SICK TR110 Lock Operating Instructions Manual

TR110 Lock
Safety locking device

O P E R A T I N G I N S T R U C T I O N S

Described product
TR110 Lock
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 modifica‐ tion, abridgment or translation of this document is prohibited without the express writ‐ ten 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

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 Requirements for the qualification of personnel.................................... 7
3 Product description........................................................................... 8
3.1 Structure and function............................................................................. 8
3.2 Product characteristics............................................................................ 9
3.3 Manual unlocking..................................................................................... 12
4 Project planning................................................................................ 15
4.1 Manufacturer of the machine.................................................................. 15
4.2 Operator of the machine.......................................................................... 15
4.3 Design........................................................................................................ 15
4.4 Integration in the electrical control system............................................. 17
4.5 Testing plan............................................................................................... 23
5 Mounting............................................................................................. 24
5.1 Safety......................................................................................................... 24
5.2 Changing the actuation direction............................................................. 24
5.3 Mounting the safety switch...................................................................... 25
5.4 Mounting straight and angled actuators................................................. 25
5.5 Mounting the radius actuator.................................................................. 26
5.6 Mounting the escape release.................................................................. 26
5.7 Mounting the emergency unlocking........................................................ 27
5.8 Mounting the cover caps.......................................................................... 27
5.9 Removing the cover caps......................................................................... 28
6 Electrical installation........................................................................ 29
6.1 Safety......................................................................................................... 29
6.2 Notes on cULus......................................................................................... 29
6.3 Device connection.................................................................................... 29
6.4 Connection of a safe series connection.................................................. 32
7 Commissioning.................................................................................. 35
7.1 Switching on.............................................................................................. 35
7.2 Teach-in..................................................................................................... 35
7.3 Testing....................................................................................................... 37
7.4 Regular thorough check........................................................................... 38
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CONTENTS
8 Operation............................................................................................ 39
8.1 Actuating the mechanical unlocking mechanism................................... 39
8.2 Actuating the emergency release............................................................ 39
8.3 Actuating the escape release.................................................................. 40
9 Troubleshooting................................................................................. 42
9.1 Safety......................................................................................................... 42
9.2 System status........................................................................................... 42
10 Decommissioning............................................................................. 44
10.1 Disposal..................................................................................................... 44
11 Technical data.................................................................................... 45
11.1 Data sheet................................................................................................. 45
11.2 Connecting cables.................................................................................... 48
11.3 Safety switch dimensional drawings....................................................... 49
11.4 Actuator dimensional drawings................................................................ 55
11.5 Dimensional drawings of the mounting bracket..................................... 60
12 Ordering information........................................................................ 62
12.1 Scope of delivery....................................................................................... 62
12.2 Ordering information................................................................................. 62
13 Accessories........................................................................................ 63
13.1 Actuator..................................................................................................... 63
13.2 Connectivity............................................................................................... 63
13.3 Additional accessories............................................................................. 65
14 Annex.................................................................................................. 66
14.1 Compliance with EU directives................................................................. 66
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1 About this document

1.1 Scope

These operating instructions are valid for the TR110 Lock safety locking device.
This document is included with the following SICK part numbers (this document in all available language versions):
8023116

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.
Table 1: Target groups and selected chapters of these operating instructions
Target group Chapter of these operating instructions
Project developers (planners, developers, designers)
Installers "Mounting", page 24
Electricians "Electrical installation", page 29
Safety experts (such as CE authorized repre‐ sentatives, compliance officers, people who test and approve the application)
Operators "Troubleshooting", page 42
Maintenance personnel "Troubleshooting", page 42
ABOUT THIS DOCUMENT 1
"Project planning", page 15 "Technical data", page 45
"Project planning", page 15 "Commissioning", page 35 "Technical data", page 45

1.3 Additional information

www.sick.com
The following information is available on the Internet:
This document in other languages
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.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious injuries if not prevented.
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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
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
LED symbols
The arrow denotes instructions to action.
The check mark denotes the result of an instruction.
These symbols indicate the status of an LED:
The LED is off.
o
The LED is flashing.
Ö
The LED is illuminated continuously.
O
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2 Safety information

2.1 General safety notes

The safety locking device must be configured and operated correctly by qualified safety personnel according to the machine requirements.

