SICK flexLock User manual

OPERATING INSTRUCTIONS
flexLock
Safety locking device

Described product
flexLock
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Scope......................................................................................................... 5
1.2 Target groups of these operating instructions........................................ 5
1.3 Additional information.............................................................................. 5
1.4 Symbols and document conventions...................................................... 5
2 Safety information............................................................................ 7
2.1 General safety notes................................................................................ 7
2.2 Intended use............................................................................................. 7
2.3 Improper use............................................................................................. 7
2.4 Requirements for the qualification of personnel.................................... 8
3 Product description........................................................................... 9
3.1 Design and function................................................................................. 9
3.2 Product characteristics............................................................................ 9
3.3 Manual unlocking..................................................................................... 11
4 Project planning................................................................................ 13
4.1 Manufacturer of the machine.................................................................. 13
4.2 Operating entity of the machine.............................................................. 13
4.3 Design........................................................................................................ 13
4.4 Integration in the electrical control system............................................. 16
4.5 Testing plan............................................................................................... 19
5 Mounting............................................................................................. 21
5.1 Orientation of the safety switch............................................................... 21
5.2 Mounting several safety switches............................................................ 21
5.3 Mounting the safety switch...................................................................... 21
5.4 Mounting the actuator.............................................................................. 23
5.5 Mounting the escape release.................................................................. 24
6 Electrical installation........................................................................ 25
6.1 Notes on cULus......................................................................................... 25
6.2 Device connection.................................................................................... 25
6.3 Connection of a safe series connection.................................................. 25
7 Commissioning.................................................................................. 28
7.1 Teach-in..................................................................................................... 28
7.2 Thorough check during commissioning and modifications................... 30
8 Operation............................................................................................ 31
8.1 Actuating the auxiliary release................................................................. 31
8.2 Actuating the escape release.................................................................. 31
8.3 Preventing unintentional closing of the movable physical guard.......... 31
CONTENTS
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9 Maintenance...................................................................................... 33
9.1 Cleaning..................................................................................................... 33
9.2 Regular thorough check........................................................................... 33
10 Troubleshooting................................................................................. 34
10.1 LED indicators........................................................................................... 34
11 Decommissioning............................................................................. 38
11.1 Disposal..................................................................................................... 38
12 Technical data.................................................................................... 39
12.1 Data sheet................................................................................................. 39
12.2 Classification according to ZVEI, CB24I.................................................. 41
12.3 Connecting cables.................................................................................... 41
12.4 Safety switch dimensional drawings....................................................... 42
12.5 Actuator dimensional drawings................................................................ 43
12.6 Dimensional drawings of the mounting bracket..................................... 44
12.7 Spacers dimensional drawings................................................................ 44
13 Ordering information........................................................................ 45
13.1 Scope of delivery....................................................................................... 45
13.2 Ordering information................................................................................. 45
14 Accessories........................................................................................ 46
14.1 Actuator..................................................................................................... 46
14.2 Connectivity............................................................................................... 46
14.3 Mounting bracket...................................................................................... 48
15 Annex.................................................................................................. 49
15.1 Conformities and certificates................................................................... 49
CONTENTS
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1 About this document
1.1 Scope
Product
This document applies to the following products:
•Product code: flexLock
•“Operating instructions” type label entry: 8025630
Document identification
Document part number:
•This document: 8020562
•Available language versions of this document: 8025630
You can find the current version of all documents at www.sick.com.
1.2 Target groups of these operating instructions
Some sections of these operating instructions are intended for certain target groups.
However, the entire operating instructions are relevant for intended use of the product.
Table 1: Target groups and selected sections of these operating instructions
Target group Sections of these operating instructions
Project developers (planners, developers,
designers)
"Project planning", page 13
"Technical data", page 39
Installers "Mounting", page 21
Electricians "Electrical installation", page 25
Safety experts (such as CE authorized repre‐
sentatives, compliance officers, people who
test and approve the application)
"Project planning", page 13
"Commissioning", page 28
"Technical data", page 39
Operators "Troubleshooting", page 34
Maintenance personnel "Troubleshooting", page 34
1.3 Additional information
www.sick.com
The following information is available on the Internet:
•Data sheets and application examples
•CAD data and dimensional drawings
•Certificates (e.g. EU declaration of conformity)
•Guide for Safe Machinery Six steps to a safe machine
1.4 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
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WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
bThe arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓The check mark denotes the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
oThe LED is off.
