs. Reset/Auto reset 1 resets both input func-
tions (Reset/Auto Reset 2 is not used).
5/15 2TLC172001C0202 | ABB Safety Handbook
5
Time delay - Vital 2
Output group 2 can have disconnection delay by connecting inputs 0.5s and 1.0s being connected to +24 V. The system is
binary, which means that the time values of the inputs are added together to give the total delay time.
Connection of reset - Vital 2
Manual monitored reset
For manual resetting, a push button must be connected between X1 (Reset 1) or X11 (Reset 2) and +24 V. The monitoring con-
tactors for external devices are to be connected in series with the push button. For manual reset, X4 (for Reset 1) and X14 (for
Reset 2) serve as output for resetting the indicator lamps.
Automatic reset
For automatic reset, X1 and X4 (Auto reset 1) or X11 and X14 (Auto reset 2) must be connected to +24 V. Monitoring contacts
for external devices must be connected between +24 V and X1 (Auto reset 1) or X11 (Auto reset 2) . If monitoring contacts are
not used, X1 and X11 must be connected to +24 V.
X4 X1 +24 V
0 V
X11 X14
X4 X1 +24 V
X11 X14
There are two separate reset functions; Reset 1 and Reset 2. The function of these is dependent
on the operating mode selected (see Selection of operating mode). Reset 1 and Reset 2 can be
configured for manual or automatic reset independently of each other by means of the input's
Auto reset 1 and Auto reset 2.
Connection of outputs - Vital 2
Q1
Q11
1L
11L
-24 V
Q2
Q12
+24 V
Q13
Connection of safe relay output
The safe relay outputs that are duplicated in series break between 1L-Q1 (output group 1) and
11L-Q11 (output group 2). The loads that break should be fitted with spark arresters to protect
the outputs. The correct selection of VDR circuit, RC circuit or diode is appropriate. Note that the
diode extends the disconnection time of the load.
Connection of safe transistor output (-24 V)
The safe transistor outputs Q2 (output group 1) and Q12 (output group 2) have an output voltage
of -24 V.
Connection of information output
The non-safe transistor output Q13 is high (+24 V) when the outputs from output group 2 are active. The function is therefore
dependent on the operating mode selected (see Selection of operating mode).
Connection of protection/sensors - Vital 2
Depending on the input function and the number of sensors connected to the safety circuit (odd
or even number), the dynamic signal is connected between different terminals;
R2 T1 R1
T11 R12 R11
Input function 1
A dynamic signal is transmitted from T1, and depending on the number of sensors in the safety
circuit, the signal connects back to R1 (odd number of sensors) or R2 (even number of sensors).
Input function 2
A dynamic signal is transmitted from T11, and depending on the number of sensors in the safety circuit, the signal connects
back to R11 (odd number of sensors) or R12 (even number of sensors).
1.0s 0.5s +24 V
No delay
1.0s 0.5s +24 V
0.5 s delay
1.0s 0.5s +24 V
1.0 s delay
1.0s 0.5s +24 V
1.5 s delay
ABB Safety Handbook | 2TLC172001C0202 5/16
5
Technical data Vital 2
Article number 2TLA020070R4300
Level of safety
ENISO13849-1 PLe/Cat. 4
EN62061 SIL3
IEC/EN61508-17 SIL3
EN 954-1 Cat. 4
PFH
D
Relay output 2.00 10
-9
Transistor output 1.50 10
-9
Colour Grey
Weight 390 g
Power supply 24 VDC 15%
Fuse
An external fuse must be con-
nected in series with the supply
voltage to A1 6 A
Max line resistance
at nominal voltage to X1 150 Ohm
Power consumption
Total current consumption 300 mA
Input function 1
(dynamic safety circuit)
Dynamic output signal T1
Dynamic input signal R1 (odd number of sensors in a
circuit)
R2 (even number of sensors in a
circuit)
Input function 2
(dynamic safety circuit)
Dynamic output signal T11
Dynamic input signal R11 (odd number of sensors in a
circuit)
R12 (even number of sensors in a
circuit)
Reset input X1/X11
Voltage at X1/X11 when reset +24VDC
Reset current 30 mA (300 mA peak during contact
closure)
Minimum contact closure time
for reset 80 ms
Number of sensors
Max. number of Eden or Tina units
per input function 10
Total max. cable length (depen-
ding on the number of Eden/Tina
units) 500 m
Max. number of light beams (Spot
T/R) per input function
Spot 10 1
Spot 35 3
Total max. cable length (depen-
ding on the number of Spot T/R) 100 m
Maximum number of units varies depending on the installation andcable
size. For more information, see the examples in this chapter.
Response time
Relay output (Q1, Q11) 15 24 ms
Safe transistor outputs
(Q2, Q12) 11 20 ms
Non-safe transistor output
(Q2, Q12) 11 20 ms
Relay outputs
Number of outputs 2 NO
Max. load capacity, res. load 6A/250 VAC
Max. load capacity, ind. load AC-12: 250 V/1,5 A
AC-15: 250 V/1,5 A
DC-12: 50 V/1,5 A
DC-13: 24 V/1,5 A
Safe transistor outputs
Number of outputs 2
Output voltage (rated) 24V
Output voltage (at load) > 22V at 800 mA/24V
supply voltage
23.3V at 150 mA/24V
supply voltage
Max. load 800 mA
Short circuit protection
Output 0V Yes
Output +24V Normal (not guaranteed)
Non-safe transistor output (infor-
mation)
Output voltage (rated) +24 VDC
Max. load 1 A
Mounting
DIN rail 35 mm DIN rail
Operating temperature range -10C to + 55C
Connection blocks (detachable)
Max screw torque 1 Nm
Max connection area:
Solid conductors 1x4 mm
2
/ 2x1,5 mm
2
/ 12AWG
Conductor with socket contact 1x2.5 mm
2
/ 2x1 mm
2
Air and creep distance 4kV/2 DIN VDE 0110
Protection class
Enclosure IP40 IEC 60529
Connection blocks IP20 IEC 60529
Approved standards EN ISO 13849-1/EN 954-1, EN ISO
13849-2, EN 62061, EN 61496-1, EN
574, EN692, EN 60204-1, EN50178,
EN61000-6-2, EN 61000-6-4, EN
61000-4-, IEC/EN61508-17
Connector blocks are detachable
(without cables having to be disconnected)
5/17 2TLC172001C0202 | ABB Safety Handbook
5
Vital 3 is a safety controller that combines functionality with the quick and easy
installation of safety sensors. With two safe input functions and two different output
groups, Vital 3 offers the capability to exclusively control smaller machine safety sys-
tems that would otherwise have required a programmable controller or multiple safety
relays. How the two output groups are controlled by the input functions depends on
which of the three operating modes is selected (see Selection of operating mode).
Input function 1
A two-channel safety circuit designed for opening contacts, e.g. two-channel emer-
gency stop or ABB JokabSafety's safety switch JSNY5. One channel is fed with the
dynamic signal and the other with static +24 VDC.
Input function 2
A dynamic safety circuit where ABB JokabSafety's safety sensors Eden, Tina and
Spot can easily be connected in series. Up to 12 Eden or Tina devices can be con-
nected in series per input function.
Output group 1
A safe relay output in a duplicated series and a safe transistor output with output
voltage of -24 VDC.
Output group 2
A safe relay output in a duplicated series and a safe transistor output with output
voltage of -24 VDC. In addition, output group 2 contains a non-safe transistor output
with output voltage of +24 VDC, intended for information. The output group can have
time delay from 0 to 1.5 s.
Selection of operating modes
Vital 3 can be congured to operate in one of three operating modes M1, M2 or M3.
The selection of operating modes is done by connecting one of the terminals M1, M2
or M3 to +24 V.
Vital 3
ABB Safety Handbook | 2TLC172001C0202 5/18
5
Operating mode M2 - Input 1,
master function Vital 3
Input function 1 stops all outputs, and input function 2 stops
output group 2.
Operating mode M3 - Parallel
function Vital 3
Input function 1 and input function 2 operate in parallel and
control all outputs. Reset/Auto reset 1 resets both input func-
tions (Reset/Auto Reset 2 is not used).
Operating mode M1 - Separate
function Vital 3
Input function 1 controls output group 1, and input function 2
controls output group 2.
5/19 2TLC172001C0202 | ABB Safety Handbook
5
Time delay - Vital 3
Output group 2 can have disconnection delay by connecting inputs 0.5s and 1.0s being connected to +24 V. The system is
binary, which means that the time values of the inputs are added together to give the total delay time.
1.0s 0.5s +24 V
No delay
1.0s 0.5s +24 V
0.5 s delay
1.0s 0.5s +24 V
1.0 s delay
1.0s 0.5s +24 V
1.5 s delay
Connection of reset - Vital 3
Manual monitored reset
For manual resetting, a push button must be connected between X1 (Reset 1) or X11 (Reset 2) and +24 V. The monitoring
contactors for external devices are to be connected in series with the push button. For manual reset, X4 (for Reset 1) and X14
(for Reset 2) serve as output for resetting the indicator lamps.
Automatic reset
For automatic reset, X1 and X4 (Auto reset 1) or X11 and X14 (Auto reset 2) must be connected to +24 V. Monitoring contacts
for external devices must be connected between +24 V and X1 (Auto reset 1) or X11 (Auto reset 2) . If monitoring contacts are
not used, X1 and X11 must be connected to +24 V.
X4 X1 +24 V
0 V
X11 X14
X4 X1 +24 V
X11 X14
There are two separate reset functions; Reset 1 and Reset 2. The function of these is depen-
dent on the operating mode selected (see Selection of operating mode). Reset 1 and Reset 2
can be configured for manual or automatic reset independently of each other by means of the
input's Auto reset 1 and Auto reset 2.
Connection of outputs - Vital 3
Q1
Q11
1L
11L
-24 V
Q2
Q12
+24 V
Q13
Connection of safe relay output
The safe relay outputs that are duplicated in series break between 1L-Q1 (output group 1) and
11L-Q11 (output group 2). The loads that break should be fitted with spark arresters to protect
the outputs. The correct selection of VDR-circuit, RC circuit or diode is appropriate. Note that
the diode extends the disconnection time of the load.
Connection of safe transistor output (-24 V)
The safe transistor outputs Q2 (output group 1) and Q12 (output group 2) have an output
voltage of -24 V.
Connection of information output
The non-safe transistor output Q13 is high (+24 V) when the outputs from output group 2 are active. The function is therefore
dependent on the operating mode selected (see Selection of operating mode).
Connection of protection/sensors - Vital 3
Depending on the input function and the number of sensors connected to the safety loop (odd
or even number), the dynamic signal is connected between different terminals;
+24 V
S1 T1 S2
T11 R12 R11
Input function 1
One of the two opening contacts is connected between T1 and S1 (dynamic signal). The se-
cond opening contact is connected between +24 V and S2 (static signal).
Input function 2
A dynamic signal is transmitted from T11, and depending on the number of sensors in the safety loop, the signal connects
back to R11 (odd number of sensors) or R12 (even number of sensors).
ABB Safety Handbook | 2TLC172001C0202 5/20
5
Technical data Vital 3
Article number 2TLA020070R4400
Level of safety
ENISO13849-1 PLe/Cat. 4
EN62061 SIL3
IEC/EN61508-17 SIL3
EN 954-1 Cat. 4
PFH
D
Relay output 2.0010
-9
Transistor output 1.5010
-9
Colour Grey
Weight 390 g
Power supply 24 VDC 15%
Fuse
An external fuse must be con-
nected in series with the supply
voltage to A1 6 A
Max line resistance
at nominal voltage to X1 150 Ohm
Power consumption
Total current consumption 300 mA
Input function 1
(two channel, normally closed
circuit)
Dynamic output signal T1
Dynamic input signal S1
Static input signal (+24 V) S2
Input function 2
(dynamic safety circuit)
Dynamic output signal T11
Dynamic input signal R11 (odd number of sensors in a
circuit)
R12 (even number of sensors in a
circuit)
Reset input X1/X11
Voltage at X1/X11 when reset +24VDC
Reset current 30 mA (300 mA peak during contact
closure)
Minimum contact closure time
for reset 80 ms
Number of sensors
Max. number of Eden or Tina units
per input function 2 10
Total max. cable length (depen-
ding on the number of Eden/Tina
units) 500 m
Max. number of light beams (Spot
T/R) per input function 2
Spot 10 1
Spot 35 3
Total max. cable length (depen-
ding on the number of Spot T/R) 100 m
Maximum number of units varies depending on the installation andcable
size. For more information, see the examples in this chapter.
Response time
Relay output (Q1, Q11) 15 24 ms
Safe transistor outputs
(Q2, Q12) 11 20 ms
Non-safe transistor output
(Q2, Q12) 11 20 ms
Relay outputs
Number of outputs 2 NO
Max. load capacity, res. load 6A/250 VAC
Max. load capacity, ind. load AC-12: 250 V/1,5 A
AC-15: 250 V/1,5 A
DC-12: 50 V/1,5 A
DC-13: 24 V/1,5 A
Safe transistor outputs
Number of outputs 2
Output voltage (rated) 24V
Output voltage (at load) > 22V at 800 mA/24V
supply voltage
23.3V at 150 mA/24V
supply voltage
Max. load 800 mA
Short circuit protection
Output 0V Yes
Output +24V Normal (not guaranteed)
Non-safe transistor output (infor-
mation)
Output voltage (rated) +24 VDC
Max. load 1 A
Mounting
DIN rail 35 mm DIN rail
Operating temperature range -10C to + 55C
Connection blocks (detachable)
Max screw torque 1 Nm
Max connection area:
Solid conductors 1x4 mm
2
/ 2x1.5 mm
2
/12AWG
Conductor with socket contact 1x2.5 mm
2
/ 2x1 mm
2
Air and creep distance 4kV/2 DIN VDE 0110
Protection class
Enclosure IP40 IEC 60529
Connection blocks IP20 IEC 60529
Approved standards EN ISO 13849-1/EN 954-1, EN ISO
13849-2, EN 62061, EN 61496-1, EN
574, EN692, EN 60204-1, EN50178,
EN61000-6-2, EN 61000-6-4, EN
61000-4-, IEC/EN61508-17
Connector blocks are detachable
(without cables having to be disconnected)
5/21 2TLC172001C0202 | ABB Safety Handbook
5
Why should you use the Tina adapter units?
to adapt safety sensors to the dynamic single channel
circuit according to PL e!
The Tina devices adapt safety sensors with mechanical
positive forced disconnecting contacts, such as emergency
stops, switches and light grids/curtains with dual outputs to
the dynamic safety circuit in Vital and Pluto. This means Pluto
complies with EN ISO 13849-1 and SIL 3 in EN 62061 and
EN 61508 for the connected safety sensors with the Vital/
Pluto controller. Note that ABB JokabSafety's dynamic safety
sensors, such as Eden and Spot can be connected directly to
the Vital/Pluto circuit without intermediate Tina devices.
for bypassing of safety sensor in a dynamic circuit!
The Tina 5A bypass unit is used for bypassing of safety
sensor in a dynamic circuit and provides the possibility for
supervision of bypass lamp indication. During bypassing of
safety devices e.g. a light grid or an interlocked gate switch/
sensor, it must only be possible to allow the bypass function if
a lamp indication is given. The lamp indication must therefore
be supervised. With this system it is possible to bypass one
or more safety sensor at the same time.
as a connection block for simplified connection to a
dynamic circuit!
The Tina 4A/8A connection blocks are available with 4 or
8 M12 connections. They are used to enable several safe-
ty sensor having M12 connection terminated cables to be
connected together. The blocks are connected with a suitable
multi-core cable, that contains status information from each
safety component, to the control cabinet. This enables simp-
lified wiring. The connection block contains electronic circuits
which modify the coded dynamic signal in the safety circuit.
Note Several connection blocks can be connected to one
Vital/Pluto. Using Tina 4A/8A connection blocks eliminates
connection faults and can significantly reduce system cable
costs.
Tina 7A Tina 2A Tina 10A Tina 3A
1
Tina 6A
2
Tina 1A Tina 8A Tina 4A
3
Tina 5A
4
Pluto Vital
Tina 2B Tina 10 B/C
Tina 11A Tina 12A
Up to 30 Tina-units in series. Individual indication for
every connected safety
mat, strip or bumper.
Simple connection arrangements Bypassing & lamp supervision
Vital/Pluto safety circuit,
PLe, using Tina adapter units
ABB Safety Handbook | 2TLC172001C0202 5/22
5
Tina 7A
Tina 2A
Tina 10A
Tina 3A
Tina 10 B/C
Tina 2B
1
Tina 6A
2
3
Tina 11A Tina 12A
Tina 1A Tina 4A Tina 8A
Tina 5A
4
Safety circuit, PLe, ENISO13849-1
Individual status indication of every connected unit in the safety circuit
Supervision of lamp indicating bypassing of safety device
Quick release M12 connector
Tina is available in several versions
Tina 4A, Tina 8A, Tina 11A and Tina 12A are used as
terminal blocks and simplify connection to a Vital safety
circuit. Each safety component is connected to the terminal
block via an M12 connection. A terminal block is connected
to the apparatus enclosure by means of a cable that also
contains status information from each safety component that
is connected to Tina 4A/Tina 8A and summed information
from Tina 11A/Tina 12A. Tina 1A must be used as a blanking
plug in unused M12 connections.
Tina 6A is used to connect door sensitive edges and safety
mats, and provides an indication for each unit (Tina 7A may
also be used). If a Tina 6A is connected close to the edge or
mat, the risk of electrical interference is reduced.
Tina 5A is used to bypass the safety sensors in Vital security
loop and for monitoring the indicator light switch off. Tina 5A
bypass units are used for bypassing of safety sensors in a
dynamic circuit and provides the possibility for supervision of
bypass lamp indication.
Tina 2A/B, Tina 3A and Tina 7A are used to connect safety
components with mechanical positive forced disconnecting
contacts, such as emergency stops, switches and light
curtains/light beams with relay outputs. NOTE! In order
to maintain safety category 4 and to reduce the risk of
electrical interference, Tina 2 A, 3A and 7A units must be
installed within the same physical encapsulation as the
safety component that is to be monitored, and this is to be
connected to the Tina unit with as short a cable as possible.
Tina 10A/B/C units are used for connection of Focus light
beams/curtains to Vital or Pluto. Tina 10B has an extra M12
connector that enables reset, a reset lamp and switching of
the Focus supply voltage. The Tina 10C has an additional
M12 connector that permits a Focus transmitter to receive
power.
Tina is available in several versions depending on the type of safety component that is connected to the Vital or Pluto
circuit. Also available is a bypassing unit, three connector blocks with 2, 4 or 8 M12 connectors, and a blind plug for
unused connections. As an accessory there is a Y-connector for series or parallel connection and even for connection
of light beams with separate transmitter and receiver. Tina units are also included in emergency stop models Smile
Tina and INCA Tina. This is to adapt ABB JokabSafety's products to dynamic safety circuits.
All Tina units are designed to decode the dynamic signal in the safety circuit of Vital/Pluto.
Reasons to choose Tina
5/23 2TLC172001C0202 | ABB Safety Handbook
5
Blanking plug for connection block
Tina 1A
Description
Tina 1A is a device that is designed for use with the connec-
tion blocks Tina 4A or Tina 8A where it is used as a blind plug
in unused M12 connections. The device is fitted with a LED
for status indication of the dynamic safety circuit.
Technical data Tina 1A
Article number 2TLA020054R0000
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat. 4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -25%
Total current consumption 17 mA (27 mA with max information
output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal
operation (protection OK) and 24
VDC supply voltage
Dynamic input: between 9 and 13
volt (RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connector M12 5-pole male
Size 48 23 15 mm (L x W x H)
Weight ~20 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003,
ENISO12100-2:2003,
EN60204-1:2007,
ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
47
32
2
4
,
5
11, 2
L
E
D
1
2
3
4
5
5-pin M12 male contact
1. +24VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Not used
Approvals:
Application:
Is used as a blanking plug in
unused M12 connectors at
connection blocks
Features:
Indication of status by LED
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/24
5
Adaptation unit
Tina 2A/B
Description
Tina 2A/B is a device that adapts the safety sensors with
mechanical positive forced disconnecting contacts, such as
emergency stops, switches and light curtains/light grids with
their own relay outputs to the dynamic safety circuit.
Tina 2A is fitted with M20 contact which simplifies connection
to safety sensors prepared for M20 connection. Tina 2B is
very small and can often be placed in the safety components'
enclosure. Both Tina 2A and Tina 2B are fitted with LEDs for
status indication of the dynamic safety circuit.
Technical data Tina 2A
Article number
Tina 2A
Tina 2B
2TLA020054R0100
2TLA020054R1100
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + 15%, 25%
Total current consumption 17 mA (27 mA with max information
output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal
operation (protection OK) and 24
VDC supply voltage
Dynamic input: between 9 and 13
volt (RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connector 5 x 0.34 mm
2
wires, 0.15 m
Size Tina 2A: 43 24 24mm
Tina 2B: 28 21 7mm (L x W x H)
Weight Tina 2A: ~30g
Tina 2B: ~20 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003, ENISO 12100-
2:2003,
EN60204-1:2007, EN9541:1996,
ENISO13849-1:2008,EN62061:2005
Certicates TV Nord
2
6
,
5
45, 3
36, 3 11, 2
24
M
2
0
x
1
,5
1
2
3
4
5
2
1
26 6, 8
LED
1
2
3
4
5
Cable connection:
Brown: +24 VDC
White: Dynamic input signal
Blue: 0 VDC
Black: Dynamic output signal
Grey: Information
Approvals:
Application:
Adaptation of safety sensors
with mechanical contacts to
the dynamic safety circuit.
Example:
Emergency stops
Switches
Light beams / light curtains
with relay outputs
Features:
Simplifies the system as well
as maintaining the safety level
Indication of status by LED
TV
NORD
5/25 2TLC172001C0202 | ABB Safety Handbook
5
Adaptation unit
Tina 3A/Aps
Description
Tina 3A/Aps is a device that adapts the safety sensors with
mechanical positive forced disconnecting contacts, such as
emergency stops, switches and light curtains/light grids with
their own relay outputs to the dynamic safety loop.
Both Tina 3A and Tina 3Aps are fitted with M20 contacts
which simplifies connection to safety sensors prepared for
M20 connection. The devices are then easily connected to
the dynamic safety loop through a 5-pin M12 contact to the
Tina device. Tina 3Aps has an extra conductor for the supply
voltage to the safety sensor.
Technical data Tina 3A
Article number
Tina 3A
Tina 3Aps
2TLA020054R0200
2TLA020054R1400
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -25%
Total current consumption 47 mA (57 mA with max information
output)
Information output: Max 10 mA
Time delay t (in/out) t < 70 s
Current through safety device
contacts 12mA
Short circuit current between
contacts 10mA
Voltage supply at normal operation
(protection OK) and 24 VDC supply
voltage
Dynamic input: between 9 and 13 volt
(RMS)
Dynamic output: between 9 and 13 volt
(RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors M12 5-pole connector
Green loop wires (A1 & A2)
Orange loop wires (B1 & B2)
Brown (+24 VDC), Blue (0 VDC) wires
(Tina 3Aps only)
Size 54 24 24mm (L x W x H)
Weight ~30 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC, ENISO12100 1:2003,
ENISO12100-2:2003, EN60204-
1:2007, ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
5-pin M12 male contact:
1. +24VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Not used
Cable connection:
1. Safety circuit A1-A2
2. Safety circuit A1-A2
3. Safety circuit B1-B2
4. Safety circuit B1-B2
5. Brown: +24 VDC (only Tina 3 Aps)
6. Blue: 0 VDC (only Tina 3Aps)
11, 2
24
2
6
,
5
36, 3
47, 1
56, 1
LED 2
M
1
2
M
2
0

1
,5
1
2
3
4
5
1
2
3
4
11, 2
24
2
6
,
5
36, 3
47, 1
56, 1
LED 2
M
1
2
M
2
0

1
,5
1
2
3
4
5
1
2
3
4
11,2
24
LED 2
5
6
1
2
3
4
1
2
3
4
5
2
6
,5
47,1
36,3
56,1
M
1
2
M
2
0

1
,5
Tina 3
Aps
Approvals:
Application:
Adaptation of mechanical
positive forced disconnecting
contacts to the dynamic
safety circuit.
Example:
Emergency stops
Switches
Light beams / light curtains
with relay outputs
Features:
Simplifies the system as well
as maintaining the safety level
Indication of status by LED
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/26
5
1
2
3
4
5
6
7
8
13
Shield
Connection block
Tina 4A
Description
Tina 4A is a connection block with four 5-pin M12 connec-
tions. It is used to connect multiple safety sensors with M12
contacts via a single cable to a controller or PLC. This simpli-
fies cable running and reduces cable costs. Multiple connec-
tion blocks can be connected to a Vital/Pluto. Tina 1A is used
for unused M12 connections.
Technical data Tina 4A
Article number
Tina 4A 2TLA020054R0300
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -15%
Total current consumption 10 mA (20 mA with max information
summary output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13
volt (RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors M12 5-pole female (4x)
9-pin connection block
Size 99 50 43mm (L x W x H)
Weight ~100 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003,
ENISO12100-2:2003,
EN60204-1:2007,
ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
5-pin M12 female contact (x4):
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information
Connection block:
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
Cable shield
5. Information (contact #1)
6. Information (contact #2)
7. Information (contact #3)
8. Information (contact #4)
13. Summarized information (contact #1-4)
Approvals:
Application:
Connection block for up to
four safety sensors adapted
to the dynamic safety circuit.
Features:
Simplifies cable routing and
reduces cable costs.
Allows branching of up to four
safety sensors to the dynamic
safety circuit.
TV
NORD
5/27 2TLC172001C0202 | ABB Safety Handbook
5
Adaptation unit
Tina 5A
Function
The Tina 5A is designed for bypassing of safety devices con-
nected to the Vital/Pluto safety circuit and for supervision of
lamp indication.
During bypassing of safety devices e.g. a light grid or an
interlocked gate, it must only be possible to allow the bypass
function if a lamp indication is on. The lamp indication must
therefore be supervised. Whether indication is required de-
pends on the specific situation and result of risk analysis.
When the Tina 5A receives a coded dynamic signal to S1 and
the bypass indication lamp is on (connected across L1-L2), a
bypassing output signal is provided on S2 and S3. A broken
or short circuit in the indication lamp leads to an interruption
of the bypass output signal on S2 and S3, therefore stopping
the bypassing.
The dynamic signal to S1 on Tina 5A must be the input signal
from the first of the safety devices intended to bypass. The si-
gnal can be connected via output contacts from a safety relay,
a safety timer or be initiated via a unit providing the dynamic
coded signal as for example an Eden sensor or a Spot light
beam. The dynamic output from S2 or S3 is connected to the
output of the safeguards to be bypassed
Approvals:
Application:
Bypassing of safety device
connected to the dynamic
safety circuit and for supervi-
sion of lamp indication.
Features:
One or more safety devices
can be bypassed
supervised lamp indication
Indication of status by LEDs
S2 is used if:
an odd number of dynamic safety units is to be bypassed
using an odd number of dynamic safety units, i.e. the sum
of Tina + Eden and Spot units (incl. Tina 5A). See drawing
HE3824C
an even number of dynamic safety units is to be bypassed
using an even number of dynamic safety units, i.e. the sum
of Tina + Eden and Spot units (incl. Tina 5A). See drawing
HE3824F
S3 is used if:
an odd number of dynamic safety units is to be bypassed
using an even number of dynamic safety units, i.e. the sum
of Tina + Eden and Spot units (incl. Tina 5A). See drawing
HE3824D
an even number of dynamic safety units is to be bypassed
using an odd number of dynamic safety units, i.e. the sum
of Tina + Eden and Spot units (incl. Tina 5A). See drawing
HE3824E
The total number of dynamic safety units is calculated by
adding the number of Eden, Spot and Tina units connected in
the Vital circuit. See the connection examples HE3824C, D, E,
F or G.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/28
5
Technical data Tina 5A
Article number 2TLA020054R1900
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +10%, -10%
Current consumption, A1-A2 No bypass: 10 mA
Bypass using a 5 W indication lamp: 240 mA
Bypass connection Tina 5A can bypass max. 30 Eden/Tina-units or 6 Spot T/R
Time delay t (in/out) t < 260 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13 volt (RMS)
Dynamic output: between 9 and 13 volt (RMS)
Information output: ~ 23 VDC
Protection class Enclosure: IP40
Connection block: IP20
Ambient temperature -10+55C
Humidity range 35 to 85 % (with no icing or condensation)
Housing material Based on polyamide, Macromelt OM646 (V0)
Connectors Connection blocks with a total of 8 terminals (2 x 4)
Mounting 35 mm DIN rail
Size 120 84 22.5mm (L x W x H)
Weight ~135 g
Colour Grey
Approved standards European Machinery Directive 2006/42/EC, ENISO12100-1:2003, ENISO12100-2:2003, EN60204-1:2007,
ENISO13849-1:2008, EN62061:2005, EN61496-1:2004 + A1:2008
Certicates TV Nord
Connections:
+A1: +24 VDC
Y14: Information of bypass
L1-L2: Bypass lamp
(or 820 ohm/2W resistor)
-A2: 0 VDC
S1: Dynamic signal in
S2: Dynamic signal out,
transcoded
S3: Dynamic signal out,
transcoded twice
Bypassing of Eden and Tina units
If one or more Eden or Tina units are bypassed by a Tina 5A,
a diode, such as a 1N4007 must be inserted with forward cur-
rent out from pin 4 of the last bypassed unit. If one or more
Eden or Tina units are bypassed by one or more Eden or Tina
units direct to each other, a diode, such as a 1N4007 must be
inserted by the last unit in both loops with forward current out
from pin 4. Refer to example HD3801A.In the case of bypas-
sing of a Tina 10A, B or C or of more than one unit towards
each other, it is recommended that a Tina 5A or M12-3M is
used. See the examples HE3824C, D, E, F or G.
5/29 2TLC172001C0202 | ABB Safety Handbook
5
Adaptation unit
Tina 6A
Description
Tina 6A monitors short circuits. It is used to adapt the safety
sensors with safety contact strips and safety mats with relay
outputs to the dynamic safety circuit. The device is fitted with
a LED for status indication of the dynamic safety circuit.
Technical data Tina 6A
Article number
2TLA020054R0600
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -25%
Total current consumption 47 mA (57 mA with max information
output) Information output: Max 10 mA
Current through safety device
contacts 12mA
Short circuit current between
contacts 10mA
Time delay t (in/out) t < 70 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13
volt (RMS) Dynamic output: between
9 and 13 volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors M12 5-pole male
M12 5-pole female
Size 63 31 15 (L W H)
Weight ~30 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC ENISO12100-1:2003,
ENISO12100-2:2003, EN60204-
1:2007, ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
3
3
62, 2
33 11, 2
M12 M12
LED
2
1
2
3
4
5
1
2
3
4
5
5-pin M12 male contact:
1. +24VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
Information
5-pin M12 female contact:
1. Safety circuit A1-A2
2. Safety circuit A1-A2
3. Safety circuit B1-B2
4. Safety circuit B1-B2Not used
Approvals:
Application:
Short circuit monitoring and
adaptation of safety sensors
to the dynamic safety circuit
For example:
Contact edges
Bumpers
Safety mats
Features:
Simplifies the system as well
as maintaining the safety level
Indication of status by LED
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/30
5
Adaptation unit
Tina 7A
Description
Tina 7A is a device that adapts the safety sensors with
mechanical positive forced disconnecting contacts, such as
emergency stops, switches and light curtains/light grids with
their own relay outputs to the dynamic safety circuit.
The device is designed for installation in an equipment
cabinet where it can be mounted directly on a 35 mm DIN
busbar, and the conductors are then connected directly to
the screw terminals.
Technical data Tina 7A
Article number 2TLA020054R0700
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat. 4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -25%
Total current consumption 47 mA (57 mA with max information
output) Information output: Max 10 mA
Current through safety device
contacts 12mA
Short circuit current between
contacts 10mA
Time delay t (in/out) t < 70 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13 volt
(RMS)
Dynamic output: between 9 and 13
volt (RMS) Information output: ~ 23
VDC
Protection class IP20
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors 5-pin connection block (power sup-
ply, dynamic in/out, info)
4-pin connection block (safety loop
A1-A2, B1-B2)
Mounting DIN rail
Size 61 46 14 (L W H)
Weight ~35 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC, ENISO12100-1:2003,
ENISO12100-2:2003, EN60204-
1:2007, ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
1
3
62
4
5
,
7
3
5
,
5
2
4
3
1
5
6
7
8
9
Connection block:
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information
6. Safety circuit A1-A2
7. Safety circuit A1-A2
8. Safety circuit B1-B2
9. Safety circuit B1-B2
Approvals:
Application:
Adaptation of safety sensors
with mechanical contacts to
the dynamic safety circuit.
For example:
Emergency stops
Switches
Light beams / light curtains
with relay outputs
Features:
Simplifies the system as well
as maintaining the safety level
Indication of status by LED
Adapted for easy installation
on 35 mm DIN rail in cabinets
TV
NORD
5/31 2TLC172001C0202 | ABB Safety Handbook
5
1
2
3
4
5
6
12
13
Shield
Connection block
Tina 8A
Tina 8A is a connection block with eight 5-pin M12 connec-
tions. It is used to connect multiple safety sensors with M12
contacts via a single cable to a controller or PLC. This simpli-
fies cable running and reduces cable costs. Multiple connec-
tion blocks can be connected to a Vital/Pluto. Tina 1A is used
for unused M12 connections.
Technical data Tina 8A
Article number 2TLA020054R0500
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat. 4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -15%
Total current consumption 15 mA (25 mA with max information
summary output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13 volt
(RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors M12 5-pole female (8x)
13-pin connection block
Size 149 50 43 (L W H)
Weight ~140 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC, ENISO12100-1:2003,
ENISO12100-2:2003, EN60204-
1:2007, ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
5-pin M12 female contact (x8):
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information
Connection block:
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal Cable shield
5. Information (contact #1)
6. Information (contact #2)
7. Information (contact #3)
8. Information (contact #4)
9. Information (contact #5)
10. Information (contact #6)
11. Information (contact #7)
12. Information (contact #8)
13. Summarized information (contact #1-8)
Approvals:
Application:
Connection block for up to
eight safety sensors adapted
to the dynamic safety circuit.
Features:
Simplifies cable routing and
reduces cable costs.
Allows branching of up to four
safety sensors to the dynamic
safety circuit.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/32
5
Tina 4A
Connection examples of safety sensors to Tina 8A
Safety controller,
Vital
Connection 1
One Eden is connected directly to the Tina 8A. The Eden
status is shown by an LED on the Adam sensor. A status
information signal is also connected to Tina 8A.
Connection 2
One Focus safety light grid is connected to the Tina 8A via a
Tina 10A. The output from the Tina 10A is via a M12 connec-
tor. The connection between Tina 10A and Tina 8A is achie-
ved using a cable with M12 connectors on each end.The Tina
10A has two LEDs which show the status of the light grid.
The same status information signal is connected to the Tina
8A. Tina10A and the Focus transmitter are connected, via an
M12-3B, to Tina8A.
Connection 3
A Spot 10 light beam is connected directly to Tina 8A. A Y
connector M12-3B for M12 plugs is connected to the trans-
mitter and the receiver. The status information shown on the
Spot LED is also connected to Tina 8A.
Connection 4
A safety mat (same for safety strip and safety bumper) is
connected via a Tina 6 A to the Tina 8A. Two LEDs in Tina
6A shows the status of the mat. The same status information
signal is connected to Tina 8A.
Connection 5
One Smile is connected to the Tina 8A. The information
shown by an LED on the Smile is also connected to the termi-
nal block on the Tina 8A.
Connection 6
A safety interlock switch is connected via a Tina 3A mounted
directly on the switch. The output from the Tina 3A is via a
M12 connector. The connection between the Tina 3A and
the Tina 8A is therefore simply made with a cable with M12
connectors on each end. On the Tina 3A there is a LED which
shows the status of the switch. The same information signal is
connected to the Tina 8A.
Connection 7
A Spot 35, transmitter and receiver are connected directly to
the Tina 8A via a M12-3B Y connector. The status informa-
tion shown by the LED on the Spot is also connected to the
Tina 8A.
Connection 8
Tina 1A is a plug which has to be connected to Tina 8A
inputs when no sensor is required, in order to complete the
safety connection circuit.
NOTE! All input connectors on the Tina 8A must be
connected to sensors or have Tina 1A plugs fitted.
5/33 2TLC172001C0202 | ABB Safety Handbook
5
Tina 10 A/B/C are three connection units with M12 connections, that make it easy
to connect a light curtain or light beam Focus with OSSD outputs to the dynamic
safety circuits of Vital and Pluto. This also enables complete external interconnec-
tions, with M12 cabling, which reduces the cabling to and connections in the appa-
ratus enclosure. Tina 10 A/B/C has LEDs for function indication, with green, red or
flashing green/red indications.
Tina 10A: has two M12 connections that are connected to 1: Vital/Pluto and 2: a
light curtain/light beam Focus receiver. See the connection examples HH3300F,
HR7000L-01.
Tina 10B: has three M12 connections that are connected to 1: Vital/Pluto and 2: a
light curtain/light beam Focus receiver, and 3: An external reset button and muting
lamp, such as unit FMI-1C.See the connection examples HR7000L-01.
Tina 10C: has three M12 connections that are connected to 1: Vital/Pluto and 2:
a light curtain/light beam Focus receiver, and 3: a light curtain/light beam Focus
Transmitter. See the connection examples HH3302D, HR7000L-01.
Adaptation unit
Tina 10A/B/C
Approvals:
Application:
Adaptation of safety sensors
with OSSD outputs to the
dynamic safety circuit.
For example:
Focus lightcurtain/lightbeam
Features:
Simplifies the system as well
as maintaining the safety level
Indication of status by LED
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/34
5
Tina 10A, 10B and 10C connections
1 1 1
3
2
3
2
Tina 10B Tina 10C Tina 10A
13,4
11,2
3
6
77
4
, 5
46,5
3
6
77
46,5 11,2
13,4
3
6
77
46,5 11,2
13,4
Technical data Tina 10A/B/C
Article number
Tina 10A
Tina 10B
Tina 10C
2TLA020054R1200
2TLA020054R1300
2TLA020054R1600
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat.4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +20%, -20%
Total current consumption 60mA (70mA with max. info signal out)
Info signal out: Max. 10 mA
Time delay t (in/out) t < 120 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input signal: 9 to 13 V (RMS)
Dynamic output signal: 9 to 13V
(RMS)
Info signal out: ~23 VDC
Protection class IP67
Ambient temperature Storage: 10+55C
Operation: 10+55C
Humidity range 35 to 85% (without icing or condesa-
tion)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Size 74 36 11mm (L W H)
Weight ~40 g
Colour Black
Number of units connected to
Vital1
Max. number of Tina 10A:
Max. number of Tina 10B/C:
6
4 when Focus is supplied by Vital and
a reset lamp is used
6 when Focus is supplied separately
or no reset lamp is used
Number of units connected to
Pluto, Vital 2 or 3, per input
Max. number of Tina 10A/B/C: 2
Connectors
Tina 10A
Tina 10B
Tina 10C
1: for Vital or Pluto
2: for Focus receiver
1: for Vital or Pluto
2: for Focus receiver
3: for Reset unit
1: for Vital or Pluto
2: for Focus receiver
3: for Focus transmitter
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003,
ENISO12100-2:2003,
EN60204-1:2007,
ENISO13849-1:2008,
EN62061:2005, EN61496-1:2004 +
A1:2008
Certicates TV Nord
5/35 2TLC172001C0202 | ABB Safety Handbook
5
Terminal block
Tina 11A
Description
Tina 11A is a connection block with two 5-pin M12 connec-
tions. It is used to connect two safety sensors with M12 con-
tacts via a single cable to a controller or PLC. This simplifies
cable running and reduces cable costs. Multiple connection
blocks can be connected to a Vital/Pluto.
Technical data Tina 11A
Article number 2TLA020054R1700
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat. 4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -15%
Total current consumption 17 mA (27 mA with max information
output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13 volt
(RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors Out: M12 5-pole male (nr 2)
In: M12 5-pole female (nr 1,3)
Size 74 36 11mm (L W H)
Weight ~40 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003, ENISO12100-
2:2003,
EN60204-1:2007,
ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
11, 2
13, 4
46, 5
77
3
6
1
2
3
4
5
5
2
4
3
1
5
2
4
3
1
5-pin M12 male connector
(contact #1):
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Summarized information
(contact #2-3)
5-pin M12 female connector
(contact #2-3)
1. +24 VDC
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information
Approvals:
Application:
Terminal block for connection
of two safety sensors with
5-pin M12 connectors and
adaptation to the dynamic
safety circuit.
Features:
Simplifies cable routing and
reduces cable costs.
Allows connection of two
safety sensors to the dynamic
safety circuit.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 5/36
5
Terminal block
Tina 12A
Description
Tina 12A is a connection block with two 8-pin M12 connec-
tions. It is used to connect two process locks Dalton or Mag-
ne 2A/B with integrated Eden sensors via a single cable to a
controller or PLC. This simplifies cable running and reduces
cable costs. Multiple connection blocks can be connected to
a Vital/Pluto.
Tina 12A has three 8-pin M12 contacts that connect to
1: Pluto/Vital, information for sensors and locks and lock
signals
2: Dalton with Eden No 1
3: Dalton with Eden No 2
Technical data Tina 12A
Article number 2TLA020054R1800
Level of safety
IEC/EN61508-17 SIL3
EN62061 SIL3
ENISO13849-1 PLe/Cat. 4
PFH
D
4.50 10
-9
Power supply
Operating voltage 24 VDC + +15%, -15%
Total current consumption 60 mA (70 mA with max information
output)
Information output: Max 10 mA
Time delay t (in/out) t < 60 s
Voltage supply at normal opera-
tion (protection OK) and 24 VDC
supply voltage
Dynamic input: between 9 and 13 volt
(RMS)
Dynamic output: between 9 and 13
volt (RMS)
Information output: ~ 23 VDC
Protection class IP67
Ambient temperature Storage: -30+70C
Operation: -10+55C
Humidity range 35 to 85 % (with no icing or conden-
sation)
Housing material Based on polyamide, Macromelt
OM646 (V0)
Connectors To Vital/Pluto:
M12 8-pole male (nr 2)
From safety device:
M12 8-pole female (nr 1,3)
Size 74 36 11mm (L W H)
Weight ~40 g
Colour Black
Approved standards European Machinery Directive
2006/42/EC
ENISO12100-1:2003, ENISO12100-
2:2003,
EN60204-1:2007,
ENISO13849-1:2008,
EN62061:2005
Certicates TV Nord
11,2
13,4
3
6
77
46,5
Approvals:
Application:
Terminal block for connection
of two safety sensors with
8-pin M12 connectors and
adaptation to the dynamic
safety circuit.
For example:
Dalton
Magne
Features:
Simplifies cable routing and
reduces cable costs.
Allows connection of two
safety sensors to the dynamic
safety circuit.
TV
NORD
5/37 2TLC172001C0202 | ABB Safety Handbook
5
M12-C01 M12-C02 M12-C03 M12-C04
* * * *
Female Male
Female Male Female Male
Accessories
Y branch with M12 connection and M12-connection device
with screw connectors
Cabling
Many of ABB JokabSafety's products are connected using
standard M12 connectors. This facilitates installation, saving a
lot of time, and also dramatically reduces the risk of incorrect
connection.
We have therefore developed cables with 5 conductors,
5 x 0.34 mm + screening or 8 conductors; 8 x 0.34 mm +
screening which offer the advantages that we believe a good
cable should have. These are available in any length and in
various standard lengths, with moulded straight or angled
male or female connectors. Particularly suitable cables for the
Tina 4A and Tina 8A units are C9 and C13. They have thicker,
0.75 mm
2
conductors for the feed line and 0.5 mm
2
for the
other conductors + screening. Refer to the component list for
the variants that are available.
Advantages
Area 0.34 mm
2
and 0.25 mm
2
Always screened cable
The screen is always connected to negative in male
connectors.
The guide pin in the small connector is indicated by a
recessed arrow that is easy to recognise.
Convenient cable in PVC
The cable is also available in bulk length.
3
1
2
M12-3E
Female Female
Male
1
2
3
M12-3D
Male
Female
Female
1
3
2
M12-3B
Male
Female Female
2
3
1
M12-3A
Male
Female
Female
See the connection examples
HA3306C, D
HH3300A, D
See the connection
examples HA3306C, D.
HH3300D, F.
HH3302D
See the connection examples
HB0008A
HR7000O, L.
See the connection examples
HB0001A, 2A, 4A and 6A
ABB Safety Handbook | 2TLC172001C0202 5/38
5
T
i
n
a
-
1
1
A
T
i
n
a
-
1
0
C
T
i
n
a
-
6
A
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1 1
2 2
3 3
2 3 2
2
1
3
1 1
1
Example of safety sensor connections based on Y branch
Vital 1 safety controller
M12-3B
M12-3A
5/39 2TLC172001C0202| ABB Safety Handbook
5
ABB Safety Handbook | 2TLC172001C0202 5/40
5
HA3300A-01 Connection example Vital 1 5/41
HA3301A Vital 1 with several Eden 5/41
HA3302A Vital 1 and Tina 4A with 4 Eden 5/42
HA3302B-01 Vital 1 and 2 Tina 4A and 4 Eden and emergency stop 5/42
HA3303A Vital 1 with emergency stop/Tina 2A 5/43
HA3304A Vital 1 with emergency stop/Tina 3A 5/43
HA3305A Vital 1 with Eden and lightgrid Focus/Tina 10C 5/44
HA3306C Vital 1 with 2 lightbeams Spot 5/44
HA3306D Vital 1 with 3 lightbeams Spot 5/45
HA3307A Vital 1 with Eden, lightgrid/Tina 3A and e-stop/Tina 7A 5/45
HD3800A-01 Vital 1 with safety light beam Spot 5/46
HD3801A-01 Vital 1, series and parallel 5/46
HE3811B-01 Safety light beam Spot with time-limited reset 5/47
HE3824C-01 Lightbeam with time-limited bypass 0.240 s. 5/47
HE3824D-01 Eden and bypassed lightbeam with Eden 5/48
HE3824E-01 Lightbeams with time-limited bypass 0.240 s. 5/48
HE3824F-01 Eden and 2 bypass lightbeams with Eden 5/49
HE3824G-01 Eden and 2 separetely bypassed lightbeams 5/49
HH3300A Vital 1 with different types of safety devices and M123A 5/50
HH3300D Vital 1 with Tina 4A and different types of safety devices 5/50
HH3302D-01 Vital 1 with Tina 8A and different types of safety devices 5/51
HH3301E-01 Connection example Vital 1 5/51
HH3400A2 Vital 1 solutions 5/52
HB0005A-01 Vital with Eden and Inca e-stop, with separate reset 5/52
HB0006A-01 Vital with 4 Eden units + Reset via M12-3E and Tina 4A 5/53
HB0007A Vital with two Dalton units via Tina 12A 5/53
HB0001A-01 Pluto with Smile e- stop, Reset and Adam via Tina 4A 5/54
HB0002A-01 Pluto with Eden units, two zones via M12-3E and Tina 4A 5/54
HB0003A-01 Pluto with e-stop units, via Tina 11A and Tina 4A 5/55
HB0004A Pluto with different zones for Eden + Reset and Eden units 5/55
HH3301D-01 Vital 1 and Tina 8A with different safety device types 5/56
Connection examples
5/41 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HA3301A Vital 1 with several Eden
HA3300A-01 Connection example Vital 1
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/42
5
Connection examples
HA3302B-01 Vital 1 and 2 Tina 4A and 4 Eden and emergency stop
HA3302A-01 Vital 1 and Tina 4A with 4 Eden
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
5/43 2TLC172001C0202| ABB Safety Handbook
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Connection examples
HA3304A Vital 1 with emergency stop/Tina 3A
HA3303A Vital 1 with emergency stop/Tina 2A
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/44
5
Connection examples
HA3304A Vital 1 with emergency stop/Tina 3A
HA3305A Vital 1 with Eden and lightgrid Focus/Tina 10C
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
5/45 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HA3307A Vital 1 with Eden, lightgrid/Tina 3A and emergency stop/Tina 7A
HA3306D Vital 1 with 3 lightbeams Spot
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/46
5
Connection examples
HD3801A-01 Vital 1, series and parallel
HD3800A-01 Vital 1 with safety light beam Spot
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
5/47 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HE3824C-01 Lightbeam with time-limited bypass 0.240 s.
HE3811B-01 Safety light beam Spot with time-limited reset
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/48
5
Connection examples
HE3824E-01 Lightbeams with time-limited bypass 0.240 s.
HE3824D-01 Eden and bypassed lightbeam with Eden
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
5/49 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HE3824G-01 Eden and 2 separetely bypassed lightbeams
HE3824F-01 Eden and 2 bypass lightbeams with Eden
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/50
5
Connection examples
HH3300D Vital 1 with Tina 4A and different types of safety devices
HH3300A Vital 1 with different types of safety devices and M123A
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
a a b c b
Dominate
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
5/51 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HH3301E-01 Connection example Vital 1
HH3302D-01 Vital 1 with Tina 8A and different types of safety devices
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/52
5
Connection examples
HB0005A-01 Vital with Eden and Inca emergency stop, with separate reset
HH3400A2 Vital 1 Solutions
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel and
local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
5/53 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HB0007A Vital with two Dalton units via Tina 12A
HB0006A-01 Vital with 4 Eden units + Reset via M12-3E and Tina 4A
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/54
5
Connection examples
HB0002A-01 Pluto with five Eden units, for two zones via M12-3E and Tina 4A
HB0001A-01 Pluto with Smile emergency stop unit + Reset via M12-3E and Adam via Tina
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
5/55 2TLC172001C0202| ABB Safety Handbook
5
Connection examples
HB0004A Pluto with different zones for Eden + Reset and two Eden units +via M12-3E
HB0003A-01 Pluto with Smile and Inca emergency stop units, via Tina 11A and Tina 4A
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European, nationel
and local codes/regulations. Subject to change without notice.
ABB Safety Handbook | 2TLC172001C0202 5/56
5
Connection examples
HH3301D-01 Connection example Vital 1 and Tina 8A with different safety device typesTina 4A
It is the user's responsibilty to ensure that all control devices are correctly installed, cared for and operated to meet European,
nationel and local codes/regulations. Subject to change without notice.
6/1 2TLC172001C0202 | ABB Safety Handbook
6
ABB Safety Handbook | 2TLC172001C0202 6/2
6
Why should you use Safety relays? 6/3
The most flexible safety relays on the market! 6/4
Safety relay summary 6/5
Safety relay - RT-Series
RT6 6/7
RT7 6/11
RT9 6/15
JSBRT11 6/19
Safety relay - JSB-Series
JSBR4 6/21
JSBT4 6/23
BT50 (T) 6/25
BT51 (T) 6/27
JSBT5 (T) 6/29
Safety timers
JSHT1 6/31
JSHT2 6/33
Expansion relays
E1T 6/35
JSR1T 6/37
JSR2A 6/39
JSR3T 6/41
Connection examples 6/44
Safety Relays
6/3 2TLC172001C0202 | ABB Safety Handbook
6
A fault in the hardware or the software of the control system
does not lead to hazardous situations. This is the require-
ment in the EUs Machinery Directive 2006/42/EC under the
heading 1.2.1. Safety and reliability of control systems. The
directive implies that no person should be put at risk if for
example, a relay sticks or if a transistor or two electrical con-
ductors short-circuit.

A safety relay will fulfill these requirements. A safety relay has,
for example, inputs that are checked for short-circuits and
Three position
devices
Safety interlock
switches
Two-hand
devices
Emergency
stop
Safety mats Light curtains/Light
grids
Light beams
to supervise safety devices!
for safe stops and reliable restarts!
Dual stop signals when the
gate is opened.
Entering or putting a hand or
limb into a hazardous area
must cause all machinery
that can cause personal
injury to stop safely. Many
serious accidents occur
when machinery is believed
to have stopped but is in fact
only pausing in its program
sequence. The safety relay
monitors the gate interlock
switch and cables and gives
dual stop signals.
Timed reset when you
cannot see the entire risk
area.
Sometimes a double reset func-
tion is necessary to make sure
that no one is left behind in the
risk area. First, after ensuring no
other person is inside the hazar-
dous area, the pre-reset button
must be activated, followed by
the reset button outside the risk
area within an acceptable time
period e.g 10 seconds. A safety
timer and a safety relay can
provide this function.
Why should you use safety relays?
dual redundant circuits that are checked at each operation.
This can be compared to the dual brake circuits in a car. If
one of the circuits is faulty the other will stop the car. In a
safety relay there is an additional function which only allows a
machine to start if both circuits are ok.
The standard for safety related parts of the control system
describes various safety categories depending on the level of
risk and application. One single universal relay with selectable
safety categories solves this.
Supervised reset when
there can be a person
within the risk area.
To make sure that nobody
is within the restricted area
when activating the reset
button. A supervised reset
button must be pressed and
released before a reset can
occur. Many serious acci-
dents have been caused by
an unintentional and unsu-
pervised reset.
Automatic reset for small
hatches.
Where body entry is not
possible through a hatch, the
safety circuit can be automa-
tically reset.
The safety relays are reset
immediately when the hatch
interlock switch contacts are
closed.
Safety strips
& Bumpers
to meet existing safety standards!
ABB Safety Handbook | 2TLC172001C0202 6/4
6
The most flexible safety relays on the market!
We have the most flexible safety relays on the market. Our
first universal relay was developed in 1988. Nowadays, the
flexibility is even greater and size has been reduced by 85%.
A universal relay is a safety relay with various input options for
various safety devices and risk levels.
Internally, the safety relay is of the highest safety level (PLe
according to EN ISO 13849-1). A machine supplier can there-
fore, with one single safety relay, select the input configura-
tion that best suits their customers' safety requirements. In
addition, our safety relays have detachable connector blocks
for ease of replacement and testing. As our universal relays
incorporate all input options, they are compatible with all our
previous safety relays as well as with other manufacturers'
products.
Is a universal relay expensive? No, our latest patented cons-
truction is extremely simple and the number of major com-
ponents is less compared to our previous universal relays.
This means that the safety relays are even more reliable than
before.
We also have a great deal of experience from safety solutions
in our own system developments. It would be our pleasure to
share these experiences with you! Please see the complete
safety solutions in the section Connection examples. Please
do not hesitate to contact us if you should require any other
safety solutions.
Safety outputs for immediate and
delayed stops at optional times.
Inputs for various
safety devices.
Input for manual or
automatic resetting.
Detachable
connector
blocks.
Outputs for program stop,
gate opened or closed
and reset indication.
RT7: the most
flexible safety
relay on the
market!
Some of the advantages with ABB Jokab Safetys safety
relays
Universal relays
Excellent reliability
Approved in Europe, USA, Canada
Supervised reset
Time reset
Small and compact
Detachable connector blocks
Low power consumption
Permits the use of long emergency stop cables
EX compatibility
Functions set by external hardwired links
LED indication for inputs and outputs
Powerful switching capacity
6/5 2TLC172001C0202 | ABB Safety Handbook
6
Which safety relay should you choose?
First of all, we would recommend the selection of one of our latest universal relays in the RT-series. These are both practical
and cost effective.
To facilitate the choice of safety relay or combinations of safety relays, please see:
the table below dividing the safety relays into application fields
the table on the opposite page showing possible input and output options
the relevant data sheet giving comprehensive information about each specific safety relay
the circuit diagram for various applications in the section Connection examples.
Note! All earlier types of relays that can now be replaced by those in this manual are still kept as stock items and can be
supplied upon request.
Input alternatives (see also technical data on the next page)
Two-channel, 1 NO from 0 V &
Category 4, up to PL e
Both the inputs must be closed
before the outputs can be activated.
A stop signal is given if one or both
of the inputs are opened. Both the
inputs must be opened and reclosed
before the outputs can be reactiva-
ted. A Stop signal is given if there
is a short-circuit between the inputs.
Summary Safety Relays
Application fields
Safety relays Safety timers Expansion relays
R
T
6
R
T
7
R
T
9
J
S
B
R
T
1
1
J
S
B
R
4
J
S
B
T
4
J
S
B
T
5
T
,

B
T
5
0
T
,
B
T
5
1
T
J
S
B
T
5
,

B
T
5
0
,
B
T
5
1
J
S
H
T
1
A
/
B
J
S
H
T
2
A
/
B
/
C
E
1
T
J
S
R
1
T
J
S
R
2
A
J
S
R
3
T
Interlocking switch/Gate/
Hatch

Light curtains

Light beams

Safety mats

Contact strips

Two-hand control device

Emergency stop

Hold to run/enabling device

Foot control device

Area supervision

Time resetting

Time bypassing

Inching

Output expansion

Delayed output

Single-channel, 1 NO
from +24 V
Category 1, up to PL c
The input must be
closed before the out-
puts can be activated.
A stop signal is given
when the input is
opened.
Two-channel, 2 NO from +24 V
Category 3, up to PLd
Both the inputs must be closed before the outputs
can be activated. A stop signal is given if one or
both of the inputs are opened. Both the inputs
must be opened and reclosed before the outputs
can be reactivated. A short-circuit between the
inputs is not monitored by the safety relay. Cate-
gory 4 can only be achieved if a safety device with
short circuit monitored outputs is connected.
Two-channel, 1 NO & 1 NC from
+24V Category 4, up to PL e
One input must be closed and one
must be opened before the outputs
can be activated. A stop signal is
given if one or both of the inputs
change position or if the inputs
short-circuit. Both inputs must be
put into their initial position before
the outputs can be reactivated.
ABB Safety Handbook | 2TLC172001C0202 6/6
6
Technical data
Safety relays Safety timers Expansion relays
R
T
6
R
T
7
R
T
9
J
S
B
R
T
1
1
J
S
B
R
4
J
S
B
T
4
J
S
B
T
5
T
B
T
5
0
T
B
T
5
1
T
B
T
5
0
B
T
5
1
J
S
H
T
1
A
/
B
J
S
H
T
2
A
/
B
/
C
E
1
T
J
S
R
1
T
J
S
R
2
A
J
S
R
3
T
Safety category 1-4 1-4 1-4- 1-4 4 4 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1-4
Safety input
Single-channel, 1 NO from
+24 V

Two-channel, 2 NO from
+24 V

Two-channel, 1 NO & 1 NC
from +24 V

Two-channel, 1 NO from 0 V
& 1 NO from + 24 V

Contact strips/Safety mats

Reset & test input
Monitored manual

Automatic/Unmonitored
manual

Testing of contactors, re-
lays, valves, etc.

