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SA F E T Y PR OD U CTS

ASK-Series
Product manual Safety Mat
Product Manual

2TLC010047M0201_J ORIGINAL INSTRUCTIONS

 Read and understand this document
Please read and understand this document before using the products. Please contact
ABB for any questions or comments.

Suitability for use

ABB Electrification Sweden AB shall not be responsible for conformity with any stand-
ards, codes, or regulations 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 combi-
nation 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 inter-
ference, 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 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.[Enter year][Select Publish Date]e.g. 8VZZxxxxxxT0000e.g. A,
B, C...

2TLC010047M0201_J ORIGINAL INSTRUCTIONS

 Table of Contents
1 Introduction ............................................................................................................................... 4
1.1 Scope ............................................................................................................................................. 4
1.2 Audience ....................................................................................................................................... 4
1.3 Prerequisites ................................................................................................................................ 4
1.4 Special notes................................................................................................................................ 4

2 Overview ......................................................................................................................................5
2.1 General description .....................................................................................................................5
2.2 Safety regulations........................................................................................................................5

3 Installation and maintenance ....................................................................................................6

3.1 Safety mat – general .................................................................................................................. 6
3.2 Operation principle ..................................................................................................................... 7
3.3 Installation of safety mats ........................................................................................................ 8
3.3.1 Molded ramp .............................................................................................................. 9
3.3.2 Electrical installation ............................................................................................... 11
3.4 Electrical connections............................................................................................................... 12
3.5 Installation precautions ........................................................................................................... 13
3.6 Maintenance ................................................................................................................................ 13

4 Model overview ......................................................................................................................... 14

5 Technical data ........................................................................................................................... 15

6 Declarations of conformity...................................................................................................... 17
6.1 Sentry ........................................................................................................................................... 17
6.2 Pluto .............................................................................................................................................. 19

List of Figures
Figure 1: Safety mat cross section ............................................................................................................ 6
Figure 2: Setup of connected safety mats ............................................................................................... 7
Figure 3: Handling of safety mat............................................................................................................... 8
Figure 4: Dimensions of safety mat ......................................................................................................... 9
Figure 5: Mounting of safety mat ............................................................................................................. 9
Figure 6: Adjustment of safety mat ........................................................................................................ 10
Figure 7: Several safety mats side by side ............................................................................................. 11
Figure 8: M8 Male pin configuration ....................................................................................................... 12
Figure 9: M8 Female pin configuration ................................................................................................... 12
Figure 10: Safety mat electrical view ....................................................................................................... 12

2TLC010047M0201_J ORIGINAL INSTRUCTIONS

1 Introduction

1.1 Scope
The purpose of the product manual is to describe the safety mat and to provide the
necessary information required for installation and use.

1.2 Audience
This document is intended for authorized users.

1.3 Prerequisites
It is assumed that the reader of this document has knowledge of the following:

• Basic knowledge of ABB safety products.

• Knowledge of machine safety.

1.4 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 user.

Caution! Danger of damage to the equipment!

An instruction or procedure which, if not carried out correctly, may
damage the equipment.

Note! Important or explanatory information.

4
2 Overview

2.1 General description

The safety mat is used as personal protection within the hazardous areas around presses,
robots, production lines, machines etc. When connected to a suitable safety control unit,
stepping on the safety mat will immediately be detected causing hazardous machine
movements to be stopped. This is made possible by the detection of electrical contacts
closing within the sandwich construction. The safety mat is provided with a slip-free surface.
The safety mat and its connection cabling are to be monitored by a suitable ABB safety control
unit, Sentry or Pluto.

2.2 Safety regulations

Warning! Carefully read through the entire manual before using the device.

Warning! The devices shall be installed by a trained electrician following the Safety
regulations, standards and the Machinery directive.

Warning! 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.

Warning! 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.

Warning! In case of failure to comply with the instructions or standards, especially

when tampering with and/or modifying the product, any liability is
excluded.

Warning! The safety mat is NOT intended for wheeled vehicles.

Warning! The safety mat is NOT intended for children, or persons weighing < 20 kg.

