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Профессиональный Документы
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Sweden
Global sales
Australia Sensorplex Pty Ltd +61 (03) 9562 6699
Austria Contra GmbH +43 (0)1 278 25 55
Belgium Jokab Safety AB, Sweden +46 (0) 300 67 59 00
Brazil Jokab Safety Div. of ABG +55 41 3643 1384
Canada NCC Electronics LTD. +1 519 735 1106
China Jokab Safety China +86 21 613 242 77
Czech Republic Contra spol. S R.O. +420 5 43 210 046
Denmark Jokab Safety DK A/S +45 44 34 14 54
France Jokab Safety France SAS +33 810 08 36 20
Germany
Jokab Safety (D) GMBH +49 (0) 7424 95865-0
Jokab Safety (D) GMBH Bro Gnzburg +49 (0) 8221 204313 0
Debra GMBH (Cologne) +49 (0) 2234 78898
United Kingdom Jokab Safety (UK) Ltd +44 (0) 1908 261595
USA/Mexico Jokab Safety North America +1 734 595 6087
For other countries see www.jokabsafety.com
www.jokabsafety.com
Innovations in safety
Experience
We have great experience of practical application of safety requirements and standards from both
authorities and production. We represent Sweden in standardisation organisations for machine
safety and we work daily with the practical application of safety requirements in combination with
production requirements.
Systems
We deliver everything from a safety solution to complete safety systems for single machines or
entire production lines. We combine production demands with safety demands for productionfriendly solutions.
Products
We market a complete range of safety products, which makes it easy to build safety systems.
We develop these innovative products continuously. Our extensive program of products, safety
solutions and our long experience in machine safety makes us a safe partner.
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# 1:2007
www.jokabsafety.com
Introduction
Your partner for machine safety, locally and globally. Our products revolutionise the market. Safety history.
Standards and regulations. This is how you choose safety category. Product overview. Explanations of safety terms.
Safety relays
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2
3
Focus, Spot, Look, Bjorn, Focus Wet, Blanking programmer, Connection examples
Sensors/Switches
Eden, JSNY series, Magne, Dalton, Knox
Control devices
3-position device JSHD4, Two-handed control unit Safeball, Foot-operated control device Fox
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Fencing systems
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Componentlist
12
EC Declaration of Conformity
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Flexibility
Programmable
Pluto AS-i
Not programmable
Vital
Dynamic "doubled up"
safety signal that tests a
sensor, for example, 200
times per second.
Pluto All-Master
Safety PLC with static and dynamic
safety inputs.
Master
Safety relay
Double static inputs that
only test the switches
each time they are used.
Slaves
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1:3
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Safety history
Developments of the 70's
Our background in safety started in the seventies when there was a signicant
focus on the safety of manually operated presses, the most dangerous machine
in those days. The probability of loosing a nger or hand while working with these
machines was very high. New safety solutions for both safety devices as well as
for the control systems for presses were developed and introduced on both old
and new machines. We were directly involved in this work through the design of
Two-Hand devices, control systems for presses, making safety inspections for the
Health and Safety authorities and writing regulations for safety of these machines.
This work provided an excellent base for our knowledge in machinery safety.
The numbers of accidents involving presses decreased signicantly during
these years however there is still room for new ideas to enable safety equipment
become more practical and ergonomic.
Developments 2000 Internationally the work on safety has now been intensied within ISO. The
objective is to have the same structure of safety requirements and standards
within ISO as within EN. Jokab Safety is active both internationally and nationally in different standard working groups. The co-operation between countries is
leading to better safety solutions, making it much easier to create safe working
environments around the world.
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www.jokabsafety.com
2007
AS-i
Probus DP
2006
DeviceNet
CANopen
Ethernet
2005
HMI
2004
2003
2002
2001
Vital with dynamic safety circuit
to category 4
Non-contact sensor
Eden
2000
1999
1998
1997
1996
1995
Three-position
switch for robots
1994
9
Quick-Guard aluminium
fencing system
1993
1992
10
Smallest safety
relays JSBT5 and
JSBR4
Stop time
measurement
3-position
devices
1991
11
1990
Timer reset and rst light beam
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1989
1988
First safety relay
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Directives and
Standards
Directives and standards are of great importance for manufacturers of machines and safety components. EU Directives giving
requirements for the minimum level of health and safety are
mandatory for manufacturers to fulfil. In every member country
the Directives are implemented in each countries legislation.