Output
NO 3 2 2 7 3 3 3 4 4* 4* 4
NO delayable 2 3

3 4 4* 4* 2

NO impulse outputs 2

NC info 1 1 2 1 1 1 1* 1
NC info delayable 1

1 1*
Info. output 2 3 1 1 1
Switching capacity (resistive
load)
4 3 2 9 4 4 4 4

4

4 4 4 5
6A/250VAC/1500VA/150W 2

4A/250VAC/1000VA/100W 2

6A/250VAC/1380VA/138W 5
Width (mm)
10A/250VAC/1840VA/192W
45 45 22.5 100 45 45 22.5 22.5 22.5 22.5 22.5 45 45 22.5 45 45 22.5
Supply voltage
12VDC

24VDC

24VAC

115VAC

230VAC

* Indicates the possibility of selecting delayed outputs Indicates one relay contact per output (other relays having two contacts per output)
delay-able Category 4 depending on connection (When used as expansion relay with Pluto Safety PLC, then Category 4) xed 0.5 s delay
Contact strips/Safety mats
Category 3, up to PLd
For an unpressurised mat/strip, both
the relay inputs must be closed for the
outputs to be activated. In the case of
an activated mat/strip and short-circuit
input channels, the relay will be de-
energized. Current limitation prevents
the safety relay from being overloaded
when the channels short-circuit.
Monitored manual reset
A monitored reset means that the
safety relay will not be reset if the
reset button gets jammed when
pressed in or if the input short-
circuits. In order for the resetting
to be complete, the input must
be closed and opened before the
outputs can close.
Automatic/unmonitored manual
reset
Automatic reset means that the
outputs are closed immediately
when both the input conditions
are satisfied and the test input is
closed.
Testing of contactors, relays &
valves
Can be carried out with both
automatic and manual reset.
6/7 2TLC172001C0202 | ABB Safety Handbook
6
Approvals:
Safety relay for:
Emergency stops
Light curtains
Three position devices
Interlocked gates/hatches
Magnetic switches
Light beams
Safety mats
Contact strips
Foot operated switches
Features:
Five input options
Single or dual channel
input
Manual supervised or
automatic reset
Test input for supervision
of external contactors
Width 45 mm
LED indication of supply,
inputs, outputs, short-
circuit and low voltage
level.
3 NO/1 NC relay outputs
Two voltage free
transistor information
outputs
Supply 24 VDC, 24, 115
or 230 VAC
Quick release connector
blocks
Would you like a single safety relay for all your safety applications?
Then choose the RT6 universal relay to supervise both your safety devices and the
internal safety of your machinery. In addition you can select the safety level requi-
red for each installation. All this is possible because the RT6 has the most versatile
input option arrangement available on the market. Many other relays can therefore
be replaced by the RT6.
The relay also comes with other options such as manual or automatic reset. Manual
supervised reset can be used for gates and other safety devices that can be by-
passed. Automatic reset can be used for small hatches, if deemed acceptable from
risk assessment.
The RT6 also has information outputs that follow the inputs and outputs of the
relay. These outputs will for example indicate if a gate is open or closed and if the
safety relay needs to be reset.
The RT6 is designed with a minimum amount of components thus keeping both
production costs and component acquisitions to a minimum.
Choose the RT6 to simplify your safety circuits and reduce your costs.
Safety relay
RT6
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/8
6
Inputs
The inputs from the safety devices must be connected ac-
cording to one of the following options in order to fulfill the
expected safety level and to avoid unsafe situations.
1. Single channel, 1NO contact from +24 VDC, category 1, up to
PL c
2. Dual channel, 2NO contacts from +24 VDC, category 3, up to
PL d
3. Dual channel 1NO, 1 NC contact from +24 VDC, category 4,
up to PL e
4. Dual channel, 1NO contact from 0V and 1NO contact from +24
VDC, category 4, up to PL e
5. Safety mats/contact strips 1 contact from 0V and 1 contact
from +24 VDC, category 3, up to PL d
When the input/inputs are activated and the test/supervised
reset is complete, relays 1 and 2 are energized. Simultaneous
activation is not required where there are dual channels. The two
relays are de-energized when the input/inputs are de-activated in
accordance with the input option chosen or in case of a power fai-
lure. Relays 1 and 2 must both be de-energized before the outputs
can be activated again.
Transistor output status information
The RT6 has two voltage free transistor outputs that can be
connected to a PLC, computer or other monitoring device.
These outputs give the input and output status of the relay.
Reset and testing
The RT6 has two reset options; manual and automatic. The
manual supervised reset is used when the RT6 is monitoring
safety devices that can be bypassed, i.e. to ensure that the
outputs of the safety relay do not close just because a gate is
closed. The automatic reset should only be used if deemed an
acceptable risk.
In addition, the RT6 can also test (supervise) whether, for
example, contactors and valves etc are de-energized/de-acti-
vated before a restart is allowed.
Indication of low voltage
The On LED will flash if the relay supply voltage falls below
an acceptable level. This indication will also be given if a mo-
nitored safety mat/contact strip is actuated. See connection
option 5.
Safety level
The RT6 has internal dual and supervised safety functions. A
short-circuit, internal faulty component or external interference
will not present a risk to options with the highest safety level.
A manual reset requires that the reset input is closed and
opened before the safety relay outputs are activated. A short-
circuit or a faulty reset button is consequently supervised.
When the RT6 is configured for dual channel input, both the
inputs are supervised for correct sequence operation before
the unit can be reset.
The input options 3 and 4 have the highest safety levels as all
short-circuits and power failures are supervised. This in com-
bination with internal current limitation makes the relay ideal
for supervision of safety mats and contact strips.
Regulations and standards
The RT6 is designed and approved in accordance with appro-
priate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, see the section Connection examples.
**Only for AC supply
RT6
Technical information
Connection of supply - RT6
DC supply
The RT6 DC option should be supplied with +24 V
on A1 and 0 V on A2.
AC supply
The RT6 AC option should be supplied with the
appropriate supply voltage via connections A1 and
A2.
The S23/ must be connected to protective
earth.
DC-supply of AC-units
All AC-units can also be supplied by +24 VDC to
S53 (0VDC to S23).
NOTE! With both DC and AC modules, if cable shielding
is used this must be connected to an earth rail or an
equivalent earth point.
6/9 2TLC172001C0202 | ABB Safety Handbook
6
Connection of safety devices - RT6
1. SINGLE CHANNEL, 1 NO from +24V
The input (contact to S14) must be closed before the outputs can be activated.
When the input contact is opened the relay safety output contacts open.
2. DUAL CHANNEL, 2 NO from +24V
Both input contacts (S14 and S34) must be closed before the relay outputs can be
activated. The safety relay contacts will open if one or both of the input contacts
are opened. Both the input contacts must be opened and reclosed before the relay
can be reset. A short-circuit between inputs S14 and S34 can only be supervised if
the device connected to the inputs has JOKAB Focus light curtains.
3. DUAL CHANNEL, 1 NO, 1 NC from +24V
One input contact must be closed (S14) and one opened (S44) before the relay
outputs can be activated. The safety relay contacts will open if one or both of the
inputs change state or in case of a short-circuit between S14 and S44. Both inputs
must return to their initial positions before the relay outputs can be reactivated.
Both contact inputs from a inactivated safety mat/contact strip must be made in
order to allow the RT6 relay outputs to be activated. When the safety mat/contact
strip is activa
4. DUAL CHANNEL, 1 NO from +24V, 1 NO to 0V
Relay functions as for option 2, but a short-circuit, in this case between inputs S14
and S24, is supervised (safety outputs are opened).
5. Safety mat/Contact strip
Both contact inputs from a inactivated safety mat/contact strip must be made in
order to allow the RT6 relay outputs to be activated. When the safety mat/contact
strip is activated or a short-circuit is detected across S14-S23, the relay will de-
energize (safety outputs open) and the ON LED will flash. As output S13 has an
internal current limit of 70 mA, the RT6 will not be overloaded when the mat/con-
tact strip is activated or a short-circuit is detec
Manual supervised reset
Automatic reset
*connected to S13 for
safety mat/contact
strip
Testing external contactor status
Reset connections - RT6
The manual supervised reset contact connected to input X1 must be closed and
opened in order to activate the relay outputs
Automatic reset is selected when S53, X1 and X4 are linked. The relay outputs are
then activated at the same time as the inputs.
Contactors, relays and valves can be supervised by connecting test contacts bet-
ween S53 and X1. Both manual supervised and automatic reset can be used.
Relay outputs
Transistor outputs
Output connections - RT6
The RT6 has three (3 NO) safety outputs and 1 NC information output.
In order to protect the output contacts it is recommended that loads (inductive) are
suppressed by fitting correctly chosen VDRs, diodes etc.
Diodes are the best arc suppressors, but will increase the switch off time of the
load.
The RT6 has two(2) voltage free transistor outputs for information.
The transistor outputs are supplied with voltage to Y13, either from S53 (+24V) or
an external 5-30 VDC supply. Y14 and Y24 follow the relay inputs and outputs as
follows:
Y14 becomes conductive when the relay input conditions are fulfilled.
Y24 becomes conductive when both the output relays are activated.
***Note These outputs are only for information purposes
and must not be connected to the safety circuits of the
machinery.
ABB Safety Handbook | 2TLC172001C0202 6/10
6
Technical data - RT6
Article number
RT6 24 VDC
RT6 24VAC
RT6 48 VAC
RT6 115VAC
RT6 230VAC
2TLA010026R0000
2TLA010026R0200
2TLJ010026R0300
2TLA010026R0400
2TLA010026R0500
Colour Grey
Weight 335 g (24 VDC)
485 g (24-230 VAC)
Supply
Voltage (A1-A2) 24 VDC +15/-20%,
24/115/230 VAC,
+15/-10%, 50-60 Hz
Power consumption
DC supply, nominal voltage
AC supply, nominal voltage
2.3W
5.2VA
Connection S13 Short-circuit protected voltage output, 70mA 10% cur-
rent limitation. Is used for the inputs S14, S34 and S44.
Connection S53 Short-circuit protected voltage output, internal automatic
fuse 270mA. Is used for the reset and autoreset inputs X1 and X4
Connection S23 0V connection for input S24
Safety inputs
S14 (+) input 20mA
S24 (0V) input 20mA
S34 (+) input 20mA
S44 (+) input 30mA
Reset input X1
Supply for reset input
Reset current
Minimum contact closure time for
reset
+24 VDC
300mA current pulse at contact,
then 30mA
100 ms
Maximum external connection
cable resistance at nominal voltage
for
S14, S24, S34 300 Ohm
S44, X1 150 Ohm
Response time
At Power on DC/AC
When activating (input-output)
When deactivating (inputoutput)
<90ms/<220ms
<20 ms
<20 ms
At Power Loss <150 ms
Relay outputs
NO 3
NC 1
Maximum switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Maximum total switching capacity
Resistive load 12A distributed on all contacts
Minimum load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material Ag+Au ash
Fuses Output (External) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Mechanical life >10
7
operations
Transistor outputs Short-circuit proof
External supply to Y13 +5 to +30 VDC
Y14 Indicates that the input conditions
have been fullled
Y24 Indicates that the output relays are
activated
Maximum load of Y14, Y24 15mA /output
Maximum voltage drop at maximum
load 2.4 V
LED indication
On
Supply voltage OK, the LED is on.
Flashing light in case of under-volta-
ge or overload
In1 In2
Indicates that the input conditions
are fullled.
1 2
Indicates that the output relays are
activated.
Mounting
Rail 35mm DIN rail
Connection blocks (detachable)
Maximum screw torque 1 Nm
Maximum connection area:
Solid conductors 1x4mm
2
/ 2x1.5mm
2
/ 12AWG
Conductor with socket contact 1x2.5mm
2
/2x1mm
2
Protection class
Enclosure IP40 IEC 60529
Connection blocks IP20 IEC 60529
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
Impulse withstand Voltage 2.5kV
Pollution degree 2
Performance (max.)
The relays must be cycled at least
once a year.
PL e/Cat. 4 (EN ISO13849-1:2008)
SIL 3 (EN 62061:2005)PFH
D
1.35
E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC,
EN 62061:2005, EN ISO 13849-
1:2008
Connector blocks are detachable
(without cables having to be disconnected)
6/11 2TLC172001C0202 | ABB Safety Handbook
6
Approvals:
Safety relay for:
Emergency stops
Light curtains
Three position devices
Interlocked gates/hatches
Magnetic switches
Light beams
Safety mats
Contact strips
Foot operated switches
Features:
4 NO / 1 NC relay outputs, 2
NO outputs can be delayed
for soft stops
Delay times RT7A 0; 0.5; 1.0;
1.5 s RT7B 0; 1.0; 2.0; 3.0 s
Five input options
Single or dual channel input
Manual supervised or
automatic reset
Test input for supervision of
external contactors
Width 45 mm
LED indication of supply,
inputs, outputs, short-circuit
and low voltage level
Three voltage free transistor
information outputs
Supply 24 VDC, 115 or 230
VAC
Quick release connector
blocks
Universal relay with delayed outputs
The RT7 is a universal relay that can be used to supervise both safety devices and
the internal safety of your machinery. In addition, you can select the safety level that
is required for each installation. All this is possible because the RT7 has the most
versatile input options arrangement available on the market. The RT7 can therefore
replace many other relays.
The RT7 has four (4 NO) dual safety outputs of which two may be delayed for up
to three seconds in order to achieve a safe and soft stop. A soft stop allows
machinery to brake and stop gently before power is removed. A soft stop has
many benefits: the machinery life will be prolonged, processed products will not be
damaged, and restarts from the stopped position are made possible and easier.
Another option with the RT7 is manual or automatic resetting. A manual supervised
reset is used for gates and other safety devices that can be bypassed, while an
automatic reset is used for small safety hatches if deemed appropriate from a risk
point of view.
In addition, the RT7 has information outputs that follow the inputs and outputs of
the relay. These outputs indicate if for example a gate is opened or closed, if there
is a delay or if the relay needs to be reset.
Choose the RT7 to simplify your safety circuits and reduce your costs.
Safety relay
RT7
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/12
6
Inputs
The RT7 can be configured to operate in either of the fol-
lowing input options:
1. Single channel, 1 NO contact from +24 VDC, safety
category1, up to PLc
2. Dual channel, 2 NO contacts from +24 VDC, category3, up to
PLd
3. Dual channel, 1 NO, 1 NC contact from +24 VDC, category4,
up to PLe
4. Dual channel, 1 NO contact from 0V and 1 NO contact from
+24 VDC, category4, up to PLe
5. Safety mats/contact strips, 1 contact from 0V and 1 contact
from +24 VDC, category3, up to PLd
When the input/inputs are activated and the test/supervised reset
is complete, relays 1,2,3 and 4 are activated. Relays 1 and 2 are
immediately de-energized when the inputs are deactivated in ac-
cordance with the input option selected. Relays 3 and 4 are either
de-energized immediately or after the selected time delay. All the
relays (1,2,3 and 4) must be de-energized before the RT7 can be
reset.
Transistor output status information
The RT7 has three(3) voltage free transistor outputs that can
be connected to a PLC, computer or other monitoring device.
These outputs give the input and output status of the relay.
Reset and testing
The RT7 has two reset options; manual and automatic. The
manual supervised reset is utilised when the RT7 is used to
monitor safety devices that can be bypassed, i.e. to ensure
that the outputs of the safety relay do not close just because
the gate is closed.
The automatic reset should only be used if acceptable from
a risk point of view. The RT7 can also test (supervise), if for
example, contactors and valves etc are de-energized/de-
activated before a restart is allowed.
Indication of low voltage
The On LED will ash if the relay voltage falls below an acceptable
level. This indication will also be given if a monitored safety mat
contact strip is actuated. See connection option 5.
Safety level
The RT7 has internal dual and supervised safety functions.
Power failure, an internal faulty component or external interfe-
rence will not present a risk to options with the highest safety
level. A manual reset requires that the reset input is closed
and opened before the safety relay outputs are activated. A
short-circuit or a faulty reset button is consequently super-
vised.
When the RT7 is configured for dual channel input, both the
inputs are supervised for correct sequence operation before
the unit can be reset. The input options 3 and 4 have the
highest safety levels as all short-circuits and power failures
are supervised. This in combination with internal current limi-
tation makes the relay ideal for supervision of safety mats and
contact strips.
Regulations and standards
The RT7 is designed and approved in accordance with appro-
priate directives and standards. Se tekniska data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, see the section Connection examples.
**Only for AC supply
RT7 A/B
Technical information
Connection examples RT7
DC supply
The RT7 DC option should be supplied with +24
V on A1 and 0 V on A2.
AC supply
The RT7 AC option should be supplied with the
appropriate supply voltage via connections A1
and A2.
The S23/ must be connected to protective
earth
DC-supply of AC-units
All AC-units can also supplied by +24 VDC to
S53 (0 VDC to S23).
6/13 2TLC172001C0202 | ABB Safety Handbook
6
Connection of safety devices - RT7 A/B
Reset connections - RT7 A/B
Output connections - RT7 A/B
Manual supervised reset Automatic reset
*connected to S13 for
safety mat/contact
strip
Testing external contactor status
The manual supervised reset contact connected to input X1 must be closed and
opened in order to activate the relay outputs.
Automatic reset is selected when S53, X1 and X4 are linked. The relay outputs are
then activated at the same time as the inputs.
Contactors, relays and valves can be supervised by connecting test contacts bet-
ween S53 and X1. Both manual supervised and automatic reset can be used.
1. SINGLE CHANNEL, 1 NO from +24V
The input (contact to S14) must be
closed before the outputs can be activa-
ted. When the input contact is opened
the relay safety output contacts open.
2. DUAL CHANNEL, 2 NO from +24V
Both input contacts (S14 and S34) mus-
be closed before the relay outputs can
be activated. The safety relay contacts
will open if one or both of the input
contacts are opened. Both the input
contacts must be opened before the re-
lay can be reset. A short-circuit between
the inputs S14 and S34 can only be
supervised if the device connected to
the inputs has short-circuit supervised
outputs, e.g. ABB Jokab Safetys Focus
light curtains.
3. DUAL CHANNEL, 1 NO, 1 NC from
+24V
One input contact must be closed (S14)
and one opened (S44) before the relay
outputs can be activated. The safety
relay contacts will open if one or both of
the inputs change state or in the case
of a short-circuit between S14 and S44.
Both inputs must be returned to their
initial positions before the relay outputs
can be reactivated.
4. DUAL CHANNEL, 1 NO from +24V,
1 NO from 0V
Relay functions as option 2, but a short-
circuit, in this case between inputs S14
and S24, is supervised (safety outputs
are opened)
5. Safety mat/Contact strip
Both contact inputs from an inactiva-
ted safety mat/contact strip, must be
made in order to allow the RT7 relay
outputs to be activated. When the
safety mat/contact strip is activated or
a short-circuit is detected across S14-
S23, the relay will de-energize (safety
outputs open) and the ON LED will
flash. As output S13 has an internal
current limit of 70 mA, the RT7 will not
be overloaded when the mat/contact
strip is activated or a short circuit is
detected.
Relay outputs
The RT7 has four (4 NO) safety outputs
of which two can be delayed, and 1 NC
information output.
In order to protect the RT7 output
contacts it is recommended that loads
(inductive) are suppressed by fitting cor-
rectly chosen VDRs, diodes etc. Diodes
are the best arc suppressors, but will
increase the switch off time of the load.
Transistor outputs
The RT7 has three(3) voltage free tran-
sistor information outputs.
The transistor outputs are supplied with
voltage to Y13 either from S53 (+24V) or
externally from 5 to 30 VDC. Y14, Y24
and Y34 follow the inputs and outputs
as follows:
Y14 becomes conductive when the
relay input conditions are fulfilled.
Y24 becomes conductive when both
the output relays are activated.
Y34 becomes conductive when both
the delay output relays are activated.
Time delay outputs
Time delays are selected by linking the
appropriate T0, T1 and T2 connections.
When a stop signal is detected a pro-
gram stop command is first given to the
PLC/servo which brakes the dangerous
machine operations in a soft and con-
trolled way.
The delayed relay safety outputs will
then turn off the power to the motors,
i.e. when the machinery has already
stopped. It takes usually around 0.5 to
3 seconds for a dangerous action to be
stopped softly.
ABB Safety Handbook | 2TLC172001C0202 6/14
6
Technical data - RT7 A/B
Article number
RT7B 24VDC 3s
24 VAC 3s
2TLA010028R1000
2TLA010028R1200
115 VAC 3s 2TLA010028R1400
230 VAC 3s 2TLA010028R1500
RT7A 24 VDC 1.5s
24 VAC 1.5s
2TLA010028R2000
2TLA010028R2200
115 VAC 1.5s 2TLA010028R2400
230 VAC 1.5s 2TLA010028R2500
Colour Black and beige
Weight 405 g (24 VDC)
550 g (24-230 VAC)
Supply
Voltage (A1-A2) 24 VDC +15/-20%,
115/230 VAC,
15%, 50-60 Hz
Power consumption
DC supply, nominal voltage 4.6 W
AC supply, nominal voltage 8.8VA
Connection S13 Short-circuit protected voltage output, 70mA 10%
current limitation. Is used for the inputs S14, S34 and S44.
Connection S53 Short-circuit protected voltage output, internal automatic
fuse, max 270mA. Is used for the reset and autoreset inputs X1 and X4.
Connection S23 0V connection for input S24.
Safety inputs
S14 (+) input 20mA
S24 (0V) input 20mA
S34 (+) input 20mA
S44 (+) input 25mA
Reset input X1
Supply for reset input +24VDC
Reset current 600mA current pulse at contact
closure, then 30mA.
Minimum contact closure time for
reset 100 ms
Maximum external connection cable
resistance at nominal voltage for
S14, S24, S34 300 Ohm
S44, X1 150 Ohm
Response time
At Power on DC/AC <90/<140 ms
When activating (input-output) <20 ms
When deactivating (inputoutput) <20 ms
At Power Loss <80 ms
Delay time options
RT7A 0; 0.5; 1.0; 1.5 secs
RT7B 0; 1.0; 2.0; 3.0 secs
Relay outputs
NO direct (relays 1/2) 2
NO direct or delayed (relays 3/4) 2
NC (relays 1/2) 1
Maximum switching capacity
Relays 1/2 Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Relays 1/2 total Max 9A distributed on all contacts
Relays 3/4 Resistive load AC 6A/230 VAC/1380 VA
Inductive load AC AC15 230 VAC 4A
Resistive load DC 6A/24 VDC/144W
Inductive load DC DC13 24 VDC 2A
Relays 3/4 total Max 6A distributed on all contacts
Contact material AgSnO
2
+Au ash
Fuses output 1/2 (external) 5A gL/gG
Fuses output 3/4 (external) 3A gL/gG
Conditional short-circuit current
(1 kA), each output 6A gG
Mechanical life >10
7
operations
Transistor outputs
External supply to Y13 +5 to +30 VDC
Y14 Indicates that the input conditions
are fullled
Y24 Indicates that the output relays 1/2
are activated
Y34 Indicates that the delay output
relays 3/4 are activated
Maximum load of Y14,Y24, Y34 15mA /output
Maximum voltage drop at maximum
load 2.4 V
LED indication
On
Supply voltage OK, the LED is on.
Flashing light in case of under-volta-
ge or overload.
In1 In2
Indicates that the input conditions
are fullled.
1 2
Indicates that the output relays 1/2
are activated.
t
Indicates that the delay output
relays 3/4 are activated.
Mounting
Rail 35mm DIN rail
Connection blocks (detachable)
Maximum screw torque 1 Nm
Maximum connection area:
Solid conductors 1x4mm
2
/ 2x1,5mm
2
/12AWG
Conductor with socket contact 1x2.5mm
2
/ 2x1mm
2
Protection class
Enclosure IP40 IEC 60529
Connection blocks IP20 IEC 60529
Operating temperature range
24 VDC -10 C to +55 C (with no icing or
condensation)
24-230 VAC -10 C to +45 C (with no icing or
condensation)
Operating humidity range 35% to 85%
Impulse withstand Voltage 2.5kV
Pollution degree 2
Performance (max.)
The relays must be cycled at least
once a year.
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005)
PFH
D
1.86 E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC EN 62061:2005
EN ISO 13849-1:2008
Connector blocks are detachable
(without cables having to be disconnected)
120
84
45
6/15 2TLC172001C0202 | ABB Safety Handbook
6
Would you like a small safety relay for all your safety applications?
Then choose the compact RT9 universal relay to supervise both your safety devices
and the internal safety of your machinery. In addition, you can select the safety
level that is required for each installation. All this is possible due to the RT9 offering
the most versatile input option arrangement available on the market. The RT9 can
therefore replace many other relays.
Other RT9 options include selection of either manual supervised or automatic
resetting. The manual supervised reset can be used for gates and other safety de-
vices that can be bypassed. Automatic reset can be used for small safety hatches,
if deemed acceptable from risk assessment.
In addition, the RT9 has a double information output that will indicate e.g if a gate is
open or if the relay needs resetting.
The RT9 uses the latest component technology and modern assembly techniques
to ensure a highly cost effective solution.
Choose the RT9 to simplify your safety circuits and reduce your costs.
Safety relay
RT9
Approvals:
Safety relay for:
Emergency stops
Light curtains
Three position devices
Interlocked gates/hatches
Magnetic switches
Light beams
Safety mats
Contact strips
Foot operated switches
Features:
Five input options
Single or dual channel input
Manual supervised or
automatic reset
Test input for supervision of
external contactors
Width 22.5 mm
LED indication of supply,
inputs and outputs, short-
circuit and low voltage level
2 NO relay outputs
One changeover relay with
a double information output
Supply 24 VDC
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/16
6
Inputs
The RT9 can be configured to operate in either of the fol-
lowing input options:
1. Single channel, 1 NO contact from +24VDC, category 1, up
to PLc
2. Dual channel, 2 NO contacts from +24VDC, category 3, up to
PLd
3. Dual channel, 1 NO, 1 NC contact from +24VDC, category 4,
up to PL e
4. Dual channel, 1 NO contact from 0V and 1 NO contact from
+24VDC, category 4, up to PLe
5. Safety mat/contact strips, 1 contact from 0V and 1 contact
+24VDC, category 3, up to PLd
When the input/inputs are activated and the test/supervised
reset is complete, relays 1 and 2 are energised. These are
de-energised when the input/inputs are de-activated in ac-
cordance with the input option chosen or in case of a power
failure.
Relays 1 and 2 must both be de-energized before the RT9
can be reset.
Relay output status information
The RT9 has a changeover contact relay output that can be
connected to a PLC, control lamp, computer or similar. The
output gives information about the status of the relay.
Reset and testing
The RT9 has two reset options; manual and automatic. The
manual supervised reset can be used when the RT9 is mo-
nitoring safety devices that can be bypassed, i.e. to ensure
that the outputs of the safety relay do not close just because
a gate is closed. The automatic reset option should only be
used if appropriate from a risk point of view.
Due to special internal circuits the RT9 can be automatically
reset regardless of the operational voltage rise time, this being
an important factor when large loads are started up on the
same power supplies at the same time.
In addition, the RT9 can also test (supervise), if for examp-
le, contactors and valves etc are de-energised/de-activated
before a restart is made.
Indication of low voltage
The On LED will flash if the relay supply voltage falls below
an acceptable level. This indication will also be given if a
monitored safety mat/contact strip is actuated. Please see
Connection option 5.
Safety level
The RT9 has internal dual and supervised safety functions.
Power failure, an internal faulty component or external
interference will not present a risk to options with the highest
safety level. A manual reset requires that the reset input is
closed and opened before the safety relay outputs are acti-
vated. A short-circuit or a faulty reset button is consequently
supervised.
When the RT9 is configured for dual channel input, both the
inputs are supervised for correct operation before the unit can
be reset.
The input options 3 and 4 have the highest safety levels as
all short-circuits and power failures are supervised. This in
combination with an internal current limitation makes the relay
ideal for supervision of safety mats and contact strips.
Regulations and standards
The RT9 is designed and approved in accordance with appro-
priate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
RT9
Technical information
Short circuit
protection
Automatic
fuse

DC supply
The RT9 should be supplied with +24 V on A1 and 0 V on A2.
Connection of supply - RT9
NOTE! If cable shielding is used this must be connected to an
earth rail or an equivalent earth point.
6/17 2TLC172001C0202 | ABB Safety Handbook
6
Connection of safety devices - RT9
Output connections - RT9
Relay outputs
The RT9 has two (2 NO) safety outputs.
In order to protect the output contacts
it is recommended that loads (inductive)
are suppressed by fitting correctly cho-
sen VDRs, diodes etc. Diodes are the
best arc suppressors, but will increase
the switch off time of the load.
Information outputs
The RT9 has a single changeover con-
tact information relay output.The relay
output Y14 is connected internally to 0V
and 24V in the following way:
Y14 is internally closed to 0V when
the RT9 is not reset.
Y14 is internally closed to +24V when
the relay is reset.
Reset connections - RT9 Manual supervised reset
The manual supervised reset contact connected to input X1 must be closed and
opened in order to activate the relay outputs.
Automatic reset
Automatic reset is selected when A1(+), X1 and X4 are linked. The relay outputs are
then activated at the same time as the inputs.
Testing external contactor status
Contactors, relays and valves can be supervised by connecting test contacts bet-
ween A1(+) and X1. Both manual supervised and automatic reset can be used.
1. SINGLE CHANNEL, 1 NO from +24V
The input (contact to S14) must be
closed before the outputs can be activa-
ted. When the input contact is opened,
the relay safety output contacts open.
2. DUAL CHANNEL, 2 NO from +24V
Both input contacts (S14 and S34) must
be closed before the relay outputs can
be activated. The safety relay contacts
will open if one or both of the input
contacts are opened. Both the input
contacts must be opened and reclosed
before the relay can be reset.
A short-circuit between inputs S14 and
S34 can only be supervised if the device
connected to the inputs has short-cir-
cuit supervised outputs, e.g. ABB Jokab
Safetys Focus light curtains
3. DUAL CHANNEL, 1 NO, 1 NC from
+24V
One input contact must be closed (S14)
and one opened (S44) before the relay
outputs can be activated.
The safety relay contacts will open if one
or both of the inputs change state or
in case of a short-circuit between S14
and S44. Both inputs must be returned
to their initial status before the relay
outputs can be reactivated.
4. DUAL CHANNEL, 1 NO from +24V,
1 NO from 0V
Relay functions as option 2, but a short-
circuit, in this case between inputs S14
and S24, is supervised (safety outputs
are opened).
5. Safety mat/Contact strip
Both contact inputs from a inactivated
safety mat/contact strip must be made
in order to allow the RT9 relay outputs
to be activated. When the safety mat/
contact strip is activated or a short-
circuit is detected across S14-S23, the
relay will de-energize (safety contacts
open) and the ON LED will flash. As
output S13 has an internal current limit
of 70 mA, the RT9 will not be over-
loaded when the mat/contact strip is
activated or a short-circuit is detected.
ABB Safety Handbook | 2TLC172001C0202 6/18
6
Technical data RT9
Article number
RT9 24 VDC 2TLA010029R0000
Colour Grey
Weight 210 g
Supply
Voltage (A1-A2) 24 VDC 20%
Power consumption
Nominal voltage 2W
Connection S13 Short-circuit protected voltage
output
70mA 10% current limitation. Is
used for the inputs S14, S34 and
S44.
Input currents
(at nominal supply voltage)
S14 (+) input 30mA
S24 (0V) input 20mA
S34 (+) input 20mA
S44 (+) input 25mA
Reset input X1
Supply for reset input +24 VDC
Reset current 300mA current pulse at contact
closure, then 30mA
Minimum contact closure time
for reset 80 ms
Minimum contact closure time
(at low limit voltage -20%)

