ABB Knox Original Instructions Manual

ABB Jokab Safety Varlabergsvägen 11, SE-434 39, Sweden

www.abb.com/jokabsafety

Original instructions

Knox

Safety and process lock

2TLC172250M0201, rev. D 2 www.abb.com/jokabsafety
2013-08-12

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.

2TLC172250M0201, rev. D 3 www.abb.com/jokabsafety
2013-08-12

Table of Contents

1 Introduction ......................................................................................................................................... 4

Scope ........................................................................................................................................................................ 4

Audience ................................................................................................................................................................... 4

Prerequisites ............................................................................................................................................................. 4

Special notes ............................................................................................................................................................ 4

2 Overview .............................................................................................................................................. 5

General description ................................................................................................................................................... 5

Safety regulations ..................................................................................................................................................... 5

Function description .................................................................................................................................................. 6

3 Connections ........................................................................................................................................ 7

Connection examples ............................................................................................................................................... 9

4 Installation and maintenance ........................................................................................................... 11

Installation precautions ........................................................................................................................................... 11

Maintenance ........................................................................................................................................................... 11

Assembly – conventional door ................................................................................................................................ 12

Assembly – sliding door .......................................................................................................................................... 16

5 Operation ........................................................................................................................................... 19

Locking: ................................................................................................................................................................... 19

Unlocking: ............................................................................................................................................................... 19

Escape release: ...................................................................................................................................................... 19

Auxiliary release (Knox 1Ax, -1Bx, -1Fx): ............................................................................................................... 19

Maintenances mode ............................................................................................................................................... 20

LED indication ......................................................................................................................................................... 20

6 Model overview .................................................................................................................................. 21

Available models ..................................................................................................................................................... 21

Accessories ............................................................................................................................................................. 22

7 Technical data ................................................................................................................................... 23

Dimensions ............................................................................................................................................................. 24

Hole pattern ............................................................................................................................................................ 26

8 EC Declaration of conformity ........................................................................................................... 27

2TLC172250M0201, rev. D 4 www.abb.com/jokabsafety
2013-08-12

1 Introduction

Scope

The purpose of these instructions is to describe the safety lock Knox and to provide the necessary information
required for assembly, installation, checks and adjustments after installation, and maintenance. The instructions
also include information necessary to connect Knox 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.

2TLC172250M0201, rev. D 5 www.abb.com/jokabsafety
2013-08-12

2 Overview

General description

The safety lock Knox with frame part Knox 2A, is a lock that complies with the highest safety level (two locking bolts
with monitored positions) that can be used both as a safety and a process lock. The locking function is
electronically controlled and is bi-stable, i.e. it retains its position (unlocked/locked) in the event of a power failure.
Connection is made to an 8-pole M12 connector, where dual signals for locking/unlocking are used for safe
operation, i.e. no dangerous situation will occur because of short-circuits or cable breakage.

Knox, with frame part Knox 2X, is a process lock with a built in safety sensor to monitor that door is closed and
locked. While powered, a single locking signal must be applied to keep the device locked. However, the locking
function is bi-stable in case of a power failure, i.e. the lock retains its position (unlocked/locked) if power to the
device is cut off. Connections to Knox 2X is made through a 5-pole M12 connector, with a pin configuration which
allows connection to an Urax unit for easy connection to the AS-i bus.

The handles operate as they would on a normal door apart from the exterior handle also having a reset function,
reducing the need for an extra reset button for this device, and an interior handle that can be used for escape
release when the device is in a locked state. Its design and durability makes the device ideal for harsh
environments as the sensors in the lock are non-contact and the lock is manufactured out of stainless steel.

Shielded cable is recommended between this unit and the rest of the safety circuit.

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.

2TLC172250M0201, rev. D 6 www.abb.com/jokabsafety
2013-08-12

Function description

Handle positions

Open

Door open, outer handle pressed down and escape release handle in horizontal position.

Reset, openable

The safety device is reset but the door is unlocked and can be opened from either side.
Outer handle in upward position and escape release handle turned upwards slightly from
the horizontal position.

Escape release

Door opened by escape release. The door can always be opened from the hazardous
area. The door unlocks and the safety circuit is opened when the escape release is
pressed down. Independent of the outer handle position.

