Safemaster STS Safety Switch And Key Interlock System Mounting Operating Instruction Installationmanual

User Manual: Safemaster STS Safety switch and key interlock system mounting and operating instruction Dold Trapped Key ation - AutomationDirect

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SAFEMASTER STS
Mounting and
operating instruction
Modular safety switches and key transfer
systems for the highest requirements.

Our experience.Your safety.

Index

1. General..............................................................................................................................................................................................3
1.1 Safety notes...............................................................................................................................................................................3
1.2 Mounting rules and type numbering..........................................................................................................................................3
1.3 Key transfer plan........................................................................................................................................................................4
1.4 Recommended mounting position.............................................................................................................................................4
1.5 Recommended ergonomic mounting height..............................................................................................................................4
1.6 Safety condition of the modules during assembly / modification...............................................................................................5
1.7 Operating a module during composition of a unit......................................................................................................................5
2. Mounting...........................................................................................................................................................................................6
2.1 Actuator modules and key modules...........................................................................................................................................6
2.2 Modifying a unit or extending.....................................................................................................................................................6
2.3 Units and a safety guards..........................................................................................................................................................7
2.4 Option module............................................................................................................................................................................8
2.5 Escape release........................................................................................................................................................................10
2.6 Mounting dimensions of actuators and actuator modules........................................................................................................11
2.7 Power Interlocking....................................................................................................................................................................12
3. Circuit diagrams and connection examples.....................................................................................................................................14
3.1 Circuit diagrams for switching modules (SX-, SV-, RX-, RV-modules).....................................................................................14
3.2 Circuit diagrams for solenoid locking modules (ZRX, YRX, ZAX, YAX-modules).....................................................................15
3.3 Terminal designation option module........................................................................................................................................18
3.4 Connection examples Power Interlocking................................................................................................................................19
4. Operation.........................................................................................................................................................................................21
4.1 Mechanical Units......................................................................................................................................................................21
4.2 Switch units with locking mechanism.......................................................................................................................................21
4.3 Solenoid locking module with auxiliary release........................................................................................................................21
4.4. Solenoid locking module with emergency release...................................................................................................................21
4.5 Solenoid locking module with escape release.........................................................................................................................22
4.6 F-Kit.........................................................................................................................................................................................23
4.7 Power Interlocking....................................................................................................................................................................24
5. Cleaning..........................................................................................................................................................................................26
6. Lubrication.......................................................................................................................................................................................26
7. Test .................................................................................................................................................................................................27
7.1 System blocking as safety function..........................................................................................................................................27
8. Repairs............................................................................................................................................................................................27
Frequently asked questions – FAQs..................................................................................................................................................27

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

Mounting- and operating instruction

0258068

Safety switch- and key interlock system
SAFEMASTER STS
1. General
1.1 Safety notes
ATTENTION!
Please read these mounting instructions before starting the installation. Mounting, electrical connection and test must only be carried out
by trained staff that have read these instructions and have a full understanding of their content. Before installing the system the user has
to decide if the suggested key transfer plan solution fulfils the application requirements and that the gates are secured according to the
relative standards. The suggested key transfer plan has been designed and forms one solution based on the requirements as advised to
Dold.
For a safe installation all the available mounting points must be used. When making changes to an existing system please take care to follow the
mounting rules as described in this document. Do not remove or re-adjust any parts inside the (electrical) units. Please note that the mechanical
modules have two cleaning holes. Please make sure that at least one hole remains open so that dirt can exit. Please make sure that appropriate
seals are used for all the cable entries. The connection (integration of electrical modules) must be carried out according to the required safety
category DIN EN ISO 13849-1. A validation in conformity with DIN EN ISO 13849-2 is mandatory. Before starting the system it must be checked for
function according to the corresponding key transfer plan. After completing the tests the covers of the electrical units must then be fitted and fixed
with the appropriate screws. Maximum torque = 1 Nm ± 0.1 Nm. Please make sure that the front covers of the electrical units are mounted properly
before operation. Only when the lids are mounted correctly, function and protection class will be as specified.
It is recommended to carry out planned maintenance min. twice a year to remove dirt and other contaminants from the units to keep the system
working correctly. In case of intense fouling, cleaning should be carried out more often.
ATTENTION!
Do not use grease for lubrication! If lubrication is necessary please check the table on page 14 for chosing the lubricant.
Please also pay attention to the standards DIN EN ISO 14119, DIN EN ISO 13849-1 and DIN ISO 12100.
For correct mounting and usage of devices with Auxiliary-, Emergency-, or Escape release, refer to the requirements of DIN EN ISO 14119
Please contact DOLD if you have any doubts or questions regarding the installation.
Take notice of the requirements of EN ISO14119:2013 in reference to foreseeable manipulation, especially to §7.1 and 7.2
Upon installation electric modules must be connected to the ground, to avoid any potential differences.
The statements and safety notes contained in these mounting instructions must be strictly adhered too.

