Safety Roller Door RD344

ABB Jokab Safety Varlabergsvägen 11, SE-434 39 Kungsbacka, Swedenwww.abb.com/jokabsafety

2TLC172213M0201, rev. B

Original instructions

Safety Roller Door RD344Roller door with safe interlocking

2TLC172213M0201, rev. B 2 www.abb.com/jokabsafety

Read and understand this documentPlease 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.

www.abb.com/jokabsafety 3 2TLC172213M0201, rev. B

Table of Contents1 Introduction .......................................................................................................................5 Scope.............................................................................................................................................................5 Audience ....................................................................................................................................................... 5 Prerequisites ................................................................................................................................................. 5 Special notes ................................................................................................................................................. 5

2 Preparations before installation ......................................................................................6 Check the manual and the parts of the door ................................................................................................. 6 Space needed for the door ............................................................................................................................ 7 Safety distance .............................................................................................................................................. 7 Important safety information .......................................................................................................................... 7 To lift/move the door and its parts ......................................................................................................................................................... 8

3 Description of the roller door safety devices .................................................................9

4 Mechanical installation ...................................................................................................10 Exploded view with parts list ....................................................................................................................... 10 Fixing points ................................................................................................................................................ 13 Mounting instructions, step by step ............................................................................................................. 14 Step 1 – Frame ................................................................................................................................................................................... 14 Step 2 – Back Plate............................................................................................................................................................................. 14 Step 3 – Aligning ................................................................................................................................................................................. 14 Step 4 – Attachment ............................................................................................................................................................................ 14 Step 5 – Fit the drive unit .................................................................................................................................................................... 15 Step 6 – Roller package ...................................................................................................................................................................... 15 Step 7 – Centering .............................................................................................................................................................................. 16

5 Electrical installation ......................................................................................................17 Cable requirements ..................................................................................................................................... 17 Electrical conditions .................................................................................................................................... 17 Electrical installation, step-by-step .............................................................................................................. 17 Step 8 – Drive unit............................................................................................................................................................................... 17 Step 9 – Electrical cabinet................................................................................................................................................................... 18

6 Adjustments, testing and mounting of cover plates ....................................................19 Final installation, step-by-step ..................................................................................................................... 19 Step 10 – Adjustment of the lower stop position ................................................................................................................................. 19 Step 11 – Adjustment of the upper stop position ................................................................................................................................. 19 Step 12 – Test run the door ................................................................................................................................................................. 20 Step 13 – Adjustment of Eden sensors ............................................................................................................................................... 20 Step 14 – Fronts.................................................................................................................................................................................. 20

Stand for mounting ...................................................................................................................................... 21

7 Checklist for mechanical and electrical installation, test run and adjustments .......22

8 Troubleshooting ..............................................................................................................23


9 Maintenance.....................................................................................................................24

10 Technical data ..................................................................................................................25

11 EC Declaration of Conformity ........................................................................................26

12 Connection examples .....................................................................................................27


1 IntroductionScope

These instructions contain information on the efficiency in the use of Safety Roller Door RD344 in accordance with the intended applications. These instructions constitute a part of the scope of the delivery.

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.


2 Preparations before installation

Check the manual and the parts of the door

Figure 2.1 - Tools that will be needed.

Check

• that the width and height of the supplied door match the actual opening (see section 1.2).

• when mounting the door in ABB JOKAB Safety’s Quick Guard system; that necessary parts of the fencing system are at hand.

• when mounting the door in other types of guarding or fixture; that it is of suitable strength and capable of rigidly supporting the door (see section 2.2)

• that all components (according to delivery note) are at hand and undamaged, see parts list section 4.1.

NB! When installing the door it is of vital importance that the frame columns are erected absolutely vertically and the top roll perfectly horizontal.

Warning! Read through the manual before mounting the door.

Warning! Electrical installations must be carried out by trained personnel only


Space needed for the door

Safety distanceThe door must be placed in front of the machine/machines in such a way that the safety distance is fulfilled. The standard EN ISO 13855 ”Safety of machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body” gives the requirements especially for trip devices but could also be used as guidance when installing a Safety Roller Door. The installer has the responsibility to place the Safety Roller Door with such distance that all moving parts are stopped in a safe way when the operator reaches them.