Maskiner som slpps ut p marknaden/tas i drift frn och med
den 29 december 2009 skall flja kraven i det nya maskindirektivet 2006/42/EG.
The objectives of the Machinery Directive, 98/37/EC, are to
maintain, increase and equalise the safety level of machines
within the members of the European Community. Based on
this, the free movement of machines/products between the
countries in this market can be achieved. The Machinery
Directive is developed according to The New Approach
which is based on the following principles
T
he directives give the basic health and safety requirements,
which are mandatory.
D
etailed solutions and technical specifications are found
in harmonised standards.
S
tandards are voluntary to apply, but products designed
according to the harmonised standards will fulfil the basic
safety requirements in the Machinery Directive.
Examples of standards
The Machinery
Directive
EN ISO 12100-1
EN ISO 12100-2
EN ISO 14121-1
EN ISO 13857
EN 349
EN 954-1/EN ISO 13849-1
EN 999
Harmonised standards
98/37/EC
A-standard
Giving basic concepts, principles for design, and general aspects that can
be applied to all machinery
B1-standard
B2-standard
EN ISO 13850
EN1088
EN 60204-1
EN ISO 10218-1
EN 692
EN 693
C-standard
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1
2
2. ... safety components means a component, provided that it is not interchangeable equipment, which
the manufacturer or his authorised representative
established in the Community places on the market
to fulfil a safety function when in use and the failure
or malfunctioning of which endangers the safety or
health of exposed persons.
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CE-marking and Declaration of conformity
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For a machine to be safe it is not enough that the manufacturer has been fulfilling all valid/necessary requirements.
The user of the machine also has requirements to fulfil. For
the use of machinery there is a Directive, 89/655/EEC
(with amendment 96/63/EC and 2001/45/EC). A new
Machinery Directive, 2006/42/EC, will come into force on
29 December 2009.
About CE-marked machinery the Directive gives the following requirement
This means that when repair/changes are made on the machine it shall still fulfil the requirements of the Machinery Directive. This doesnt have to mean that a new CE-marking is
required. (Can be required if the changes are extensive)..
Old machines
"Old" machines
"New" machines
CE-marking +
Declaration of
conformity
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EMC-directive 2004/108/EC
The Machinery Directive
98/37/EC
www.jokabsafety.com
Possibly
more
directives
A well thought-out risk assessment supports manufacturers/users of machines to develop production friendly
safety solutions. One result of this is that the safety components will not be a hindrance. This minimizes the risk of
the safety system being defeated.
Machines in use
Risk assessment must be carried out on all machines that
are in use; CE-marked as well as not CE-marked.
New machines
The following requirement is given by the Machinery Directive
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2
3
4
The standard EN ISO 14121-1 gives guidance on the information required to allow risk assessment to be carried out.
The standard does not point out a specific method to be
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Protection or warning?
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Priority
3. Use guard/safety
Hazard:
devices
Safety
measure:
4. Safe working
Hazard:
routines/information
Safety
measure:
5. Warnings
The possibilities will increase to achieve a well thought-through safety system if each risk is handled
according to the described prioritizing.
Combine the five step method with production friendly thinking.
This can give you e.g.
fast and easy restart of machines after a stop from a safety device
enough space to safely program a robot
places outside the risk area to observe the production
electrically interlocked doors, instead of guards attached with screws, to be able to take the
necessary measures for removing production disturbances
a safety system that is practical for all types of work tasks, even when removing production
disturbances
We have long experience of the practical application of directives and standards from both authorities
and production. We represent Sweden in standardization groups within machine safety and we work daily
with the practical application of safety demands in conjuction with production demands.
1:10
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EN ISO 12100-1
EN ISO 12100-2
EN ISO 13857
Safety of machinery - Safety distances to This standard establishes values for safety distances to prevent danger zones
prevent hazard zones being reached by
being reached by the upper limbs. The distances apply when adequate safety
upper and lower limbs
can be achieved by distances alone.
EN 349
(ISO 13854)
The object of this standard is to enable the user (e.g. standard makers, designers of machinery) to avoid hazards from crushing zones. It specifies minimum
gaps relative to parts of the human body and is applicable when adequate
safety can be achieved by this method.