The STS-system made of stainless steel can be within limitation used as mechanical stop.
Follow values must not be exceeded:
F < 50 N
v < 500 mm/s

• F = 50 N
• v = 500 mm/s
ATTENTION!
The STS-system made of plastic must not be used as mechanical stop.

1.2 Mounting rules and type numbering
The type identification of a combined unit is built up from the bottom module to the top.
Mechanical key module numbers are added together, e.g. on a mechanical lock with 2 keys to be inserted (10 + 10) and one to be extracted (01).
This sums up to be 21. At the upper end of the mechanical guard lock an actuator module (A) is required. The type reference for this assembly is
then, M21A.
An M module should always be mounted on the open end of a unit.
If a key module 10, a padlock module W or an actuator module K is mounted directly on a switch or on a solenoid locking switch, the position of the
key or actuator has to be monitored for category 3 or 4 as shown in wiring examples 3 and 4 on page 15 and 16.
Above a B, D, K and E actuator module there should always be mounted one or more mechanical modules or an M end module.
Below A, B, D, K and E actuator modules there should always be mounted one or more mechanical modules or an electrical module.
Products of the SAFEMASTER STS plastic series are indicated with a /K at the end of the type name.
Example: M10A/K, Key module 01/K, Actuator module B/K, End module M/K.

All technical data in this list relate to the state at the moment of edition. We reserve the right
for technical improvements and changes at any time.

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

1.3 Key transfer plan
For assembly, mounting and function testing a key transfer plan must be used.
Dold will be happy to assist you creating one.
M10BM

ZRH02M
Hatch 2

•

Mixer

•

Hatch 1
3.

M10BM

Example ZRH02M with 2 x M10BM
1. When the machine is in safe mode and the solenoid lock is released,
the 1st key can be removed.
2. Removal of the key can be monitored and a signal can be
integrated into the machine control.
3. Key is inserted into mechanical lock.
4. Hatch 1 can be opened
5. Only when the 1st key is removed, the 2nd key can be obtained.
6. 2nd key is inserted into mechanical lock.
7. Hatch 2 can be opened.
To restart the machine, steps 7-1 have to be processed in reverse order.
Both keys have the same code and can operate both covers.

1.4 Recommended mounting position

0°

180°

Top

90° / 270°

1.5 Recommended ergonomic mounting height

90 cm ± 20 cm

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

1.6 Safety condition of the modules during assembly / modification
When assembling or modifying STS-units, the individual modules must be in a safe condition, as described in the table below.
Safety mounting state of the modules
Module

State

Switch module SX / SV

switched off

Switch module RX / RV

switched off

Solenoid locking switch ZR_ / YR_ (closed circuit operation)

switched off, operate solenoid manually

Solenoid locking switch ZA_ / YA_ (open circuit operation)

switched off

Key module 10 / 10S

key inserted, at mounting on RX, RV or Y-modules the key is extracted

Key module 01 / 01S

key extracted

Padlock module V

key extracted

Padlock module W

key inserted, see key module 10, 10S

Actuator module A / B / D

actuator extracted

Actuator module K / E

actuator inserted, at mounting on RX, RV or Y- modules the der actuator is extracted