100 ms
Maximum external connection
cable resistance at a nominal
voltage for
S14, S24, S34 300 Ohm
S44, X1 150 Ohm
Response time
At Power on <100 ms
When activating (input-output) <20 ms
When deactivating (inputoutput) <20 ms
At Power Loss <80 ms
Relay outputs
NO 2
Maximum switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. total switching capacity: 8A distributed on all contacts
Minimum load 10mA/10V (if load on contact has
notexceeded 100mA)
Contact material Ag+Au ash
Fuses output (External) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Mechanical life 10
7
operations
Relay information output Y14
(Changeover contacts)
-(0V) Indicates that RT9 is not reset.
+(24V) Indicates that RT9 is reset.
Maximum load of Y14 250mA
Short-circuit protection for
information output Internal automatic fuse
LED indication
On
Supply voltage OK, the LED is on.
Flashing light in case of under-volta-
ge, overload or current limiting
In1 In2
Indicates that the input conditions
are fullled.
1 2
Indicates that the output relays have
been activated.
Mounting
Rail 35mm DIN rail
Connection blocks
(detachable)
Maximum screw torque 1 Nm
Maximum connection area:
Solid conductors 1x4mm
2
/ 2x1.5mm
2
/ 12AWG
Conductor with socket contact 1x2.5mm
2
/ 2x1mm
2
Protection class
Enclosure IP40 IEC 60529
Connection blocks IP20 IEC 60529
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
Impulse withstand Voltage 2.5kV
Pollution degree 2
Performance (max.)
The relays must be cycled at least
once a year.
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005)PFH
D
9.55E-09
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC EN 62061:2005
EN ISO 13849-1:2008
Connector blocks are detachable
(without cables having to be disconnected)
6/19 2TLC172001C0202 | ABB Safety Handbook
6
A flexible safety relay with many outputs
The JSBRT11 has been designed to provide the safety
system circuit designer with the ability to select from both a
range of input connection configurations and either automatic
or supervised reset.
The unit can be hardwire configured to operate in either of the
following input configurations:
Mode 1: Single Channel (1 NO contact from +24 VDC),
category 1 PL c
Mode 2: Dual Channel (2 NO contacts from +24 VDC),
category 3 PL d
Mode 3: Dual Channel (1 NO, 1NC contacts from
+24VDC), category 4 PL e.
Mode 4: Dual Channel (1 NO contact from 0 V and 1 NO
contact from + 24 VDC), safety category 4.
In addition the unit can also be used to test that contactors
and valves have fallen/returned to their reset state before a
new start signal is given.
Safety level
The JSBRT11 has dual and monitored internal safety func-
tions. Power failure, internal component failures or ex ternal
interference (with the exception of short circuiting of input
contact when used in a single channel input mode) do not
result in a dangerous function.
Safety relay
JSBRT11
Approvals:
Safety relay for:
Emergency stops
Light curtains
Three position devices
Interlocked gates/hatches
Magnetic switches
Light beams
Safety mats
Foot operated switches
Features:
Selectable inputs and safety
category
Manual supervised or
automatic reset
Width 100 mm
LED indication for supply,
inputs and outputs
7 NO + 2 NC relay outputs
Supply 24 VDC 15 or
230VAC
Quick release connector
blocks
When wired for supervised reset, should a short circuit appear
across the reset input the relay will not automatically reset
when the input/inputs are made. Only when the super-vised
reset input is made and broken will the relay reset.
The JSBRT11 provides de tection of contact failure in the
inputs when wired in dual channel mode. Both inputs have to
be opened and closed in order to enable the reactivation of
the relay. The highest safety level of the JSBRT11 is in con-
figuration mode 3 and 4 because all short circuits are super-
vised i.e. a short circuit between the inputs leads to a safe
state as the outputs drop out.
Regulations and standards
The JSBRT11 is designed and approved in accordance with
appropriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/20
6
Electrical connection JSBRT11
DUAL CHANNEL*, 1 NO, 1 NC from +24V SINGLE CHANNEL *, 1 NO from +24V
Technical data JSBRT11
Article number
JSBRT11 24VDC 2TLA010025R0000
JSBRT11 115VAC 2TLA010025R0400
JSBRT11 230VAC 2TLA010025R0500
Colour Grey
Power supply A1 - A2 24 VDC 15%
115, 230 VAC 15%, 50-60 Hz
Power consumption 3.2 W/7.9VA
Relay Outputs 7NO and 2NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. total switching capacity 21A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material AgSnO
2
+Au ash
Fuses Output (External) 6A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max. Input wire res. at nom.
voltage
200 Ohm (S14,S24,S34,X1,X4); 100
Ohm (S44)
Response time at deactivation
(input-output) <20 ms
Response time at activation
(input-output) <30 ms
Terminals (max. screw torque 1 Nm)
Single strand: 1x4mm
2
/ 2x1.5mm
2
Conductor with socket contact: 1x2.5mm
2
/ 2x1 mm
2
Mounting 35mm DIN-rail
Protection class
enclosure IP40 IEC 60259
terminals IP20 IEC 60259
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
Function indication Electrical Supply, Input 1 and 2,
Output relays 1 and 2
Weight 610 g (24 VDC) 790 g (24-230 VAC)
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005) PFH
D
1.69E-08
Conformity 2006/42/EC, 2006/95/EC, 2004/108/
EC, EN 62061:2005 EN ISO 13849-
1:2008
Technical description JSBRT11
S
u
p
p
l
y
*
**
*Supervision circuit **Test and Automatic reset circuit
*** Only for AC-supply
***
K
K
*
**
***
K
K
The supply voltage is connected across A1 and A2. The input
connection configuration and type of reset required is set by
connecting the unit as shown in the diagrams below
When the input/inputs and the test/supervised reset are
made K1 and K2 energise. K1 and K2 will de-energize if the
power is disconnected or a stop signal is given in accordance
to the configuration mode wired. Both K1 and K2 have to
be de-activated before the outputs of the JSBRT11 can be
closed again.
Configuration mode 1.
When the single input opens both K1 and K2 relays are deac-
tivated.
Configuration mode 2.
Both inputs have to be closed in order to enable the unit
to be activated. A stop signal is given if both or one input is
opened. Both inputs have to be opened and reclosed in order
to enable the reactivation of the unit. If the possibility of short
circuits between the inputs cannot be excluded, configurati-
on mode 3 or 4 should be used in order to reach the highest
safety level.
Configuration mode 3.
One input has to be closed and the other input has to be
opened in order to enable the unit to be activated. A stop
signal is given if both or one input change state. Both inputs
have to change state in order to give a dual stop function and
to allow a new start after stop.
Configuration mode 4.
Operation as mode 2 but short circuits between the inputs
leads to a safe state i.e. the relays inside the JSBRT11 will
drop out.
Supervised reset connection.
The input to X1 (see diagram below) has to be closed and
opened in order to activate the unit, after input/inputs are
made according to the configuration mode selected. This
mode is selected when X1 - X4 is open-circuit.
Automatic reset connection.
The input has to be closed in order to activate the unit after
input/inputs are made according to the configuration mode
selected. This mode is selected when a connection between
X1 and X4 is made.
Test.
Test contacts of contactors can be connected between S53
and X1 for supervision.
6/21 2TLC172001C0202 | ABB Safety Handbook
6
A universal relay for two-hand and many other safety
devices
The JSBR4 has two inputs, which both have to be closed
to keep the safety output contacts closed. A short-circuit
across the inputs will cause the output contacts to open.
The inputs can however be subjected to a continuous short-
circuit without damaging the safety relay.
In order to make the safety outputs close the reset input
must be closed and opened. In this way an unintentional
reset is prevented in the case of a short-circuit in the reset
button cable or if the button gets jammed in the actuated
position. The reset input can also be used for test/supervision
to ensure that contactors or valves have returned to their
initial off/stop position before a new start can be allowed by
the safety relay.
When the JSBR4 is used as a two-hand device relay, both
buttons have to be pressed within 0.5 seconds of each other
in order to close the outputs.
When the JSBR4 is used for Safety Mats and Safety Strips
the stop condition is given following detection of a short-
circuit between input channels A and B. The safety mat,
safety strip or the relay will not be damaged by a continuous
short-circuit. This also gives the advantage that if there is a
failure between the inputs in the installation, the safety relay
will not be damaged.
Safety relay
JSBR4
Approvals:
Safety relay for:
Two-hand devices of type IIIc
Emergency stop
Three position devices
Interlocked Gates/Hatches
Contact strips
Safety mats
Foot operated switches
Features:
Two channel with
concurrency requirement of
0.5 s
Supervised reset
Test input
Width 45 mm
LED indication for supply,
inputs and outputs
3 NO/1NC relay outputs
Supply 24 VDC, 24, 115 or
230 VAC
Quick release connector
blocks
Safety level
The JSBR4 has a twin supervised safety function. Component
failure, short-circuit or external disturbance (e.g. loss of power
supply) will not prevent the safe function of the relay. This is
valid both for the inputs A and B as well as for the reset input.
The JSBR4 operates at the highest safety level for safety
relays (PLe according to EN ISO13849-1).
Regulations and standards
The JSBR4 is designed and approved in accordance with
appropriate directives and standards. See technical data.The
JSBR4 complies with the highest safety level for the con-
nection of a two-hand device of type IIIc in accordance with
EN574.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/22
6
* Only for AC-supply
Prot.
circ.
Reset & Supervision circ.
*
Technical data JSBR4
Article number
JSBR4 24VDC 2TLA010002R0000
JSBR4 24VAC 2TLA010002R0200
JSBR4 115VAC 2TLA010002R0400
JSBR4 230VAC 2TLA010002R0500
Colour Black and beige
Power supply 24 VDC 15%
24/115/230 VAC 15%, 50 - 60 Hz
Power consumption 1.3 W/3.3VA
Relay outputs 3NO +1NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. res. load total switching
capacity 12A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material Ag +Au ash
Fuses output (external) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max. Input wire res. at nom.
voltage
300 Ohm (S13 - S14 and S23 - S24)
Response time at deactivation < 20 ms (145 ms at power loss)
Terminals
(max. screw torque 1 Nm)
Single strand: 1x2.5mm
2
/ 2x1mm
2
.
Conductor with socket contact: 1x4mm
2
/ 2x1.5mm
2
.
Mounting 35mm DIN-rail
Protection class IP40 / IP20 IEC 60529
Operating temperature range -10C to +55C (with no icing or
condensation)
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating humidity range 35% to 85%
LED indication Electrical Supply, Inputs, Outputs
Weight 350 g (24 VDC),
460 g (24-230 VAC)
Values
(With Proof test interval 1 year)
Safety Category 4 according to
EN954-1, PLe, SIL 3,
PFH
D
1.35E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC,EN 62061:2005
EN ISO 13849-1:2008
Technical description JSBR4
The electrical supply is connected across A1 and A2. After
Voltage reduction and Rectification (AC-versions) or reverse
polarity protection (DC-version) there is an overload protec-
tion-circuit.
When the inputs S13-S14 and S23-S24 have closed and the
reset is made, the relays K1 and K2 are activated. A dual stop
signal is given when K1 and K2 drop, due to short circuiting
between the inputs, opening of the inputs or power failure. If
one input is opened the other input must also be opened for
K1 and K2 to be activated again.
The monitoring circuit checks K1 and K2 and that the reset
circuit to X2 is both closed and opened before K1 and K2 are
energized. Both the stop and reset function therefore comply
with the requirement that a component fault, short circuit or
external interference do not result in a dangerous function.
The safety outputs consist of contacts from K1 and K2 con-
nected internally in series across terminals 13 - 14, 23 -24
and 33 - 34. These contacts are used to cut the power to
components which stop or prevent hazardous movements/
functions. It is recommended that all switched loads are ade-
quately suppressed and/or fused in order to provide additio-
nal protection for the safety contacts.
NOTE! Output 41-42 is intended for indication purposes only,
e.g. gate opened.
No load between S14 and S24 allowed.
Electrical connection JSBR4
Emergency stop with manual
resetting.
Two hand device with buttons in
separate or same enclosure. But-
tons to be pressed in within 0.5 s
of each other. Footpedal switches
can be connected in the same
configuration.
Interlocked gate with manual reset.
Enabling device, JSHD4. Stop
condition is given in both top and
bottom PB positions.
Contact mat/strip with manual
reset.
Control and supervision of ex-
ternal conductor, relay, valve or
ABB Jokab Safetys expansion
relays.
6/23 2TLC172001C0202 | ABB Safety Handbook
6
Safety relay with synchronised dual input channels
(within 0.5s)
The JSBT4 has two inputs, both of which have to be closed
in order to keep the safety output contacts closed. A short
circuit between inputs A and B will cause the output contacts
to open. The inputs can be continuously short circuited wit-
hout damaging the safety relay.
For the outputs to close, the test input must be closed. The
test input is intended to monitor that contactors or valves
have dropped/returned before a new start is permitted.
This test input must not be confused with the reset function
required for gates that a person can walk through and where
there is a high safety requirement (see JSBR4).
If the JSBT4 is used for safety Mats and safety Strips, the
"stop" condition is given following detection of a short circuit.
The safety mat, safety strip or the relay will not be damaged
by a continuous short-circuit. This also provides the advan-
tage that if there is a failure between inputs A and B in the
installation, the safety relay will not be damaged.
Safety level
The JSBT4 has a twin supervised safety function. Component
failure, short-circuit or external disturbance (e.g. loss of pow-
er supply) will not prevent the safe function of the relay. Safety
category level 3 or 4, depending on use.
The true two-channel safety function has the advantage that
the cabling installation demands for safety can be reduced,
due to the fact that a short-circuit between the inputs will
directly open the relay's safety outputs.
Regulations and standards
The JSBT4 is designed and approved in accordance with
appropriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
Safety relay
JSBT4
Approvals:
Safety relay for:
Emergency stops
Three position devices
Interlocked Hatches
Safety mats
Contact strips
Foot operated switches
Features:
Dual input channels
synchronism 0.5 s
Test input
Width 45 mm
LED indications for power on,
inputs and outputs
3 NO/1NC relay outputs
Supply 24 VDC
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/24
6
TEST
TEST
TEST
TEST
LOAD
TEST
TEST
Technical data JSBT4
Article number
JSBT4 24VDC
JSBT4 24 VAC
JSBT4 230 VAC
2TLA010004R0000
2TLJ010004R0200
2TLJ010004R0500
Colour Grey
Power supply 24 VDC 15%
Power consumption BT50 1.4W/BT50T 1.8W
Relay outputs 3NO +1NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24VDC 1A
Max. res. load total switching
capacity 12A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material Ag +Au ash
Fuses output (external) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max. Input wire res. at nom.
voltage
300 Ohm (S13 - S14 and S23 - S24)
Response time at deactivation < 20 ms, 145 ms with switched
supply/power loss
Terminals
(max. screw torque 1 Nm)
Single strand 1x4mm
2
/ 2x1.5mm
2
Conductor with socket contact 1x2.5mm
2
/ 2x1mm
2
Mounting 35mm DIN-rail
Protection class IP40/IP20 IEC 60529
Operating temperature range -10C to +55C (with no icing or
condensation)
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating humidity range 35% to 85%
LED indication Electrical Supply, Inputs, Outputs
Weight 350 g (24 VDC), 460 g (24-230 VAC)
Values
(With Proof test interval 1 year)
Safety Category 4 according to,
PLe, SIL 3, PFH
D
1.51E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC, EN 62061:2005,
EN ISO 13849-1:2008
Technical description JSBT4
The electrical supply is connected across A1 and A2. After
Voltage reduction and Rectification (AC-versions) or reverse
polarity protection (DC-version) there is an overload protec-
tion-circuit.
When the inputs S13-S14 and S23-S24 are closed within 0.5
seconds of each other the relays K1 and K2 are energized . A
dual stop signal is given, K1 and K2 de-energize, when there
is a short circuit between or an opening of the inputs or at po-
wer loss. If one input is opened the other one also has to be
opened in order to activate K1 and K2 again. The test circuit,
X1 - X2,has to be closed in order to activate the outputs, the-
reafter the test circuit can be opened or closed continously.
If the test circuit is closed after the inputs there is no require-
ment to close them within 0.5 seconds of each other.
The internal supervision circuit monitors the two Inputs and
relays K1, K2. The stop function then fulfils the requirement
that one failure (short circuit, component, external distur-
bance) shall not prevent the safe function of the JSBT4.
The safety outputs consist of contacts from K1 and K2 con-
nected internally in series across terminals 13 - 14, 23 -24
and 33 - 34. These contacts are used to cut the power to
components which stop or prevent hazardous movements/
functions. It is recommended that all switched loads are ade-
quately suppressed and/or fused in order to provide additional
protection for the safety contacts.
The NC output 41 - 42 should only be used for monitoring
purposes e.g. Indication lamp or PLC input etc. The output
contacts are closed until the module is reset.
NOTE! Output 41-42 is intended for indication purposes only,
e.g. gate opened. No load between S14 and S24 allowed.
Prot.
circ.
*Only for AC-supply
Reset & Supervision circ.
Prot.
circ
Electrical connection JSBT4
Emergency stop with automatic
resetting.
Monitoring to ensure that the Start
button cannot stick in pressed posi-
tion. Short circuiting over the closing
contact is not monitored. The RT-
series and JSBR4 have built in short
circuiting monitored re setting.
Interlocked hatch with automatic
resetting.
Enabling device, JSHD4. Stop condition is given
in both top and bottom positions.
Contact mat/strip with automatic
reset
Control and supervision of external contactor,
relay, valve or ABB Jokab Safetys expansion
relays.
*
6/25 2TLC172001C0202 | ABB Safety Handbook
6
Safety relay/expansion relay to Pluto
The BT50 is designed to connect safety devices, such as
emergency stops, directly in the voltage supply circuit to the
relay. Despite a maximum built-in width of 22.5 mm the relay
is very powerful.
With 3NO safety outputs, 1NC output (for monitoring purpo-
ses), a test input and complete internal supervision, the BT50
is quite unique. In addition, delayed outputs (BT50T) can be
ordered.
In order for the safety outputs to close, the supply voltage,
e.g. by means of an emergency stop button, must be connec-
ted to A1 and A2 and the test input closed. After actuation of
the relay the test input can be opened again.
The test input is intended to supervise that contactors or
valves have dropped/returned before a new start can be
permitted.The test input can also be used for starting and the
start button can be supervised (see the connection example
on the next page).
More outputs
By connecting a BT50 to a safety relay/PLC it is easy to incre-
ase the number of safe outputs. This means that an unlimited
number of dangerous machine operations and functions can
be stopped by using just one safety-PLC.
Safety relay/expansion relay
BT50(T)
Approvals:
Safety relay for:
Emergency stop
Interlocked hatch
Expansion of Pluto
Features:
Single and dual channel
Test/reset input
Width 22.5 mm
LED indication
3 NO/1NC relay outputs
Supply 24 VDC
Quick release connector
blocks
BT50 - Additional power
terminals
BT50T - One changeover
relay with a double
information output (Y14)
BT50T - Delay times
selectable from 0 - 1.5 s
Safety level
BT50 have an internal redundant and monitored safety
function. Power failure, internal component faults or external
interference cannot result in dangerous functions.
Input via A1 on its own is not protected from short circuiting,
and therefore installation is critical for the safety level to be
achieved. To achieve a higher safety level a screened cable
can be used and/or connection made to both A1 and A2 (see
the example on the next page).
Regulations and standards
The BT50 is designed and approved in accordance with ap-
propriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the chapter Connection examples.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/26
6
Technical description BT50(T)
Emergency stop with dual
connection direct to the supply
voltage.
Controlled monitoring of external
contactor, relay, valve or ABB
Jokab Safetys expansion relays.
Emergency stop with reset when
emergency button returns.
Hatch with automatic reset.
Electrical connection BT50(T)
1.0 s
1.5 s
0 s
0.5 s
A2 T1 T2 A2 T1 T2
BT50T - Delay times BT50T - Info. output
* BT50 has additional power terminals A1 and A2.
*
*
*
Supervision circuit
K1
K2
Max load 250 mA
A1 X4
A1 X4
Technical data BT50(T)
Article number
BT50 2TLA010033R0000
BT50T 2TLA010033R1000
Colour Black and beige
Operational voltage 24 VDC +15%/-25%
Power consumption BT51 1.4W/BT51T
Relay outputs 3NO +1NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. res. load total switching
capacity 12A distributed on all contacts
Min. load 10mA/10 V(if load on contact has
notexceeded 100mA)
Contact material Ag +Au ash
Fuses output (external) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max Input wire res. at nom.
voltage 200 Ohms
Response time at deactivation
(input - output)
Version B <20 ms or delayed max
1500 ms (old version of BT50 <60 ms)
Terminals (max. screw torque 1 Nm)
Single strand 2x1.5mm
2
Conductor with socket contact 2x1mm
2
Mounting 35mm DIN-rail
Protection class enclosure/ter-
minals IP40/IP20 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Electrical Supply, Relay and X4
Weight 200 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PL e/Cat. 4 (ENISO13849-1:2008)
SIL 3 (EN 62061:2005)
PFH
D
1.22E-08
When supply voltage is connected to A1 and A2, relays K1
and K2 are activated. K1 and K2 drop if the supply voltage is
disconnected. Both relays K1 and K2 must drop for them to
be activated again. Another requirement is that the test circuit,
A1 - X4, must be closed for the outputs to be activated. The-
reafter A1 - X4 can either be open or constantly closed.
The supervising circuit ensures that both K1 and K2 have
dropped before they can be reactivated. The stop function
complies with the requirement that a component fault or ex-
ternal interference cannot lead to a dangerous function.
The safety outputs consist of contacts from K1 and K2 con-
nected internally in series across terminals 13 - 14, 23 - 24,
and 33 - 34. These contacts are used to cut the power to
components which stop or prevent hazardous movements/
functions. It is recommended that all switched loads are ade-
quately suppressed and/or fused in order to provide additional
protection for the safety contacts.
The NC output 41 - 42 should only be used for monitoring
purposes e.g. indication lamp for emergency stop pressed.
BT50 as emergency stop and
control relay with Start and Stop
function.
Monitoring to ensure that the On
button is not stuck in pressed
position. A short circuit over the
closing contact is not monitored.
6/27 2TLC172001C0202 | ABB Safety Handbook
6
Safety relay/expansion relay to Pluto
The BT51 is designed to connect safety devices, such as
emergency stops, directly in the voltage supply circuit to the
relay. Despite a maximum built-in width of 22.5 mm the relay
is very powerful.
With 4 NO safety outputs, test input and complete internal su-
pervising, the BT51 is quite unique. In addition you can order
delayed outputs (BT51T).
In order for the safety outputs to close, the supply voltage,
e.g. by means of an emergency stop button, must be connec-
ted to A1 and A2 and the test input closed. After actuation of
the relay the test input can be opened again.
The test input is intended to supervise that contactors or
valves have dropped/returned before a new start can be
permitted.The test input can also be used for starting and the
start button can be supervised (see connection example
on next page).
More outputs
By connecting BT51 to a safety relay/PLC it is easy to incre-
ase the number of safe outputs. This means that an unlimited
number of dangerous machine operations and functions can
be stopped from one safety relay/PLC.
Safety level
BT50 has an internal redundant and monitored safety func-
tion. Power failure, internal component faults or external
interference cannot result in dangerous functions.
Safety relay/expansion relay
BT51(T)
Approvals:
Safety relay for:
Emergency stop
Interlocked hatch
Expansion of Pluto
Features:
Single and dual channel
Test/reset input
Width 22.5 mm
LED indication
4 NO relay outputs
Supply 24 VDC
Quick release connector
blocks
BT51 - Additional power
terminals
BT51T - One changeover
relay with a double
information output (Y14)
BT51T - Delay times
selectable from 0 - 1.5 s
Input via A1 only is not protected from short circuiting,
and therefore installation is critical for the safety level to be
achieved. To achieve a higher safety level a screened cable
can be used and/or connection made to both A1 and A2 (see
example overleaf).
Regulations and standards
The BT51 is designed and approved in accordance with ap-
propriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the chapter Connection examples.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/28
6
Technical description BT51(T)
When supply voltage is connected to A1 and A2, relays K1
and K2 are activated. K1 and K2 drop if the supply voltage is
disconnected. Both relays K1 and K2 must drop for them to
be activated again. Another requirement is that the test cir-
cuit, A1 - X4, must be closed for the outputs to be activated.
Thereafter A1 - X4 can either be open or constantly closed.
The supervising circuit ensures that both K1 and K2 have
dropped before they can be reactivated. The stop function
complies with the requirement that a component fault or ex-
ternal interference cannot lead to a dangerous function.
The safety outputs consist of contacts from K1 and K2
connected internally in series across terminals 13 - 14, 23 -
24, 33 - 34 and 43 - 44. These contacts are used to cut the
power to components which stop or prevent hazardous mo-
vements/functions. It is recommended that all switched loads
are adequately suppressed and/or fused in order to provide
additional protection for the safety contacts.
1.0 s
1.5 s
0 s
0.5 s
A2 T1 T2 A2 T1 T2
BT51T - Delay times BT51T - Info. output
Supervision circuit
Max load 250 mA
Emergency stop with dual connec-
tion direct to the supply voltage.
Controlled monitoring of external
contactor, relay, valve or ABB Jo-
kab Safetys expansion relays.
Emergency stop with reset when
emergency button returns.
Hatch with automatic reset.
Electrical connection BT51(T)
* BT51 has additional power terminals A1 and A2.
*
*
*
A1 X4
A1 X4
Technical data BT51(T)
Article number
BT51 2TLA010033R2000
BT51T 2TLA010033R3000
Colour Grey
Operational voltage 24 VDC +15%/-25%
Power consumption 1.4 W/1.8 W
Relay Outputs 4NO
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. res. load total switching
capacity 12 A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA
Contact material Ag +Au ash
Fuses Output (External) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max Input Wire res. at nom.
voltage 200 Ohms
Response time at deactivation <20 ms or delayed max 1500ms
(BT51T)
Terminals (Max. screw torque 1 Nm)
Single strand: 2x1.5mm
2
Conductor with socket contact: 2x1mm
2
Mounting 35mm DIN-rail
Protection class enclosure/ter-
minals IP40/IP20 IEC 60529
Impulse Withstand Voltage 2.5kV
Pollution Degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Electrical Supply, Relay and X4
Weight 200 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PLe/Cat. 4 (EN ISO13849-1:2008)
SIL 3 (EN 62061:2005)PFH
D
1.63E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC, EN 62061:2005
EN ISO 13849-1:2008
BT51 as emergency stop and
control relay with Start and Stop
function.
Monitoring to ensure that the On
button is not stuck in pressed
position. A short circuit over the
closing contact is not monitored.
6/29 2TLC172001C0202 | ABB Safety Handbook
6
Regulations and standards
The JSBT5 is designed and approved in accordance with
appropriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
Single channel safety relay
The JSBT5 is designed to connect safety devices, such as
emergency stops, directly in the voltage supply circuit to the
relay. Despite a maximum built-in width of 22.5 mm the relay
is very powerful.
With 3 NO safety outputs, 1 NC, test input and complete in-
ternal supervising, the JSBT5 is quite unique. In addition you
can order delayed outputs (JSBT5T).
In order for the safety outputs to close, the supply voltage,
e.g. by means of an emergency stop button, must be connec-
ted to A1 and A2 and the test input closed. After actuation of
the relay the test input can be opened again.
The test input is intended to supervise that contactors or
valves have dropped/returned before a new start can be
permitted.The test input can also be used for starting and the
start button can be supervised (see connection example
on next page).
Safety level
The JSBT5 has a twin and supervised internal safety function.
Power failure, internal component faults or external interfe-
rence cannot result in dangerous functions.
Input via A1 only is not protected from short circuiting,
and therefore installation is critical for the safety level to be
achieved. To achieve a higher safety level a screened cable
can be used and/or connection made to both A1 and A2 (see
example overleaf).
Safety relay
JSBT5(T)
Approvals:
Safety relay for:
Emergency stop
Interlocked hatch
Features:
Single and dual channel
Test/start input
Width 22.5 mm
LED indication
3 NO/1NC relay outputs
(T) = delayed outputs 0.5sec.
Supply 12 VDC, 24 VDC/AC
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/30
6
Technical description JSBT5(T)
Emergency stop with dual connec-
tion direct to the supply voltage.
Controlled monitoring of external
contactor, relay, valve or ABB
Jokab safetys expansion relays.
Emergency stop with automatic
reset when emergency button
returns.
Hatch with automatic reset.
Electrical connection JSBT5(T)
Technical data JSBT5(T)
Article number
JSBT5 24VAC/VDC 2TLA010005R0100
JSBT5 12VDC 2TLA010005R0700
JSBT5T 24VAC/VDC 2TLA010005R1100
Colour Grey
Operational voltage
JSBT5: 24 VDC/AC +15%25%, 5060 Hz
JSBT5T: 12 VDC, 24 VDC/AC +15% 25%,
50 - 60 Hz
Power consumption 1 W/1.9VA
Relay Outputs 3NO +1NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. res. load total switching
capacity: 9A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material AgCuNi
Fuses Output (External) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max Input Wire res. at nom.
voltage 200 Ohm
Response time at deactivation <60 ms or delayed max 500ms
(JSBT5T)
Terminals (Max. screw torque 1 Nm)
Single strand: 2x1.5mm
2
Conductor with socket contact: 2x1mm
2
Mounting 35mm DIN-rail
Protection class enclosure/ter-
minals IP40/IP20 IEC 60529
Impulse Withstand Voltage 2.5kV
Pollution Degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
Function indication Electrical Supply
Weight 200 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005) PFH
D
1.22E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC, EN 62061:2005
EN ISO 13849-1:2008
When supply voltage is connected to A1 and A2, relays K1
and K2 are activated. K1 and K2 drop if the supply voltage is
disconnected. Both relays K1 and K2 must drop for them to
be activated again. Another requirement is that the test cir-
cuit, X1 - X2, must be closed for the outputs to be activated.
Thereafter X1 - X2 can either be open or constantly closed.
The supervising circuit ensures that both K1 and K2 have
dropped before they can be reactivated. The stop function
complies with the requirement that a component fault or ex-
ternal interference cannot lead to a dangerous function.
The safety outputs consist of contacts from K1 and K2 con-
nected internally in series across terminals 13 - 14, 23 - 24,
and 33 - 34. These contacts are used to cut the power to
components which stop or prevent hazardous movements/
functions. It is recommended that all switched loads are ade-
quately suppressed and/or fused in order to provide additio-
nal protection for the safety contacts.
The NC output 41 - 42 should only be used for monitoring
purposes e.g. indication lamp for emergency stop pressed.
JSBT5 as emergency stop and
control relay with Start and Stop
function.
Monitoring to ensure that the On
button is not stuck in pressed
position. A short circuit over the
closing contact is not monitored.
The JSBR4 has built in short cir-
cuit monitored re setting.
6/31 2TLC172001C0202 | ABB Safety Handbook
6
2
1
Time reset procedure. First push PB1, then exit
dangerous area and close the door, then push
PB2 (PB1 and PB2 must be pressed within the
predetermined time period selected). After this
procedure the machine can be safely restarted.
Light beam being bypassed for a maximum
pre-set time e.g. 5 sec. by the jsht1 during ent-
rance and exit with the JSHD4 Three Position
Enabling device.
The JSHT1A/B closes two independent relay outputs during a guaranteed
maximum time when the inputs are opened.
Time reset
Time reset can prevent uni ntentional reset of safety systems when someone is still
in the dangerous area of the machine. During a guaranteed maximum time, one
or several PBs for reset must be activated. The reset buttons should be sited in
such a way that operatives have a clear overview of the whole area which is gu-
arded. Time reset is made by the combi nation of a safety relay and the timer relay
JSHT1A/B.
Time bypassing
The JSHT1 can also be used for time bypass of light beams for e.g. autotruck into a
dangerous area.
Operation
When the inputs open the output contacts close. The output contacts open when
the inputs close or when the time period has expired. The time period is hardwire
selectable on terminals T1, T2 and T3. The time given is the maximum time. One or
two channel operation is also hardwire selectable.
Regulations and standards
The JSHT1A/B is designed and approved in accordance with appropriate directives
and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safety problems, please
see the section Connection examples.
Safety timer
JSHT1
Approvals:
Safety relay for:
Time reset
Time bypassing
Features:
Hardwire time selection
5 40 s
Selectable single or dual
channel input
Test input
Width 45 mm
LED indication for supply,
inputs and outputs
1+1 NO relay outputs
Supply 24 VDC
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/32
6
JSHT1A JSHT1B
Electrical connection JSHT1 A/B
Technical description JSHT1 A/B
The electrical supply is connected across A1 and A2. The
internal supervising circuit is activated directly when the
supply is on. The inputs A and B must both be closed and
then opened. Thereafter K1 and K2 are activated and the
outputs close. K1 and K2 are activated for the hardwired
selected time (set by connections on the terminals T1, T2 and
T3). If there is a short circuit between the inputs or the inputs
are closed again before the set time period has expired the
outputs will open. In order to close the outputs again both
the inputs have to be closed and both internal relays K1 and
K2 deactivated (cont rol led by the super vising circuit) and the
inputs again opened.
By external hardwire connections the JSHT1 can be made
single or dual channel input. See figure below.
Connection for dual channel input
Connection for single channel input
* It is recommended that all switched loads are adequately suppressed and/or fused in
order to provide additional protection for the safety contacts. In the gure the monito-
ring of two contactors in the test input is shown.
Selection of time by hardwire links
** Only for AC-supply.
Connection
and monito-
ring circuit
Timer
**
Technical data JSHT1 A/B
Article number
JSHT1A 24VDC 2TLA010011R0000
JSHT1B 24VDC 2TLA010011R1000
Colour Grey
Power supply 24 VDC 15 %
Power consumption 1.8 W/3.7VA
Max Input wire res. at nom voltage/
channel
100/200 Ohm (1 Channel/ 2
Channel)
Response time at activation <30ms
Response time at deactivation < 15 ms
Selectable time
( 15 % at nom.V.)
JSHT1A: 5-10-15-20 sec
JSHT1B: 5-15-30-40 sec
Relay outputs 2x1NO
Max. switching capacity resistive
load AC 4A/250 VAC/1000 VA
Inductive load AC AC15 250VAC 3A
Resistive load DC 4A/24 VDC/100 W
Inductive load DC DC13 24VDC 2A
Max. total switching capacity: 8A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material AgCuNi
Fuses output (external) 3A gL/gG or 4A fast
Conditional short-circuit current
(1 kA) 6A gG
Max input wire res. at nom. voltage 100 Ohm
Terminals (max. screw torque 1 Nm)
Single strand 1x4mm
2
, 2x1.5mm
2
Conductor with socket contact 1x2.5mm
2
, 2x1mm
2
Mounting 35mm DIN-rail
Protection class enclosure/termi-
nals IP20/IP40 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range 10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Electrical Supply, Inputs, Outputs
Weight 24 VDC: 330 g
24/48/115/230 VAC: 430 g
Performance (max.)
Functional test: The relays must be
cycled at least once a year.
PL e/Cat. 4 (ENISO13849-1:2008)
SIL 3 (EN 62061:2005)
PFH
D
4.42E-09
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC
EN 62061:2005
EN ISO 13849-1:2008
6/33 2TLC172001C0202 | ABB Safety Handbook
6
The JSHT2A/B/C closes two independent relay outputs during a guaranteed
maximum period of time when the inputs are closed.
Time bypassing
Sensors detect the autocarrier and are connected to the JSHT2 which supervises
the sensors and by pas ses the light beam for a maximum predeter mined time.
Inching
Inching applications require safety outputs to be closed for a predetermined maxi-
mum period of time, allowing the machine to move only a short distance each time
the inching control is activated. For each new motion the inching control e.g. PB or
pedal must be released and activated again.
Operation
When the inputs close the output contacts close. The output contacts open when
the input opens or when the time period has expired. The time is hardwire selecta-
ble on the terminals T1, T2 and T3. The time given is the maximum time. Single or
dual channel operation is also hardwire selectable.
Regulations and standards
The JSHT2A/B/C is designed and approved in accordance with appropriate directi-
ves and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safety problems, please
see the section Connection examples.
Safety timer
JSHT2
Light beam being bypassed only for the time it
takes the auto carrier to pass.
Shaft only turns a small amount each time the
PB is pressed.
Approvals:
Safety relay for:
Time bypassing
Inching
Features:
Hardwire time selection
0.2 40 s
Selectable single or dual
channel input
Test input
Width 45 mm
LED indication for supply,
inputs and outputs
1+1 NO relay outputs
Supply 24 VDC
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/34
6
JSHT2A JSHT2B JSHT2C
Technical description JSHT2 A/B/C
Electrical connection JSHT2 A/B/C
The electrical supply is connected across A1 and A2. The
internal supervising circuit is activated directly when the sup-
ply is on. The inputs A and B must both be opened and then
closed. Thereafter K1 and K2 are activated and the outputs
close. K1 and K2 are activated for hardwired selected time
(set by connections on the terminals T1, T2 and T3). If there
is a short circuit between the inputs or the inputs are opened
again before the set time period has expired the outputs will
open. In order to close the outputs again both the inputs have
to be opened and both internal relays K1 and K2 deactiva-
ted (controlled by the supervising circuit) and then the inputs
closed again.
By external hardwire connectors the JSHT2 can be made to
operate from either single or dual channel inputs. See figure
below.
Connection for dual channel input
Connection for single channel input
Selection of time by hardwire links
* It is recommended that all switched loads are adequately suppressed and/or fused in
order to provide additional protection for the safety contacts. In the gure the monito-
ring of two contactors in the test input is shown.
** Only for AC-supply.
Connection and
monitoring circuit
Timer
**
Technical data JSHT2 A/B/C
Article number
JSHT2A 240VDC 2TLA010012R0000
JSHT2B 24VDC 2TLA010012R1000
JSHT2C 24VDC 2TLA010012R2000
Colour Grey
Power supply 24 VDC 15 %
Power consumption 1.8 W/3.8VA
Max input wire res. at nom volta-
ge/channel
100/200 Ohm (1 Channel/ 2 Chan-
nel)
Response time at activation < 30 ms
Response time at deactivation < 15 ms
Selectable time
( 15 % at nom.V.)
JSHT2A: 0.2 - 0.5 - 0.7 - 1.0 sec
JSHT2B: 5 - 10 - 15 - 20 sec
JSHT2C: 5 - 15 - 30 - 40 sec
Relay outputs 2x1NO
Max. switching capacity
Resistive load AC 4A/250 VAC/1000 VA
Inductive load AC AC15 250VAC 3A
Resistive load DC 4A/24 VDC/100 W
Inductive load DC DC13 24VDC 2A
Max. total switching capacity: 8A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material AgCuNi
Fuses output (external) 3A gL/gG or 4A fast
Max input wire res. at nom.
voltage 100 Ohm
Terminals (max. screw torque 1 Nm)
Single strand: 1x4mm
2
or 2x1.5mm
2
Conductor with socket contact: 1x2.5mm
2
or 2x1mm
2
Mounting 35mm DIN-rail
Protection class IP20/IP40 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range 10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Electrical Supply, Inputs, Outputs
Weight 24 VDC: 310 g
24/48/115/230 VAC: 410 g.
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PL e/Cat. 4 (ENISO 13849-1:2008)
SIL 3 (EN 62061:2005) PFH
D
4.42E-09
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC
EN 62061:2005
EN ISO 13849-1:2008
6/35 2TLC172001C0202 | ABB Safety Handbook
6
Stop category 1 may also be permitted when it is not possible
to gain physical access to the machine before the safe stop is
affected e.g:
Gates, access time is normally over 1 sec.
Covers and gates which are locked until dangerous opera-
tions and functions have been stopped.
Long distances between a safety device and a dangerous
machine function.
Safety level
The E1T has twin stop functions, that is, two relays with
mechanically operated contacts. A monitored stop function
is achieved by con necting the test output (terminals X1 and
X2) to the test or reset input on the safety relay which is being
expanded.
One condition for a safe delayed stop is that the delay time
cannot increase in the event of a fault. The E1T complies with
this requirement.
Regulations and standards
The E1T is designed and approved in accordance with appro-
priate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
More outputs
By connecting expansion relays to a safety relay it is easy to
increase the number of safe outputs. This means that an unli-
mited number of dangerous machine operations and functions
can be stopped from one safety relay.
Safe soft stop
When a gate is opened a program stop is first given to the
machines PLC/servo which brakes the dangerous operations
in a soft and controlled way. The safety outputs then break
the power to the motors, that is, when the machine has alrea-
dy stopped. Normally between 0.5 and 1 second is needed to
brake a dangerous machine operation softly.
Soft stop ensures many advantages:
The machine lasts longer.
Parts being processed are not damaged.
Restart from stopped position is enabled and simplified.
A safe soft stop is achieved by means of a safety relay which
gives the program stop, and an expansion relay, E1T, which
gives safe delayed stop signals. See section Connection
examples. The drop time delay on a E1T can as standard be
selected from 0 to 3 seconds. By connecting several E1Ts in
series even longer times can be achieved.
When are delayed safe stops used?
Delayed safety stop signals can be used for emergency stops
according to EN ISO 13850:2008 4.1.4. Stop category 1, i.e. a
controlled stop with power to the actuator(s) available to achieve
the stop and then removal of power when stop is achieved.
Expansion relay
E1T
Approvals:
Safety relay for:
More safety outputs
Delayed safety outputs
Features:
Width 22.5 mm
Supply 24 VDC
LED output indication
4 NO relay outputs
Single or dual channel
operation option
Quick release connector
blocks
TV
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ABB Safety Handbook | 2TLC172001C0202 6/36
6
Technical description E1T
The E1T has to be connected to a safety relay in order to
fulfill the necessary safety requirements (see connection
examples below). The safety relay controls and monitors the
E1T (The E1T can be connected for single or dual channel
operation - see below). When the inputs S14 and S24 close,
relays K1 and K2 are activated. A stop signal is given, K1 and
K2 drop, if the inputs are opened or during power failure. K1
and K2 drop either directly or after a delay* (if incorporated).
Delay time of module is fixed and shown on front panel of
device. The delay circuit is so arranged that the design time
cannot be exceeded.
To check that both the relays K1 and K2 drop during a stop
signal they must be monitored. This is achieved by connec-
ting X1 and X2 to the test or reset input on the safety relay
which is expanded (see below). K1 and K2 are mechanically
operated relays, therefore, if one of the output contacts
should stick closed then the relays contact in X1-X2 cannot
be closed thus preventing a new ready signal being given to
the safety relay.
Inductive loads should be equipped with an arc suppressor to
protect the output contacts.
Diodes are the best arc suppressors but will increase the
switch off time of the load.
Electrical connection E1T
SAFETY RELAY RT6 SAFETY RELAY RT6
DELAYED SAFETY STOP
Technical data E1T
Article number
E1T 0s 24 VDC 2TLA010030R0000
E1T 0.5s 24 VDC 2TLA010030R1000
E1T 1s 24 VDC 2TLA010030R2000
E1T 1.5s 24 VDC 2TLA010030R3000
E1T 2s 24 VDC 2TLA010030R4000
E1T 3s 24 VDC 2TLA010030R5000
Colour Grey
Operational voltage 24 VDC 15%
Power consumption 1.5 W
Relay Outputs 4NO
Max. switching capacity
Resistive load AC 6A/250 VAC/1500VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150W
Inductive load DC DC13 24 VDC 1A
Max. total switching capacity 12A distributed on all contacts
Min. switching load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material Ag +Au ash
Fuses output (external) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Maximum external resistance at a
nominal voltage 150 Ohm (S14, S24)
Response time at deactivation
(input - output)
< 0,020 s, 0,5 s, 1 s, 1,5 s, 2 s, 3 s,
20%
Response time at activation
(input-output) <30 ms
Terminals (max. screw torque 1 Nm)
Single strand: 1x4mm
2
/ 2x1.5mm
2
Conductor with socket contact: 1x2.5mm
2
/ 2x1mm
2
Mounting 35mm DIN-rail
Protection class
enclosure IP40 IEC 60529
terminals IP20 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range -10C +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Output status
Weight 220 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PLe/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005)
PFH
D
1.55E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC
EN 62061:2005
EN ISO 13849-1:2008
Connector blocks are detachable
(without cables having to be disconnected)
120
84
22,5
Single channel expansion of outputs
for a safety relay connected to an
emergency stop.
Dual channel expansion with
delayed safety outputs for a safety
relay monitoring a gate.
6/37 2TLC172001C0202 | ABB Safety Handbook
6
More outputs
By connecting expansion relays to a safety relay it is easy to
increase the number of safe outputs. This means that an unli-
mited number of dangerous machine operations and functions
can be stopped from one safety relay.
Safe soft stop
When a gate is opened a program stop is first given to the
machines PLC/servo which brakes the dangerous operations
in a soft and controlled way. The safety outputs then break
the power to the motors, that is, when the machine has alrea-
dy stopped. Normally between 0.5 and 1 second is needed to
brake a dangerous machine operation softly.
Soft stop ensures many advantages:
The machine lasts longer.
Parts being processed are not damaged.
Restart from stopped position is enabled and simplified.
A safe soft stop is achieved by means of a safety relay which
gives the program stop, and an expansion relay, JSR1T, which
gives safe delayed stop signals. See section Connection
examples. The drop time delay on a JSR1T can as standard
be selected from 0 to 10 seconds. By connecting several
JSR1Ts in series even longer times can be achieved.
When are delayed safe stops used?
Delayed safety stop signals can be used for emergency stops
according to EN418 4.1.4 Stop category 1, i.e. a controlled
stop with power to the actuator(s) available to achieve the
stop and then removal of power when stop is achieved.
Stop category 1 may also be permitted when it is not possib-
le to gain physical access to the machine before the safe stop
is affected e.g:
Gates, access time is normally over 1 sec.
Covers and gates which are locked until dangerous
operations and functions have been stopped.
Long distances between a safety device and a
dangerous machine function.
Safety level
The JSR1T has twin stop functions, that is, two relays with
mechanically operated contacts. A monitored stop function
is achieved by con necting the test output (terminals X1 and
X2) to the test or reset input on the safety relay which is being
expanded.
One condition for a safe delayed stop is that the delay time
cannot increase in the event of a fault. The JSR1T complies
with this requirement.
Regulations and standards
The JSR1T is designed and approved in accordance with
appropriate directives and standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
Expansion relay
JSR1T
Approvals:
Safety relay for:
More safe outputs
Delayed safe outputs
Information output
Features:
Width 45 mm
Supply 24 VDC
LED function indication
4 NO/1 NC relay outputs
Single and dual channel
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/38
6
Technical description JSR1T
The JSR1T has to be connected to a safety relay in order to
fulfill the necessary safety requirements (see connection ex-
amples below). The safety relay controls and monitors the JS-
R1T. (The JSR1T can be connected for single or dual channel
operation - see below). When the inputs S14 and S24 close,
relays K1 and K2 are activated. A stop signal is given, K1 and
K2 drop, if the inputs are opened or during power failure. K1
and K2 drop either directly or after a delay* (If incorporated).
Delay time of module is fixed and shown on front panel of
device. The delay circuit is so arranged that the design time
cannot be exceeded.
To check that both the relays K1 and K2 drop during a stop
signal they must be monitored. This is achieved by connecting
X1 and X2 to the test or reset input on the safety relay which
is expanded (see below). K1 and K2 are mechanically ope-
rated relays, therefore, if one of the output contacts should
stick closed then the relays contact in X1-X2 cannot be
closed thus preventing a new ready signal being given to the
safety relay.
Inductive loads should be equipped with an arc suppressor to
protect the output contacts.
Diodes are the best arc suppressors but will increase the
switch off time of the load.
Electrical connection JSR1T
SAFETY RELAY RT6
JSR1T
JSR1T
Technical data JSR1T
Article number
JSR1T 0 2TLA010015R0000
JSR1T 1.5 2TLA010015R0500
JSR1T 8 2TLA010015R0600
JSR1T 0.5 2TLA010015R1000
JSR1T 10s 2TLA010015R2000
JSR1T 1 2TLA010015R3000
JSR1T 2 2TLA010015R4000
JSR1T 3 2TLA010015R5000
JSR1T 5 2TLA010015R6000
Colour Grey
Power supply 24 VDC 15%
Power consumption 1.2W
Relay outputs 4NO +1NC
Max. switching capacity
Resistive load AC 6A/250 VAC/1500 VA
Inductive load AC AC15 240 VAC 2A
Resistive load DC 6A/24 VDC/150 W
Inductive load DC DC13 24 VDC 1A
Max. total switching capacity: 16A distributed on all contacts
Min. load 10mA/10 V (if load on contact has
notexceeded 100mA)
Contact material Ag +Au ash
Fuses output (external) 5A gL/gG
Conditional short-circuit current
(1 kA) 6A gG
Max. Input wire res. at nom.
voltage 150 Ohm (S14, S24)
Response time at deactivation
(input- output)
< 0.020 s, 0.5 s, 1 s, 1.5 s, 2 s, 3 s,
5 s, 8 s, 10 s 20 %
Terminals (max. screw torque 1 Nm)
Single strand: 1x2.5mm
2
/ 2x1mm
2
Conductor with socket contact: 1x4mm
2
/ 2x1.5mm
2
Mounting 35mm DIN-rail
Protection class enclosure/ter-
minals IP40/IP20 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Output Relay Supplies
Weight 280 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year
PLe/Cat. 4 (EN ISO13849-1:2008)
SIL 3 (EN62061:2005)
PFH
D
1.55E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC EN 62061:2005
EN ISO 13849-1:2008
Connector blocks are detachable
(without cables having to be disconnected)
mm
120
74
45
Expansion of outputs for safety
relay connected to emergency stop
with automatic reset.
Dual-channel expansion with
delayed safety outputs for safety
relay monitoring a gate.
JSR1T
SAFETY RELAY RT6
DELAYED SAFETY STOP
PROGRAM STOP
6/39 2TLC172001C0202 | ABB Safety Handbook
6
More outputs
The JSR2A expansion relay is used to provide increased switching capacity and
number of safety outputs to a safety relay. This means that an unlimited number of
dangerous machine operations and functions can be stopped from one safety relay.
Greater current switching capacity
The JSR2A Expansion relay enables switching of up to 10 amps per output contact.
Safety level
The JSR2A has twin stop functions, that is, two relays with mechanically positively
guided contacts. A monitored stop function is achieved by connecting the test
output (terminals X1 and X2) to the test or reset input on the safety relay which is to
be expanded.
Regulations and standards
The JSR2A is designed and approved in accordance with appropriate directives and
standards. See technical data.
Connection examples
For examples of how our safety relays can solve various safety problems, please
see the section Connection examples.
Expansion relay
JSR2A
Approvals:
Safety relay for:
More safe outputs
Greater current switching
capacity
Information output
Features:
Switching capacity of up to
10 A/250V per output
Width 45 mm
LED function indication
4 NO/1 NC relay outputs
5 supply versions
Supply 24 VDC/VAC, 115 and
230 VAC
Quick release connector
blocks
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/40
6
S
u
p
p
l
y
Outputs Test
The JSR2A has to be connected to a suitable safety relay in
order to fulfill the necessary safety requirements (see chapter
Connection examples). The Safety Relay controls and moni-
tors the JSR2A unit. (The JSR2A can be connected for single
or dual channel operation - see Electrical connection dia-
grams below). When the inputs to S14 and S24 close, internal
relays K1 and K2 are activated. A stop signal is given, K1 and
K2 drop, if the inputs are opened or during power failure.
To check that both the K1 and K2 relays drop during a stop
signal they must be monitored. This is achieved by connecting
X1 and X2 to the test or reset input on the safety relay which
is expanded. K1 and K2 have mechanically positively guided
contacts, therefore, if one of the output contacts should stick
closed then the relays contact in X1-X2 cannot be closed
thus preventing a new ready signal being given to the safety
relay.
Dual channel expansion of RT6
with JSR2A connected for automa-
tic reset.
One channel expansion of RT6
with JSR2A connected for manual
reset.
Electrical connection JSR2A
Technical description JSR2A
Reset
Technical data JSR2A
Article number
JSR2A 10A 24VAC/VDC 2TLA010027R0100
JSR2A 10A 115VAC 2TLA010027R0400
JSR2A 10A 230VAC 2TLA010027R0500
Colour Grey
Supply A1 - A2 24 VDC/AC, 115,
230 VAC +15%, 50-60 Hz
Power consumption 2.7W/2.44 VA
Relay outputs 4NO +1NC
Max. switching capacity
Resistive load AC 8A/230 VAC/1840 VA
10A/115VAC/48VAC/24VAC/
1840 VA
Inductive load AC AC15 230 VAC 4A (NO-contact) 1.5A
(NC-contact)
Resistive load DC 8A/24 VDC/192 W
Inductive load DC DC13 24 VDC 1.2A (NO/NC-contact)
Max. total switching capacity: 16A distributed on all contacts
Min. load 10mA/10V/100mW (if load on con-
tact has notexceeded 100mA)
Contact material AgSnO2 +Au ash
Fuses output (External) 6A gL ( 8A fast if short-circuit current
>500A )
Conditional short-circuit current
(1 kA)
10A gG
Max. Input wire res. at nom.
voltage
24 VDC/VAC: 100 Ohm
48/115/230 VAC: 200 Ohm
Mechanical operational Life
>10
7
operations
Response time at
deactivation (input- output) <25 ms
activation (input - output): <15 ms
Terminals (removable)
Max. screw torque 1 Nm
Connection area (max.)
Single strand 1x4mm
2
or 2x1.5mm
2
/ 12AWG
Conductor with socket contact 1x2.5mm
2
or 2x1mm
2
Mounting 35mm DIN-rail
Protection class terminals
Enclosure IP40 IEC 60529
Terminals IP20 IEC 60529
LED indication
On
Supply voltage
1 2
Output relays 1 and 2
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range -10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
Weight 313 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005) PFH
D
1.55E-08
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC EN 62061:2005
EN ISO 13849-1:2008
Connector blocks are detachable
(without cables having to be disconnected)
mm
120
74
45
6/41 2TLC172001C0202 | ABB Safety Handbook
6
Delayed outputs
By connecting the JSR3T expansion relay to a compatible
Safety relay it is easy to obtain safe "delayed" outputs.
The JSR3T provides the system designer with the facility to
hardwire selected time delays in steps between 0.5 and 10
seconds.
Use of delayed outputs
There are many applications where delayed outputs are
necessary and permissible. For example delayed stop
signals can be used for emergency stops according to
ENISO13850:2008 4.1.4 Stop Category 1 (a controlled
stop with power to the machine actuator(s) available to achie-
ve the stop and then removal of power when stop is achie-
ved). Stop Category 1 may also be permitted when it is not
possible to gain physical access to the machine before the
safe stop is effected e.g. by:
Covers and Gates which are locked until dangerous ope-
rations and functions have been stopped.
Long distances between a safety device and dangerous
machine functions.
Using this technique of stopping a machine provides many
advantages i.e.:
Machines last longer as they are not subjected to excessi-
ve loading etc when requested to stop.
Parts being processed are not damaged.
Restarting machines from stopped position is simplified.
A safe "Soft" stop is achieved by means of a safety relay
giving a programme stop to the machine control system. e.g.
when a gate is opened or emergency stop is activated. The
output of the Safety relay is used to provide both a stop signal
to the machine control system i.e. via a PLC which applies
the necessary braking/stopping of the machine in a controlled
way, and to switch a delayed expansion relay e.g JSR3T. The
delayed safety outputs of the JSR3T expansion relay are then
used to control the safe disconnection of the power to the
actuators/motors etc. of the machine.
Safety level
The JSR3T has twin stop functions, using two positively gui-
ded contact relays.
In order to achieve the level of monitoring required the JSR3T
must be used with a suitable Safety Relay e.g. JSBR4, or
RT6. The JSR3T test output (terminals X1 and X2) must be
connected to the test input of the Safety relay being expan-
ded (see connection examples).
The JSR3T provides delay times that even in the event of an
internal fault condition complies with the requirement that the
set delay cannot increase in time.
Regulations and standards
The JSR3T is designed and approved in accordance with
appropriate directives and standards. Examples of such are
98/37/EC, EN ISO 12100-1/-2, EN 60204-1, EN 954-1/
EN ISO 13849-1.
Connection examples
For examples of how our safety relays can solve various safe-
ty problems, please see the section Connection examples.
Expansion relay
JSR3T
Approvals:
Safety relay for:
Safe delay of stop signals
with selectable value
Delayed safe outputs
Features:
Width 22.5 mm
Supply 24V AC/DC
Output indication
2 x 1 NO relay outputs
Hardwire Selectable
Delay 0.5-10.0 sec by
hardwire links and Time trim
potentiometer
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 6/42
6
Electrical connection JSR3T
When supply voltage is connected to A1 and A2, relays K1
and K2 are activated. When the supply voltage is removed re-
lays K1 and K2 remain energized for a time period determined
by the hardwire link configuration chosen (set by connecting
links on the terminals Y1, Y2, Y3 and Y4.) and the setting of
the Time Trim potentiometer.
NOTE 1! Max. time set by hardwire links can only be reduced
(up to approx. 30% reduction) by Time Trim potentiometer.
NOTE 2! Both the output contacts of K1 and K2 (13 - 14
and 23 - 24) must be used. Output contacts must be either
connected in series (forming one safety output) or used in
parallel circuits in order to obtain necessary redundancy.
Technical description JSR3T
It is recommended that all switched loads are adequately sup-
pressed and/or fused in order to provide additional protection
for the safety contacts.
Selection of time delay by hardwire links (Y1, Y2, Y3, Y4).
Selected delay can be lowered by up to approx. 30% by me-
ans of preset potentiometer on front panel.
Technical data JSR3T
Article number
JSR3T 24 VAC/VDC 2TLA010017R0100
Colour Grey
Power supply 24 VAC/VDC, 50 - 60 Hz
Power consumption 1.3VA/W
Relay outputs 2x1NO (See Connection examples)
Max. switching capacity
Resistive load AC 4A / 250 VAC/1000 VA
Inductive load AC AC15 240 VAC 3A
Resistive load DC 4A / 24 VDC /100 W
Inductive load DC DC13 24 VDC 2A
Max. res. load total switching
capacity: 6A distributed on all contacts
Min. load 10mA/10V (if load on contact has
notexceeded 100mA)
Contact material AgNi
Fuses output (external) 3A gL/gG or 4A fast
Conditional short-circuit current
(1 kA) 6A gG
Max Input wire res. at nom.
voltage 100 Ohm
Response time at activation <20ms
Response time at deactivation <0.5 - 10.0 sec. at nom. voltage.
Selected delay can be lowered by up
to approx. 30% by means of preset
potentiometer on front panel.
Terminals (max. screw torque 1 Nm) Single strand: 2x1.5mm
2
Conductor with socket contact:
2x1mm
2
.
Mounting 35mm DIN-rail
Protection class enclosure/ter-
minals IP40/IP20 IEC 60529
Impulse withstand voltage 2.5kV
Pollution degree 2
Operating temperature range 10C to +55C (with no icing or
condensation)
Operating humidity range 35% to 85%
LED indication Outputs
Weight 158 g
Performance (max.)
Functional test: The relays must
be cycled at least once a year.
PL e/Cat. 4
(EN ISO13849-1:2008)
SIL 3 (EN 62061:2005) PFH
D
3.67E-09
Conformity 2006/42/EC, 2006/95/EC,
2004/108/EC EN 62061:2005
EN ISO 13849-1:2008
6/43 2TLC172001C0202 | ABB Safety Handbook
6
ABB Safety Handbook | 2TLC172001C0202 6/44
6
Connection examples
HA5400A Connection examples JSBR4 6/45
HA6400A Connection examples JSBT4 6/45
HA6500A Connection examples JSBT5 6/46
HA6500B Connection examples BT50 6/46
HA6501B Connection examples BT50T 6/47
HA6500C Connection examples BT51 6/47
HA6501C Connection examples BT51T 6/48
HA7100A Connection examples JSBRT11 6/48
HA7600A Connection examples RT6 6/49
HA7600B Principle drawing RT6 6/49
HA7672A Enabling device JSHD4 - EX with RT6 6/50
HA7700A Connection examples RT7 6/50
HA7900A Connection examples RT9 6/51
HE3811B Safety Light Beam Spot with time-limited reset 6/51
HE3824C-01 Lightbeam with time-limited bypass 0.240 s 6/52
HE3824E-01 Lightbeams with time-limited bypass 0.240 s 6/52
HG7636B Focus light grid/curtain with three-position device 6/53
HG7611A Interlocked door with RT6 and pre-reset 6/53
HG7636A Interlocked door with three-position device 6/54
HG7646A Interlocked door with three-position device 6/54
HG7654A Interlocked door with RT6 and output expansion JSR1T 6/55
HG7658A Interlocked door with RT6 and output expansion JSR2A 6/55
HG7673A Interlock switch JSNY8 with RT6 6/56
HG7674A Safety interlock switch JSNY9M/MLA with RT6 6/56
HG7674B Safety interlock switch JSNY9S/SLA with RT6 6/57
HH0000C Three-position device JSHD4 with various safety controllers 6/57
HI8552A Connection examples JSHT2 intermittent running 6/58
HK7600A Safety mat/Contact strip with RT6 6/58
HL7600B Several JSNY7 connected to one RT6 with unique indication 6/59
HM0000A Magnetic switch JSNY7 with various safety controllers 6/59
HN7660A Delayed outputs RT6 with output expansion JSR3T and RT7 6/60
HP7600A Machine control - Isolation of PLC inputs and outputs 6/60
HP7600B Machine control-Isolation of PLC outputs 6/61
HR7200B Focus light curtain/beam 6/61
HR7800B Focus lightbeam/curtain 6/62
HT5400A Two-hand device with safety relay JSBR4 6/62
HB0008A Focus light curtain/light beam with RT9 and M12-3D 6/63
6/45 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HA6400A Connection examples JSBT4
HA5400A Connection examples JSBR4
ABB Safety Handbook | 2TLC172001C0202 6/46
6
Connection examples
HA6500B Connection examples BT50
HA6500A Connection examples JSBT5
6/47 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HA6500C Connection examples BT51
HA6501B Connection examples BT50T
ABB Safety Handbook | 2TLC172001C0202 6/48
6
Connection examples
HA7100A Connection examples JSBRT11
HA6501C Connection examples BT51T
6/49 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HA7600B Principle drawing RT6
HA7600A Connection examples RT6
ABB Safety Handbook | 2TLC172001C0202 6/50
6
Connection examples
HA7700A Connection examples RT7
HA7672A Enabling device JSHD4 - EX with RT6
6/51 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HE3811B Safety Light Beam Spot with time-limited reset
HA7900A Connection examples RT9
ABB Safety Handbook | 2TLC172001C0202 6/52
6
Connection examples
HE3824E-01 Lightbeams with time-limited muting 0.240 s
HE3824C-01 Lightbeam with time-limited muting 0.240 s
6/53 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HG7611A Interlocked door with RT6 and pre-reset
HG7636B Focus light grid/curtain with three-position device
ABB Safety Handbook | 2TLC172001C0202 6/54
6
Connection examples
HG7646A Interlocked door with three-position device and time-limited entrance/exit
HG7636A Interlocked door with three-position device
6/55 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HG7658A Interlocked door with RT6 and output expansion JSR2A
HG7654A Interlocked door with RT6 and output expansion JSR1T
ABB Safety Handbook | 2TLC172001C0202 6/56
6
Connection examples
HG7674A Safety interlock switch JSNY9M/MLA with RT6
HG7673A Interlock switch JSNY8 with RT6
6/57 2TLC172001C0202 | ABB Safety Handbook
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Connection examples
HH0000C Three-position device JSHD4 with various safety controllers
HG7674B Safety interlock switch JSNY9S/SLA with RT6
ABB Safety Handbook | 2TLC172001C0202 6/58
6
Connection examples
HK7600A Safety mat/Contact strip with RT6
HI8552A Connection examples JSHT2 intermittent running
6/59 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HM0000A Magnetic switch JSNY7 with various safety controllers
HL7600B Several JSNY7 connected to one RT6 with unique indication
ABB Safety Handbook | 2TLC172001C0202 6/60
6
Connection examples
HP7600A Machine control - Isolation of PLC inputs and outputs
HN7660A Delayed outputs RT6 with output expansion JSR3T and RT7
6/61 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HR7200B Focus light curtain/beam
HP7600B Machine control-Isolation of PLC outputs
ABB Safety Handbook | 2TLC172001C0202 6/62
6
Connection examples
HT5400A Two-hand device with safety relay JSBR4
HR7800B Focus lightbeam/curtain
6/63 2TLC172001C0202 | ABB Safety Handbook
6
Connection examples
HB0008A Focus light curtain/light beam connected to an RT9 with the aid of a M12-3D
ABB Safety Handbook | 2TLC172001C0202 6/64
6
7/1 2TLC172001C0202 | ABB Safety Handbook
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ABB Safety Handbook | 2TLC172001C0202 7/2
7
Light curtains, Light grids and Light beams
Why use light grids and light curtains? 7/3
Reset - 3 alternatives 7/5
Muting and blanking 7/6
Light curtain for short safety distance 7/7
Cycle initiation with light curtain 7/8
Safety distance 7/9
Light curtains, Light grids
Focus II 7/11
Muting units - MF-T, MF-L 7/16
Muting sensors - Mute R 7/18
Muting accessories - FMC, FMI 7/20
Accessories - MFII mirrors 7/22
Light protection stand - Bjorn 7/23
Protection against water and dust - WET 7/25
Blanking program - BP-1 7/26
Connection examples Focus II 7/27
Safety Light Beam
Spot 7/34
Connection examples 7/37
7/3 2TLC172001C0202 | ABB Safety Handbook
7
Why use light grids and light curtains?
Light grids and light curtains are production friendly safety components that causes no physical obstruction for the
machine operator. Light barrier protection is also a good safety component to use when goods are to be passed in and
out of a hazardous area.
How does a light grid/light curtain work?
Both light grids and light curtains utilise optical transmitter
and receiver units. From the transmitters beams of infrared
light are sent to the receiver. When a light beam is interrupted
a dual stop signal is given to the dangerous machines inside
the light grid/curtain protected area.
What is the difference between a light curtain and a light
grid?
A light curtain has several beams that are placed closely to-
gether whereas a light grid consists of only one, two, three or
four light beams. The beams are closest on a light curtain that
is used for finger detection. Then the resolution is 14 mm. For
light grids the beams are normally placed at a relative distance
of 300 to 500 mm. The choice between light grid or light cur-
tain is often a question of available safety distance, reach and
price. Light curtains are often chosen for short safe/minimum
distances. Light grids are chosen for longer safe/minimum
distances, long range up to 40m and for a low price.
ABB Safety Handbook | 2TLC172001C0202 7/4
7
What safety requirements are there for a light protection
device?
High safety demands are stated in the standard EN61496-1
which deals with light protection. The main demands are on a
safe stopping function and that light from light sources other
than the transmitter or other disturbances do not affect the
safety function.
Depending on how the safety function is built up there are
safety components of type 2 and 4 to choose between. Type
2 and 4 relates in principle category 2/PLc and category 4/
PLe according to ENISO13849-1.
Type 4 which has the highest safety level, states that a fault is
not allowed to affect the safety function and that the fault shall
be detected by the outputs falling immediately or that they do
not re-connect after being disconnected. Maximum allowed
scattering angle for the light is 2.5.
Light grids for long distances Light grids with monitored by-
passing during material transport
Light curtain for short safe/minimum distances
Light curtain as area protection
Light curtain to protect during
cycle initiation
Type 2 states that a simple but monitored safety function is
required, which means that the safety function shall be moni-
tored through periodic tests which break the output when a
fault occurs. Between the testing times there can though be
faults which result in the safety component malfunctioning.
The test function can either be built into the safety device or
an external unit (e.g. the machines control system) can initiate
a test. Maximum allowed scattering angle for the light is 5.
Light grids and light curtains are included among the products
in the machine directives appendix 4, which means that an
external certifying procedure with an officially recognised
institution is called for.
Light curtain for inner area limiting
7/5 2TLC172001C0202 | ABB Safety Handbook
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1
2
A
a
b
B
Button 1 is pressed and afterwards, within a chosen time
e.g. 5 seconds, button 2 is pressed for resetting the light
beam.
Reset button with light indication.
A light beam b indicates that the robot is situated in
area A. In this position it is possible to walk in through
the gate to area B without stopping the robot.
Reset 3 alternatives
Supervised manual reset
When a light curtain/grid is interrupted it will give a stop signal
to dangerous machines within the hazardous area it protects
and a reset-lamp can be lit. For a new start of the machine
the light curtain/grid has to be reset. This is done with the
reset button which is placed where the whole hazardous area
can be supervised and can not be reached from within the
area which it protects.. There are high requirements on the
reset function - neither a short circuit nor a component fault
shall give automatic reset. When the reset button has been
set the outputs are activated and the reset-lamp is turned off.
Automatic reset
Automatic reset is used when the light beam is used for area
monitoring. When the light beam is actuated this indicates
that e.g. a robot is in the area. The robot is stopped if a per-
son enters the same area e.g. through a gate. When the light
beam is free again the control unit will be reset automatically.
Supervised time-reset
When supervised time-reset (pre-reset) is in use, its purpose
is not to allow a reset from outside the protected area without
first having confirmed that no-one is out of sight within the
area. To reset the light beam (see figure) button 1 must first
be pressed and afterwards button 2 within e.g. 5 seconds.
This is especially important when one cannot see the entire
area that is protected by the light beam.
ABB Safety Handbook | 2TLC172001C0202 7/6
7
Bypassing may be needed for different reasons. One of the
most common reasons for bypassing is during in and out
feeding of material on a conveyor, Automated guided vehicle
(AGV), etc. Another common application is bypassing while
passing with a three-position device to the hazardous area.
Important aspects for bypassing is that it shall be safe, not be
activated by mistake and be difficult to defeat. In other words
it shall give a reliable bypassing when a loading carrier enters
but not allow a human to pass. To achieve the highest safety
level a dual and supervised bypassing system is needed
(usually with at least two independent signals). If this is done
with sensors, it is recommended they be of different kinds,
because of the probability of them both malfunctioning for
the same reason e.g. common cause failure. An example of a
solution is to use a mechanical limit switch and a photo-cell
sensor.
To avoid deliberate defeating/manipulation of the bypassing
sensors/signals a safety relay or a safety-PLC is connected
thereby monitoring that the sensors are both activated and
deactivated in every bypassing cycle.
The number of variations in bypassing systems are almost
infinite. This depends on the specific requirements of each
plant/machine. For Focus II there are a number of bypassing
possibilities prepared.
Automatic bypassing of light grid when an Automated guided vehicle
passes.
Muting (bypassing)
Blanking
Blanking means permanent switching off of a number of be-
ams in the detection zone of a light curtain. This is a function
that is permitted and used when an object that is larger than
the resolution of the light curtain is permanently located in
the detection zone, without deactivating the safety outputs
(OSSD). If the object is removed from the detection zone, the
safety outputs are deactivated.
Blanking function has different tolerance settings that allow
movement or vibration of the objects that obscure the detec-
tion zone.
One tolerance setting can be called Floating blanking, that
means that the part of the zone which is intentionally blocked
can be moved around in the detection zone while the ma-
chinery is operating. Other beams are active and providing
normal protection, but often with reduced resolution.
When a blanking function is used, it is very important that
the light curtain provides protection and can detect objects,
as small as a finger or hand, depending on the resolution,
anywhere outside the zone that is rendered inactive because
the object is there. Blanking may require an additional fixed
guard and may require additonal minimum distance to the
dangerous movment.
It must not be possible to select the blanking function wit-
hout using a key, tool or similar unlocking device.
7/7 2TLC172001C0202 | ABB Safety Handbook
7
A light curtain can be used in a machine or a production
plant in the same way as a hatch. There is a great difference
though when it comes to the risk situation. When one has a
light curtain installed with a short minimum distance in front
of a dangerous machine, there is a high risk for spontaneous
engagement into the machine, often called after-grasp. If the
dangerous machine movement does not stop during such an
engagement, one has a small chance of avoiding injury.

Therefore it is of great importance that the whole chain in
the stopping circuit is dual and supervised. Even valves and
contactors which ultimately control dangerous movements
normally have to be doubled up and supervised.

Regulations concerning safety distances are given in specific
C-standards such as EN 692 for mechanical presses. If no
specific C-standard is available, EN ISO 13855 is used.
Automatic machines
For light curtains on automatic machines there shall be a reset
function which is active when the machine is set for automatic
production whether or not it is a passable protection. After
affected a light curtain, one must first use a reset function
then the restart of the cycle shall be made with a separate
starting device. The same reset applies for machines with
semi-automatic drive.
Operator protection during manually serviced machines
Manually operated machines where one or more operators
pick in and out parts between every cycle are the most risky
light curtain applications. This because of the number of en-
gagements into the machines hazardous area is often several
times per minute.
Light curtains on presses
Light curtains have traditionally been a common protection
method among press applications and there has since long
existed detailed information on the usage of light curtains on
presses. (see next spread for Cycle initiation with light cur-
tain). Only light curtains of type 4 are accepted on presses.
Reset
On the servicing side i.e. the side or sides where there is an
operator that picks in and out parts, there shall be a separate
reset function for the light curtain, usually a button. If there are
several light curtains e.g. on the front and back there shall be
one for each. If the light curtain is actuated during a dange-
rous movement the press shall not be able to restart without
being reset. During engagement after the end of the cycle no
reset is needed.
Hand resolution
Finger resolution
Light curtain for short safety distance
ABB Safety Handbook | 2TLC172001C0202 7/8
7
max 75 mm
Installation correct and incorrect during cycle initiation
Cycle initiation
Cycle initiation is a concept when the machine is designed
so that a new cycle initiated by affecting the light curtain. A
cycle is defined as the hand being placed in and taken out
once. Usually it is possible to choose between one-cycle and
two-cycle operation. During one-cycle a new action is started
when the light curtain has been actuated once and during
two-cycle when the light curtain has been actuated twice.
The operator thereby operates the machine by the action of
putting parts in and out.
On presses this Cycle initiation function is very common.
But because the press starts without any particular command
there are some risks involved and therefore many conditions
have to be met before the machine operates.
Smaller presses which cannot be entered have certain regu-
lations that means some limitations: The table height may not
be lower than 750 mm, the stroking length may not be larger
than 600 mm and the table depth may not be larger than
1000 mm. The light curtain shall have 30 mm or higher reso-
lution. If the press is not started within approx. 30 seconds
after the end of the cycle, a new cycle shall not be accepted
without the light curtain being again manually reset. NB. For
machines with cycle initiation, the installation of the light cur-
tain must be in accordance with machine parameters and all
relevant standards and regulations.
Correctly installed.
The operator cannot reach
into the machine without
actuating the light curtain.
Incorrect installation.
Gap below the light curtain.
The operator can reach into
the machine without actua-
ting the light curtain.
Incorrect installation.
Gap above the light curtain.
The operator can reach into
the machine without actua-
ting the light curtain.
Cycle initiation with light curtain
Correctly installed.
Light curtain complemented
with a horizontal light curtain
to detect the operator.
Installation of light curtain
The light curtain must be installed so no-one can reach a
trapping/crushing risk without actuating the light curtain.
The most important thing is that there are no gaps under, on
the sides and over the top during cycle operation. The lower
edge of the light curtain must therefore be slightly below the
press table edge. Also if it is open above the light curtain the
height must be adapted so that it is not possible to reach
over the detection zone (see ISO13855). Physical adjustment
possibilities must be limited so that dangerous motions are
placed out of reach.

