ABB Jokab Safety Application Examples - RS Components

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© Copyright 2021 ABB. All rights reserved. Rev.:Document ID.:

JUNE 2021

ABB Jokab SafetyApplication Guide

—Important Notice

Important information, the connection diagrams and application examples in this document are only general recommendations from ABB. The conditions of a specific application could make alternative connections more suitable.

With regards to the stated functional safety levels, they can only be guaranteed under the assumption that the installation complies with all other functional safety requirements, such as product selection, product placement, cable installation, environmental effects on the system etc.

ABB does not accept any responsibility for any errors or lack of information in this document. It is the responsibility of the machine builder to make sure the correct functional safety levels are achieved.

Click here for the latest release of the “Application Guide”

Application Selector

Component Selector 1



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—Application Selector

Robot Cell

Wrapping Machine

Food and Beverage

Material Handling

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June 30, 2021

(Click images to select component)

Component Programming and Wiring Selector

EStrong Z/Linestrong 2Z MKEY Orion 1 Base Tina 2A/B

Tina 3A Tina 7A Inca 1 Tina Smile 11EA Tina





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June 30, 2021



Eden DYN GKEY JSHD4 HD5

Statusbus Magne 4 DYN Tina 6A Smile 11RB





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June 30, 2021



Smile 41 EWWWP Safeball BSR23 BSR11

AFS Contactors





—Robot Cells

Note: Picture is not of application on this page but only of a similar machine

June 30, 2021

Overview

Need to guard a robot cell utilizing an ABB robot with IRC5 controller. There are 2 doors and 2 operator stations.

Additional Notes

Operators interacts with both stations.

Doors need to be processed locked.

Additional pendant needed for another person to enter in teach mode.

Communication (non-safe) needed between safety system and robot controller.

Emergency stops needed.

Application Notes





—Robot Cells

June 30, 2021

ABB Jokab Safety Solution

Top View of Cell





Doors

Light Curtain

Enabling Device

Robot Position

Controller

Emergency Stops, Request to Enter and Reset

—Robot Cells

June 30, 2021

Front View Side View






—Robot Cells

June 30, 2021

Orion Light Curtain for entry/exit Magne 4 and Smile 41 on door






—Robot Cells

June 30, 2021

Emergency Stops, Request to Enter and Reset (Smile 41’s by doors for emergency

stop, request to enter and reset, Smile 11RB by light curtains for resetting)

(2)Smile 41 – 2TLA030057R0100

(2)M12-C103 – 2TLA020056R4000– 10m cable for Smile 41

(2)Smile 11RB – 2TLA030053R0100

(2)M12-C101 – 2TLA020056R1000 – 10m cable for Smile 11RB

Robot Position (to bypass each area operator interacts with)

(2)Adam DYN Info – 2TLA020051R5100

(1)Eva General Code – 2TLA020046R0800

(2)M12-C101 – 2TLA020056R1000 – 10m cable for Adam DYN Info

Controller

(1)Pluto B20 v2 – 2TLA020070R4600

(1)Gate E1P – 2TLA020071R9000

(1)BSR23 – 2TLA010041R0600 – for robot fence

(1)Programming Cable – 2TLA020070R5800

Doors (process lock)

(2)Magne 4 DYN Info – 2TLA042022R3400

(2)Anchor Plate 32B – 2TLA042023R0400


(2)M12-C103 – 2TLA020056R4000 – 10m cable for Magne 4

(2)JSMD21B – 2TLA042023R0500 – bracket for anchor plate

(2)JSMD24 – 2TLA042023R0300 – bracket for Eva

Light Curtain (where operator interacts, operators can only reach through light curtains

they can pass through them, 900mm height covers opening)

(2)Orion 1-4-30-090-B – 2TLA022302R0500

(2)M12-C101 – 2TLA020056R1000– 10m cable for transmitter

(2)M12-C103 – 2TLA020056R4000– 10m cable for receiver

Enabling Device (for additional person when robot is in teach mode)

(1)JSHD4-2 – 2TLA020006R2200

(1)AD Bottom – 2TLA020005R1300

(1)M12-C103 – 2TLA020056R4000






—Wrapping Machine

Note: Picture is not of application on this page but only of a similar machine.

June 30, 2021

Overview

Need to safe-guard a wrapping machine. There is an entry and exit conveyor that also needs to be guarded. Pallets with product comes into the cell, gets wrapped and exits the cell.

Additional Notes

2 door need to be interlocked. Safety lock is needed.

Emergency stops needed.

Wrapping machine uses an ABB drive with STO (Safe Torque Off)

Entry and exit need to be fully guarded with light curtains which both need to be muted.