Important safety informationWhen the door is mounted in front of a machine and the operator can pass the door and go into the machine, the door must be prevented from being closed and the machine being started while the operator is inside the machine area. One way of doing this, is to install a horizontal light curtain/s to protect the area/s where the operator can stand in the machine. Another way of securing that nobody is inside the risk area, when the door is to be operated downwards, is by timed reset. A facility like this is not a part of door and has to be ordered separately. Contact ABB/JOKAB Safety for more information.

If the door is going to be used as control guard it must be installed according to the requirements in EN 953 “Safety of machinery – General requirements for the design and construction of fixed and movable guards” (see clause 5.4.9).

DH

DW

450

180

80

A

A

D D

365

570

290

120

255

B

SECTION A-A SCALE 1 : 10

27

48

DETAIL B SCALE 1 : 2

SECTION D-D SCALE 1 : 2


To lift/move the door and its parts

How to safely lift the top roll

• Attach two slings, which are adequately rated and approved to lift the roll weight (Minimum 150 kg lifting capacity), around the top roll. Place the slings so that the top roll can be lifted securely and in balance without risk of tipping or dropping.

• Use lifting equipment that is approved and suitable for the size and weight of the top roll.

Fasten the frames when dismantling

• When the frames have to be dismantled the upper parts must be secured with appropriate lifting equipment.

Fasten the drive unit when mounting/dismantling

• When the drive unit is to be mounted/dismantled it must be secured in appropriate lifting equipment.

Caution! Never lift the top roll, placed on a pallet unless the top roll is securely fixed.


3 Description of the roller door safety devicesTo monitor the position of the door blade, the door is equipped with two PL e/Category 4 Eden sensors (contact free) in both sides of its frame. When the door is closed the Eden sensors are actuated and the machine is ready to be restarted. When the door starts to open, a stop signal is sent to the machine.

As the door has Eden sensors on both sides, this prevents the door being lifted or pushed to one side without a stop signal being given to the machine.

To protect personnel from being injured by the door it is equipped with a contact strip on the bottom beam profile. If the door hits a person the contact strip will be actuated, and the control system will reverse the door to its fully open position.


4 Mechanical installation

Exploded view with parts list

Figure 4.1 - Exploded view

04

02

0506

15

20

19

24

31

29

23

34 35

40

38

37

25

33

0910

11

22

03

18

26

27 28

32

30

36

13

12

05

01

0708

17

21

04

30

4241

44

43

39

3442

2511

14

49

48

61 6260

45 9347

72

56

51

46

59

63

68

69

16

71

67

74

70

74

57

57

57

OPTION

73

5453

52

55

38

46

50

64

6665

85

7779

78

848081

75

88

87 86

89

90

8283

76

91 92


Pos No Title Note

01 1 Motor cover Right / left

02 1 Roller cover

03 1 Wall

04 2 Axle assembly

05 2 Bearing plate

06 1 Bearing

07 1 Roller

08 1 Roller moulding

09 1 Upper wall mounting Right

10 1 Frame profile Right

11 2 Frame reinforcement

12 1 Drive unit

13 1 Motor plate

14 4 Motor spacer

15 1 Upper wall mounting Left

16 2 Brush

17 1 Back plate

18 2 Guide wheel

19 1 Cover profile Left

20 1 Frame profile Left

21 1 Electrical cabinet

22 1 Cover profile Right

23 1 Beam profile

24 1 Door leaf

25 2 Guide fitting

26 1 Attachment bracket, cable chain

27 8 Screw MFT-TT M6x20

28 2 Decorative moulding (JSM T3)

29 1 Anti-crush guard rubber

30 2 Fork bracket

31 1 Contact strip

32 2 Eden safety switch, EVA part

33 2 Cable chain, end piece

34 2 Adjustment plate

35 1 Fork moulding Left

36 1 Lower wall mounting Right

37 1 Cable chain

38 4 Decorative moulding, frame (JSM T3)

39 1 Fork mounting Right

Pos No Title Note

40 1 Lower wall mounting Left

41 2 Eden safety switch, ADAM part

42 2 End position damper

43 1 End piece, 2 m cable

44 1 End piece, 2 m cable

45 2 ULG joint clamp

46 2 Sealing strip 17

47 1 Cable, chain flex.

