ABB Sense7 Series User manual

2TLC172249M0201, REV. C ORIGINAL INSTRUCTIONS
—
SAFETY PRODUCTS
Non-contact coded safety switch
Sense7-series
Product Manual
----C

2TLC172249M0201, REV. C 2021-10-12 2
Read and understand this document
Please read and understand this document before using the products. Please consult your ABB Motor Start-
ing & Safety representative if you have any questions or comments.
Suitability for use
ABB Electrification Sweden AB shall not be responsible for conformity with any standards, codes, or regula-
tions that apply to the combination of products in the customer’s application or use of the product. Third
party certificates for the products are available at
https://new.abb.com/low-voltage/products/safety-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 govern-
ment 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 PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE
OVERALL EQUIPMENT OR SYSTEM.
Descriptions and examples show how the product works and can be used. It does not mean that it fulfills
the requirements for all types of machines and processes. The buyer/user is responsible for installing and
using the product according to applicable standards and regulations. We reserve the right to make changes
to the product and the documentation without prior notice.

2TLC172249M0201, REV. C 2021-10-12 3
Table of Contents
1Introduction ...................................................................................................................................................................4
Scope. .............................................................................................................................................................................................. 4
Audience.......................................................................................................................................................................................... 4
Prerequisites .................................................................................................................................................................................. 4
Special notes.................................................................................................................................................................................. 4
2Overview.........................................................................................................................................................................5
General description ...................................................................................................................................................................... 5
Safety regulations......................................................................................................................................................................... 5
Function description .................................................................................................................................................................... 5
3Connections ...................................................................................................................................................................6
4Installation and maintenance.......................................................................................................................................8
Installation and maintenance..................................................................................................................................................... 8
Maintenance ................................................................................................................................................................................... 8
Minimum safety distance............................................................................................................................................................ 9
5Application examples..................................................................................................................................................10
Solution for two NC-contacts .................................................................................................................................................. 10
Solution for one NC-contact and one NO-contact ............................................................................................................... 11
6Model overview............................................................................................................................................................12
Accessories....................................................................................................................................................................................12
Dimensions....................................................................................................................................................................................12
7Technical data .............................................................................................................................................................. 13
8EC Declaration of conformity.....................................................................................................................................15

2TLC172249M0201, REV. C 2021-10-12 4
1Introduction
Scope
The purpose of these instructions is to describe the non-contact coded safety switch Sense7-series, and to
provide the necessary information required for assembly, installation, operations, checks and adjustments
after installation, and maintenance. The instructions also include information necessary to connect Sense7
to a safety circuit.
Audience
This document is intended for authorized personnel.
Prerequisites
It is assumed that the reader of this document has knowledge of the following:
•Basic knowledge of ABB Electrification Sweden AB products.
•Knowledge of safety devices.
•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 tech-
nician 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.

2TLC172249M0201, REV. C 2021-10-12 5
2Overview
General description
The coded non-contact switches Sense7 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, placed on the frame of the guard. Its
design makes it advantageous to operate in environments that require the highest level of safety.
Safety regulations
Warning!
Carefully read through this entire manual before using the device.
Installation shall be conducted by authorized personnel following the Safety regulations, standards and lo-
cal legal regulations. Carefully read through the entire original instruction before using the device.
Failure to comply with instructions, operation that is not in accordance with the use prescribed in these in-
structions, 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 mod-
ifying the product, any liability is excluded.
Function description
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 paramount. The non-contact coded safety switch has a long working life since no mechani-
cal contact is necessary for operation. The Sense7 has 2NC and 1NO contacts and a sensing distance to the
actuator of 14mm. It has a high tolerance to misalignment. Actuator is always delivered with the non-con-
tact switch.
Depending on the environment where the switch will be used, different material can be chosen on the
Sense7. The basic version is in a full plastic body (polyester). In harsh applications as for food processing
and chemical industry there is a Sense7Z with a total rugged stainless steel 316 body. Both versions have an
enclosure protection up to IP69K and can be high pressure hosed with detergent at high temperature.
r
Warning! Application consideration must be given to the fixing of the actuator which has to be in a way
that prevents
disassembly by easy means..