Application Notes





—Wrapping Machine

June 30, 2021


Top View of Cell





Doors

Light Curtain

Controller (in Panel not shown)

Reset

—Wrapping Machine

June 30, 2021

Top View Side View






—Wrapping Machine

June 30, 2021

GKEY on Door Orion Light Curtain for Conveyors






—Wrapping Machine

June 30, 2021

Light Curtain (muting done through Pluto S20 v2, X pattern mute)

(2)Orion 1-4-30-120-B – 2TLA022302R0700


(2)M12-C103 – 2TLA020056R1000– 10m cable for basic receiver

(4)Mute R2 - 2TLA022044R0500

(4)Reflect 1 - 2TLA022044R2000

(2)KL70-306C – for mute lamp

(2)KT70-1002 – for mute lamp

(2)KA70-1034 – for mute lamp

Controller

(1)Pluto S20 v2 – 2TLA020070R4700

(2)BSR23 – 2TLA010041R0600


(4)AFS09Z-30-22-30 – for shutting down exit and entry conveyors.

Doors

(2)2TLA050304R0002 - GKey4 RU

(2)2TLA050310R0032 - FHS GKey4

(2)2TLA050040R0510 - RHS GKey MKey

(2)2TLA050040R0511 - SCS GKey MKey

(2)2TLA050040R0002 – M20 cable gland

(2)MA1-8130 – blanking plug

(2)CP1-11L-10 – Compact Series Blue Illuminated button

(2)CE3T-10R-02 – Compact Series Emergency Stop Twist to release

(2)CP1-11Y-10 – Compact Series Yellow Illuminated button

(2)CP1-11G-10 – Compact Series Green Illuminated button

Reset (Smile 11RB by light curtains for resetting/override).

(2)Smile 11RB – 2TLA030053R0100

(2)M12-C101 – 2TLA020056R1000






—Food and Beverage


June 30, 2021

Overview

Need to safe-guard a bottle filling machine.

Additional Notes

Devices used need to be wash down rated.

Need to be able to bypass light curtain to safely make adjustments

Conveyor needs be guarded.

Application Notes






June 30, 2021


Top View of Cell





Doors

Light Curtains Enabling Device

Controller

Emergency Stops

Reset


June 30, 2021

Side View Linestrong 2Z Rope Pull







June 30, 2021

Estrong Z HD5 Enabling Device with Holster







June 30, 2021

Eden on Door Orion Light Curtain in WET tube







June 30, 2021

Light Curtains

(2)Orion 1-4-30-090-B – 2TLA022302R0500

(2)Orion WET-090 – 2TLA022313R0500

(2)Orion 1-4-30-120-B – 2TLA022302R0700

(2)Orion WET-120 – 2TLA022313R0700


(4)M12-C103 – 2TLA020056R1000– 10m cable for receiver

Controller

(1)Pluto S46 v2 – 2TLA020070R1800

(1)BSR23 – 2TLA010041R0600


(2)AFS09Z-30-22-30 – for shutting down conveyor.

Doors

(5)Adam DYN Info – 2TLA020051R5100


(5)M12-C101 – 2TLA020056R1000 – 10m cable for Adam DYN Info

Emergency Stops and Reset

(1)Compact Range Blue Illuminated push button with 1NO contact - CP1-10L-11

(1)Compact Range Green Illuminated push button with 1NO contact - CP1-10G-11

(1)Compact Range Red Illuminated push button with 1NO contact - CP1-10R-11

(2)Linestrong 2Z – 2TLA050202R1322

(3)Estrong Z – 2TLA050220R1030

(5)2TLA050040R0001 – ½ NPT cable gland

Enabling Device

(1)HD5-S-111 - 2TLA023001R0100

(1)HD5-M-001 Active Holster - 2TLA920509R0001






—Material Handling


June 30, 2021

Overview

Need to safe-guard a material handling machine. The arm picks up filled cardboard boxes off a conveyor and stacks them on a pallet for a forklift to take it to a wrapper.

Additional Notes

Light curtains needed to be muted entry and exit.

Need a process lock on 2 doors

Application Notes






June 30, 2021


Top View of Cell





Doors

Light Curtains

Controller

Emergency Stops, Request to Enter and Reset


June 30, 2021

Front View Side View







June 30, 2021

Magne 4 and Smile 41 on Door Orion Light Curtain for Conveyors







June 30, 2021

Light Curtains (muting done through Pluto S20 v2, X pattern mute)

(2)Orion 1-4-30-120-B – 2TLA022302R0700


(2)M12-C103 – 2TLA020056R1000– 10m cable for basic receiver

(4)Mute R2 - 2TLA022044R0500

(4)Reflect 1 - 2TLA022044R2000

(2)KL70-306C – for mute lamp

(2)KT70-1002 – for mute lamp

(2)KA70-1034 – for mute lamp

Controller

(1)Pluto S46 v2 – 2TLA020070R180000

(2)BSR23 – 2TLA010041R0600


(2)AFS09Z-30-22-30 – for shutting down conveyor.

