OPERATING INSTRUCTIONS flexLock Safety locking device Review version 2021-04-30
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.
CONTENTS Contents 1 2 3 About this document........................................................................ 5 1.1 1.2 1.3 1.4 Scope......................................................................................................... Target groups of these operating instructions........................................ Additional information.............................................................................. Symbols and document conventions.........................................
CONTENTS 9 Maintenance...................................................................................... 29 9.1 10 Cleaning..................................................................................................... Troubleshooting................................................................................. 30 10.1 Safety......................................................................................................... 10.2 LED indicators...........................................
ABOUT THIS DOCUMENT 1 1 About this document 1.1 Scope These operating instructions are valid for the flexLock safety locking device. This document is included with the following SICK part numbers (this document in all available language versions): 8025630 1.2 Target groups of these operating instructions Some chapters of these operating instructions are intended for certain target groups. However, the entire operating instructions are relevant for intended use of the product.
1 ABOUT THIS DOCUMENT 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 b The arrow denotes instructions to action. 1. 2. ✓ The sequence of instructions for action is numbered. Follow the order in which the numbered instructions are given.
SAFETY INFORMATION 2 2 Safety information 2.1 General safety notes DANGER If the safety component is integrated incorrectly, the dangerous state may be ended to late. b 2.2 Plan the integration of the safety component in accordance with the machine requirements, see "Project planning", page 13.
2 SAFETY INFORMATION Mechanical mounting, electrical installation, and commissioning For the task, a person is considered qualified when he/she has the expertise and experience in the relevant field and is sufficiently familiar with the application of the protective device on the machine to be able to assess whether it is in an operationally safe state.
PRODUCT DESCRIPTION 3 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 comprises a safety switch with transpondermonitoring 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 guard, the actuator on the moving part. When the protective device is closed, the actuator is inserted into the safety switch.
3 PRODUCT DESCRIPTION 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 Important information 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 device unlocks regardless of whether the dangerous state of the machine has ended.
PRODUCT DESCRIPTION 3 Variants for process protection (actuator monitoring) OSSDs go into the ON state as soon as the following requirements are all fullfilled. • Movable physical guard is closed. • There is a valid signal at the inputs In1 and In2. Important information DANGER Hazard due to lack of effectiveness of the protective device b 3.2.5 Do not use variants for process protection in applications in which the dangerous state cannot be ended immediately (stopping/run-down time).
3 PRODUCT DESCRIPTION ! Figure 2: auxiliary release 1 Auxiliary release Only the power to release variants have a auxiliary release.
PROJECT PLANNING 4 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 safety locking device. The device must not be tampered with or changed, except for the procedures described in this document. The device must not be repaired. Defect devices have to be replaced.
4 PROJECT PLANNING Flexible Rigid Max. offset angle about Z-axis 2,5° % 0° Rotable and spring loaded actuator No Yes ! " $ § % Figure 3: Offsets and offset angle 4.3.2 Actuating direction The safety locking device can be actuated horizontally within a continous 180° radius. 180° Figure 4: Possible actuating directions The flexible actuator can only move for‐ wards for actuation.
PROJECT PLANNING 4 Figure 5: Sideways approach with flexible actua‐ Figure 6: Sideways approach with rigid actuator tor 4.3.3 Measures to protect against unintentional damage You can use the following measures to avoid unintentional damage to the safety switch: • • 4.3.4 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 PROJECT PLANNING • • • 4.4.1 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. Closing or locking the protective device must not trigger the automated 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.
PROJECT PLANNING 4 Table 3: Maximum number of safety switches in a series connection depends on the voltage Voltage Connection cables, uni‐ form for the entire series connection Input voltage at 30th safety switch Maximum number of safety switches in ser‐ ies connection 24 V Length: 2 m 19.2 V 4 Cable cross-section: • General: 0,34 mm² • Connection between safety switch and junc‐ tion: 0,25 mm² 19.
5 MOUNTING 5 Mounting 5.1 Safety DANGER Hazard due to unexpected starting of the machine Death or severe injury b Make sure that the dangerous state of the machine is and remains switched off. NOTICE If incorrectly installed or if the ambient conditions are not suitable, the safety locking device can be damaged. b b b b b b b b b b 5.2 Arrange the safety switch and actuator so that damage due to unintentional out‐ side influences is prevented. Do not use a safety switch and actuator as a stop.
MOUNTING 5 5.4 Mounting the safety switch Approach 1. 2. 3. 5.5 Select a position for the safety switch on the fixed part of the protective device. The safety switch must be positioned in such a way that the actuator is inserted into the safety switch when the movable physical guard is closed. Attach the safety switch to the protective device. Minimum requirements for mounting screws ° Number: 4 ° Size: M5 × 25 (or longer) ° Strength class: Class 8.