EN ISO 13850
This standard specifies design principles for emergency stop equipment for
machinery. No account is taken of the nature of the energy source.
EN 574
EN 953
This standard specifies general requirements for the design and construction
of guards provided primarily to protect persons from mechanical hazards.
EN ISO 13849-1
(replaces EN 954-1)
EN ISO 13849-2
This standard specifies the procedures and conditions to be followed for the
validation by analysis and testing of:
the safety functions provided, and
the category achieved of the safety-related parts of the control system in compliance with EN 954-1 (ISO 13849-1), using the design
rationale provided by the designer.
EN 62061
Safety of machinery. Functional safety of The standard defines the safety requirements and guiding principles for the
safety-related electrical, electronic and
design of safety-related electrical/electronic/programmable parts of a control
programmable electronic control systems system.
This standard provides parameters based on values for hand/arm and approach
speeds and the methodology to determine the minimum distances from specific
sensing or actuating devices of protective equipment to a danger zone.
EN 1088
and EN 1088/A1
This standard specifies principles for the design and selection - independent of the nature of the energy source - of interlocking devices associated
with guards. It also provides requirements specifically intended for electrical
interlocking devices. The standard covers the parts of guards which actuate
interlocking devices.
EN 60204-1
Safety of machinery. Electrical equipment This part of IEC 60204 applies to the application of electrical and electronic
of machines. General requirements
equipment and systems to machines not portable by hand while working,
including a group of machines working together in a co-ordinated manner
but excluding higher level systems aspects (i.e. communications between
systems).
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Key
1 The starting point for evaluating the contribution of the
protective function to risk reduction.
L A low contribution to risk reduction
H A high contribution to risk reduction
PLr The required performance level
1:12
Risk parameters
S Seriousness of the injury
S1 Light (usually temporary) injury
S2 Severe (usually permanent) injury, including fatality
F Frequency and/or exposure time to the source of
risk
F1 Seldom or less often and/or a brief exposure time
F2 Frequent or continuous and/or a long exposure time
P Possibility to avoid or limit injury
P1 Possible under special conditions
P2 Hardly possible
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How do you achieve the performance level (PLr) that is determined by the risk graph?
There are a number of parameters to take into account when designing a certain protection function. These are as follows:
MTTFd for each individual component Mean Time To Failure, dangerous
DC, Diagnostic Coverage to what extent dangerous faults are detected
the structure which categories are to be used for the parts in their protective functions
CCF, Common Cause Failure measures that will be relevant when working with some form of redundancy (for
categories 2,3 and 4)
how the function acts in a fault condition also given by the selected category
systematic fault measures to avoid these in the design
The Performance Level (PL) is expressed as the Probability of Dangerous Failure Per Hour within certain ranges.
Performance Level, PL
PFHD
3x10-6 to <10-5
10-6 to <3x10-6
10-7 to <10-6
10-8 to <10-7
1
2
3
4
5
6
The values of MTTFd, DC and the categories of our products will be given to you when you contact us. In some
cases we can state a PL straight away for a protective
function or part of a protective function.
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Frklaring
PL prestandaniv
1 MTTFd fr varje kanal = lg (kort tid)
2 MTTFd fr varje kanal = medel (medellng tid)
3 MTTFd fr varje kanal = hg (lng tid)
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1:13
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PLlow
Nlow
PL
>3
>2
>2
>3
>3
b
c
d
e
NOTE The calculated values in the table are based on the centre
point of each interval for the respective PL.
Example:
Safety interlock
MTTFd = 100 years
Category 1
PL = c
Safety relay
MTTFd = 600 years
DC = 99.9%
Category 4
PL = e
PLlow is PL = c and Nlow is 1. With the aid of the table one can see that PL for the entire safety function
will be PL = c.
The safety interlock is inherently in category 1 and can never be more than this even if both its contacts
are used to obtain short-circuit supervision of a connaction to the safety relay.
Designers of safety systems can use this simple method. Contact us so that we can give you the performance levels (PL) of our products, and also guide you as to how the performance levels (PL) are to be
calculated for the components that will be connected in order to remove the energy to moving parts.
1:14
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Applying EN 62061
If one chooses to design a safety function in accordance with EN 62061, the level of reliability is expressed as the
Safety Integrity Level, SIL. There are a total of 4 levels, but in the EN 62061 standard SIL 3 is the highest level. SIL also
(similar to the Performance Level PL), is expressed as the Probability of Dangerous Failure Per Hour.