Between the light curtains detection zone and mechanical
parts there shall only be max 75 mm gap to prevent a person
from standing there. In practise to achieve this demand and
the required safety distance one usually has to complement
with e.g. additional mechanical protection or additional
horizontally positioned light curtains i.e. step-in light curtain.
Another solution could be a lying or an angled light curtain.
7/9 2TLC172001C0202 | ABB Safety Handbook
7
Minimum distance for light protection according to EN ISO13855
The distance S is a minimum distance between a light curtain and a hazardous
area. The distance shall prevent that a person is not able to reach a hazardous ma-
chine part before the machine movement has stopped. This is calculated with the
formula from EN ISO13855 - Safety of machinery - Positioning of safeguards with
respect to the approach speeds of parts of the human body.
S = (K x T) + C
Minimum distances for vertical and horizontal installed light curtains according to EN ISO 13855
S = minimum distance in mm
H1 = the lower beam may not be situated higher than 300
mm above the ground
H2 = the upper beam may not be situated lower than 900 mm
above the ground
S = minimum distance in mm
H = the light curtain detection zone must be positioned bet-
ween 0 and 1000 mm above the floor
S = minimum distance in mm
K = body/part of body (e.g. hand) speed in mm/s
T = T1 + T2
where
T1 = the safety devices reaction time in seconds
T2 = the machines reaction time in seconds
C = additional distance in mm based upon the bodys intrusi-
on 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 curtains resolution in mm.
K here is 2000 mm/s which represents the speed of the hand.
The expression (8 x (d-14)) may never be less than 0. Mini-
mum distance S is 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 is1600 mm/s which represents the speed of the body. Mini-
mum 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 refe-
rence 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 minimum
height that the detection zone may be placed. This is calcula-
ted 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 1000mm.
When you use a horizontal light curtain as entry protection,
the depth of the light curtain shall be at least 750 mm to pre-
vent people from inadvertently stepping over it. The estimated
minimum distance is measured from the machines hazardous
section to the outermost beam of the horizontal light curtain
(seen from the machine).
Resolution for finger (14 mm) gives C = 0
NB If it is possible to reach the hazard zone by reaching over
the light beam, an addition is made to the formula. In table 1
in EN ISO 13855 an alternative safety distance addition (C
ro
) is
given to the formula S = (K x T) + C. The greatest value out of
C and C
ro
is to be used to prevent reaching the hazard zone
by reaching over the light curtain/grid.
ABB Safety Handbook | 2TLC172001C0202 7/10
7
Minimum distances for new and old presses
New presses
For new CE-marked presses there are specific requirements
from the standards EN 692 Machine tools Safety Mecha-
nical presses Safety and EN 693 Machine tools Safety
Hydraulic presses.
The same requirements apply for vertical installation on pres-
ses as with vertical installation on other machines with the
difference that C is given according to the following:
Other manually serviced machines
The rules for presses may well be applied to other machines
which function in a similar way and that have the same risk
situation. There is no other standard which is as detailed on
the usage of light curtains.
For cycle initiation the light curtains resolution, d, must be
30 mm. This applies to both old and new (CE-marked)
presses.
Old presses
NB For old presses there are different rules for each
country.
The formula that applies here is:
S = (2500 x T) + C
The minimum distance addition C for different resolutions of
the light curtain is given in the following table
Minimum distance for light beams according to EN ISO 13855
For light beams the minimum distance is calculated from the
following:
S = (1600 x T) + 850 mm
NOTE! The additional distance will in most cases be more
than 850 mm due to the possibility to reach over a light beam.
(C
ro
)

The formula applies whether one installs 2,3 or 4 beams. It is
the risk assessment that decides the number of beams that
are to be chosen. The following possibilities must be conside-
red.
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:
Number of beams Height over the reference plane, e.g.
ground
4 300, 600, 900, 1200
3 300, 700, 1100
2 400, 900
Resolution,
d, (mm)
Minimum distance
addition, C (mm)
Cycle
initiation
14 0
Permitted >14 - 20 80
>20 - 30 130
>30 - 40 240
Not
permitted
>40 850
Resolution,
d, (mm)
Minimum distance
addition, C (mm)
<16 0
16 70
20 110
25 130
30 140
35 240
40 270
45 300
50 330
55 360
>55 850
7/11 2TLC172001C0202 | ABB Safety Handbook
7
A light grid/light curtain with many possibilities
Focus II is a new version of our previous light grid/light curtain
Focus. Features such as muting and override are standard
in all Focus II light curtains and light grids. For light curtains,
blanking and break functions are also standard. The optical
sensors on Focus II also have variable coding. The Focus II
units are light grids/curtains with safety functions intended for
applications where it is of great importance to protect persons
from a dangerous machine, robot or other automated systems
where it is possible to access to a hazardous area.
Focus II creates a detection zone with infrared beams. If any
beam is interrupted the safety mechanism is triggered and the
dangerous machine is stopped. Focus II fulfills the require-
ments for non-contact safety equipment type 4 according to
the international regulation standard EN 61496-1.
Units are available with safety heights between 150 and 2400
mm. All electronic control and monitoring functions are inclu-
ded in the light curtain profiles. External connection is made
via a M12 connection at the end of the profile. Synchronizati-
on between transmitter and receiver is achieved optically. No
electrical connection between the units is required. Control
and monitoring of the beam transmission is carried out by two
micro-processors which also give information on the status
and alignment of the light curtain via several LEDs.
Muting and Override included in all Focus II
The Muting and Override functions are available on all
Focus II light grids/curtains and is enabled directly when an
indication lamp LMS is connected. Muting implies that one or
more segments or the whole light curtain can be bypassed
during in and out passage of material.
In the Focus II with muting enabled there is also an Override
function which makes it possible to bypass the light grid/
curtain i.e. activate the outputs if a machine start is necessary
even if one or more light beams are interrupted. This is the
case when the muting function is chosen and the A and B in-
puts are activated. If for example during the muting operation
a loading pallet has stopped inside the detection zone after a
voltage loss, the override function is used to enable the pallet
to be driven clear.
Safety Light Grids and Safety Light Curtains
Focus II
Approvals:
Application:
Optical protection in an ope-
ning or around a hazardous
area
Features:
Type 4 according to
EN61496
Flexible assembly
LED indication
High protection class (IP65)
Range 0.2-40 m
Time reset
Fixed / floating blanking
Muting
Single/Double Break funktion
External Device Monitoring
(EDM)
Available with different
resolutions
Up to PL e according to
ENISO13849-1
ABB Safety Handbook | 2TLC172001C0202 7/12
7
Blanking
It is also possible to obtain the Focus II light curtains with
blanking. Floating blanking is a tolerance setting that makes it
possible to disconnect a dened number of beams from the
detection zone. The object is then free to move in the detec-
tion zone without the safety function being triggered. Other
tolerance settings allows less movment of the interfering object.
Blanking may require an additional xed guard and may require
additonal minimum distance to the dangerous movment.
Safety outputs OSSD1 and OSSD2
Focus II has two PNP outputs - OSSD1 and OSSD2. If the
load to be switched is alternating current or requires a higher
current than 500 mA then one should use a safety relay e.g.
RT9, Pluto PLC or the FRM-1 unit (converts the outputs to
relay contacts) from ABB JokabSafety. The FMC-Tina and
Tina 10A/10B/10C converts the outputs to a dynamic signal
for connection to Pluto or Vital. Pluto can also work directly
with the OSSD-outputs.
Single/Double Break function
This function is used for presses when the operator prepares
or picks out a detail. With the Single Break function the light
curtain allows operation after entry and withdrawal out of the
curtain. Similarly, the Double Break function allows operation
after entry and withdrawal twice.
External Device Monitoring (EDM)
In all light grids and light curtains an EDM function is available
which allows Focus II to test if the external control element
responds correctly. A test channel is connected through the
respective contactor, in order to detect any faults and thereby
prevent a reset.
Reset
On every Focus II there are inputs for reset. The reset option
is chosen through dual switches in the Focus II receiver. At
delivery, Focus II is set to automatic reset.
Automatic reset When the detection zone is free the
outputs are closed directly. (Setting when delivered).
Manual reset When the light field detection zone is free,
the reset button has been actuated before the outputs are
activated.
Time reset To reset the Focus II a pre-reset button must
first be actuated and afterwards within 8 seconds a reset
button outside the hazardous area must be actuated.
Focus II light grid
Standard:
Muting (bypassing) of one, two, three or four beams
Supervised output for muting lamp
Override
Manually supervised or automatic reset
Time-reset.
EDM
Option:
Light grids for tough environments with parallel beams of
light for improved reliability.
Focus II light curtain
Standard:
Muting (bypassing) partly or completely
Supervised output for muting lamp
Override
Manually supervised or automatic reset
Time-reset
Blanking
Single/Double Break
EDM
With the switches at the
bottom of Focus II you can
choose the function you
desire.
JSM 66
2TLA022090R1300
JSM 66 Bracket for Focus II
7/13 2TLC172001C0202 | ABB Safety Handbook
7
Standard With Tina 10A/10B/10C or FMC-Tina
NOTE! For ordering data and article number see the product list. For more information see the manual on our home page.
Focus ll light curtain/grid, Type 4 (FII-4)
Summary
Model name FII-4-14-zzzz FII-4-30-zzzz FII-4-K4-zzzz FII-4-K3-800 FII-4-K2-500 FII-4-K4-zzzz D FII-4-K3-800 D FII-4-K2-500 D FII-4-K2C-zzzz FII-4-K2C-800 FII-4-K1C-500
Resolution
14 30
Beam distance
300 400 400 500 300 400 400 500 300 400 400 500
Height (mm=zzzz)
150
300
450
600
750
900
1050
1200
1350
1500
1650
1800
1950
2100
2250
2400
150
300
450
600
750
900
1050
1200
1350
1500
1650
1800
1950
2100
2250
2400
900 1200 800 500 900 1200 800 500 900 1200 800 500
Range (m)
SR
LR
0.2-3
3-6
0.2-7
7-14
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-7 0.5-8 0.5-12
Reaction time off (ms) 18-103 14-47 13 13 13 13 13 13 13 13 13
Reaction time on (ms) 138-104 141-119 142 142 142 142 142 142 142 142 142
Manual reset
Automatic reset
Pre reset
Muting inputs
Muting lamp supervision
Override
Muting T/L/X
Blanking 3 types
Single/Double break
EDM
Dyn. Adaption to Vital/Pluto
ABB Safety Handbook | 2TLC172001C0202 7/14
7
Model name FII-4-14-zzzz FII-4-30-zzzz FII-4-K4-zzzz FII-4-K3-800 FII-4-K2-500 FII-4-K4-zzzz D FII-4-K3-800 D FII-4-K2-500 D FII-4-K2C-zzzz FII-4-K2C-800 FII-4-K1C-500
Resolution
14 30
Beam distance
300 400 400 500 300 400 400 500 300 400 400 500
Height (mm=zzzz)
150
300
450
600
750
900
1050
1200
1350
1500
1650
1800
1950
2100
2250
2400
150
300
450
600
750
900
1050
1200
1350
1500
1650
1800
1950
2100
2250
2400
900 1200 800 500 900 1200 800 500 900 1200 800 500
Range (m)
SR
LR
0.2-3
3-6
0.2-7
7-14
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-20
20-40
0.5-7 0.5-8 0.5-12
Reaction time off (ms) 18-103 14-47 13 13 13 13 13 13 13 13 13
Reaction time on (ms) 138-104 141-119 142 142 142 142 142 142 142 142 142
Manual reset
Automatic reset
Pre reset
Muting inputs
Muting lamp supervision
Override
Muting T/L/X
Blanking 3 types
Single/Double break
EDM
Dyn. Adaption to Vital/Pluto
7/15 2TLC172001C0202 | ABB Safety Handbook
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Technical data Focus ll
Article number
Light curtains
FII-4-14-150 2TLA022200R0000
FII-4-14-300 2TLA022200R1000
FII-4-14-450 2TLA022200R2000
FII-4-14-600 2TLA022200R3000
FII-4-14-750 2TLA022200R4000
FII-4-14-900 2TLA022200R5000
FII-4-14-1050 2TLA022200R6000
FII-4-14-1200 2TLA022200R7000
FII-4-14-1350 2TLA022200R8000
FII-4-14-1500 2TLA022200R9000
FII-4-14-1650 2TLA022201R0000
FII-4-14-1800 2TLA022201R1000
FII-4-14-1950 2TLA022201R2000
FII-4-14-2100 2TLA022201R3000
FII-4-14-2250 2TLA022201R4000
FII-4-14-2400 2TLA022201R5000
FII-4-30-150 2TLA022201R6000
FII-4-30-300 2TLA022201R7000
FII-4-30-450 2TLA022201R8000
FII-4-30-600 2TLA022201R9000
FII-4-30-750 2TLA022202R0000
FII-4-30-900 2TLA022202R1000
FII-4-30-1050 2TLA022202R2000
FII-4-30-1200 2TLA022202R3000
FII-4-30-1350 2TLA022202R4000
FII-4-30-1500 2TLA022202R5000
FII-4-30-1650 2TLA022202R6000
FII-4-30-1800 2TLA022202R7000
FII-4-30-1950 2TLA022202R8000
FII-4-30-2100 2TLA022202R9000
FII-4-30-2250 2TLA022203R0000
FII-4-30-2400 2TLA022203R1000
Light grids
FII-4-K2-500 2TLA022204R0000
FII-4-K3-800 2TLA022204R1000
FII-4-K4-900 2TLA022204R2000
FII-4-K4-1200 2TLA022204R3000
FII-4-K2-500D 2TLA022204R4000
FII-4-K3-800 D 2TLA022204R5000
FII-4-K4-900 D 2TLA022204R6000
FII-4-K4-1200 D 2TLA022204R7000
FII-4-K1C-500 2TLA022204R8000
FII-4-K2C-800 2TLA022204R9000
FII-4-K2C-900 2TLA022205R0000
FII-4-K2C-1200 2TLA022205R1000
Supply voltage 24VDC 20%
Power consumption
Transmitter
Receiver
Protective height
Object resolution
70 mA maximum
100 mA maximum
Light curtains: 150 mm - 2400 mm
Light grids: 500 mm - 1200 mm
Light curtains: 14 mm and 30 mm
2
2
,
3
0
18,50
37
4
8
1
6
,
7
0

1
8
PFH
D
2.5x10
-9
Light source Infrared Emitting LEDs, Wavelength
880 nm
Enclosure Housing: Aluminium painted yellow
Front: Polycarbonate
Connector: Polyamide
End cap: Polyamide
Prole dimensions 37 x 48 mm
Protection class IP65
Operating temperature -10 to +55 C
Storage temperature -25 to +70 C
Safety outputs (OSSD) Two PNP safety outputs, each sour-
cing 500 mA 24 VDC. Short circuit
protection.
Response time ON to OFF Maximum: 13-103 ms
(depending on model)
Connection transmitter M12 5-pin male
Connection receiver M12 8-pin male
Indication LEDs on transmitter and receiver
indicating alignment, dirt, power
supply and outputs
Safety level
EN/IEC 61496
EN ISO 13849-1
IEC 61508
Type 4
PL e/Cat. 4
SIL 3
Conformity EN ISO 12100-1:2010, EN ISO
13849-1:2008, EN 62061:2005, EN
60204-1:2007+A1:2009, EN 61496-1/
AC:2010, EN 60664-1:2007, EN
61000-6-2:2005, EN 61000-6-4:2007
ABB Safety Handbook | 2TLC172001C0202 7/16
7
F
o
c
u
s
ll
F
o
c
u
s
ll
Focus MF-L Focus MF-T
Built-in muting for Focus II is available in three ways:
Pre-made muting units MF-T and MF-L, which have integral
photocells.
Connection of muting sensors via a FMC.
Separate connection of muting sensors (MuteR) directly to
the Focus II receiver unit.
Muting-lamp
To the Focus II receiver unit it is also possible to directly con-
nect a external muting-lamp. It is also possible to connect the
muting-lamp via a FMC. During bypassing the muting-lamp is
lit. Bypassing is only possible if the muting-lamp is functioning
or a resistor of 220 Ohm is used in its place.
MF-T and MF-L are muting units with integrated photocells
built into a aluminum profile. They work with all Focus II light
grid and curtain. No additional sensors are required because
the muting units contain the required components. MF-T/MF-L
is connected between the Focus II and the supervising unit
(e.g safety relay, safety PLC). The cable between the Focus II
and MF-T/MF-L is included with the muting unit.
Muting with MF-T and MF-L units
MF-T
The muting unit MF-T consist of a transmitter unit and a
receiver unit with four photocells A1, B1, B2 and A2. A1 and
A2 are connected in parallell and B1 and B2 connected in
parallell. In this way the unit is congured for installations where
material is transported into and/or out of a hazardous area.
MF-L
The muting unit MF-L consist of a transmitter unit and a
receiver unit with two photocells A1 and B1. The A1 and
B1 sensor are actuated before the material is transported
through the light grid/curtain. The light grid is an active
part in upholding the muting function once A1 and B1 have
been passed by the material. The light grid/curtain is being
bypassed just as long as the material exiting. Unit MF-L is
primarily intended for material transport out of a hazardous
area.
MF-T Reflex
The muting unit MF-T Reex consist of a transmitter/receiver
side and a reector unit. The active side contains four transmit-
ters/receivers photocells. The MF-T Reex works as the MF-T
with a limited range (6m). These units, together with a light grid
with one active and one passive side provides a good solution
were electrical connections is only necessary on one side!
MF-L Reflex
The muting unit MF-L Reex consist of a transmitter/receiver
unit and a reector unit. The active side contains two transmit-
ters/receivers photocells. The MF-L Reex works as the MF-L
with a limited range (6m). These units, together with a light grid
with one active and one passive side provides a good solution
were electrical connections is only necessary on one side!
M12 connection between
Focus II and MF-T Reflex
out from
hazardous area
MF-L
out/in from
hazardous area
MF-T
Focus II
Muting (bypassing)
Focus II muting types
T-muting. Four NO muting sensors are used in two pairs
(OR function), allowing bi-directional transport of material.
Maximum muting time is 600 s. Muting A and Muting B
need an activation time difference of 30 ms.
L-muting. Two NO muting sensors works together with the
light protection, allowing transport out from the hazardous
area. Maximum muting time is 600 s. Muting A and Muting
B need a activation time difference of 30 ms.
X-muting. One NO and one NC muting sensor is like a
cross through the light protection, allowing bi-directional
transport of material. An alternative X-muting (only on Fo-
cus Light beams) with 2 NO muting sensor is also possi-
ble, but then with the condition of a 30 ms activation time
difference on the muting sensors. Both solutions gives an
infinite muting time.
7/17 2TLC172001C0202 | ABB Safety Handbook
7
Focus II
Muting with MF-T and MF-L
A solution with Focus Muting unit MF-T with integrated muting sensors.
A solution with Focus Muting unit MF-L with integrated muting sensors
NOTE! The muting sensors A and B must be placed so that the sensor A is always
activated at least 30 ms before sensor B.
D: indicates the minimum length of the material that is to actuate the muting sen-
sors that must be maintained during the passage through the light grid/curtain.
d2: indicates the measurement between the two/four pre-assembled muting sen-
sors within the MF-L and MF-T.
This solution shall only be used for movement out from a hazardous area.
Possible direction of movement - in/out of hazardous area.


A1 B1
d2 = 260 mm
D = 300 mm
Hazardous area
Hazardous area
ABB Safety Handbook | 2TLC172001C0202 7/18
7
10...30 VDC
PNP
dark-on output
FSTR 1
1
4
2
3
R
l
10...30 VDC
PNP
1
2
3
4
Muting sensors Mute R
Retro-reflective with polarizing filters
Technical data
Article number
Mute R (FSTR-1) 2TLA022044R0000
Output PNP, dark on
Connection Connector M12
Range adjustment Yes
Range 0.15... 2.5 m (with reector FZR 1)
0.15...5m (with reector FZR 2A)
Light source Visible-red, 660 nm, pulsed with
polarizing lter
Supply voltage 10...30 VDC
Allowable ripple 10% of Us
Current consumption (without
load)
<15 mA
Max. load current 100 mA
Residual voltage <1.6 V
Max. switching frequency 1000 Hz
Protection class IP67
Temperature
(operating and storage)
-25 to +65 C
Weight approx. 15 g
All technical data at 25 C and 24V.
1 (+) Supply voltage 10...30 V
4 Dark-on output
3 (-) Supply voltage
Dark-on output
The output is activated when
an object interrupts the light.
Connector M12
1. Connector M12
2. Range adjustment and
function indicator
3. Plastic housing
PNP output
Dark-on output
FZR 1 2TLA022044R0100
Reflector 80mm incl.screw
MC6S M5x14 +Locking nut
M5.
FZR 2A 2TLA022044R0400
Reflector 100x100mm incl.
screw MC6S M5x14 +Lo-
cking nut M5.
Approvals:
Features:
Range adjustable
Light reserve warning indictor
Transistor output, PNP
1000 Hz switching frequency
Short-circuit protection,
reverse polarity protection
and power-up output
suppression
Connector M12
EMC tested according to
IEC 801 and EN50081-1/
EN50082-2
m
a
x
.
1
5
7/19 2TLC172001C0202 | ABB Safety Handbook
7
Muting with Mute R
A solution with two sensors and one movement direction for material transport:
A solution with four sensors and two movement directions for material transport:
D: indicates the minimum length on the material that is to
actuate the muting sensors that must be maintained during
the passage through the light grid/curtain.
d1 must be as short as possible, and denitely less than 200 mm
d2: indicates the distance between A1 and B1

A1 B1
S
A2 B2
d2
D
D
d1
d1 < 200mm
d2 > 250mm
D=(d1x2)+d2+40

A solution with four sensors and one movement direction for material transport:
Possible direction of movement - IN.
Hazardous area

A1 B1
S
B2 A2
d2
D
D
d1
d1 < 200mm
d2 > 250mm
D=(d1x2)+(d2x2)+40

Possible direction of movement - IN/OUT.
Hazardous
area

A
S
B
d3
d4
Possible direction of movement - IN (Even IN/OUT is possible)
Hazardous area
d3 > 500 mm
d4 the least possible
S = safety light curtain/light grid
d1 > 200 mm
d2 > 250 mm
D = (d1x2)+d2+40
d1 > 200 mm
d2 > 250 mm
D = (d1x2)+d2+40
ABB Safety Handbook | 2TLC172001C0202 7/20
7
Various FMC, FMI, FRM- versions and Tina units
The Tina-versions have dynamic safety outputs for Vital/Pluto.
Muting accessories
FMC and FMI units
Model Description
FMC-1(2) with connectors for muting sensors (A+B),
reset, power off and muting lamp (R) and
muting lamp (M).
FMI-1A with muting lamp only.
FMI-1B with reset, power off and muting lamp.
FMI-1C with reset and power off.
FMI-1D with reset, power off and internal resistor for
the muting lamp.
FMI-1E as pre reset connected to connector A (A2)
on FMC-1(2) (Tina).
FMI-1G with reset, and internal resistor for the muting
lamp.
FMC-1
(2) Tina
same as FMC-1(2) but connected to Vital or
Pluto.
Tina 10A adaptor unit for connecting Focus II to Vital
or Pluto.
Tina 10B simplied FMC-1(2) Tina including only the
connector (R).
Tina 10C simplied FMC-1(2) Tina including only power
supply on con.no.3.
FRM-1A translates the two OSSD outputs to relay
outputs (and power supply).
JS SP-1 protection plug for not used connectors.
JS AP-1 adaptor for FMC units to use instead of
FMI-1B or -1D on the (R) connector including
muting resistor.
Approvals:
Application:
FMC: Muting connection box
FMI: Muting Indicator
Features:
Small
Easy to connect
7/21 2TLC172001C0202 | ABB Safety Handbook
7
Connection of Focus II and muting components as FMC and FMI
Ex 1. Connection of light curtain with connection block FMC-
1, test/reset button and switch for supply voltage placed in
(by) the control cabinet.
Ex 2. Connection of light curtain with connection block FMC-
1. The Reset unit FMI must be placed out of reach from the
hazardous area.
Connection of Focus II and muting components directly
to the control cabinet
The TEST /RESET button shall be placed so the opera-
tor can see the protected area during reset, testing, and
bypassing. It shall not be possible to reach the button from
within the hazardous area.
The LMS lamp for indication of muting and bypassing shall
be placed so that it can be seen from all directions from
where it is possible to access the hazardous area.
If photocells are used as muting sensors then the sensor
receivers shall be assembled on the light curtains transmit-
ter side to minimise the interference risk.
The system is protected against dangerous functions
caused by damage on the transmitter cable and/or the
receiver cable. However, we recommend that the cables be
protected so that physical damage to them can be mini-
mised.






Muting lamp
Connection
unit FMC-1
Muting
photocells
Cabinet
Power
off
Test/Reset









Muting lamp
Test & reset
buttons
Protect
cables
Cable to
lamp
Supply
cable
Muting
cable
FR-cable
FT-cable






FMI
Muting
photocells
Muting lamp
Connection
unit FMC-1
Cabinet
Power
off
Reset
Muting with FMI and FMC
ABB Safety Handbook | 2TLC172001C0202 7/22
7
2
0

2
2
0
R
5,50
260
1
7
0
10
Bracket for MFII
mirrors. 2 pcs
needed for each
mirror.
JSM 70, 2TLA040001R1500.
Plate for easy adjustment on uneven floors.
Technical data Mirrors
Type Article No
Height mirror
glass, mm
Height total,
mm
MFII-300 2TLA022041R0200 356 361
MFII-450 2TLA022041R0300 506 511
MFII-600 2TLA022041R0400 653 658
MFII-750 2TLA022041R0500 796 801
MFII-900 2TLA022041R0700 953 958
MFII-1050 2TLA022041R1200 1103 1108
MFII-1200 2TLA022041R0800 1253 1258
MFII-1350 2TLA022041R1300 1403 1408
MFII-1500 2TLA022041R0900 1546 1551
MFII-1650 2TLA022041R1000 1703 1708
Bracket for
MFII mirrors.
2TLA022041R2000
Accessories
Adjustment plate
MFII mirrors for light curtain
7/23 2TLC172001C0202 | ABB Safety Handbook
7
Bjorn is a very stable and flexible stand system in which Focus II safety light grids/
curtains and mirrors are mounted in the stand. The fixings for the mirrors in the
stand can be turned to provide either vertical or horizontal angles. The robust
material of the Bjorn protects Focus II units from direct collisions, and thus prevents
unnecessary material damage and halts in production.
Light protection stand
Bjorn
M3
M2
M4
M1
Receiver
Transmitter
Bjorn N2
Bjorn H2
horizontal
Bjorn V2
vertical
Application:
Protects light curtain, light
grids and mirror
Features:
Robust
Adjustable
ABB Safety Handbook | 2TLC172001C0202 7/24
7
1
5
4
3
181
1
4
4
230
1
9
0
Bjorn N2
2TLA022041R4500
Bjorn N3
2TLA022041R4600
Bjorn N4-1
2TLA022041R4700
Bjorn N4-2
2TLA022041R4700
Bjorn N5
2TLA022041R4900
Bjorn H2
2TLA022041R4000
Bjorn H3
2TLA022041R4200
Bjorn H4-1
2TLA022041R4300
Bjorn H4-2
2TLA022041R4400
Bjorn V2
2TLA022041R4100
Technical data Bjorn
Article number
Bjorn H2
Bjorn V2
Bjorn H3
Bjorn H4-1
Bjorn H4-2
Bjorn N2
Bjorn N3
Bjorn N4-1
Bjorn N4-2
Bjorn N5
H = Horizontal reection
V = Vertical reection
N = For the light guard unit
2TLA022041R4000
2TLA022041R4100
2TLA022041R4200
2TLA022041R4300
2TLA022041R4400
2TLA022041R4500
2TLA022041R4600
2TLA022041R4700
2TLA022041R4800
2TLA022041R4900
Colour Yellow powder-coated (RAL 1018)
Material 3 mm steel
Dimensions
Cross section
Foot
146 mm x 130 mm
230 mm x 190 mm
Weight
N2
H2, V2
N3
H3, N4-1
H4-1
N4-2:
H4-2
N5
14 kg/piece
15 kg/piece
17 kg/piece
18 kg/piece
20 kg/piece
22 kg/piece
24 kg/piece
27 kg/piece
Mirror reduction ~10 % per mirror
7/25 2TLC172001C0202 | ABB Safety Handbook
7
Protection against water and dust
WET
WET is used for protection against water (or dust) where
extreme washing conditions are encountered. The protective
encapsulation rating (IP68) now enables Focus II light curtains
and light grids to be used for such applications as the food
industry where the use of high pressure washing for cleaning
machinery often occurs.
WET, with Focus II light curtains or light grids, is pre-assem-
bled complete with cabling, on request. During installation
on a machine a WET unit can be adjusted by 20 with the
accompanying angle bracket.
Technical data WET
Article number
WET-150 FII 2TLA022038R4000
WET-300 FII 2TLA022038R4100
WET-450 FII 2TLA022038R4200
WET-600 FII 2TLA022038R4300
WET-750 FII 2TLA022038R4400
WET-900 FII 2TLA022038R4500
WET-1050 FII 2TLA022038R4600
WET-1200 FII 2TLA022038R4700
WET-1350 FII 2TLA022038R4800
WET-1500 FII 2TLA022038R4900
WET-1650 FII 2TLA022038R5000
WET-1800 FII 2TLA022038R5100
WET-K-500 FII 2TLA022038R5200
WET-K-800 FII 2TLA022038R5300
WET-K-900 FII 2TLA022038R5400
WET-K-1200 FII 2TLA022038R5500
WET-L FII 2TLA022038R5600
WET-T FII 2TLA022038R5700
Colour Transparent plastic
Length including lid light curtain/light grid + 54mm
Material
Tube
Lid
Angle bracket
PC
PEHD-300
Stainless steel
Max. ambient temperature +55C
Installation adjustment 20
Protection rating IP68 (IP69K)
Application:
Protection in severe
environments
Features:
Adjustable
IP68
ABB Safety Handbook | 2TLC172001C0202 7/26
7
Blanking programmer
BP-1
Technical data BP-1 Blanking programmer
Article number
BP-1 Blanking programmer 2TLA022090R2300
Colour yellow and black
Programming blanking is made easy by using the Blanking
programmer BP-1. The BP-1 is easily connected between
the receiver unit of the light curtain and the cable otherwise
connected to the receiver. The blanking object is placed in
the light curtain detection zone and the button on the BP-1 is
then pressed. 11 seconds later blanking is programmed for
the object.
If the object needs to be changed a new programming is
needed.
The unit can stay fitted during operation if required.
Application:
Program blanking
Features:
Easy to connect
Can stay fitted during
operation
7/27 2TLC172001C0202 | ABB Safety Handbook
7
Connection examples
HR7000E-01 Focus II - Connection with pre-reset function
HR7000C-01 Focus II - Connection without and with muting function
ABB Safety Handbook | 2TLC172001C0202 7/28
7
Connection examples
HR7000G-01 Focus II - Connection with MF-T/MF-L units
HR7000F-01 Focus II - Connection with muting to safety relay
7/29 2TLC172001C0202 | ABB Safety Handbook
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Connection examples
FMC - Connection possibilities
HR7000H-01 Focus II - Connection with FMC/Tina Interface
ABB Safety Handbook | 2TLC172001C0202 7/30
7
Connection examples
HR7000K-01 FMC-1 or FMC-1 Tina connected with Pre-Reset
HR7000J-01 FMC-1 or FMC-1 Tina with muting sensors and reset unit
7/31 2TLC172001C0202 | ABB Safety Handbook
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Connection examples
HR7000M FRM-1 - Changing OSSD outputs to relay contacts
HR7000L-01 Tina 10A, 10B and 10C connection example
ABB Safety Handbook | 2TLC172001C0202 7/32
7
Connection examples
HR7000P Cable connection example
HR7000O-01 Connection example FMC/FMI
7/33 2TLC172001C0202 | ABB Safety Handbook
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Connection examples
HR7000S Focus II; Muting with the aid of Pluto, FMC and a transfer cable
HR7000Q Cable connection example
ABB Safety Handbook | 2TLC172001C0202 7/34
7
*
*
10 m
35 m
10 m
35 m
Transmitter 1 Receiver 1
Spot T Spot R
Transmitter 2 Receiver 2
Spot T Spot R
Coded
pulse
transmission
Coded pulse transmission
24VDC This supply does
not need to be the same as
connected to the Vital.
Vital Safety controller can accomodate
up to 6 Spot systems.
A light beam for the highest safety level
The light beam is available in two versions Spot 10 for distan-
ces up to 10 m and Spot 35 for up to 35 m . The light beams
can be mounted at different heights and be angled around a
machine using our mirrors and brackets.
Spot and Vital/Pluto in combination fulfils the requirements for
PLe according to EN ISO 13849-1 and type 4 according to
EN 61496. Several light beams, Eden sensors and emergency
stops can be connected in series achieving the high safety
level for the safety circuit. A number of solutions for bypassing
of light beams for material transport are available.
For indication there are LEDs on the transmitter and on the
receiver which indicate contact between transmitter and re-
ceiver and safety status. The contact information is available
via the light beam receiver connection cables.
Function
The Spot light beam is supervised by the Vital safety controller
or by the Pluto safety-PLC. A unique coded signal is sent
out from the control unit to the transmitter (Spot T). The
signal which comes back from the receiver (Spot R) is then
compared in the Vital/Pluto. If the correct coded signal is
received the Vital/Pluto switches the necessary safety output
contacts to permit dangerous machine movements. Coding
guarantees that no output signals can be produced by light
from other sources, interference or faults in components in
the transmitter or receiver. The light beam is dynamically
Coded pulse transmission
*
Safety Light Beam
Spot
Approvals:
Application:
Photoelectric guarding of an
entrance or around a risk area
Features:
Safety level Type 4 according
to EN 61496
Versatile mounting
LED indication
IP67
10 m or 35 m range
Bypassing possibility
Light beam, emergency
stop and Eden in the same
safety circuit together with
Vital/Pluto achieves PLe
according to ENSO13849-1
supervised which means that if the signal stops pulsating at
the correct frequency it is immediately detected. By means of
coding, the dynamic signal can pass between up to 6 pairs of
transmitters and receivers, with only one pair needing to be
electrically connected to a Vital.
TV
NORD
7/35 2TLC172001C0202 | ABB Safety Handbook
7
R
T
Spot
Mounting and alignment
Safety distance
The basic principle is that dangerous machine movements
should be stopped before a person reaches the dangerous
area, which should be at least 850 mm from the light beams.
When determining the correct safety distance the stopping
time of the machine and the risk level must be taken into ac-
count (see also ENISO13855).
Accessories and Mounting
The Spot light beam can be mounted using a variety of bra-
ckets, posts and mirrors.
Alignment
When aligning the light beam, look towards the transmitter. In
the lens will be seen a strong red light. When this light is seen
from the receiver (via mirrors if fitted) the light beam is basi-
cally aligned. The LED on the receiver is on when the receiver
is aligned with the transmitter. By moving the transmitter up/
down and left/right the best alignment can be found.
When vertically mounting, (as shown in the diagram) the
receiver should be mounted above the transmitter as this will
simplify the alignment and minimise the risk of extraneous light
disturbance. In exceptional light disturbance environments
the received light can be adjusted by a screw on the rear
of the Spot 35 receiver. On Spot 10 this adjustment can be
made on the transmitter.
Different sizes of mirrors, mounting brackets and profiles are
available.
NOTE! Every mirror reduces the sensing distance of the beam
by approx. 20%.
JSM64
Pivot M18 bracket for Spot10
or MUTE R (FSTR1) for example
ABB Safety Handbook | 2TLC172001C0202 7/36
7
Technical data - Spot
Article number
Spot 10 T/R
Spot 35 T/R
2TLA020009R0600
2TLA020009R0500
Safety level
EN/IEC 61496
EN ISO 13849-1
Type 4 with Vital/Pluto
PL e/Cat. 4
PFH
D
1.14x10
-8
Power supply 17 27 VDC, ripple 10%
Current consumption
Transmitter
Receiver
< 25mA
< 15mA
Output currents
Info. output
Dynamic signal out
10mA max.
30mA max.
Light source Red visible light, 660 nm, <2
Optical power
Spot 10
Spot 35
< 0.1 mW
< 0.2 mW
LED indication
Green LED on transmitter (power)
Green LED on receiver status
On
Flashing
Off
Power supply OK
Alignment OK, safety circuit closed
Alignment OK, earlier safety
circuit open
Beam interrupted, safety circuit open
Protection class IP67
Range
Spot 10
Spot 35
0 - 10 m
0 - 35 m
Range adjustment
Spot 10
Spot 35
Trim pot. on transmitter
Trim pot. on receiver
Installation
Spot 10
Spot 35
2xM18 nuts (provided)
Either via mounting holes in the
casing or with angle bracket JSM63
(provided)
Operating temperature range -25C +65C
Cable connection M12 xed connector
Casing Material
Spot 10
Spot 35
Steel housing with polyacryl lens
protection.
Polyamide housing with polyacryl
lens protection.
Colour
Spot 10
Spot 35
Steel grey
Yellow/black
Weight
Spot 10
Spot 35
2x21 g
2x100 g
Connections
Transmitter:
Brown (1)
White (2)
Blue (3)
Receiver:
Brown (1)
White (2)
Blue (3)
Black (4)
Grey (5)
+24 VDC
Dynamic signal in
0 VDC
+24 VDC
0 VDC
Dynamic signal out
Info output
24 VDC when LED is green or as-
hing (tolerance -2 VDC)
0 VDC when LED is off (tolerance
+2 VDC)
Conformity EN ISO 12100:2010, EN ISO
13849-1:2008, EN 62061:2005,
EN 61508:2010, EN 60204-
1:2006+A1:2009, EN 61496-
1:2004+A1:2008, EN 60664-1:2007,
EN 61000-6-2:2005, EN 61000-6-
4:2007
Certications TV Nord, cCSAus
7/37 2TLC172001C0202 | ABB Safety Handbook
7
Connection examples
HA3306D Vital 1 with 3 lightbeams Spot
HD3800A-01 Connection of Spot T/R to Vital1
*For more connection examples see chapters for Vital or Pluto
ABB Safety Handbook | 2TLC172001C0202 7/38
7
8/1 2TLC172001C0202 | ABB Safety Handbook
8
ABB Safety Handbook | 2TLC172001C0202 8/2
8
Why measure stopping time? 8/3
Smart 8/4
Smart Manager 8/5
Smart and accessories 8/7
Stopping time and machine diagnosis tool
Smart
8/3 2TLC172001C0202 | ABB Safety Handbook
8
Stopping time
Why measure stopping time?
to find out which safety arrangements can be used in a certain area around a machine, and where
they should be located.
Stopping time
The safety distance (how far away from the risk area a safety
component must be placed) is based upon the machines
stopping time. The basic idea is that a safety component
should be placed so far from the risk area that it is not possi-
ble to enter the area before the machine has stopped.
The stopping time for manually operated machines is espe-
cially important when light beams and light curtains are used
as safety components. By reflex action the operator tries to
grab or adjust if something has gone wrong in the machine
tool, even if the machine has started. It is then imperative that
the machine stops before the hand reaches the risk area. A
short stopping distance is also of importance for getting good
ergonomics.
Grabbing or adjusting is also common when using automatic
machines. Usually this is done to prevent production down-
time by quickly adjusting a work piece. The stopping time is
also of great importance if someone trips and falls into the
machine.
Stopping time, walking speed (1.6 m/s) and hand speed (2.0
m/s) is used for the calculation of safety distances. Someti-
mes a fixed minimum distance is also used. See the standard
ENISO13855 for more details on the calculation of safety
distances.
Stopping distance
For safety contact strips it is extra important that the stopping
distance is monitored. An incorrect stopping distance could in
many cases result in very high risks. The stopping distance is
also needed during area limiting e.g. for robots when dividing
the working area into sectors.
For door sensitive edges, it is important that the stopping distance is
shorter than the soft part of the sensitive edge.
Regulations and standards
It is also important to measure the stopping time, to meet
the requirements set by the machinery standards, directives
and regulations. Here we can help, with our long experience
in the practical application of regulations and standards,
from the viewpoints of both the authorities and production. In
addition we collaborate with the standardisation committees
responsible for producing these standards. One example is
ENISO13855, which deals with the placing of safety devices
around a machine based on its stopping time. The standard
is general for all types of machinery, although for some, where
there is a harmonised C standard, the requirements for mini-
mum distance and stopping time measurement will apply. In
the case for example of mechanical press tools there is also a
requirement in EN 692 for how stopping time measurements
are to be performed, and in the case of hydraulic press tools
this is in EN 693.
Annual checks
Wear in a machine is something that can affect braking and
motors, which means that the stopping time of a machine can
change with time. Certain other changes in a machine, such
as changing the weight of a workpiece or alterations in pneu-
matic pressure, can also affect the stopping time. For these
and other reasons it is important to perform an annual check
on the stopping time.
How the stopping time affects the choice of protective
equipment an example
There was a case where we measured the stopping time of
the rollers in a textile industry company. The company had
planned to place light beams or a light curtain in front of the
rollers to prevent the operators from being caught in the ma-
terial and dragged in. The stopping time measurement show-
ed that it took over one second for the rollers to stop. During
this time the material was pulled in by almost two metres. In
order to obtain sufficient protection distance, the light beams
would have needed to be positioned almost three metres from
the machinery, and a light curtain about two metres away. The
factory did not have so much space, nor was it realistic. The
solution became instead vertical sliding safety barriers.
Where the safety distance is small, one can for example sit close to the
machine and work, as in the picture on the left. If the safety distance is
greater, it may be necessary to approach the machine to intervene, and
also perhaps use additional protection to prevent starting when someone
is within the protected distance.
ABB Safety Handbook | 2TLC172001C0202 8/4
8
Approvals:
Smart shows graphs/
values for:
Stopping time
Stopping distance
Speed
Position of stopping signal
Features:
Easy to use
Measurements with or
without electrical connection
Ideal for machine
performance diagnosis
Calculation of correct safety
distances
Stopping time and Machine Diagnosis Tool
Smart
Smart is ideal for safety supervision and for diagnosis of machine operation
Smart has many valuable features for machine diagnosis:
Graphic presentation of measurements
Easy to analyse stopping characteristics and movement
Gives parameters for safety design (e.g. stop time)
Calculates minimum allowed safety distance
Shows how the stop distance can be optimised
Electrical reaction time and mechanical/hydraulic breaking can be identified and
analysed
Digital in/out signals and analogue inputs
Smart is perfect for periodic monitoring of safety parameters and other conditions
for the maintenance and trouble-shooting of machines. Because Smart can com-
pare old and new graphs, it becomes easy to find out the reasons for machine
malfunctions. One can also supervise machines during operation and compare how
they perform over time.
Stopping units and sensors
Smart is a further development of our well established JSSM1 Stopping Analyser.
All the stopping units and sensors for the JSSM1 can also be used with Smart. The
amount of connection possibilities have also increased. Smart has 9 digital I/O, one
input for an incremental sensor (for position and speed) and two analogue inputs.
This makes it easy to measure sequences in conjunction with motion lapse and
other analogue values.
8/5 2TLC172001C0202 | ABB Safety Handbook
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Smart Manager
Smart is controlled in real time by a computer using the Smart
Manager program. This performs measurements, and the mea-
sured data can be saved and analysed. The measurements
are saved in an SQL database, with the ability to export data
to Microsoft Excel if necessary. The program calculates the
stopping time and protective distance, and can print out the
results, together with a graph of the event sequence. Smart
Manager is available in several languages: English, Swedish,
Danish, German, French, Czech and Polish. Translation into
other languages can easily be arranged as necessary. The
program is free, and is available for downloading from our web
site when purchasing equipment to measure stopping times.
Start menu
Current values from sensors and the system
Start conditions
Stop signal conditions
Shutdown conditions
Measuring settings can be saved
Calculations
Min., max. and average value and standard deviation from
a series of measurements
Protective distance can be calculated
Measured result
Measuring form
Stop signal given
Relay contacts
drop out
Machine
stopped
Stop time data
Zoom control
Own cursors
Benets:
Simple program structure
Shows the entire stop
sequence
Provides a machine
movement fingerprint
Compares measurements
Calculates stopping time
Saves measurements to a
database
Exports measured data to
Excel
Prints out a complete
measurement report
ABB Safety Handbook | 2TLC172001C0202 8/6
8
Printout
Printing out is one of the most important functions of the program. Here is shown all the vital information about the measure-
ments that is needed for such items as annual checking or providing the basis for CE labelling of a machine. Since the entire
measuring sequence is shown in graphical format, one can understand why the stopping time has a certain value and also, in
some cases, see what needs to be done to minimise the stopping time. The graph also acts as a kind of fingerprint" of the
machine movements, which means that different measurements can be compared with each other to see how the stopping
sequence varies from time to time, or from year to year. In this way the effects of e.g. worn brakes or the effect on the machine
control system can be seen. In order to get a complete basis from a measurement it is also important to state what assump-
tions have been made and what conditions applied when deciding when and how the stop signal was given.
Among other things, the stop signal details the person measuring, the measuring equipment, the machinery, the calculations
and the protective distance. The printout also has a replaceable company logo and a field for extra information.
Conversion of analogue signals
Smart can measure and show graphs for two different analogue sensors at the
same time, with its inputs for 0/4-20 mA. Conversion of the measured current
values can be done automatically by setting minimum and maximum values and the
units for the inputs. In this way, for example, the results from an analogue pressure
sensor can be shown and calculated as 0-400 bar instead of 4-20 mA, or an ana-
logue load cell as 0-2 kN. This also means that if it is desired for the system to be
triggered at a certain force, that force can be defined instead of needing to calcula-
te the equivalent current value.
Saving
Select measurement series
State extra information, e.g. the conditions and special circumstances for the
measurements.
Archiving
Search filter
Saved measurements
Exported measurements
8/7 2TLC172001C0202 | ABB Safety Handbook
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Smart Logger
Article number 2TLA070300R0100
The Smart Logger is the principal unit for data collection. The logger
has a USB connection to the PC and 8 M12 connections: one for the
power supply to the I/O, one connection for an incremental sensor,
two connections for analogue sensors and four connections for
other I/O signals.
The Logger encapsulation is watertight, with M12 connections to
prevent the entry of particles and uids in the workshop envi-
ronment. To prevent the Smart Logger from being damaged by
incorrect currents and voltages from external equipment, all inputs
and outputs, and external units, are electrically isolated from the
processor in the Smart Logger by means of opto-couplers.
Dimensions 62 x 220 x 80 mm. (wxhxd)
Weight 0.5 kg
Protection class IP67
Supply voltage 24 VDC
Response speed max 1 ms
Positional accuracy +/- 0.1 mm
Digital I/O 8 inputs, 4 outputs (NPN OC)
Analogue inputs 2 off, 0/4-20 mA
Encoder 1 connection for a pulse sensor
SM2 Button unit
Article number 2TLA070300R0200 The SM2 is used in conjunction with the Smart Logger for measu-
ring with a manual stop impulse, without an electrical connection
to the machine. When an SM2 is, for example, pressed against an
emergency stop button to stop the machine, the SM2 sends a signal
to the Smart Logger to start the measurement. An LED on the SM2
lights when the desired stop position is reached. The SM2 is con-
nected to the Smart Logger by an M12 connection.
Dimensions Size: 50 x 100 x 25 mm. (wxhxd)
Weight 0.2 kg
Application area Two-handed control unit, Emer-
gency stop, etc.
Supply voltage Fed from the Smart Logger
SM3 Relay unit
Article number 2TLA070300R0300 The SM3 is used in conjunction with the Smart Logger for automatic
stopping time measurements at the set position, or alternatively a
manual stop pulse. When a stop signal comes from the Smart Log-
ger a relay switches in the SM3.
The SM3 then sends a signal to the Smart Logger to start measu-
ring, and also activates the relay outputs to stop the machine. The
relay in the SM3 is reset via the software when a new measurement
is to be made. The SM3 is connected to the Smart Logger by an
M12 connection.
Dimensions 85 x 72 x 49 mm. (wxhxd)
Weight 0.2 kg
Application area Electrical connection providing a
stop pulse.
Supply voltage Fed from the Smart Logger
Relay outputs 2 NO, 2 NC, 6A/250 VAC.
Encoder 1 connection for a pulse sensor
SM11 Flag unit
Article number 2TLA070300R1100 The Smart Logger is used in conjunction with the SM11 for automa-
tic measurements of the stopping time and stopping distance. The
unit is located in a light curtain with the ag parallel to the beam.
When the ag is activated, the light beam/light curtain is interrupted,
and the machine stops. The SM11 is connected to the Smart Logger
by an M12 connection.
Dimensions 145 x 85 x 37 (wxhxd).
Shaft 3 x 45 mm
Weight 0.6 kg
Application area Ligh curtain, light beam
Protection class IP40
Batteries 10 rechargeable 1.2 V NiMH bat-
teries. Total 12 V
Power Max 1200 mAh (approx. 200
operations).
Temperature 0 to +45C.
Installation On a table or a standard came-
ra tripod
Charger SM14
Smart and accessories
ABB Safety Handbook | 2TLC172001C0202 8/8
8
SM7 Rotation sensor
Article number 2TLA070300R0700 The SM7 is an incremental sensor for connection to a Smart Log-
ger. The sensor detects rotational movement via a wheel rolling
against a shaft. The stand secures the sensor with the aid of just
one knob. The stand itself is secured to the machine by a power-
ful magnetic foot. The SM7 is connected to the Smart Logger by
an M12 connection.
Dimensions Sensor size: 46 x 40 x 59 (wxhxd)
Stand size: Extended, approx. 400 x
50 x 80 (wxhxd)
Weight 1.7 kg including stand
Application area Rotating motion, e.g. lathes, rollers
Supply voltage Fed from the Smart Logger
Max speed 5 m/s
Resolution 0.1 mm
Wheel circumference 125 mm
SM13 Battery pack
Article number 2TLA070300R2300
SM13 is a battery pack for the Smart Logger, which makes the
Smart a completely mobile measuring tool. With the SM13 you
dont need to connect the Logger to a wall socket for power,
and can easily move it from one machine to another when you
are measuring. Since the SM13 battery pack is the same physi-
cal size as the SM11 ag unit, it ts snugly into the SM9 carrying
case. The charger for the SM13 is called the SM14 and provides
a charging time of about 3 hours 15 minutes (2100 mAh). The
SM14 also acts as afast charger for the SM11.
Dimensions 145 x 85 x 37 mm (LxWxH)
Weight 0.8 kg
Protection class IP40
Connector Negative pole at the centre of the
charging connector
Current rating Maximum 0.9A
Power 2100 mAh. With normal use lasts
about 10-12 hours. (Higher capacity
on request.)
Batteries 20 rechargeable 1.2 V NiMH batteries
of size AA (R06). Total 24 V
SM9 Carrying case
Article number 2TLA070300R0900 The SM9 is a practical carrying case with pockets to suit the
various Smart units. Part of the protective foam insert in the lid of
the case can be removed to make room for a laptop computer,
so that all the equipment required can be carried in a single
case.
Dimensions 535 x 155 x 430 mm (LxWxH)
Weight 3.5 kg
SM5 1250/2500 Linear sensor
Article number
SM5/1250 Linear sensor
SM5/2500 Linear sensor
2TLA070300R0400
2TLA070300R0500
The SM5 is an incremental pulse sensor for connection to a
Smart Logger. The sensor is protected by a robust enclosure.
The sensor and end of the cable are secured to the machine by
powerful magnets. The SM5 is connected to the Smart Logger
by an M12 connection.
Dimensions 1250: 106 x 88 x 100 mm (wxhxd)
2500: 114 x 125 x 116 mm (wxhxd)
Weight SM5/1250: 1 kg SM5/2500: 1.4 kg
Application area Linear movement, e.g. press tools
Supply voltage Fed from the Smart Logger
Max length 1250 or 2500 mm
Max speed 5 m/s
Resolution 0.1 mm
Other accessories
Name Article number Description
SM6 2TLA070300R0600 AC/DC converter for Smart
SM14 2TLA070300R2400 Charger for ag unit SM11 and battery pack SM13.
USB cable 2TLA070300R1500 USB cable for communication with computer
Extension cables ABB JokabSafety's extension cables with 5 conductors ideal
for all Smart accessories
9/1 2TLC172001C0202 | ABB Safety Handbook
9
ABB Safety Handbook | 2TLC172001C0202 9/2
9
Sensors/Switches/Locks
Why should you use sensors/switches? 9/3
Non-contact safety sensor
Eden 9/5
Eden AS-i 9/7
Safety Magnetic Switch - Sense7 9/13
Magnetic lock
Magne 9/15
Process lock
Dalton 9/21
Safety and process lock
Knox 9/27
Safety Interlock Switch
Safety Interlock Switch - MKey5 9/33
Safety Interlock Switch - MKey8 9/35
Safety Interlock Switch - MKey9 9/39
9/3 2TLC172001C0202 | ABB Safety Handbook
9
Why should you use sensors/switches?
to supervise doors and hatches around dangerous
machines!
Assurance that a machine stops, when a door or a hatch
is opened, can be solved by using different types of swit-
ches and sensors, which are monitored with a safety relay
or a safety PLC. Switches and sensors are available both
as non-contact (dynamic or magnetic) and various types of
interlocking devices. Interlocking devices can be used when it
is required, via a signal, to lock a gate during processes that
cannot be stopped during certain operations. They are also
used with machines that have a long stopping time to prevent
someone from entering before the machine has stopped.
to manage the safety in harsh environments!
Non-contact dynamic sensors have a long lifetime because
they are not physically mechanically operated. They also
endure very harsh environments, e.g. cold, heat, high-pres-
sure wash-down which is important in the food industry for
example. Because the sensors are small, they are very easy
to position and can even be completely concealed in doors
and hatches.
to ensure that a position is reached!
The sensor monitors that the robot is standing still in a moni-
tored position when someone enters the robots working area.
The robot is then only stopped by the program , not by loss
of power. If the robot leaves the position the power will be cut
directly. This is used when the robot can not be stoped safely
without resolving in restarting problems.
ABB Safety Handbook | 2TLC172001C0202 9/4
9
What requirements should one have on sensors/switches?
The sensor/switch shall be reliable from both the safety and
production point of view.
A person must be able to trust that dangerous movements
and functions are safely stopped by the sensors/switches.
From the production point of view unintentional stops
should be avoided.
Standard EN ISO 13855 now includes requirements for
safety distances for interlocked doors without locking
function.
Eden highest safety level and reliability
Our recommendation is to use the Eden sensor because it
is the safest and most reliable solution. The Eden sensor is
a non-contact switch and has a dynamic function. Also it is
possible to connect up to 30 Eden sensors in series and still
achieve PL e according to 13849-1.
Reliability
Safety Interlock
switch
Magnetic switch
Eden -
sensor with
dynamic signal
Safety level
How safe is a sensor/switch?
In order to trust the safety function it is essential to be aware that a safety sensor/switch must be mounted
and be used according to the specifications. The certification authorities only test the product according to the
appropriate standards and to the specifications from the manufacturer.
Mechanical switches
For mechanical switches, e.g. key operated, this
means that a door or a hatch has to constructed to
small tolerances in order for the switch, the key or the
mounting brackets to last according to the life time
specification from the supplier. The screws holding
the parts have to be locked in such a way that they
cannot be loosened. In order to prevent material from
getting into the slot for the key the environment has to
be clean. If a door goes outside the design tolerances
from wear, the screws loosen or material comes into
the slot, this may lead to the interlocked switch not gi-
ving a stop signal when the door is opened. Even two
mechanical switches on a door could fail to an unsafe
state if the door somehow gets outside the tolerances
of the switches. To prevent accidents the mechanical
switch normally needs continuous checks of both the
switch and the installation.
Non-contact sensors/switches
For non contact sensors the risks associated with
mechanical switches (see above) do not exist. If
screws, brackets or sensors get loose, it will lead to
a stop signal. Therefore only one sensor with dual or
dynamic function is needed in order to reach the high-
est safety level. There are two types of non-contact
sensors - active and passive. The active sensor, Eden,
is constantly communicating via a dynamic signal
between the two parts and any failure will directly lead
to a stop signal. The passive type, a magnet switch,
has two reed contacts which are activated by a coded
magnet. Both the passive and the active sensors are
checked every time a door is opened. From a safety
point of view the active sensor, Eden, is to be pre-
ferred because it is checked constantly whereas the
passive sensor is only checked when a door opens.
From the reliability point of view a long detection
distance with large tolerances and a well defined on
and off position is needed. The active sensor, Eden,
fulfils these demands. A magnet switch has smaller
tolerances and an intermediate position where only
one contact opens. A bad installation or vibrations
can lead to an unintentional stop if one contact opens
and closes again. The supervision of a two channel
system is based on both contacts having to be opera-
ted in order to permit a new start. In a dynamic safety
circuit there is only one pulsed signal and therefore no
intermediate position.
9/5 2TLC172001C0202 | ABB Safety Handbook
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A non-contact safety sensor for the highest safety level
Eden - Adam and Eva is a non-contact safety sensor for use
on interlocked gates, hatches etc. The safety sensor Eden is
built on the principle of a dynamic safety signal that can be
generated an interpreted by the control device Vital, or Safety
PLC Pluto. The maximum sensing distance between Adam
and Eva is 15 mm 2 mm.
Up to 30 Edens can be connected in series to Vital and still
achieve the same safety level in the safety circuit. It is also
possible to connect safety light beams and E-stops in the
same safety circuit.
Adam is available with only a M12 connector or with cable
lengths up to 20 m (also with M12 connector). For harsh en-
vironments there is a special version of Eden cast in Polyure-
thane; Eden E.
In addition to the safe signal out from Adam, there is also a
non-safe status signal (on pin 5) that indicates contact/non-
contact between Adam and Eva.
LED indication
The LED on Adam provides a green indication of contact
between Adam and Eva, and a red indication indicates a
non-contact. A rapid flash indicates that an alignment of
the sensor is necessary. If the LED is flashing between red
and green the sensor is not receiving a dynamic signal from
previous sensor or Vital/Pluto.
Non-contact safety sensor
Eden
Approvals:
Application:
Door and hatches
Position control
Sector detection
Slot detection
Features:
PL e/Cat. 4 according to
ENISO13849-1 together with
Vital or Pluto
Non-contact detecetion, large
sensing distance 0-15mm
+/-2mm
Up to 30 sensors in series
with the highest level of safety
PLe
Versitile mounting, 360
detection
Protection class IP67/IP69K
The dynamic signal passes
through wood and plastic (not
metal)
Status information with LED
on the sensor and in the
cable connection,
Small hysteresis (<1mm)
TV
NORD
0-13 2
0-15 2
mm
5
5
0-13 2
Flexible mounting
ABB Safety Handbook | 2TLC172001C0202 9/6
9
Technical data Eden
Article number
Eva 2TLA020046R0000
Eva E 2TLA020046R0600
Adam M12 (with 4 DA1) 2TLA020051R0000
Adam 3 m (with 4 DA1) 2TLA020051R0200
Adam 10 m (with 4 DA1) 2TLA020051R0400
Adam 20 m with (4 DA1) 2TLA020051R0500
Adam E 10 m 2TLA020051R0600
Adam E 0.5 M12 2TLA020051R0700
Adam E 20 m 2TLA020051R0800
Level of safety
IEC/EN 61508-1...7
EN 62061
EN ISO 13849-1
SIL3
SIL3
PL e/Cat. 4
PFH
D
4.5010
-9
Colour Yellow and black
Weight Eva: 26 g
Eva E: 36 g
Adam M12: 30 g
Adam 3 m: 220 g incl. cable
Adam 10 m: 650 g incl. cable
Adam E10 m: 660 g incl. cable
Adam E 0,5 m + M12: 100 g incl. cable
Power supply 24VDC +15%-25%
Power consumption Adam: without info output 45 mA
with info output max 55 mA
Max cable length see Vital technical data
Ambient temperature
Eden
Eden E
-25C +70C (operation)
-25C +70C (stock)
-40C +70C (operation)
-25C +70C (stock)
Protection class
Eden
Eden E
IP67
IP67 and IP69K
Mounting
Installation Eden
Installation Eden E
M4 screw, e.g. safety screw
2TLA020053R4200. Max. torque
2Nm. Screw to be locked with
Loctite or similar.
M4 screw, e.g. safety screw
2TLA020053R4300. Max. torque
0.8Nm. Screw to be locked with
Loctite or similar.
Detection distance max
Adam/Eva 15 2 mm
Adam E/Eva E 12 2 mm
Hysteresis approx. 1 mm
Flash 2 mm before red position.
Flash 2 mm before red position.
Metal may have inuence on detection distance.
This can be prevented by protection plates, DA1.
Minimum distance to metal when
there is metal on one or more
sides.
Adam/Eva
Adam E/Eva E
One More
0 mm 2.5 mm
0 mm 0 mm
Minimum distance between Eden
pairs
50 mm
Mechanical life >10
7
cycles
Material Eden: Macromelt
Eden E: Polyurethane (PU)
Chemical resistance
Macromelt:
PU (EdenE):
Cutting oils, vegetable and animal
oils, hydrogen peroxide, diluted acids
and bases: good
Alcohol and strong acids: not recom-
mended
Cutting oils, vegetable and animal
oils,hydrogen peroxide, diluted acids
and bases,
alcohols: good
Strong oxidating acids: not
recommended
LED on Adam
Green:
Flashing:
Red:
Rapid ashing:
Eva within range, safety circuit
closed (door closed)
Eva within range, earlier safety circuit
open (door closed)
Eva out of range, safety circuit open
(door open)
Eva is within 2 mm from maximum
sensing distance (door closed)
Cable 3, 10 or 20 m, 5.7mm, black, PVC
5 x 0.34mm + screen, UL 2464
Connector M12: 5-pin male contact
Connections
Brown (1)
White (2)
Blue (3)
Black (4)
Grey (5)
+24 VDC
Dynamic signal in
0 VDC
Dynamic signal out
Info output, see below
24 VDC when LED is green or ashing
(tolerance -2 VDC), 10 mA max
0 VDC when LED is red. (tolerance +2 VDC)
Warning: Incorrect connection may cause permanent damage to Adam
devices.
Conformity 2006/42/EG
EN ISO 12100 1/2, EN 60204-1,
EN ISO 13849-1, EN 1088
Eden E Eden
9/7 2TLC172001C0202 | ABB Safety Handbook
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0-13 2
0-15 2
mm
5
5
0-13 2
Non-contact safety sensor
with integrated AS-i node
Eden AS-i
A non-contact safety sensor for the highest safety level
Eden AS-i is a non-contact safety sensor for use on inter-
locked gates, hatches etc. Eden AS-i consists of two com-
plementary parts called Adam and Eva. The sensor is only
activated if the gate or hatch is closed e.g. when Adam and
Eva are within sensing distance. Eden AS-i is constantly com-
municating between the two parts and any failure will directly
lead to a stop signal.
A non-contact safety sensor for AS-i
Eden AS-i has an integrated AS-i node and is connected via
an M12 connection directly to the AS-i cable.
Eden AS-i has a protective encapsulation that enables Eden
AS-i to be used in harsh environments. Each Eden AS-i is indi-
vidually coded which makes it secure against manipulation.
The advantage of safety within AS-i is that it is very easy to in-
stall since connection of the safety devices is just to the buss
cable. The function of the safety devices is determined by the
software program in the safety monitor/master. Each safety
device (node) has its own address and a unique safety code.
It is simple to add, move and disconnect safety devices on
the AS-i cable as well as to extend the AS-i cable. Traditional
safety systems require new cable running from the electrical
cabinet for each new protection. Connection with Eden AS-i is
simple as all units are connected to the same cable.
Flexible mounting
Approvals:
Application:
Door and hatches
Position control
Sector detection
Slot detection
Features:
PL e/Cat. 4 according to EN
ISO 13849-1
Non contact detection 0-15
mm +/- 2 mm
Versatile mounting, 360
degrees
Protection class IP69K
The signal passes through
wood and plastic (not metal)
Status information LED
Small hysteresis (1-2 mm)
Individually coded
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 9/8
9
LED Setting (hex) Setting (binary) Description
LED on Adam AS-i 1 0,0,0,1 LED lights red
3 0,0,1,0 LED lights green
All other All other LED OFF
Manual Status LED indication
LED Indication Description
LED on Adam AS-i Green Eva within sensing distance of Adam
Green and/or Red (fast ash) or both lights at the same
time
Eva within ~2 mm of maximum sensing distance
Red Eva not within sensing distance of Adam
Automatic Status LED indication
AS-i (green) Fault (red) Description
OFF OFF AS-i power missing
ON OFF Normal operation
ON ON No data exchange with master
Flash ON No data exchange because address = 0
AS-i LED and Fault LED in combination
LED Indication Description
LED on Adam AS-i Green-Red (ash) No contact with AS-i master
Red (ash) Internal fault. Power cycle, replace if still present
Status LED indication (independent of manual or automatic control)
Connection to the AS-i bus
AS-i makes safety easy
Installation is easy as all units are con-
nected to the same yellow AS-i cable/
bus. This thereby minimises the risk of
faulty connection. Each safety node has
its own address and a unique safety
code.
Eden AS-i has a built-in AS-i safety
node and is supplied with 30 VDC from
the AS-i bus.
Connection to the AS-i bus is through a
flat cable connector to M12, making it
possible to quickly and easily connect
Eden AS-i to the AS-i cable.
Our Pluto is the most flexible AS-i Safety
Controller on the market. Pluto can be
used as Safety Master, Monitor or I/O
and can control and monitor the safety
of a machine at the same time.
9/9 2TLC172001C0202 | ABB Safety Handbook
9
1.
2.
Technical data Eden AS-i
Article number
Adam AS-i with 4 DA2 B
Eva AS-i
2TLA020051R6000
2TLA020051R8000
AS-i data
AS-i prole
Slave address at delivery
Adressing via
Response time over AS-i bus
S-7.B.E
0
M12-connector
10 ms
Safety data - annual usage
PFH
D
Proof test interval (life)
6.0*10e-10
20 years
Power supply, operating voltages 30VDC, AS-i bus. Tolerance
26.5-31.6 VDC
Switching distance
(target to target)
15 +/- 2mm
Total current consumption 65mA
Assured release distance (Sar) 45 mm
Assured operating distance (Sao) 7.5 mm
Enclosure protection IP67 and IP69K
Cable type M12-connector 4-pole male
(only pin1 and pin3 used)
Ambient temperature Storage: -40+85C
Operation: -25+55C
Weight
~150g
Material Housing: Polybutylene
terephthalate (PBT)
Moulding: Epoxy
Colour Yellow, black text
Mounting bolts SM4
ENISO13849-1 Up to PLe/Cat.4
EN62061 Up to SIL3
IEC/EN 61508-1...7 SIL3, PFH
D
: 9.11x 10
-10
Approved standards European Machinery Directive
2006/42/EG
EN ISO 12100-1:2003+A1:2009,
EN ISO 12100-2:2003+A1:2009,
EN ISO 13849-1:2008,
EN 62061:2005,
EN 60204-1:2006+A1:2009,
EN60664-1:2007,
EN 61000-6-2:2005,
EN 61000-6-4:2007,
EN 60947-5-1:2003+A1:2009,
EN 1088+A2:2008
M12 - connector:
(4-pole male)
1)Brown: AS-i +
2)White: Not connected
3)Blue: AS-i -
4)Black: Not connected
Eden AS-i electrical connections
Dimensions
Accessories:
1. Protection plate DA1:2TLA020053R0000
2. Safety screws, SM4x20:2TLA020053R4200
3. SBITS: 2TLA020053R5000
4. DA2B, Mounting spacer: 2TLA020053R0300
5.M12-C112 1 m cable, 5-pole, 0.34 mm
2
, M12 female + male:
2TLA020056R2000,
M12-C312 3 m cable, 5-pole, 0.34 mm
2
, M12 female + male:
2TLA020056R2100
6.AS-i T-connector with M12, Flat cable connector to M12:
2TLA020073R0000
4.
5.
6.
3.
ABB Safety Handbook | 2TLC172001C0202 9/10
9
DA1
DA1 x 2
115
120
Mounting Eden
DA2 B
*
DA1,
protection plate 2.5 mm
* Safety screw
Eden and Eden AS-i
Application examples
Installation and maintenance for Eden
Eva can be turned in a number of different ways relative
Adam. Depending on the cable connector used to connect
Eden, different protection plates can be necessary in order to
avoid damage to Adam. The protection plates (DA1) supplied
with Adam M12-models connector are recommended for this,
see figure below. Also, the mounting spacers supplied must
be used in order to physically protect Eden from damage.
Mounting with one protection plate (DA1) for Adam M12
using prewired moulded M12 connector. For M12 connec-
tion, a straight contact is recommended.
Mounting with two protection plates (DA1) for Adam M12
using M12 connector with glanded cable.
Wrong mounting without protection plate may cause per-
manent damage to sensor.
Sensing distance between Adam and Eva: 0-15mm+/- 2 mm
Minimum distance between two Eden pairs: 100 mm
Eden to detect position
Adam and Eva can be used to ensure that a safe position
is kept/reached. The safety sensor has contact if they are
within 15 mm from each other.
Eden is used for sector detection
Additional Eden sensor(s) can be mounted on a machine to
detect working place.
Eden can communicate through wood and plastic
Wood, plastic and other non-metallic materials between Adam
and Eva let the communication signal pass.
Eden can be hidden in doors and hatches
Because of the small size, Eden can easily be hidden in
frames or guards.
Adam
on wall.
Eva on robot.
Metal
Wood,
plastic etc
9/11 2TLC172001C0202 | ABB Safety Handbook
9
Adam M12
Dimensions
Adam M12
Adam M12 AS-i
ABB Safety Handbook | 2TLC172001C0202 9/12
9
Eden
Connection examples
Connection of Eden to Pluto
Connection of Eden to Vital 1
9/13 2TLC172001C0202 | ABB Safety Handbook
9
Quick connected version fitted
with 250 mm cable and M12.
Sensing distance 14mm
NOTE! Sense7 versions have 2NC and 1NO circuits. For all
Sense7 switches the NC circuits are closed when the guard is
closed and the actuator present.
Switch operational description
The coded non-contact switches Sense7 are designed to
interlock hinged, sliding or removable guard doors. Its design
makes it advantageous to operate in environments that
require the highest level of safety.
The magnetic switch is small in size which makes it easy to
position and hide on gates and hatches. Sense7 is resistant
to both dirt and water, and has no dust collecting cavities,
which make it useful in environments where hygiene is pa-
ramount. The magnetic switch has a long working life since
no mechanical contact is necessary for operation. Sensing
distance of Sense7 is 14mm and it has a high tolerance to
misalignment. Actuator is always delivered with the non-con-
tact switch.
Material
The Sense7 switch is available in UL approved polyester
and in stainless steel 316. The stainless steel has a mirror
polished finished (Ra4) suitable for CIP cleaning - food splash
zones according to EHEDG guidelines.
Protection from unauthorised or incidental access
To avoid unauthorised operation of the Sense7 switch, it is
only possible to actuate the coded magnetic switch with the
coded magnet. Other magnets, screwdrivers and tools have
no affect on the switch contacts.
Safety level
The Sense7 has two closing and one opening contact. Two
contacts have to be monitored to achieve the highest level of
safety regulations, PL e/Cat. 4 according to EN ISO13849-1
together with safety relay or Safety Pluto PLC.
Regulations and Standards
The Sense7 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
EN1088, IEC/EN 60947-5-3, EN 60204-1, ENISO13849-1,
EN 62061 and UL 508.
Safety Magnetic Switch
Sense7
Approvals:
Application:
Gates
Hatches
Position control
Features:
Small size
Up to IP69K
LED
2NC+1NO
Solid State outputs
ABB Safety Handbook | 2TLC172001C0202 9/14
9
Dimension Sense7
Dimension Sense7Z
Cable configuration
88
78
4.60
2
5
1
4
1
4
33
2
5
1
8
.
5
0
3
.
5
0
7
5.40
88
78
ORANGE
BROWN
YELLOW
GREEN
WHITE
BLACK
-BLUE
+RED
NO
Auxillary
Circuit
External
Suppl y
24VDC
NC
Circuit 2
NC
Circuit 1
Electrical connection
RED BLUE
ACTUATOR
BLACK
WHITE
YELLOW
GREEN
ORANGE
BROWN
NC
Circuit 1
NC
Circuit 2
NO
Auxillary
Circuit
POWER
RECEIVER 1 RECEIVER 2
&
&
&
M12 8pol
Sense7 - 250 mm cable withM12
(Pin view from switch)
Colours
1 2
3 7
8
4
5
6
1 White
2 Red
3 Blue
4 Yellow
5 Brown
6 Green
7 Black
8 Orange
Technical data Sense7 series
Article number
Plastic
Sense7 - 2 m cable
Sense7 - 5 m cable
Sense7 - 10 m cable
Sense7 - 250 mm cable with M12
Stainless steel
Sense7Z - 2 m cable
Sense7Z - 5 m cable
Sense7Z - 10 m cable
Sense7Z - 250 mm cable with M12
2TLA050056R4100
2TLA050056R5100
2TLA050056R6100
2TLA050056R2100
2TLA050056R4120
2TLA050056R5120
2TLA050056R6120
2TLA050056R2120
Level of Safety
ENISO 13849-1
EN 62061
Up to PL e/Cat. 4 depending upon
system architecture
Up to SIL3 depending upon system
architecture
Safety data
PFH
D
Switching reliability
Proof test interval (life)
MTTF
d
2.52 x 10
-8
3.3 x 10
6
operations at 100mA load
47 years
470 years (8 cycles per hour/24
hours per day/365 days)
Safety channel 1NC 24VDC 0.2 A max. rating
Safety channel 2NC 24 VDC 0.2 A max. rating
Safety channel 3NO 24 VDC 0.2 A max. rating
Power supply 24 VDC 10%
Minimum switched current 10 VDC 1mA
Dielectric withstand 250 VAC
Insulation resistance 100 MOhm
Recommended setting gap 5 mm
Switching distance
(target to target)
Sao 10 mm close (on)
Sar 20 mm open (off)
Tolerance to misalignment 5 mm in any direction from
5 mm setting gap
Switching frequency 1.0 Hz maximum
Approach speed 200 mm/m to 1000 mm/s
Vibration resistance IEC 68-2-6, 10-55 Hz 1 mm
Shock resistance IEC 68-2-27, 11 ms, 30 g
Enclosure protection IP67 and IP69K
Cable type PVC 8 core 6 mm O.D
Operating temperature
Sense7
Sense7Z
-25C to +80C
-25C to +105C
Material
Sense7
Sense7Z
UL approved polyester
Stainless steel 316
Colour Red or stainless steel
Mounting position Any
Mounting bolts
(Tightening torque)
2 x M4
(1.0 Nm)
88
78
4.50
2
5
1
3
1
3
33
2
5
1
8
.
5
0
3
.
5
0
7
5.20
88
78
9/15 2TLC172001C0202 | ABB Safety Handbook
9
Magnetic lock with indication
Magne is a electro-magnetic lock that is designed for indust-
rial applications and that can withstand harsh environments.
As it is designed with no moving parts, it is durable and long
lasting. The unit is intended for use in preventing unnecessary
process stoppages, i.e. it is not a safety lock. Magne, with
its electro-magnet, keeps a door locked with a holding force
up to 1500 N and magnetic material does not attach to the
magnetic surface when the power is off.
Use of M12 connectors makes it easy to connect several
Magne units and Eden sensors in series enabling control and
monitoring by either a Pluto safety PLC or a Vital safety cont-
roller. Via the connection cable it is also possible to obtain an
indication signal informing if the Magne unit is locked or not.

