The Safety Handbook ABB Jokab - Automation Systems and Controls

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Applying EN 62061If one chooses to design a safety function in accordance with EN 62061, the level of reliability is expressed asthe Safety Integrity Level, SIL. There are a total of 4 levels, but in the EN 62061 standard SIL 3 is the highestlevel. SIL also (similar to the Performance Level PL), is expressed as the Probability of Dangerous FailurePer Hour.Safety Integrity Level, SIL Probability of dangerous Failure per Hour (PFH D )3 ≥10 -8 to
A mechanical switch doesnot give a safe function!A mechanical switch does not give a safe function!When it comes to mechanically operated interlockedswitches, it has long been accepted a Category 1 switchis adequate for many installations, which is also supportedby several standards. However some companies have nowre-evaluated this and have instead started to demand twomechanical switches or non-contact switches/sensors,where they previously accepted single mechanical switches.Many reported incidents form the background to this. Therequirements for switches to provide safe functioning arethat they are mounted correctly and that their positionsdo not change during their life-cycle, in other words, idealconditions. In many installations the location of hatches ordoors changes over time. This has led to a switch not givinga stopping signal when an interlocked gate has opened. Thereasons for this are many, but they can be summarized inmechanical deterioration or physical damage to a door/hatch.In turn this has led to an interlocked switch being affectedby higher stress than the switch manufacturer’s specifications.To avoid this type of malfunction it is more appropriateto use non-contact switches/sensors because mechanicaldeterioration does not affect the safety function, i.e. the stopsignal is given directly if the position is wrong.A non-contact switch/sensor does not have a guided functionand is designed to fulfill the requirements in another way.The requirements are fulfilled either with dynamic sensorswhere the safety signal is monitored all the time and a faultdirectly leads to a stop signal or with a magnetic switch whichhas two independent contact elements which are monitoredevery time a gate opens. From the user's perspective thedynamic function is preferable because several sensors canbe connected to a single safety module and still achievePL e. Also the sensor’s safety function is monitored withouthaving to open a gate. For a magnetic switch the requirementsfor PL e are only fulfilled if one switch per monitoringunit 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.Door 1 Door 2 Door 3Dynamic sensors*Dynamic monitoring,Vital/PlutoThis means that it is only with Eden that several doors canbe supervised with one safety module and achieve PL e.Since the standard EN 954-1 was written, developmenthas progressed and the costs to fulfill category 4 havedropped dramatically. Generally mechanical switches arereplaced with non-contact sensors to increase the reliabilityof production equipment. The same goes for the safety side.With electronic non-contact switches, with a transmitterand a receiver, one avoids the problems of deteriorationand excessive stress which harm the sensor. For that kindof sensor dynamic monitoring is required to enable a safefunction. This means that its function is constantly beingmonitored, hundred of times per second. The reaction timefor a safe stop will then be the same during a malfunctionas during the activation of a stop (e.g. a gate opening). Themonitoring frequency will also be astronomical compared tothat of mechanical switches and magnetic switches, whichare only monitored every time they are used. In the new ENISO 13849-1, which will replace 954-1, probability calculationsare used together with different category levels tocompare different “performance levels”. Even when usingEN ISO 13849-1 it can be so that one achieves reasonablyhigh theoretical reliability with an electromechanicalswitch, although this presumes correct installation, properuse and otherwise ideal conditions. A non-contact switchinstead provides high levels of both theoretical and practicalreliability.Our conclusion, use dynamic signals!Our conclusion is that today it is more cost effective, saferand more reliable to work with dynamic signals to achievecategory 4 for sensors and monitoring units. In that caseit is also possible to fulfill the Machinery Directive, 1.2.7.requirement: “A fault in the control circuit logic, or failure ofor damage to the control circuit, must not lead to dangeroussituations”. Also one does not have to discuss whether thecorrect safety category has been chosen!Interlocked switch* *Door 1*Static monitoring,e.g. RT61234567891011Up to 30 doors (Eden sensors) can be connected to the dynamicmonitoring maintaining category 4.Maximum 1 door (2 interlocked switches) canbe connected to the static monitoring for category4 to be maintained for the entire system.1213ABB1:1914
Page 1 and 2: The Safety HandbookExperience - Sys
Page 3 and 4: IntroductionWe develop innovative p
Page 5 and 6: Our products revolutionise the mark
Page 7 and 8: Jokab Safetys developments of the 8
Page 9 and 10: The Machinery Directive; for machin
Page 11 and 12: Protection or warning?How is it pos
Page 13 and 14: New standards for safety incontrol
Page 15 and 16: Risk estimationTo calculate the per
Page 17 and 18: CategoryThe structure for the compo
Page 19: Theoretical approach for multiple m
Page 23 and 24: Training in risk analysisWe regular
Page 25 and 26: ContentsPage1Why you should use the
Page 27 and 28: - to supervise safety devices!Light
Page 29 and 30: 1Pluto B46Pluto AS-i246 I/OSafe bus
Page 31 and 32: Technical info - PlutoDynamic signa
Page 33 and 34: Technical data - generalManufacture
Page 35 and 36: Input connectionThe system offers s
Page 39 and 40: Certificates12345678910111213ABB2:1
Page 41 and 42: Electrical connections1234567891011
Page 43 and 44: Pluto 1 settings - Machine cabinet1
Page 45 and 46: 2:21ABB1234567891011131412
Page 47 and 48: 2:23ABB1234567891011131412
Page 49 and 50: Technical data - GATE-P2Manufacture
Page 51 and 52: Technical data - GATE-D2Manufacture
Page 53 and 54: Technical data - GATE-C2Manufacture
Page 55 and 56: Technical data - GATE-E2Manufacture
Page 57 and 58: Technical data - Safe Encoder RSA 5
Page 59 and 60: Safe EncoderFunction block for a si
Page 61 and 62: ContentsPage1Why should I use the b
Page 63 and 64: How does the bus system AS-Interfac
Page 65 and 66: 1Easy connections to the AS-i cable
Page 67 and 68: Technical information - Pluto AS-iI
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Why should you usesafety node Urax?
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Technical data - Urax-A1/A1RManufac
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Technical data - Urax-B1RManufactur
