en Original
instructions
8068039
2017-07b
[8068041]
Control block for two-hand start
ZSB-1/8-B
ZSB-1/8-B
2 Festo – ZSB-1/8-B – 2017-07b
Original instructions
ZSB-1/8-B-EN
Identification of dangers and instructions on how to avoid them:
Danger
Immediate dangers which could lead to death or serious injuries
Warning
Dangers which could lead to death or serious injuries
Caution
Dangers which could lead to minor injuries
Other symbols:
Note
Material damage or loss of function
Recommendation, tip, reference to other documentation
Essential or useful accessories
Information on environmentally friendly use
Text designations:
Actions that may be carried out in any order
1. Actions that should be carried out in the order stated
– General lists
è Result of an action/reference to additional information
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English – Control block for two-hand start ZSB-1/8-B
Table of contents
1 About this document 5......................................................
1.1 Product identification 5......................................................
1.1.1 Product labelling 5.................................................
1.1.2 Manufacturing date 5...............................................
1.2 Specified standards 6.......................................................
2 Safety 7..................................................................
2.1 Safety function to EN 574 7...................................................
2.2 Intended use 7.............................................................
2.3 Foreseeable misuse 7.......................................................
2.4 Range of applications and certifications 7.......................................
2.5 Training of specialized personnel 8.............................................
3 Further information 8.......................................................
3.1 Accessories 8..............................................................
3.2 Service 8.................................................................
4 Connections 9.............................................................
5 Function and application 10...................................................
6 Installation 11..............................................................
6.1 Mechanical installation 11.....................................................
6.2 Pneumatic installation 11.....................................................
7 Commissioning 12...........................................................
7.1 Preparing for commissioning 12................................................
7.2 Functional testing 12.........................................................
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8 Fault clearance 13...........................................................
9 Operation 13...............................................................
10 Maintenance and care 14.....................................................
11 Disassembly 14.............................................................
12 De-commissioning and waste management 14....................................
13 Technical data 15............................................................
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1 About this document
For all available product documentation è www.festo.com/pk
1.1 Product identification
1.1.1 Product labelling
Product labelling (example) Significance
bar/8
ZSB-1/8-B
576656 H7XX
EN 574: TYPE III A
4 --58 120 psi
1
2
3
4
5
1 Order code
2 Serial number with manufacturing date
(encoded, è Chap. 1.1.2)
3 CE marking
4 Operating pressure
5 Part number
Tab. 1 Product labelling (rating plate) of the product
1.1.2 Manufacturing date
In the product labelling, the first two characters of the serial number indicate the manufacturing date in
encrypted form è Tab. 1, 2. The letter specifies the year of manufacture and the character following it
(number or letter) the month of manufacture.
Manufacturing year
H = 2016 J = 2017 K = 2018 L = 2019 M = 2020 N = 2021
P = 2022 R = 2023 S = 2024 T = 2025 U = 2026 V = …
Tab. 2 Manufacturing year
Manufacturing month
1 January 2 February
3 March 4 April
5 May 6 June
7 July 8 August
9 September O October
N November D December
Tab. 3 Manufacturing month
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1.2 Specified standards
Version status
ISO 8573-1:2010-04 EN ISO 13849-1:2015-12
EN 574+A1:2008-06 EN ISO 13849-2:2012-10
EN 60068-2-27:2009-05
Tab. 4 Specified standards
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2 Safety
Take into consideration the legal regulations for the respective destination.
Use the product only within the defined values è Technical data.
Observe product labelling.
2.1 Safety function to EN 574
The control block for two-hand start is a Type III A two-hand control system according to EN574. It has
been developed and manufactured according to the pertinent fundamental and proven safety principles
of EN ISO 13849-2. The control block for two-hand start exhibits structural properties which enable
performance level c/category 1 to be achieved for implementation of the safety function.
The control block for two-hand start is not a complete safety solution. It can be used as part of a safety
solution. The achievable safety level of the system depends on the other components used to
implement a safety function. The operator is responsible for specification of the safety function.
2.2 Intended use
The control block for two-hand start is intended only for the manual triggering of a control signal
through the simultaneous activation of two actuators.
The control block for two-hand start is intended for installation in machines or automation technology
systems and must be used exclusively as follows:
– Use only in standard operation: This also includes rest, set-up and service operation, as well as
emergency operation.
– Only use the product in its original condition without unauthorised modifications.
– Only use the product if it is in perfect technical condition.
2.3 Foreseeable misuse
The following examples of foreseeable misuse are among those not approved as intended use:
– Outdoor use
– Bypass of the safety function
2.4 Range of applications and certifications
This product is a safety device as defined in the Machinery Directive 2006/42/EC and carries the
CEmarking.
