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

Our experience. Your safety.

Mounting and

operating instruction

Modular safety switches and key transfer

systems for the highest requirements.

2Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

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

3Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

F < 50 N

v < 500 mm/s

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

Safety switch- and key interlock system

SAFEMASTER STS

1.1 Safety notes

1. General

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.

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.

0258068

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

ATTENTION!

The STS-system made of plastic must not be used as mechanical stop.

4Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

ZRH02M

M10BM

•

3. 4.

5. 6. 7.

0° 90° / 270° 180°



To p



To p

90 cm ± 20 cm

For assembly, mounting and function testing a key transfer plan must be used.

Dold will be happy to assist you creating one.

1.4 Recommended mounting position

1.3 Key transfer plan

1.5 Recommended ergonomic mounting height

Hatch 2

Hatch 1

Mixer

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.

5Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

1.6 Safety condition of the modules during assembly / modiﬁcation

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

Function check of the modules 10, 10S, 01, 01S, B, D, K, E, V and W

Function check module A

Example: Module A

Example: Module 10

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

6Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

M4058_c

30°



To p



To p

M4057_d

30°



To p



To p



To p

M4379_a

606060



To p



To p



To p

M4380_a



To p



To p



To p

M4377_b

30°



To p



To p



To p

M4378_a

10.

11.



To p



To p



To p

30°



To p



To p

30° 6.



To p



To p



To p



2.1 Actuator modules and key modules

Example M10A; module A rotated at 90°

C: Test

2.2 Modifying a unit or extending

Example STS-SXA into STS-SX01A

A: Disassembling B: Rotation / Mounting

A: Disassembling

C: Mounting D: Insert acuator and key

E: Test Example: ZR_B01M

Dimension tolerance ± 2%

Module A

SX-module

Module M

Module 01

Module B

ZR_-module

Special case: ZR_ / YR_ Modul

Module M

Module 10

B: Add 01 module

Module A

Module 01

SX-module

Module A

2. Mounting

7Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

M4381_a

12060

M4382_a

M4383_a

M4384_a

M4385_a

M4 x 50 mm

V4A / AISI 316L

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

F: Test

Dimension tolerance ± 2%

e.g. M5

Mount lid only when key

or actuator is removed e.g

actuator

and horizontal eccentric

tappet 1 (Position 1) of the

manual / e-stop / emer-

gency unlocking

Actuators should be mounted in a way,

that they are not constantly under stress in

closed state.

A: Unit mounting

E: Mount actuator

B: Remove lid C: Release actuator

coded

D: Lid mounting

Cover inside

eccentric

position 1

8Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

M4891_a

120

240

M4892_a

1. mount option module on fence frame

2. place seal (O-ring 24 x 1.5)

3. mount swicth or solenoid lock (here e.g. ZRH01A)

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

(A) and (B)

2. run connection cable through the opening and plug it in PCB

adapter and PCB.

A - A; B - B; C - C

A: Mounting

2.4 Option module

B: Connecting connection set

9Mounting- and operating instruction SAFEMASTER STS / 03.02.16 en / 639

M4893_a

M4896_a

M4897_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

C: Connecting control signals D: Connect front plate E: Mount front plate

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

M4389_c

M4390_b

M4391_b

M4386_a

M4415_a

M4387_d

2-3m 1m

4518_a

2.5 Escape release

Example STS-ZRFA

Example STS-F-Kit (escape release kit)

A: Mounting of the steel rope B: Press

activation bolt

Dimension tolerance ± 1% Dimension tolerance ± 2%

A: Mounting of frame proﬁle insert B: Mounting of the SVBM-unit

C: Mounting of the mechanical unit on the door D: Fixing the actuator

Fix actuator through the hole with

a strong hit until 2.

Frame proﬁle 50 mm x 50 mm

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.

C: Tensioning of steel rope

coded

radii ≥ 60 mm

tensioner system

active position

eyebolt

rope tensioner

spring

idler pulley

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

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

M4431_c

27,9



5,3

822

32,1

M4432_a

27,9

32,1

15 5

5 10

M4433_b

27,9

MAX 15



4,5

32,1

4,5

15 10 27

20 10

184

M4434_b

27,9

55,5

48,7

M5x10

6,5

4,5

27,75

32,1

15 5

5,5

7,25

2.6 Mounting dimensions of actuators and actuator modules

Actuator module A + standard actuator T

Actuator module B + actuator C

Actuator module B + actuator CS

Actuator module A + actuator J

Dimension tolerance ± 2%

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

M4673_a

5,5

206,6

60,5

5,5

360,5

M4674_a

5,5

206,6

60,5

421

121

2x60,5=

5,5

M4675_a

5,5

206,6

60,5

481,5

181,5

3x60,5=

5,5

M4710_a

2.7 Power Interlocking

Dimensions / Drilling plan control cabinet

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

M4677_b

M4678_b

M4679_a

M4680_b

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.