Doors (process lock)

(2)Magne 4 DYN Info – 2TLA042022R3400

(2)Anchor Plate 32B – 2TLA042023R0400


(2)M12-C103 – 2TLA020056R4000 – 10m cable for Magne 4

(2)JSMD21B – 2TLA042023R0500 – bracket for anchor plate

(2)JSMD24 – 2TLA042023R0300 – bracket for Eva

Emergency Stops, Request to Enter and Reset (Smile 11RB by light curtains for

resetting/override).

(2)Smile 11RB – 2TLA030053R0100

(2)M12-C101 – 2TLA020056R1000 – 10m cable for Smile 11RB

(2)Smile 41 – 2TLA030057R0100

(2)M12-C103 – 2TLA020056R4000– 10m cable for Smile 41






—Wiring/Programming Examples for Pluto Safety Controller

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Pluto Manager Example Programming Device (ex. Estrong Z, Linestrong)

IO Option Configuration Example (Pluto Manager)

June 30, 2021

Dual Channel Estop (Programming)





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Electrical Wiring to Pluto Safety PLC Device (ex. Estrong Z, Linestrong)

Notes

June 30, 2021

One channel Static (24VDC) and the other DYNLINK signal (ex. A Pulse, Non-Inverted) to detect a cross short between channels.

Dual Channel Estop (Wiring)





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Pluto Manager Example Programming Device (ex. MKEY)


June 30, 2021

Dual Channel Gate Switch (Programming)





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Electrical Wiring to Pluto Safety PLC Device (ex. MKEY)

Notes

June 30, 2021

One channel Static (24VDC) and the other DYNLINK signal (ex. A Pulse, Non-Inverted) to detect a cross short.

Dual Channel Gate Switch (Wiring)





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Pluto Manager Example Programming Device


June 30, 2021

Orion 1 Base Light Curtain (Programming)





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Electrical Wiring to Pluto Safety PLC Device Internal Wiring

Notes

June 30, 2021

Light curtain will fault out if there is a cross short between OSSD’s or other voltage.

OSSD’s should be wired both to an “I” input or only one OSSD can be wired to an “IQ” input. Both OSSD’s must never be connected both to an “IQ”.

Orion 1 Base Light Curtain (Wiring)





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June 30, 2021

Estop with Tina 2A/B (Programming)





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Notes

June 30, 2021

-The Tina device inverts the DYNLINK signal (ex. A Pulse) 180 degrees and sends it out. This allows for any short to be detected in the cable.

-Tina device connections to the safety device should be in the same enclosure .

Estop with Tina 2A/B (Wiring)





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June 30, 2021

Estop with Tina 3A/APS (Programming)





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Notes

June 30, 2021


-Tina device connections to the safety device should be in the same enclosure.

Estop with Tina 3A/APS (Wiring)





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June 30, 2021

Estop with Tina 7A (Programming)





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Notes

June 30, 2021


-Tina device connections to the safety device should be in the same enclosure.

Estop with Tina 7A (Wiring)





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Pluto Manager Example Programming Device (ex. Inca 1 Tina)


June 30, 2021

Inca 1 Tina (Programming)





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Notes

June 30, 2021


Inca 1 Tina (Wiring)





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June 30, 2021

Smile 11EA Tina (Programming)





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Notes

June 30, 2021


Smile 11EA(SA) Tina (Wiring)





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June 30, 2021

Eden DYN Info (Programming)





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Notes

June 30, 2021

-The Eden inverts the DYNLINK signal (ex. A Pulse) 180 degrees and sends it out. This allows for any short to be detected in the cable

Eden DYN Info (Wiring)





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June 30, 2021

GKEY Info (Programming)





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Notes

June 30, 2021


Internal Wiring Above is with no extra buttons installed.

Unlocking signal could come from Pluto or External source depending on application.

GKEY Info (Wiring)





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June 30, 2021

JSHD4-2 + AD Bottom Info (Programming)





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Notes

June 30, 2021


JSHD4-2 + AD Bottom Info (Wiring)





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Pluto Manager Example Programming Device (HD5-S-111)


June 30, 2021

HD5 Info (Programming)





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Electrical Wiring to Pluto Safety PLC Device Internal Wiring (HD5-S-111)

Notes

June 30, 2021

For 3 position button(Pins 1 to 4) one channel Static (24VDC) and the other DYNLINK signal (ex. A Pulse, Non-Inverted) to detect a cross short between channels.