Certificates and declaration of conformity for the product è www.festo.com/sp
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2.5 Training of specialized personnel
Installation, mounting, commissioning, maintenance, repair and de-commissioning should only be
performed by qualified personnel who are familiar with the following tasks and information:
– Installation and operation of pneumatic control systems
– Applicable regulations for operating safety-related systems
– Applicable regulations for accident prevention and occupational safety
– Documentation for the product
Note
Only authorised and appropriately trained personnel are permitted to work on
safety-related systems.
3 Further information
3.1 Accessories
è www.festo.com/catalogue
3.2 Service
Contact your regional Festo contact person if you have technical questions
è www.festo.com.
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4 Connections
1
2
3
4
5
6
7
1 Port (1) for inlets (1.1) and (1.2), size G 1/8”
2 Port (2) for outlet, size G 1/8”
3 Port (3) for exhaust, size G 1/8”
4 Filter for venting hole
5 Blind holes with M5 mounting thread,
drillhole distance 38 mm (rear)
6 Screw with filter element
7 Through-holes for mounting using
M5screws, drill hole distance 40 mm
Fig. 1 Ports on the control block for two-hand start
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5 Function and application
The control block for two-hand start is a pneumatic AND gate.
If pneumatic signals with a time offset of a maximum of 0.5 s are supplied to the ports (1.1) and (1.2),
an outlet signal is provided at the outlet port (2). Control is implemented using two external, manually
operated pushbutton valves.
– If both pushbutton valves are activated, the outlet port (2) is pressurised.
– If no or only one pushbutton valve is activated, the outlet port (2) is depressurised. The system
exhausts from port (2) to (3).
To trigger an additional outlet signal:
1. Release both pushbuttons.
2. Actuate the pushbutton again.
Fig. 2 Simple control – example
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6 Installation
6.1 Mechanical installation
1. Place the control block for two-hand start in such a way that the filter of the venting hole
(è Fig. 1,4) is not covered.
2. Mount the control block for two-hand control with 2 M5 mounting screws:
– Using through-holes (è Fig. 1, 7) or
– Using mounting threads (è Fig. 1, 5)
3. Install 3/2-way pushbutton valves (2x) (è Fig. 2).
6.2 Pneumatic installation
Prerequisite:
– Use hoses with the same nominal width and length between the pushbutton valves and control
block for two-hand start.
1. Remove particles in the supply lines through appropriate measures.
2. Connect pneumatic connections according to the pneumatic circuit diagram of the system.
3. Optional: Use the silencer at the outlet port (3) (è Fig. 2) è www.festo.com/catalogue.
4. Clamp the hoses to the system.
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7 Commissioning
7.1 Preparing for commissioning
1. Pressurise the system.
2. Set a minimum operating pressure of at least 4 bar.
3. Perform a functional test è Chapter 7.2.
7.2 Functional testing
1. Make sure an operating pressure (p0) of at least 4 bar is present at both pushbutton valves.
2. Pressurise the inlets (1.1) and (1.2) according to the signal sequence shown in Fig. 3.
3. At every step, check whether the outlet port (2) is behaving as shown in Fig. 3.
The time offset between the inlet signals (steps 7 and 8) must be no more than 0.5 s.
Fig. 3 Functional test, step 1 to 15
Note
The maximum permissible time offset between the inlet signals (1.1) and (1.2) (steps 7
and 8) depends on the operating pressure and ambient temperature è Tab. 8. The
higher the operating pressure and ambient temperature, the smaller the time offset
must be.
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8 Fault clearance
If defects are noticed on the control block for two-hand start or its function, suitable
measures to maintain the safety level must be taken.
Malfunction
Possible cause Remedy
The outlet port (2) is
depressurised even though
both inlets are pressurised at
the same time (t 0.5 s).
Inlet pressure too high Reduce the inlet pressure
at(1.1) and (1.2)
Pressure reduction at outlet
port (2) takes too long.
Tubing connection error Use short tubing
Avoid elbow connectors
Silencer dirty Clean or replace silencer
Air outlet at exhaust (3) if both
inlets are pressurised at the
same time (t 0.5 s).
Functional fault è Chap. 12
Tab. 5 Malfunction table
9 Operation
Checking the operational reliability:
Check the function of the control block for two-hand start monthly è Chap. 7.2.
Keep a record of the functional tests.
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10 Maintenance and care
Maintenance:
Check the function of the control block for two-hand start monthly è Chap. 7.2.
Cleaning:
1. Depressurise the control block for two-hand start.
2. Unscrew the screw with the filter element (è Fig. 1, 6). Do not lose the seal.
3. Only clean the components of the control block for two-hand start using cleaning agents according
to è Tab. 6.
4. Screw in the screw with the filter element (è Fig. 1, 6) again.
– Tightening torque: 4Nm
5. Perform a functional test è Chap. 7.2.
Component
Cleaning agent Cleaning interval
Housing Water (max. +60 °C) As required
– Screw with filter element
(è Fig. 1, 6)
– Silencer (optional)
– Compressed air
– Water (max. +60 °C)
– Petroleum ether
– Every six months or
– After 100,000 switching
cycles
Tab. 6 Overview of cleaning agents and cleaning intervals
11 Disassembly
Exhaust the entire system and control block for two-hand start.