2TLC172249M0201, REV. C 2021-10-12 6
3Connections
See Chapter Installation and Maintenance for more information regarding installation.
Connections
For all ABB switches the NC circuits are closed when the guard is closed and the actuator present.
Cable configurations
BLACK (IN)
RED
(24VDC)
POWER
&
&
&
RECEIVER 1
RECEIVER 2
ACTUATOR
BLUE
(0VDC)
WHITE (OUT)
YELLOW (IN)
GREEN (OUT)
ORANGE (IN)
BROWN (OUT)
NC
Circuit 1
NC
Circuit 2
NO
Circuit
RED (24VDC)
BLUE (0VDC)
BLACK (IN)
WHITE (OUT)
GREEN (OUT)
YELLOW (IN)
BROWN (OUT)
ORANGE (IN)
External Supply 24VDC
NC
Circuit 1
NC
Circuit 2
NO
Circuit

2TLC172249M0201, REV. C 2021-10-12 7
Pin configurations
Quick Connect (QC)
M12 8 way
Male Plug
(Pin view from switch)
Flying Lead
Colors
Circuit
(Actuator present)
Output Types
Solid State
8
Orange
Auxiliary (NO)
200mA Max. 24Vdc
5
Brown
Auxiliary (NO)
4
Yellow
NC2
+ve
200mA Max. 24Vdc
6
Green
NC2
-ve
7
Black
NC1
+ve
200mA Max. 24Vdc
1
White
NC1
-ve
2
Red
Supply +24Vdc
+/- 10%
3
Blue
Supply 0Vdc
Connection colours:
(Important: The NC1 and NC2 Outputs are polarity sensitive).

2TLC172249M0201, REV. C 2021-10-12 8
4Installation and maintenance
Installation and maintenance
1. The installation of all ABB Electrification Sweden AB interlock switches must be done in accordance
with a risk assessment for the individual application. Installation must only be carried out by compe-
tent personnel and in accordance with these instructions.
2. The use of a safety relay is required for monitoring coded switches. These relays monitor 2 redundant
circuits as per ISO13849-1 for up to PL e / Category 4 protection. Coded non-contact switches are de-
signed to operate with most dual channel safety relays.
3. M4 mounting bolts must be used to fix the switches. Tightening torque for mounting bolts to ensure
reliable fixing is 1.0 Nm.
Installation on ferrous materials may reduce the sensing distance.
The recommended setting gap is 5 mm. The Safety switch must not be used as a mechanical stop or be
adjusted by striking with a hammer.
The actuator must not be allowed to strike the switch. Do not mount adjacent switches or actuators
closer than30mm. Typical misalignment tolerance after setting is 5 mm.
4. After installation always check each switch function by opening and closing each guard individually in
turn and ensuring that the Green LED on the switch and the LED’s on the safety relay are illuminated
when the switch is closed and are extinguished when the switch is open.
5. Check that the machine stops and cannot be re/started when each switch is open.
r
Warning! All the safety functions must be tested before starting up the system.
Maintenance
Monthly: Check alignment of actuator and look for signs of mechanical damage to the switch casing. Check
wiring for signs of damage.
Every 6 months: Check each switch function by opening and closing each guard individually in turn and en-
suring that the Green LED on the switch and the appropriate LED’s on the safety relay are illuminated when
the switch is closed and are extinguished when the switch is open. Check that the machine stops and can-
not be re-started when each switch is open.
Specific requirements
If the products are used in safety related applications with infrequently operated guards, then the safety
function shall be checked for hidden faults at least once per year for PL d and at least once per month for PL
e. Please see EN ISO 14119.
r
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.
r
Warning! In case of breakdown or damage to the product, contact the nearest ABB Electrification
Sweden AB 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.

2TLC172249M0201, REV. C 2021-10-12 9
Caution! ABB Electrification Sweden AB will not accept responsibility for failure of the switch functions if
the installation and maintenance requirements shown in this sheet are not implemented. These require-
ments form part of the product warranty.
Minimum safety distance
When using interlocking guards without guard locking to safeguard a hazard zone, the minimum allowed
safety distance between the guarded opening and the hazardous machine must be calculated. In order to
ensure that the hazardous machine motion will be stopped before it can be reached, the minimum safety
distance is calculated according to EN ISO 13855 (“Positioning of safeguards with respect to the approach
speeds of parts of the human body”).
The minimum safety distance is calculated according to the formula:
S = (K x T) + C
Where
S= minimum safety distance (mm)
K= approach speed of a human body; 1600 mm/s
T= the total time from opening of the guard until the hazardous machine movement has stopped, i.e. in-
cluding control system reaction times and other delays (s)
C= a safety distance taken from Table 4 or Table 5 of EN ISO 13857:2008, if it is possible to push fingers or a
hand through the opening towards the hazard before a stop signal is generated
In some cases, T might be reduced by the opening time of the guard until the opening size permits access
of the relevant parts of the body. Refer to EN ISO 13855 for further details and EN ISO 13857 for specified
values.