For the estop(Pins 14 to 17) B pulse and C pulse are used. These come in as Non-Inverted into the Pluto.

HD5 Info (Wiring)





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Pluto Manager Example Programming Device (ex. Eden Statusbus, Smile or Inca Statusbus)


June 30, 2021

Status Bus Devices (Programming)





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Electrical Wiring to Pluto Safety PLC Device (ex. Eden Statusbus, Smile or Inca Statusbus)

Notes

June 30, 2021

Up to 30 devices can be wired to one IQ for status. Internal bits from slave can be sent to standard PLC via Gateways (Either through a register or single bits)

Statusbus devices given a slave number via Pluto under the Tools Menu/Statusbus/Teach Addresses

M12-3S splitters can be used for daisy chaining or ran back to the panel individually (pins 1 to 4 normal DYNLINK wiring, pin 5 info is wired in parallel

with other info lines.

Status Bus Devices (Wiring)





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June 30, 2021

Magne 4 DYN Info(Programming)





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Notes

June 30, 2021

The Magne 4 inverts the DYNLINK signal (ex. A Pulse) 180 degrees and sends it out. This allows for any short to be detected in the cable

Magne 4 DYN Info(Wiring)





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June 30, 2021

Safety Mat/Safety Edge with Tina 6A (Programming)





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Notes

June 30, 2021

The Tina device inverts the DYNLINK signal (ex. A Pulse) 180 degrees and sends it out. This allows for any short to be detected in the cable

Safety Mat/Safety Edge with Tina 6A (Wiring)





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Pluto Manager Example Programming Device (ex. Smile 11RB)


June 30, 2021

Illuminated Reset (Programming)





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Electrical Wiring to Pluto Safety PLC Device Internal Wiring (Smile 11RB)

Notes

June 30, 2021

The illuminated reset uses the DYNLINK signal (ex A pulse). A diode is needed to allow the DYNLINK signal through when the button is pressed but will block the 24VDC as well as the plutoseeing a fault “IQ shorted to another IQ”.

Illuminated Reset (Wiring)





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June 30, 2021

Smile 41 EWWWP (Programming)





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Notes

June 30, 2021

The illuminated reset uses the DYNLINK signal (ex A pulse). A diode is needed to allow the DYNLINK signal through when the button is pressed but will block the 24VDC as well as the plutoseeing a fault “IQ shorted to another IQ”.

Smile 41 EWWWP (Wiring)





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Pluto Manager Example Programming Device (Safeball)


June 30, 2021

Two Hand Control (Programming)





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Electrical Wiring to Pluto Safety PLC Device Internal Wiring(Safeball)

Notes

June 30, 2021

One button or Safeball connected to 24VDC (NO + NC) and other button or Safeball to DYNLINK signal (ex A pulse, Non-Inverted). This allows for both buttons to come back to the panel in 1 cable.

NOTE: Pushbuttons could also be used with NO/NC contacts.

Two Hand Control (Wiring)





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IO Option Configuration (Pluto Manager) - Monitoring

June 30, 2021

Output Expansion to BSR23 (Programming)

Select “Safety Outputs” in Pluto Manager under variables and type in a Symbolic Name. These are already configured as safety outputs. Monitoring setup as below:





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Electrical Wiring to Pluto Safety PLC Device

Notes

June 30, 2021

If BSR23 is in the same panel as the Pluto they can be driven single channel

Output Expansion to BSR23 (Wiring)





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IO Option Configuration (Pluto Manager) - None

June 30, 2021

Select “Safety Outputs” in Pluto Manager under variables and type in a Symbolic Name. These are already configured as safety outputs.

Output Expansion to BSR10/11 (Programming)





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Electrical Wiring to Pluto Safety PLC Device

Notes

June 30, 2021

If BSR10/11 is in the same panel as the Pluto they can be driven single channel

Output Expansion to BSR10/11 (Wiring)





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Pluto Manager Example Programming Device (ex. AFS Contactors)

IO Option Configuration (Pluto Manager) - Monitoring

June 30, 2021

Output connection to Contactors/Control Relays (Programming)

Note: Above is ABB AFS contactors for safety applications

Select “Safety Outputs” in Pluto Manager under variables and type in a Symbolic Name. These are already configured as safety outputs. Monitoring setup as below:





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Electrical Wiring to Pluto Safety PLC Device (ex. AFS Contactors)

Notes

June 30, 2021

If contactors/control relays are in the same panel as the Pluto they can be driven single channel

Output connection to Contactors/Control Relays (Wiring)





ABB Jokab Safety Application Examples - RS Components

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