1.7 Operating a module during composition of a unit
Example: Module 10
Function check of the modules 10, 10S, 01, 01S, B, D, K, E, V and W

Example: Module A
Function check module A

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

2. Mounting
2.1 Actuator modules and key modules
Example M10A; module A rotated at 90°
A: Disassembling

B: Rotation / Mounting

C: Test

Module A

Top

Module 10

Top

30°



3.
30°

Top

Top

Module M

2.2 Modifying a unit or extending
Example STS-SXA into STS-SX01A
A: Disassembling

Special case: ZR_ / YR_ Modul
E: Test

B: Add 01 module

Example: ZR_B01M

Top

Module A

Module 01

Module B

Top
Top

D: Insert acuator and key

Top

M4380_a

11.

Top

30°

Top

M4379_a

10.

Top

M4057_d

C: Mounting

SX-module

Top

7.
M4058_c

SX-module

30°
2.

Top

30°

Module 01

Top

Module M

Top

Module A

Dimension tolerance ± 2%
ZR_-module

M4378_a

M4377_b

Top

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

2.3 Units and a safety guards
Example STS-ZRHB01M; All threads and cut-outs in a guard have to be made by the user
B: Remove lid

A: Unit mounting

D: Lid mounting

C: Release actuator

Mount lid only when key
or actuator is removed e.g
actuator
and horizontal eccentric
tappet 1 (Position 1) of the
manual / e-stop / emergency unlocking

30
coded

eccentric
position 1

M4383_a

M4382_a

120

Cover inside
F: Test

E: Mount actuator

M4381_a

coded

Dimension tolerance ± 2%

e.g. M5

Actuators should be mounted in a way,
that they are not constantly under stress in
closed state.

M4385_a

M4384_a

M4 x 50 mm
V4A / AISI 316L

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

2.4 Option module
A: Mounting

120

B: Connecting connection set

240

A
M4891_a

M4892_a

1. mount option module on fence frame

1. plug pcb adapter into the terminals of the switch (C) or solenoid lock
(A) and (B)

2. place seal (O-ring 24 x 1.5)
3. mount swicth or solenoid lock (here e.g. ZRH01A)

2. run connection cable through the opening and plug it in PCB
adapter and PCB.
A - A; B - B; C - C

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

D: Connect front plate

E: Mount front plate

M4896_a

C: Connecting control signals

M4897_a

M4893_a

1. connect shortened wires to the terminals
2. mount coded terminal blocks to the
connection pins in the option module

plug the 14-pole connectioncable from the
front cover to the pin connector in the
option module

1. place and srew the front cover of the switch /
solenoid lock.
2. place and screw the front cover to the option
module
Attention!
No wire between front plate and
enclosure

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

2.5 Escape release
Example STS-ZRFA
B: Press
activation bolt

A: Mounting of the steel rope

C: Tensioning of steel rope
idler pulley
tensioner system
1m

M4518_a

2-3 m

M4415_a

eyebolt

rope tensioner

M4387_d

M4386_a

spring

Adjust rope with rope tensioner until active position is reached.
Please make sure that the hooks of the spring are correctly
fixed when installing the tensioning system.
active position

radii ≥ 60 mm

Example STS-F-Kit (escape release kit)
A: Mounting of frame profile insert

B: Mounting of the SVBM-unit
coded

M4389_c

coded

Dimension tolerance ± 1%

Frame profile 50 mm x 50 mm

D: Fixing the actuator

M4391_b

M4390_b

C: Mounting of the mechanical unit on the door

Dimension tolerance ± 2%

coded

Fix actuator through the hole with
a strong hit until 2.