2.2 Intended use

When used in conjunction with a movable physical guard and the machine controller, the safety locking device prevents the protective device from being opened while a dan‐ gerous machine function is being executed.
The safety locking device may only be used on the machine on which it was configured, mounted, installed, and commissioned by qualified safety personnel in accordance with these operating instructions.
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.
NOTE
The safety locking device is also suitable for process protection.
SAFETY INFORMATION 2

2.3 Requirements for the qualification of personnel

The safety locking device must be configured, installed, connected, commissioned, and serviced only by qualified safety personnel.
Project planning
For project planning, a person is considered competent when he/she has expertise and experience in the selection and use of protective devices on machines and is familiar with the relevant technical rules and national work safety regulations.
Mechanical mounting, electrical installation, and commissioning
For the task, a person is considered qualified when he/she has the expertise and expe‐ rience in the relevant field and is sufficiently familiar with the application of the protec‐ tive device on the machine to be able to assess whether it is in an operationally safe state.
Operation and maintenance
For operation and maintenance, a person is considered competent 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 and has been instructed by the machine operator in its operation.
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3 PRODUCT DESCRIPTION

3 Product description

3.1 Structure and function

Structure
Figure 1: Structure of the TR110 Lock safety locking device
Safety switches
1
Coded actuator
2
Actuating head
3
Locking pin
4
The safety locking device is an interlocking device with a locking function. The safety locking device consists of a safety switch and a coded actuator. The actuator has a high coding level (uniquely coded).
Function
When the protective device is closed, the actuator is inserted into the actuating head of the safety switch. In doing so, the locking pin is pressed downward by the actuator. If the actuator reaches the end position, the locking pin moves into the provided hole of the actuator.
Further functioning depends on whether the safety locking device is based on the power to release or the power to lock principle.
In the power to release principle, the inserted actuator is immediately blocked and
the locking device is locked (to unlock the locking device, the locking solenoid must be energized). In the power to lock principle, the locking solenoid must be energized in order to
lock the locking device. If the locking solenoid is not energized, the actuator is only held in position by retaining force (spring force). The actuator can be pulled out again by overpowering the retaining force.
Complementary information
The code of the actuator is read out and evaluated using transponder technology.
If the code is valid, the door application diagnostic output (Out AUX DOOR) switches to the ON state. If the locking device is locked, the safe output signal switching devices (OSSD) are switched to the ON state. In addition, the locking function application diagnostic output (Out AUX LOCK) switches to the ON state.
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If the locking device is locked, the actuator cannot be removed from the actuating
head. The locking device can only be locked when the protective device is closed (pre‐
vention of incorrect closing).

3.2 Product characteristics

3.2.1 Product variants

Overview
The safety locking device is delivered with or without pushbuttons. You will find an overview of important distinguishing features of the variants in the following.
PRODUCT DESCRIPTION 3
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Figure 2: Device variants
TR110 Lock
1
TR110 Lock with pushbuttons
2
TR110 Lock
The TR110 Lock safety locking device differs between the following variants:
Power to lock principle
Power to release principle
Power to release principle with escape release
The variants also each have the following connection types:
For stand-alone connection, e.g. to a safety controller or a safety relay.
For connection to Flexi Loop
For OSSD cascading with T-connectors or in the control cabinet
TR110 Lock with pushbuttons
The TR110 Lock safety locking device with pushbuttons features two pushbuttons:
9
3 PRODUCT DESCRIPTION
The TR110 Lock safety locking device with pushbuttons differs between the following variants:
Further topics

3.2.2 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.
The pushbuttons contain single-channel normally open contacts which can be used to trigger control signals. LEDs are located in the pushbuttons which can be controlled, e.g. to signal opera‐ tional statuses. The pushbuttons can be assigned colors using cover caps.
Power to lock principle Power to release principle Power to release principle with escape release
"Ordering information", page 62

3.2.3 Application diagnostic outputs

Important information
NOTE
In the case of safety locking devices cascaded with T-connectors, the locking function application diagnostic output (Out AUX LOCK) cannot be evaluated.
Different application diagnostic outputs
Depending on the device connection, the variants feature various application diagnostic outputs.
Door application diagnostic output (Out AUX DOOR)
Locking device application diagnostic output (Out AUX LOCK)
Diagnostic application diagnostic output (Out AUX DIA)

3.2.4 Status indicators

The safety locking device indicates status information using multiple LEDs.
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  
  
PRODUCT DESCRIPTION 3
Figure 3: Status LEDs
STATE
1
LOCK
2
DIA
3
Figure 4: Status LEDs
STATE
1
LOCK
2
DIAG
3
LEDs in the pushbuttons
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3 PRODUCT DESCRIPTION
Table 2: Status LEDs
Item Name Color
1
2
3
The variants with 2 pushbuttons feature two LEDs in the pushbuttons. The LEDs of the pushbuttons are controlled using two inputs.
STATE Green
LOCK Yellow
DIA Red
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.
Important information
NOTICE
After manual unlocking, a function test must be performed (see "Testing", page 37).

3.3.1 Mechanical unlocking mechanism

Using the mechanical unlocking mechanism, the safety locking device can be unlocked regardless of the status.
Figure 5: Mechanical unlocking mechanism
1 2

3.3.2 Emergency release

The emergency release can be retrofitted as an accessory. The emergency release can be used to actuate the mechanical unlocking mechanism without tools.
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Retaining screw Mechanical unlocking mechanism
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PRODUCT DESCRIPTION 3
NOTICE
The emergency release must be able to be actuated manually outside of the pro‐
tected area without tools. The emergency release must have a label stating that it may only be actuated in
an emergency.

