ABB LineStrong2 Series User manual

ABB Electrification Sweden AB / Jokab Safety Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden
www.abb.com/jokabsafety
Original instructions
LineStrong-series
Emergency Stop Grab Wire Safety Switch

2TLC172248M0201, rev. C 2 www.abb.com/jokabsafety
2020-11-11
Read and understand this document
Please read and understand this document before using the products. Please consult your ABB JOKAB SAFETY
representative if you have any questions or comments.
WARRANTY
ABB JOKAB SAFETY’s exclusive warranty is that the products are free from defects in materials and workmanship for a
period of one year (or other period if specified) from date of sale by ABB JOKAB SAFETY.
ABB JOKAB SAFETY MAKES NO WARRANTY OR REPRESENTATION, EXPRESSED OR IMPLIED, REGARDING NON-
INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS, ANY BUYER OR USER
ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE
REQUIREMENTS OR THEIR INTENDED USE. ABB JOKAB SAFETY DISCLAIMS ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED.
LIMITATIONS OF LIABILITY
ABB JOKAB SAFETY SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF
PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON
CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
In no event shall responsibility of ABB JOKAB SAFETY for any act exceed the individual price of the product on which
liability asserted.
IN NO EVENT SHALL ABB JOKAB SAFETY BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE
PRODUCTS UNLESS ABB JOKAB SAFETY’S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED,
STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR
REPAIR.
SUITABILITY FOR USE
ABB JOKAB SAFETY shall not be responsible for conformity with any standards, codes, or regulations that apply to the
combination of products in the customer’s application or use of the product. At the customer’s request, ABB JOKAB
SAFETY will provide applicable third party certification documents identifying ratings and limitations of use that apply
to the products. This information by itself is not sufficient for a complete determination of the suitability of the
products in combination with the end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be
an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for
the products:
Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not
described in this document.
Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment,
amusement machines, vehicles, and installations subject to separate industry or government regulations.
Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT
ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE ABB JOKAB
SAFETY PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR
SYSTEM.
PERFORMANCE DATA
While every effort has been taken to ensure the accuracy of the information contained in this manual ABB JOKAB
SAFETY cannot accept responsibility for errors or omissions and reserves the right to make changes and improvements
without notice. Performance data given in this document is provided as a guide for the user in determining suitability
and does not constitute a warranty. It may represent the result of ABB JOKAB SAFETY’S test conditions, and the users
must correlate it to actual application requirements. Actual performance is subject to the ABB JOKAB SAFETY Warranty
and Limitations of Liability.

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Table of Contents
1 Introduction .................................................................................................................................... 4
Scope ........................................................................................................................................................................ 4
Audience .................................................................................................................................................................. 4
Prerequisites ........................................................................................................................................................... 4
Special notes ........................................................................................................................................................... 4
2 Overview .......................................................................................................................................... 5
General description................................................................................................................................................. 5
Safety regulations ................................................................................................................................................... 5
Distance between the eyebolts ............................................................................................................................. 5
Function description for the variants ................................................................................................................... 6
3 Connections .................................................................................................................................. 11
4 Installation and maintenance ...................................................................................................... 12
Installation of the Safety Switch.......................................................................................................................... 12
Installation of the wire .......................................................................................................................................... 14
Tensioner/Gripper ................................................................................................................................................ 15
Maintenance .......................................................................................................................................................... 17
5 Application examples ................................................................................................................... 18
6 Model overview ............................................................................................................................. 19
Dimensions ............................................................................................................................................................ 19
Accessories ............................................................................................................................................................ 21
7 Technical data ............................................................................................................................... 22
LineStrong1 ........................................................................................................................................................... 22
LineStrong2 series ................................................................................................................................................ 24
LineStrong3 series ................................................................................................................................................ 26
8 EC Declaration of conformity ...................................................................................................... 28

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1 Introduction
Scope
The purpose of these instructions is to describe the Emergency Stop Grab Wire Safety Switch system
LineStrong-series, and to provide the necessary information required for assembly, installation, checks and
adjustments after installation, and maintenance. The instructions also include information necessary to
connect LineStrong to a safety circuit.
Audience
This document is intended for authorized installation personnel.
Prerequisites
It is assumed that the reader of this document has knowledge of the following:
 Basic knowledge of ABB Jokab Safety products.
 Knowledge of machine safety.
Special notes
Pay attention to the following special notes in the document:
Warning!
Danger of severe personal injury!
An instruction or procedure which, if not carried out correctly, may result in injury to the
technician or other personnel.
Caution!
Danger of damage to the equipment!
An instruction or procedure which, if not carried out correctly, may damage the equipment.
NB: Notes are used to provide important or explanatory information.