Units based on solenoid modules with emergency release (e.g. ZRN-), escape release (e.g.ZRF-) and the escape release kit (STS-F-Kit)
have to be installed/protected in a way that unintended opening of the lock is avoided
10

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

2.6 Mounting dimensions of actuators and actuator modules

Actuator module A + standard actuator T

37
5
30
5

M4431_c

5,3

27,9

6
12

32,1

Dimension tolerance ± 2%

Actuator module B + actuator C
30

16
15 5

30
20
5 10

27,9

10 5
20
30

32,1

M4432_a

Dimension tolerance ± 2%
Actuator module B + actuator CS
51
30
15

16
MAX 15

15 10

4 ,5

4,5

27,9

32,1

M4433_b

184

Dimension tolerance ± 2%
Actuator module A + actuator J

M5x10

7,25

6,5

5
6

4,5

30
15

95
80

55,5

5,5

27,9

24
12

27,75

32,1

M4434_b

48,7
Dimension tolerance ± 2%
11

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

M4710_a

2.7 Power Interlocking

Dimensions / Drilling plan control cabinet

M4674_a

5,5

481,5

60,5

206,6

421

3x 60,5=181,5

206,6

60,5

5,5

360,5

206,6

2x 60,5=121

M4675_a

5,5

M4673_a

5,5

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

Mounting remarks
Before mounting, the key must be removed. To this purpose the disconnector switch must be in the “off” position and the locking switch
is to be unlocked via the auxiliary release. For devices without locking function it is sufficient switching the disconnector switch in the “off”
position.
Versions 25 ... 125 A

cabinet inside
cabinet outside

M4678_b

M4677_b

Versions 160 ... 800 A

3.
3.
1.

M4680_b

M4679_a

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

3. Circuit diagrams and connection examples
3.1 Circuit diagrams for switching modules (SX-, SV-, RX-, RV-modules)
All examples shown in active state
1.) STS-switching module (SX-Module) + 1-channel E-stop-module (LG 5924.48)

22
24

L1(+)

7
8
4

red

Key- /
door position

K3
A1(+)

green

6
12

A2(-)

S21(-)

STS-Solenoid locking mode

3
2

9
11
10
7
8

22
24
32

emergency stop module LG5924.48

rot

Signalling

Active state SX-Module
Non-active state RX-Module

3
2
1
9
11
10

5
grün
6
12

N(-)
M9890_c

M9713_g

When monitoring of the key or door position is required,
terminals 7 and 8 must be used!!!
2.) STS-switching module (SX-Module) + 2-channel E-stop-modulel (LG 5925)

3 2

1_
2_
3_
4_
5_
6_

1 9

red

green

STS-Solenoid locking mode

11 10

7 8

_ 7
_ 8
_ 9
_ 10
_ 11
_ 12

6 12

K2
A1(+) S11

S33

S34

S12 S22

S21

emergency stop module LG5925

A2(-)

24 ..

K1
N

K2
M9889_c

At 2-channel redundant monitoring of the key or door position
d o n o t connect to terminal 10!!!
3.) STS-switching module (SX-Module) + input module (BG5913); exclusive OR circuit with C/O contact
L+
L-

1 9

3 2

11 10 7 8

transmitter
-

OSSD

red

green

STS-Solenoid locking mode

6 12

E-Stop
X1

S12 S14

S22 S24

S32 S34

S42 S44

control unit
BH5911

input module BG5913.08/02MF0

(-)

error indication,
enabling active

(-)

waiting for start,
error

M9891_d

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

3.2 Circuit diagrams for solenoid locking modules (ZRX, YRX, ZAX, YAX-modules)

All examples shown in active state
1.) STS-solenoid locking module (ZRX-module) + 2-channel E-stop module (LG 5925)

Active state ZR_-module
Non-active state YR_-Module

Key- /
Door position

Minimum wiring for 2-channel monitoring

STS-Locking module

3
2

6
4
5
20
19

Solenoid position

green

red
62

31
32

6 4

5 20 19

11 9

10 8

7 17

21 12

8
7

17
18
16

15
rot

Solenoid / Signalling

11
12

14
3 2

yellow

11
9

22
24

K2
A1(+) S11

S33

S34

S12 S22

S21

23
22

grün

21
12

M9712_h

emergency stop module LG5925

A2(-)

14
K1

gelb

24 ..
K2

1 _
2 _
3 _
4 _
5 _
6 _
7 _
8 _
9 _
10_
11_
12_

M10809

For single channel monitoring
terminals 7 and 8 or 17 and 18 must a l w a y s be used!!!.