48 1 Motor cable

49 1 Limit position, cable

50 1 Supply cable

51 1 Handle Std extension with universal joint, gfa

52 1 Bend protection

53 1 Screw

54 1 Cable clamp

55 1 Spiral cable

56 1 Mounting bracket, motor cover

57 6 Screw

58 6 Nut

59 4 Screw

60 1 Key 7x8x100 / 6x6x95

61 12 Screw roller

62 20 Rivet

63 4 Screw M6x20

64 1 Main switch

65 1 Foil pressure

66 1 Emergency stop

67 6 Screw KT6 M6x20

68 4 Screw M6S M8x16



71 2 Screw M4x12

72 2 Screw MRX M3x6

73 2 Screw MRX M3x10

74 2 Nut Hexflange M6

75 4 Screw KT6 M6x6

76 2 Screw KT6 M6x6



79 3 Washer BRB 8.4


Pos No Title Note


81 2 Nut

82 6 Nut

83 2 Screw MLC6S M4x12

84 1 Manufacturing sign

85 1 Back plate, motor cover Option

86 1 Nut

87 1 Screw MF6S M8x16

88 1 Velcro fastener


90 1 Nut


92 1 Nut


Fixing points

120

263

250

148

125

DW

DH

+450

80

252

DH

A

B

9C

25

175

35

13

DETAIL A SCALE 1 : 2

DW75

36

11

DETAIL B SCALE 1 : 2

60

11

36DETAIL C

SCALE 1 : 2

DW

100


Mounting instructions, step by stepAll position numbers refer to the exploded view. See ”Figure 4.1 - Exploded view”.

Warning! Follow the instructions precisely when mounting the door. Not doing so runs the risk of the door falling down with personal injuries as a result.

Step 4 – Attachment

The lower holes require a long drill (150 mm). Screw the door tight in the wall. Use the pre-drilled holes and at least M10 screws in the upper wall attachments (09/15) and the lower wall attachments (36/40). See ”Figure 4.4”.

Step 3 – Aligning

Align the door using a spirit level or an aligning instrument and check that the top seal is horizontal and that the frames are vertical.

Step 2 – Back Plate

Mount the back plate (17) against the wall mountings’ upper edge. The back plate determines the distance between the frames. See ”Figure 4.3”.

Step 1 – Frame

Remove the cover profiles 19 and 22 from frame profiles 10 and 20. Raise both frames, right and left respectively (10/20), against the wall on the respective sides of the door opening and attach them temporarily with the help of screw clamps. See ”Figure 4.2”. Protect the frame profiles to prevent scratches.

17

Figure 4.3

2010

Figure 4.2

Figure 4.4


Step 5 – Fit the drive unit

The drive unit can be fitted on either the left side or the right side. Fit the motor attachment (13) on the gearbox. Use the thread lock on the screw’s threads. See ”Figure 4.5”.

Mount the bearing plate (05) on the motor plate using motor spacers (14) and screw (68) See ”Figure 4.6”.

Place the key in the axle’s key slot, slide the motor onto the axle.

Figure 4.5 Figure 4.6

Step 6 – Roller package

• Mount the bearing plate with bearing on the “non-motor side”. See ”Figure 4.7”. The screws for the bearing shall not be tightened.

• Unscrew the two lower attachment screws on the bearing plate but leave the upper screw slightly loose so that it fits against the upper wall mounting. See ”Figure 4.7”.

• Lift the roller into position with the bearing side first. Lower the roller so that the screw in the bearing plate fits into the wall mounting’s long hole (place the bearing plate on the inside of the wall mountings).

• Fit the other four screws in the bearing plate and wall mounting. Remove the strap that secures the roller. Slide in the door fabric and guides in the frame. Fit the side with the safety sensor first. See ”Figure 4.8”.

07

06

05



Step 7 – Centering

• Check that the roller package is centred between the frames’ wall attachments. See ”Figure 4.9”. If necessary, adjust the roller laterally by carefully bending between the bearing plate and roller.