Operational mode

Door is locked and reset, closing the safety circuit (i.e. allowing a process to start). Both
handles on the device are in their upward position. The door can only be opened from
the hazardous area (using the escape release handle) causing the process to stop.

Maintenance mode

The two holes in the locking bolts (one on each bolt) are intended for padlocks to be
fitted during maintenance work within the hazardous area, as an additional measure to
reduce the risk of entrapment.

Opened
Reset, openable

Escape released

Operational mode, locked and reset

2TLC172250M0201, rev. D 7 www.abb.com/jokabsafety
2013-08-12

3 Connections

Electrical connections – Knox 2A

Locking

The internal motor will lock Knox when supplied with 24 VDC, with pin-3 as the positive pole (+) and pin-4 as the
negative pole (-).

The locking signals must be applied for at least 2 seconds or until the dynamic output signal from the Eden sensor
is active. There is no maximum time limit; the locking signals may be applied continuously during the time Knox is
locked.

Unlocking

The internal motor will unlock Knox when supplied with 24 VDC, with pin-3 as the negative pole (-) and pin-4 as the
positive pole (+).

The unlocking signals must be applied for at least 2 seconds. There is no maximum time limit; the unlocking signals
may be applied continuously during the time Knox is unlocked.

NB: Knox 2A will retain its locked/unlocked state when power is cut off.

Warning! All information output signals are non-failsafe and must therefore never be used to control a safety

application. To control a safety application the safe dynamic signals from Eden must be used to determine if a door
is locked or not.

Warning! The system must be connected using a fuse of max 6A.

ADAM

EDEN

Knox 2A

+ 24 V

1 7 6 5 3 4 82

Reset
Sensor

Motor

M12 8-pole male seen

from cable side

M12 8-pole female

seen from cable side

8-pole M12-connector:

1 ) White: Dynamic input signal
2 ) Brown: +24 VDC
3 ) Green: Lock
4 ) Yellow: Lock inverse
5 ) Grey: Information Locked
6 ) Pink: Dynamic output signal
7 ) Blue: 0 VDC

8 ) Red: Information Reset

Caution! All cable colours according to ABB Jokab Safety standard cable.

2TLC172250M0201, rev. D 8 www.abb.com/jokabsafety
2013-08-12

Electrical connections – Knox 2X

Locking

The locking signal at pin-5 must be continuously applied (+24 VDC) to keep the device locked. When the locking
signal is applied, it may take up to 2 seconds for Knox to fully reach the locked state.

Unlocking

Knox will be unlocked when no locking signal is applied. It may take up to 2 seconds until Knox is unlocked.
NB: Knox 2X will retain locked/unlocked state if the device power supply (pin-1 and -3) is cut off.

Warning! The system must be connected using a fuse of max 6A.

ADAM

EDEN

Knox 2X

41 32

Motor

5

M12 5-pole male seen

from cable side

M12 5-pole female

seen from cable side

5-pole M12-connector:

1) Brown: +24 VDC

2) White: Dynamic input signal

3) Blue: 0 VDC

4) Black: Dynamic output signal

5) Grey: Lock (+24 VDC)

Unlock (0 VDC)

Caution! All cable colours according to ABB Jokab Safety standard cable.

2TLC172250M0201, rev. D 9 www.abb.com/jokabsafety
2013-08-12

Connection examples

Connection example – Knox 2A with signal for unlocking from other safety system

NB: The info reset signal is HIGH when the outer handle on Knox is set in its upward position.
NB: The system will lock Knox if there is no signal for unlocking.
NB: Vital 1 is used to monitor the locking

Warning! The system must be connected using a fuse of max 6A.
Warning! Signal for unlocking must be a safe signal from system in the same enclosure.

ADAM

EDEN

1 7 6 5 3 4 82

1 7 6 5 3 4 82

T1 B2 R1

A1 A1

A2 A2

B1

+24 V

Knox 2A

JOKAB SAFETY

Type: Vital 1

Motor

Reset
Sensor

Info reset

Info locked

Signal for unlocking
Safe signal

ABB JOKAB SAFETY

Type: Vital 1