Accessories:
Mounting kit for conventional door, with fitting and screws
for assembly on ABB JokabSafety Quick-Guard fencing
system (5-15 mm door gap)
Plastic handle
Handle profile for mounting on a hinged door with ABBJo-
kabSafetys Quick-Guard fencing system (5-15mm door
gap).
Magne is easy to install, adjust and
dismantle in and out of the T-slot of the
Quick-Guard fencing system.
Magnetic lock
Magne
Approvals:
Application:
Electrical locking of doors
and hatches for production
applications that are sensitive
to unintentional/unnecessary
interruptions.
For safety supervision the
Magne 2 has an integrated
Eden.
Features:
No moving parts
Strong Magnetic holding
force: 1500N
Can withstand and operate in
harsh environments
Locked/unlocked indication
Possible to connect in series
with Eden sensors
No current peaks on activa-
tion
Magne2 in combination with
a handle profile provides a
complete door solution
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 9/16
9
Models and ordering data
Magne 1A v2 1500N 2TLA042022R2100 Electro-magnet with 5-pole M12-contact. Anchor plate. Cell rubber.
Magne 1B v2 1500N 2TLA042022R2200 Electro-magnet with 5-pole M12-contact. Anchor plate with perma-
nent magnet. Cell rubber.
Magne 2A v2 Eden
incl. EVA, 8-pol M12
2TLA042022R1600 Magnetic lock with indication. Electro-magnet with 8-pole M12-
contact. Anchor plate. Cell rubber.
Adam (built-in)+Eva(free) door position sensor.
Magne 2B v2 Eden
incl. EVA, 8-pol M12
2TLA042022R1800 Magnetic lock with indication. Electro-magnet with 8-pole M12-con-
tact. Anchor plate with permanent magnet. Cell rubber. Adam
(built-in)+Eva(free) door position sensor.
Magne 2Ax v2 Eden
incl. EVA, 5-pol M12
2TLA042022R1700 Magnetic lock with indication. Electro-magnet with 5-pole M12-
contact. Anchor plate. Cell rubber.
Adam (built-in)+Eva(free) door position sensor.
Magne 2Bx v2 Eden
incl. EVA, 5-pol M12
2TLA042022R1900 Magnetic lock with indication. Electro-magnet with 5-pole M12-con-
tact. Anchor plate with permanent magnet. Cell rubber. Adam
(built-in)+Eva(free) door position sensor.
JSMD28 2TLA042023R0100 Aluminum prole used as both door handle and mounting kit for
Magne. Completely covers Magne unit when the door is closed.
JSMD21B 2TLA042023R0500 Mounting kit for Magne. For conventional door (5-15mm door
gap). Fits all Magne. Note: When used with Magne 2A/B,2Ax/Bx a
mounting kit for Eva is also required (JSMD24).
JSMD23 2TLA042023R0200 Mounting kit for Magne. For sliding door. Fits all Magne.
JSMD24 2TLA042023R0300 Mounting kit for Eva. For conventional door.
JSM D27 2TLA042023R1000 Handle/screw for JSMD21 Magne installation kit.
Magne cellular
rubber
2TLA042023R3600 Spare part. Cellular rubber t=10 mm
Magne Anchor plate
32A
2TLA042023R1300 Spare part. Anchor plate A (without permanent magnet). Width 32
mm. Included with Magne 1/2
Magne Anchor plate
34A
2TLA042022R2300 Spare part. Anchor plate A (without permanent magnet). Width 34
mm.
Magne Anchor plate
32B
2TLA042023R0400 Spare part. Anchor plate B (with permanent magnet). Width 32 mm.
Included with Magne 1/2
Magne Anchor plate
34B
2TLA042022R2400 Spare part. Anchor plate B (with permanent magnet). Width 34 mm.
Magne 2A with installation kit
JSMD21B, JSM D24 and JSMD27.
Magne 2A with installation kit
JSMD23.
Magne 1A with installation kit
JSM D21B and JSM D27.
JSM D28 handle prole which cover
Magne completely when the door
is closed.
Magne
Models and accessories
9/17 2TLC172001C0202 | ABB Safety Handbook
9
Technical data Magne
Level of safety
For interlocking switch Eden. Not valid for
locking function.
IEC/EN 61508-1...7
EN 62061
EN ISO 13849-1
SIL3
SIL3
PL e/Cat. 4
PFH
D
4.5010
-9
Power supply Magnet: 24 VDC +/- 15%
Eden: 1727 VDC, ripple max 10%
Power consumption Magnet: 7 W (300 mA at 24VDC)
Eden: 4555 mA (see data for Eden)
Operating temp. range -20C to +50C
Protection class IP65
Weight Magne 1: 610 g, Magne 2: 700 g, Anchor 32A/B: 290 g, Anchor 34A/B: 308 g
Material Anchor plate and magnet: steel
Housing: Aluminium
Potting: PUR, epoxy
Holding force 24 VDC: Min 1500 N
0 VDC: 0 N (Magne 1A/2A/2Ax)
0 VDC: 30 N (Magne 1B/2B/2Bx)
Contacts Reed sensor (not safe)
Switch current max 100 mA
Mechanical life >10
7
switch operations
Connector M12 5-pole male connector (Magne 1A/B, 2Ax/Bx)
M12 8-pole male connector (Magne 2A/B)
Connections Magne 1A/B:
(1) Brown: Locking, +24 VDC
(2) White: Sensor supply
(3) Blue: 0 VDC
(4) Black: NO-contact
(5) Grey: NC-contact
Magne 2A/B:
(1) White: Dynamic signal input
(2) Brown: +24V DC
(3) Green: Locking, +24V DC
(4) Yellow: Locking, 0V DC
(5) Grey: Info closed (max 10 mA)
(6) Pink: Dynamic signal output
(7) Blue: 0V DC
(8) Red: Info locked (max 100 mA)
Magne 2Ax/Bx:
(1) Brown: +24 VDC
(2) White: Dynamic signal input
(3) Blue: 0 VDC
(4) Black: Dynamic signal output
(5) Grey: Locking
Conformity EN ISO 12100-1:2010, EN ISO 13849-1:2008, EN ISO 13849-2:2008, EN 62061:2005,
EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007,
EN 60947-5-1:2004, EN 1088+A2:2008
ABB Safety Handbook | 2TLC172001C0202 9/18
9
Dimensions Magne 1A/B
Dimensions Anchor plate 32A/34 (without permanent magnet)
Dimensions Anchor plate 32B/34B (with permanent magnet)
Dimensions - cellular rubber
Installation tolerance (general)
Dimensions Magne 2A/B, -2Ax/Bx
Magne
Dimensions
3
2
/
3
4
130
100 0,20
M8(2X)
A A
14
SECTION A-A

0
,
1
0
9
,
1
0
5
,
5
0
4
,
1
0
0
+
0
,
1
0
3
2
/
3
4

1
1
,
7
5

21,65
20,75

3
5

M12 5-pole
6,6(2x)
18,5 23,5 123
158
205
10,7 DEEP 7(2x)
File name: MAGNE 1_V2
Article no: xx-xxx-xx
2013-02-05
ABB
- - -
D
E
F
C
1 2 3 4
B
A
3 2 1 5
C
D
4 6 7 8
A
B
Material Finish Dimension
Designed by Drawn by Appr. / Checked by Date created Date saved
Colour General tolerance
Proj.method Format Scale
Owner Name/description
-
-
Drawing no.
This document shall not be copied without our written
sed to any third party, nor be use for anyauthorized
permission, and the contents thereof shall not be disclo-
purpose.
ABB JOKAB SAFETY - 2013
A3
ISO 2768m
1/1
1:1
MAGNE 1_V2 -
- - -
Ra 1,6
Release Sheet
Unless otherwise stated following applies
Sharp edges broken
No remains from production (oil, burrs etc) allowed
All dimensions are in mm
ITEMMAY UNDER NO CIRCUMSTANCES CONTAIN SILICONE PRODUCTS
Surf.roughness
Article no: xx-xxx-xx
2013-02-05
File name: MAGNE 2_V2
ABB
D
E
F
C
1 2 3 4
B
A
3 2 1 5
C
D
4 6 7 8
A
B
Material Finish Dimension
Designed by Drawn by Appr. / Checked by Date created Date saved
Colour General tolerance
Proj.method Format Scale
Owner Name/description
Drawing no. Release Sheet
This document shall not be copied without our written
permission, and the contents thereof shall not be disclo-
sed to any third party, nor be use for anyauthorized
purpose.
ABB JOKAB SAFETY - 2013
A3
ISO 2768m
1/1
1:1
MAGNE 2_V2 -
- - -
Ra 1,6
MAGNE 2_
-
-
Unless otherwise stated following applies
Sharp edges broken
No remains from production (oil, burrs etc) allowed
All dimensions are in mm
ITEMMAY UNDER NO CIRCUMSTANCES CONTAIN SILICONE PRODUCTS
- -
Surf.roughness
M12 5/8-pole
158
260
123
6,6(2x) 11 DEEP 7(2x)
91 18,5

1
1
,
7
5


3
5

20,75
21,65

3
NOTE!
All dimensions are in mm
9/19 2TLC172001C0202 | ABB Safety Handbook
9
Holding force / Hllkraft
0
200
400
600
800
1000
1200
1400
1600
0 5 10 15 20 25 30 35
Volt
N
e
w
t
o
n
Magne
Connection examples
Connection example - Magne 1 and 2
Holding force - Magne 1 and 2
ABB Safety Handbook | 2TLC172001C0202 9/20
9
Magne
Connection examples
Connection example - Magne 2 in series
Connection example - Magne 1 in series
9/21 2TLC172001C0202 | ABB Safety Handbook
9
Dalton the intelligent process lock
Dalton is a locking unit that is intended for use in preventing unnecessary process
stoppages, i.e. it is not a safety lock. It can be used either as a free-standing lock
or integrated with Eden as a safety sensor. In the unlocked state the door is held
closed by a ball catch and in locked state the balls are mechanically blocked so
the lock tongue can not be pulled out. If necessary, the holding force of the ball
catch can be adjusted. The device only allows to lock when the ball latch is centred
around the lock tongue, and when Eva is with Adam (depending on version). When
an input is supplied with voltage, the ball catch is locked.
Dalton is easily connected with an M12 connector. The Tina junction block can be
used for distribution of both the safety and locking functions. The Dalton status is
indicated by LEDs and can also be read by a PLC via the information output.
Dalton has a modular structure
The Dalton process lock has a modular structure and can be combined in different
ways depending on position, installation and function. You choose the lock housing,
lock tongue and fixing plate yourself to create a complete Dalton.
Installation
Dalton offers many different installation possibilities as the lock tongue may enter
the ball catch from three directions. In order to ensure that Dalton works without
any problems, the ball catch must be resting, i.e. the balls not pressed in by the
lock tongue when the door is in closed position. Dalton's brackets are therefore
made to ensure easy adjustment of the lock tongue and ball latch positions.
Dalton is easy to install, adjust and dismantle in
the Quick-Guard fence system's T-slots.
Process lock
Dalton
Use:
Door and hatches
Features:
Small and robust
Integrated with Eden
High enclosure classification
IP67
Withstands harsh enviroments
Low current consumption
Status information with LED
on the lock housing and in the
cable connection.
ABB Safety Handbook | 2TLC172001C0202 9/22
9
1. Choose Dalton lock housing according to your preferences:
Dalton M11/M31 If you only need to be able to lock your door/hatch (8-pin/5-pin M12)
Dalton M12 If you want to lock your door/hatch and also have the interlocking switch Eden
installed with one cable, common for both Dalton and Eden.
Dalton L00 If you only need to use Dalton to keep the door fixed and closed
2. Choose a lock tongue depending on how the door/hatch is closed.
3. Choose a fixing kit that fits your installation.
Dalton M11
with 8-pin male contact
Dalton M12
with 8-pin male contact, 5 pin female
contact for Adam
Dalton M31
with 5-pin male contact
Dalton L00
as ball latch, no electrical functions.
Lock tongue A
Selected when the door
closes to the Dalton front
Lock tongue B
Selected when the door closes to
Daltons upper or lower side
For Dalton L00 both lock tongues can
be used regardless of the operating
direction
Fixing kit 1
for Dalton and
lock tongue
Fixing kit 4
for Dalton and Eden
adapted to ABB
Jokab Safety fencing
system
Fixing kit 2
for Dalton and Adam
and also for lock
tongue and Eva
Fixing kit 5
for Dalton, small
bracket for lock
tongue
Fixing kit 3
for Dalton ad-
apted to ABB
Jokab Safety
fencing system
Fixing kit 6
for Dalton and Eden,
small bracket for lock
tongue
Tina 12A junction block
Tina 12A can be used to connect two Daltons with Edens with
one cable to the apparatus enclosure. The summed informati-
on that indicates the states of both the Dalton and Eden also
goes to the apparatus enclosure.
Dalton
Modular structure
Accessories - Dalton
Transfer cables
A transfer cable can be used when the Dalton's 8-pole con-
nector is to be connected to the 5-pole M12 connector of
Tina 4A or Tina 8A. Note that the info-signals from Dalton and
Adam can not be used.
Read the manual for further information about correct installation of Dalton
Lock from front - Tongue A Lock from lower side - Tongue B Lock from upper side - Tongue B
9/23 2TLC172001C0202 | ABB Safety Handbook
9
Technical data Dalton
Article number
Dalton L00 2TLA020038R3000
Dalton M11 2TLA020038R3100
Dalton M12 2TLA020038R3200
Dalton M31 2TLA020038R3300
Lock tongue A 2TLA020039R0800
Lock tongue B 2TLA020039R1000
Fixing kit 1 2TLA020039R0000
Fixing kit 2 2TLA020039R0100
Fixing kit 3 2TLA020039R0200
Fixing kit 4 2TLA020039R0300
Fixing kit 5 2TLA020039R0400
Fixing kit 6 2TLA020039R0500
Accessories
DA 1 2TLA020053R0000
M12-CT0214 2TLA020060R0100
Tina 12A 2TLA020054R1800
Level of safety
For interlocking switch Eden. Not
valid for locking function.
IEC/EN 61508-1...7
EN 62061
EN ISO 13849-1
SIL3
SIL3
PL e/Cat. 4
PFH
D
For interlocking switch Eden. Not
valid for locking function.
4.5010
-9
Locking function M - Locked when energised
L - Only ball latch
Colour Black
Operating voltage 24 VDC +25/20%
Current consumption
Unlocked
Locked
Lock input
Information output
40 mA
130 mA
5 mA
Max. 10 mA
Eden See the data for Adam M12
Operating temp. range -10C to +55C
Enclosure classication IP67
Holding force
Unlocked
Locked
25-100 N
2000 N
Material
Ball catch, securing plate
Enclosure
Lock tongue, securing plate
Anodised aluminium
Anodised aluminium
Stainless steel
Chemical resistance
Stainless steel
Anodised aluminium
Good resistance against most
acids except hydrochloric acid and
sulphuric acid.
Very good resistance against
corrosion, good resistance to most
acids.
Connections Connector to connect Dalton (varies
depending on type)
8-pole male plug, M12
5-pole male plug, M12
Outlet for externally connected
Adam female plug M12, 5-pole
Colour markings (pins)
Function
Dynamic input signal, Adam
+24 VDC
Lock signal
Not used
Information Adam
Dynamic output signal, Adam
0 VDC
Information Dalton
8-pole
1
2
3
4
5
6
7
8
Colour
(White)
(Brown)
(Green)
(Yellow)
(Grey)
(Pink)
(Blue)
(Red)
5-pole
1
4
2
3
5
Colour
(Brown)
(Black)
(White)
(Blue)
(Grey)
Warning Dalton locks mechanically. If the lock is forced, the Dalton can
be permanently damaged.
Conformity (lock only) EN 61000-6-4:2007,
EN 61000-6-2:2005
LED indication Dalton
LED indication
=Red =Green =Paus
Information function
1 Locked
0 Closed but unlocked
0 Open
Alarm:
1Hz Lock has not entered the
unlocked state
1Hz Eden or ball catch not in
position = open
1Hz Open, locking not permitted
1Hz Lock has not entered the
locked state
1Hz Undervoltage - locking not
permitted
1Hz Overvoltage
1Hz Overtemperature (> 80C)
ABB Safety Handbook | 2TLC172001C0202 9/24
9
33
9
8
2
63
17,5
115
R
4
6
27
26
2
7
101
28
87
33
9
7
2
137
49,5
202,5
2
27
26
6
7
101
101
7
26
27

8
x

R
4

6
2
115
37,5
6
28
2
x

5
,5

40
17,5
8,5
17
26 28
87
78
10
70
2
32
144
8
X
R
4
87
Bracket 1 with Dalton Bracket 2 with Dalton and Eden
Bracket 5 with Dalton Bracket 6 with Dalton and Eden
Bracket 3 with Dalton Bracket 4 with Dalton and Eden
Dalton
Dimensions
9/25 2TLC172001C0202 | ABB Safety Handbook
9
Dalton
Connection examples
Connection example Dalton M12 and Vital
Connection example Dalton M11, M31 and M12
ABB Safety Handbook | 2TLC172001C0202 9/26
9
Dalton
Connection examples
Connection example Dalton M12 and Eden through Urax (AS-i)
Connection example Dalton M12 and Eden through Tina 4A
9/27 2TLC172001C0202 | ABB Safety Handbook
9
Knox - Double safety lock as specified in PLe/Cat.4
Knox is a double lock that complies with the highest safety level (two lock cylinders
with monitored positions) that can be used both as a safety and process lock. The
locking function is electrically controlled and is bi-stable, i.e. it retains its position
(unlocked/locked) in the event of a power failure. Dual signal for unlocking is safe at
both short-circuits and cable breaks.
The handles operate as they would on a normal door but the exterior handle also
have a reset function, why a separate reset button is not necessary and the interior
handle that can be used for emergency opening also in locked state. The design
and durability of the lock mean that it is ideal for harsh environments as the sensors
are non-contact and the lock is manufactured of stainless steel. Knox is available
in a number of adaptations such as left-hung door, right-hung door, inward and
outward opening, with manual unlocking and for sliding door.
Knox is easy to assemble, adjust and dismant-
le in and out of the T-slot of the Quick-Guard
fencing system.
Safety and process lock
Knox
Approvals:
Application:
Safe locking of door to a cell/
line with long stopping time.
Prevents unintentional inter-
rupts of processes
Features:
Double locking function
as specified in PLe/Cat.4
(ENISO13849-1)
Withstands harsh enviroments
Status information with LEDs
on the lock and at cable con-
nection.
Controlled in locked and
unlocked positions-position
power failure.
Electronic connection only on
the door frame.
Robust design
ABB Safety Handbook | 2TLC172001C0202 9/28
9
Operational mode locked and reset
(emergency opening only)
Reset, openable
Emergency opened Open
Knox in 4 different states
9/29 2TLC172001C0202 | ABB Safety Handbook
9
Knox door part 1A-R
and frame part 2A
Knox door part 1B-R
and frame part 2A
Knox door part 1B-L
and frame part 2A
Knox door part 1F-R
and frame part 2A
Door part Knox1
Frame part
Knox 2
Knox door part 1A-L
and frame part 2A
Knox door part 1F-L
and frame part 2A
Models and ordering data
Door part Right Left
Outward opening without manual unlocking Knox 1A-R v2
2TLA020105R5000
Knox 1A-L v2
2TLA020105R5100
Outward opening with manual unlocking Knox 1AX-R v2
2TLA020105R5800
Knox 1AX-L v2
2TLA020105R5900
Inward opening without manual unlocking Knox 1B-R v2
2TLA020105R5200
Knox 1B-L v2
2TLA020105R5300
Inward opening with manual unlocking Knox 1BX-R v2
2TLA020105R6100
Knox 1BX-L v2
2TLA020105R6300
Sliding door without manual unlocking Knox 1F-R v2
2TLA020105R6400
Knox 1F-L v2
2TLA020105R6500
Sliding door with manual unlocking Knox 1FX-R v2
2TLA020105R6400
Knox 1FX-L v2
2TLA020105R6500
Frame part
Knox safety lock Knox 2A v2
2TLA020105R2200
Knox process lock Knox 2X v2
2TLA020105R2300
Accessories
PC plate for Knox on mesh door 2TLA020106R0000 When mounting Knox on door with mesh the accessory PC
plate for Knox is recommended. This is to avoid emergency
opening from the outside.
Escutcheon plate for Knox (without emergency
release handle)
2TLA020106R0600 When mounting Knox on a low door it is recommended to
replace emergency release handle to prevent opening from the
outside by reaching over.
Maintenance mode
If any work is to be carried out inside
the hazardous area, a padlock can be
put in place in any of the two locking
bolts to prevent the door from locking.
This can also act as an indication of
presence within the hazardous area
(only helpful if operators are informed of
the use of padlocks).
NOTE! The use of padlocks is not a part
of the safety function and only serves as
an additional measure to reduce the risk
of entrapment.
NOTE! Cable outlet on frame part must
be mounted upwords.
ABB Safety Handbook | 2TLC172001C0202 9/30
9
Technical data Knox
Level of safety
EN ISO 13849-1 PL e/Cat. 4
PFH
D
4.5010
-9
Lock function S/M - unlocked and locked with voltage.
Operating voltage 24 VDC +/- 10%
Operating temperatur +5C...+55C
Power consumption
Electronics
Lock/lock inverse
Total max
Information output
70 mA (in locked position)
135 mA (when locking/unlocking)
Knox 2A 160mA, Knox 2x 165mA
Max. 10 mA
Insulation class IP65
Holding strength
Unlocked
Locked
5000 N (10,000 N ultimate breaking strength)
5000 N (10,000 N ultimate breaking strength)
Connection Male plug M12, 8-pole
Connections Knox 2A
Function
Dynamic input signal
+24 VDC
Lock
Lock inverse
Information Locked
Dynamic output signal
0 VDC
Information reset
Connections Knox 2X
Function
+24 VDC
Dynamic signal input
0 VDC
Dynamic signal output
Lock
8-pole Colour
1 (White)
2 (Brown)
3 (Green)
4 (Yellow)
5 (Grey)
6 (Pink)
7 (Blue)
8 (Red)
5-pole Colour
1 (Brown)
2 (White)
3 (Blue)
4 (Black)
5 (Grey)
Warning
Knox locks mechanically. Forcing the lock may damage Knox permanently.
When mounting Knox on door with mesh the accessory PC plate for Knox is recommended. This is to prevent emergency opening from the outside.
When mounting Knox on a low door it is recommended to replace emergency release handle with the accessory Escutcheon plate for Knox to prevent
opening from the outside by reaching over.
Conformity 2006/42/EG EN ISO 12100-1/2:2003, EN ISO 13849-1:2008, EN 62061:2005, EN 1088
LED indicator Knox
LED indicator
LED 1
LED 2
Function
Locked (and reset)
Locked, no dynamic signal in
Unlocked
Reset
Not reset
Alarm LED 2 Dirt indicator reset sensor
Reset
Not reset
=Red =Green =Paus
LED1
LED2
9/31 2TLC172001C0202 | ABB Safety Handbook
9
Knox
Connection examples
Connection example - Knox with other unlocking
Connection example - Knox
ABB Safety Handbook | 2TLC172001C0202 9/32
9
Knox
Connection examples
Connection example - Knox with downtime monitor
9/33 2TLC172001C0202 | ABB Safety Handbook
9
Switch operational description
MKey5 Interlock switches are designed to provide position
interlock detection for moving guards. They are designed to fit
the leading edge of sliding, hinged or lift off machine guards.
The actuator is fitted to the moving part of the guard and is
aligned to the switch entry aperture.
The head can be rotated to provide four given actuator entry
positions. When the actuator is inserted into the switch the
safety contacts close and allow the machine start circuit to
be enabled. MKey5 has two versions regarding holding force,
12N and 40N. MKey5 has several types of actuators as an op-
tion. A standard actuator key is always delivered with interlock
switches.
Material
Depending on the environment where the switch will be used,
different material can be chosen on the Mkey5. The basic
version is in a full plastic body (polyester) and in cases where
the demands are higher on the interlock switch head, there is
a version with a plastic body and with a stainless steel head.
Both these types give the MKey5 interlock switch a rating of
IP67.
In harsh applications as for food processing and chemical
industry there is a MKey5Z Interlock switch with a total rugged
stainless steel 316 body. This version has IP69K enclosure
protection (maintained by a double seal lid gasket) and can be
high pressure hosed with detergent at high temperature.
Positive forced disconnected contacts
A positive forced contact provides a forced disconnect of the
safety contacts at the withdrawal of the actuator. The design
of the MKey5 ensures that the contacts will not fail or be held
in a normally closed position, due to failure of the spring me-
chanism or that welding/sticking of the contacts can occur.
Safety level
The positive forced disconnect contacts gives a high safety
level and the interlock switch has an anti-tamper mechanism.
By combining the MKey5 with one of our suitable safety
control module, for example a safety relay from the RT-series,
Pluto safety-PLC or Vital module, the requirements for both
hatch and gate switch supervision can be fulfilled. To obtain
the highest level of safety, two switches per gate are required.
Explosion Proof version (X)
MKey5 also exist in versions with certified explosion proof
contact block (X-versions). MKey5ZX is in stainless steel and
can be used in European Zone 1, 2, 21,22 enviroments (Gas
and Dust). Preassembled with 3meter cable.
Regulations and Standards
The MKey5 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
EN1088, IEC/EN60947-5-1, EN60204-1, ENISO13849-1,
EN62061 and UL508.
Safety Interlock Switch
MKey5
Approvals:
Application:
Gates
Hatches
Features:
2NC + 1NO (actuator in)
4 actuating positions
Holding force 12 or 40N
Up to PL e/Cat.4
Plastic, Plastic with stainless
steel head or stainless steel
(X-versions)
TV
Rheinland
ABB Safety Handbook | 2TLC172001C0202 9/34
9
Actuator
1.Standard Key for plastic head 2TLA050040R0201
2.Standard Key for SS head 2TLA050040R0202
3. Flat Key 2TLA050040R0220
4.Flexible Key with plastic housing 2TLA050040R0221
5.Flexible Key with metal housing 2TLA050040R0203
6.Flexible Key with SS housing 2TLA050040R0204
(Key always in Stainless steel)
Contact block configurati-
on 2NC, 1NO
Contacts at withdrawal of actuator
For all MKey the normally closed (NC) circuits are closed
when the guard is closed (actuators inserted).
Dimension MKey5Z
Dimension MKey5
11/12 Open
21/22 Open
33/44 Open
6.80 6 0mm 2NC 1NC
1
6
4
3
2
5
Technical data MKey5 series
Article number
Standard
MKey5 - 12N
Mkey5+ - 40N
Stainless steel head
MKey5 - 12N
MKey5+ - 40N
Full stainless steel
MKey5Z - 12N
MKey5+Z - 40N
MKey5ZX (EX)
2TLA050003R0100
2TLA050003R0101
2TLA050003R0110
2TLA050003R0111
2TLA050003R0120
2TLA050003R0121
2TLA050003R0125
Level of safety
ENISO 13849-1
EN 62061
Up to PL e/Cat. 4 depending upon
system architecture
Up to SIL3 depending upon system
architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life)
MTTF
d
2.5 x 10
6
operations at 100mA load
35 years
356 years (8 cycles per hour/24
hours per day/365 days)
Utilisation category AC15 A300 3A
Force/travel for
positive opening
6 mm
Acuator entry mini. radius 175 mm Standard Key
100 mm Flexible Key
Max. approached/withdrawal
speed
600 mm/s
Actuator Stainless steel
Mechanical life 1 million switch operations
Rated insulation/withstand voltage 500VAC/2500VAC
Vibration resistance IEC 68-2-6, 10-55Hz+1Hz,
excursion: 0.35 mm,
1 octave/min
Contacts
(actuator key inserted)
2NC + 1NO
(NC are direct opening action)
Thermal current (lth) 10A
Enclosure protection
MKey5
MKey5Z(X)
IP67
IP69K and IP67
Operating temperature -25C to +80C
Conduit entries 3xM20
Material
MKey5
MKey5Z(X)
Polyester or/and stainless steel 316
Stainless steel 316
Colour Red or stainless steel
Mounting position Any
Mounting bolts Body 2 x M5, actuator 2 x M5
Explosion Proof version (X)
Classication
Rated Voltage
Rated Current
Ex d IIC T6
(-20C Ta +60C) Gb
Ex tb IIIC T85C
(-20C Ta +60C) Db
250V AC/DC
2 pole 4A
4 pole 2.5A
9/35 2TLC172001C0202 | ABB Safety Handbook
9
Switch operational description
MKey8 interlock safety switches are design to provide position
interlock detection and locking for moving guards.They are desi-
gned to t the leading edge of sliding, hinged or lift off machine
guards. The actuator is tted to the moving part of the guard and
is aligned to the switch entry aperture. The possibility to lock the
switch in the protective position prevents unwanted access to
machinery until dangerous operations have ceased.
The locking is useful when applications include:
processes which cannot be interrupted, such as welding.
machinery with a long stopping procedure, such as paper
machinery that requires a long braking operation.
prevention of unauthorised access to a particular area.
The head can be set in four positions, thus providing the safety
device with eight different operating positions. The leading edges
of the actuator key are reinforced and beveled in order to guide
it properly into the hole. The MKey8 series have been developed
with a high holding force of 2000N. MKey8 has several types of
actuators as an option. Astandard actuator key is always deli-
vered with interlock switches.
Material
Depending on the environment where the switch will be used,
different material can be chosen for the Mkey8. The basic versi-
on has a rugged die cast housing with a rating of IP67.
In harsh applications as for food processing and chemical
industry there is a MKey8 Interlock switch with a total rugged
stainless steel 316 body. This version has IP69K enclosure
protection (maintained by a double seal lid gasket and seals) and
can be high pressure hosed with detergent at high temperature.
Safety Interlock Switch
MKey8
Two ways to interlock
The MKey8 is available in two basic versions, either with a spring
lock or an electro-magnetic lock.
In the spring lock version, the locking mechanism moves into the
locked position directly when the door is closed and the actua-
tor key is pushed into the switch. The actuator key can only be
released and the gate opened by supplying operational voltage
to the solenoid (A1-A2). The MKey8 also has an emergency
rear release unlocking facility to enable the actuator key to be
released without the energisation of the solenoid (A1-A2). This
version is called MKey8ER.
MKey8M is the electro-magnetic lock version, the locking me-
chanism is only in the locked position when the solenoid (A1-A2)
is supplied with operating voltage. Release of the actuator key
is only possible when the operating voltage is removed from
the solenoid (A1-A2). The solenoid voltage can be 24VDC or
230VAC depending on choice.
Safety level
The MKey8 has double forced disconnection contacts connec-
ted to the actuator key and the locking mechanism. The actuator
key is designed to protect against unauthorised access; no
tools, magnets or similar allow that the MKey8 can be tam-
pered with. To achieve highest safety level in connection with
the machine control system, it is recommended that the MKey8
is monitored by an appropriate ABB Jokab Safety safety relay,
Pluto safety-PLC or Vital system. To obtain the highest level of
safety, two switches per gate are required.
Approvals:
Application:
Gates
Hatches
Features:
Robust design
8 actuating positions
High holding force
Up to PL e/Cat.4
Painted metal or stainless
steel
LED status indication
TV
Rheinland
ABB Safety Handbook | 2TLC172001C0202 9/36
9
MKey8M, Contacts at withdrawal of actuator.
MKey8/8Z, Contacts at withdrawal of actuator.
Schematic circuit: LED1 status of solenoid, LED2status of lock
(Terminals33-34 are selectable to be used either as power feed to
LED2 or as a voltage free auxiliary circuit to indicate lock status).
Dimensions MKey8, MKey8M and MKey8Z
MKey8 -Standard version with spring lock
The version of MKey8 with die cast housing and spring lock.
The switch has a contact block configuration of 2NC + 2NC
with positive force disconnection contacts. One pair closes
when the actuator key is pushed into the head (2NC). The
other pair closes when the locking mechanism is in the locked
position (2NC). There are two NO auxiliary circuits, 1NO circuit
with indication of guard open and on another 1NO circuit
indication of lock status.
MKey8Z - Stainless Steel version with spring lock
The version of MKey8 with rugged stainless steel housing and
spring lock. The switch has a contact block configuration of
2NC + 2NC with positive force disconnection contacts. One
pair closes when the actuator key is pushed into the head
(2NC). The other pair closes when the locking mechanism is in
the locked position (2NC). There are two NO auxiliary circuits,
1NO circuit with indication of guard open and on another 1NO
circuit indication of lock status.
MKey8M-Power to lock version with magnetic lock
The version of MKey8 with die cast housing and magne-
tic lock. The switch has a contact block configuration of
2NC+1(NC+NO) with positive force disconnection con-
tacts. One pair closes when the actuator key is pushed into
the head (1NC+1NO). The other pair closes when the locking
mechanism is in the locked position(2NC). A 1NO/1NC circuit
gives an indication of actuator status.
MKey8M MKey8Z MKey8
MKey8, MKey8M and MKey8Z
11/12 Open
21/22 Open
33/44 Open
43/44 Open
6.0 5.0 0mm
11/12 Open Solenoid energised
21/22 Open Solenoid energised
33/34 Open Tongue Inserted
43/44 Open Tongue Inserted
6.0 5.0 0mm
SOLENOID
DE-ENERGISED
GUARD OPEN
MKey8M
GUARD
OPEN
MKey8/8Z
9/37 2TLC172001C0202 | ABB Safety Handbook
9
MKey8ER-Standard version with escape release
The version of MKey8 with die cast housing and spring lock
with escape release. The switch has a contact block con-
figuration of 2NC + 2NC with positive force disconnection
contacts. One pair closes when the actuator key is pushed
into the head(2NC). The other pair closes when the locking
mechanism is in the locked position (2NC). There are two NO
auxiliary circuits, 1NO circuit that indicates guard open and
1NO circuit that indicates lock status.
Features
The MKey8ER has manual release button at the rear of the
housing. This can be used where the risk assessment for
the application permit, a non latching manual escape of the
switch lock in case of emergency. The switch must be moun-
ted so that the release button is reachable from inside the ac-
tive guard area. Press and holding the red button will release
the lock mechanism and lock monitoring contacts while the
guard can be pushed open.
LED1 status of solenoid LED2 status of lock (terminals 33-34 are selecta-
ble to be used either as power feed to LED2 or as a voltage free auxiliary
circuit to indicate lock status).
Dimensions MKey8ER
MKey8ER
1. Press and hold
2. Open the
guard door
2
1
5
4
0
4
6
9.50
3
0
32 124
3
0
Fixing Holes
for M5 Screws
FRONT ENTRY
4
1
.
5
0
176
4
7
1
6
23.50
2
8
.
5
0
70
67
21
9
.
5
0
5
25
END ENTRY
TYPE: KLM-RR
ABB Safety Handbook | 2TLC172001C0202 9/38
9
8 actuators entry positions
rotatable head
Regulations and Standards
The MKey8 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
EN1088, IEC/EN60947-5-1, EN60204-1, ENISO13849-1,
EN62061 and UL508.
Top or side
manual release
points (not on MKey8M)
Manual release key
for MKey8Z
2TLA050040R0400
Actuator
1.Standard Key for SS head 2TLA050040R0202
2. Flat Key 2TLA050040R0220
3.Flexible Key with metal housing 2TLA050040R0203
4.Flexible Key with SS housing 2TLA050040R0204
(Key always in Stainless steel)
1
2
3
4
Technical data MKey8 series
Article number
MKey8 - Standard
MKey8 - 24VDC
MKey8 - 230VAC
MKey8M - Power to Lock
MKey8M - 24VDC
MKey8M - 230VAC
MKey8ER - Escape release
MKey8ER - 24VDC
MKey8ER - 230VAC
MKey8Z - Stainless Steel
MKey8Z - 24VDC
MKey8Z - 230VAC
2TLA050011R0132
2TLA050011R0134
2TLA050013R0132
2TLA050013R0134
2TLA050015R0132
2TLA050015R0134
2TLA050011R0122
2TLA050011R0124
Level of safety
ENISO 13849-1
EN 62061
Up to PL e/Cat. 4 depending upon
system architecture
Up to SIL3 depending upon system
architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life)
MTTF
d
2.5 x 10
6
operations at 100mA load
35 years
356 years (8 cycles per hour/24
hours per day/365 days)
Utilisation category AC15 A300 3A
Solenoid voltage (by part number) 24 VDC or 230 VAC, +/- 10%
Solenoid power consumption 12 W (MKey8M inrush 50 W)
LED 2 supply voltage 24 VDC, +/- 10%
(MKey8, MKey8ER, MKey8Z)
Travel for positive opening 10 mm
Actuator entry mini. radius 175 mm Standard Key
100 mm Flexible Key
Max. approached/withdrawal
speed
600 mm/s
Rated insulation/withstand voltages 600VAC/2500VAC
Vibration resistance IEC 68-2-6, 10-55 Hz+ 1 Hz
excursion: 0.35 mm
1 octave/min.
Thermal current (lth) 5A
Enclosure protection
MKey8/M/ER
MKey8Z
IP67
IP69K and IP67
Operating temperature
MKey8
MKey8M
MKey8ER
MKey8Z
-25C to +55C
-25C to +40C
-25C to +55C
-25C to +55C
Conduit entries 3xM20
Material
MKey8/M/ER
MKey8Z
Die cast painted red
Stainless steel 316
Colour Red or stainless steel
Mounting position
Any
Mounting bolts 4 x M5
9/39 2TLC172001C0202 | ABB Safety Handbook
9
Switch operational description
The MKey9 interlock safety switches are design to provide
position interlock detection and locking for moving guards.
They are designed to fit the leading edge of sliding, hinged
or lift off machine guards. The actuator is fitted to the moving
part of the guard and is aligned to the switch entry aperture.
The possibility to lock the switch in the protective position
prevents unwanted access to machinery until dangerous ope-
rations have ceased.
The locking is useful when applications include:
processes which cannot be interrupted, such as welding.
machinery with a long stopping procedure, such as paper
machinery, that requires a long braking operation.
prevention of unauthorised access to a particular area.
The head can be set in four positions, thus providing the sa-
fety device with eight different operating positions. The leading
edges of the actuator key are reinforced and bevelled in order
to guide it properly into the hole. The safety switch is design
to have a high holding force of 2000N. MKey9 has several
types of actuators as an option. A standard actuator key is
always delivered with interlock switches.
Material
The MKey9 is made in a rugged polyester housing with a
stainless steel head which give the switch a rating of IP67.
Two versions
The MKey9 is available in two basic versions, either with a
spring lock or an electro-magnetic lock.
In the spring lock version, the locking mechanism moves into
the locked position directly when the door is closed and the
actuator key is pushed into the switch. The actuator key can
only be released and the gate opened by supplying operatio-
nal voltage to the solenoid (A1-A2).
MKey9M is the electro-magnetic lock version, the locking me-
chanism is in the locked position when the solenoid (A1-A2) is
supplied with operating voltage. Release of the actuator key is
only possible when the operating voltage is removed from the
solenoid (A1-A2). The solenoid voltage is 24VDC.
Safety level
The MKey9 has double forced disconnection contacts to the
actuator key and the locking mechanism. The actuator key is
designed to protect against unauthorised access; no tools,
magnets or similar allow that the MKey9 can be tampered
with. To achieve maximum safety level in connection with the
machine control system, it is recommended that the MKey9 is
monitored by an appropriate ABB Jokab Safety safety relay,
Pluto safety-PLC or Vital system. To obtain the highest level of
safety, two switches per gate are required.
Regulations and Standards
The MKey9 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
EN1088, IEC/EN60947-5-1, EN60204-1, ENISO13849-1,
EN62061 and UL508.
Safety Interlock Switch
MKey9
Approvals:
Application:
Gates
Hatches
Features:
Compact and robust
8 actuating positions
High holding force
Up to PL e/Cat.4
LED status indication
TV
Rheinland
ABB Safety Handbook | 2TLC172001C0202 9/40
9
SOLENOID
DE-ENERGISED
GUARD OPEN
MKey9M
MKey9
Top or side
manual release points
(not on MKey9M)
8 actuator entry positions
rotatable head
Schematic circuit MKey9 LED1 status of solenoid LED2 status of lock
(Terminals 33-34 are selectable to be used either as power feed to LED2
or as a voltage free auxiliary circuit to indicate lock status).
Dimensions MKey9 and MKey9M
MKey9, Contacts at withdrawal of actuator. MKey9M, Contacts at withdrawal of actuator.
11/12 Open
21/22 Open
33/34 Open
43/44 Open
11/12 Open Solenoid energised
21/22 Open Solenoid energised
33/34 Open Tongue Inserted
43/44 Open Tongue Inserted
6.0 5.0 0mm
Actuator
1.Standard Key for SS head 2TLA050040R0202
2. Flat Key 2TLA050040R0220
3.Flexible Key with metal housing 2TLA050040R0203
4.Flexible Key with SS housing 2TLA050040R0204
(Key always in Stainless steel)
1
2
3
4
6.0 5.0 0mm
GUARD
OPEN
MKey9
Technical data MKey9 series
Article number
MKey9- 24VDC
MKey9M - 24VDC (powertolock)
2TLA050007R0112
2TLA050009R0112
Level of Safety
ENISO 13849-1
EN62061
Up to PL e/Cat. 4 depending upon
system architecture
Up to SIL3 depending upon system
architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life)
MTTF
d
2,5 x 10
6
operations at 100mA load
35 years
356 years (8 cycles per hour/24
hours per day/365 days)
Utilisation category AC15 A300 3A
Solenoid voltage 24VDC or 230 VAC, +/- 10%
Solenoid power consumption
MKey9
MKey9M
12 W
12 W (Inrush 50W)
LED 2 supply voltage 24 VDC, +/- 10%
Travel for positive opening 10 mm
Actuator entry mini. radius 175 mm Standard Key
100 mm Flexible Key
Max. approached/withdrawal
speed
600 mm/s
Rated insulation/withstand voltages 600VAC/ 2500VAC
Vibration resistance IEC 68-2-6, 10-55 Hz+ 1 Hz
excursion: 0.35 mm
1 octave/min.
Thermal current (lth) 5A
Conduit entry 1xM20
Enclosure classication IP67
Operating temperature
MKey9
MKey9M
-25C to +55C
-25C to +40C
Head/body material Stainless steel 316/polyester
Colour Red
Mounting position Any
Mounting bolts 4 x M5
10/1 2TLC172001C0202 | ABB Safety Handbook
10
ABB Safety Handbook | 2TLC172001C0202 10/2
10
Control devices
Why should control devices be used? 10/3
Three-position devices
JSHD4 10/5
Safeball
One- and two-hand devices - Safeball 10/15
Two-hand control station JSTD25 10/19
Two-hand device
JSTD20 10/23
10/3 2TLC172001C0202 | ABB Safety Handbook
10
-for the machine operator to be able to directly start and stop
dangerous machine movement.
Why should Control Devices be used?
Three-position device
Three-position devices, hold-to-run devices and enabling devices are used during
trouble-shooting, programming and test running when no other safety components
are possible or suitable. The device is held in the hand and the operator can in an
emergency situation either press harder or entirely release the device to stop the
machine.
Ergonomic three-position device, JSHD4 with
double three-position button that gives a stop
signal when released or fully pressed in.
In an emergency situation the operator can either press harder or release the
three-position device to stop the machine.
Three-position device fitted to a machi-
ne control unit.
Panel assembly of JSHD4H2 on a
programming unit for robots.
Three-position devices in different versions
ABB Safety Handbook | 2TLC172001C0202 10/4
10
Two-hand control device
A two-hand control device is used when it is necessary to
ensure that the operator's hands will be kept outside the risk
area. If there is a risk that someone else other than the opera-
tor can reach into the machine without the operator seeing it,
the safety device must be supplemented by something more,
e.g. a light beam.
To be able to operate the machine with the two-hand device,
all the buttons on the device have to be operated within 0.5
seconds of each other. This is called concurrence. All the
buttons also have to be returned to their initial position before
one can start again. If any button is released during the ma-
chine movement the machine will be stopped. Using the stop-
ping time one can calculate the necessary safety distance. A
safety distance of less than 100 mm must not be used.
The highest safety level is assured by connecting the buttons
of the two-hand device to a safety relay. The safety relay
checks for concurrence and that all the buttons have returned
to their initial position before a new start can be made. The
safety relay also gives a stop signal if any of the buttons are
released.
The two-hand device protects against "after-grasp"; if the
operator by reflex tries to enter or reach into a machine
during the dangerous machine movement.
Two-channel all the way out to the hand
Safeball is an ergonomic two-hand control device with four built-in but-
tons.
Foot operated switches
A foot operated switch is used when the operator has to
hold the material during processing. The pedal must have a
safety cover to prevent unintentional start. For seated work
one must also have a foot support to facilitate the operator
holding his foot in the pedals off position.
The highest safety level is secured by monitoring the pedal
with a safety relay.
The foot operated switch is used when the operator has
to hold the material with both hands during processing.
Safety foot operated switch with three-position function.
10/5 2TLC172001C0202 | ABB Safety Handbook
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The safest solution during trouble shooting, programming
and testing
Why three-positions?
An operator who is under pressure must be able to give a
stop signal, whether in panic he/she pushes harder on the
button or just lets go of it.
Three-position devices, hold-in and acceptance devices can
be used for trouble shooting, programming and test running in
situations where no other protection is available or feasible.
If the operator has to enter a risk area to trouble shoot or run
a test, it is extremely important that he/she is able to stop the
machinery without having to rely on someone else to stand
by a stop button that is further away. In addition, no-one else
should be able to start the machinery from the outside after it
has been stopped by use of the three-position device.
Hold to run device or Acceptance device, what is the
difference?
Hold to run device: The start signal is given when the
button is pressed. The stop signal is given when the button is
released or pushed fully in.
Acceptance device: The start signal for separate starting is
given when the button is pressed. The stop signal is given
when the button is released or pushed fully in. Separate
start means, for example, that a program start signal is sent
to the robot via a separate button in the acceptance device.
The three-position device is designed to be ergonomic
The device is ergonomic, both in respect of its shape, fitting
to the hand, and the way the buttons are operated. It is easy
to operate the three-position device using just the fingers,
and the middle position provides a secure resting position.
The device has LED indications that show the operational
status, i.e. stop or ready signal. The two additional buttons
can be used, for example, for start/stop, up/down or forward/
back. Internally the device is duplicated. The three-position
function itself is built up of two completely independent three-
position buttons which are felt by the user to be one button.
Cheat Safe three-position device with hand recognition
The three-position device JSHD4 has sensors which ensure
that it is a human hand holding it. By using this, the safety le-
vel is increased, and the risk of manipulation or bypass of the
safety function is reduced. It is no longer possible to expose
the operator to danger by trying to lock the three-position
device in run mode.
Three-position device adapted for AS-i
The three-position device JSHD4 also comes in a version
adapted for direct attachment to the AS-i bus.
Three position device
JSHD4
Approvals:
Use:
Troubleshooting
Test running
Programming
Features:
Ergonomic
LED information
Adaptable
Cheat Safe (option)
Available for AS-i
TV
NORD
(AS-i versions)
ABB Safety Handbook | 2TLC172001C0202 10/6
10
How does a a three-position device work?
Safety level
A safe Enabling or Hold to Run device should function as
follows:
1.The Stop signal in released (top) and bottom position shall
have the same safety level.
2. Provide a Start or Ready signal in a distinct middle
position.
3. After a Stop in the bottom position, a Start signal or
Ready signal is not permitted until the three position push-
buttons have been totally released and again pressed to the
middle position. This function is achieved mechanically within
the three position push-buttons in the device.
4. A Short or Open circuit in the connection cables shall not
lead to a dangerous function e.g. Start or Ready signal.
In order to meet the above conditions, the three-position
switch must be connected to a suitable safety relay with a
two channel function, or Safety PLC, which can monitor that
both three-position buttons are working and that there is no
short or open circuit in the connection cable or the switch.
Regulations and standards
The JSHD4 is designed and approved in accordance with
appropriate directives and standards. See technical data.
Highest safety level whether the button is pushed or released
When the three-position button is released you will obtain a dual stop. It
is essential that the machine stops when you put aside the three-position
device, for example during adjustment.
When the three position button is pushed all the way in you will obtain a
dual stop. It is essential that the machine stops in an emergency situation.
Middle position Bottom position
Released position
10/7 2TLC172001C0202 | ABB Safety Handbook
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Design a three-position device for your needs
3. Choose hand recognition for making your three position device cheat protected (option)
Anti-tamper PCB
2TLA020005R0900
1. Choose between five different top units
JSHD4-2
2TLA020006R2200
LEDs
Front button
Top button
JSHD4-3
2TLA020006R2300
LEDs
JSHD4-1
2TLA020006R2100
JSHD4-4
2TLA020006R2400
LEDs
Front button
JSHD4-5
2TLA020006R2500
LEDs
Top button
2. Choose a bottom part suitable for your assembly
AA 2TLA020005R1000 with cable gland
AH 2TLA020005R1700 with cable gland and PCB with 10screw connections
AJ 2TLA020005R1800 with cable gland and PCB with 16screw connections
AC 2TLA020005R1200 with M12 connection (5 poles)
AD 2TLA020005R1300 with M12 connection (8 poles)
AF 2TLA020005R1500 with M12 connection (4 poles) and 2AS-i nodes (for front and top button)
AG 2TLA020005R1600 with M12 connection (4 poles) and 1AS-i node
(without front and top button)
AE 2TLA020005R1400 with M12 connection (8 poles) and emergency stop
AB 2TLA020005R1100 with Cannon connection
ABB Safety Handbook | 2TLC172001C0202 10/8
10
4. Check the table if your combination is available
5. Choose a bottom plate (option)
JSM50G, bottom plate for Safety
Interlock switch MKey5/JSNY5
2TLA020205R6300
JSM50H, bottom plate for
non-contact sensor Eden (Eva)
2TLA020205R6400
JSHD4-1 JSHD4-2 JSHD4-3 JSHD4-4 JSHD4-5
AA without Cheat Safe JSHD4-1-AA
AA with Cheat Safe
AB without Cheat Safe JSHD4-2-AB JSHD4-3-AB JSHD4-4-AB JSHD4-5-AB
AB with Cheat Safe JSHD4-2-AB-A JSHD4-3-AB-A JSHD4-4-AB-A JSHD4-5-AB-A
AC without Cheat Safe JSHD4-1-AC
AC with Cheat Safe
AD without Cheat Safe JSHD4-2-AD JSHD4-3-AD JSHD4-4-AD JSHD4-5-AD
AD with Cheat Safe JSHD4-2-AD-A JSHD4-3-AD-A JSHD4-4-AD-A JSHD4-5-AD-A
AE without Cheat Safe JSHD4-3-AE
AE with Cheat Safe
AF without Cheat Safe JSHD4-2-AF JSHD4-3-AF JSHD4-4-AF JSHD4-5-AF
AF with Cheat Safe JSHD4-2-AF-A JSHD4-3-AF-A JSHD4-4-AF-A JSHD4-5-AF-A
AG without Cheat Safe JSHD4-3-AG
AG with Cheat Safe
AH without Cheat Safe JSHD4-2-AH JSHD4-3-AH JSHD4-4-AH JSHD4-5-AH
AH with Cheat Safe JSHD4-2-AH-A JSHD4-3-AH-A JSHD4-4-AH-A JSHD4-5-AH-A
AJ without Cheat Safe JSHD4-2-AJ JSHD4-3-AJ JSHD4-4-AJ JSHD4-5-AJ
AJ with Cheat Safe JSHD4-2-AJ-A JSHD4-3-AJ-A JSHD4-4-AJ-A JSHD4-5-AJ-A
10/9 2TLC172001C0202 | ABB Safety Handbook
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Technical data - JSHD4
Level of safety
EN ISO 13849-1 PLe/Cat. 4
Electrical rating
Three-position button
Extra button
Maximum 30 VDC, 20mA
(Minimum 10 VDC, 8mA)
Maximum 50 VAC/VDC 0.2A
Protection class IP65
Operating temperature -10 to +50 C
Function indication
Three-position buttons ready signal `Yes, green LED
`No, red LED
Material
Handle
Rubber
Polyamide and Noryl
Neoprene
Operation force Approx. 15 N for three-position buttons (ON)
Approx. 45 N for three-position buttons (OFF)
Approx. 25 N for top/front push button
Mechanical life 1 000 000 cycles to middle position
Conformity ENISO1200-1:2010, ENISO13849-1:2008, EN60204-1:2006+A1:2009
Cabel with Cannon connector Cabel with M12 connector
Pin 12 conductors Pin 8 conductors 5 conductors
A White 1 White Brown
B Brown 2 Brown White
C Green 3 Green Blue
D Yellow 4 Yellow Black
E Grey 5 Grey Grey
F Pink 6 Pink -
G Blue 7 Blue -
H Red 8 Red -
J Black
K Purple
L Grey and Pink
M Red and Blue
JSM5B Wall bracket for
interlock switches and three-
position device.
JSHD4 protection coat
JSM55 Wall bracket for three-
position device.
JSHK0 12 pole
connector for JSHD4.
Cable, available in different
lengths.
Spiral cable, available in different
lengths.
Cable drum
Accessories
ABB Safety Handbook | 2TLC172001C0202 10/10
10
Accessories
Article number
Connectors:
M12-C01 M12 5-pole female, straight 2TLA020055R1000
M12-C03 M12 8-pole female, straight 2TLA020055R1600
JSHK0 12-pole cannon female connector for JSHD4 2TLA020003R0300
Cable with 5 conductors:
C5 Cable 5x0.34 cut to length (meters) 2TLA020057R0000
M12-C101 10 m cable and M12 female connector 2TLA020056R1000
M12-C201 20 m cable and cannon female connector 2TLA020056R1400
Cable with 8 conductors:
C8 Cable 8x0.34 cut to length (meters) 2TLA020057R1000
M12-C103 10 m cable and M12 female connector 2TLA020056R4000
M12-C203 20 m cable and M12 female connector 2TLA020056R4100
Cable with 12 conductors:
HKC12 Cable 12x0.25 cut to length (meters) 2TLA020003R5500
HK5 Cable 5 m and cannon female connector 2TLA020003R4700
HK10 Cable 10 m and connector 2TLA020003R4800
HK20 Cable 20 m and connector 2TLA020003R4900
HK16S4 spiral cable 1.6 m and cannon female
connector
2TLA020003R5000
HK20S4 spiral cable 2.0 m and cannon female
connector
2TLA020003R5100
HK32S4 spiral cable 3.2 m and cannon female
connector
2TLA020003R5200
HK40S4 spiral cable 4.0 m and cannon female
connector
2TLA020003R3500
HK60S4 spiral cable 6.0 m and cannon female
connector
2TLA020003R3600
HK80S4 spiral cable 8.0 m and cannon female
connector
2TLA020003R5300
HK-T2 Cable drum and connector 2TLA020003R5400
Brackets:
JSM55 Wall bracket for three position device 2TLA040005R0500
JSM5B Wall bracket for 2 MKey5/JSNY5 2TLA040005R0700
Others:
JSHD4 protection coat 2TLA020200R4600
Three position devices - JSHD4
Article number
JSHD4-1-AA 2TLA019995R0000
JSHD4-1-AC 2TLA019995R0100
JSHD4-2-AB 2TLA019995R0200
JSHD4-2-AB-A 2TLA019995R0300
JSHD4-2-AD 2TLA019995R0400
JSHD4-2-AD-A 2TLA019995R0500
JSHD4-2-AF 2TLA019995R0600
JSHD4-2-AF-A 2TLA019995R0700
JSHD4-2-AH 2TLA019995R0800
JSHD4-2-AH-A 2TLA019995R0900
JSHD4-2-AJ 2TLA019995R1000
JSHD4-2-AJ-A 2TLA019995R1100
JSHD4-3-AB 2TLA019995R1200
JSHD4-3-AB-A 2TLA019995R1300
JSHD4-3-AD 2TLA019995R1400
JSHD4-3-AD-A 2TLA019995R1500
JSHD4-3-AE 2TLA019995R1600
JSHD4-3-AF 2TLA019995R1700
JSHD4-3-AF-A 2TLA019995R1800
JSHD4-3-AG 2TLA019995R1900
JSHD4-3-AH 2TLA019995R2000
JSHD4-3-AH-A 2TLA019995R2100
JSHD4-3-AJ 2TLA019995R2200
JSHD4-3-AJ-A 2TLA019995R2300
JSHD4-4-AB 2TLA019995R2400
JSHD4-4-AB-A 2TLA019995R2500
JSHD4-4-AD 2TLA019995R2600
JSHD4-4-AD-A 2TLA019995R2700
JSHD4-4-AF 2TLA019995R2800
JSHD4-4-AF-A 2TLA019995R2900
JSHD4-4-AH 2TLA019995R3000
JSHD4-4-AH-A 2TLA019995R3100
JSHD4-4-AJ 2TLA019995R3200
JSHD4-4-AJ-A 2TLA019995R3300
JSHD4-5-AB 2TLA019995R3400
JSHD4-5-AB-A 2TLA019995R3500
JSHD4-5-AD 2TLA019995R3600
JSHD4-5-AD-A 2TLA019995R3700
JSHD4-5-AF 2TLA019995R3800
JSHD4-5-AF-A 2TLA019995R3900
JSHD4-5-AH 2TLA019995R4000
JSHD4-5-AH-A 2TLA019995R4100
JSHD4-5-AJ 2TLA019995R4200
JSHD4-5-AJ-A 2TLA019995R4300
JSHD4
Models and accessories
10/11 2TLC172001C0202 | ABB Safety Handbook
10
mm 1
0
6
5
2
3
9
6
5
3
4
M5
mm
1
8
6
0
8
0
2
2
1
2
2
1
External assembly JSHD4H2A
The external assembly is similar to the
panel assembly unit, although it is a
handle design making it suitable for
assembly on the outside of a control
box.
Panel assembly JSHD4H2
A panel assembly suitable for building
into programming units or similar control
boxes. Provides simultanous activation
of both of the three-position buttons.
Three-position push button JSHD2C
The button is the main component in a
safe three-position solution. To achieve
the highest safety level two buttons are
used in a two-channel system.
16
1
,4
2
6
,5
5
1
7
,3
5,1
2
0
,
7
1
4
,
3
3
,
4
8
,
5
1
3
,
5
1
0
,
3