• Install the bearing’s excenter-locking ring on the “non-motor side” and turn clockwise. Lock the locking ring by knocking it with hard blows for ½ - ¾ turn. Use a drift that is inserted in a pre-drilled hole. Tighten the locking screw. See ”Figure 4.10a-d”.

• Tighten all the screws in the bearing.

same distance locking ring with locking screw

Figure 4.9 Figure 4.10a Figure 4.10b

1/2 - 3/4

Figure 4.10c Figure 4.10d


5 Electrical installation

Cable requirementsElectrical supply via 5 conductor cable, 3 phase, neutral, ground (min 1.5 mm2).

Cable

Colour marked cables

• 4 core (1.5 mm2) cable + earth for motor

• 8/10 core (0.75 mm2) cable for cam switches and safety circuits

• 4 core (0.50 mm2) cable for contact strip. (Spiral Cable supplied)

• 6/8/10 core (0.50 mm2) cable for up/down/stop controls

• 4 core (0.50 mm2) cable for machine interface

Electrical conditionsElectrical supply needed for the Safety Roller Door is 3 phase, 3 x 400V or 3 x 230V. Motors for other voltage levels can be ordered.

• The drive unit has an electromagnetic brake, oil-cooled gearbox, thermo fuse and built in cam-box.

• Motor and connection blocks are protected according to IP54. Always use screw caps that preserve the IP class. (If the door is mounted in such a position that the drive unit could be affected by rain or wash-down then the motor should be fitted with an additional cover).

• Control voltage is 24 VDC.

Electrical installation, step-by-step

Step 8 – Drive unit

Connecting the motor:

• Check that the motor is marked as follows: 360-415/208-240 Volt. (3-phase system)

• If the supply voltage is 360-425 V the motor shall be Y-connected. See ”Figure 5.1 - Y-connection”.

• If the supply voltage is 208-240 V the motor shall be D-connected. See ”Figure 5.2 - D-connection”.

1 2 3

U2

V2 W2

U1 V1 W1

Y U V W1 2 3

U2 V2W2

U1 V1 W1

Y U V W

Figure 5.1 - Y-connection Figure 5.2 - D-connection

NB! Before phase sequence (the rotation direction of the motor) is checked by running the door short distances, always initially, place the door in an half open position by using the motor crank. Then follow the instructions in ”Step 12 – Test run the door”.


Step 9 – Electrical cabinet

Make the connections as follows. See chapter 11 ”Connection examples”.

Connection block Equipment

L1, L2, L3 Electrical supply

N, PE Neutral, Earth

1-4 (X1) Supply for motor

3-4 (X3) Connection of external button/signal for controlling door movement upwards

5-6 (X3) Connection of external button/signal for controlling door movement downwards

7-8 (X3) Connection of external button/signal for stopping the door

20 (X3) Reset button

21 (X3) Reset button

22 (X3) Lamp in reset button

23-27 (X3) Eden 1. Safety switch for supervision of closed position of the door.

28-32 (X3) Eden 2. Safety switch for supervision of closed position of the door.

33-36 (X3) Connection of contact strip

37-44 (X3) Option: Focus II Receiver M12

45-48 (X3) Option: Focus II Transmitter M12

50-51 Safety output; to be connected to the machine

52-53 Safety output; to be connected to the machine


6 Adjustments, testing and mounting of cover plates

Final installation, step-by-step

Step 10 – Adjustment of the lower stop position

Remove the cover of the cam switch box. In the box are the cam plates that set the cam switches. Check that the bolts fixing the bracket holding the cam switches are fully tightened.

To operate the door; use the crank and put it in the location in the bottom of the motor. Disengage the brake with the brake handle and turn the crank.

Follow the steps thoroughly to adjust the lower stop position. See ”Figure 6.1 - Cam switch”.

• Put the door in closed position.

• Turn the cam plate 1 for the “CLOSE” cam switch so that the cam is positioned in front of the switch 2 . Tighten the locking screw 3 with an Allen key.

• Operate the door to a half open position.

• Close the door again.

• Fine adjust the “CLOSE” stop position by turning the adjustment screw 4 .

• The “CLOSE SAFETY” cam switch follows the adjustments made on the “CLOSE” cam switch. Fine adjustments can be made on “CLOSE SAFETY” by turning the adjustment screw 4 .