ÖThe LED is flashing.
OThe LED is illuminated continuously.
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2 Safety information
2.1 General safety notes
Product integration
DANGER
The product can not offer the expected protection if it is integrated incorrectly.
bPlan the integration of the product in accordance with the machine requirements
(project planning).
bImplement the integration of the product in accordance with the project planning.
Mounting and electrical installation
DANGER
Death or severe injury due to electrical voltage and/or an unexpected startup of the
machine
bMake sure that the machine is (and remains) disconnected from the voltage
supply during mounting and electrical installation.
bMake sure that the dangerous state of the machine is and remains switched off.
Repairs and modifications
DANGER
Improper work on the product
A modified product may not offer the expected protection if it is integrated incorrectly.
bApart from the procedures described in this document, do not repair, open, manip‐
ulate or otherwise modify the product.
2.2 Intended use
The safety locking device is a locking unit with a safety locking function and is suitable
for the following applications:
•Temporarily preventing access to a hazardous area
•Monitoring of movable physical guards
•Locking for process protection
In conjunction with a movable physical guard and the machine controller, the safety
locking device prevents the movable physical guard from being opened. The locking
function remains locked for as long as the hazardous machine function is performed or
until the production step has finished.
The product is only suitable for use in industrial environments.
Incorrect use, improper modification of or tampering with the safety locking device will
invalidate any warranty from SICK AG; in addition, any responsibility and liability of SICK
AG for damage and secondary damage caused by this is excluded.
2.3 Improper use
The safety locking device is not suitable, among other things, for the following ambient
conditions:
•Outdoor areas
•Residential areas
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•Vacuum
•High pressure
•Strong UV exposure
•Near low-frequency RFID
•Near magnetic fields
•Increased radioactivity (> natural radioactivity)
•High sulfur concentration
•High salt concentration
2.4 Requirements for the qualification of personnel
The safety locking device must be planned in, installed, connected, commissioned, and
serviced only by qualified safety personnel.
Project planning
You need safety expertise to implement safety functions and select suitable products
for that purpose. You need expert knowledge of the applicable standards and regula‐
tions.
Mounting, electrical installation and commissioning
You need suitable expertise and experience. You must be able to assess if the machine
is operating safely.
Operation and maintenance
You need suitable expertise and experience. You must be instructed in machine oper‐
ation by the machine operator. For maintenance, you must be able to assess if the
machine is operating safely.
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3 Product description
3.1 Design and function
Design
The safety locking device is a locking unit with a safety locking function. The safety
locking device consists of a safety switch with RFID monitoring and a coded actuator.
Function
The safety locking device is used on a movable physical guard. The safety switch is
located on the frame of the movable physical guard, the actuator on the moving part.
When the movable physical guards closes, the actuator is inserted into the safety
switch. The safety switch reads the code of the actuator. If the code is valid, the safety
locking function can be locked via a signal. The movable physical guard is held closed.
3.2 Product characteristics
3.2.1 Device overview
4
1
9
2
3
5
ß
ß
6
1
7
8
á
Figure 1: Device overview
1Retaining ball
2Locking pin
3safety switch
4LED display
5Connection
6Auxiliary release
7Mounting holes
8Escape release
9Protective cap for mounting holes of the safety switch
ßActuator tongue
àMounting plate of the actuator
áProtective cap for actuator mounting holes
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3.2.2 Locking principle
Overview
The method of locking depends on the safety locking device variant selected. There are
two variants:
•Power to lock
•Power to release
Power to lock
•Locking the locking function: voltage at locking function input
•Unlocking the locking function: no voltage at locking function input
If voltage is interrupted, the locking function is unlocked and movable physical guard
can be opened immediately.
DANGER
Hazard due to lack of effectiveness of the protective device
For power to lock variants only: In the event of a voltage drop, the locking function
unlocks regardless of whether the dangerous state of the machine has ended.
bDo not use the safety switch in applications in which the dangerous state cannot
be ended immediately (stopping/run-down time).
Power to release
•Locking the locking function: no voltage at locking function input
•Unlocking the locking function: voltage at locking function input
If the voltage is interrupted, the locking function retains its last state (bistable sole‐
noid). If the locking function was locked before, the movable physical guard cannot be
opened. If the locking function was not locked before, the movable physical guard can
be opened.
Only the power to release variants have an auxiliary release.
3.2.3 OSSD
Output signal switching device: signal output for the protective device, which is used for
stopping the dangerous movement.