_
_
_
_
_
_
_
_
_
_
_
_

13
14
15
16
17
18
19
20
21
22
23
24

The contacts of the door or keyposition must only be used for additional purposes.
They are intended to be used for extended feedback e.g. set-up mode
(see example on page 16).

On dual channel redundant monitoring of the lock position and using the changeover
contact 9, 10 and 11, the terminal 10 must not be used.
At antivalent monitoring terminal 9 must not be connected.
In applications where the key or door position is monitored dual channel,
terminal 5 must not be connected (see wiring example page 16)

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

All examples shown in active state
2.) STS-solenoid locking module (ZRX-Modul) + SAFEMASTER M (input module BH 5913, control Unit BH 5911, output module BG 5912)
State: Door closed and locked. Suitable for applications with set-up operation (door closed but not locked)
and full operation (door closed and locked).

S14 S12

3
2

Key- /
Door position

6
4

22
24

Not-Aus

32 31

Solenoid position

11
9

BWS

OSSD

S44 S42

6
4
5
20
19

52
51

3
2

22
24
32

S34 S32

Warten auf Start
Fehler

S24 S22

Fehleranzeige,
Freigabe aktiv

Eingangsmodul
BG5913.08/02MF0
(Zugeordnet zum BG5912)

(-)

L-

L+

Active state ZR_-module
Non-acttive state YR_-Module

8
42

11
9
10

8
7

17
18
16

(-)

Sender

17
62

23
grün

22
21
12

gelb

23
22

grün

21
12

M9712_h

1 _
2 _
3 _
4 _
5 _
6 _
7 _
8 _
9 _
10_
11_
12_

Y1 X12
Y2

_
_
_
_
_
_
_
_
_
_
_
_

13
14
15
16
17
18
19
20
21
22
23
24

M9810_g

Maschinenfreigabe 34 33

A1+

(-)

Ausgangsmodul
BG5912

14
58

Solenoid / Signalling

gelb

STS-Zuhaltemodul

T1 X11 X12 S14 S13 S11 S12 X11 A1+

rot

13
23
24

Warten auf Start
Fehler

GeschwindigkeitsReduzierung
33

Fehleranzeige,
Freigabe aktiv

(-)

A2-

Steuereinheit
BH5911
(Zugeordnet zu seinen
Ausgängen)

rot

When monitoring of the key or door position is required,
terminals 19 and 20 must be used.
16

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

All examples shown in active state
3.) STS-Zuhaltungen mit Hilfs- oder Notenriegelung oder Fluchtentsperrung zusammen mit einer akkustischen und visuellen Alarmierung.

L1
L2
L3

L+
LAlarm

EscapeEmergencyAuxiliary-

Release
IK3079.02

ZRH03M
Locking
with coded key

I> I> I>

24
Reset
Alarm

K1
A1 A2
K2

11 23 33

S11

LH5946
standstill monitor

L1 L2 L3

S21

S22

S12

LG5925
emergency stop module
12 24 34

S33

S34 14

Ein
M
3~

K1
K2
K1

M11565

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

3.3 Terminal designation option module

Locking module ZRH

Switch module SX

M4914_a
3
2
1
6
4
5
20
19
11
9
10
8
7
17
18
16

M4941_b
3
2
1
9
11
10
7
8
4
rt

6
12

15
rt

21/23
22

21/23
12

double cage clamp terminal
1
2
3
4
5
6
7
8
9

Option module

ST2451.001

double cage clamp terminal
connection by
connection set
solenoid lock
ST2453.1
(see variants
and accessories)

Option module

1
2
3
4
5
6
7
8
9

ST2451.002

10
11
12

10
11
12
15
16
17
18
19
20
21/23
22
24

T1
T2
T3
T4
T5
T6
T7
T8
T9
T10
T11
T12

Flat cable
(included)
T6
T1

Flat cable
(included)

T5
T4

T3
T2
ws

T6
T1

T12

T3
T2

T12

T8
T7
T12

T8
T7

T12

connection by
connection set
switch ST2453.1
(see variants
and accessories)

T10
T9

T10

T11

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

3.4 Connection examples Power Interlocking
All application examples are in zero voltage state
1.) Application example with mechanical design

POWER
INTERLOCKING

M
M11214

Power Interlocking without monitoring function and without redundancy (Stop 0).
After disconnecting the load isolator 1 to 5 keys can be removed.