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2 Overview
General description
All ABB Jokab Safety Emergency strop grab wire safety switches conform to European Standard EN ISO
13850 and IEC 60947-5-5. They have a positive mechanical linkage between the switch contacts and the wire
as per
IEC 60947-5-1. The emergency stop switches are brought into the operational condition by pre-tensioning
the wire by use of a tensioner / gripper device which clamps the wire and then hooks to the switch eyebolts.
Correct tension can be observed by viewing the tension indicator on the switch housing. Once tensioned
the switch contact blocks can be set to the operational condition (safety contacts closed, auxiliary contacts
open) by pressing a blue reset button on the switch cover.
All of the grab wire safety switches have wire-breakage monitoring. 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 a pressing the reset
button as required by EN ISO 13850.
Safety regulations
Warning! Carefully read through this entire manual before using the device.
The devices shall be installed by a trained electrician following the Safety regulations, standards and the
Machine directive.
Failure to comply with instructions, operation that is not in accordance with the use prescribed in these
instructions, improper installation or handling of the device can affect the safety of people and the plant.
For installation and prescribed use of the product, the special notes in the instructions must be carefully
observed and the technical standards relevant to the application must be considered.
In case of failure to comply with the instructions or standards, especially when tampering with and/or
modifying the product, any liability is excluded.
Distance between the eyebolts
We recommend installing the eye bolts across the whole length of the rope, min. 2.5 m to max. 3 m apart
If this cannot be achieved,
Distance between eyebolts
Actions
Less than 0,5 m
These areas must be clearly marked as inactive zones
.
0,5 to 2,5 m Appropriate installation checks must be made at each end and the middle
of the rope system.
These checks must ensure that the system operates when the rope is pulled
in any direction and the parameters to trip the system are satisfied.
2,5
m to 3
m
Recom
mended
More than 3 m Checks must be where the distances are extended.
These checks must ensure that the system operates when the rope is pulled
in any direction and the parameters to trip the system are satisfied.
If not satisfied, these areas must be clearly marked as inactive zones.

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Function description for the variants
LineStrong1
LineStrong1 is a compact and small, yet robust switch that can handle wires up to 30 meters on a single
switch (50 meters on two switches).
When someone pulls the wire of Linestrong1 or if the wire is broken, the switch goes to a safe state, e.g. the
machine is emergency-stopped. After a emergency stop 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.
The LineStrong1 is made of a rugged die cast housing with a rating of IP67.
A positive forced connection 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 contacts
can occur. The LineStrong1 switch has 2NC and 2NO contacts.
We recommend installing the eye bolts across the whole length of the rope between the switches at min.
2.5 m to max. 3 m. If this cannot be achieved, please see “Distance between eyebolts”.
Up
to 50 m
500 mm
Every 3 meter Every 3 meter
500 mm
Up to 30 m
Eyebolt
500 mm
500 mm
Every 3 meter Every 3 meter
Eyebolt
Safety Spring
1) LineStrong1 with another LineStrong1
2) LineStrong1 with safety spring
)
)
Up to 50 m
Up to 30 m

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LineStrong2
LineStrong2 is a robust switch that can handle wires up to 80 meters on a single switch (100 meters on two
switches). When someone pulls the wire of LineStrong2 or if the wire is broken, the switch goes to a safe
state, e.g. the machine is emergency-stopped. After a emergency stop 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.
Depending on the environment where the switch will be used, different material can be chosen for the
LineStrong2. The basic version has a rugged yellow die cast housing with a rating of IP67. In severe
applications as for food processing and chemical industry there is a LineStrong2Z with a total rugged
stainless steel 316 body. This version has IP69K enclosure protection (maintained by a double seal lid gasket
and seals) and can be high pressure hosed with detergent at high temperature.
A positive forced connection provides a forced disconnect of the safety contacts when the wire is being
pulled or broken. The design of the LineStrong2 ensures that the contacts will not fail or be held in a
normally closed position, due to failure of the spring mechanism or that welding/sticking of the contacts
can occur. The LineStrong2 switch has 2NC and 2NO contacts.
We recommend installing the eye bolts across the whole length of the rope between the switches at min.
2.5 m to max. 3 m. If this cannot be achieved, please see “Distance between eyebolts”.
Up to 80 m LineStrong2
Up to 100 m LineStrong2Z
500 mm
500 mm
500 mm
500 mm
Every 3 meter Every 3 meter
Every 3 meter Every 3 meter
Eyebolt
Eyebolt
Safety Spring
1) LineStrong2 with another LineStrong2
2) LineStrong2 with safety spring
Up to 60 m LineStrong2
Up to 80 m LineStrong2Z
)
)