An OSSD is a safety switching output. The functionality of each OSSD is tested periodi‐
cally. OSSDs are always connected in pairs and must undergo dual-channel analysis for
safety reasons. An OSSD pair is formed from 2 OSSDs that are connected and analyzed
together.
3.2.4 Switching behavior of the OSSDs
Overview
The safety locking device is available in variants for protecting people or for process
protection. The variants differ with regards to the switching behavior of the OSSDs.
Variants for protecting people (locking monitoring)
OSSDs go into the ON state when the following conditions are all met.
•Movable physical guard is closed.
•Locking function is locked.
•A valid signal is present at the inputs In1 and In2.
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Variants for process protection (actuator monitoring)
OSSDs go into the ON state when the following conditions are all met.
•Movable physical guard is closed.
•A valid signal is present at the inputs In1 and In2.
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
bDo not use variants for process protection in applications where the dangerous
state cannot be ended immediately (stopping/run-down time).
3.2.5 Application diagnostic output
Important information
NOTE
The application diagnostic output cannot be evaluated for a safe series connection with
T-connectors.
Switching behavior
The application diagnostic output switches depending on the detection of the actuator.
This is not a safety output.
Status of the movable physi‐
cal guard
Switching behavior of the application diagnostic output
Open OFF
Closed ON
3.2.6 Coded actuators
The safety locking device comes with RFID-coded actuators.
•Uniquely coded
Only one actuator is valid at any one time. Actuators need to be taught-in
to become valid. Each time a new actuator is taught-in, the previous actuator
becomes invalid.
Coding level: High (ISO14119)
•Universally coded
The device accepts all actuators that are suitable for the device.
Coding level: Low (ISO14119)
3.3 Manual unlocking
In some situations, it necessary to unlock the locking device manually (e.g. if faults are
present). When unlocking, the safe output signal switching devices (OSSD) switch to the
OFF status. A stop command must be generated as a result.
After manual unlocking, a function check-out must be performed (see "Thorough check
during commissioning and modifications", page 30).
3.3.1 Auxiliary release
Using the auxiliary release, the safety locking device can be manually unlocked regard‐
less of the status.
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1
Figure 2: Position of the auxiliary release
1Auxiliary release
Only the power to release variants have an auxiliary release.
3.3.2 Escape release
The escape release makes it possible to open a closed movable physical guard without
tools from within the hazardous area.
WARNING
•The escape release must be able to be actuated manually from inside the pro‐
tected area without tools.
•Mount the escape release so that actuation can only take place from inside of
protected area (hazardous area).
1
1Escape release
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4 Project planning
4.1 Manufacturer of the machine
The manufacturer of the machinery must carry out a risk assessment and apply appro‐
priate protective measures. Further protective measures may be required in addition to
the product.
The product must not be tampered with or changed, except for the procedures descri‐
bed in this document.
The product must only be repaired by the manufacturer of the product or by someone
authorized by the manufacturer. Improper repair can result in the product not providing
the expected protection.
Observe EN ISO 14119 for using interlocking devices associated with physical guards.
4.2 Operating entity of the machine
Changes to the electrical integration of the product in the machine controller and
changes to the mechanical mounting of the product necessitate a new risk assess‐
ment. The results of this risk assessment may require the entity operating the machine
to meet the obligations of a manufacturer.
After each change to the configuration, it is necessary to check whether the protective
measure provides the necessary protection. The person making the change is responsi‐
ble for ensuring that the protection measure provides the necessary protection.
The product must not be tampered with or changed, except for the procedures descri‐
bed in this document.
The product must not be repaired. Defective products must be replaced.
Restrict access to replacement actuators, so they cannot be used for bypassing.
4.3 Design
4.3.1 Features of the actuator
The actuator is available in different designs.
•Rigid actuator
•Flexible actuator
Table 2: Features of the actuator
Flexible actuator Rigid actuator
Alignment of actuator to
mounting surface
Straight Angled
Minimum door radius for door
stop above the device
500mm 800mm
Minimum door radius for door
stop on left or right of device
180mm 150mm
Max. horizontal offset 13mm 0.5mm
Max. vertical offset 33mm 0.5mm
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Flexible actuator Rigid actuator
Max. offset angle about the X-
axis 4
2.5° 0°
Max. offset angle about the Y-
axis 2
2.5° 0°
Max. offset about the Z-axis 52.5° 0°
Rotatable and spring-loaded
actuator
Yes No
12
4 5
3
Figure 3: Offset and offset angle
4.3.2 Actuating direction
The safety locking device can be actuated horizontally within a 180° radius with infinite
adjustment.