6 ELECTRICAL INSTALLATION 6 Electrical installation 6.1 Safety Overview You can directly integrate the safety switch into the machine controller via the safety outputs (OSSDs). The OSSDs indicate the ON state with the HIGH signal level (non-iso‐ lated). The OFF state is indicated with the LOW signal level. Downstream control elements must evaluate the output signals of the protective device in such a way that the dangerous state of the machine is safely ended.
ELECTRICAL INSTALLATION 6 Avoiding any potential difference between load and protective device 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.
6 ELECTRICAL INSTALLATION PIN Wire color 1) Designation Description 8 Red In 1 Enable input for OSSD12) 1) 2) 6.4 Applies to the extension cables recommended as accessories. When used as an individual safety locking device or as the first safety locking device in a safe series connection, apply 24 V DC. Connection of a safe series connection Overview The safe series connection can be implemented using special T-connectors and an end connector.
ELECTRICAL INSTALLATION 6 1 2 3 4 5 1 1 2 2 3 3 4 4 5 5 Figure 14: Internal circuitry: nodes for voltage supply 2 1 5 3 4 Figure 15: Connection of the safe series connection (M12, 5-pin, A-coded, male connector) Table 5: Pin assignment connection of the safe series connector (male connector, M12, 5-pin, A-coded) PIN Wire color 1) Designation Description 1 Brown +24 V DC Voltage supply 24 V DC 2 White OSSD 1 OSSD 1 output 3 Blue 0V Voltage supply 0 V DC 4 Black OSSD 2 OSSD
7 COMMISSIONING 7 Commissioning 7.1 Teach-in 7.1.1 Teaching in the first actuator Important information NOTE Safety locking devices in the delivery condition have a teach-in-window of 30 minutes after being switched on. After this, the Safety locking device switches into safe state. For a new teach-in-window the device needs to be restarted (disconnect and restore the voltage supply). NOTE The teach-in process is invalid if canceled, e.g.
COMMISSIONING 7 7.1.2 Teaching in the replacement actuator Overview The safety locking device can only be operated using the actuator that was last taught in. Important information NOTE Safety locking devices with an actuator that has already been taught-in have a teach-in readiness of approx. 5 minutes after being switched on. in this time window, the following is true: • • • • If the actual valid actuator is detected, the teach-in process is canceled. The safety switch returns to normal mode.
7 COMMISSIONING 7.2 Testing DANGER Hazard due to unexpected starting of the machine Death or severe injury b Before carrying out the functional test, make sure that there are no people in the hazardous area. Approach Check that the device is functioning properly after installation and after every fault. To do this, proceed as follows: Mechanical functional test b Open the protective device and close it again. The components of the safety locking device must not collide with other parts.
COMMISSIONING 7 Monitoring The following checks must be done to ensure permanent and proper function: • • • • • • 8020562/2021-04-30 | SICK Subject to change without notice Proper switching function Manual unlock function (e.g.
8 OPERATION 8 Operation 8.1 Actuating the mechanical unlocking mechanism Prerequisites • TX10 Torx screwdriver Approach 1. 2. 3. Ensure that the actuator is not under strong tensile stress (≤ 20 N). Loosen the retaining screw with the screwdriver. Use the screwdriver to rotate the mechanical unlocking mechanism in the direc‐ tion of the arrow to the following symbol: ✓ The locking device is unlocked.
MAINTENANCE 9 9 Maintenance 9.1 Cleaning NOTICE b b b 8020562/2021-04-30 | SICK Subject to change without notice Do not use aggressive cleaning agents (such as isopropanol or spirit). Do not use any substances that hinder the wetting properties of lacquers. We recommend anti-static cleaning agents.
10 TROUBLESHOOTING 10 Troubleshooting 10.1 Safety DANGER Hazard due to lack of effectiveness of the protective device Persons and parts of the body to be protected may not be recognized in case of non-observance. b b b Immediately shut the machine down if the behavior of the machine cannot be clearly identified. Immediately put the machine out of operation if you cannot clearly identify or allocate the fault and if you cannot safely remedy the fault.
TROUBLESHOOTING 10 In combination, these LEDs indicate detailed status and error states. In general, the STATUS and LOCK LEDs indicate the following states. Table 9: ! STATUS LED Display Status Ö Green Valid actuator detected. OSSD LOW. O Green Valid actuator detected. OSSD HIGH. O Red No valid actuator detected. OSSD LOW. Table 10: " LOCK LED Display Status o No active locking signal Ö Green Locking signal active, locking device not locked.