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LineStrong3
LineStrong3 is a quite robust switch that can handle long wires, up to 200 meters on a single switch. When
someone pulls the wire of LineStrong3 or if the wire is broken, the switch goes to a safe state, e.g. the
machine is emergency-stopped. After a emergency stop the LineStrong3 needs to be reset to be able to run
again and this is made on the local reset button. Additional features on the LineStrong3 is a "normal"
emergency stop fitted on the top of the grab wire safety switch and also a two-coloured LED for indication.
LineStrong3 is equipped with an indication of how taut the wire is, which makes the installation and
adjustment easy.
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 enclosure protection (maintained by a double seal lid gasket
and seals) and can be high pressure hosed with detergent at high temperature.
A positive forced connection 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 contacts.
Single wire - LineStrong3L/3R and LineStrong3LZ/3RZ
The Linestrong3L/3R are two different versions depending on installation.
L - "Left hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the left in
the installation.
R - "Right hand" - is the version of LineStrong3 where the placement of the grab wire switch is to the right in
the installation.
LineStrong3L/3R have die-cast housings and are robust to manage 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.
LineStrong3LZ/3RZ are in stainless steel 316 housings and are designed specifically to withstand the tough
environments found in the food and pharmaceutical industries. LineStrong3LZ/3RZ are designed to protect
a length up to 100 meters on a single switch. If two switches are used together, the wire can go up to 125
meters.
NB: The picture shows the left hand version NB: The picture shows the right hand version

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We recommend installing the eye bolts across the whole length of the rope between the switches at min.
2.5 m to max. 3 m. If this cannot be achieved, please see “Distance between eyebolts”.
1) LineStrong3L with a
Linstrong3R
2) LineStrong3L with
safety spring
500 mm
500 mm
500 mm
500 mm
Every 3 meter
Every 3 meter
Every 3 meter
Every 3 meter
Up to 125 m
Up to 100 m
Eyebolt
Eyebolt
Safety Spring
)
)

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Double wire – LineStrong3D and 3DZ
With wire entries from both sides of the grab wire switch, LineStrong3D can be used for a long protection
length. LineStrong3D has a die-cast housing and is robust to manage severe indoor or outdoor use.
LineStrong3D is designed to protect a length up to 200 meters on a single switch. If several switches are
used together, it will be possible with a length up to 125 meters between the switches. A two colour LED
ensures switch status can be seen easily from a distance.
LineStrong3DZ has stainless steel 316 housing and is designed specifically to withstand the tough
environments found in the food and pharmaceutical industries. LineStrong3DZ is designed to protect a
length up to 200 meters on a single switch. If several switches are used together it will be possible with a
length up to 125 meters between the switches.
We recommend installing the eye bolts across the whole length of the rope between the switches at min.
2.5 m to max. 3 m. If this cannot be achieved, please see “Distance between eyebolts”.
Up to 125 m
Every 3 meter
Up to 125 m
Every 3 meter
Up to 100 m
Every 3 meter
Up to 100 m
Every 3 meter
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
Eyebolt
Eyebolt
Safety Spring
Safety Spring
1) Several LineStrong3D
2) LineStrong3D with safety springs
)
)

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3 Connections
See Chapter Installation and Maintenance for more information regarding installation.
Connections
LineStrong1 & LineStrong2 LineStrong3
LineStrong2, explosion proof LineStrong3, explosion proof
2NC 2NC 2NO
Contact blocks
LED wiring example

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4 Installation and maintenance
Installation of the Safety Switch
1. The installation of all Emergency Stop Grab Wire Safety Switch systems must be in accordance with
a risk assessment for the individual application. Installation must only be carried out by competent
personnel and in accordance with these instructions.
2. According to ISO 13850, corner pulleys may only be mounted such that a complete length of the wire
can be observed.
3. Wire support eyebolts must be fitted at 2.5 m. min. to 3m. max.intervals along all wire lengths
between switches. The wire must be supported no more than 500mm from the switch eyebolt or
Safety Spring (if used). It is important that this first 500mm is not used as part of the active
protection coverage.
4. M5 mounting bolts must be used to fix the switches. Tightening torque for mounting bolts to
ensure reliable fixing is 4 Nm. Tightening torque for the lid screws,conduit entry plugs and cable
glands must be 1.5 Nm to ensure IP seal. Only use the correct size gland for the conduit entry and
cable outside diameter.
5. Tensioning of wire is achieved by use of ABB tensioner / gripper assemblies.
Upon installation, tension to mid position is indicated by the green arrows in the viewing window of
each switch. Check operation of all switches and the control circuits by pulling the wire at various
locations along the active protection area and resetting each switch by pressing the blue Reset
button. Ensure each time that the switches latch off, and require manual resetting by pressing the
Reset button. Increase the system tension further, if required, depending upon the checks along the
active length of coverage.
If safety switch is fitted with a Mushroom type E-Stop button (Red) then test and reset this part of
the switch to ensure correct function of the safety control circuits. Typical operational conditions
for successful operation of system are less than 75N pulling force and less than 150mm deflection of
rope between eyebolt supports.
6. Recommended wire span options and fittings - (subject to an individual risk assessment for the
installation) See Function description for correct wire span for each variant.
7. Wiring LED (Not on LineStrong1):
Black or Terminal 2 is 0VDC.
When 24VDC is applied to the Red wire or Terminal 1, the lamp will illuminate Red.
When 24VDC is applied to the Green wire or Terminal 3, the lamp will illuminate Green.
If the LED is fitted but is not used ensure the conductors remain coiled and fixed away from the
internal mechanism.
8. To fit Mushroom type Emergency Stop button (Not on
LineStrong1):
a) Remove M12 threaded plug from the mounting port.
b) Apply thread locking solution to the threads of the E Stop
mechanism.
c) Insert the Emergency Stop Mechanism into the mounting
port and tighten to 1.5 Nm.
d) After installation test and reset to ensure all safety circuits are functioning correctly.
1) Terminal 1 – red
2) Terminal 2 – black
3)
Terminal 3
–
green