2
,8
(2
x
)
Three-position devices for different types of assembly
Standard versions
Article number Model
2TLA020002R0200 JSHD4H2A Three-position device for external panel assembly
2TLA020002R3100 JSHD4H2 Three-position device for internal panel assembly
2TLA020001R1000 JSHD2C type E Three-position button
2TLA020001R1300 JSHD2C type K Three-position button
Complete JSHD4 with standard options are available to order separately
ABB Safety Handbook | 2TLC172001C0202 10/12
10
JSHD4 to Pluto
Time-limited entrance/exit
After lifting the three-position device out of its holder the door can be opened and shut for entrance to the safety zone within X
seconds. To exit zone press S3. The time is set in the Pluto programme. The device detects the operators hand and prohibits
tampering.
JSHD4 with various safety controllers
JSHD4
Connection examples
**Only for AC supply
10/13 2TLC172001C0202 | ABB Safety Handbook
10
Connection with bottom parts AB
Connection with bottom parts AC
Connection with bottom parts AD
Molex contact
Screw terminal
*
Molex contact
*A jump must be placed over pins 14-16 on the 2x8 Molex connector if an anti-tamper PCB is not used.
ABB Safety Handbook | 2TLC172001C0202 10/14
10
Connection with bottom parts AE
Connection with bottom parts AH
Connection with bottom parts AJ
Molex contact
Molex contact
Molex contact
10/15 2TLC172001C0202 | ABB Safety Handbook
10
Safeball Unique World Wide Two-hand device
Safeball consists of a spherical ball containing two embed-
ded pushbutton switches, one on each side of the ball. By
using this pushbutton configuration, the risk of unintentional
activation is minimised and the device is simple and ergono-
mic to use.
Safeball can be utilised for either One-hand (one Safeball)
or Two-hand (two Safeballs) applications. In either appli-
cation, and in order to meet the required level of safety, the
Safeball switches are monitored by specified/certified ABB
JokabSafety Safety relays (see electrical connection).
In the case where Two-hand control is used, both Safeballs
i.e. all four pushbuttons have to be activated within 0.5 se-
conds. If one or more pushbuttons are released a Stop signal
is given to the machine. In order to provide the highest level of
safety the Safeball design provides the operator with a dual
switching function and short-circuit supervision in each hand.

Each Safeball is ergonomically designed and has both its
cover and actuator made of environmentally-friendly polypro-
pylene. The design allows for comfort of use for all hand sizes
and operation from numerous gripping positions. Mounting of
the Safeball is also very flexible allowing the device to be
mounted in the most ergonomic position for the operator.
When can a Two-hand or One-hand control be used?
A Two-hand control can be used when it is necessary to
ensure that the operator is outside and must be prevented
from reaching into the hazardous area. If the operator deci-
des, after the start signal has been given to the machine, to
make an after-grasp i.e. try to adjust the part that has been
placed into the machine, then a dual stop signal is given to
the machine.
An One-hand control device can be used when the operator
cannot reach the hazardous area with his/her free hand or on
less dangerous machines.
Highest Safety Level
The Safeball is certified by Inspecta in Sweden for use as
a Two-hand control device, when used with a JSBR4 ABB
JokabSafety Safety relay or Pluto Safety-PLC, in accordance
with the highest safety level in standard EN 574 (type IIIc).
Safeball adapted for AS-i
Safeball also comes in a version adapted for direct attach-
menent to the AS-i bus. For using the safeball AS-i as a
Two-hand device the AS-i safety monitor needs to be able to
handle simultaneous monitoring otf the channels.
A two-hand device which is
comfortable and easy to use.
One- and two-hand devices
Safeball
Approvals:
Safeball for:
Presses
Punches
Fixtures
Shearing machines
Features:
Ergonomic
Low activation force
Flexible mounting
Several grip possibilities
Highest safety level
Two channel switching in
each hand
Available for AS-i
ABB Safety Handbook | 2TLC172001C0202 10/16
10
Two-hand control device
The Two-hand control device is implemented by using two
Safeballs, each having two internal pushbuttons. The
Safeballs must be mounted a minimum distance between
each other (see Mounting description).
By utilising two pushbuttons in each device a double safety
function is provided in each hand.
The highest safety level is achieved by connecting all four
pushbuttons to the ABB JokabSafety JSBR4 safety relay or
Pluto Safety-PLC. The safety relay gives a dual and super-
vised safety function and requires input activation within 0.5
seconds in order to start the machine. It also checks that all
four pushbuttons have returned to their deactivated posi-
tions before a new start is allowed. The JSBR4 safety relay
also provides a stop signal if one or more pushbuttons are
released.
One-hand control device
Safeball is also a very practical method of providing a
one-hand control device as it is very easy to find and activa-
te by the machine operator. One-hand devices should only
be used when the operator cannot reach into the hazardous
area with his/her free hand or on less dangerous machines.
Before fitting the necessary risk assessment must be made
to determine suitability of this type of control. To achieve the
highest safety level for One-hand control the Safeball must
be connected to a safety control system (E.g. safety relay or
safety PLC).
Versions
Safeball is available in several versions to meet different
mounting requirements.
JSTD1-A - Safeball 1NO + 1 NC with 2m cable
JSTD1-B - Safeball 1 NO + 1NC with 0.2 m cable
JSTD1-C - Safeball 1NO + 1 NC with 10 m cable
JSTD1-E - Safeball 2NO 0.2 m cable
JSTD1-G - AS-i Safeball
Technical data - Safeball
Article number
JSTD1-A 2TLA020007R3000
JSTD1-B 2TLA020007R3100
JSTD1-C 2TLA020007R3200
JSTD1-E 2TLA020007R3400
JSTD1-G AS-i 2TLA020007R3900
Material Polypropylene
Colour Yellow and black
Size Height: approx. 71 mm
Diameter, min.: 68 mm
Diameter, max.: 72 mm
Diameter, base: 42 mm
Weight 0.2 kg with 2 m cable
0.7 kg with 10 m cable
0.1 kg with 4x0.2 m wires
Level of Safety
EN ISO 13849-1 Up to PL e/Cat. 4
Ambient temperature -25C to +50C (operating)
Protection class IP67. Not intended for use under
water
Operating force Approx. 2 N
Actuator travel 1.3 +/- 0.6 mm
Max switching load 30 V 2A DC, resistive load
Max current (resistive load) 2 A at 30 VDC (max)
20 mA at 24 VDC (recommended)
Min switching load 6V 10mA DC, resistive load
Contact resistance 100 mohm
Life, mechanical > 1x10
6
operations at max. 1 Hz
Life, electrical Dependant upon electrical load
characteristics
Connection cable
JSTD1-A
JSTD1-B, JSTD1-E
JSTD1-C
JSTD1-G AS-i
2m PVC-cable, 4 x 0.75mm
2
4 x 0.75 mm
2
wires, approx. 0.2m
10 m PVC-cable, 4x0.75 mm
2
2 x 0.75mm
2
wires, approx. 0.25m
Conformity EN ISO 12100:2010
EN574+A1:2008
Activation of a pushbutton.
A top cover is not needed as activation switches are
fitted on each side of the Safeball.
Safeball
Function
7
1
72
68
23
4,5 (4x)
23
mm
Chemical resistance at 20C
Chemical Resistance
Alcohols good
Parafn oil good
Milk good
Silicon oil good
Acetone good
Please contact us for more information.
10/17 2TLC172001C0202 | ABB Safety Handbook
10
S
1
2
0
120 180
mm
Safeball
Mounting
Alternative mounting methods The Safeballs can be mounted in many different ways.
They can be mounted on a table, a machine, on a support or
wherever suitable for ergonomic reasons. The Safeball can
be mounted in a fixed position or on a tilting and/or rotating
support. This flexibility of mounting permits the Safeball
to be fitted in the best ergonomic position for the ease of
operation by the operator. The distance requirement between
two Safeballs or between a Safeball and a wall or edge of
a table depends on how the Safeball is mounted. Safeball
can be mounted with four M5 screws or ST4.8 self-tapping
screws.
NOTE! When Safeballs are mounted in such a way that
the distance between them can be adjusted to less than the
specified minimum, the mounting screws must be locked to
ensure any changes in the distance between the two balls
cannot be made.
Approved Two-hand device
To be an approved Two-hand device, both Safeballs must be mounted a minimum distance apart in order to prevent
operation of both balls with one hand. Safeballs must be fitted a minimum distance from the edges of tables or a wall. It
is essential that Safeballs are correctly installed in order to prevent unintended activation of the devices with part of the
body in combination for example with a wall.
Mounting distance
Table mounting of two Safeballs.
In order to prevent cheating the distan-
ces shown are the minimum allowed.
The safety distance is the distance between the
Safeballs and the dangerous machine movement. Note
that S must never be less than 100 mm.
Where
S = safety distance in mm
K = hand speed, 1600 mm/s
T = total stopping time for the dangerous movement
(including the response time of the safety relays
in seconds)
C = Constant = 0 mm for Safeball.
Safety distance
The Safety distance is the distance between the Safeballs
and the dangerous machine movement. The safety distance
requirement can be calculated using the following formula for
Safeball in accordance with the approving authority and
ENISO13855: S= KxT+C
Mounting distance -Safety distance - Safeball
Example of alternative
mounting.
Mounting on a table.
Mounting with ball joint, which
can be rotated and angled.
ABB Safety Handbook | 2TLC172001C0202 10/18
10
Safeball
Electrical connection
r
e
d
b
l
a
c
k
b
l
a
c
k

(
1
)
b
l
a
c
k

(
2
)
w
h
i
t
e
g
r
e
y
b
l
u
e
r
e
d
r
e
d
b
l
a
c
k
g
r
e
y
b
l
u
e
Twohand device
Safeballs are designed to be connected to a
ABBJokabSafety JSBR4 Safety relay or Safety PLC to
achieve the highest safety requirements for a Two-hand
device.
Example of two devices connected to a ABB JokabSafety
JSBR4 safety relay. Response time on receiving a stop signal
from JSTD1 < 15 ms.
One-hand device
When used as a One-hand device the Safeball is designed
to be connected to a ABB JokabSafety RT6, RT7 or RT9 Sa-
fety relay in order to achieve the highest possible safety level
for this type of control.
Example of a single Safeball connected to a
ABBJokabSafety relay RT9. The response time at stop is
< 20 ms.
10/19 2TLC172001C0202 | ABB Safety Handbook
10
The JSTD25 replaces the traditional two-hand device. With the JSTD25 control station you have a prepared two-hand
unit that is easy to install, while utilizing the good ergonomics of the Safeball. There are several versions to meet
differing needs, all versions meet EN 574 and EN ISO 13849-1.
JSTD25K
Article number - 2TLA020007R6900
The JSTD25K is a fully equiped two-hand control device that
is very similar and has all the advantages from the JSTD25F/
JSTD25H.
JSTD25K has just as JSTD25F/H, two Safeballs mounted on
the ends of an aluminum profile and the same length. The
additional equipment is double protection shields protecting
for unintended press from several directions and a Smile
10 EA emergency stop placed on the middle of the profile.
Connection is made easily with a 8-pole M12 male connector
underneath the device.
JSTD25P-1
Article number - 2TLA020007R6500
Two-hand control unit, portable. Two Safeballs mounted on
the ends of an aluminium profile, shielded by over hand gu-
ards. With built-in Eva sensor for position control. Developed
as a portable two-hand device, where the response of the
JSTD25F/JSTD25H
Article number - 2TLA020007R6000/2TLA020007R6300
An ergonomic two-hand control unit with two Safeballs
mounted on the ends of an aluminum profile. Both Safeball
are protected with shields for unintended press of the Safe-
ball buttons. The device can be easily mounted with the aid
of grooves in the aluminum profile and an quick connection
is made to the M12 connector underneath the device. For
mobile applications with repositioning of the two hand device
this unit is very suitable because of its low weight.
JSTD25F is equipped with a 5-pole M12 male connector and
the JSHD25H is equipped with an 8-pole M12 male connec-
tor.
Both units can be equipped with an external emergency stop
(Smile) and an Eden sensor for position control (ordered sepa-
rately and assembled by the customer).
Two-hand control station JSTD25 with Safeball
For mobile or fixed installation
For mobile installation with a built-in Eden sensor
machine to operation can vary at different operating stations,
since each station can be connected separately. Connection
via an 8+1 Zylin connector.
ABB Safety Handbook | 2TLC172001C0202 10/20
10
23
2
3
3
2
43 JSM C5
Article number - 2TLA020007R0900
Angled ball joint for installation
of a Safeball on a table or a steel housing.
JSM C7
Article number - 2TLA020007R1200
Suspension shelf for JSTD25F/H/G/K
JSM C14
Article number - 2TLA020007R8000
Suspension shelf for JSTD25P-1
Safeball protection coat
Article number - 2TLA020007R1900
Extra protection coat for Safeball.
JSTK25S
Article number - 2TLA020007R6700
2.5 m long spiral cable for JSTD25P-1
JSTK50S
Article number - 2TLA020007R6800
8 m long spiral cable for JSTD25P-1
JSTK0-A
Article number - 2TLA020007R6600
Female connector for JSTD25P-1
Accessories
10/21 2TLC172001C0202 | ABB Safety Handbook
10
Connection examples
JSTD25H
JSTD25F
ABB Safety Handbook | 2TLC172001C0202 10/22
10
Connection examples
Dimensions
JSTD25
JSTD25P-1
M12, 5-pole male
370

2
356
9
5
2200.5
1
2
1
2
9
4
90.5 0.5
JSTD25F
JSTD25P-1
10/23 2TLC172001C0202 | ABB Safety Handbook
10
Conventional Two-hand device
The conventional JSTD20 Two-hand device utilises a welded
steel housing. Two operating pushbuttons are protected by
over hand guards. Between these pushbuttons there is space
for a emergency pushbutton and two extra controls or indica-
tion lamps. Below each of the operating pushbuttons is one
normally open and one normally closed contact. To start and
run the machine both pushbuttons must be activated within
0.5 seconds. If one or both pushbuttons are released a stop
signal is given to the machine, and all contacts must return to
their deactivated positions before a new start is allowed.
The design is robust and can withstand harsh environments
and long use. The pushbuttons and contact blocks are simple
to assemble for quick and easy installation. The device can be
mounted directly on the machine, on the ABB JokabSafety
fencing system or on the JSTS30 floor mount. For use with
portable Two-hand devices the JSTS31 floor mount, which
is provided with a spacer ring to fulfil the requirements of
EN574, is recommended. The JSTD20 is available with or
without an emergency stop pushbutton.
Highest level of safety
Correct connection to a ABB JokabSafety JSBR4 safety
relay or Pluto Safety PLC ensures the highest level of safety
with dual and supervised safety function and requires input
activation of both operating pushbuttons within 0.5 seconds
(two hand device type III C in accordance with EN 574). If the
emergency pushbutton is installed it should be provided with
two normally closed contacts and be connected to a separate
safety relay, e.g. from the RT series or Pluto.
Why use a Two-hand device?
A Two-hand device can be used when it is necessary to
ensure that the operator is outside and must be prevented
from reaching into the hazardous area. If the operator deci-
des, after the start signal has been given to the machine, to
make an after grasp i.e. try to adjust the part that has been
placed inside the machine, then a dual stop signal is given to
the machine.
The JSTD20 is equipped with a type of large over hand gu-
ards in accordance with EN 574. These prevent unintended
activation by for instance a knee or elbow.
A Two-hand device only protects the operator using it. Large
machines operated by several operators can be equipped
with one control for each operator.
To calculate the correct safety distance, which depends on
the machines stopping time including the response time of
the relay, the use of the ABB JokabSafety Smart Stopping
analyser is recommended.
Two-hand device
JSTD20
Approvals:
Use:
Presses
Punching machines
Cutting machines
Fixtures
Features:
Durable material
With or without emergency
stop pushbutton
Fulfils requirements of EN574
Highest level of safety
ABB Safety Handbook | 2TLC172001C0202 10/24
10
Connection example - JSTD20
The Two-hand device is intended for use with ABB JokabSafetys JSBR4 safety relay (or Pluto Safety PLC ) to ensure the
highest level of safety. The JSBR4 ensures that all contacts have returned to their deactivated positions before a new start is
allowed. The safety relay also requires that all contacts are activated within 0.5 seconds. The JSBR4 gives a stop signal if one
or both of the pushbuttons are released.
Technical data - JSTD20
Article number
JSTD20A
JSTD20B
JSTD20C
2TLA020007R2000
2TLA020007R2100
2TLA020007R2200
Weight 6.4 Kg
Colour Black housing, Black pushbuttons,
Black oor stand.
Temperature -10C+70C (Operating)
-20C to +70C (storage)
Level of Safety
EN ISO 13849-1 Up to PL e/Cat. 4
Material Housing: 3mm Steel
Gasket: Rubber
Pushbuttons: Plastic
Operating pushbuttons
Diameter
Operating force
Operating distance
Mechanical life
60 mm
Approx. 9N
3.51mm
10
6
operations
Emergency pushbutton
(JSTD20B only)
Diameter
Operating force
Mechanical life
Contacts
40 mm
40N
3 x 10
5
operations
Mechanically separated contact
blocks
Operating pushbuttons 1 NO + 1 NC /button
Emergency pushbuttons 2 x NC
Isolation voltage 690V rms
Contact resistance 20 mohm
Rated current 10A
JSTD20A Two-hand device
without emergency stop
JSTD20B Two-hand device with
emergency stop
Utilisation categories AC 15 240V 3A
DC 13 240V 0.27A
Cabling screw clamp terminals, 1 or 2 wires
with max. cross-section 2.5 mm
2
.
Contact material silver alloy on brass
Protection class IP65
Accessories
JSTS30 oor stand
JSTS31 oor stand + distance ring
JSTS32 distance ring
2TLA020007R4000
2TLA020007R4100
2TLA020007R4200
Conformity ENISO 13850, ENIEC 60947-5-5,
EN 574+A1:2008, EN12100:2010,
EN ISO 13849-1, EN 60947-1,
EN 60947-5-1, EN ISO 12855
JSTD20A Two-hand device, without emergency stop
JSTD20B Two-hand device, with emergency stop
JSTD20C Only housing, no buttons
4
9
0

1
4
5

mm
1
7
0
11/1 2TLC172001C0202 | ABB Safety Handbook
11
ABB Safety Handbook | 2TLC172001C0202 11/2
11
Emergency stops and Safety stops
Why do you need an Emergency stop? 11/3
Emergency stop
For enclosure installation - INCA 1 11/4
For enclosure installation - INCA 1 Tina 11/5
With indication - Smile 11/7
With indication - Smile TIna 11/11
With indication - Smile AS-i 11/15
Compact 11/17
EStrongZ 11/19
Other buttons
Safety stop - INCA, Smile and Compact 11/21
Reset button - Smile 11 R 11/22
Emergency Stop Grab Wire
Emergency Stop Grab Wire Safety Switches 11/23
LineStrong1 11/25
LineStrong2 11/27
LineStrong3 11/29
Accessories 11/33
11/3 2TLC172001C0202 | ABB Safety Handbook
11
so that anyone shall be able to stop a machine during a
machine break-down or if someone is in danger.
Why do you need an Emergency stop?
How do I recognise an E-stop?
E-stop buttons shall according to relevant standards be red
with a yellow background. An emergency stop grab wire shall
be red for high visibility. A sign that indicates the location of
the E-stop shall be green with a white picture and possibly
with text in the local country's language.
How shall an E-stop stop the machine?
An E-stop shall stop the machine as quickly as possible. To
obtain a quick stop one either removes the power directly or
one lets a frequency converter 'run down' and afterwards af-
ter a little delay, remove the power. An E-stop shall not create
other hazards. Therefore a risk analysis must be made for the
E-stop to be correctly connected.
From 2006/42/EC, clause 1.2.4.3
...
This device must:
- have clearly identifiable, clearly visible and quickly
accessible control devices,
- stop the hazardous process as quickly as possible,
without creating additional risks,
- where necessary, trigger or permit the triggering of
certain safeguard movements.
...
2006/42/EC The Machinery Directive
Clause 1.2.4.3 in Annex 1 gives requirements for the emer-
gency stop function for new machines). See also clause 1.2.2
Control devices. (see chapter Standard and Regulations)
Council Directive 89/655/EEC (with amendments)
concerning the minimum safety and health requirements
for the use of work equipment by workers at work
Clause 2.4 gives the requirements for the emergency stop
function for older machines. See also clause 2.1. (see chapter
Standard and Regulations)
EN ISO 13850 Safety of machinery Emergency stop
Principles for design
A harmonized standard that gives technical specifications for
the requirements in the Machinery Directive. Could also be
used for older machinery.
EN 60204-1 Safety of Machinery - Electrical equipment of
machines Part 1: General requirements.
Harmonized standard that gives requirements for the elec-
trical equipment of machinery including the emergency stop
actuator/function. Se clauses 9.2.2 and 9.2.5.4.2.
Requirements for E-stops are stated in the following standards and regulations
ABB Safety Handbook | 2TLC172001C0202 11/4
11
Description
INCA 1 is an emergency stop designed for installation in 22.5 mm holes on
cabinets. INCA 1 has potential free contacts for connection to safety relays. The
connection is made in cabinets via a removable terminal which also have excellent
measuring points. Inca 1 is also available with a black pushbutton and used as a
safety stop. See section on Safety stops.
In the emergency stop button there is a LED that displays current status on:
Green = everything ok
Red = this emergency push button has been pressed
Off = a unit earlier in the circuit is affected
Emergency stop for enclosure installation
INCA 1
Approvals:
Application:
To stop a machine or a
process
Features:
Terminal blocks
Emergency push button
up to PLe/Cat.4 acc. to
ENISO13849-1
Only 53 mm construction
depth
With LED info in push button
Push button IP65, connector
IP20
Available as safety stop
(black push button)
0V
1
2
4
3
5
(+) S13
A2
+24V
IQ 10
A pulse
0V
I1
I0
0V
1
2
4
3
5
A
A1
R
A2
A
(A2) S23
T
Info
Pluto
Vital INCA 1(S) Tina
INCA 1(S) Pluto
S34
S24
S14
+24V
IQ 10
A pulse
0V
I0
Pluto RT6 INCA 1
INCA 1S. See more information on section - Safety stop.
11/5 2TLC172001C0202 | ABB Safety Handbook
11
0V
1
2
4
3
5
(+) S13
A2
+24V
IQ 10
A pulse
0V
I1
I0
0V
1
2
4
3
5
A
B1
R1
B2
A
(A2) S23
T1
Info
Pluto
Vital INCA 1(S) Tina
INCA 1(S) Pluto
S34
S24
S14
+24V
IQ 10
A pulse
0V
I0
Info PLC
Pluto Vital INCA 1 Tina
Description
INCA 1 Tina is an emergency stop designed for installation in 22.5 mm holes in
equipment cabinets. In addition to the INCA 1 version, INCA 1 Tina is adjusted to
work in dynamic safety cirucits for connection to the safety relay Vital and safety
PLC Pluto units. The connection is made in equipment cabinets via a removable
terminal block which also has marked measuring points. Inca 1 Tina is also available
with black push button and is used in this case as a safety stop. See section on
safety stops.
The emergency stop button has a LED that displays the current status:
Green = everything is OK
Red = this emergency stop has been pressed.
Flashing red/green = a protection device earlier in the circuit has been actuated.
Emergency stop for enclosure installation
INCA 1 Tina
Approvals:
Application:
To stop a machine or a
process
Features:
Terminal blocks
Emergency push button
up to PLe/Cat.4 acc. to
ENISO13849-1
Only 53 construction depth
With LED info in push button
Info output (INCA1 Tina)
Push button IP65, connector
IP20
Available as safety stop
(black push button)
INCA 1S Tina. See more information on section - Safety stop.
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 11/6
11
Yellow front ring and emergency stop signs for emergency stop.
Technical data - INCA 1/INCA 1 Tina
Article number
INCA 1
INCA 1 Tina
2TLA030054R0100
2TLA030054R0000
Impact resistance
(half sinusoidal)
Max. 150m/s, pulse width 11 ms,
3-axis, acc. to EN IEC 60068-2-27
Vibration resistance
(sinusoidal)
Max. 50 m/s at 10 Hz500Hz,
10 cycles, 3 axis, acc. to EN IEC
60068-2-6
Climate resistance
Damp heat, cyclical
Damp heat, sustained
Dry heat
Cooling
Salt mist
96 hours, +25 C / 97%, +55 C / 93
% relative humidity, as per
EN IEC 60068-2-30
56 days, +40 C / 93 % relative
humidity, as per
EN IEC 60068-2-78
96 hours, +70 C, as per
EN IEC 60068-2-2
96 hours, -40 C, as per
EN IEC 60068-2-1
96 hours, +35 C in a chemical
solution with NaCl as per
EN IEC 60068-2-11
Level of safety
EN ISO 13849-1
EN 62061
IEC/EN 61508-1...7
Up to PL e/Cat. 4 depending upon
system architecture
SIL 3 depending upon system
architecture
SIL3
PFH
D
INCA 1
INCA 1 Tina
PFH
D
: 1.6010
-10
PFH
D
: 4.6610
-9
Colour Yellow, red and black
Weight Approx. 45 grams
Size See drawing
Material Polyamide PA66, Macromelt,
Polybutylenterephthalate PBT
UL 94 V0
Temperature -10C to +55C (operation), -30C to
+70C (storage)
Protection class Button: IP65, Connector: IP20
Installation 22.5 mm
Emergency stop LEDs INCA 1:
Green: Safety device OK.
Not lit: A unit earlier in the circuit is
affected.
Red: This emergency stop has been
pressed.
INCA 1 Tina:
Green: Safety device OK, safety
circuit OK
Flashing: Safety device OK, safety
circuit previously interrupted.
Red: This button is pressed in, and
the safety circuit is interrupted.
Operating voltage (LED) INCA 1: 24 VDC
INCA 1 Tina: 24VDC +15% -25%
Current consumption (LED) INCA 1: 15 mA
INCA 1 Tina: 47 mA
Actuating force 22 4 N
Operating movement Approx. 4 mm to locked position
Contact material Gold-plated silver alloy
Minimum current INCA 1: 10 mA, 10 VDC/10 VAC
INCA 1 Tina:
Maximum current INCA 1: 2 A 24 VDC
INCA 1 Tina:
Mechanical life > 50 000 operations
Accessories
Front ring yellow for INCA
Emergency Stop Sign S DK FIN,
22.5mm
Emergency Stop Sign EN F D,
22.5mm
Emergency Stop Sign (blank)
22.5 mm
2TLA030054R0400
2TLA030054R0500
2TLA030054R0600
2TLA030054R0900
Conformity EN 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 13850:2006
11/7 2TLC172001C0202 | ABB Safety Handbook
11
1
2
3
4
Smile - small and cost effective E-stop
In order to fulfill the need for a small and easy to install E-stop, Smile has been de-
veloped. The size of the device makes it possible to be installed wherever you want.
With M12 connection/s or cable and centralised mounting holes Smile is very easy
to install, especially on aluminium extrusions. Smile is available for E-stops in both
dynamic and static safety circuits i.e. for interfacing to Vital/Pluto and Safety relays.
Each version is available with either one or two M12 connections or cable. At the
top of Smile, a LED shows the current status as: green = protection OK, red = this
emergency stop has been pressed and if the LED is off, an emergency stop earlier
in the circuit has been actuated. Smile is also available with black push button and
is used as a safety stop. See section on safety stops.
Smile emergency stop comes in five different versions:
1. Smile 10 EA has a 1 m cable connected through the base of the unit.
2. Smile 10 EK has four 1 m connecting leads through the base of the unit. No LED.
3. Smile 11 EA has a 5-pole M12 connector on one end of the unit.
4. Smile 12 EA has two 5-pole M12 connectors, one on each end of the unit.
5. Smile 11 EAR has one 5-pole M12 connector at one end of the unit.
Smile 11 EA adapted for AS-i
The Smile 11 EA also comes in a version adapted for direct attachment to the AS-i
bus.
Emergency stop with indication
Smile
Approvals:
Application:
To stop a machine or a pro-
cess
Features:
Emergency push button
up to PLe/Cat. 4 acc. to
ENISO13849-1
With LED info in push button
Robust
IP65
Available as safety stop
(black push button)
Available for AS-i
5
ABB Safety Handbook | 2TLC172001C0202 11/8
11
Smile
Connection examples
Smile 10 EA connected to either Pluto or a safety relay with LED indication. The connection cable exits from underneath.
Smile 11 EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connector.
Smile 12 EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connector + termination.
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
A
(+) S13
S14
S24
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
A
(A2)
(A2)
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 10EA
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
A
(+) S13
S14
S24
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
A
(A2)
(A2)
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 10EA
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
A
(+) S13
S14
S24
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
A
(A2)
(A2) Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 11EA
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
0V
1
2
4
3
5
A
(+) S13
S14
S34
A2
+24V
0V
I0
0V
1
2
4
3
5
A
(+) S13
S14
S24
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
A
(A2)
(A2)
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 11EA
0V
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
1
2
4
3
5
1
2
4
3
5
A
0V
(+) S13
S14
S34
A2
+24V
0V
I0
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
0V
S14
S24
1
2
4
3
5
1
2
4
3
5
C B
(+) S13
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
16
13
(A2)
(A2)
JST2 JST2
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 12EA
0V
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
1
2
4
3
5
1
2
4
3
5
A
0V
(+) S13
S14
S34
A2
+24V
0V
I0
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
0V
S14
S24
1
2
4
3
5
1
2
4
3
5
C B
(+) S13
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
16
13
(A2)
(A2)
JST2 JST2
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 12EA
Single channel - Safety category 1.
Single channel - Safety category 1.
Single channel - Safety category 1.
Single channel - Safety category 1.
Dual channel - Safety category 4.
Dual channel - Safety category 4.
Dual channel - Safety category 4.
Dual channel - Safety category 4.
Smile 10 EA / 11 EA / 12 EA connected to either Pluto or a safety relay without LED indication.
0V
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
1
2
4
3
5
1
2
4
3
5
A
0V
(+) S13
S14
S34
A2
+24V
0V
I0
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
0V
S14
S24
1
2
4
3
5
1
2
4
3
5
C B
(+) S13
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
16
13
(A2)
(A2)
JST2 JST2
Pluto
safety
PLC
1
2
4
3
5
Output 1
Input 1
Input 2
Output 2
1
2
4
3
5
Output 1
Input 1
1
2
4
3
5
1
2
4
3
5
0V
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
A B
(A2)
C
Safety
relay
E.g.
RT6,
RT9
Smile 11EA
Safety
relay
E.g.
RT6,
RT9
1
2
4
3
5
Output 1
Input 1
Input 2
Output 2
1
2
4
3
5
Output 1
Input 1
1
2
4
3
5
1
2
4
3
5
0V
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
A B
(A2)
C
Smile 11EA
0V
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
1
2
4
3
5
1
2
4
3
5
A
0V
(+) S13
S14
S34
A2
+24V
0V
I0
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
0V
S14
S24
1
2
4
3
5
1
2
4
3
5
C B
(+) S13
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
16
13
(A2)
(A2)
JST2 JST2
Pluto
safety
PLC
11/9 2TLC172001C0202 | ABB Safety Handbook
11
Smile
Connection examples
Smile 12EA and 11EA connected to either Pluto or safety relay with LED indication. Connection via M12 connectors. Note
that there is no termination connector as the Smile 11EA (C) completes the circuit without the need for a termination connector
(JST2) or return cable.
1. Input 1
2. Input 2
3. 0 VDC (if use of LED)
4. Output 2
5. Output 1
1. Output 1
2. Output 2
3. 0 VDC
4. Input 2, feedback
5. Input 1, feedback
1. Input 1
2. Input 2
3. 0 VDC (if use of LED)
4. Output 2, feedback
5. Output 1, feedback
0V
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
1
2
4
3
5
1
2
4
3
5
A
0V
(+) S13
S14
S34
A2
+24V
0V
I0
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
1
2
4
3
5
A
1
2
4
3
5
0V
S14
S24
1
2
4
3
5
1
2
4
3
5
C B
(+) S13
A2
S34
+24V
S23
IQ 10 A-pulse
0V
I0
I1
16
13
(A2)
(A2)
JST2 JST2
Pluto
safety
PLC
Safety
relay
E.g. RT6,
RT9
Smile 12EA Smile 12EA Smile 11EA
Brown
White
Blue
Black
Grey
Brown
White
Blue
Black
Grey
Smile 12EA
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1. Input 1
2. Input 2
3. 0 VDC (if use of LED)
4. Output 2
5. Output 1
Brown
White
Blue
Black
Grey
Smile 10EA
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Brown
White
Blue
Black
Grey
Smile 11EA (R)
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Smile 10EK
E-Stop Button status LED Indication
A B C A B C
R R R G G G
R R P G G Rd
R P R G Rd B
R P P G Rd B
P R R Rd B B
P R P Rd B B
P P R Rd B B
P P P Rd B B
Dual channel series connection - Safety category 3.
Smile 12EA connected to either Pluto or a safety relay with LED indication. Connection via M12 connectors. Reconnection to
the Pluto/safety relay is made via a separate cable. You can also use JST2 as a termination device after Smile12EA (C).
1
2
4
3
5
Output 1
Input 1
Input 2
Output 2
1
2
4
3
5
Output 1
Input 1
1
2
4
3
5
1
2
4
3
5
0V
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
1
2
4
3
5
(+) S13
S14
S24
A2
S34
+24V
S23 IQ 10 A-pulse
0V
I0
I1
A B
(A2)
C
Smile 12EA Smile 12EA Smile 12EA
Pluto
safety
PLC
Safety
relay
E.g.
RT6,
RT9
Dual channel series connection - Safety category 3.
1. Input 1
2. Input 2
4. Output 2
5. Output 1
Brown
White
Black
Grey
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
4
5
LED Indication for the connection example above, where two
Smile 12 EA and one Smile 11 EA are connected in series, is
showed in the following table (applies for all Smile).
A = Smile 12EA R = Released
B = Smile 12EA P = Pressed
C = Smile 11EA G = Green light
Rd = Red light
B = Blank, no light
ABB Safety Handbook | 2TLC172001C0202 11/10
11
Termination device JST2
Smile side shield
Sign for emergency stop
Technical data Smile
Article number
Smile 10EA
Smile 10EK
Smile 11EA
Smile 12EA
Smile 11EAR
Smile 11EA AS-i
Note. There are other versions for
dynamic technology (with Tina).
2TLA030051R0400
2TLA030051R0600
2TLA030051R0000
2TLA030051R0200
2TLA030051R0100
2TLA030052R0000
Impact resistance
(half sinusoidal)
max. 150 m/s
2
, pulse width 11ms,
3-axis, as per
EN IEC 60068-2-27
Vibration resistance (sinusoidal) max. 50 m/s
2
at 10 Hz,
10cycles, 3-axis, as per
EN IEC 60068-2-6
Climate resistance
Damp heat, cyclical
Damp heat, sustained
Dry heat
Cooling
Salt mist
96 hours, +25 C / 97%, +55C / 93
% relative humidity, as per EN IEC
60068-2-30
56 days, +40 C / 93 % relative
humidity, as per
EN IEC 60068-2-78
96 hours, +70 C, as per
EN IEC 60068-2-2
96 hours, -40 C, as per
EN IEC 60068-2-1
96 hours, +35 C in a chemical
solution with NaCl as per
EN IEC 60068-2-11
Level of safety
EN ISO 13849-1
EN 62061
IEC/EN 61508-1...7
Up to PL e/Cat. 4 depending upon
system architecture
SIL 3 depending upon system
architecture
SIL3
PFH
D
1.60E-10
Colour Yellow, red and black
Weight Approx. 65 grams
Size Length: 84 mm + M12 contact(s)
(12.5 mm each)
Width: 40 mm
Height: 52 mm
Material Polyamide PA66, Macromelt,
Polybutylentere phthalate PBT,
Polypropylene PP, UL 94 V0
Ambient temperature -10C to +55C (operation),
-30C to +70C (stock)
Protection class IP65
Actuating force 22 4 N
Actuator travel Approx. 4 mm to latch
Mechanical life > 50 000 operations
Mounting Two M5 recessed hexagon head
screws, L 25 mm.
Hole cc: 44 mm
LED on E-Stop Green: Safety device OK, Safety
circuit OK
Off: Safety circuit is previously
interrupted.
(When an E-Stop is depressed all
following units in the circuit lose the
LED function).
Red: This button is pressed, and the
safety circuit is interrupted.
Operating voltage (LED) 17-27 VDC ripple 10%
(LED supply voltage)
Current consumption (LED) 15 mA
Material, contacts Silver alloy gold plated
Min current 10 mA 10 VDC/ 10 VAC
Max current 2 A 24 VDC
Accessories
Emergency Stop Sign S DK FIN,
32.5mm
Emergency Stop Sign EN F D,
32.5mm
Emergency Stop Sign (blank)
32.5mm
JST2 termination for Smile 12
Smile side shield
2TLA030054R0700
2TLA030054R0800
2TLA030054R1000
2TLA030051R1300
2TLA030054R1100
Conformity EN ISO 12100:2010,
EN ISO 13849-1:2008,
EN 62061:2005, IEC 60664-1:2007
EN 60204-1:2006+A1:2009,
EN 61000-6-2:2005,
EN 61000-6-4:2007,
EN 60947-5-5:2005,
EN ISO 13850:2006
11/11 2TLC172001C0202 | ABB Safety Handbook
11
1
2
3
4
Smile Tina - small and cost effective E-stop
In order to fulfill the need for a small and easy to install E-stop, Smile has been
developed. The size of the device makes it possible to be installed wherever you
want. With M12 connections or cable and centralised mounting holes Smile is very
easy to install, especially on aluminium extrusions. Smile is available for E-stops
in both dynamic and static safety circuits i.e. for interfacing to Vital system/Pluto
safety PLC and Safety relays. Each version is available with either one or two M12
connections or cable. Two M12 connectors are used to enable the connection of
E-stops in series, which is often used with dynamic safety circuits fulfilling safety
category 4. In the top of the Smile Tina E-stop unit, LEDs show the actual status
according to the dynamic system:
Green = everything is OK
Red = E-stop activated.
Flashing Red/Green = Stop activated from another preceding device.
Smile is also available with black push button and used as a safety stop. See sec-
tion on safety stops.
The Smile Tina emergency stop is available in four versions:
1. Smile 10EA Tina has a 1 m cable connected via the base of the unit.
2. Smile 11EA Tina has a 5-pole M12 connector on the end of the unit.
3. Smile 12EA Tina has two 5-pole M12 connectors, one on each end of the unit.
4. Smile 11EAR Tina has one 5-pole M12 connector at one end of the unit.
Emergency stop with indication
Smile Tina
Approvals:
Application:
To stop a machine or a
process
Features:
Emergency push button
up to PLe/Cat. 4 acc. to
ENISO13849-1
Light grids, emergency stop
and Eden in the same safety
circuit together with Vital or
Pluto gives PLe/Cat. 4 acc.
to ENISO13849-1
With LED indication on push
button
Robust
Info-signal from each
emergency stop
IP65
Available as safety stop
(black push button)
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 11/12
11
Smile Tina
Connection examples
Smile 10EA Tina connected to either a Pluto or Vital system with LED indication/information. The connection cable exits from
underneath the unit. Safety circuit category 4.
Smile 11EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 11EA Tina units
connected via M12 connectors in a serie via connection terminals in the electrical cabinet. Safety circuit category 4.
Smile 11EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 11EA Tina units and
one Eden connected via M12 connectors in a serie via a Tina 4A connection block. Safety circuit category 4.
Pluto
M12-3A M12-3A
M12-3B
T
R
IQ10
I0
3
2
1
4
T
R
IQ10
I0
C
B
A
Smile 11EA Tina
Smile 11EA Tina
Smile 11EA Tina
Vital
Tina 4A
Eden = Adam & Eva
T
R
IQ10
I0
A B C
T
R
IQ10
I0
A
B
C
T
R
IQ10
I0
Smile 11EA Tina
Smile 11EA Tina
Smile 11EA Tina
Pluto
Vital
Electrical cabinet
C
o
n
n
e
c
t
i
o
n

t
e
r
m
i
n
a
t
i
o
n
Pluto Vital
Smile 10EA Tina
T
R
IQ10
I0
A B C
T
R
IQ10
I0
A
B
C
T
R
IQ10
I0
Focus
Pluto Vital
Smile 12EA Tina Smile 12EA Tina
Eden = Adam & Eva
Tina 10A
M12-3A M12-3A
M12-3B
T
R
IQ10
I0
3
2
1
4
T
R
IQ10
I0
C
B
A
Smile 12 EA Tina connected to either a Pluto or Vital system with LED indication/information. Two Smile 12 EA Tinas, one
Eden sensor and one Focus Light Curtain connected via M12 connectors in a serie. Safety circuit category 4.
11/13 2TLC172001C0202 | ABB Safety Handbook
11
T
R
IQ10
I0
A B C
T
R
IQ10
I0
A
B
C
T
R
IQ10
I0
Pluto Vital
Smile 12EA Tina Smile 12EA Tina Smile 12EA Tina
Smile Tina
Connection examples
1. Input voltage,17-27 VDC ripple+/- 10%
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information output
1. Input voltage,17-27 VDC ripple+/- 10%
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information output
1. Input voltage,17-27 VDC
ripple+/- 10%
2. Dynamic input signal
3. 0 VDC
4. Not used
5. Not used
1. Output voltage to next unit
2. Dynamic output signal (To next
Smile or to Pluto or Vital system)
3. 0 VDC
4. Not used
5. Information output
Smile 12 EA Tina connected to either a Pluto or Vital system with LED indication/information. Three Smile 12 EA Tina units
connected via M12 connectors in a serie. Reconnection to the Pluto/safety relay is made via a separate cable. Safety circuit
category 4.
LED Indication for the connection example above, where three Smile 12 EA
Tina units are connected in series, is showed in the following table (applies for all
SmileTina).
Information output signal for the connection example above, where three
Smile12 EA Tina units are connected in series, is showed in the following table
(applies for all SmileTina). The status information signal can be connected to e.g.
PLC input. Note. The information signal must not be used as a safety signal. The
signal should only be used to indicate the status of connected devices.
E-Stop Button status LED Indication
A B C A B C
R R R G G G
R R P G G Rd
R P R G Rd F
R P P G Rd Rd
P R R Rd F F
P R P Rd F Rd
P P R Rd Rd F
P P P Rd Rd Rd
E-Stop Button status Information
output signal
A B C A B C
R R R H H H
R R P H H L
R P R H L H
R P P H L L
P R R L H H
P R P L H L
P P R L L H
P P P L L L
Brown
White
Blue
Black
Grey
Smile 11 EA Tina
1
2
+
3 -
4
5
+
-
1
2
3
4
5
1
2
+
3 -
4
5
1
2
+
3 -
4
5
Brown
White
Blue
Black
Grey
Brown
White
Blue
Black
Grey
Smile 12 EA Tina
1
2
+
3 -
4
5
+
-
1
2
3
4
5
1
2
+
3 -
4
5
1
2
+
3 -
4
5
Brown
White
Blue
Black
Grey
1
2
+
3 -
4
5
+
-
1
2
3
4
5
1
2
+
3 -
4
5
1
2
+
3 -
4
5
Smile 10 EA Tina
A = Smile 12 EA Tina R = Released
B = Smile 12 EA Tina P = Pressed
C = Smile 12 EA Tina G = Green light
Rd = Red light
F = Flashes, changing between red and green
light.
A = Smile 12 EA Tina R = Released
B = Smile 12 EA Tina P = Pressed
C = Smile 12 EA Tina H = High (i.e. supply voltage)
L = Low (= 0 VDC)

ABB Safety Handbook | 2TLC172001C0202 11/14
11
1. Input voltage,17-27 VDC ripple+/- 10%
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information output
1. Input voltage,17-27 VDC ripple+/- 10%
2. Dynamic input signal
3. 0 VDC
4. Dynamic output signal
5. Information output
Sign for emergency stop
Technical data Smile Tina
Article number
Smile 10 EA Tina
Smile 11 EA Tina
Smile 12 EA Tina
Smile 11 EAR Tina
Note. There are versions for use
with relay technology (without Tina).
2TLA030050R0400
2TLA030050R0000
2TLA030050R0200
2TLA030050R0100
Impact resistance
(half sinusoidal)
max. 150 m/s
2
, pulse width 11ms,
3-axis, as per
EN IEC 60068-2-27
Vibration resistance (sinusoidal) max. 50 m/s
2
at 10 Hz, 10 cycles,
3-axis, as per
EN IEC 60068-2-6
Climate resistance
Damp heat, cyclical
Damp heat, sustained
Dry heat
Cooling
Salt mist
96 hours, +25 C / 97%, +55 C / 93
% relative humidity, as per EN IEC
60068-2-30
56 days, +40 C / 93 %
relative humidity, as per
EN IEC 60068-2-78
96 hours, +70 C, as per
EN IEC 60068-2-2
96 hours, -40 C, as per
EN IEC 60068-2-1
96 hours, +35 C in a chemical solu-
tion with NaCl as per
EN IEC 60068-2-11
Level of safety
EN ISO 13849-1
EN 62061
IEC/EN 61508-1...7
Up to PL e/Cat. 4 depending upon
system architecture
SIL 3 depending upon system
architecture
SIL3
PFH
D
4.66E-09
Colour Yellow, red and black
Weight Approx. 65 grams
Size Length: 84 mm + M12 contact(s)
(12.5mm each)
Width: 40 mm Height: 52 mm
Material Polyamid PA66, Macromelt, Polybu-
tylenterephthalate PBT, Polypropylen
PP, UL 94 V0
Ambient temperature -10C to +55C (operation) -30C to
+70C (stock)
Protection class IP65
Mounting Two M5 hexagon socket screws, L
25 mm.
Hole centres: 44 mm
LED on E-Stop Green: Safety device OK, Safety
circuit OK
Flashing: Safety device OK, safety
circuit previously interrupted
Red: This button is pressed, and the
safety circuit is interrupted
Time delay 1:1.5 (Two Smile units are equal to
three Edens in time delay)
Operating voltage 17-27 VDC ripple 10%
Current consumption 47 mA (57mA with max. current from
information output)
Current from information output 10 mA max
Actuating force 224 N
Actuator travel Approx. 4 mm to latch
Material, contacts Silver alloy gold plated
Mechanical life > 50 000 operations
Accessories
Emergency Stop Sign S DK FIN,
32.5mm
Emergency Stop Sign EN F D,
32.5mm
Smile side shield
2TLA030054R0700
2TLA030054R0800
2TLA030054R1100
Conformity EN 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 13850:2006
Smile side shield
11/15 2TLC172001C0202 | ABB Safety Handbook
11
Smile 11 EA AS-i is an emergency stop with a built-in dual channel safe AS-i input
node. The AS-i bus and the safety around it is specified by the two organisations
AS-International Association and AS-Interface Safety at Work, and is described
in publications such as AS-Interface The Automatic Solution.
Smile 11 EA AS-i is supplied with 30 VDC from the AS-i bus. The recommended
connection to the AS-i bus is made via a flat cable terminal to M12 (see Figure),
which makes it possible to quickly and easily connect the device to the yellow AS-i
cable.
Smile 11EA AS-i can also be connected directly to the AS-i bus using only two
conductors (pins 1 and 3 on the unit's M12 contact). Smile is also available with
black push button and is used in this case as a safety stop. See section on safety
stops.
The possibility with LED indication is also avalible on the Smile 11 EA AS-i, with the
difference that the AS-i version has programable LEDs. This gives the customer full
flexibility for making own indication.
Emergency stop with indication
Smile AS-i
Approvals:
Application:
To stop a machine or a
process
Safe input node in AS-i
systems
Features:
Emergency push button
up to PLe/Cat. 4 acc. to
ENISO13849-1
Simple connection to AS-i
bus
With LED indication on
push button and AS-i status
indication
Robust
IP65
Available as safety stop
(black push button)
TV
NORD
ABB Safety Handbook | 2TLC172001C0202 11/16
11
LED in emergency stop button
LED is individually programmed in the PLC program as shown below.
LED in push button Indicator Description
Red ON Output bit 1 ON
OFF Output bit 1 OFF or
Output bit 1 & 2 ON
Green ON Output bit 2 ON
OFF Output bit 2 OFF or
Output bit 1 & 2 ON
AS-i LED and Fault LED
in combination LED pair at the M12 contact.
AS-i (Green) Fault (Red) Description
OFF OFF AS-i voltage missing
ON OFF Normal operation
ON ON No data exchange with master
Flash ON No data exchange due to address = 0
Technical data Smile AS-i
Article number
Smile 11 EA AS-i 2TLA030052R0000
AS-i data
AS-i prole S-7.B.0
Addressing M12-contact
Node address on delivery 0
Response time across the AS-i bus 5 ms (+ response time for safety monitor)
Pin conguration
(1) AS-i +
(2) Not used
(3) AS-i
(4) Not used
(5) Not used
Operating voltage 30 VDC from the AS-i bus. Tolerance 26.5 31.6VDC.
Total current consumption < 60 mA
Protection class IP65
Ambient temperature -25+50C
Dimensions 52 x 40 x 84 (+12,5 mm M12 contact) (H x W x L)
Colour Yellow, red and black
Actuating force 22 4 N
Actuating travel Approx. 4 mm to latch
Mechanical life > 50 000 operations
PFH
D
6.95x10
-9
Level of safety
EN ISO 13849-1
EN 62061
IEC/EN 61508-1...7
Up to PL e/Cat. 4 depending upon system architecture MTTF
d
: high
SIL 3 depending upon system architecture
SIL 3, PFD
avr
: 2.95 x 10
-5
, PFH
D
: 6.95*10
-9