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3 Installation and maintenance

3.1 Safety mat – general

The safety mat is made up of a sandwich construction; the pressure contact switch
consisting of two conducting sheets separated from each other by a webbed isolating layer.
The internal switching surface is cast into a durable polyurethane to protect against moisture
and is then covered with a top layer of slip-free rubber mat. Attachment to the floor is by
means of a ramped rail. Two cable exits are provided. These cables consist of one M8 male
plug and one M8 female plug in standard construction.

1) Polyurethane incl. structure surface

2) Contact plate 2
3) Isolation layer
4) Contact plate 1

Figure 1: Safety mat cross section

6
3.2 Operation principle
The safety mat is fitted with two two-core connecting cables were both ends are connected
to the safety control unit. Different dynamic signals are used in each of the two cores. This
connection makes a safety circuit where the safety control unit provides the monitoring of
the entire circuit including the cabling route and the safety mat.

The two surfaces of the safety mat make contact when stepped on, causing a short circuit
which is detected by the safety control unit. This immediately causes the safe outputs to be
turned off. The entire switching circuit is at the same time monitored for damage to cables or
manipulation.

If several safety mats are to be connected to one safety control unit, they need to be
connected in series.

1-3) Safety mats

4) Safe output
5) Voltage supply
6) Safety control unit

Figure 2: Setup of connected safety mats

7
3.3 Installation of safety mats
Caution! The safety mats shall not be broken or bent. Safety mats must not be
rolled/twisted or modified in any way. It is also essential that safety mats are
not cut into any shape or shortened following delivery. The mounting surface
must be absolutely even, clean and dry. Safety mats should not be glued on the
bottom.

Warning! The safety mat shall be installed with a minimum safety distance according to
EN ISO 13855.

Place the safety mat in required position with the ground plate downwards. If more than one
safety mat is to be installed, make sure to place the safety mats tight together without space.

Correct! Incorrect!

Figure 3: Handling of safety mat

Safety mats with cast-in rubber edge trim can be secured to the floor by screws straight
through the ramp rail.

The safeguarded area (same as ordered size) on a safety mat with a ramp rail is the dimen-
sions of the safety mat without the ramp rails. Therefore, the width of the edge trim (for ex-
ample 30 mm for mats with cast-in rubber edge trim) must be added for each ramp rail side
to get the over-all dimension for the floor space. The ramp rail serves for fixation to the
ground.

Maximum producible size of a safety mat is 2000 mm x 1250 mm. All dimensions larger than
this must be realized by using several safety mats.

8
3.3.1 Molded ramp

1) Area for safeguard

2) Area for safeguard + 30 mm at each side

Figure 4: Dimensions of safety mat

Cut out the cable output at appropriate side in a way that the cables coming out are not
squeezed or sheared while placing the safety mat afterwards. Place and adjust the safety mat
at the appropriate place. To provide against slipping use suitable screws and dowels on each
side of the safety mat.

3) Cut out
4) Cables

Figure 5: Mounting of safety mat

9
To place several safety mats side by side, the relevant ramp rails have to be cut off. To do this,
cut off the ramp rail with a knife in the given slit (B) (spray the knife and the cutting area with
soapy water (A)).

Figure 6: Adjustment of safety mat

If needed, the ramp rail can be cut off also when safety mats not are joined together.

10
3.3.2 Electrical installation
Connect the safety mat electrically and check connection on the different cores (channels).

5) Connection cable with M8 female and male plug

6) Supplied cables with M8 female and male plug

Figure 7: Several safety mats side by side

11
3.4 Electrical connections

M8-connector:
Figure 8: M8 Male pin configuration 1) Brown connected to pin 1
2) Blue connected to pin 3

Figure 9: M8 Female pin configuration

BROWN BROWN

BLUE BLUE

Figure 10: Safety mat electrical view

The safety mat shall be connected to an ABB Sentry safety relay (USR10 or USR22) or Pluto
safety-PLC (A20, B20, S20, D20, B22, D45, B46, S46, AS-i, B42 AS-i or O2) which monitors the
functionality of the safety mat and detects any disconnections or short-circuits in the lines.
Several safety mats can be connected in series while still retaining the same level of safety.
Note! For maximum safety mat area and maximum number of safety mats, see
section ‘Technical Data’, ‘Mounting’ table.

When pressure is applied, the active surface of the contact area in the safety mat is closed
and the safety output on the safety control unit trips.

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3.5 Installation precautions
Warning! All safety functions shall be tested before starting up the system.