Safety Integrity Level, SIL
10-8 to <10-7
10-7 to <10-6
10-6 to <10-5
1
2
3
Class (Cl)
3-4
5-7
8-10
11-13
14-15
SIL2
SIL2
SIL2
SIL3
SIL3
(OM)
SIL1
SIL2
SIL3
(OM)
SIL1
SIL2
(OM)
SIL1
3
2
1
4
5
OM = Other Measures
The seriousness of injury that can occur is defined at one of
four levels. Class is the addition of the values of frequency
(Fr, stated as a value between 1 and 5, where 5 represents
the highest frequency), probability that a dangerous event
will occur (Pr, stated as a value between 1 and 5, where
5 represents the highest proability) and the possibility
of avoiding or limiting injury (Av, sated as a value of 1, 3
or 5, where 5 represents the least chance of avoiding or
limiting an injury).
The safety function that is to be designed must at least
fulfil the SIL that has been assigned to it in the analysis.
The safety function consists of a number of sub-elements.
Example: a door is interlocked by a non-contact sensor
which is in turn monitored by a Pluto safety PLC, with outputs that break the power to two supervised contactors.
The sensor is sub-element 1, Pluto is sub-element 2 and
the two supervised contactors are sub-element 3. If in the
analysis it has been established that SIL2 shall be used,
every individual sub-element in the safety function must
fulfil the SIL2 requirements. The safety function must then
in its entirety fulfil the SIL2 requirements.
If the SIL requirements are not fulfilled in any of the sub-elements or by the safety function in its entirety, there must be
a re-design.
You will get the PFHD values of our products when you
contact us.
Finally
This is just a brief introduction to the EN ISO 13849-1 and
EN 62061 standards. You are welcome to contact us so
that we can prepare suitable training and guide you in how
to apply the standards to our products.
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Choice of category
It is above all a question of the technique available. Gate operation
equipment can for example be fitted with a monitored interlocking
switch (category 1) or a dynamic sensor (category 4). However,
interlocking circuits with relays and transistors, etc. normally require
solutions in categories 2 4 in order to achieve a higher safety
level than for standard control circuits.
Appendix B to EN954-1 shows an example of how a category
is chosen. The example gives some guidance but has its limitations. The safety category is chosen based on the safety risk of
the machinery. The risk is estimated based on the parameters S,
F and P.
S Severity of injury
S1 Slight (normally reversible) injury
S2 Serious (normally irreversible) injury including death
F Frequency and /or exposure time to the hazard
F1 Seldom to quite often and/or the exposure time is
short
Category
Category 1
All conditions of B apply
Well-tried safety components and safety principles
Components with a greater reliability.
Category 2
All conditions of B apply
Individual supervised components
The safety function may fail
The loss of the safety function is detected by monitoring
Category 3 and 4
All conditions of B apply
The safety function is always retained during a failure
Fig. 1 Method for selecting a safety category for safetyrelated parts of control system. Annex B (informative) of
standard EN 954-1.
1:16
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Door 1
Door 2
Door 3
Dynamic sensors
the safety signal is monitored all the time and a fault directly
leads to a stop signal or with a magnetic switch which has two
independent contact elements which are monitored every time
a gate opens. From the user's perspective the dynamic function
is preferable because several sensors can be connected to
a single safety module and still achieve category 4. Also the
sensors safety function is monitored without having to open
a gate. For a magnetic switch the requirements for category 4
are only fulfilled if one switch per monitoring unit is used and
if the gate is opened regularly.
Since the standard EN 954-1 was written, development has
progressed and the costs to fulfill category 4 have dropped
dramatically. Generally mechanical switches are replaced with
non-contact sensors to increase the reliability of production
equipment. The same goes for the safety side. With electronic
non-contact switches, with a transmitter and a receiver, one
avoids the problems of deterioration and excessive stress
which harm the sensor. For that kind of sensor dynamic
monitoring is required to enable a safe function. This means
that its function is constantly being monitored, hundred of
times per second. The reaction time for a safe stop will then
be the same during a malfunction as during the activation of a
stop (e.g. a gate opening). The monitoring frequency will also
be astronomical compared to that of mechanical switches
and magnetic switches, which are only monitored every time
they are used. In the new EN ISO 13849-1, which will replace
954-1, probability calculations are used together with different
category levels to compare different performance levels. Even
when using EN ISO 13849-1 it can be so that one achieves
reasonably high theoretical reliability with an electromechanical
switch, although this presumes correct installation, proper
use and otherwise ideal conditions. A non-contact switch
instead provides high levels of both theoretical and practical
reliability.