2.) Application example with a switching version

L1 L2 L3

POWER INTERLOCKING
on

Q1
emergency
stop

K2
ST1

S21

S11

S12

S22 ST2

S41

S42

S31

S32

A1
on

UG6970

RES
14
K1

24
K2

M11216_a

(K2 not shown)

Power Interlocking with monitoring function.
After disconnecting the load isolator 1 key can be removed immediately. This key is equipped, in addition, with monitoring contacts. If necessary, they
can be included in a safety circuit together with an auxiliary contact of the switch disconnector.

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

3.) Application example with a solenoid locking version
L1 L2 L3

LL+ (24V)

POWER INTERLOCKING
Y

Q1
17

18
X

M11147

Disconnected state, magnet energized (24 V), key inserted and removable.
Power Interlocking where standstill monitoring, time delay or other monitoring functions can be added.
The key can be removed only after disconnecting the load isolator and release by the magnet.

4.) Application example with a solenoid locking version

L1 L2 L3

POWER INTERLOCKING
emergency
stop

S21

S22

S11

S12

S41

S42

S31

S32

UG6970

UH5947

EO
RJ45

Encoder

RES
14
K1

24
K2

(K2 not shown)

+24V

24
M11218

Disconnected state, solenoid energized (24 V), key inserted and removable.
Power Interlocking with monitoring function and mechanical redundancy;
- Stop 0 over Q1;
- Stop 1 over circuit logic

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

4. Operation
SAFEMASTER STS-units are parts of the DOLD safety switch and key interlock system. When supplied by DOLD it comes always with a key exchange plan (see page 4). The specifications stated in the key exchange plan have to be observed implicitly. The operation of the SAFEMASTER
STS-units has to be done according to the data sheets.
Before using the system the operator has to make him selve acquainted with the operating sequence state in the key exchange plan. The coding of
the keys and locks make sure that the system can only be operated in the defined sequence. Keys, actuators and padlock modules must only be
operated manually. Tools must not be used for operation!
4. 1. Mechanical Units

4. 2. Switch units with locking mechanism

Example: M10A

Example: SVA
Lock

Release

klick

k l i ck

M4393_a

M4392_a

1. Push the key in fully, until it latches.
The latching is only to keep keys and actuators in position and
prevents ejection.
4. 3. Solenoid locking module with auxiliary release

4. 4. Solenoid locking module with emergency release
Example: ZRNA

Example: ZRHA
Release

Lock

Release

Long-nose
pliers

E
E

M ≤ 1Nm

M4395_a

Alternatively
snake eye
screw driver M4
(from 01.09.14)

M4394_a

M4400_a

M4399_a

_a
39

Before returning to normal operation, the protective function must have been reactivated.
21

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

4. 5. Solenoid locking module with escape release
Example: ZRFA
Activation

M4415_a

M4396_c

Lock

Release

Reset
1. The STS-ZRFA has to be reseted before it is ready for use.

M4397_b

3. Active postion is reached automatically.
If not please check the rope and rope tension, see page 10; C: Tensioning of steel rope.

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

4.6 F-Kit
Example: STS-F-Kit
Activation
1. To reset the system, the actuator has to be removed according to the procedure.
See also page 10; D: Fixing the actuator.

M4416_a

2. Door can be opened and allows escape.

Reset

M4391_b

3.
Handle should reach active
position automatically

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

4.7 Power Interlocking
Switching off (all models)
M4681_a

M4682_a

1. Disconnect energy via
switch disconnector

2. Remove key, this locks
switch disconnector
in off position

Auxiliary release (variants with electromechanical locking function)
M4683_b

M4684_c

A
2.