2TLC172249M0201, REV. C 2021-10-12 10
5Application examples
For the latest connection diagrams, please see our web page:
https://library.abb.com/r?cid=9AAC170124&dk=connection%20diagram
Solution for two NC-contacts
Note: The PL should be calculated using ISO/TR 24119 and EN ISO 13849-1/2

2TLC172249M0201, REV. C 2021-10-12 11
Solution for one NC-contact and one NO-contact
Note: The PL should be calculated using ISO/TR 24119 and EN ISO 13849-1/2

2TLC172249M0201, REV. C 2021-10-12 12
6Model overview
Type Product ID Description
Sense7 2TLA050056R4100* 2 m cable, 2NC/1NO, LED
Sense7 2TLA050056R5100* 5 m cable, 2NC/1NO, LED
Sense7 2TLA050056R6100* 10 m cable, 2NC/1NO, LED
Sense7 2TLA050056R2100* 250 mm cable with M12, 2NC/1NO, LED
Sense7Z 2TLA050056R4120 2 m cable, 2NC/1NO, LED, Stainless Steel
Sense7Z 2TLA050056R5120 5 m cable, 2NC/1NO, LED, Stainless Steel
Sense7Z 2TLA050056R6120 10 m cable, 2NC/1NO, LED, Stainless Steel
Sense7Z 2TLA050056R2120 250 mm cable with M12, 2NC/1NO, LED, Stainless Steel
* Classic in LCM.
Accessories
Type Product ID Description
Sense7, actuator 2TLA050040R0211* Spare actuator plastic
Sense7, SSactuator 2TLA050040R0212 Spare actuator stainless steel
* Classic in LCM.
Dimensions
NB: All measurements in millimetres
Sense7 Sense7Z

2TLC172249M0201, REV. C 2021-10-12 13
7Technical data
Manufacturer
Address ABB Electrification Sweden AB
SE-721 61 Västerås
Sweden
Electrical characteristics
Minimum switched current
10VDC 1mA
Dielectric withstand
250 VAC
Safety channel 1-NC
24VDC 0.2 A max. rating
Safety channel 2-NC
24VDC 0.2 A max. rating
Safety channel 3-NO 24VDC 0.2 A max. rating
Insulation resistance
100 MOhms
General
Recommended setting gap 5 mm
Switching Dis-
tance(target to
target)
Sao 8 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
Protection class IP69K
Cable Type PVC 8 core 6 mm O.D
Ambient temperature Sense7: -25°C to +80°C
Sense7Z: -25°C to +105°C
Size
See drawing
Material Sense7: UL approved polyes-
terSense7Z: Stainless steel
316
Colour Red or stainless steel
Mounting position Any
Mounting bolts 2 x M4 Tightening torque 1.0 Nm

2TLC172249M0201, REV. C 2021-10-12 14
Safety-related characteristic data and Conformity
Conformity European Machinery Directive 2006/42/EC
EN ISO 12100:2010, EN ISO 14119:2013, EN ISO 13849-1:2015, EN 60947-5-
3:2013
EN ISO 13849-1 Up to PLe Category 4 (if both channels are used with a PLe control device)
EN 62061 Up to SIL3 depending on system architecture
Safety data
PFHD2.6 x 10-10 (1/h)
Proof test
interval
(life)
20 years
MTTFd866 years
Certifications TÜV, cULus
Information with regard
to UL 508
Type 1 Enclosure
Control No: 48W5
Max. Temp: 70ºC (Plastic version), 90ºC (Stainless Steel)

2TLC172249M0201, REV. C 2021-10-12 15
8EC Declaration of conformity
ABB Electrification Sweden AB
SE-721 61 Västerås, Sweden
https://new.abb.com/low-voltage/