DOLD SAFEMASTER STS Service manual

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 / 08.01.21 en / XXXX
Index
Page
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 ........................................................................................................................................ 12
2.10 Door Handle Actuator TG ...................................................................................................................................................................................... 18
2.11 Power Interlocking .................................................................................................................................................................................................. 19
Mounting remarks........................................................................................................................................................................................................... 20
3. Circuit diagrams and connection examples ................................................................................................................................................................ 21
3.1 Circuit diagrams for switching modules (SX-, SV-, RX-, RV-modules)...................................................................................................................... 21
3.2 Circuit diagrams for solenoid locking modules (ZRX, YRX, ZAX, YAX-modules)...................................................................................................... 22
3.4 Terminal designation option module ......................................................................................................................................................................... 25
3.5 Connection examples Power Interlocking................................................................................................................................................................. 26
4. Operation .................................................................................................................................................................................................................... 28
4. 5. Solenoid locking module with escape release ........................................................................................................................................................ 29
4.6 F-Kit .......................................................................................................................................................................................................................... 30
4.7 Power Interlocking .................................................................................................................................................................................................... 31
4.7 Power Interlocking .................................................................................................................................................................................................... 32
5. Cleaning...................................................................................................................................................................................................................... 33
6. Lubrication .................................................................................................................................................................................................................. 33
Notes .............................................................................................................................................................................................................................. 33
7. Test / Inspection .......................................................................................................................................................................................................... 34
7.1 System blocking as safety function........................................................................................................................................................................... 37
8. Repairs ....................................................................................................................................................................................................................... 37
Frequently asked questions – FAQs............................................................................................................................................................................... 38
Notice ............................................................................................................................................................................................................................. 39
Notice ............................................................................................................................................................................................................................. 40
Notice ............................................................................................................................................................................................................................. 41

3Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
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.
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 (see 6. lubrification) 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 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.
!
1. General
1.1 Safety Notes
1.2 Mounting rules and type numbering
Mounting- and operating instruction
SAFEMASTER STS
Safety switch- and key interlock system
F < 50 N
v < 500 mm/s

4Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
ZRH02M
M10BM
M10BM
x
x
1.
2.
3. 4.
5. 6. 7.
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.
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.
1.3 Key transfer plan
1.4 Recommended mounting position
1.5 Recommended ergonomic mounting height
0° 90° / 270° 180°
Ö
To p
Ö
To p
!
Do not cover holes for drainage and dedusting!

5Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
!
!
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
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
1.6 Safety condition of the modules during assembly / modification
1.7 Operating a module during composition of a unit

6Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Disassembling B: Add 01 module E: Test Example: ZR_B01M
M4058_c
30°
3.
2.
1.
4.
Ö
To p
Ö
To p
5.
M4057_d
30°
7.
6.
Ö
To p
Ö
To p
Ö
To p
M4379_a
606060
30
Ö
To p
Ö
To p
Ö
To p
A
A
M4380_a
1.
3.
2.
Ö
To p
Ö
To p
Ö
To p
C: Mounting D: Insert acuator and key
M4377_b
8.
9.
30°
Ö
To p
Ö
To p
Ö
To p
M4378_a
10.
11.
Ö
To p
Ö
To p
Ö
To p
A: Disassembling B: Rotation / Mounting C: Test
30°
1.
4.
2.
3.
Ö
To p
Ö
To p
7.
5.
30° 6.
Ö
To p
Ö
To p
Ö
To p
To p
Ö
Example M10A; module A rotated at 90°
Example STS-SXA into STS-SX01A
Dimension tolerance ±2%
Module A
SX-module
Module M
Module 01
Module B
ZR_-module
Special case: ZR_ / YR_ Modul
Module M
Module 10
Module A
Module 01
SX-module
Module A
2. Mounting
2.1 Actuator modules and key modules
2.2 Modifying a unit or extending

7Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Unit mounting B: Remove lid C: Release actuator D: Lid mounting
M4381_a
60
12060
30
M4382_a
A
A
M4383_a
1.
2.
1.
E: Mount actuator F: Test
M4384_a
M4385_a
!
M4 x 50 mm
V4A / AISI 316L
Example STS-ZRHB01M; All threads and cut-outs in a guard have to be made by the user
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.
Coded
Coded
Cover inside
Eccentric
position 1
2.3 Units and a safety guards

8Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Mounting B: Connecting connection set
M4891_a
60
60
120
240
M4892_a
C
A
B
1.
2.
3.
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
2.4 Option module

9Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
C: Connecting control signals D: Connect front plate E: Mount front plate
M4893_a
K
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

10 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Mounting of the steel rope B: Press
activation bolt C: Tensioning of steel rope
M4386_a
M4415_b
M4387_e
2-3 m 1 m
M4518_a
Example STS-ZRFA
Example STS-F-Kit (escape release kit)
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.
Radii t60 mm
Tensioner system
Active position
Eyebolt
Rope tensioner
Spring
idler pulley
2.5 Escape release
D: Installation of T-handle E: Installation of T-handle at fence
M_
a20630
M02629_a

11 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
2.6 Covers
Attachment of covers with SAFEMASTER STS/K
A: Mounting of frame profile insert B: Mounting of the SVBM-unit
M4389_c
C: Mounting of the mechanical unit on the door D: Fixing the actuator
M4390_b
M4391_b
2.
1.
Example STS-F-Kit ( Escape release-Kit)
Dimension tolerance ±1%
Coded
Coded
Dimension tolerance ±2%
kodiert
Fix actuator through the hole
with a strong hit until 2.
Frame profile 50 mm x 50 mm
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
!