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Technical data - Urax-C1 and C1RMan
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Technical data - Urax-D1RManufactur
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Technical data - Urax-E1Manufacture
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ContentsPage1Pluto Manager ________
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List of standards and special funct
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ContentsPage1Safety system - Dynami
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Vital is available in three variant
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Number of Tinas that can be used wi
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How does a dynamic circuit of Vital
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Vital 1 Safety controller1Dynamicci
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Technical data - Vital 1Manufacture
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Three connection alternativesAccord
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Operating mode M1 - Separate functi
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Operating mode M1 - Separate functi
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Tinais available in several version
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Adaptation unitTina 2A/BTina 2A/B i
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Connection blockTina 4ATina 4A is a
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Bypassing of Eden and Tina units.If
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Adaptation unitTina 7ATina 7A is a
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Connection examples of safety senso
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Technical data - Tina 10A/B/CManufa
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Terminal blockTina 12ATina 12A is a
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1Example of safety sensors connecti
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HA3300A-01 Connection example Vital
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HA3303A Vital 1 with emergency stop
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HA3306D Vital 1 with 3 lightbeams S
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HE3811B-01 Safety light beam Spot w
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HE3824F-01 Eden and 2 bypass lightb
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HH3302D Vital 1 with Tina 8A and di
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HB0006A Vital with 4 Eden units + R
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HB0003A Pluto with Smile and Inca e
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ContentsPage1Why should you use Saf
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The most flexible safety relayson t
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1Technical dataSafety categorySafet
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Technical information - RT6InputsTh
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Technical data - RT6ManufacturerArt
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Technical information - RT7 A/BInpu
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ABBTechnical data - RT7 A/BManufact
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Technical information - RT9InputsTh
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Technical data - RT9ManufacturerABB
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ABBTechnical data - JSBRT11Manufact
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Technical data - JSBR4ManufacturerA
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Technical data - JSBT4ManufacturerT
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Technical data - BT50(T)Manufacture
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Technical data - BT51(T)Conductor w
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Technical data - JSBT5(T)Manufactur
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Technical data - JSHT1 A/BManufactu
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Technical data - JSHT2 A/B/CManufac
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Technical data - E1TManufacturerArt
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Technical data - JSR1TManufacturerA
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Technical data - JSR2AManufacturerA
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Technical data - JSR3TManufacturerT
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HA5400A Connection examples JSBR412
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HA6501B Connection examples BT50T12
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HA7600A Connection examples RT61234
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HA7900A Connection examples RT91234
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HG7636B Focus light grid/curtain wi
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HG7654A Interlocked door with RT6 a
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HG7674B Safety interlock switch JSN
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HL7600B Several JSNY7 connected to
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HP7600B Machine control-Isolation o
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HB0008A Focus light curtain/light b
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ContentsPage1Why use light beams/li
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Light grids for long distancesLight
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Muting(bypassing)Automatic bypassin
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Cycle initiation withlight curtain1
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Safety distance for light beams acc
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are activated. If for example durin
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12FII-4-K2-500 FII-4-K4-zzzz D FII-
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Muting (bypassing)- Focus II12Built
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Muting with FMC and FMI units1234Th
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Muting sensors - Mute RRetro-reflec
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Muting with Mute R and Mute D1A sol
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Technical data - BjornManufacturer:
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Blanking programmerBP1- a quick way
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HR7000C-01 Focus - Connection witho
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HR7000H-01 Focus - Connection with
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HR7000L-01 Tina 10A, 10B and 10C co
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HR7000Q Cable connection example123