Our conclusion, use dynamic signals!
Our conclusion is that today it is more cost effective, safer and
more reliable to work with dynamic signals to achieve category
4 for sensors and monitoring units. In that case it is also
possible to fulfill the Machinery Directive, 1.2.7. requirement:
A fault in the control circuit logic, or failure of or damage to
the control circuit, must not lead to dangerous situations.
Also one does not have to discuss whether the correct safety
category has been chosen!
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3
4
5
6
7
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*Dynamic monitoring,
Vital/Pluto
*Static monitoring,
e.g. RT6
Interlocked switch
10
Door 1
11
Up to 30 doors (Eden sensors) can be connected to the dynamic
monitoring maintaining category 4.
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A distinguishing feature of all the engineers at Jokab Safety is that they work daily with practical applications of standards
and regulations. This is true for everything from safety components for individual machines to entire deliveries of safety
systems for larger production lines. Within the company there is also a very good knowledge of machine control and
production. We are also represented in standardisation groups which decide on European and International standards
concerning machine safety. Because Jokab Safety is represented globally, we have the knowledge of safety requirements
in different countries.
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Product training
Our unique Pluto Safety PLC gives new and great possibilites to build-up a cost effective and flexible safety
system. With this also comes the demands of higher knowledge. For you as a customer to be able to quickly get
started using Pluto in the most effective way and to learn about its possibilities, we regularly offer trainings at our
local sales offices. In the training course cost is included a Pluto, software for Pluto and full documentation. We
also offer training on the other Jokab Safety products such as the Vital solution, safety relays and light beams/
curtains.
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Consulting
Do you need assistance in CE-marking a machine? Do you want a third party to carry out a risk analysis on a machine
line? Do you have the need of a partner to examine how various regulations effect the safety of your machines?
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Consulting - Contact us
Come to us with your needs and we
will plan with you a suitable project
programme. You can also contact us
with short questions which we can solve
directly over the phone or via e-mail.
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Light beams/light
curtains/scanner
Dynamic circuits
Vital, Pluto and Tina adaptation
Dynamic safety circuits for multiple sensors in accordance
with the highest safety category. Tina converts volt free
contacts to dynamics safety signals, etc.
.
System
Industrial robots for different sectors
Level crossings with barriers
Safety relays
RT-series, JSB-series, safety timers
and expansions relays
Mechanical/Hydraulic presses
Packaging machinery
1:20
Sensors/switches
E-stops
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Safety PLC
Pluto
Profibus DP
AS-i
DeviceNet
CANopen
Smart
Ethernet
HMI
4
5
Control devices
Safeball, JSHD4
and Fox
Protection systems
Programming
Product training
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Fencing system/SafeCAD/
Roller door
Quick-Guard and SafeCad
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Rails/bumpers/mats
Safety contact rails, bumpers and mats.
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Supervised Reset
The input must both be closed and opened before the
outputs of the safety relay are activated. Using this
method both the reset device and the interconnecting
cable are supervised.
Contact Strip/Mat
Contact Strips/Mats can be supervised by a true two
input channel safety relay. A stop signal being generated
when both inputs are connected (shortcircuited) to
each other.
Test
The input is used to supervise contactors and valves,
and must be closed before the safety relay can be
reset. It can also be used as a simple form of reset only
requiring a contact closure. In this case however, the
risk of short circuit must be prevented and the reset
device supervised separately.
Brake Strip
When a Brake Strip is squeezed the contacts within
the strip are forced open and provides a stop signal via
a suitable safety relay.
Time Reset
This is used to prevent unintentional reset when
somebody is in the risk area. Within a guaranteed
maximum time two or more reset push buttons must be
activated. The PBs must be placed in such physical
positions so that the users can overview the total
danger area. The Time Reset function can be achieved
using a JSHT1 in combination with a safety relay
incorporating a supervised reset.