3

2

1

4

1

2

3

4

Cam

Switch

Lock screw

Adjustments

Figure 6.1 - Cam switch

Step 11 – Adjustment of the upper stop position

Operate the door to the fully open position and adjust the “OPEN” and “OPEN SAFETY” cam switches in the same way as in step 10.

Important! The “OPEN” cam switch should be adjusted so that a distance of 60 mm is left between the upper part of the bottom beam profile and the top cover (02). The reason for this is to minimize the risk for personal injuries of squeezing hands or fingers between the bottom beam and top cover.

Warning! The following steps must be carried out with with the electrical supply isolated from the door motor and controls.


Step 12 – Test run the door

Place the door in the half open position by using the crank. Then remove the crank and connect the electrical supply to the door.

• Push the “OPEN ” (S21) button (if fitted) on the control panel. Stop the door immediately by pushing the “STOP” button (S22).

- If the door is moving upwards the phases are connected correct.

- If the door moves downwards two phases have to change places on the connection blocks (1, 2, 3).

• Always finally adjust the limit position cams in small steps to ensure that the door does not go past its end positions and is damaged. Disconnect all external “OPEN” signals. Release the emergency stop but be prepared to stop the door if necessary.

Step 13 – Adjustment of Eden sensors

• Push the “CLOSE ” (S23) button on the control panel to close the door.

• Adjust both adjustment plates (34) until the door’s guide rails (25) rest in the bottom of both the fork brackets (30). The locking head (32) is mounted on the guide fitting’s right or left sides. See ”Figure 6.2”.

• Adjust the Eden ADAM sensor (41) so that it is positioned opposite the Eden EVA sensor at a distance of no more than 8 mm. See ”Figure 6.3”.

• Check that the two parts of the Eden sensor cannot physically collide when the door is manoeuvred up or down.

• Manoeuvre the door to its end positions several times and check that the safety equipment receives a signal when the door is in its closed position.

• Mount the front frame cover (19/22)

32

41

25

30

2-8 mm


Step 14 – Fronts

• Lift the front (02) into position and screw it against the bearing plates’ collar.

• Mount the motor cover (01) on the motor, and wall (03) on the non-motor side.

• Install the cable duct protection and decorative moulding (38) for the frame cover.


Stand for mountingCan be ordered separately for the Safety Roller Doors.

DH+4

50

DW

400

DW+160A

A

D D

H

VKR 80x40x3

VKR 40x40x2

VKR 40x40x2

VKR 40x40x2

Pls 80x8x300

VKR 40x40x2

Pls 40x6VKR 40x40x2

Drawing showing no pre-drilled hole for door frame

E

SECTION A-A SCALE 1 : 10 30

0

80

F

SECTION D-D SCALE 1 : 10

100

200

12

20

12

DETAIL E SCALE 1 : 5

50

20

110

120 20 17

DETAIL F SCALE 1 : 5

DETAIL H SCALE 1 : 5


7 Checklist for mechanical and electrical installation, test run and adjustments

Company Date

Type Idendification number

Measure Check Comment

Check that bolts and rubber mounts for the drive unit are securely fixed.

Check that cam switches for door open and closed are correctly adjusted.

Check that the door in its upper stop position leaves a minimum distance of 60 mm between the upper part of the bottom beam and the top cover.

Check that control signals/customer connected push puttons are installed and function correctly (e.g. correct direction of motion).

Check that the contact strip is connected correctly and makes the door move to its fully open position when actuated.

Check that the Eden sensors are correctly adjusted.

Check that machine/machines inside risk area is stopped correctly when door leaves its bottom position.

Check that chosen safety distance is fulfilled and sufficient for the machinery to stop before operator can reach moving parts.


8 TroubleshootingOperating the door when electrical supply is disconnected

The door can be opened/closed manually by the crank for the drive unit. Place the crank in the tap in the bottom of the motor. Disengage the brake by pulling the brake handle and turn the crank at the same time.

Warning! When the crank is placed in the tap in the bottom of the motor the electrical supply to the motor is automatically switched off. Electrical supply to the door should always be switched off via the line circuit breaker before the door is operated by the crank.