Remove the control block for two-hand start from the system.
12 De-commissioning and waste management
Within the scope of quality assurance, Festo is interested in the return of replaced control
blocks for two-hand start.
Please get in touch with your regional Festo contact person to clarify the conditions
for the return shipment.
When the end of the period of use has been reached, disassemble the control block for two-hand start
and dispose of it in an environmentally appropriate manner.
Observe the local regulations when disposing of the control block for two-hand start and the
packaging.
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13 Technical data
Safety engineering
Conforms to EN 574 Type III A
Characteristics
Safety level EN ISO 13849
Max. achievable category 1
Max. achievable performance level PL c
Service-life value B
10
1 million switching cycles
Probability of dangerous failure
perhour (PFHd)
[1/h] ≤200,000 actuations/year: 1.14 × 10
-6
>200,000 actuations/year è Fig. 4
Mission time T
M
20 a
Proven component Yes
Fault exclusion
1)
– Deformation due to overloading
– Automatic change of the initial switching
position (without an inlet signal)
– Cracking of the valve housing
– Breakage of moving component
Type of two-hand control
Type III A according to EN574
Design characteristics – No overlap
– Mechanical spring return
– Poppet valve with spring return
Type test The functional safety engineering of the
product has been certified by an independent
testing authority. (EC-type examination
certificate è www.festo.com/sp)
CE marking According to the EC Machinery Directive
(Declaration of Conformity:
è www.festo.com/sp)
Certificate issuing authority IFA 1201046
1) Errors which do not need to be taken into consideration by the user when analysing possible errors of a safety-related part of
acontrol system.
Tab. 7 Safety engineering
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The PFHd value of the subsystem (è Fig. 4) can be calculated, for example, with SISTEMA1) using the
following values:
– Service-life value B10d = 2 x B10 (according to EN ISO 13849-1, Table C.1, Note 1)
– Average number of actuations per year (n
op
)
Fig. 4 PFHd value2) as a function of the average number of actuations per year n
op
Note
Observe the operating time (T10d, according to EN ISO 13849-1, C.3) of the control
block for two-hand start.
The operating time is dependent on the service-life value (B10d) and the average
number of actuations per year (nop), and it may be shorter than the specified mission
time depending on your application è Tab. 7. The control block for two-hand start must
be replaced by the end of the mission time at the latest.
1) Software assistant for “Evaluation of safety-related machine applications according to EN ISO 13849” è www.dguv.de
2) Calculation with SISTEMA in expert setting, with limitation of the MTTFd value to 2500 a.
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General information
Product weight [g] 420
Operating pressure
1)
[bar] 4 … 8
Standard nominal flow rate [l/min] 50
Ambient temperature
2)
[°C] 0 … + 60
Nominal size [mm] 4
Type of actuation Pneumatic
Mounting position Any
Type of mounting Optionally:
– Via through-hole
– Via female thread
Information on materials – seals NBR
Information on materials – housing Anodised wrought aluminium alloy
1) At ambient temperatures under +10 °C, an operating pressure of at least 6 bar must be observed.
2) Use suitable compressed air (see the operating medium) at a minimum temperature under +1 °C. The freezing of condensed water
is avoided.
Tab. 8 General information
Shock resistance (according to IEC 60068: Part 2-27)
Acceleration [m/s2] Duration [ms] Shocks per direction
±300 11 5
Tab. 9 Shock resistance
Pneumatics
Operating medium
1)
Compressed air according to ISO 8573-1:2010 [7:4:4]
Residual oil content2)
when using ester oil
[mg/m3] < 0.1, corresponds to ISO 8573:2010 [-:-:2]
Pneumatic port Gx
Corrosion resistance class 1
Internal exhaust Unducted
Quick exhaust Present
Permissible leakage after
mounting in case of nominal
conditions at the port (2)
[l/h] 0.5
Switching operation: max. offset
of the pilot signals
3)
[s] 0.5
1) The pressure dew point must be at least 10 K lower than the temperature of the medium, since ice would otherwise form in the
expanded compressed air.
2) Operation with lubricated medium possible, in which case lubricated operation will always be required.
3) The higher the operating pressure, the lower the maximum offset time.
Tab. 10 Pneumatics
Reproduction, distribution or sale of this document or communica
tion of its contents to others without express authorization is
prohibited. Offenders will be liable for damages. All rights re
served in the event that a patent, utility model or design patent is
registered.
Copyright:
Festo AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
+49 711 347-0
Fax:
+49 711 347-2144
E-mail:
service_international@festo.com
Internet:
www.festo.com
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