Mounting remarks

cabinet inside

cabinet outside

Versions 25 ... 125 A

Versions 160 ... 800 A

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

L1(+)

M9890_c

N(-)

A2(-) S21(-)

A1(+)

STS-Solenoid locking mode

emergency stop module LG5924.48

13 33

14 34

23 41

24 42

red

green

Y1 Y2

rot

grün

M9713_g

M9889_c

A2(-)

A1(+) S11 S33 S34 S12 S22 S21

STS-Solenoid locking mode

red

green

911 10 7 8 45612

K1 K2

12 11

emergency stop module LG5925

_ 7

_ 8

_ 9

_ 10

_ 11

_ 12

input module BG5913.08/02MF0 control unit

BH5911

(-)

X2S12 S14 S22 S24 S32 S34 S42 S44

58 (-)48

waitingfor start,

error

errorindication,

enabling active

M9891_d

trans-

mitter

L+

L-

E-Stop

OSSD

STS-Solenoid locking mode

red

green

31911 10 7 8 4 56122

3. Circuit diagrams and connection examples

3.1 Circuit diagrams for switching modules (SX-, SV-, RX-, RV-modules)

When monitoring of the key or door position is required,

terminals 7 and 8 must be used!!!

At 2-channel redundant monitoring of the key or door position

d o n o t connect to terminal 10!!!

All examples shown in active state

Key- /

door position

Signalling

Active state SX-Module

Non-active state RX-Module

2.) STS-switching module (SX-Module) + 2-channel E-stop-modulel (LG 5925)

1.) STS-switching module (SX-Module) + 1-channel E-stop-module (LG 5924.48)

3.) STS-switching module (SX-Module) + input module (BG5913); exclusive OR circuit with C/O contact

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

L1 L1

M10809

A2(-)

A1(+) S11 S33 S34 S12 S22 S21

STS-Locking module

emergency stop module LG5925

32164520 19 11 9108 7171816152423222112

K1 K2

yellow

red

green

14 11

gelb

rot

grün

M9712_h

14 11

1 _

2 _

3 _

4 _

5 _

6 _

7 _

8 _

9 _

10 _

11 _

12 _

_ 13

_ 14

_ 15

_ 16

_ 17

_ 18

_ 19

_ 20

_ 21

_ 22

_ 23

_ 24

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

All examples shown in active state

Minimum wiring for 2-channel monitoring

Key- /

Door position

Solenoid / Signalling Solenoid position

Active state ZR_-module

Non-active state YR_-Module

1.) STS-solenoid locking module (ZRX-module) + 2-channel E-stop module (

LG 5925)

For single channel monitoring

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

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)

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

L+

L -

Warten auf Start

Fehler

Fehleranzeige,

Freigabe aktiv

Warten auf Start

Fehler

Fehleranzeige,

Freigabe aktiv

Not-Aus

BWS

Sender

OSSD

A1+

Y1 X11

Y2 S12S11S13S14

X12

X11T1

X12 X1

X2 S12S14S22S24S32S34S42S44

Steuereinheit

BH5911

(Zugeordnet zu seinen

Ausgängen)

A2-

(-)

13233334

(-)

K1 K2

Geschwindigkeits-

Reduzierung

Eingangsmodul

BG5913.08/02MF0

(Zugeordnet zum BG5912)

(-)

gelb

grün

rot

A1+

Ausgangs-

modul

BG5912

132333

Maschinenfreigabe 34

M9810_g

STS-Zuhaltemodul

gelb

rot

grün

M9712_h

14 11

1 _

2 _

3 _

4 _

5 _

6 _

7 _

8 _

9 _

10 _

11 _

12 _

_ 13

_ 14

_ 15

_ 16

_ 17

_ 18

_ 19

_ 20

_ 21

_ 22

_ 23

_ 24

When monitoring of the key or door position is required,

terminals 19 and 20 must be used.

All examples shown in active state

Key- /

Door position

Solenoid / Signalling Solenoid position

Active state ZR_-module

Non-acttive state YR_-Module

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).

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

LH5946

standstill monitor

L1 L+

A1 S11 S21 S22

13 S12

L2 L-

A2 11 23 33

L3 12 24 34 14S33 24S34

LG5925

emergency stop module

M11565

I> I> I>

17 9715

18 10 A2 14 24

A1 13 23

Escape-

Emergency- Release

Auxiliary-

IK3079.02

Reset

Alarm

816

Ein

K1 K2

ZRH03M

Locking

with coded key

All examples shown in active state

3.) STS-Zuhaltungen mit Hilfs- oder Notenriegelung oder Fluchtentsperrung zusammen mit einer akkustischen und visuellen Alarmierung.

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

T11

T10

T12

T10

T12

T11

21/23

M4914_a

21/23

T12

Option module

ST2451.001

Locking module ZRH

connection by

connection set

solenoid lock

ST2453.1

(see variants

and accessories)

Flat cable

(included)

double cage clamp terminal

T11

T10

T12

T10

T12

T11

M4941_b

T12

Switch module SX

Option module

ST2451.002

connection by

connection set

switch ST2453.1

(see variants

and accessories)

double cage clamp terminal

Flat cable

(included)

3.3 Terminal designation option module

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

M11214

POWER

INTERLOCKING

3.4 Connection examples Power Interlocking

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.