3.3.3 Escape release

Figure 6: Emergency release
Emergency release
1
Stop bolt
2
The escape release makes it possible to open a closed protective device without tools from within the hazardous area.
NOTICE
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 pro‐
tected area (hazardous area).
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3 PRODUCT DESCRIPTION
Figure 7: Escape release
1
Red button of the escape release
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4 Project planning

4.1 Manufacturer of the machine

DANGER
Failure to comply with manufacturer’s obligations Hazard due to lack of effectiveness of the protective device
Carry out a risk assessment before using the safety locking device.
b
Do not tamper with or modify the components of the safety locking device.
b
Make sure that the safety locking device is only repaired by the manufacturer or by
b
someone authorized by the manufacturer. Improper repair can lead to a loss of the protective function. Make sure that switch-on commands which bring about a dangerous state of the
b
machine are not enabled until the protective device is closed and the lock is acti‐ vated. Make sure that the lock is not deactivated until the dangerous state of the
b
machine has stopped. Make sure that closing a protective device and activating the lock does not cause
b
a dangerous machine function to start by itself. This must be controlled by a sepa‐ rate start command. The safety locking device must not be bypassed (contacts jumpered), turned away,
b
removed, or rendered ineffective in any other way. Take measures to reduce bypassing options as necessary.
PROJECT PLANNING 4
Observe EN ISO 14119 for using interlocking devices associated with physical guards.

4.2 Operator of the machine

DANGER
Failure to observe operator obligations Hazard due to lack of effectiveness of the protective device
Changes to the machine and changes to the mechanical mounting of the safety
b
locking device necessitate a new risk assessment. The results of this risk assess‐ ment may require the operator of the machine to meet a manufacturer’s obliga‐ tions. Apart from the procedures described in this document, the components of the
b
safety locking device must not be opened or modified. Do not carry out any repair work on components. Improper repair of the safety
b
locking device can lead to a loss of the protective function. Make sure that replacement actuators are not used for bypassing. Restrict access
b
to actuators.

4.3 Design

4.3.1 Selection of the actuator

NOTICE
Selecting unsuitable actuators or improper mounting can damage the device.
Select the right actuator (see table 26).
b
Pay attention to the door radius and mounting options (see "Actuator dimensional
b
drawings", page 55).
Pay attention to the door hinge.
b
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4 PROJECT PLANNING

4.3.2 Actuating direction

Actuating direction
The safety locking device can be actuated from three horizontal directions (from the left, from the front and from the right). If the safety locking device is to be actuated from behind, an actuating head has to be used.
The safety locking device is not suited for an approach from a vertical angle.

4.3.3 Escape release

Figure 8: Directions of approach
Left
1
Front
2
Right
3
Rear (only possible with switched actuating head)
4
Further topics
"Changing the actuation direction", page 24
In order to mount the variant with the escape release, corresponding holes must be made in the mounting surface.
The shaft of the escape release can be extended by 30 mm or 50 mm using with spac‐ ers
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44/74/94
35
14
Figure 9: Escape release shaft
Escape release flange
1
Escape release shaft
2
Extension spacer
3
PROJECT PLANNING 4

4.4 Integration in the electrical control system

Switch-on commands that put the machine in a dangerous state may only be activated when the protective device is closed and the locking device is locked. The locking device may only be unlocked when the dangerous state has ended. Depending on the safety concept, the signal is analyzed by safety relays or a safety controller, for example.
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 safety locking device is inte‐ grated must be validated in accordance with ISO 13849-2.