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Warning! All the safety functions must be tested before starting up the system.

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Installation of the wire
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. The installation of the
tensioner accessory reduces the installation time. The eyehook, tensioner thimble and the wire strength
gripper are in one assembly which enables rapid connection to the switch eyebolts and fast and accurate
tensioning of the wire. Thanks to the switch viewing window, systems can be accurately and quickly
tensioned. The double clamp mechanism prevents wire slippage.
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.
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.
1. Tension to mid position as indicated by the green arrows in the viewing window of each switch
2. The tensioner thimble allows immediate accurate and final tensioning of the wire, whilst viewing the
tension marker through the viewing window on the switch
3. For systems up to 50 meter Quick Link termination is provided for easy connection to either a Safety
spring or Switch eyebolt. (Note for systems above 50 meter a Tensioner / Gripper is required each
side).
Examples of using the corner pulley 1) Machine
Inside
corners
Outside
corners Outside
corners

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Tensioner/Gripper
1.
2
.
3
.
4
.
5
.
6.
7.
8
.

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9
.
10
.
11
.
12
.
13
.
14
.

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Maintenance
The recommendations below are general, and the frequency of the checks can be adapted to suit the history
of use and the environment.
Every week: Check correct operation of system at locations along all coverage length and also the switch
latching mechanism. Check for nominal tension setting, re-tension wire if necessary.
Every 6 months: Isolate power and remove cover. Check screw terminal tightness and check for signs of
moisture ingress.
Warning! The safety functions and the mechanics shall be tested regularly, at least once every year, to
confirm that all the safety functions are working properly.
Warning! In case of breakdown or damage to the product, contact the nearest ABB Jokab Safety Service
Office or reseller. Do not try to repair the product yourself since it may accidentally cause permanent
damage to the product, impairing the safety of the device which in turn could lead to serious injury to
personnel.
Caution! ABB Jokab Safety will not accept responsibility for failure of the switch functions if the installation
and maintenance requirements shown in this sheet are not implemented. These requirements form part of
the product warranty.

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5 Application examples

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6 Model overview
Type Article number Description
LineStrong1 2TLA050200R0030 2NC/2NO, M20
LineStrong2 2TLA050202R0332 2NC/2NO, M20, E-Stop, LED
LineStrong2Z 2TLA050202R0322 2NC/2NO, M20, E-Stop, LED, stainless steel
LineStrong3L 2TLA050206R0332 4NC/2NO, M20, E-Stop, LED, left
LineStrong3R 2TLA050208R0332 4NC/2NO, M20, E-Stop, LED, right
LineStrong3LZ 2TLA050206R0322 4NC/2NO, M20, E-Stop, LED, left, stainless steel
LineStrong3RZ 2TLA050208R0322 4NC/2NO, M20, E-Stop, LED, right, stainless steel
LineStrong3D 2TLA050204R0332 4NC/2NO, M20, E-Stop, LED, double
LineStrong3DZ 2TLA050204R0322 4NC/2NO, M20, E-Stop, LED, double, stainless steel
Dimensions
LineStrong1
LineStrong2 / LineStrong2Z
4 Mounting Holes
Clearence for M5
screws
2 Mounting Holes
Clearance for M5
Screws

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LineStrong3L/R and LineStrong3LZ/3RZ
LineStrong3D and LineStrong3DZ
NB: All measurements are in mm
4 Mounting Holes
Clearence for M5
screws
4 Mounting Holes
Clearence for M5 screws