180°
Figure 4: Possible actuating directions
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The flexible actuator can only be inserted
frontally.
The rigid actuator can be inserted fron‐
tally and laterally.
Figure 5: Actuation direction of flexible actua‐
tor Figure 6: Actuation direction of rigid actuator
4.3.3 Measures against accidental damage
You can use the following measures to avoid unintentional damage to the safety switch:
•Select the mounting location so that the safety switch is protected from impacts
and mechanical pressure.
•Fit an additional stop for the door. The safety switch must not be used as a stop.
4.3.4 Measures against manipulation
The safety switch must not be defeated (contacts jumpered), rotated away, removed, or
rendered ineffective in any other way. You must put measures in place, if necessary, to
reduce the possibilities for circumventing the device.
4.3.5 Preparing the mounting surface
Overview
If the safety locking device is used without mounting brackets, appropriate holes must
be provided in the mounting surface. The necessary drill holes can be seen from the
dimensional drawings of the safety switch.
For variants with escape release, the maximum wall thickness must be taken into
account.
Maximum wall thickness
It must be possible to reset the escape release after actuation. The button of the
escape release must therefore not lie flat after actuation. The wall thickness of the
mounting surface must therefore be max. 34mm.
Using spacers, the axis of the escape release can be extended in 30mm increments.
This enables the maximum wall thickness to be increased to 64mm or 94mm.
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6
34
50
Figure 7: Maximum wall thickness of the mounting surface (without spacers)
Further topics
•"Safety switch dimensional drawings", page 42
4.4 Integration in the electrical control system
You need to take the following into consideration when integrating the safety locking
device into the electrical control system.
Requirement for use
•The safety locking device must not be bypassed by electrical means, e.g. by
bridging the contacts. You may need to take measures to prevent this.
•The connected controller and all devices responsible for safety must comply with
the required performance level and the required category (for example according
to ISO13849-1).
•The overall concept of the control system in which the device is integrated must be
validated in accordance with ISO13849-2.
•The inputs of a connected evaluation unit must be positive-switching (PNP) inputs
because the two outputs of the safety switch supply a level of the supply voltage in
the switched-ON state.
Generating the signals for the safety locking device
•For variants for protecting people only: The locking function may only be unlocked
when the dangerous state has ended. Depending on the safety concept, the signal
is analyzed, for example, by a safety relay or a safety controller.
•Use control without test pulses. The safety switch generates its own test pulses.
Evaluating the signals from the safety locking device
•In the closed or locked state, the OSSDs signal the ON state with the signal level
HIGH (non-isolated). When opened or unlocked or there is a device fault, the
OSSDs signal the OFF state with the signal level LOW.
•Downstream control elements must evaluate the output signals of the safety
switch in such a way that the dangerous state of the machine is safely ended. The
machine switches to the safe state if, at any time, at least one OSSD in the OSSD
pair switches to the OFF state.
•Switch-on commands that put the machine in a dangerous state may only be
activated when the OSSDs of the safety locking device are in the ON state.
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•Closing or locking the movable physical guard must not trigger the automatic
starting of a hazardous machine function. This must occur by means of a separate
start command.
•The safety switch tests the OSSDs at regular intervals. To do this, the safety switch
switches each OSSD briefly (for max. 300µs) to the OFF state and checks whether
this channel is voltage-free during this time. Make sure that the machine’s control
does not react to these test pulses and the machine does not switch off.
4.4.1 OSSDs
Overview
You can integrate the safety component directly into the machine controller via the
safety outputs (OSSDs). The OSSDs indicate the ON state with the HIGH signal level
(non-isolated). The OFF state is indicated with the LOW signal level.
Downstream control elements must evaluate the output signals of the safety compo‐
nent in such a way that the dangerous state of the machine is safely ended. Depending
on the safety concept, the signal is analyzed by, e.g., safety relays or a safety controller.
Isolated connection of OSSD1 and OSSD2
•It must be possible to electrically influence the control of the machine.
•The electrical control of the machine must meet the requirements of IEC 60204-1.
•When using a safety controller, different signal levels of both OSSDs must be
detected depending on applicable national regulations or required reliability of the
safety function. The maximum discrepancy time tolerated by the controller must
be selected according to the application
•The OSSD1 and OSSD2 output signals must not be connected to each other.