Error indication Eden sensors

The LED has the following states:

LED Indication Description

LED on Eden

Green Eva within range, safety circuit closed; door closed.

Green-Red (flashing) Eva within range; the door is closed but the signal is not OK.

Red Eva out of range, safety circuit open; door open.


9 MaintenanceCompany Date

Type Idendification number

Daily checks:


Check that bolts and rubber mounts for the drive unit are securely fixed.

Check that the door reverses to its upper position when the contact strip is actuated.

Look for oil leaks from gearbox and shaft,

Check that the door is undamaged.

Check that the door is working correctly according to door controls.

Monthly checks (or every 40,000 cycles interval):

NB: Checks according to daily checks together with the following checks.


Check the brake performance and cam switch settings by checking that

• the door when stopping at its upper stop position leaves a distance of 60 mm between the upper part of the bottom beam and the top cover,

• the door blade does not get crinkled in the bottom position


10 Technical dataManufacturer

Address ABB JOKAB SAFETY Varlabergsvägen 11 434 39 Kungsbacka Sweden

Ordering data Safety Roller door + viewing window. Viewing window with weld splash protection. Daylight height & Daylight width.

Mechanical characteristics

Maximum size, door cloth 10 m² If a larger size is needed, contact ABB Jokab Safety AB.

Maximum width 4000 mm

Maximum height 3500 mm

Speed, roller door 0.7 – 1.0 m/s up/down

Max. number of cycles/minute 3 (during continous operation 24 hours a day)

Material frames Aluminum extrusion

Material upper bracket 4 mm steel painted black

Electrical characteristics

Driving unit Three-phase motor 200-415 VAC 50-60 Hz

General

Protection class Motor and gearbox are delivered with IP54 rating.

Colour Frame - aluminium, door cloth - grey Other colours available on request.

Door fabric material Multi-layer polyester fabric cloth with PVC, 2 mm thick or transparent PVC. The viewing window can also be supplied with protection against welding flash light. (Removes 99% of the UV-transmision from the welding process)

Door fabric colour Grey (RAL 7038), can be supplied with recessed window (only in full width). Other colours are available.

Sound absorption approx. 10 dB

Ambient temperature 0˚C to +55˚ When operating in temperatures below -5˚C, the oil in the gear-box should be replaced with an oil suitable to withstand cold temperatures.

Durability towards chemicals Ammoniac, sodium hydrate, phosphoric acid, tartaric acid, oxalic acid, hydrochloric acid, citric acid, acetic acid, oil, detergent, calcium chloride (contact ABB Jokab Safety for more specifications)

Safety

Control monitoring unit for roller door

ABB Jokab Safety´s Safety-PLC, Pluto

Outputs 4 safe outputs for connection to machine/plant.

Monitoring of position of the roller door

2 Eden sensors one on each side of the door.

Contact strip Mounted on the bottom frame of the door fabric. The door motion is reversed if the contact strip is compressed.

Safety level Category 4/PL e, in accordance with EN ISO 13849-1


11 EC Declaration of Conformity

www.abb.com www.jokabsafety.com

Original

EC Declaration of conformity (According to 2006/42/EC, Annex 2A)

We ABB AB JOKAB Safety Varlabergsvägen 11 434 39 Kungsbacka Sweden

declare that the safety components of ABB AB make with type designations and safety functions as listed below, are in conformity with the Directives 2006/42/EC 2006/95/EC 2004/108/EC

Authorised to compile the technical file

ABB AB JOKAB Safety Varlabergsvägen 11 SE-434 39 Kungsbacka Sweden

ProductSafety Roller Door with monitoring of closed position by contact free sensor Eden and safety-PLC Pluto

Safety Roller Door 344 / 350 / 700

Used harmonized standards EN ISO 12100:2010, EN ISO 13849-1:2008, EN 62061:2005, EN 60204-1:2006+A1:2009, EN 60664-1:2007, EN 61000-6-2:2005, EN 61000-6-4:2007, EN 61000-4-1…6, EN 50178:1997, EN 1088+A2:2008

