ABB Sense7 Series User manual

ABB AB / Jokab Safety Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden
www.abb.com/jokabsafety
Original instructions
Sense7-series
Non-contact coded safety switch

2TLC172249M0201, rev. B 2 www.abb.com/jokabsafety
2013-04-10
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
1Introduction ......................................................................................................................................... 4
Scope........................................................................................................................................................................4
Audience...................................................................................................................................................................4
Prerequisites.............................................................................................................................................................4
Special notes ............................................................................................................................................................4
2Overview .............................................................................................................................................. 5
General description...................................................................................................................................................5
Safety regulations .....................................................................................................................................................5
Function description..................................................................................................................................................5
3Connections ........................................................................................................................................ 6
Connection................................................................................................................................................................6
Cable configurations .................................................................................................................................................6
Pin configurations .....................................................................................................................................................6
4Installation and maintenance ............................................................................................................. 7
Installation and maintenance....................................................................................................................................7
Maintenance .............................................................................................................................................................7
Minimum safety distance ..........................................................................................................................................8
5Application examples.......................................................................................................................... 9
6Model overview.................................................................................................................................. 11
Accessories.............................................................................................................................................................11
Dimensions .............................................................................................................................................................11
7Technical data ................................................................................................................................... 12
8EC Declaration of conformity ........................................................................................................... 14

2TLC172249M0201, rev. B 4 www.abb.com/jokabsafety
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1 Introduction
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 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 safety devices and safety locks.
•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
The coded non-contact switches Sense7 are designed to provide position interlock detection for moving gards.
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.
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.
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 mechanical 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-contact 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.
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.

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

2TLC172249M0201, rev. B 7 www.abb.com/jokabsafety
2013-04-10
4 Installation and maintenance
Installation and maintenance
1. The installation of all ABB Jokab Safety interlock switches must be done 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. 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 designed to operate
with most dual channel safety relays to satisfy IEC 60947-5-3 PDF-S.
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 than
30mm. 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.
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 ensuring
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 cannot be re-started when
each switch is open.
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.

2TLC172249M0201, rev. B 8 www.abb.com/jokabsafety
2013-04-10
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. including
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. B 9 www.abb.com/jokabsafety
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5 Application examples
Application example

2TLC172249M0201, rev. B 10 www.abb.com/jokabsafety
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2TLC172249M0201, rev. B 11 www.abb.com/jokabsafety
2013-04-10
6 Model overview
Type Article number 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
Accessories
Type Article number Description
Sense7, actuator 2TLA050040R0211 Spare actuator plastic
Sense7, SS
actuator
2TLA050040R0212 Spare actuator stainless steel
Dimensions
Sense7 Sense7Z
NB: All measurements in millimetres.

2TLC172249M0201, rev. B 12 www.abb.com/jokabsafety
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7 Technical data
Manufacturer
Address ABB AB / JOKAB SAFETY
Varlabergsvägen 11
SE-434 39 Kungsbacka
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
Switching reliability 3.3 x 106operations at 100mA load
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
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 polyester
Sense7Z: Stainless steel 316
Colour Red or stainless steel
Mounting position Any
Mounting bolts 2 x M4 Tightening torque 1.0 Nm

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Safety-related characteristic data and Conformity
Conformity European Machinery Directive 2006/42/EC
EN ISO 12100:2010, EN 1088:1995+A2:2008, EN ISO 13849-1:2008
EN 60947-5-2:2007, EN 60947-5-3:1999+A1:2005
EN ISO 13849-1 Up to PL e, cat. 4 depending on system architecture
EN 62061 Up to SIL3 depending on system architecture
Safety data
PFHD
B10d
Proof test interval (life)
MTTFd
2.52 x 10-8
3,300,000 operations at 100 mA load
47 years
470 years (8 cycles per hour/24 hours per day/365 days)
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. B 14 www.abb.com/jokabsafety
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8 EC Declaration of conformity
ABB AB / JOKAB SAFETY Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden
www.abb.com/jokabsafety

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