4.4.1 Locking function

Prerequisites
A shared power supply is used for the control system and for the locking solenoids
of the safety locking device. A clocked power supply is not used.
When connecting the locking solenoids to the output of a controller, this output
must supply sufficient current.
The activation of the locking solenoids of the safety locking device changes depending on the locking principle.
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Power to release principle
Locking the locking device: Close the protective device, no voltage on the magnet
Unlocking the locking device: Apply voltage to magnet
If voltage is interrupted at the magnet, the locking device remains locked and the pro‐ tective device cannot be opened immediately.
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4 PROJECT PLANNING
WARNING
The locking device locks even when voltage is not present People could get trapped!
If people are in the hazardous area, do not close the protective device even if volt‐
b
age is not present. Or: Use the variant with an escape release.
b
Power to lock principle
Locking the locking device: Apply voltage to magnet
Unlocking the locking device: Disconnect voltage from magnet
If voltage is disconnected at the magnet, the locking device is unlocked and the protec‐ tive device can be opened immediately.
DANGER
Hazard due to lack of effectiveness of the protective device In the event of a voltage drop, the safety locking device unlocks regardless of whether
the dangerous state of the machine has ended.
Assess the risk of accident. Use for protecting people requires correct project plan‐
b
ning.
Activating the locking function
For single-channel activation of the locking function, the controller and the safety lock‐ ing device must have the same ground.
For dual-channel activation of the locking function, clock pulses are tolerated up to a max. length of 5 ms. If possible, switch off the clocking of outputs in the control system.
NOTICE
The locking solenoid of the TR110 Lock safety locking device is controlled exter‐
nally (no control function within the device). Therefore, the TR110 Lock safety lock‐ ing device does not have any characteristic safety values for controlling the locking function. The safety level for controlling the locking function is determined exclusively by
external control (e.g. by the PFHd of an external standstill monitor).
Types for series connection of OSSDs have a separate pin MAG 0 V DC in order to apply 0 V to the locking solenoids (see "Device connection", page 29). In the other types, the 0 V connection of the locking solenoid is connected using the 0 V connection of the safety locking device.
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MAG +24 V DC
MAG 0 V DC
MAG +24 V DC
0 V

4.4.2 OSSDs

PROJECT PLANNING
Figure 10: Connection of the locking solenoid
In types for series connection of OSSDs
1
In all other types
2
Safety locking devices with local inputs and outputs can be directly integrated into the machine controller.
4
DANGER
Hazard due to lack of effectiveness of the protective device In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
Make sure that the following control and electrical requirements are met so the
b
protective function can be fulfilled.
The output signals from an OSSD pair must not be connected to each other.
In the machine controller, both signals from an OSSD pair must be processed sep‐
arately.
Figure 11: Dual-channel and isolated connection of OSSD 1 and OSSD 2
The machine must switch to the safe state at any time if at least one OSSD in an
OSSD pair switches to the OFF state.
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4 PROJECT PLANNING
Prevent the formation of a potential difference between the load and the protec‐
tive device. If you connect loads to the OSSDs (safety outputs) that then also switch if controlled with negative voltage (e.g. electro-mechanical contactor with‐ out reverse polarity protection diode), you must connect the 0 V connections of these loads and those of the corresponding protective device individually and 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 protective device.
Figure 12: No potential difference between load and protective device
DANGER
Hazard due to lack of effectiveness of the protective device In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner. Downstream contactors must be positively guided and monitored depending on applic‐
able national regulations or required reliability of the safety function.
Make sure that downstream contactors are monitored (external device monitoring,
b
EDM).
The OSSDs are short-circuit protected to 24 V DC and 0 V. If the safety locking device is locked, the OSSDs signal the ON state with the HIGH signal level (non-isolated). If the safety locking device is unlocked or there is a device fault, the OSSDs signal the OFF state with the LOW signal level.
Do not use a control system with clocking or switch off the clocking function of the con‐ trol system. The device generates its own test pulses at the OSSDs. A downstream con‐ troller must tolerate these test pulses, which can have a length of up to 1 ms. The test pulses are also output when the OSSDs are switched off. Depending on the sluggish‐ ness of the downstream device (controller, relay, etc.), this can lead to short switching processes.
For inductive loads, the OSSDs must be protected with a freewheeling diode. RC sup‐ pressors must not be used:

4.4.3 Application diagnostic outputs

Door application diagnostic output (Out AUX DOOR)
The signal of the door application diagnostic output changes as soon as the actuator is moved into or leaves the response range of the safety switch. In other words, the output signal changes when the protective device is opened and closed. This is not a safety output.
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PROJECT PLANNING 4
Table 3: Switching behavior of the door application diagnostic output
Actuator Door application diagnostic output
Actuator not in response range OFF
Actuator in response range ON
Locking function application diagnostic output (Out AUX LOCK)
The signal of the locking function application diagnostic output changes as soon as the locking function has been activated. This is not a safety output.
Table 4: Switching behavior of the locking function application diagnostic output
Locking function Locking function application diagnostic output
Locking function active ON
Locking function not active OFF
Fault application diagnostic output (Out AUX DIA)
The signal of the fault application diagnostic output changes as soon as a fault occurs. This is not a safety output.
Table 5: Switching behavior of the fault application diagnostic output
Fault Fault application diagnostic output
Fault has occurred ON
No fault OFF

4.4.4 Switching behavior

Table 6: Switching behavior
Figure 15: Protective device
Figure 13: Protective device closed and locked
Activating the locking func‐ tion
OSSDs ON OFF OFF
Out AUX LOCK ON OFF OFF
Out AUX DOOR ON ON OFF
ON OFF Not relevant
Figure 14: Protective device closed but not locked
open

4.4.5 Safe series connection

OSSDs of several safety locking devices can be connected by safe series connection. The connected OSSDs act like the OSSDs of a single device.
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