Conformity EN ISO 12100:2010, EN ISO 13849-1:2008/AC:2009, EN ISO 13849-2:2008, EN 60204-1:2007+A1,
EN ISO 13850:2006
11/17 2TLC172001C0202 | ABB Safety Handbook
11
The Compact emergency stop with an enclosure
The emergency stop comes from the Compact range of ABB:s Pilot Devices. The
Compact is an All-in-one design solution, with button and contact block in one
unit. It has a building hight of 42 mm.
The emergency stop complemented with a robust enclosure gives a high IP ra-
ting that fulfills the demands in severe and moist environments, such as food and
beverage industry. This unit is also available with a black push button and a grey
enclosure and is then used as a safety stop. See section on safety stops.
Adjustment for dynamic circuits
If the emergency stops are used with Pluto or Vital, a Tina adaptation product can
be used. Tina 2A, Tina 2B and Tina 3A all work with the Compact emergency stop
and its enclosure.
Emergency stop
Compact
Approvals:
Application:
To stop a machine or a
process
Features:
Assembled compact
emergency stop
Emergency push button
up to PL e/Cat. 4 acc. to
EN ISO 13849-1
Robust
IP67 and IP69K
Available as safety stop (black
push button)
Compact as a machine stop. See more infor-
mation on section - Safety stop.
ABB Safety Handbook | 2TLC172001C0202 11/18
11
Technical data Compact
Article number
Emergency stop and enclosure
(CEPY1-1002)
Emergency stop with enclosure and shroud
(CEPY1-2002)
1SFA619821R1002
1SFA619821R2002
Reset action Pull release
Contact material Silver
Termination Clamp Up to 1.5 mm
2
conductors
Torque settings
Cable terminals
Nut (M22)
0.8 Nm
Min. 2 Nm, Max. 2.3 Nm
Conduit entries 2 x M20
Rated insulation/withstand voltages 300 V
Thermal current (lth) 5 A
Utilisation category AC-15; 1 A (240 V), 1.5 A (120 V)
DC-13; 0.3 A (24 V), 0.2 A (125 V)
Short circuit overload protection Max. fuse 16 A
Level of safety
B10
d
50 000
Colour Yellow, red, black and grey
Weight 135 g (with Shroud)
118 g
Size Length: 65 mm
Width: 65 mm
Height: 78.1 mm (with Shroud 79.6 mm)
Ambient temperature -25C to +70C (operation)
-30C to +85C (stock)
Protection class IP66, IP67 and IP69K
Mounting 2 x M4
Mechanical life 50 000 operations
Accessories
Shroud Yellow (CA1-8053)
Shroud Grey (CA1-8054)
Tina 2A
Tina 2B
Tina 3A
1SFA619920R8053
1SFA619920R8054
2TLA020054R0100
2TLA020054R1100
2TLA020054R0200
Conformity EN 60947-1:2007, EN 60947-5-1:2004, EN 60947-5-5:1997+A1:2005
Adaptation units: Tina 2A and Tina 3A
11/19 2TLC172001C0202 | ABB Safety Handbook
11
Emergency stop
EStrongZ
Switch operational description
The EStrongZ is an emergency stop designed to provide a robust unit in exposed
and severe environments. Perfect for industries that have special demands.
The contact block configuration is a 2NC and 2NO and the emergency stop is
mounted with 4 x M4 screws from the inside.
The EStrongZ has a special lid that is mechanical linked to the emergency stop sa-
fety mechanism. This means that the safety contacts will open if the lid is removed.
An optional feature gives the EStrongZ a two colour LED that can be seen easily
from a distance.
Material
The EStrongZ is available in a total rugged stainless steel 316 body, developed for
applications such as food processing and chemical industry. With a double seal lid
gasket and seals, the EStrongZ has an IP69K enclosure protection and therefore
can be high pressure hosed with detergent at high temperature.
Explosion Proof version (X)
EStrongZ also exist in versions with certified explosion proof contact block (X-versi-
ons). EStrongZX have a stainless steel body and can be used in European Zone 1,
2, 21, 22 enviroments (Gas and Dust). Preassembled with 3 meter cable.
Regulations and Standards
The EStrongZ is designed and approved in accordance to relevant standards. Ex-
amples of relevant standards are IEC/EN60947-5-1, IEC/EN60947-5-5, EN62061,
UL508, ENISO13850 and ENISO13849-1.
Approvals:
Application:
To stop a machine or a
process
Features:
Compact and robust
Universal installation
Stainless steel
LED status indication (optional)
2NO + 2NC
EX version
(X-versions)
TV
Rheinland
ABB Safety Handbook | 2TLC172001C0202 11/20
11
Dimensions EStrongZ (LED) EStrongZ (LED) EStrongZ
Technical data EStrongZ series
Article number
EStrongZ
EStrongZ (LED)
EStrongZX
2TLA050220R0020
2TLA050220R0222
2TLA050220R0025
Level of Safety
EN ISO13849-1 Up to PL e/Cat. 4 depending upon system architecture
EN62061 Up to SIL3 depending upon system architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life) MTTF
d
1.5 x 10
6
operations at 100mA load 21 years
214 years (8 cycles per hour/24 hours per day/365 days
Torque settings Mounting M5 4.0Nm, Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm
Termination Clamp up to 2.5 mm
2
conductors
Short circuit overload protection Fuse externally 10A (FF)
Rated insulation/withstand voltages 500VAC / 2500VAC
Utilisation category AC15 A300 3A
Shock resistance 15g 11ms
Thermal current (lth) 10A
Conduit entries 3xM20
Enclosure classication IP67 and IP69K
Operating temperature -25C to +80C
Weight 820g
Contact type IEC/EN60947-5-1 double break typ Zb snap action
Contact material Silver
Enclosure / Cover Stainless steel 316
Mounting position Any
Mounting bolts 4 x M4
Explosion Proof version (X)
Classication Ex d IIC T6
Rated Voltage
Rated Current
(-20C Ta +60C) Gb Ex tb IIIC T85C (-20C Ta +60C) Db
250V AC/DC
2 pole 4A
4 pole 2.5A
11/21 2TLC172001C0202 | ABB Safety Handbook
11
Model Article number
Smile 11 SA 2TLA030051R0900
Smile 12 SA 2TLA030051R1000
Smile 11 SAR 2TLA030051R1100
Smile 11 SA Tina 2TLA030050R0500
Smile 12 SA Tina 2TLA030050R0600
Smile 11 SAR Tina 2TLA030050R0700
Smile 12 SAR Tina 2TLA030050R0800
Smile 11SA AS-i 2TLA030052R0100
When should I use the safety stop?
Safety stops are used to stop the operation of a machine in
a safe manner. It must not be used as an emergency stop,
but only as a stop for an individual hazardous motion. This
is indicated by black push button. Likewise, an emergency
stop push button with red push button must not be used as a
safety stop.
INCA machine stop for panel mounting
The INCA series is available with black push button and is
called INCA 1S/INCA 1S Tina. The safety stop is identical to
the corresponding emergency stop apart from the black push
button. For technical data see the INCA emergency stop.
Smile machine stop with indication
The Smile emergency stop series is also available with black
push button as safety stops. These stops are identical to the
corresponding emergency stops apart from the button. The
Smile with the black push button has a similar designation
apart from an S in the name instead of E. For technical data
see the Smile emergency stop.
The Compact Machine stop with an enclosure
This machine stop comes from the Compact range of ABB:s
Pilot Devices, built on the All-in-one design. The black
machine stop complemented with a robust enclosure gives
a high IP rating the fulfills the demands in severe and moist
environments. The machine stop has one normal open and
one normally closed contact (1NO+1NC). For technical data
see the Compact emergency stop.
Model Article number
INCA 1S 2TLA030054R0300
INCA 1S Tina 2TLA030054R0200
Model Article number
Machine stop and enclosure
(CEP1-1002)
1SFA619811R1002
Machine stop with enclosure and
shroud (CEP1-2002)
1SFA619811R2002
Safety stop
INCA, Smile and Compact
Approvals:
Application:
To make a safe stop of a
machine or a process
Features:
Safe machine stop with black
push button
With LED info in push button
Up to IP69K
Info output (Tina)
ABB Safety Handbook | 2TLC172001C0202 11/22
11
Smile push button box with a blue button are intended to be a
reset button to safety circuits.
Smile 11RA
The Smile 11RA is an open reset push button box with one
circuit for connections though a normally open contact and
one circuit for connection of the indication LED in the push
button.
Smile 11RB
The Smile 11RB is a reset push button box adapted to be
use together with the Safety PLC Pluto.

The Safety PLC Pluto has a function called Light button
which is used in order to reduce the numbers of terminals on
the Pluto. With this function, one terminal can be used both
as an input for the reset as well as output for controlling the
LED. This function demands special connection for the reset
button and its light indication, which the Smile 11 RB offers.
Reset button
Smile 11R
Technical data Smile 11RA/B
Article number
Smile 11RA
Smile 11RB
2TLA030053R0000
2TLA030053R0100
Color
Base
Pushbutton
yellow
blue
Material
Housing
Pushbutton contact
Polyprobylene PP
Au
Power Supply
LED operating voltage
LED current consumption
Pushbutton operating voltage
Pushbutton current consumption
Pushbutton rated power
24 VDC (maximum 33 VDC)
20 mA at 24 VDC
30 mA at 33 VDC
Min: 5 V, max: 35 V
Min: 1 MA, max 100 mA
Max: 250 mW
Ambient temperature -25...+55C
Humidity range 35 to 85% (with no icing or conden-
sation)
Protection class IP65
Connectors 5-pole male M12 connector
Size 84x40x36 (LxWxH) + 12 mm for
M12 connector (L)
Weight Approx. 60 g
Mechanical life 1.000.000 operations at
10 mA/24 VDC
Switching reliability 10 x 10
-6
at 5 mA/24 VDC
Approvals:
Application:
Reset push button
Features:
With LED info in push button
IP65
Adapted version for the Pluto
feature light button
11/23 2TLC172001C0202 | ABB Safety Handbook
11
Wiring diagram for LED
Application
ABB Jokab Safety Emergency stop grab wire safety switches
are designed to be mounted on machines and sections of
conveyors which can not be protected by guards. In contrast
to traditional mushroom head type Emergency stop buttons,
Emergency stop grab wire safety switches can initiate the
emergency command from any point along the installed wire
length, and thereby provide robust emergency stop protection
for exposed conveyors and machines.
The switches have a positive mechanical linkage between the
switch contacts and the wire rope. The switches also include
wire-breakage monitoring. This means, on pulling or breakage
(tension loss) of the wire, the safety contacts are positively
opened and the auxiliary contacts are closed. The switches
are mechanically latched and can then only be returned to the
operational condition by pressing the reset button as required
according to EN ISO 13850 (EN 418).
System set up
Wire support eyebolts must be fitted at 2.5-3 meters intervals
along the hole wire length and the wire must be supported no
more than 500 mm from the switch eyebolt or Safety Spring
(if used). It is important that the first 500 mm not are used
as part of the active protection coverage. When using one
switch, the wire must be anchored at the other end using a
Safety spring. When using a Safety spring, a maximum of
one corner pulley may be used, to ensure that the complete
length of the wire is visible to either the switch or the spring
anchorage. The emergency stop switches are brought into
the operational condition by pre-tensioning the wire by using
a tensioner/gripper device which clamps the wire and then
hooks to the switch eyebolts. Correct tension can be obser-
ved by viewing the tension indicator on the switch housing.
Once tensioned, the switch contact blocks can be set to
the operational condition (safety contacts closed, auxiliary
contacts open) by pressing a blue reset button on the switch
cover.
Emergency Stop Grab Wire Safety Switches
1.Tension indicator-Ensures the system is easy to set up and maintain
the correct wire tension.
2.Reset button-The blue button must be pushed to reset the switch fol-
lowing activation by pulling or slackening of the wire.
3.Indicator LED-Can be wired to flash red in the event of the wire being
pulled-switch activated, or illuminate steady green to indicate a reset
switch in machine 'Run'state. Visible from long distances.
4.Mushroom type Emergency stop button -Can be installed or repositi-
oned left or right after installation.
Safety level
All ABB Jokab Safety Emergency stop grab wire safety swit-
ches conform to European Standard ENISO13850 (EN418)
and IEC/EN60947-5-5. They have a positive mechanical
linkage between the switch contacts and the wire rope as per
IEC/EN60947-5-1.
In combination with a dual channel safety monitoring relay (or
safety PLC) an Emergency stop grab wire system can be used
as emergency stop device monitored for up to PL e, Cat4
according to ENISO13849-1.
Tensioner/Gripper Pull
Eyebolt
Wire
Pull Slack
Quick Link Safety Spring
Inactive zone
(500mm)
Inactive zone
(500mm)
Zone of protection
1
2
3
4
ABB Safety Handbook | 2TLC172001C0202 11/24
11
Reliable connectivity
When setting up an Emergency stop grab wire system from
ABB Jokab Safety it is recommended to do the tensioning of
the wire by using of ABB Jokab Safety Tensioner / Gripper
accessory. Traditional grab wire systems normally need turn-
buckle and clamps, which are difficult to tension and adjust,
and also normally require frequent re-tensioning.
For greater reliability and ease, of installation the Tensio-
ner/Gripper accessory significantly reduces the installation
time. This by offering an eyehook, tensioner thimble and wire
strength gripper in one assembly which enables rapid connec-
tion to the switch eyebolts and fast and accurate tensioning
of the wire. Thanks to the switch viewing window, systems
can be accurately and quickly tensioned. The double clamp
mechanism prevents wire slippage and significantly reduces
machine 'down time' which can occur which traditional turn-
buckle systems.
1.Tension to mid position as indicated by the green arrows in the viewing
window of each switch.
2.The tensioner thimble allows immediate accurate and final tensioning of
the wire, whilst viewing the tension marker through the viewing window on
the switch.
3.For systems up to 50meter Quick Link termination is provided for easy
connection to either a Safety spring or Switch eyebolt. (Note for systems
above 50meter a Tensioner/Gripper is required each side).
Tensioner/Gripper installation
The end of the safety wire is fed through a central hole in a
cone shaped guide which protrudes from the main housing.
After being fed through the guide hole, the wire enters
the main housing by going through a feed hole and then
is looped back through 180 degrees and is fed through a
second feed hole on the opposite side of the mechanism.
The wire is then pulled for maximum tension and is locked
in position by a locking bar inside the main housing which is
moved by turning an Allen type locking bolt.
Navigating Corners
Because of the added friction on the eyebolts and wire when
navigating corners, a corner pulley can be used to navigate
inside or outside corners without causing damage to the wire.
They are stainless steel and can be rigidly mounted.
Wire Tensioner / Gripper, Stainless Steel article no: 2TLA050210R4020,
Wire Tensioner / Gripper, Galvanized article no: 2TLA050210R4030.
Examples of using the corner pulley
Inside Corners
Outside
Corners
Outside
Corners
M
a
c
h
i
n
e
Machine
Machine
Machine
Machine
1
2
3
11/25 2TLC172001C0202 | ABB Safety Handbook
11
Approvals:
Application:
Machines
Transportation lines
Features:
Easily accessible
Forced contacts
Double switching in both
directions of travel
Up to 50m Wire length
IP67
2NO + 2NC
Emergency Stop Grab Wire Safety Switch
LineStrong1
Switch operational description
LineStrong1 is an emergency stop grab wire safety switch
used for easy reach of an emergency stop along machines,
conveyors and processes. LineStrong1 is a compact and
small, yet robust switch that can handle wires up to 30meters
on a single switch (up to 50meters on two switches).
Agrab wire emergency stop is easier to install than a system
of several emergency stop buttons along a carriage path.
LineStrong1 can be used as protection, for example along a
conveyors with low risks where the wire can be installed at
waist height in front of the conveyor, which provides an emer-
gency stop if someone walks or falls towards the conveyor.
LineStrong1 has double switching in both directions of the
wire. So if someone pulls the wire or if the wire is broken, the
switch goes to a safe state, e.g. the machine is emergency-
stopped. After a safe state the LineStrong1 needs to be reset
to be able to run again and this is made on the local reset
button. LineStrong1 is equipped with an indication of how taut
the wire is, which make the installation or adjustment easy.
Material
The LineStrong1 is made a rugged die cast housing with a
rating of IP67.
Positive forced disconnected contacts
A positive forced contact provides a forced disconnect of the
safety contacts when the wire is being pulled or broken.
The design of the LineStrong1 ensures that the contacts will
not fail or be held in a normally closed position, due to failure
of the spring mechanism or that welding/sticking of the con-
tacts can occur. The LineStrong1 switch has 2NC and 2NO
contacts.
Safety level
The forced disconnected contacts provide a high level of
safety. To achieve a maximum safety level in connection with
the machine control system, it is recommended that the
LineStrong1 is monitored by an appropriate ABB Jokab Safety
safety relay, Pluto safety-PLC or a Vital system.
Regulations and Standards
The LineStrong1 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
IEC/EN60947-5-1, IEC/EN60947-5-5, EN62061, UL508,
ENISO13850 and ENISO13849-1.
Emergency stop grab wire easily accessible during normal work operation
along a machine.
ABB Safety Handbook | 2TLC172001C0202 11/26
11
Dimension LineStrong1
500mm
500mm
500mm
500mm
every 3 meter
every 3 meter
every 3 meter
every 3 meter
up to 30 meter
eyebolt
eyebolt
Safety Spring
up to 50 meter
Technical data LineStrong1 series
Article number
LineStrong1 2TLA050200R0030
Level of Safety
ENISO13849-1 Up to PL e /Cat. 4 depending upon system architecture
EN62061 Up to SIL3 depending upon system architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life) MTTF
d
1.5 x 10
6
operations at 100mA load 21 years
214 years (8 cycles per hour/24 hours per day/365 days)
Wire span up to 50m
Wire tension device Tensioner / Gripper- Quick Fixing
Wire type PVC sheath steel wire 4.0mm outside diameter
Torque settings Mounting M5 4.0Nm, Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm
Termination Clamp up to 2.5 mm
2
conductors
Tension force (typical mid setting) 130N
Tension operating force (wire pulled) < 125N <300mm deection
Short circuit overload protection Fuse externally 10A (FF)
Rated insulation/withstand voltages 500VAC / 2500VAC
Utilisation category AC15 A300 3A
Vibration resistance 10-500Hz 0.35mm
Shock resistance 15g 11ms
Thermal current (lth) 10A
Contact type IEC/EN60947-5-1 double break Typ Zb snap action
Contact material Silver
Conduit entries 3xM20 x 1.5
Enclosure classication IP67
Ambient temperature -25C to +80C
Enclosure material/cover Die cast painted yellow
Mounting position Any
Mounting bolts 4 x M5
11/27 2TLC172001C0202 | ABB Safety Handbook
11
Emergency Stop Grab Wire Safety Switch
LineStrong2
Switch operational description
LineStrong2 is an emergency stop grab wire safety switch
used for easy reach of an emergency stop along machines,
conveyors and processes. LineStrong2 is a robust switch
that can handle wires up to 80meters on a single switch
(up to 100meters on two switches). A grab wire emergency
stop is easier to install than a system of several emergency
stop buttons along a carriage path. LineStrong2 can be used
as protection, for example along conveyors with low risks,
where the wire can be installed at waist height in front of the
conveyor, which provides an emergency stop if someone
walks or falls towards the conveyor. LineStrong2 has double
switching in both directions of the wire. If someone pulls the
wire or if the wire is broken, the switch goes to a safe state,
e.g. the machine is emergency-stopped. After a safe state
the LineStrong2 needs to be reset to be able to run again and
this is made with the local reset button. Additional features
on the LineStrong2 are a "normal" emergency stop that is
fitted on the side of the grab wire safety switch and also a two
coloured LED for indication. LineStrong2 is equipped with an
indication of how taut the wire is, which make the installation
and adjustment easy.
Material
Depending on the environment where the switch will be used,
different material can be chosen for the LineStrong2. The ba-
sic version has a rugged yellow die cast housing with a rating
of IP67. In severe applications as for food processing and
chemical industry there is a LineStrong2Z with a total rugged
stainless steel 316 body. This version has IP69K enclosure
protection (maintained by a double seal lid gasket and seals)
and can be high pressure hosed with detergent at high tem-
perature.
Positive forced disconnected contacts
A positive forced contact provides a forced disconnect of the
safety contacts when the wire is being pulled or broken.
The design of the LineStrong2 ensures that the contacts will
not fail or be held in a normally closed position, due to failure
of the spring mechanism or that welding/sticking of the con-
tacts can occur. The LineStrong2 switch has 2NC and 2NO
contacts.
Safety level
The forced disconnected contacts provide a high level of
safety. To achieve a maximum safety level in the connection
with the machine control system, it is recommended that the
LineStrong2 is monitored by an appropriate ABB Jokab Safety
safety relay, Pluto safety-PLC or a Vital system.
Explosion Proof version (X)
LineStrong2 also exist in versions with certified explosion
proof contact block (X-versions). LineStrong2ZX have a stain-
less steel body and can be used in European Zone 1, 2, 21,
22 enviroments (Gas and Dust). Preassembled with 3meter
cable.
Regulations and Standards
The LineStrong2 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
IEC/EN60947-5-1, IEC/EN60947-5-5, EN62061, UL508,
ENISO13850 and ENISO13849-1.
Approvals:
Application:
Machines
Transportation lines
Features:
Duplicate extraction in two
directions
Up to 100m length
Up to IP69K
Integrated emergency stop
button
2NO + 2NC
EX version
(X-versions)
ABB Safety Handbook | 2TLC172001C0202 11/28
11
Dimensions LineStrong2 and LineStrong2Z
500mm 500mm every 3 meter every 3 meter
up to 80 meter
LineStrong2
up to 100 meter
LineStrong2Z
eyebolt
eyebolt
Safety Spring
500mm 500mm every 3 meter every 3 meter
up to 60 meter
LineStrong2
up to 80 meter
LineStrong2Z
Technical data LineStrong2 series
Article number
LineStrong2
LineStrong2Z
LineStrong2ZX (EX)
2TLA050202R0332
2TLA050202R0322
2TLA050202R7125
Level of Safety
EN ISO13849-1 Up to PL e/Cat. 4 depending
upon system architecture
EN62061 Up to SIL3 depending upon
system architecture
Safety data
Mechanical Reliability B
10d
Proof test interval (life)
MTTF
d
1.5 x 10
6
operations at 100mA
load
21 years
214 years (8 cycles per hour/24
hours per day/365 days)
Wire span
LineStrong2
LineStrong2Z(X)
Up to 80m
Up to 100m
Wire tension device Tensioner / Gripper- Quick
Fixing
Wire type PVC sheath steel wire 4.0mm
outside diameter
Torque settings Mounting M5 4.0Nm
lid T20 Torx M4 1.5Nm
terminals 1.0Nm
Termination Clamp up to 2.5 mm
2
conduc-
tors
Tension force (typical mid setting) 130N
Tension operating force (wire pulled) < 125N <300mm deection
Short circuit overload protection Fuse extenally 10A (FF)
Rated insulation/withstand voltages 500VAC / 2500VAC
Utilisation category AC15 A300 3A
Vibration resistance 10-500Hz 0.35mm
Shock resistance 15g 11ms
Thermal current (lth) 10A
LED 24 VDC
Contact type IEC/EN60947-5-1 double break
Typ Zb snap action
Contact material Silver
Conduit entries 3xM20 x 1.5
Enclosure classication
LineStrong2
LineStrong2Z(X)
IP67
IP69K and IP67
Ambient temperature:
LineStrong2
LineStrong2Z(X)
-25C to +80C
-25C to +80C (100Ccleaning)
Enclosure material/cover
LineStrong2
LineStrong2Z(X)
Die cast painted yellow
Stainless steel 316
Mounting position Any
Mounting bolts 4 x M5
Explosion Proof version (X)
Classication
Rated Voltage
Rated Current
Ex d IIC T6
(-20C Ta +60C) Gb
Ex tb IIIC T85C
(-20C Ta +60C) Db
250V AC/DC
2 pole 4A
4 pole 2.5A
11/29 2TLC172001C0202 | ABB Safety Handbook
11
Emergency Stop Grab Wire Safety Switch
LineStrong3
Switch operational description
LineStrong3 is an emergency stop grab wire safety switch
used for easy reach of an emergency stop along machines,
conveyors and processes. LineStrong3 is a quite robust
switch that can handle long wires, up to 250 meters on a
single switch. A grab wire emergency stop is easier to install
than a system of several emergency stop buttons along a
carriage path. LineStrong3 can be used as protection, for
example along conveyors, with low risks where the wire can
be installed at waist height in front of the conveyor, which
provides an emergency stop if someone walks or falls towards
the conveyor.
LineStrong3 has double switching in both directions of the
wire. If someone pulls the wire or if the wire is broken, the
switch goes to a safe state, e.g. the machine is stopped.
After a safe state the LineStrong3 needs to be reset to be able
to run again and this is made on the local reset button.
Additonal features on the LineStrong3 is a "normal" emergen-
cy stop fitted on the top of the grab wire safety switch and
also a two coloured LED for indication.
LineStrong3 is equipped with an indication of how taut the
wire is, which make the installation and adjustment easy.
Material
Depending on the environment where the switch will be used,
different materials can be chosen for the LineStrong3. The
basic version has a rugged yellow die cast housing with a
rating of IP67. In severe applications as for food processing
and chemical industry, there is a LineStrong3Z with a total
rugged stainless steel 316 body. This version has IP69K en-
closure protection (maintained by a double seal lid gasket and
seals) and can be high pressure hosed with detergent at high
temperature.
Positive forced disconnected contacts
A positive forced contact provides a forced disconnect of the
safety contacts when the wire is being pulled or broken. The
design of the LineStrong3 ensures that the contacts will not
fail or be held in a normally closed position, due to failure of
the spring mechanism or that welding/sticking of the contacts
can occur. The LineStrong3 switch has 4NC and 2NO.
Safety level
The forced disconnected contacts provide a high level of
safety. To achieve a maximum safety level in the connection
with the machine control system, it is recommended that the
LineStrong3 is monitored by an appropriate ABB Jokab Safety
safety relay, Pluto safety-PLC or a Vital system.
Explosion Proof version (X)
LineStrong3 also exist in versions with certified explosion
proof contact block (X-versions). LineStrong3LZX/RZX/DZX
have a stainless steel body and can be used in European
Zone 1, 2, 21, 22 enviroments (Gas and Dust). Preassembled
with 3meter cable.
Regulations and Standards
The LineStrong3 is designed and approved in accordance to
relevant standards. Examples of relevant standards are
IEC/EN60947-5-1, IEC/EN60947-5-5, EN62061, UL508,
ENISO13850 and ENISO13849-1.
Approvals:
Application:
Machines
Transportation lines
Features:
Duplicate extraction in two
directions
Up to 250m length
Up to IP69K
Intergrated emergency stop
button
4NC + 2NO
EX version
(X-versions)
ABB Safety Handbook | 2TLC172001C0202 11/30
11
Single Wire
LineStrong3L/3R and LineStrong3LZ/3RZ
LineStrong3L/3R - Standard version
The Linestrong3L/3R are two different versions depending on
installation.
L - "Left hand" - is the version of LineStrong3 where the
placement of the grab wire switch is to the left in the installa-
tion.
R - "Right hand" - is the version of LineStrong3 where the
placement of the grab wire switch is to the right in the instal-
lation.
Both versions have die-cast housings and are robust to
severe indoor or outdoor use. LineStrong3L/3R are designed
to protect a length up to 100 meters on a single switch. If two
switches are used together, up to 125 meters. A two colour
LED ensures switch status can be seen easily from a dis-
tance. They have 4NC and 2NO contacts to ensure flexibility
with all modern control application.
LineStrong3LZ/3RZ - Stainless steel version
The Linestrong3LZ/3RZ are two stainless steel switches with
different installations possibilites.
L - "Left hand" - is the version of LineStrong3Z where the
placement of the grab wire switch is to the left in the installa-
tion.
R - "Right hand" - is the version of LineStrong3Z where the
placement of the grab wire switch is to the right in the instal-
lation.
Both versions are in stainless steel 316 housings and are de-
signed specifically to withstand the tough environments found
in the food and pharmaceutical industries. LineStrong3LZ/3RZ
are designed to protect a length up to 100 meters on a single
switch. If two switches are used together, up to 125 meters.
A two colour LED ensures switch status can be seen easily
from a distance. They have 4NC and 2NO contacts to ensure
flexibility with all modern control application.
Dimensions LineStrong3L/R and LineStrong3LZ/RZ
Left hand Right hand
500mm
500mm
500mm
500mm
every 3 meter
every 3 meter
every 3 meter
every 3 meter
up to 125 meter
up to 100 meter
eyebolt
eyebolt Safety Spring
Left hand
side
Right hand
side
11/31 2TLC172001C0202 | ABB Safety Handbook
11
LineStrong3D - Standard version
The Linestrong3D is a third version of the Linstrong3.
With wire entries from both sides of the grab wire switch,
LineStrong3D can be used for a long protection length.
The LineStrong3D has a die-cast housing and is robust to
manage severe indoor or outdoor use. LineStrong3D is desi-
gned to protect a length up to 200 meters on a single switch.
If several switches are used together, it will be possible with a
length up to 125 meters between the switches. A two colour
LED ensures switch status can be seen easily from a dis-
tance. LineStrong3D have 4NC and 2NO contacts to ensure
flexibility with all modern control application.
LineStrong3DZ - Stainless steel version
The Linestrong3DZ is a third version of the Linstrong3Z.
As a stainless steel version with wire entries on both sides of
the grab wire switch, LineStrong3DZ can be used for a long
protection length.
The LineStrong3DZ has stainless steel 316 housing and is de-
signed specifically to withstand the tough environments found
in the food and pharmaceutical industries. LineStrong3DZ is
designed to protect a length up to 200meters on a single
switch. If several switches are used together it will be possible
with a length up to 125 meters between the switches. A two
colour LED ensures switch status can be seen easily from
a distance. LineStrong3DZ have 4NC and 2NO contacts to
ensure flexibility with all modern control application.
Double Wire
LineStrong3D and LineStrong3DZ
Dimensions LineStrong3D and LineStrong3DZ
eyebolt Safety Spring Safety Spring
500mm
500mm
500mm
500mm 500mm 500mm
500mm 500mm 500mm every 3 meter
every 3 meter
every 3 meter every 3 meter
up to 125 meter
up to 100 meter up to 100 meter
up to 125 meter
eyebolt
eyebolt Safety Spring Safety Spring
ABB Safety Handbook | 2TLC172001C0202 11/32
11
Technical data LineStrong3 series
Article number
LineStrong3L
LineStrong3R
LineStrong3LZ
LineStrong3RZ
LineStrong3LZX (EX)
LineStrong3RZX (EX)
LineStrong3D
LineStrong3DZ
LineStrong3DZX (EX)
2TLA050206R0332
2TLA050208R0332
2TLA050206R0322
2TLA050208R0322
2TLA050204R7125
2TLA050206R7125
2TLA050204R0332
2TLA050204R0322
2TLA050208R7125
Level of Safety
ENISO13849-1 Up to PL e, Cat. 4 depending upon system architecture
EN62061 Up to SIL3 depending upon system architecture
Safety data
Mechanical reliability B
10d
Proof test interval (life) MTTF
d
1.5 x 10
6
operations at 100mA load 21 years
214 years (8 cycles per hour/24 hours per day/365 days)
Wire span
LineStrong3L/R/LZ(X)/RZ(X)
LIneStrong3D/DZ(X)
Up to 125m
Up to 250m
Wire tension device Tensioner / Gripper- Quick Fixing
Wire type PVC sheath steel wire 4.0mm outside diameter
Torque settings Mounting M5 4.0Nm, Lid T20 Torx M4 1.5Nm, Terminals 1.0Nm
Termination Clamp up to 2.5 mm2 conductors
Tension force (typical mid setting) 130N
Tension operating force (wire pulled) < 125N <300mm deection
Short circuit overload Protection Fuse extenally 10A (FF)
Rated insulation/withstand voltages 500VAC / 2500VAC
Utilisation category AC15 A300 3A
Vibration resistance 10-500Hz 0.35mm
Shock resistance 15g 11ms
Thermal current (lth) 10A
LED 24 VDC
Contact type IEC/EN60947-5-1 double break Typ Zb snap action
Contact material Silver
Conduit entries 4xM20 x 1.5
Enclosure classication
LineStrong3D/L/R
LineStrong3LZ(X)/RZ(X)/DZ(X)
IP67
IP69K and IP67
Ambient temperature:
LineStrong3L/R/D
LineStrong3LZ(X)/RZ(X)/DZ(X)
-25C to +80C
-25C to +80C (100Ccleaning)
Enclosure material/cover:
LineStrong3L/R/D
LineStrong3LZ(X)/RZ(X)/DZ(X)
Die cast painted yellow
stainless steel 316
Mounting position Any
Mounting bolts 4 x M5
Explosion Proof version (X)
Classication
Rated Voltage
Rated Current
Ex d IIC T6 (-20C Ta +60C) Gb Ex tb IIIC T85C (-20C Ta +60C) Db
250V AC/DC
2 pole 4A
4 pole 2.5A
11/33 2TLC172001C0202 | ABB Safety Handbook
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Emergency Stop Grab Wire Safety Switch
Accessories
Accessories
Type Article number
Wire pull kit includes:
Wire, Eyebolts, Tensioner /Gripper, Allen key
Galvanized wire pull kits 10m wire kit 2TLA050210R0130
20m wire kit 2TLA050210R0330
80m wire kit 2TLA050210R0630
100m wire kit 2TLA050210R0730
Stainless steel wire pull kits 50m wire kit 2TLA050210R0520
100m wire kit 2TLA050210R0720
Wire only 10m wire 2TLA050210R2120
80m wire 2TLA050210R2520
100m wire 2TLA050210R2620
1m wire (order by length) 2TLA020034R0500
Wire Tensioner / Gripper Tensioner / Gripper, galvanized 2TLA050210R4030
Tensioner / Gripper, stainless steel 2TLA050210R4020
Corner pulley Corner pulley, galvanized 2TLA050210R6030
Corner pulley, stainless steel 2TLA050210R6020
Eyebolt Eyebolt, M8 x 1.25, galvanized 2TLA050210R8030
Eyebolt, M8 x 1.25, stainless steel 2TLA050210R8020
General wire pull accessories Safety spring, 220mm long, stainless steel 2TLA050211R0004
Screw driver, Anti-Tamper, Torx T20 2TLA050211R0006
Gland and plug M20x1.5 gland 2TLA050040R0002
M20x1.5 conduit plug 2TLA050040R0004
ABB Safety Handbook | 2TLC172001C0202 11/34
11
12/1 2TLC172001C0202 | ABB Safety Handbook
12
ABB Safety Handbook | 2TLC172001C0202 12/2
12
Contact edges, Bumpers and Safety mats
When shall I use Contact edges, Bumpers and Safety mats? 12/3
Safety contact edges 12/4
Safety bumpers 12/7
Safety mats 12/9
Electrical connections 12/12
12/3 2TLC172001C0202 | ABB Safety Handbook
12
When shall I use Safety contact edges, Safety bumpers and
Safety mats?
Contact edges and Bumpers
Contact edges are used as protection against squeezing accidents, i.e.
on moving machine parts and automatic doors and hatches. The strips
come in customised lengths and various cross sections.
Bumpers are used as safety buffers to protect against remote control
transport vehicles and other dangerous moving objects that require long
stopping distances.
Safety mats
Safety mats are used for protection around hazardous machinery. They
are well suited for monitoring an area used for loading and unloading of
material to a machine.

Standard: EN 1760-2 Safety of machinery -

Pressure sensitive protective devices - Part
2: General principles for the design and tes-
ting of pressure sensitive edges and pressure
sensitive bars
Standard: EN 1760-1 Safety of machinery -
Pressure sensitive protective devices - Part
1: General principles for the design and tes-
ting of pressure sensitive mats and pressure
sensitive floors

Fields of Application
ABB Safety Handbook | 2TLC172001C0202 12/4
12
Safety contact edges
Contact!
Approvals:
Application:
Protection against squeezing
accidents on moving machine
parts and automatic doors.
Features:
Can be connected to a safety
relay, Vital or Pluto
Supplied in customized
lengths
IP65
Simple assembly on site
Lengths up to 25 m.
General
Safety contact edges are employed to guard closing edges
at possible crushing or shearing points. They are used in
gates, machines and handling facilities to protect people and
equipment. They consist of an aluminium support profile, the
contactor profile and the safety contact edge.
Contact edges with cast-in contact strips
The safety contact edges GE series consist of a rubber profile
with a cast-in contact strip. In the ends there are special
connection plugs and terminal caps (End caps) adapted ac-
cording to the rubber profile. The end components are glued
together with a certain two component glue. The contact edge
is mounted on an aluminium C-profile. The easy to handle
subcomponents allows customer assemble of the GE contact
edges, good for stock handling, but of course a preassembled
contact edge can also be ordered. The GE series is available
in EPDM design and can be supplied in lengths up to 25 m.
Contact edges with contact strips SKS 18
The safety contact edges GP series consists of a rubber
profile with a separate safety contact strip (SKS 18) inside.
The contact edge is mounted on an aluminium C-profile. The
special design of profiles in EPDM or NBR rubber, protect the
inner contact strip in the best way possible against dama-
ge and allows actuating angles to exceed 90. GP series is
normally supplied in lengths up to 6 m and is allways delivered
preassembled.
Material
EPDM design that has a good resistance to ozone and wea-
ther, especially against chemicals.
NBR has good resistance to oil and petrol.
Supervision
The Safety Contact edge must be connected to a suitable two
input channel Safety Relay. e.g. ABB Jokab Safety type
RT6/RT7/RT9 which provides all necessary monitoring of the
contact edges activation and detection of cable faults.
The twin cable connection makes it possible to connect seve-
ral contact edges in series.
12/5 2TLC172001C0202 | ABB Safety Handbook
12
Contact edges GP - General
The safety contact edges GP series consist of a contact strip, SKS 18. This is the
actual contactor that is located inside the safety contact edge. The safety contact
strip consist of a homogeneous highly insulating outer EPDM material and has two
internal conducting contact surfaces. The conducting elastomer contains two cop-
per wires that provide low-resistance detection even in lengths exceeding 100m.
Because of the contact points, the safety contact edge has approximate 20mm of
inactive length at each end.
To provide protection against damage and to enable its proper use, the safety
contact strip is inserted into the switching chamber of the rubber profile. The rubber
profiles (EDPM or NBR) are then permanently sealed with a special elastic adhesive
and end caps to make them watertight. The rubber profile is then mounted on the
aluminium profile. The contact strip together with the rubber profile makes the GP
safety contact edge.
Safety contact strip SKS 18
Safety contact edge,
construction
Aluminium profile,
C-profile
SKS 18
Rubber profile
(1) 10m lengths of GP edges on request
(2) Measured with ( 80 mm test
specimen),10 mm/s
(3) Measuring speed 10 mm/s
(4) Not including DIN 31006-2
(GS - BE - 17)
Technical data - SKS 18
Outer material EPDM, electrical insulation >30 Mohm
Inner material EPDM, electrical elastomer with reinforce copper wire
Conductivity 60 ohm / 100 meters
Contact resistance approx. 50 ohm
Max. electrical load 24 V / 100 mA
Max. applied pressure 6.5 N/cm2
Dimensions 18 x 6 mm
NOTE! Contact us for other profile sizes.
Conductive
contact surface
Highly insu-
lated outer
material
Copper wire
Contact edges GE - General
Inside the GE contact edge there is a cast-in contact strip that consists of two
conductive alternating surfaces on the inside and a highly-effective insulating shell.
There are two conductive wires in the contact surfaces that allow for low ohm
measurements even when the contact edge has an extended length. The cast-in
contact strip is protected against damage by the surrounding chamber. The cast
end plugs ensure a permanent contact from the conductive surfaces in the contact
strip. A special flexible adhesive is used to make the connector ring watertight.
Technical data - Rubber profiles
Type GP 25-25
25
25
GP 25-40
40
25
GE 25-25
25
2
5
GE 25-45
25
4
5
Fixing Prole AL 25-14 AL 25-14 Al 25-14 Al 25-14
Material EPDM/NBR EPDM/NBR EPDM EPDM
Length max (m) (1) 6(10) 6(10) 25 25
Weight (g/m) 370 480 510 770
Weight incl. C-Prole (g/m) 690 800 820 1080
Activation force (N) (2) 34/37 39/52 64,1 69,1
Actuating distance (mm) (3) 8.0/7.5 9.4/9.7 4,7 6,73
Braking distance (mm) (3) 7.2/5.9 10.2/9.5 6.48 20.73
Max. actuating ( ) (4) 2x 45 2x 60 2x20 2x20
Connection
plug
Rubber profile with
integrated contact
strip
Terminal
cap
Connection
plug
Aluminium profile
The selected contact profile should be
mounted using a suitable aluminium
Cprofile.
ABB Safety Handbook | 2TLC172001C0202 12/6
12
5
4
1
5
3
2
Technical data - Contact edges
Article number
GP Contact edges including
aluminium prole
GP 25-25 EPDM per meter
GP 25-25 NBR per meter
GP 25-40 EPDM per meter
GP 25-40 NBR per meter
Cable, production cost
2+2 m cable
5+5 m cable
7+7 m cable
10+10 m cable
Contact us for more options
2TLA076025R2500
2TLA076125R2500
2TLA076025R4000
2TLA076125R4000
2TLA076009R0100
2TLA076009R0500
2TLA076009R0800
2TLA076009R1000
Article number
GE Contact edges
GE 25-25 EPDM per meter
GE 25-45 EPDM per meter
Connection plug with:
2.5 m cable
5m cable
10m cable
resistor 8.2k
End cap
End cap for GE 25-25
End cap for GE 25-45
Others
Al 25-14 aluminum prole
Prod. cost GE (when ready made)
Accessories
Glueing set small 5 gr/5 ml
Glueing set large 20 gr/10 ml
Scissor
Plug insert too
2TLA076005R0200
2TLA076005R0400
2TLA076005R4400
2TLA076005R4500
2TLA076005R4600
2TLA076005R4700
2TLA076005R6200
2TLA076005R6100
2TLA076002R0200
2TLA076008R0000
2TLA076005R7600
2TLA076005R7700
2TLA076005R8500
2TLA076005R8600
Mechanical load max
1
500 N
Actuating angle (DIN)
1
2x 20
Mechanical life
1
10
5
Max. operate temp. range
2
-20C to +55C
Max. temperature range -25C to +70C
Protection classication IP65
Max. electrical load 24 VDC 100mA
Resistance 0.6 Ohm/m
Conductors GP: 2x 0.38 mm
2

GE: 2x 0.34 mm
2
Conductors insulation material GP: PVC
GE: PUR matte black
1
According to DIN 31006-2 (GS - BE - 17)
2
Not including DIN 31006-2 (GS - BE - 17)
Ordering Contact edges
GP
When ordering a Contact edge GP its made out of two parts.
One article with production cost and cables and one article
with type of Contact edge in meter. Always specify length of
safety edge.
Example (complete and assembled):
1 pcs GP 25-25 EPDM, length 0.25m, 5+5m cable =
0.25m of 2TLA076025R2500 (Contact edges+alu.profile)
1pcs of 2TLA076009R0500 (cables and assemble)
GE
When ordering a Contact edge GE its necessary to or-
der every part specifically. Type of contact edge (in meter),
aluminium profile (in meter), connection plugs (one for each
end) and end caps (one for each end). If desired it can be
assemble by ABB Jokab Safety, for a production cost. Always
specify length of safety edge. Accessories for GE is ordered
separately.
Example (complete and assembled):
1 pcs GE 25-45 EPDM, length 1.35m, 2.5+5m cable =
1.35m of 2TLA076005R0400 (Contact edges)
1
1.35m of 2TLA076002R0200 (Aluminum profile)
2
1 pcs of 2TLA076005R4400 (2.5m cable)
3
1 pcs of 2TLA076005R4500 (5m cable)
4
2pcs of 2TLA076005R6100 (End cap)
5
1 pcs of 2TLA076008R0000 (Prod. cost GE)
12/7 2TLC172001C0202 | ABB Safety Handbook
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Safety bumpers
Approvals:
Application:
Protection against squeezing
accidents on moving machine
parts and automatic doors.
Features:
Can be connected to a safety
relay, Vital or Pluto
Customized lengths
Customized shape
IP65
Lengths up to 3 m
Safety bumpers
Safety bumpers are safety equipment on transport vehicles, FTS vehicles, high-
reach forklifts, freely moving systems, and everywhere where the safety systems
require larger form alterations. When running against an obstacle, the short respon-
se time of the bumper initiates an immediate controller stop, while the bumpers soft
foam core provides a long braking and run out path. This provides optimum pro-
tection for individuals and materials. The exterior surface is available as PU or NBR
rubber. Standard colours for the PU exterior are either black or black with yellow
stripes. The NBR rubber exterior is black on which yellow stripes can be applied.
The principle
The contact function of the ABB Jokab Safety bumper consists of the safety con-
tact strip SKS 18 being actuated by a special mechanical construction. This cons-
truction, which is protected by a large foam cushion, is inserted and glued to the
carrier aluminum profile. The foam rubber is covered with a polyurethane or NBR
skin. By utilising this construction the bumper gives a stop signal when impacted
from all directions with soft sides. The bumpers are delivered mounted to the carrier
profile in ordered lengths (0.2 m 3 m).
Supervision
The Safety bumper must be connected to a suitable two input channel Safety Relay.
e.g. ABB Jokab Safety type RT6/RT7/RT9 which provides all necessary monitoring
of the bumpers activation and detection of cable faults. The twin cable connection
makes it possible to connect several bumpers in series.
1
5
2
3
4
1. Polyurethane exterior
2. Foam core
3. Carrier profile
4. Mounting profile
5. Sensing element
ABB Safety Handbook | 2TLC172001C0202 12/8
12
Technical data - Bumpers ASB
Article number
Bumper base price
53/100 black
100/200 black
150/300 black
200/400 black
53/100 black/yellow
100/200 black/yellow
150/300 black/yellow
200/400 black/yellow
53/100 NBR black
100/200 NBR black
150/300 NBR black
200/400 NBR black
100/200 NBR black/yellow
Contact us for more options
2TLA076200R0000
2TLA076200R0100
2TLA076200R0200
2TLA076200R0300
2TLA076200R0400
2TLA076200R0500
2TLA076200R0600
2TLA076200R0700
2TLA076200R0800
2TLA076200R0900
2TLA076200R1000
2TLA076200R1100
2TLA076200R1200
2TLA076200R1500
Dimensions in accordance with the illustration, or special dimensions
Actuating distance ~20% of height
Braking distance >50% of height
Actuating force [N] <150 N with round body 80 mm
<300 N with test object 45 x 400 mm
Mechanical life >10
5
Protection class IP65
Ambient temperature 0 to +60
Chemical resistance
Oil, grease
10% acid
10% alkaline (caustic) solutions
good
resistant
resistant
Connection 20 cm with M8 male connector on one side
20 cm with M8 female connector on one side
Cable (included) 1 x 5 m with M8 male connector; 2 x 0.25 mm
2
PU covered
1 x 5 m with M8 female connector; 2 x 0.25 mm
2
PU covered
Ordering Safety bumpers
When ordering a Safety contact bumper its made out of two
parts. One article with production cost (base price) and one
article with type of bumper in meter. Always specify length
of the Safety contact bumper. Bumpers can be supplied in
lengths of up to 3000 mm.
Example (complete and assembled):
1 pcs 150/300, black/yellow, length 2.1m =
2.1m of 2TLA076200R0700 (bumper+alu.profile)
1pcs of 2TLA076200R0000 (base price)
Dimensions/Shapes
Special designs and special available on request
Lengths and Connection
The ASB Safety bumper is available in lengths up to 3,000
mm. Wiring outputs are located at each end of the bumper.
Special designs available on request.
X = Bumper hight, Y = Bumper width, Z = Bumper length
12/9 2TLC172001C0202 | ABB Safety Handbook
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Safety mats
Personal protection within dangerous areas
The ASK Safety mat is used for safeguarding sections within
the dangerous areas around presses, robots, production
lines, machines and other types of active equipment. When
connected to a suitable monitoring system, stepping on the
Safety Mat will immediately be detected causing dangerous
machine movements to be stopped. This is made possible
by the detection of electrical contacts closing within the
sandwich construction of the mat. The safety mats offered
by ABBJokab Safety are available in two version, with our
without a cast-in moulded ramp rail. Custom made size or
shapes of the Safety mats can also be offered. Mounting to
the floor can be realized with optional aluminum ramp rails
RS14 or BS14 (for mats without moulded ramp rail).
Contact!
Slip-free Surface
Polyurethane-
Upper Surface
Contact Surface 1
Isolating Layer
Contact Surface 2
Approvals:
Safety mats for
Personal protection within
the dangerous areas around
presses, robots, production
lines, machines etc.
Features:
Can be connected to a safety
relay, Vital or Pluto
Very durable
IP65
Mat construction
The basic construction of the Safety mat is made up of a
sandwich construction. The pressure contact switch consist
of two conducting plates which are separated from each
other by a proprietary isolating layer. The internal switching
plates are cast into a durable polyurethane material to protect
against moisture, and are then covered with a top layer of
slip-free rubber. This surface provides excellent resistance
against oil, water and grease. Optional surfaces in aluminum
or stainless steel can be placed on the mat surface in areas
where high mechanical demand. Two cable exits are provided,
that consist of one M8 male plug and one M8 female plug in
the standard construction (Optional cable exits are available
upon request).
ABB Safety Handbook | 2TLC172001C0202 12/10
12
Surface layer - Safety mats
Safety mats are normally supplied with a dotted polyurethane non-slip surface layer
that withstands tough conditions very well (oil, acid or caustic substances) and has
anti-slip properties. If required, other patterns can be supplied, or for special requi-
rements even other materials, such as NBR rubber or chequer plating in aluminium
or stainless steel. Safety mats can also be supplied without a surface layer, to have
a full coverage rubber sheet glued on during installation. Please contact us for more
information about these alternatives.
Safety distance - Safety mat as per EN ISO 13855
If a safety mat is used as entry protection, the smallest per-
mitted safety distance between the hazardous area and the
outer edge of the mat (seen from the hazard) is calculated
using the formula from EN ISO 13855.
S = (K * T) + C
S = smallest permitted safety distance in mm
K = body speed (velocity of propagation 1600 mm/s)
C = additional distance in mm based on the intrusion of the
body into the risk zone before the protection device is actua-
ted (1200 mm applies for safety mats).
i.e.
S = (1600 * T) + 1200
Edge Trim - Safety mats
Edge trim RS14
Eliminates vertical edges and attaches the Safety mat to the floor. Also provides protection and channel for connection cables.
Profile BS14
Best for use on the side nearest the machine. Permits a shorter distance from, for example a wall.
Corner trim
Can be used between two RS 14 proles as an alternative to mitre cutting of proles.
Base unit Corner connection
Angle fixing profile
Fixing profile
Surface protection
Connection cable
Channel for connection cable
ASK-1U4.4-NP - Completely moulded
mat without moulded ramp rail. Ramp
rail in aluminum profile (RS14).
ASK-1T4.4-NP - Completely moulded mat
with moulded ramp rail.
Connection
cable
Area for safeguard + 70 mm
Area for safeguard
A
r
e
a

f
o
r

s
a
f
e
g
u
a
r
d

A
r
e
a

f
o
r

s
a
f
e
g
u
a
r
d

+

7
0

m
m
12/11 2TLC172001C0202 | ABB Safety Handbook
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Technical Data - Safety mats
Article number
ASK-1U4.4-NP standard no ramp
rail**
1000 x 750 mm* 2TLA076310R0500
1000 x 1000 mm* 2TLA076310R0600
1000 x 1500 mm* 2TLA076310R0700
ASK-1U4.4-NP custom made no
ramp rail**
Base price 2TLA076301R0000
Cut to size (m
2
) * 2TLA076301R0500
ASK-1T4.4-NP standard with mol-
ded ramp rail**
1000 x 750 mm* 2TLA076310R1000
1000 x 1000 mm* 2TLA076310R1100
1000 x 1500 mm* 2TLA076310R1200
ASK-1T4.4-NP custom made with
molded ramp rail**
Base price 2TLA076301R0200
Cut to size (m
2
)* 2TLA076301R0600
Accessories
Cable 2.5 m M8 Male + M8 Female
Cable 5 m M8 Male + M8 Female
Edge trim RS14
Prole BS14
Corner trim
Cutting cost BS14 and RS14
2TLA076900R3200
2TLA076900R3300
2TLA076300R0500
2TLA076300R0800
2TLA076300R0900
2TLA076300R0800
Maximum area One mat = 2350 x 1350 mm (relation max 3:1) Several mats = 10m
2
Minimum size 100 x 100 mm
Height max 14.5mm with slip-free surface
Inactive area Nominally 10 mm from Mat edge
Switching force 150N (Round body 80 mm)
Maximum pressure 2000 N over 80 mm
Material Black polyurethane, other colours on request
Protection class IP65
Ambient air temperature 0C to +60C
Chemical resistance
Oil, grease good
10% acid resistant
10% alkaline (caustic) solutions resistant
Connection 20 cm with M8 male connector on one corner
20 cm with M8 female connector on one corner
Cable (included) 1 x 5 m with M8 male connector; 2 x 0.25 mm
2
PU covered
1 x 5 m with M8 female connector; 2 x 0.25 mm
2
PU covered
Mechanical life > 1.5x10
6
load shifting
* Incl 5+5m cables
**Size applies for safeguarded area
Ordering custom made Safety mats
When ordering a custom made mat, two articles need to be ordered. A base price and a square meter price. When ordering,
the size of the mat need to be specified (X meter x Y meter).
Example:
1 pcs 0.450x1.15 m, normal surface with molded ramp rail=
0.518m
2
of 2TLA076301R0600 (ASK-1T4.4-NP custom made)
1pcs of 2TLA076301R0200 (base price)
ABB Safety Handbook | 2TLC172001C0202 12/12
12
NOTE! If alternative units are used rather than the
recommended ABB JokabSafety relays, it is essential that
the user checks their suitability with ABB JokabSafety before
use. Failure to do so may result in incorrect operation and/or
damage to the safety bumpers and invalidate warranty.
Electrical connections
Safety contact edges, Safety bumpers and Safety mats
Contact edge, bumper or safety mat should be used with a
suitable monitoring unit (e.g. ABB JokabSafety safety relays
RT6, RT7A/B, RT9, Vital with Tina 6A or Pluto safety-PLC).
The monitoring unit monitors the functionality of the contact
protection and detects any breaks or short-circuits in the li-
nes. Several crush protection units can be connected in series
while still retaining the same level of safety.
When pressure is applied, the active surface of the contact
area in the contact protection is closed and the safety output
on the monitoring unit trips. A stop signal will be sent to the
machine's safety circuits preventing any dangerous move-
ments.
HK7601A Connection contact protection for safety relay RT6
12/13 2TLC172001C0202 | ABB Safety Handbook
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HK3310A Connection contact protection for safety controller Vital 1
HK0001A Connection contact protection for safety PLC Pluto
ABB Safety Handbook | 2TLC172001C0202 12/14
12
13/1 2TLC172001C0202 | ABB Safety Handbook
13
ABB Safety Handbook | 2TLC172001C0202 13/2
13
Fencing system
Quick-Guard and Safety Roller Door
Quick-Guard

fencing system 13/3

Quick-Guard

is supplied in three ways 13/6

Quick-Guard

Express 13/7
Quick-Guard

Express - can be ordered in sections 13/8

Quick-Guard

standard and SafeCAD 13/11

Assembly using NL2 and NL3 Net-locks on welded mesh 13/13
Dimensions for aluminium profile lengths and panels 13/14
Components
Aluminium profiles 13/15
Fittings 13/18
Door Components 13/20
Fitting for Switches 13/28
Terminal Caps and Strips 13/30
Accessories 13/31
Infill materials 13/32
Safety Roller Door
Safety Roller Door 13/34
13/3 2TLC172001C0202 | ABB Safety Handbook
13
Quick-Guard