12 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
M4431_c
27,9
60
44
30
5

5,3
51
822
32,1
15
5
6
12
56
5
37
M4432_a
27,9
20
M5
60
30
32,1
30
15 5
16
5 10
5
10
20
30
30
81
M4433_b
27,9
60
MAX 15

4,5
32,1
16
15
30
4,5
15 10 27
20 10
51
184
M4434_b
27,9
60
30
51
55,5
24
48,7
M5x10
6,5
4,5
27,75
32,1
15 5
12
6
5,5
7,25
80
6
95
Actuator module A + standard actuator T
Actuator module B + actuator C
Actuator module B + actuator CS
Dimension tolerance ±2%
Dimension tolerance ±2%
Dimension tolerance ±2%
M4434_b
27,9
60
30
51
55,5
24
48,7
M5x10
6,5
4,5
27,75
32,1
15 5
12
6
5,5
7,25
80
6
95
Actuator module A + actuator J
Dimension tolerance ±2%
2.6 Mounting dimensions of actuators and actuator modules

13 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
261
12-17
96
68
5,5
98
49
12
30 59
105
150
20
131
M6220 0 _a
67,5
16,5
1-6
Actuator module B + actuator CW
A-A A
A
M20215_b
1
General tolerance ± 2 %
L1: Length of mounting plate
X : number of mechanical units above the actuator module 1 (the example shows x=0)
L1
Actual status:
Actuator inserted
113,2
max. 87,5
30
96
98,75 + X * 60,5
L1+45
10
6,5
467420
6,6
73
10,5
5,5
24
Door handle actuator TG
Dimension tolerance ±2 %
Presentation:
Actuator inserted
Presentation:
Actuator not inserted
Important for Mounting kit

14 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Preparation of assembly B: Installation slide bar CW at fence
1.
2.
M20616_a
73
98,75 +X *60,5
L + 54
2
xM6
45xM
24
M7_2061 a
96
74
46x M
C: Installation of STS-M01BM unit D: Actuate unit
1.
2.
M_a20618
M_a20619
E: Check function
M060_
22a
2.8 Slide bar CW
Installation dimensions see 2.7 Actuator module B + actuator CW Installation dimensions see 2.7 Actuator module B + actuator CW
1. Bring unit into position
2. Fix unit with screws

15 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
A: Installation at machine fence B: Position wire rope and T-handle
M02_
264a
2x M4
20
M2 60 25_a
C: Check function
M2 602
6_a
2.9 Actuator CS and CSF
Lead wire rope and T-handle through the gridInstallation dimensions see 2.7 Actuator module B + actuator CS
Lock actuator CS and check function

16 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
M6_20 01 a
M_20600 a
M0 1a262_
A: Installation C-actuator + bracket C
B: Installation CA-actuator + door handle actuator
C: Installation J-actuator + door handle actuator
2.10 Reception of different actuators with door handle actuator TG

17 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
Right hinge
M6_20 08 a
2.)
3.)
M_20607 a
M6_20 09 a
M060_21a
1.)
4.)
5.)
6.)
Note:
1.) In case of right hinge = position on the right. The
notch is directed towards the inner axis.
4.) Place emergency handle on square shaft
5.) Screw down M6 threaded pin
6.) Check function
2.) Install preloaded unit above bar for emergency handle
3.) Screw down and secure preloaded unit with 2x M3 screws
2.11 Door Handle Actuator TG

18 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
Left hinge
M06 _20
3a
M 0604_a2
M_20605 a
M0_206 6 a
1.)
2.)
3.)
4.)
5.)
6.)
Note:
1.) In case of left hinge = position on the left. The
notch is directed towards the outer axis.
4.) Place emergency handle on square shaft
5.) Screw down M6 threaded pin
6.) Check function
2.) Install preloaded unit above bar for emergency handle
3.) Screw down and secure preloaded unit with 2x M3 screws
2.10 Door Handle Actuator TG
1.)

19 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
M4673_a
60
45
35
60
45
35
R2
5,5
206,6
60,5
5,5
360,5
M4674_a
60
45
35
60
45
35
R2
5,5
206,6
60,5
421
121
2x60,5=
5,5
M4675_a
60
45
35
60
45
35
R2
5,5
206,6
60,5
481,5
181,5
3x60,5=
5,5
Dimensions / Drilling plan control cabinet
M4710_a
2.11 Power Interlocking

20 Mounting- and operating instruction SAFEMASTER STS / 08.01.21 en / XXXX
Versions 25 ... 125 A
M4677_b
1.
2.
M4678_b
Versions 160 ... 800 A
3.
1.
3.
2.
4.
M4679_a
5.
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.
!
Cabinet inside
Cabinet outside
Mounting remarks