•In the machine controller, the signals of both OSSDs must be processed sepa‐
rately.
Avoiding any potential difference between the load and safety component
If you connect loads to the output signal switching devices (switching outputs) that
then also switch if controlled with negative voltage (e.g., electro-mechanical contactor
without reverse polarity protection diode), you must connect the 0V connections of
these loads and those of the corresponding protective device separately and also
directly to the same 0V terminal strip. In the event of a fault, this is the only way to
ensure that there can be no potential difference between the 0V connections of the
loads and those of the corresponding safety component.
Figure 8: No potential difference between the load and safety component
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4.4.2 Safe series connection
Overview
Several safety switches can be connected in series in a safe series connection. The
type of safe series connection depends on the safety switch variant selected.
The following options are available:
•Safe series connection with Flexi Loop (with diagnostics)
In a series connection with Flexi Loop, the safety switches are connected to
Flexi Loop nodes. Each Flexi Loop node evaluates a safety switch and sends the
information to the evaluation unit for safety sensors from SICK.
•Safe series connection with T-connector (without diagnostics)
In a series connection with T-connectors, several safety switches are connected
via T-connectors and connected to the safe evaluation unit. The connected devices
act like a single device.
•Safe series connection in control cabinet (with diagnostics)
In a series connection in the control cabinet, the safety switches are led to the
control cabinet individually. The OSSDs of the safety switches are connected in
series there and evaluated by the evaluation unit. The Aux outputs can be individu‐
ally connected to the programmable logic controller (PLC).
Safe series connection with T-connectors or in the control cabinet
1 1 1 1 1 2
OSSD1
OSSD2
OSSD1
OSSD2
OSSD1
OSSD2
OSSD1
OSSD2
OSSD1
OSSD2
Figure 9: Switching with 5 safety switches connected in series
1Safety switch
2Safe evaluation unit
The voltage drop in the series connection must be checked so that the defined mini‐
mum voltage is still applied to the last safety switch.
For connection cables with a length of 2m and a cable cross-section of 0.25mm², the
maximum number of safety switches in connected in series depends on the voltage as
follows:
Table 3: Maximum number of safety switches in a series connection depends on the voltage
Voltage Connection cables, for ser‐
ies connection
Input voltage at the
last safety switch
Maximum number of
safety switches in ser‐
ies connection
24V Length: 2m
Cable cross-section
•General: 0.34mm²
•Between the safety
switch and series
connection nodes:
0.25mm²
19.2V 4
26V 19.5V 5
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Additional voltage supply
The voltage drop in the safe series connection must be checked so that the defined
minimum voltage is still applied to each safety switch. If the defined minimum voltage
is no longer applied to a safety switch, a node for voltage supply must be integrated.
The node for voltage supply must be integrated in the safe series connection in the
direction of the safe evaluation unit, as close as possible to the relevant switch.
Complementary information
Number of safety locking devices in a safe series connection
The maximum number of safety locking devices in a safe series connection
depends on the following factors:
•Technical implementation of the safe series connection (T-connector, Flexi Loop, or
series connection in the control cabinet)
•Applied supply voltage
•Length of cables used
•Cable cross-section of cables used
•Load current
•Node for voltage supply
•Required performance level
The number of safety locking devices in a safe series connection affects the
response times of the system (see "Data sheet", page 39).
4.5 Testing plan
Overview
The manufacturer of the machine and the operating entity must define all required
thorough checks. The definition must be based on the application conditions and the
risk assessment and must be documented in a traceable manner.
Important information
DANGER
Insufficient checks or incorrect repair
Hazard due to lack of effectiveness of the protective device
bReplace safety switch and actuator if damaged or worn. Never replace individual
parts or assemblies.
bCheck the safety switch at the inspection intervals specified in the national rules
and regulations.
Defining the thorough check
bWhen defining the thorough check, please note the following:
°Define the type and execution of the thorough check.
°Define the frequency of the thorough check.
°Notify the machine operators of the thorough check and instruct them
accordingly.
The following thorough checks are often defined in connection with a protective
device:
•Thorough check during commissioning and modifications
•Regular thorough check
Minimum requirements for the thorough check
The following checks must be done to ensure permanent and proper function:
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•Proper switching function
•Safe mounting of all components
•No damage, contamination, deposits or wear
•No loose plug connectors
•No signs of manipulation
•For safety switches with taught-in actuators: The actuators used are taught-in
actuators.
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