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Mounting and alignment - SpotSafety
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Connection of Spot T/R to Vital1123
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Software - Look scannerFunction but
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ContentsPage1Stopping time ________
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Stopping time and MachineDiagnosis
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Saving• Select measurement series
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SM5 1250/2500 Linear sensorThe SM5
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ContentsPage1Why should you use sen
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Eden -highest safety level and reli
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Application examples - EdenEden to
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Technical data - EdenManufacturerAr
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Technical data - JSNY5ManufacturerA
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13Technical data - JSNY7Manufacture
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Technical data - JSNY8ManufacturerA
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Technical data - JSNY9Utilisation c
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Models and accessoris - MagneHandle
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Dimensions - Magne123Dimensions Mag
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Connection example - Magne 1 in ser
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Modular structure - Dalton1. Choose
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Dimensions - Dalton1234Bracket 1 wi
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Connection example - Dalton M12 and
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Knox in 4 different states1OpenRese
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Technical data - KnoxMakeSafety lev
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Connection example - Knox with down
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ContentsPage1Why should control dev
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12Two-channel all the way out to th
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Highest safety levelwhether the but
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Available combinations of bottom- a
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Connection example - Three-position
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Connection with bottom parts AE1234
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Technical data - SafeballManufactur
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Electrical connection - SafeballTwo
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For mobile installation12JSTD25F/JS
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Connection example - JSTD25P-11234D
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Technical data - JSTD20Manufacturer
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ContentsPage1Why do you need an Eme
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Emergency stop for enclosureinstall
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Technical data - INCA 1/INCA 1 Tina
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Connection examples - SmileSmile 10
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Technical data - SmileManufacturer:
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Connection examples - Smile TinaSmi
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Technical data - Smile TinaManufact
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Technical data - Smile AS-iManufact
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Technical data - Stop-LineManufactu
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Ordering data - Stop-Line accessori
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Reset buttonSmile 11RWhen do I need
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ContentsPage1When shall I use conta
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Safety contact rails GP - General1T
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Mounting and electrical connection
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Standard shapes1Shape AShape BCusto
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Technical Data - Safety MatsManufac
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Electrical connection - Safety cont
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12345678910111213ABB 12:1314
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ContentsPage1Guick-Guard ® fencing
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A flexible and stable fencing syste
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Quick-Guard ® is supplied in three
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Quick-Guard ® E- can be ordered in
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IMAGE DESIGNATION ART.NO. DESCRIPTI
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Quick-Guard ® Assembly, standard v
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Dimensions for aluminum profile len
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Designation: JSM A8888Article numbe
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Cable tieDesignation: JSM X1Article
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Small Angle fitting, e.g. Electrica
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DOOR COMPONENTSTo mount conventiona
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Designation: JSM D18 HandleArticle
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Upper Door bolt1Upper Door boltDesi
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Sliding bolt for Eden1Designation:
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Guide Components for Sliding Door1G
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FITTINGS FOR SWITCHES1Eden fittings
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Fittings for Interlock Switches JSN
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ACCESSORIESAll fittings and door co
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18-12SteelplateCross-bent sheet met
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FunctionHighest protection in accor
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ContentsPage1Declaration of conform
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Declaration of conformity - JSBR4Ot
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Declaration of conformity - Eden, T
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Declaration of conformity- KnoxOthe
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NotesABB 14:9
Page 401:
NotesABB 14:11
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