Other used standards EN 61508:2010

Jesper Kristensson PRU Manager Kungsbacka 2012-01-18


12 Connection examples

432

X1

1

X1

L1 NL3L2 PE

G1

AC

AC

+ -

FRONT DOOR

M1

U W V

M Y1

X13

U V W N

S1

12

34

56

K1

12

34

56

K2

12

34

56

0V

24V

F1

Anmärkning Remark

1 2 3 4 5

Godk Appr

Sidor Pages

Konstr Design

Ritad Drawn Ritn nr Drawing no

Datum Date

Forts Cont

Blad Sheet

6 7 8 9 10

StandardSafety RollerDoorRullport

RD100010JS

JS 031113 1

2

230/24VDCJSN1A

2 3 4 5

A1 A2 + -

Anmärkning Remark

1 2 3 4 5

Godk Appr

Sidor Pages

Konstr Design


Datum Date

Forts Cont

Blad Sheet

6 7 8 9 10


RD100011JS

JS 031113 2

3

0V

X3

1325

F1

12

9

S2

12

2826

27

S10

12

S22

2122

24V

21

S1

12

4

Upp

S21

1314

Ner

S23

1314

X3

146

S3

12

5

8

X3

15

S4

12

7

1611

1712

S5

12

0V

18 19

14 15S6

12

24V

IQ12

3/1

IQ11

3/1

IQ15

3/2

IQ16

3/2

56

S24

1314

87

S26

1314

X3

4

S25

2122

X3

3

Panel

Extern

Panel

Extern Extern

Panel


35

53

0V

PLUTO A202L Q011L Q00

dyn

A

X3

50 51 52

21

K1

20

Reset

22

A1

+24V

X3

23 272524 2621 53 4

76 8

X3

33 34

3128 29 30 32

whi

te

whi

te

brow

n

S28 S29 S30 S31 S27

39

9

36 3837 444140 42 43 45

brow

n

46 47 4948

FocusTransmitter

FocusReceiver

2122

2122

K1

K2

K2

IQ12

2/6

IQ11

2/4

IQ15

2/4

IQ16

2/6

A2

Anmärkning Remark

1 2 3 4 5

Godk Appr

Sidor Pages

Konstr Design


Datum Date

Forts Cont

Blad Sheet

6 7 8 9 10


RD100012JS

JS 20110620 3

4

SAFETY MAT/ SAFETY STRIP

IQ15IQ12IQ10 IQ11 IQ13 IQ14 IQ16 IQ17 Q02 Q03

I5

JOKAB SAFETYType: PLUTO B20

+24V

24VDC

0V ID CL CH I2I0 I1 I3 I4 I6 I7

Tina

7A

2w

hite

brow

n 1

blue

blac

k

3 4

grey

5

blue

whi

te

brow

n 2 1

3

grey

blac

k 4 5

21 43 5

EDEN 1

321 54

EDEN 2

brow

n

blue

grey

whi

te

gree

n

yello

w

red

pink

blue

brow

n

whi

te

blac

k

grey

Option

Option

Q0

2

1

Q1

2

1

0L 1L

EVAADAM ADAM EVA

S1

210 mm

K1 K2

X3

F1 A1T1

380 mm

S22

S23

S21

380 mm

A2

Anmärkning Remark

1 2 3 4 5

Godk Appr

Sidor Pages

Konstr Design


Datum Date

Forts Cont

Blad Sheet

6 7 8 9 10


RD100013JS

JS 031113 4

5


W6

21 3 4

3433 35 36

1 2 3 4 G/G

W8

1 2 3 4 G/G

45 46 47 483937 38 40 4341 42 44

OPTION

FOCUS RECIVER M12

1 2 3 4 G/G

1

W7

2 3 4 G/G5 6 7 8

5 6 7 8

MACHINE

Safety output

PROCESS START

1 2 3 4 G/G

1

W9

2 3 4 G/G

50 51 52 53

FOCUS TRANSMITTER M12

OPTION

OPTION OPTION

2 independent safty output

55

49

Anmärkning Remark

1 2 3 4 5

Godk Appr

Sidor Pages

Konstr Design


Datum Date

Forts Cont

Blad Sheet

6 7 8 9 10


RD100015JS

JS 031113 6

3 1 2 4

Roller DoorSAFETY STRIP


Documents

Safety Roller Door RD344