Delayed Safety Stop
Where it is permissable to allow a machine to stop
before disconnection of power, it is necessary to
achieve a Delayed Safety Stop. The delay period being
the time between the initiation of the stop signal and the
opening of the safety contacts. The time delay must be
designed in such a way that it will not increase in time
in the case of a component failure. This type of delay
is permitted, dependant upon risk assessment, for both
emergency stops and other safety devices.
Bypass Connection
This is sometimes permissible where it is required to,
e.g., allow material transport into a dangerous area. The
Bypass Connection must be of the same safety level as
the safety device being bypassed.
Time Bypass Connection
This is the provision of a guaranteed maximum time
for the transportation of material or passing with an
enabling device.
Inching
Inching requires safety outputs to be closed for a
maximum period of time allowing the machine to
move only a short distance each time the inching
control is activated. The time must be designed so
that the specified time will not increase in the case of
component failure.
Three Position Enabling/Hold to Run Device
These devices are used during trouble shooting or
testing of machines. If the device push button is pressed
into its bottom position or released completely a safe
duplicated stop signal is given. JOKAB SAFETYs
Three Position Devices have duplicated switches and
are supervised by a true two input channel safety relay.
1:22
Interlocked Hatch
When a Interlocked Hatch is opened an interlock
device gives a stop signal via a safety relay. If the hatch
cannot be entered by a human body automatic reset
can be allowed.
Interlocked Gate
When a Interlocked Gate is opened an interlock device
gives a stop signal via a safety relay. If the gate can
be passed by a human body a safety relay with a
supervised reset should be used.
Foot Pedal
A safety foot operated switch is used when the operator
has to have both hands free. Safety relays can be
used to supervise Foot Pedals to ensure both correct
operation and to ensure shortcircuits in connecting
cables do not cause unintentional start signals.
Two Hand Control
This requires the use of a safety relay to supervise
that the two start push buttons are pressed within 0.5
sec of each other before a start signal is allowed. The
highest safety level requires two contacts in each PB,
a duplicated stop function being given even if only one
PB is released (see JSBR4). Shortcircuits between
connecting wires are detected automatically. In the
lower safety level other safety relays can be used.
Emergency Stop
When an Emergency Stop push button is activated
a stop signal is given via a safety relay. Reset of the
Emergency Stop device should not by itself lead to a
start signal being given.
Machine I/O
All types of machines have a need to interface to
emergency stops, contactors and other types of safety
devices. Approved safety relays make this easy to
perform.
True Two Channel
True Two Channel requires two inputs with different
voltages to be closed before the safety relay can be
activated. A stop signal is given even if only one input
is opened or a short circuit is detected across the
inputs.
www.jokabsafety.com
Pluto/Gateway/Encoder
AS-i
Probus DP
DeviceNet
CANopen
Ethernet
20 I/O
12 I/O
(A/D)
46 I/O
HMI
Pluto Manager
www.jokabsafety.com
Contents
Page
2
3
2:14
2:16
2:18
2:20
2:22
4
5
8
9
10
11
12
Descriptions and examples in this book show how the products work and can be used. This does not mean that they can meet the requirements for
all types of machines and processes. The purchaser/user is responsible for ensuring that the product is installed and used in accordance with the
applicable regulations and standards. We reserve the right to make changes in products and product sheets without previous notice. For the latest
updates, refer to www.jokabsafety.com. 2008.
www.jokabsafety.com
2:1
13
Approval:
EN 954-1, Category 4
EN 61496-1, Type 4
%. 3),
Pluto All-Master
Pluto All-Master
Pluto All-Master
Safe bus
Slaves
2:2
!3
I SAFETY
nodes
)/
Master
www.jokabsafety.com
Pluto AS-i
)/
)/
Light beams
Sensors/
switches
Most safety devices on the market can be connected directly to Pluto units. By using dynamic signals with sensors
from Jokab Safety only one input is needed for category 4,
COMPARED TO TWO INPUTS FOR OTHER MANUFACTURERSg 0,#S )T
is also possible to connect up to 10 sensors in series to a
single input on Pluto according to category 4.
Two-hand
controls
Emergency
stops
Strips
Mats
3
4
to save on inputs!
Dynamic signals
110 doors with one Eden per door
category 4
Dynamic signals
1-10 sensors
category 4
5
6
PU
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