60°

1. remove cover when
energy is disconnected

1.
2. activate auxiliary
release
3. key can be removed

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

4.7 Power Interlocking

LOTO facility (all variants )
M4685_b

M4686_b

2.
3.

4.8 Usage

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

5. Cleaning
SAFEMASTER STS-units work best in clean condition. Contamination can be normally removed by compressed air or water. When using cleaning
agents they have to be rinsed off afterwards, especially if aggressive chemicals like phosphoric acid are used. If this is not observed, units may be
damaged.
Dogged fouling may be removed with brake cleaner. Please observe the notices by the manufacturer.
In case of coarse fouling e.g. partially hardened concrete, mechanical devices may be cleaned with a high-pressure steam cleaner
- The key and module label plates should not be damaged.
- The high pressure of the water may damage the seals of electrical devices.
When using a steam cleaner extra care is required.
After such type of cleaning it may be necessary to grease the device. Aditional information may be found in the Table to select the right lubricant.

6. Lubrication
In most applications, due to the construction and the selected materials, SAFEMASTER STS does not require lubrication. Still, there are special cases in which additional lubrication would be wise. In those cases it is necessary to select the right lubricant for the application.

Table to select the right lubricant
Type of
pollution

Example

Clinging dirt

Recommendation
for lubricant

Remark

Dry dust

cement, flying ashes, stone,
lime

Graphite powder; slide coating on
graphite or PTFE base

Do not use grease!

Mud

concret, flying ashes,
water with lime content

yes

Gear spray with MOS2 and
graphite, Molycote spray, surface
active oil

Humid dust

Wood dust, chips

yes

Slide coating on graphite, MOS2,
or PTFE base, in some cases
surface active oil

Do not use grease!

Clinging dust

Asphalt

yes

surface active oil

Do not use graphite!

Acids and bases

Additives in detergents e.g.
acids or brine

no,
caustic

Greasing oil or grease spray

Surface rust

Rust dust

Flow grease on EP base, corrosion protective spray with additive

Use with rust film

Icing

Sleet

yes

Silicone spray,
penetrating oil

Mount cover

Notes
A simple way to apply the lubricant is by using spray cans. They allow to lubricate the relevant parts oft he mechanic modules through the actuator slots.
Using high visconse gease or oil may cause dirt to adhere, whitch may influence the operation.
In any case we recommend performing your own test to find the most efficient lubricant for your application. Please take also into account the viscosity
of the lubricant and the influence of the operating temperature. To high viscosity could result in malfunction.
Of course we are willing to assist you selecting. Please do not hesitate to adress us with your questions!

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

7. Test
SAFEMASTER STS-systems have to be tested regularly. This test must include the following elements:
1. Visual inspection of the units regarding cleanness: removing of all contaminations
2. Visual inspection of the fixtures: Possibly tighten the screws
3. Visual inspection regarding damage and wear: Function test
4. Function test according to the key exchange plan: Also try to insert at least 1 key into a wrong key module. This must not be possible!
In the case of faulty functions the machine has to be stopped/ secured. Remove system blockings or get it repaired.
If the operators are acquainted to the system and know the installation and operating manual, every actuation of the system can be regarded as test.
The yearly test (PL a to d) or monthly test (PL e) as described in the data sheets have to be performed in any case.

7.1 System blocking as safety function
SAFEMASTER STS-units have a failure diagnostic safety function. This makes the units to go into blocked state when failures are detected and
they cannot be operated after that. This function can be reseted when the fault is removed and the units are not damaged (reset function).
Procedure in case of system blocking
In the case of a system blocking we recommend the following procedure:
1. Make sure that all inserted keys, padlock modules and actuators are in the correct position and inserted correctly. (See module status page 3)
2. Start the reset procedure. Try to insert manually the blocked keys or actuators individually. Do not operate several keys or actuators at the same
time; it can prevent reset function. If after the 5th try the unit is not reseted, it has a fault.
3. Try to localize the reason for the failure, e.g. bent parts, contamination, objects in the unit. If it was possible to remove the fault,
repeat the reset procedure. Under certain circumstances greasing may help.
If after a few tries the SAFEMASTER STS-unit does not reset, there is an irremovable fault and the unit has to be repaired.