3.6 Maintenance
Warning! The safety functions and the mechanics shall be tested regularly.

Warning! In case of breakdown or damage to the product, contact the nearest ABB
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 will not accept responsibility for failure of the switch functions if the
installation and maintenance requirements shown in this document are not
implemented. These requirements form part of the product warranty.

13
4 Model overview
Order code Description
ASK-1T Cast-in ramp edge trim - Standard sizes
2TLA076310R1000 Safety mat ASK T4 with integrated ramp rail: 1000 x
750 mm, incl. 5+5 m cables
2TLA076310R1100 Safety mat ASK T4 with integrated ramp rail: 1000 x
1000 mm, incl. 5+5 m cables
2TLA076310R1200 Safety mat ASK T4 with integrated ramp rail: 1000 x
1500 mm, incl. 5+5 m cables
ASK-1T Cast-in ramp edge trim - Custom sizes
2TLA076301R0200 Safety mat ASK CM T4 production cost
2TLA076301R0600 Safety mat ASK CM T4 Order code for size (m2) and
two 5 m cables.
Specify dimensions (width x length in mm) in text.
Accessories, Cables
2TLA076900R3200 Safety mat extension cable 2.5 m with straight M8
female + male connector
2TLA076900R3300 Safety mat extension cable 5 m with straight M8
female + male connector

Custom-made safety mats

When ordering a custom-made safety mat, two articles need to be ordered, one order code
for the production cost and one for the square meter. When ordering, the size of the safety
mat needs to be specified (X mm x Y mm).

Example:

One safety mat 0.5 x 0.5m:

Ordering example
2TLA076301R0200 Safety mat ASK CM T4 Production cost 1 pcs
2TLA076301R0600 Safety mat ASK CM T4 0.25 m2 1 pcs á 500 mm x 500 mm

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5 Technical data
Manufacturer
Address ABB Electrification Sweden AB
SE-721 61 Västerås
Sweden
Technical data
Max. area Entire safety mat = 2000 x 1250 mm, 10 m2,
(divided safety mat) Rec. relation max 3:1,
Min. 150 x 150 mm
Height 14 mm
Weight U 24,9 Kg/m2; T 26 Kg/m2
Inactive area Nominally 10 mm from the safety mat ramp rail
Switching force Nominally 150 N (Round body 80 mm)
Max. Pressure 2000 N over Ø 80 mm
Material Black polyurethane
Protection class IP65
Electrical capacity 24 V, 100 mA
Switching cycles min. 1 Mio. (B10D: 2 000 000)
Tested according to EN 13856-1
Response time
Including Sentry < 20 ms
Including Pluto (single Pluto) < 30 ms
Including Pluto incl. Pluto bus Normal condition: < 40 ms
At fault condition: < 70 ms
Ambient air temperature -10 °C to +55 °C
Chemical resistance
Oil, grease Good
Fuel Resistant
Solvent Sufficient
10% acid Resistant
10% alkaline (caustic) solutions Resistant
Cable 2 x 5 m; 2 x 0.34 mm2
PU sheathed
Mechanical life >1.0 x 106 Load shifting

15
 Standard compliance and approvals
European Directives 2006/42/EC
2014/30/EU
2011/65/EU
2015/863
Applied harmonized standards, EN ISO 13856-3:2013
Machinery Directive EN ISO 13849-1:2015, PLd/Cat 4*
EN 62061:2005+A1:2013, SIL CL 2
* According to EN ISO 13849-2:2012, Table D.8, a fault exclusion for that the contacts in a
pressure sensitive device will not close, can be made. This fault exclusion is limited up to
PLd.

Other applied standards

Electrical safety EN 60204-1:2006+A1:2009
Electromagnetic compatibility EN 61326-1:2008
Approvals
TÜV Nord
cULus
Information for use in USA/Canada
Intended use Applications according to NFPA79

Mounting
Cabinet The safety control unit shall be mounted in a
cabinet with IP rating of at least IP54
Maximum cable length Sentry 25 m
Pluto 100 m
Max no. of safety mats/evaluation unit Sentry 10
Pluto N/A (see “Max safety mat area”)
Max safety mat area/evaluation unit Sentry 2.5 m2
Pluto 2 m2

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6 Declarations of conformity

6.1 Sentry

17
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6.2 Pluto

19
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