Power Interlocking without monitoring function and without redundancy (Stop 0).

After disconnecting the load isolator 1 to 5 keys can be removed.

All application examples are in zero voltage state

1.) Application example with mechanical design

2.) Application example with a switching version

M11216_a

L1 L2 L3

11987

(K2 not shown)

POWER INTERLOCKING

RES

S11 S12 S22 ST2S21ST1

emergency

stop

S42 S31 S32S41

14 24

K1 K2

UG6970

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

L1 L2 L3 L-

L+ (24V)

M11147

15 16

POWER INTERLOCKING

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.

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

L1 L2 L3

M11218

S22 S42S11 S31 S32

+24V

S12

18 15 16

1787

S21 S41

14 24

(K2 not shown)

POWER INTERLOCKING

K1 K2

UG6970

emergency

stop

RES

Encoder

UH5947 EO

RJ45

3.) Application example with a solenoid locking version

4.) Application example with a solenoid locking version

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

klick

M4392_a

M4393_a

M ≤ 1Nm

M4400_a

M ≤ 1Nm

M4399_a

M4394_a

M4395_a

M4939_a

4. Operation

Example

: ZRNA

Example

: SVA

Release

Lock

Long-nose

pliers

Example

: ZRHA

Lock Release

Example

: M10A

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

Alternatively

snake eye

screw driver M4

(from 01.09.14)

4. 1. Mechanical Units 4. 2. Switch units with locking mechanism

4. 3. Solenoid locking module with auxiliary release 4. 4. Solenoid locking module with emergency release

SAFEMASTER STS-units are parts of the DOLD safety switch and key interlock system. When supplied by DOLD it comes always with a key ex-

change 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!

1. Push the key in fully, until it latches.

The latching is only to keep keys and actuators in position and

prevents ejection.

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

M4396_c

M4415_a

M4397_b

Example: ZRFA

Activation

Reset

Release

Lock

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

3. Active postion is reached automatically.

If not please check the rope and rope tension, see page 10; C: Tensioning of steel rope.

4. 5. Solenoid locking module with escape release

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

M4416_a

M4391_b

Activation

Example: STS-F-Kit

1. To reset the system, the actuator has to be removed according to the procedure.

See also page 10; D: Fixing the actuator.

2. Door can be opened and allows escape.

Handle should reach active

position automatically

Reset

4.6 F-Kit

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

M4681_a

M4682_a

M4683_b

M4684_c





60°

4.7 Power Interlocking

Switching off (all models)

Auxiliary release (variants with electromechanical locking function)

1. Disconnect energy via

switch disconnector

1. remove cover when

energy is disconnected

2. activate auxiliary

release

3. key can be removed

2. Remove key, this locks

switch disconnector

in off position

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

M4685_b

M4686_b

LOTO facility (all variants )

4.7 Power Interlocking

4.8 Usage

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

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!

In most applications, due to the construction and the selected materials, SAFEMASTER STS does not require lubrication. Still, there are special ca-

ses in which additional lubrication would be wise. In those cases it is necessary to select the right lubricant for the application.

6. Lubrication

Notes

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.

5. Cleaning

Table to select the right lubricant

Type of

pollution Example Clinging dirt Recommendation

for lubricant Remark

Dry dust cement, ﬂying ashes, stone,

lime no 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 no Flow grease on EP base, corrosi-

on protective spray with additive Use with rust ﬁlm

Icing Sleet yes Silicone spray,

penetrating oil Mount cover

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

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.

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 re-

pair. 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.

7. Test

7.1 System blocking as safety function

8. Repairs

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.

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 ope-

rated 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).

Frequently asked questions – FAQs

E. DOLD & SÖHNE KG

Postfach 1251 • D-78114 Furtwangen

Phone +49 7723 6540 • Fax +49 7723 654356

dold-relays@dold.com • www.dold.com

Innovative

Safety Concepts

DOLD offers an integrated safety concept for

complete solutions under one roof, which have

already been successfully implemented world-

wide 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.

We would be more than happy to tell you about

our additional safety solutions.

Our experience. Your safety.

SAFEMASTER - The right solution for every application.

SAFEMASTER S

The SAFEMASTER S series

speed sensing device en-

sures increased productivity

and safety for your service

personnel thanks to a com-

bination of safe speed and

stand-still monitoring.

SAFEMASTER W

SAFEMASTER W, the wire-

less companion for your

safety. You can use it to shut

down dangerous move-

ments 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.

SAFEMASTER C

The multifunctional UG 6970

safety module from the SAFE-

MASTER 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.

SAFEMASTER PRO

The modular and programable

safety system SAFEMASTER

PRO monitors all safety cir-

cuits in your machine and sys-

tems – easy, exible and safe.

The amount of input and out-

puts on the central control

unit can be expanded at any

time using extension modules.

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

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

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