8. Repairs
Nearly all faults can be temporarily remediated by a replacement kit or by replacing actuator modules. Faulty units can also be sent to DOLD for repair. To accelerate the repair procedures please attach always a copy of the key exchange plan, or indicate the DOLD SAFEMASTER-STS Project
number.
Do not in any case disassemble a module, as every returned module is examined by us. Also it will lose warranty, if within warranty period. In case of
unprofessional assembly, the safe function of the unit can not be guaranted due to faulty assembly.

Frequently asked questions – FAQs
An electrical module cannot be joined with a mechanical module. The bayonet ring cannot be turned as described in the manual. What can
be done?
When not mounted to mechanical modules, the electrical modules of SAFEMASTER STS return to a safe switched off state and will not mount to
mechanical units unless actuated by hand. If a solenoid locking switch is used with closed circuit operation the locking solenoid must be pushed as
described in the example for ZR_-modules.
Any objects between the modules must be removed!
Mechanical modules cannot be joined. The bayonet ring cannot be turned as described in the manual. What can be done?
Both modules must be in the correct safe state, i. e. with a key module “10” the key must be inserted, with a key module “01” the key must be extracted.
You will find more information about the mounting rules on the Table Assembly / modifying - safety mounting state of the modules on page 3, 5 or 6.
How do I read the type numbers?
Please refer to the corresponding product key - table in the design guide
How can I make sure that the system works correctly?
Check the system by using the key transfer plan to detect possible false positioning or incorrect mounting of units.
One unit is blocked, why?
All SAFEMASTER STS units are able to detect internal faults. If a fault is detected the units go into a safe state which blocks the system. If the fault
can be removed when the unit is in the safe state, e. g. by adjusting the mountings on a distorted surface to reduce tension. The units can then be
reset by inserting and removing the key or actuator several times. (see sect. 7.1 page 26).
Key cannot be extracted or pushed in
Please check the label of the key and the key module, they must correspond. Also make sure, using the key exchange plan, that the key can be operated in the intended way. If the key cannot be extracted or pushed while operating it correctly, please make sure the key or actuator below or above
is inserted fully. (see sect. 4.1).

Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

Our experience. Your safety.
SAFEMASTER - The right solution for every application.

Innovative
Safety Concepts
DOLD offers an integrated safety concept for
complete solutions under one roof, which have
already been successfully implemented worldwide for many decades.
From monofunctional safety control gear for
simple safety applications to multifunctional,
modular safety systems, DOLD develops
tailor-made solutions for protecting people and
plant.

SAFEMASTER C

SAFEMASTER S

SAFEMASTER PRO

SAFEMASTER W

The multifunctional UG 6970
safety module from the SAFEMASTER C family by DOLD
monitors two independent
safety functions.You can make
any desired choice from the
following basic functions:
emergency stop, safety gate,
two-hand controls, safety
mat/safety edge, antivalent
switch and light barrier.

The SAFEMASTER S series
speed sensing device ensures increased productivity
and safety for your service
personnel thanks to a combination of safe speed and
stand-still monitoring.

The modular and programable
safety system SAFEMASTER
PRO monitors all safety circuits in your machine and systems – easy, flexible and safe.
The amount of input and outputs on the central control
unit can be expanded at any
time using extension modules.

SAFEMASTER W, the wireless companion for your
safety. You can use it to shut
down dangerous movements within a fraction of a
second. The wireless safety
system consists of a radio
controlled safety switch, a
handheld transmitter and an
optional infrared receiver.

E. DOLD & SÖHNE KG
Postfach 1251 • D-78114 Furtwangen
Phone +49 7723 6540 • Fax +49 7723 654356
dold-relays@dold.com • www.dold.com

Mounting- and operating instruction / 160203 / xxx / Translation of the german original

We would be more than happy to tell you about
our additional safety solutions.

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