10 TROUBLESHOOTING Table 13: Error indications during teach-in LED indicators STATUS LOCK OSSDs DIAG Inputs LOCK IN 1/IN 2 Cause Troubleshooting ÖÖ o Red/green (4 Hz) Ö Red (4 Hz) OFF Not rele‐ vant Not rele‐ vant Teach-in failed. Device was not restarted within the expected time Disconnect and restore the voltage supply. Repeat the teach-in. ÖÖ o Red/green (4 Hz) O Red OFF Not rele‐ vant Not rele‐ vant Teach-in failed. Actua‐ tor was removed too soon.
TROUBLESHOOTING 10 LED indicators OSSDs STATUS LOCK DIAG Ö Red (1 Hz) o Ö Red (4 Hz) Ö Red (1 Hz) o O Red Inputs Cause Troubleshooting LOCK IN 1/IN 2 OFF Not rele‐ vant Not rele‐ vant External error b Check OSSD-cables for short circuit to 0 V or 24 V or to each other. b Check cables for damage. b Disconnect and restore the voltage supply.
11 DECOMMISSIONING 11 Decommissioning 11.1 Disposal Approach b Always dispose of unusable devices in accordance with national waste disposal regulations. Complementary information SICK will be glad to help you dispose of these devices on request.
TECHNICAL DATA 12 12 Technical data 12.1 Data sheet Table 16: Features Principle of operation Transponder Frequency band 125 Hz Actuating force 20 N Retaining force 30 N Force against which unlocking is possible ≤ 25 N Actuating frequency ≤ 1 Hz Actuation speed of the actuator ≤ 20 m/min Dwell time between interlocking and unlocking 1.5 s (or vice versa) Table 17: Locking forces Locking force FZh (FZh = Fmax / 1.
12 TECHNICAL DATA Utilization category DC 13 (IEC 60947-5-3) Supply voltage UV 24 V DC (19.2 V DC … 28.8 V DC) (SELV/PELV) 1) Current consumption at 24 V (without load) FXL1-SPB***** 55 mA FXL1-SPL*****, locking device unlocked 55 mA FXL1-SPL*****, locking device locked 115 mA Peak current consumption at 24 V (without load) 800mA for max.
TECHNICAL DATA 12 Output voltage in OFF state Uv - 2 V DC … Uv (max.
12 TECHNICAL DATA 12.3 Safety switch dimensional drawings 12.4 Actuator dimensional drawings 12.
ORDERING INFORMATION 13 13 Ordering information 13.1 Scope of delivery • • • • 13.2 Safety switch Sealing plug for secure mounting Safety note Operating instructions for download: www.sick.
14 ACCESSORIES 14 Accessories 14.1 Actuator Table 29: Actuator flexLock 14.2 Description Type code Part number Actuator, flexible FXL1-AF1 1101326 Actuator, rigid FXL1-AR1 1101327 Connectivity M12 connecting cable, 8-pin (0.25 mm2) Table 30: Ordering information for M12 connecting cable, 8-pin (0.25 mm2) 1) Part Type code Part number Female connector, straight, 2.
ACCESSORIES 14 M12 connection cable, 8-pin (0.25 mm2) Table 32: Ordering information for M12 connection cable, 8-pin (0.25 mm2) 3) Part Type code Part number Female connector, straight, 0.
15 ANNEX 15 Annex 15.1 Compliance with EU directives EU declaration of conformity (extract) The undersigned, representing the manufacturer, herewith declares that the product is in conformity with the provisions of the following EU directive(s) (including all applicable amendments), and that the standards and/or technical specifications stated in the EU declaration of conformity have been used as a basis for this.
ANNEX 15 15.2 FCC and IC radio approval • • FCC ID: 2AHDRFXL1 IC: 21147FXL1 The device fulfills the EMC requirements for use in the USA and Canada, in accordance with the following extracts from the relevant approvals: FCC § 15.19 This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: • • This device may not cause harmful interference, and this device must accept any interference received, including interference that may cause undesired operation.
8020562/2021-04-30/en Australia Phone +61 (3) 9457 0600 1800 33 48 02 – tollfree E-Mail sales@sick.com.au Hungary Phone +36 1 371 2680 E-Mail ertekesites@sick.hu Slovakia Phone +421 482 901 201 E-Mail mail@sick-sk.sk India Phone +91-22-6119 8900 E-Mail info@sick-india.com Slovenia Phone +386 591 78849 E-Mail office@sick.si Israel Phone +972 97110 11 E-Mail info@sick-sensors.com South Africa Phone +27 10 060 0550 E-Mail info@sickautomation.co.za Italy Phone +39 02 27 43 41 E-Mail info@sick.