Fencing system
Quick-Guard Express with few
components and easy to angle at up
to 45.
Quick-Guard Standard with black and
transparent Polycarbonate in-fill panels
as used for medical applications.
Quick-Guard Standard assembled with mesh.
Adaption and Modification
Quick-Guard is a very flexible fencing system consisting of
a minimum of different components, e.g. aluminium profiles,
patented brackets, net-locks, mesh, solid or noise reduction
panels. Using these components there are almost no limitations
as to what can be built. Quick-Guard fencing costs little to
assemble and modify.
Assembly
Due to our patented screw-lock system, we can supply all
brackets pre-mounted with fixing screws and nuts. No holes
need to be drilled in the profiles and all cutting is straight. This
makes assembly and modification very easy.
Two versions of Quick-Guard
The Quick-Guard fencing system is available in two versions,
Quick-Guard (Standard) and Quick-Guard Express which also
can be combined. The fencing systems are also easy to adjust
when production equipment is modified and/or moved.
Proposal and ordering
By utilising our AutoCAD-based SafeCAD application we are
able to make system designs in 3D very quickly. Drawings,
cutting lists, etc. are generated from SafeCAD and the drawings
can also be used for installation purposes.
Our policy - To create systems that are environmentally
friendly and provide ergonomic working conditions
Quick-Guard is environmentally friendly. All components in
the Fencing System can easily be disassembled and reused.
All materials in the Fencing System are 100% recyclable.
Quick-Guard can also provide a pleasing ergonomic working
environment.
ABB Safety Handbook | 2TLC172001C0202 13/4
13
Fixings with pre-assembled screws and
nuts mean easy assembly
Width, length and height adapted and
easily changed according to needs
Choose from a large selection of
hatches and doors
A flexible and stable fencing system which is easy to install
Mesh Plastic Glass Plate
Sound
absorbing
13/5 2TLC172001C0202 | ABB Safety Handbook
13
0 200 500 900 0 350
2500
1600
2500
2000
mm mm
Safety distance for 1600mm
guarding with standard mesh.
Safety distance for 2000 mm
guarding with solid screens
(e.g. polycarbonate sheet).
Safety distance for 1600mm
guarding with standard
mesh. Safety distance for
2000mm guarding with
solid screens
(e.g. polycarbonate sheet).
Mount the fixtures by first slackening the screw 3/4 turn anti-
clockwise. Then tighten the screw clockwise in the usual way. The
nut will then automatically mechanically lock the fixture into the
profile.
What does the standard say?
EN ISO 13857 applies as safety distance for the risk zones.
The standard includes the dimensions that apply for safety
distances in various risk situations. The adjacent figure shows
examples of dimensions for safety distances for two different
fence heights where the risk of injury is relatively small when
you reach in.
With respect to mesh, you specify a minimum distance of 200
mm (for people 14 and above) for opening size 40 x 40 mm.
For shorter distances and for noise reduction we use solid
panels. When the fence is to protect a robot cell, for example,
the fence protection should be placed at a minimum distance
of 500 mm between the fence protection and the moving
machine part that reaches furthest out (as per EN349). When
test running or programming there must be a space between
the fencing and any moving parts to ensure the operator does
not become wedged between them.
For protection that needs to be mounted and removed again,
for example for maintenance, the Machinery Directive requires
that fasteners remain in place on the protection. We normally
deal with this using interlocked doors/gates for faster and
safer access.
Feel free to consult us about the requirements in regulations
and standards.
Patented assembly function
The ABB Jokab Safety patented guide and locking method
makes it simple to assemble and dismantle the fencing sys-
tem. The nut has several advantages, it can easily be located
into the profile and automatically positions itself when the
screw is turned 90 degrees clockwise. When in this positi-
on the bracket being fixed can be adjusted as required and
locked by turning the screw further clockwise. To remove the
bracket the fixing screw is turned anti-clockwise until the nut
is in line with the profile slot.
All fittings are supplied pre-assembled. Fittings that do not
have a cast-in tab can be provided with a centring washer.
Locking
perpendicular
to profile slot
Centralising and
turning limitations
patented
Centring
washer
Easy to adjust
the position of
fittings
The T-slot and patented nut
makes it easy to attach fittings to
the fencing profiles
ABB Safety Handbook | 2TLC172001C0202 13/6
13
Quick-Guard

Supplied in three ways

1. To be designed on site
You only order sections consisting of a few components. Then
the fencing system is built on site. A manual mesh clipping
tool, for easy cutting of the mesh, is provided with the delivery
if needed.
2. Cut to size according to drawing
You give us a simple sketch or a AutoCAD file of how you
want the fencing system to look. We input this information into
SafeCAD and design the fence in 3D. From this drawing, cut-
ting and component lists and a quotation are generated auto-
matically.
3. Pre-mounted or assembled on site
We can deliver full/partially pre-assembled fencing systems or
we can assemble them on site.
To be designed on site.
Cut to size according to drawing.
Pre-mounted or assembled on site.
13/7 2TLC172001C0202 | ABB Safety Handbook
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1. 2.
3. 4.
Quick-Guard E is easy to
assemble and to angle 45.
Quick-Guard E is installed quickly and cost effectively because
it only consists of patented net-locks, welded mesh, panels of
polycarbonate, u-profiles and fence posts (profiles with floor-
brackets). All parts for Quick-Guard and pre-assembled doors
are delivered immediately from stock. The few components of
the fencing system make it easy for you to custom build and
install the fencing system yourselves.
The strength of the fencing system originates from the fact
that the welded mesh and/or panels of polycarbonate are
locked into the profile. The outer wire of the mesh is locked
by uniquely designed netlocks into the profile making the
fixing virtually as strong as being welded. The polycarbonate
panels are locked in with specially designed infill-locks which,
according to our tests, have been as strong as the mesh net-
lock system. If you want more stable fencing posts, you can
choose a sturdier profile measuring 44 x 88 mm instead of the
standard 44 x 44 mm profile.
It is always easy to combine Quick-Guard E with Quick-Guard
standard to achieve a complete system. It is also easy to ad-
just and modify the guarding system when production equip-
ment is modified and/or moved.
Assembly of Quick-Guard Express
Premount floor fixtures on vertical posts. Mount fixtures by first
slackening the screw anti-clockwise. Then tighten the screw
clockwise in the usual way, the nut will then automatically locate
into the correct position and mechanically lock the fixture into
the profile. Make sure that the nut has turned correctly.
1. Mount a spacer screw 180 mm from the floor in the posts.
2. Attach the lower U-profile and mesh lock JSM NL2 to the
mesh.
3. Push the mesh into the profile and fix the mesh with
NL2 netlocks.
4. Fix top u-profile in place either before or after inserting
the mesh.
U-prole
Net-lock NL2
Spacer
screw
JSM 37
Assemble the next section. The distance between the posts
can be adjusted some mm after the mesh is locked in with the
Net-locks. The mesh can be angled up to 45 without using
hinges (JSM 35-K).
Lock the top of the mesh using NL3 netlocks; this way the
mesh is secured, stabilised and electrically grounded.
Grounding is needed when electrical devices or cables are
assembled on the mesh.
Quick-Guard

Express
- design directly on site
ABB Safety Handbook | 2TLC172001C0202 13/8
13
4 pcs 1500 sections
5 pcs 1100 sections
1 pc door
The same fencing sections can be erected in several ways.
Measure the number of metres of
fencing that are required and determine
the number of doors. Our two standard
sections have a cc width of 1100 mm and
1500 mm. The cc for the door is 1100
mm and fits anywhere the cc is 1100 mm
between the posts.
If dimensions other than the standard
dimensions are needed, just cut the mesh
to the correct size with a bolt cutter.
Quick-Guard

Express
- can be ordered in sections
One person can easily assemble the
Express sections. It is also possible to
angle these sections up to 45 degrees
angle. The mesh can easily be cut to the
desired size with a simple clipping tool.
Quick-Guard Express can be
ordered in different sections
consisting of a few components.
By adding the different sections,
one person can easily install a
Quick-Guard fencing system.
13/9 2TLC172001C0202 | ABB Safety Handbook
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Designation explanation
One person can easily assemble the Express sections. It is also possible to angle these sections up to 45 degrees angle. The
mesh can easily be cut to the desired size with a simple clipping tool.
JSM E11-N/PC20H8
Express
11 = c-c 1100 mm
15 = c-c 1500 mm
N = Mesh
PC = polycarbonate
20 = Height 2000 mm
22 = Height 2200 mm
H, X, Y, Z, G, S and
X = Section type
8 = 44x88 mm Profile
4 = 44x44 mm Profile
ABB Safety Handbook | 2TLC172001C0202 13/10
13
Image Designation Article number Description
Section X JSM E11-N14X4
JSM E11-N20X4
JSM E11-N20X8
JSM E11-N22X4
JSM E11-N22X8
JSM E11-N/PC20X8
JSM E11-N/PC22X8
JSM E11-PC20X8
JSM E11-PC22X8
JSM E15-N14X4
JSM E15-N20X8
JSM E15-N22X8
2TLA040106R0200
2TLA040101R0200
2TLA040101R0300
2TLA040102R0200
2TLA040102R0300
2TLA040104R0100
2TLA040105R0100
2TLA040101R5300
2TLA040102R5300
2TLA040106R1000
2TLA040101R0900
2TLA040102R0800
Components for an additional section with only one post.
The height can be varied between 1400 mm or 2200 mm.
The section is supplied unassembled.
Included parts: Floorbracket, netlocks/panel locks,
support screws, edge protection, Aluminum prole and
welded steel mesh/panel sheet.
Section Y
JSM E11-14Y4
JSM E11-20Y8
JSM E11-22Y8
2TLA040106R8000
2TLA040103R2100
2TLA040103R4100
Components for a complete post with oor bracket to
nalize the additional sections. The height can be varied
between 1400 mm or 2200 mm. The section is supplied
unassembled.
Included parts: Floorbracket, support screw, and Alumi-
num prole.
Section Z

JSM E11-N14Z
JSM E11-N20Z
JSM E11-N22Z
JSM E11-N/PC20Z
JSM E11-N/PC22Z
JSM E11-PC14Z
JSM E11-PC20Z
JSM E11-PC22Z
JSM E15-N14Z
JSM E15-N20Z
JSM E15-N22Z
2TLA040106R0400
2TLA040101R0400
2TLA040102R0400
2TLA040104R0200
2TLA040105R0200
2TLA040106R5400
2TLA040101R5400
2TLA040102R5400
2TLA040106R0800
2TLA040101R1000
2TLA040102R0900
Components for a complete section without fence posts
and oor brackets. The height can be varied between
1400mm or 2200 mm. The section is supplied unassem-
bled.
Included parts: Netlocks/panel locks, edge protection and
welded steel mesh/panel sheet.
Section G JSM E11-N14G
JSM E11-N20G*
JSM E11-N22G*
JSM E11-N/PC20G
JSM E11-N/PC22G
JSM E11-PC14G
JSM E11-PC20G
JSM E11-PC22G
* The door leaf is
supplied pre-mounted.
2TLA040106R0500
2TLA040101R0500
2TLA040102R0500
2TLA040104R0300
2TLA040105R0300
2TLA040106R5500
2TLA040101R5500
2TLA040102R5500
Components for complete conventional door with outer
prole 44x88 mm. The height can be varied between
1400mm or 2200 mm. The section is supplied unassem-
bled. The size of the door can easily be adjusted on site.
Included parts: L-brackets, oorbrackets, netlocks/panel
locks, handle, hinges, door stop, crossbar, aluminum
proles and welded steel mesh/panel sheet.
Section S JSM E11-N20S
JSM E11-N22S
JSM E11-N/PC20S
JSM E11-N/PC22S
JSM E11-PC20S
JSM E11-PC22S
JSM E15-N20S
JSM E15-N22S
2TLA040101R0600
2TLA040102R0600
2TLA040104R0400
2TLA040105R0400
2TLA040101R5700
2TLA040102R5600
2TLA040101R1100
2TLA040102R1000
Components for a complete sliding door with outer prole
44x88 mm. The height can be varied between 2000 mm or
2200 mm. The section is supplied unassembled. The size
of the door can easily be adjusted on location.
Included parts: L-brackets, T-brackets, oorbrackets,
netlocks/panel locks, handle, suspension wheels, guiding
components, door stop, crossbar, endcaps, aluminum
proles and welded steelmesh/panel sheet.
13/11 2TLC172001C0202 | ABB Safety Handbook
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Quote
Article no Description Qty Unit
40-030-06 JSM 30B-K Floorbracket 26,00 pcs
40-030-07 JSM 32B-K L-bracket 72,00 pcs
40-030-08 JSM 33B-K T-bracket 18,00 pcs
40-030-10 JSM 36-K2 Floorbracket in steel 2,00 pcs
40-033-31 JSM 37 Suport screw for Economy 6,00 pcs
40-037-28 JSM A12 Edge protection prole for welded mesh 1,06 m
Cutlist Polycarbonate
Article no Description Qty Length Width Sum m
2
40-039-10 JSM YPC5A1 Pc sheet 5mm uncoloured 2020x864 1 864 2020 1,75
40-039-12 JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size 1 532 1020 0,54
40-039-12 JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size 1 756 504 0,38
40-039-12 JSM YPC5A9 Pc sheet 5mm uncoloured, cut to size 1 810 804 0,65
Cutlist Welded Mesh
Article no Description Qty Length Width Sum m
2
40-040-13 JSM YN40W1 Welded steelmesh 40x40x3,5 black, 2020x864 1 864 2020 1,75
40-040-14 JSM YN40W2 Welded steelmesh 40x40x3,5 black, 1074x1816 2 1820 1074 3,91
40-040-16 JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size 2 864 354 0,61
40-040-16 JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size 1 864 804 0,69
40-040-16 JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size 1 864 920 0,79
40-040-16 JSM YN40W9 Welded steelmesh 40x40x3,5 black, cut to size 2 864 932 1,61
Quick-Guard

standard and SafeCAD

Order cut to length in accordance with drawing, pre-assembled

or fitted on site.
Quick-Guard consists of a minimum of
different components, such as aluminum
profiles, patented assembly parts, net-
locks, mesh, solid or noise reduction
panels. Furthermore the cost for as-
sembly and modification of the system
is low. Thanks to our patented screw-
lock system, we can supply all brackets
pre-mounted with fixing screws and
nuts. No holes need to be drilled in the
profiles and all cuts are made straight.
Assembly and modification is therefore
very easy.
To be able to quickly and easily custom
design practical safety solutions, we
have developed a computer program-
me, SafeCAD. This is a plug-in pro-
gram for AutoCAD. A simple sketch of
the guarding system that is required is
With SafeCAD

we can easily tailor your protection solution together

Example of component and cutting list print-outs from SafeCad.
Brackets are delivered pre-assembled with
screws and nuts.
used as the program input. The posi-
tions of doors and hatches, choice of
mesh, polycarbonate, aluminum/steel
sheet or noise reduction panels are
typed in. The program automatically ge-
nerates 3D drawings along with compo-
nent and cutting lists. These drawings
are also used as the basis for assembly/
installation.
It is always easy to combine Quick-Gu-
ard Express with Quick-Guard to achie-
ve a complete system. It is also easy to
adjust and modify when the production
equipment is modified and/or moved.
ABB Safety Handbook | 2TLC172001C0202 13/12
13
1. 2.
3. 4.
5.
6.
Quick-Guard

Assembly
- standard version
Premount floor fixtures by first slackening the screw anti-
clockwise. Then tighten the screw clockwise in the usual way.
The nut will then automatically locate into the correct position
and mechanically lock the fixture into the profile.
Attach lower horizontal extrusion between vertical posts. Use
a spacer block to ensure the correct distance from the floor.
Secure infill sheet with plastic strip or Net-lock fixings.
Easy, fast and quick. See more under Assembly of netlocks. If
there is a risk of the robot striking the polycarbonate, JSM PL3
panel locks must be used.
Insert top infill panel. Fix top profile with fittings on the top on
both sides.
Fix the poles to the floor.
Insert infill panel and fix middle horizontal profile. The distance
between the profiles is the width of the infill minus 20 mm.
Assembly of the Quick-Guard system is very easy. All
components are very light in weight and ergonomic in design.
This enables, in most cases, one person to be able to assemble
both simple and complex structures with ease using very
few different types of fixing components. All fixtures can be
mounted easily from outside by using the specially designed
locking nut which can be located anywhere in the extrusion
channel. The fixture components, by means of integral locating
keys, ensure that correct angles are achieved and enable the
number of bolts/nuts to be reduced to half the number that
would otherwise be required.
13/13 2TLC172001C0202 | ABB Safety Handbook
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90 mm
90 mm
Assembly using NL2 and NL3 Net-locks on welded mesh
NL2 Net-lock
When assembling the Net-lock NL2 it is first put into the
profile as the drawing shows. Then the Net-lock is turned
90. When cutting the welded mesh the wire ends should
not be longer than two (2) mm.
The outer mesh wire is
locked into the profile.
max 2 mm
When assembling the Net-lock NL3 it is first put into the
profile with the tabs on each side of the mesh wire. The
screw is then tightened. When cutting the welded mesh
the wire ends should be at least 15 mm to fit into the profi-
le. NL3 must be used to lock the mesh into the slot.
NL3 Net-lock
The Net-lock locks the mesh
against the profile.
Mesh with outer wire. Mesh without outer wire.
The outer mesh wire is locked
into the profile.
max 2 mm
min 15 mm
Number of Net-locks Quick-Guard standard version
On Quick-Guard standard version NL3 is recommended as it
can be used for mesh with or without an outer wire.
Number of Net-locks Quick-Guard Express
On Quick-Guard Express both Net-lock NL2 and NL3 can be
used. For mesh edges without outer wire NL3 must be used
instead of NL2.
NOTE! On welded mesh without an outer wire NL3 must be used.
NOTE! On both Quick-Guard Standard and Quick-Guard E at least two NL3 should be used in order to mechanically lock the mesh and to electrically ground the mesh. NL3 should
only be used on doors.
about 400 mm
approx. 350 mm
Wrong Right
Temporarily mount at least two middle profiles before drilling
and fixing posts to the floor. This method is used when infill
mesh or panels are to be fitted at a later date.
Note! Never attempt to x the posts to the oor without rst connecting at least two
middle proles to ensure the posts are parallel to each other and vertical.
Fixing posts to the floor when mesh is required to be fitted at a later date.
NL2 or NL3
NL2 or NL3
NL2 or NL3
NL2 or NL3
NL3 is used in order to me-
chanically lock the mesh
and to electrically ground
the mesh.
ABB Safety Handbook | 2TLC172001C0202 13/14
13
Material Width Height
Polycarbonate X+20 mm Y+20 mm
Welded mesh X+20 mm Y+20 mm
Steel panel X+20 mm Y+20 mm
Sound absorbing panel 25 mm X-37 mm Y-37 mm
Sound absorbing 50 mm X-37 mm Y-37 mm
Laminated glass X+15 mm Y+15mm
Double Pc 2 pcs. X-7 2 pcs. Y-7
JSM AS1 Profile for 25 mm sound
absorbing panel 2 pcs. L=X 2 pcs. L=Y-73
JSM AS3 Profile for 50 mm sound
absorbing panel 2 pcs. L=X (mitred 2 x 45 degrees) 2 pcs. L=Y (mitred 2 x 45 degrees)
JSM AS2 Profile for 2x5 mm pc sheet 2 pcs. L=X 2 pcs. L=Y-33
Dimensions
Aluminum profile lengths and infill materials
A*
*A=13 (JSM D1A), A=1 (JSM D1C)
13/15 2TLC172001C0202 | ABB Safety Handbook
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Aluminum profiles
A wide range of aluminium profiles are available and include, fencing profile, guide rails, and cable ducting. The cable
ducting is available in three sizes, and can be delivered with or without mounting holes. The cable ducting is easy to open
and can be provided with end caps. Cover strips of plastic are also available, including fencing profiles making the entire
groove cross section utilisable as installation conduit for cables. The Aluminium profiles have integral "V" grooves to aid in
centring any drilling that may be necessary.
Alloy: 6063 and 6060F22. Natural anodized aluminium 10m
Fencing Prole
Designation
Article numbers
Material
Dimensions
JSM A4416
2TLA040037R7000 (cut to size)
2TLA040037R7400 (L=6000)
Natural anodized aluminium
16.5x44 mm
44
20,25
11
1
6
,
5
32
1
1
,
5
3
,
3
5,6 (2x)
Designation
Article numbers
Material
Dimensions
JSM A4426
2TLA040037R7000 (cut to size)
2TLA040037R7400 (L=6000)
Natural anodized aluminium
44x26 mm
Designation
Article numbers
Material
Dimensions
Order Unit
JSM A44A
2TLA040037R3500 (cut to size)
2TLA040037R3600 (L=1100)
2TLA040037R9800 (L=1400)
2TLA040037R3700 (L=2000)
2TLA040037R3800 (L=2200)
2TLA040037R3900 (L=2400)
2TLA040037R4000 (L=2500)
2TLA040037R4100 (L=6000)
Natural anodized aluminium
44x44 mm
10 pcs/box
1
1
,
5
v
v
v
v
1
1
2
0
,
2
5
3
,
3
44
Designation
Article numbers
Material
Dimensions
Order Unit
JSM A4488A
2TLA040037R4200 (cut to size)
2TLA040037R4300 (L=2000)
2TLA040037R4400 (L=2200)
2TLA040037R4500 (L=6000)
Natural anodized aluminium
44x88 mm
5 pcs/box
88
44
4
4 1
1
2
0
,
2
5
1
1
,
5
v
v v
v
v
v
v v
3
,
3
Designation
Article numbers
Material
Dimensions
JSM A8888
2TLA040037R7500 (cut to size)
2TLA040037R7900 (L=6000)
Natural anodized aluminium
88x88 mm
v
v
75,4
55,8
44
8
8
2
0
,
2
5
1
1
1
1
,
5
3
,
3
88
v
v
v
v
v v
v
v
8 (4x)
5,6 (4x)
ABB Safety Handbook | 2TLC172001C0202 13/16
13
Technical data fencing profile
Angular moment Flexural resistance
Typ Vikt (kg/m) lx (mm
4
x10
4
) ly (mm
4
x10
4
) Wx (mm
3
x10
3
) Wy (mm
3
x10
3
)
JSM A4416 1.040 1.1 7.6 1.19 3.43
JSM A4426 1.023 3.2 7.4 2.47 3.36
JSM A44A 1.504 12.4 12.4 5.64 5.64
JSM A4488A 2.379 79.6 21.6 18.1 9.8
JSM A8888 3.632 143.0 143.0 32.5 32.5
U-Prole
Designation
Article numbers
Material
Weight
JSM A12
2TLA040037R2800 (cut to size, max 2.0 m)
2TLA040037R2700 (L=1076)
2TLA040037R4600 (L=1476)
2TLA040037R4700 (L=2000)
Natural anodized aluminium
0.230 kg/m
10,4
2
3
H-prole
Designation
Article numbers
Material
Weight
JSM A13
2TLA040037R5000 (cut to size)
2TLA040037R5100 (L=1076)
2TLA040037R5200 (L=1476)
2TLA040037R5300 (L=2020)
Natural anodized aluminium
0.452 kg/m
10,4
4
4
3
6,7
Guiding Rails
Designation
Article number
Material
Holes
Standard Length
Weight
JSM A3130C
2TLA040037R9900 (cut to size)
Natural anodized aluminium
C/c = 240 mm, = 5.6 mm
6.1 m (max)
0.578 kg/m
Designation
Article number
Delivered with
Material
Holes
Standard Length
Weight
JSM A56
2TLA040037R4900 (Cut to size incl. screws)
2TLA040037R0800 (L=2000, incl.screws)
2TLA040037R4800 (L=6000, incl.screws)
Screw JSM S8E
Nut JSM M8B
Natural anodized aluminium
C/c = 450 mm, = 8.5 mm
2.0; 6.0 m
1.585 kg/m
56
7
9
v
1
7
13/17 2TLC172001C0202 | ABB Safety Handbook
13
Cable Ducting
Designation
Article numbers
Material
Dimensions
Standard Length
JSM A25A
JSM A25B
Order Unit
Weight
JSM A25_
2TLA040037R1300 (JSM A25A)
2TLA040037R1400 (JSM A25B)
Natural anodized aluminium
44 x 25 mm
2.0 m
with holes C/c= 500 mm = 5 mm
without holes
10 pcs/box
0.545 kg/m JSMA25A
0.567 kg/m JSMA25B
44
2
5
v
v
v
v
Designation
Article numbers
Material
Dimensions
Standard Length
JSM A60A
JSM A60B
Order Unit
Weight
JSM A60_
2TLA040037R1500 (JSM A60A)
2TLA040037R1600 (JSM A60B)
Natural anodized aluminium
44x60 mm
2.0 m
with holes C/c = 500 mm = 5 mm
without holes
10 pcs/box
0.923 kg/m JSMA60A
0.950 kg/m JSMA60B
44
6
0
v
v
v
v
v
v
Designation
Article number
Material
Dimensions
Standard Length
Weight
JSM A88
2TLA040037R3300
Natural anodized aluminium
88x68 mm
2.0 m
1.844 kg/m
88
v
v
vvv
v
v
6
8
Cable tie
Designation
Article number
Pre-assembled with
Order Unit
Material
JSM X1
2TLA040033R4300
Screws and Nuts
10 pcs/box
Nylon 6/6 black
Profiles for installation of sound absorbing panels
Prole for 25 mm sound absorbing panel, JSM YLA25A_
Designation
Article numbers
Material
Dimensions
Weight
JSM AS1
2TLA040037R9500 (cut to size)
2TLA040037R0900 (L=2000)
Natural anodized aluminium
29x43 mm
0.545 kg/m
23,7
29,1
2
0
3
6
,
5
4
3
,
4
Prole for 50 mm sound absorbing panel, JSM YLA50A
Designation
Article numbers
Material
Dimensions
Weight
JSM AS3
2TLA042021R8000 (cut to size)
2TLA042021R8100 (L=6000)
Natural anodized aluminium
43x56
0.694 kg/m
51
55
44
22
4
3
,
3
3
6
,
5 2
0
ABB Safety Handbook | 2TLC172001C0202 13/18
13
Prole for double 5mm Polycarbonate panel, JSM YPC5_
Designation
Article numbers
Material
Dimensions
Weight
JSM AS2
2TLA040037R9600 (cut to length)
2TLA040037R1000 (L=2000)
Natural anodized aluminium
40x23 mm
0.510 kg/m
4,9
40
1
6
,
3
2
3
,
2
Fittings
ABB JokabSafetys fencing system is put together with various types of fitting. Uprights are anchored to the floor with floor
angle fittings. With a small angle fitting it is possible to hang an electrical enclosure and strengthen the corners of free-stan-
ding walls. Corners and joints are constructed with the aid of T, L and I fittings. If angles different to 90 between the fence
sections are required, a JSM D1C angle fitting can be used. This hinge has a distance between centres of 45 mm, which
means that the gap between uprights will always be less than 20 mm. According to EN ISO 13857, the minimum permitted
protection distance is 120 mm for a gap narrower than 20 mm.
Floor/Angle tting
Designation
Article numbers
Pre-assembled with
Material
Order unit
JSM 39-K
2TLA040030R1400
Screw JSM S8C (x 2), Washer 9 x 18 x 1.5 (x 2),
Nuts JSM M8B (x 2)
Aluminium
10 pcs/box
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 30B-K
2TLA040030R0600
Screw JSM S8C (x 2), Washer 9 x 18 1.5 (x 2)
Nut JSM M8B (x2)
Aluminium
10 pcs/box
Designation
Article numbers
Pre-assembled with
Material
Order unit
JSM 30B-K1
2TLA040030R1100
Screws JSM S8C (x 4), Washers 9 x 18 x 1.5 (x 4)
Nuts JSM M8B (x 4), Washers JSM B8B (x 2)
Aluminium
10 pcs/box
Small Angle tting, e.g. Electrical cabinet tting
Designation
Article number
Pre-assembled with
Material
Order unit
JSM 31B-K , Two counter sunk holes
JSM 31A1-K, One counter sunk hole
2TLA040030R1300 (JSM 31B-K)
2TLA040030R0400 (JSM 31A1-K)
Screw JSM M8C, Nut JSM M8B
Aluminium
10 pcs/box
L-bracket
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 32B-K
2TLA040030R0700
Screw JSM S8A, Nut JSM M8B
Aluminium
10 pcs/box
105
1
0
5
41
6
13/19 2TLC172001C0202 | ABB Safety Handbook
13
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 42
2TLA042020R3200
Screw K6S M8x16 Steel,
zinc-plated (2TLJ041017R0100)
Nut JSM M8B (2TLA040035R0600)
Aluminium
1 pcs
T-bracket
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 33B-K
2TLA040030R0800
Screw JSM S8A, Nut JSM M8B
Aluminium
10 pcs/box
169
1
0
5
41
6

I-bracket
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 34B-K
2TLA040030R1500
Screw JSM S8A, Nut JSM M8B
Aluminium
10 pcs/box
85
4
1
6
44
U-bracket
Designation
Article number
Pre-assembled with
Material
Order Unit
JSM 43
2TLA042020R3100
Screw K6S M8 x 16 Steel,
zinc-plated (2TLJ041017R0100)
Nut JSM M8B (2TLA040035R0600)
Aluminium
1 pcs
Distance screw
Designation
Article number
Material
Order unit
JSM 37
2TLA040033R3100
Zinc-plated steel
100 pcs/box
Angle bracket
Designation
Article number
Pre-assembled with
Material
Order unit
JSM 40
2TLA042021R5600
Screw K6S M8x16 Steel, zinc-plated
(2TLJ041017R0100)
Nut JSM M8B (2TLA040035R0600)
Steel, zinc-plated
1 pcs
Designation
Article number
Pre-assembled with
Material
Colour
Order unit
JSM D1C Hinge
2TLA040033R4800
JSM M8B, JSM B8C, JSM S8A
Polyamide, glass bre reinforced
Black
2pcs/bag, 10pcs/box
45
80
7,5
8
0
Designation
Article number
Pre-assembled with
Material
Hole
Order unit
NOTE! The JSM 35-K must only
be used for making fence angles.
JSM 35-K
2TLA040033R1400
Screw JSM S6A, Nut JSM M6B
Zinc-plated steel
C/c =47 mm
2 pcs/box
1
0
2
47
75
3
ABB Safety Handbook | 2TLC172001C0202 13/20
13
Door components
To mount conventional doors a hinge is available which permits an opening angle of 180. For mounting a sliding door, guide
rails and suspension wheels are utilised. Other sliding elements make it possible to build different types of hatches. Guide
rollers, for wide and heavy doors, door closers, fittings for sensors/switches etc are also available.
Conventional Door Sliding Door
Double Hatch Hatch
Sliding Hatch Folding Hatch
13/21 2TLC172001C0202 | ABB Safety Handbook
13
Hinge kit
Designation
Article number
Pre-assembled with
Material
Colour
Order unit
JSM D1C Hinge
2TLA040033R4800
JSM M8B, JSM B8C, JSM S8A
Polyamide, glass bre reinforced
Black
2pcs/bag, 10pcs/box
45
80
7
,5
8
0
Designation
Article number
Pre-assembled with
Material
Fixing Holes
Order Unit
NOTE! JSM D1A must not be
used as a fencing angle tting
because its gap can exceed
20 mm.
JSM D1A Hinge
2TLA040033R1500
Screw JSM S6A,Nut JSM M6B
Zinc-plated steel
C/c = 62 mm
2 pcs/box
1
0
2
62
95
3
Designation
Article numbers
Material
Pre-assembled with
NOTE! The door gap will be 28
mm when installed.
JSM D1B Spring hinge
2TLA042020R4700
Zinc-plated steel
Spacer plate, screws and nuts
1
1
5
28
76
22
Handle
Designation
Article number
Pre-assembled with
Material
JSM D2 Handle
2TLA040033R0100
Screw JSM S8D, Nut JSM M8B
Thermoplastic, black
26
44
1
5
0
Designation
Article number
Material
Pre-assembled with
Suitable for sliding door on
the inside of the fence.
JSM D18 Handle
2TLA042020R5000
Handle: Thermoplastic, black
Fittings: Aluminum
Screws and Nuts
40
26
1
5
0
22
5
70
119
ABB Safety Handbook | 2TLC172001C0202 13/22
13
Door closer
Designation
Article number
Pre-assembled with
Material
Designation
Article number
Material
Pre-assembled with
JSM D3 (conventional door)
2TLA040033R0200
Screws and Nuts
Door closer: Steel
Bracket: Aluminium
JSM D19 (sliding door)
2TLA042020R5600
Zinc-plated steel
Screws and Nuts
Gas spring
Designation
Article number
Stroke (SL)
Pre-assembled with
Material
Designation
Article number
Stroke (SL)
Pre-assembled with
Material
Fittings included
NOTE! Specify required force
(100-1200N) when ordering.
JSM D22 Gas spring with ttings
2TLA042024R1000
300 mm
Screws and Nuts
Steel
JSM D22A Gas spring with ttings
2TLA042024R1100
350 mm
Screws and Nuts
Steel
Bracket with ballcup (2TLA042021R2700)
U-bracket with ball joint (2TLA042021R2800)
Bracket for padlock
Designation
Article number
Pre-assembled with
Material
NOTE! Two pieces are required
for one complete unit.
JSM D17 Bracket for Padlock
2TLA040020R2200
Screws and Nuts
Zinc-plated steel
3
35
5
0
62
1
3
13/23 2TLC172001C0202 | ABB Safety Handbook
13
Ball Catch
Designation
Article number
Pre-assembled with
Material
JSM D11B (conventional door)
2TLA040033R4100
Screws and Nuts
Brackets: Aluminium
Ball Catch: Nickel-plated brass
40
40
5
0
7
0
5
20
Designation
Article number
Pre-assembled with
Material
JSM D11C (sliding door)
2TLA040033R4200
Screws and Nuts
Aluminium
Brackets: Aluminium
Ball catch: Nickel-plated brass
5
40
40
20
10
7
0
5
0
Designation
Article number
Pre-assembled with
Material
JSM D11D (folding door)
2TLA042020R5200
Screws and Nuts
Aluminium
Brackets: Aluminium
Ball catch: Nickel-plated brass
60
5
6
8
5
8
8
0
25
3
5
2
2
5
70
Upper Door bolt
Designation
Article number
Pre-assembled with
Material
JSM D10A
2TLA040033R2100
Screws and Nuts
Rod: Stainless steel
Brackets: Zinc-plated steel
80
60
4
0
90
30
3
5
1
1
5
6
5
40
4
0
35
5
1
1
3
0
10
5
ABB Safety Handbook | 2TLC172001C0202 13/24
13
Lower Door bolt
Designation
Article number
Pre-assembled with
Material
JSM D10
2TLA040033R2000
Screws and Nuts
Rod: Stainless steel
Brackets: Zinc-plated steel
40
1
3
0
8
10
5
5
8
3
2
8
0
2
5
18
Lower Door bolt
Designation
Article number
Pre-assembled with
Material
JSM D10B
2TLA040033R3800
Screws and Nuts
Rod: Stainless steel
Brackets: Zinc-plated steel
1
0
0
6
9
9
5
4
0
25
30
4
10
2
5
18
40
3
9
0
1
8
0
Cam lock
Designation
Article number
Pre-assembled with
Material
NOTE! Delivered without key.
Key to cam lock
Designation
Article number
Material
JSM D15
2TLA040033R3900
Screws and Nuts
Lock unit: Polyamide, black
Brackets: Aluminium
JSM D16
2TLA040033R4400
Zinc, black
13/25 2TLC172001C0202 | ABB Safety Handbook
13
Sliding bolt for Eden
Designation
Article numbers
Material
Note! Supplied without Eden
For installation on hinged doors
JSM D20 (for hinged door)
2TLA020302R1000
Steel, painted yellow
180
40
14
130
110
60
72
110
Door stop
Designation
Article number
Pre-assembled with
Material
JSM D13A
2TLA040033R2600
Screws and Nuts
Natural anodized aluminium
40
6
0
25
3
Designation
Article number
Pre-assembled with
Material
NOTE! For mounting on vertical
proles.
JSM D13
2TLA040033R2500
Screws, Nuts and vibration damper
Zinc-plated steel
60
60
6
0
5
Designation
Article number
Pre-assembled with
Material
NOTE! For mounting on horizontal
proles.
JSM D13B
2TLA040033R2700
Screws, Nuts and vibration damper
Zinc-plated steel
4
0
60
75
5
ABB Safety Handbook | 2TLC172001C0202 13/26
13
Suspension wheels
Designation
Article number

For aluminium guiding rails JSM
A3130C and JSM A56
JSM D5
2TLA040033R0400
Sliding elements
Sliding element, (rectangular)
Designation
Article number
Pre-assembled with
Material
JSM D6
2TLA040033R0500
Screw and Nut
Polyamid, white
19
8
4
0
Sliding element, (round)
Designation
Article number
Pre-assembled with
Material
JSM D7
2TLA040033R0600
Screw and Nut
Polyamid, white
19
8
4
0
Sliding element, (guide)
Designation
Article number
Pre-assembled with
Material
JSM D8
2TLA040033R0700
Screw and Nut
Polyamid, white
4
0
8
19
9,6
Sliding element, (guide)
Designation
Article number
Pre-assembled with
Material
JSM D26
2TLA042020R3700
Screw and Nut
Robalon, black
Guide Components for Sliding Door
Designation
Article number
Pre-assembled with
Material
NOTE! For mounting on vertical proles.
JSM D12
2TLA040033R2200
Screws and Nuts
Aluminium and PA6-6
5
30
6
5
50
Designation
Article number
Pre-assembled with
Material
NOTE! For mounting on horizontal
proles.
JSM D12A (Bracket)
2TLA040033R2300
Screws and Nuts
Aluminium and PA6-6
60
5
50
4
0
13/27 2TLC172001C0202 | ABB Safety Handbook
13
Designation
Article number
Pre-assembled with
Material
JSM D12B
2TLA040033R2400
Screws and Nuts
Aluminium
40
1
2
0
5
Guide roller
Swivel castor with total lock
Designation
Pre-assembled with angle bracket
Article number
Wheel diameter
Max. load
JSM D9-K
2TLA040033R1100
75 mm
60 kg
9
7
JSM D9-K
Fixed castor
Designation
Article number
Pre-assembled with angle bracket
Wheel diameter
Max. load
JSM D9A-K
2TLA040033R1300
75 mm
70 kg
9
5
JSM D9A-K
Diagonal bar for door
Designation
Article number
Length
Pre-assembled with
Material
Designation
Article numbers
Length
Pre-assembled with
Material
JSM D14
2TLA040033R2800
1160 mm
Screws and Nuts
Natural anodized aluminium
JSM D14A
2TLA042021R7300
400 mm
Screws and Nuts
Natural anodized aluminium
4
0
0
/
1
1
6
0
5
20
ABB Safety Handbook | 2TLC172001C0202 13/28
13
Fittings for switches
Fittings for Eden
Fitting for conventional- and sliding
door.
Designation
Article number
Pre-assembled with
Material
NOTE! Two ttings are needed for a com-
plete Eden.
JSM D4H
2TLA040033R3600
Screws and Nuts
Aluminium
4
40
1
0
0
Fitting for sliding door ush with fence
Designation
Article number
Pre-assembled with
Material
NOTE! One JSM D4H and one JSM D4J are
needed for a complete unit.
JSM D4J
2TLA042020R4000
Screws and Nuts
Aluminium
60
4
6
7
5
1
8
0
Fittings for JSNY5 Interlock Switches
Fitting for conventional door/hatch
Designation
Article number
Pre-assembled with
Material
JSM D4A
2TLA040033R0900
Screws and Nuts
Zinc-plated steel
50
2
0
5
5
50
12
4
Fitting for conventional door/hatch
Designation
Article number
Pre-assembled with
Material
JSM D4AA
2TLA040033R3400
Screws and Nuts
Zinc-plated steel
70
50
5
4
0
50
5
4
0
Fitting for sliding door
Designation
Article number
Pre-assembled with
Material
JSM D4B
2TLA040033R1000
Screws and Nuts
Zinc-plated steel
127
45
6
0
40
5
6
0
5
65
13/29 2TLC172001C0202 | ABB Safety Handbook
13
Fittings for JSNY7 Switches
Fitting for conventional door/hatch
Designation
Article number
Pre-assembled with
Material
NOTE! Two ttings are needed for a complete
JSNY7.
JSM D4E
2TLA040033R1800
Screws and Nuts
Aluminium 9
0
3
35
Fitting for sliding door
Designation
Article number
Pre-assembled with
Material
JSM D4G
2TLA040033R3300
Screws and Nuts
Aluminium
5
8
40
40
9
0
9
0
Fittings for JSNY8/9 Switches
Fitting for JSNY8, sliding door
Designation
Article numbers
Pre-assembled with
Material
JSM D4D
2TLA040033R1700
Screws and Nuts
Zinc-plated steel
5
4
1
3
8
90
40
5
0
Fitting for JSNY8/9, conventional door/hatch
Designation
Article number
Pre-assembled with
Material
JSM D4C
2TLA040033R1600
Screws and Nuts
Zinc-plated steel
35 42
6
0
4
55
1
5
4
9
4
5
40
Fitting for JSNY9, sliding door
Designation
Article number
Pre-assembled with
Material
JSM D4F
2TLA040033R3000
Screws and Nuts
Zinc-plated steel
40
40
40
6
0
5
5
96
60
1
3
4
ABB Safety Handbook | 2TLC172001C0202 13/30
13
Terminal caps and strips
Terminal caps are available to cover profile ends, thus eliminating sharp edges. Strips are also available, both narrow and
wide, to cover the slot of the fencing profile.
Terminal Caps
Terminal Cap for JSM A44A
Designation
Article numbers
Material
Dimensions
JSM L1A (yellow)
JSM L1B (grey)
2TLA040034R0000 (JSM L1A)
2TLA040034R0300 (JSM L1B)
Polyamide
44x44 mm

44
44
5
Terminal Cap for JSM A4488A
Designation
Article numbers

Material
Dimensions
JSM L4A (yellow)
JSM L4B (grey)
2TLA040034R0400 (JSM L4A )
2TLA040034R0500 (JSM L4B)
Polyamide
44x88 mm
44
88
5
Terminal Cap for JSM A25
Designation
Article number
Material
Dimensions
JSM L2
2TLA040034R0100
Polyamide, grey
44x25 mm
44
2
5
5
Terminal Cap for JSM A60
Designation
Article number
Material
Dimensions
JSM L3
2TLA040034R0200
Polyamide, grey
44x60 mm
44
6
0
5
Cover Strip
Narrow Cover Strip, for Alt. 1:
JSM A4416, -A4426, -A44A, -A4488A and -A8888
Alt.2: For fencing proles with 11 mm slot
Designation
Article numbers
Material
Dimensions
Order Unit
NOTE! Other colours available upon request
JSM T3A (yellow) JSM T3B (grey)
2TLA040037R3100 (JSM T3A)
2TLA040037R3200 (JSM T3B)
ABS
16 mm
2 m
2
,
5
16
Wide Cover Strip, Alt. 1:
JSM A4416, -A4426, -A44A, -A4488A and -A8888
Alt.2: For fencing proles with 11mm slot
Designation
Article number
Material
Dimensions
Order Unit
NOTE! Other colours available upon request
JSM T2A
2TLA040037R1900
PVC, yellow, soft material
40 mm
25 m/coil
40
2
,
5
13/31 2TLC172001C0202 | ABB Safety Handbook
13
Accessories
All fittings and door components are delivered pre-assembled with screws, washers and nuts.
For cable ducting the screws, S5B, and nuts, M5B, have to be ordered separately (4 pcs/2m).
Designation Image Article number Description Dimension Material Order Unit
JSM S5B 2TLA041039R0100 Screw to cable ducting M5x12 Zinc Plated Steel 100 pcs/box
JSM S6A 2TLA041039R0200 Screw for hinge cross-slotted Z
(pozidrive)
M6x12 Zinc Plated Steel 100 pcs/box
JSM S8A 2TLA041019R0000 Fixing screw
countersunk.
M8x16 Zinc Plated, Dacrolit 100 pcs/box
JSM S8C 2TLA041014R0200 Fixing screw for oor tting and
small angle
M8x20 Zinc Plated Steel 100 pcs/box
JSM S8D 2TLA041014R0100 Fixing screw M8x16 Zinc Plated Steel 100 pcs/box
JSM S8E 2TLA041019R0100 Fixing screw for Guide rail JSM
A56
M8x12 Zinc Plated Steel 100 pcs/box
JSM M4B 2TLA040035R0700 Locking nut M4 Zinc Plated Steel 100 pcs/box
JSM M5B 2TLA040035R0400 Locking nut M5 Zinc Plated Steel 100 pcs/box
JSM M6B 2TLA040035R0500 Locking nut M6 Zinc Plated Steel 100 pcs/box
JSM M8B 2TLA040035R0600 Locking nut M8 Zinc Plated Steel 100 pcs/box
JSM M10A 2TLA041069R0000 M10 Thread insert for
JSM A44A
M10x21,
18.5/25
Steel, zinc-plated 1 pcs
JSM X1 2TLA040033R4300 Cable tie 2.57.8 mm Nylon black UV-
resistant
10 pcs/box
JSM X2 2TLA041900R4300 Expansion-shell bolt M10x68 Zinc Plated Steel 50 pcs/box
JSM X3 2TLA041910R0000 Window cleaning uid (Antistatic) for
polycarbonate sheets. Actuator head 0.5 L.
per can
JSM X4 2TLA041911R0100 Mesh clipping tool L=300 each
JSM X5A 2TLA041810R0200 ABB Safety Products sign 220x40x1.5mm Aluminium, Natural
anodized
1 pcs
JSM X5B 2TLA041810R0300 ABB Safety Products sign,
pre-assembled with screws
220x40x1.5mm Aluminium, Natural
anodized
1 pcs
JSM B4C 2TLA040035R5000 Centring washer steel 4.2 Zinc Plated Steel 100 pcs/box
JSM B5C 2TLA040035R5100 Centring washer steel 5.2 Zinc Plated Steel 100 pcs/box
JSM B6C 2TLA040035R5200 Centring washer steel 6.2 Zinc Plated Steel 100 pcs/box
JSM B8C 2TLA040035R5300 Centring washer steel 8.2 Zinc Plated Steel 100 pcs/box
ABB Safety Handbook | 2TLC172001C0202 13/32
13
Infill materials
The choice of net and surfaces depends, among other things, on the protection distance. In the case of netting, a minimum
distance of 200 mm (for anyone aged 14 or older) with a mesh size of 40x40 mm in accordance with EN ISO 13857. For
closer protection distances and for noise reduction, solid panels are used. Panels are available in different materials. For
protection of welding cells, polycarbonate welding transparencies are used.
Welded mesh Designation
Square opening
Thread
JSM YN40W_/WE _
40 x 40 mm
3.5 mm
Article number Designation Material Dimensions Type
2TLA040040R1300
2TLA040040R1400
2TLA040040R1500
2TLA040040R2000
2TLA040040R2100
2TLA040040R2600
2TLA040040R2700
2TLA040040R1600
2TLA040040R2800
2TLA040040R2900
2TLA040040R2500
2TLA040040R1800
2TLA040040R1900
JSM YN40W1
JSM YN40W2
JSM YN40W3
JSM YN40W4
JSM YN40W5
JSM YN40W6
JSM YN40W7
JSM YN40W9
JSM YN40W10
JSM YN40W11
JSM YN40WE1
JSM YN40WE2
JSM YN40WE9
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Steel, black RAL 9005 powder coated
Stainless steel, SS 2333
Stainless steel, SS 2333
Stainless steel, SS 2333
2020 x 864 mm
1074 x 1816 mm
1074 x 2016 mm
1474 x 2016 mm
1474 x 1816 mm
2020 x 754 mm
2020 x 1174 mm
Cut to size
1474 x 1216 mm
1074 x 1216 mm
2020 x 864 mm
1074 x 1816 mm
Cut to size
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Welded
Other colours, hot-dip galvanized mesh or woven wire mesh netting supplied on request.
Net lock for welded mesh with outer wire
Designation
Article numbers
Material
Colour
Order unit
JSM NL2
2TLA040031R0600
PA/ABS
Grey
100 pcs/box
Net lock for welded or woven mesh
Designation
Article numbers
Pre-assembled with
Material
Order unit
JSM NL3
2TLA040031R0800
Screw
Zinc
100 pcs/box
Shockproof panelling
Plastic panel name: JSM Y_
Plastic panels
name: JSM Y_
Other materials can be supplied on request.
Article number Designation Material Thickness Dimensions
2TLA040039R1000
2TLA040039R1100
2TLA040039R1200
2TLA040039R2400
2TLA040039R2500
2TLA042150R0600
JSM YPC5A1
JSM YPC5A2
JSM YPC5A9
JSM YPC3AC9
JSM YPC3AC1
JSM YG6A9
Polycarbonate, uncoloured
Polycarbonate, uncoloured
Polycarbonate, uncoloured
Polycarbonate, dark tint, weld-protected
Polycarbonate, dark tint, weld-protected
Laminated glass
5 mm
5 mm
5 mm
3 mm
3 mm
6.4 mm
2020 x 864
2020 x 1174
Cut to size
Cut to size
2050 x 3000
Cut to size
13/33 2TLC172001C0202 | ABB Safety Handbook
13
8-12
Steel panel
X-reinforced steel panel
Other materials are available on request.
Article number Designation Material Thickness Dimensions
2TLA040039R0700
2TLA040039R0900
JSM YGP1A9
JSM YGP2A9
Galvanised sheet metal
Galvanised sheet metal
1 mm
1.5 mm
Cut to size
Cut to size
Painted sheet metal can be supplied on request.
Panel xings
Designation:
Material:
JSM PL1:
JSM PL2:
Standard package:
JSM PL1_(for 5 mm panels)
JSM PL2_(for 4 mm panels)
PVC, black
PVC, black
50 pcs/package
Article number Designation Length
2TLA040038R0100
2TLA040038R0200
2TLA040038R0300
2TLA040038R0400
2TLA040038R0700
2TLA040038R0800
2TLA040038R0900
2TLA040038R1000
JSM PL1A
JSM PL1B
JSM PL1C
JSM PL1D
JSM PL2A
JSM PL2B
JSM PL2C
JSM PL2D
842 mm
1152 mm
2000 mm
732 mm
842 mm
1152 mm
2000 mm
732 mm
Cellular rubber - To be used with e.g. 1.0 mm steel panel
Designation:
Article numbers:
Material:
Dimension:
Standard package:
JSM G2
2TLA040038R0600
Cellular rubber,
self-adhesive
5x20 mm
10 m/roll
20
5
1
2
3
U-rubberstrip - To be used with e.g. 6.4 mm laminated glass
Designation:
Article numbers:
Material:
Standard package:
JSM G3
2TLA041930R0600
EPDM
50 m/roll
10
6
1
2
1
2
Panel lock
Designation:
Article numbers:
Pre-assembled with:
Material:
JSM PL3
2TLA040038R1100
Screw
Zinc
Sound absorbing
Article number Designation Material Thickness Dimensions Weight (kg/m
2
)
2TLA040037R1100
2TLA040039R2600
2TLA042150R2300
JSM YLA25A9
JSM YLA25A1
JSM YLA50A9
Core
Rock wool
Solid surface
PVC coated steel plate, White
Perforated surface
Hot dipped galvanized Steel sheet
25 mm
25 mm
50 mm
Cut to size
1963x1200
Cut to size
13.8
13.8
21.0
Cut to size max dimension 2000 x 1200
NOTE! Use mounting prole JSM AS1 for JSM YLA25A_ Use mounting prole JSM AS3 for JSM YLA50A_
ABB Safety Handbook | 2TLC172001C0202 13/34
13
Roller door for short safety distances and narrow spaces
Safety Roller Doors make it possible to have a short safety
distance to the machine. The noise absorbing roller door is
compact and it can therefore be placed in narrow spaces. It
is easy and quick to access the machine or gain access for
servicing with the Safety Roller Door.
It demands a minimum of maintenance and offers reliable
operation. To be able to start the machine/plant the door has
to be completely closed. The closed position is monitored by
the Eden non-contact sensor from ABB JokabSafety. As soon
as the door begins to open the Eden sends a signal to the
machine/plant via the Pluto Safety-PLC from ABB JokabSafe-
ty. The roller door fulfills safety category 4 together with Eden
and Pluto.

Protects against welding splash
The roller door protects against ejected particles, such as
chips and welding splash. The roller door fabric is also resis-
tant towards a great number of chemicals, which permits it to
be installed in harsh environments.
Simple assembly
The Safety Roller Door is simple to assemble because it
consists of few components and it is supplied partly pre-
assembled. It can be integrated into the Quick-Guard fencing
system from ABB JokabSafety as well as in other types of
fencing systems. It can also be installed on the machine or
other permanent construction.
Safety Roller Door
Customized roller door
This door design is easy to customize. The largest possible
opening width is 4000 mm and the largest possible opening
height is 3500 mm. The maximum size of the door fabric is 10
m
2
. If a larger door fabric is desired, contact ABB JokabSa-
fety. The door is supplied as standard with a light-grey door
fabric. Other colours can also be supplied. The roller door
can be supplied with a viewing window in full width and at an
optional height. The viewing window can also be made in a
special material that protects against welding splash.
Approvals:
Application:
Allowing access to risk areas
Protection from ejected par-
ticles, e.g chips and welding
splash
Features:
Highest safety level according
to EN ISO 13849-1
Prevents unintentional start
Withstands harsh environ-
ments
Quick operation
High reliability
Noise absorbing
13/35 2TLC172001C0202 | ABB Safety Handbook
13
Highest protection in accordance with EN ISO 13849-1
The monitoring of the doors position by two Eden sensors
together with with a Pluto monitoring unit fulfills Cat. 4/PL e
enligt EN ISO 13849-1. These units are certified by TV.
Functions
The door protects against access to moving parts in the
machine/plant. The production process can begin when the
door is fully closed. The closed position is monitored by an
Eden sensor on both sides of the door. Because the door
is monitored by Eden sensors at both sides of the door it is
impossible to lift one side of the door and reach into the risk
area without the machine/plant stopping. When the door has
moved a maximum of 10 mm upwards a stop signal is sent to
the protected machine/plant. The Eden sensors are monitored
by a Pluto Safety-PLC which has failsafe outputs for stopping
the machine/plant in the risk area and to control the door.
The door also protects from particles ejected by the produc-
tion process, e.g. chips and welding splash. It has a good
sound absorbing ability. Because the door operates quickly, at
0.8-1.0 m/s, the operator has a good access to the machi-
ne area. The door is equipped with a safety contact strip in
the bottom preventing it from causing personal injury on any
person. When the safety contact strip is affected the door is is
Minimum safety distance
For the roller door to be able to provide good protection it has
to be installed a sufficient distance away from moving machine
parts.
Useful standards
EN ISO 13857 Safety of machinery - Safety distances to pre-
vent hazard zones being reached by upper and lower limbs.
EN ISO 13855 Safety of machinery Positioning of safeguards
with respect to the approach speeds of parts of the human
body.
Safety distances and standards
Function
compressed, the door movement reverses to move upwards.
The opening and closing of the door can be controlled via
the buttons or via the signals from the control system of the
machine.
Prevents an unintentional start
When the door is located in front of the machine/plant, where
the operator can enter the area with his entire body, safe in-
terlocking of the doors downward movement is needed. This
is to prevent the machine from being started from the outside
when somebody is inside the roller door.

One way to solve this is to use a horizontal light curtain which
covers the area which the operator can occupy within the risk
area. Another solution is to place double light beams in the
opening, combined with a reset facility. Yet another solution
is to use time-reset. A time-reset button is placed inside the
risk area and a button is placed outside the risk area. First,
the button in the risk area should be pressed and thereafter
(within a certain amount of time, e.g. 5 seconds) the button
outside should be pressed. After this the door can be mano-
euvred downwards.
NOTE! The roller door has good protection against welding
splash and smaller ejected particles from the the production
area. The roller door is not intended to act as collision
protection. The installer of the roller door has the responsibility
of ensuring that sufficient safety distance against moving
machine parts is provided.
ABB Safety Handbook | 2TLC172001C0202 13/36
13
DB
DH
F 80
G 250
H 320
I 150
J 100
K 500
L 500
M 450
Technical data Safety Roller Door
Colour Frame - aluminium, door cloth - grey. Other colours available on request.
Ordering data Safety Roller door + viewing window. Viewing window with weld splash protection.
Daylight height & Daylight width.
Maximum size, door cloth 10 m. If a larger size is needed, contact ABB JokabSafety AB.
Maximum width 4000 mm
Maximum height 3500 mm
Driving unit Three-phase motor 200-415VAC 50-60 Hz
Speed, roller door 0.8 1.0 m/s up/down
Max. number of cycles/minute 3 (during continous operation 24 hours a day)
Door fabric material Multi-layer polyester fabric cloth with PVC, 2 mm thick or transparent PVC. The viewing window can also be sup-
plied with protection against welding ash light. (Removes 99% of the UV-transmision from the welding process)
Door fabric colour Grey (RAL 7038), can be supplied with recessed window (only in full width). Other colours are available.
Material frames Aluminum extrusion
Material upper bracket 4 mm steel painted black
Sound absorption approx. 10 dB
Ambient temperature 0C to +55. When operating in temperatures below -5C, the oil in the gear-box should be replaced with an oil
suitable to withstand cold temperatures.
Safety level Category 4/PLe, in accordance with EN ISO 13849-1
Durability towards chemicals Ammoniac, sodium hydrate, phosphoric acid, tartaric acid, oxalic acid, hydrochloric acid, citric acid, acetic acid,
oil, detergent, calcium chloride (contact ABB JokabSafety for more specications)
Control monitoring unit for roller door ABB JokabSafetys Safety-PLC, Pluto
Outputs 4 safe outputs for connection to machine/plant.
Monitoring of position of the roller door 2 Eden sensors one on each side of the door.
Contact strip Mounted on the bottom frame of the door fabric. The door motion is reversed if the contact strip is compressed.
A 260
B 270
C 400
D 200
E 120
F 80
P Optional
R Optional
Notes
Notes
Notes
Notes
Notes
ABB AB
Jokab Safety
Tel. +46 21-32 50 00
www.abb.com/jokabsafety

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Note: We reserve the ri ght to make techni cal changes or
modi fy the contents of this document without prior notice.
With regard to purchase orders, the agreed parti cul ars shal l
prevai l . ABB AB, Jokab Safety does not accept any responsibility
whatsoever for potential errors or possible lack of information in this
document.
We reserve all rights in this document and in the subject matter
and illustrations contained therein. Any reproduction, disclosure to
third parties or utilization of its contents in whole or in parts is
forbidden without prior written consent of ABB AB, Jokab Safety.
Copyright 2013 ABB
All rights reserved
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