Nexen Nexsafe RLSSB-S Bedienungsanleitung

1FORM NO. L-21699-B-1120

FORM NO. L-21699-B-1120

Safety Rated Rod/Shaft Lock

Spring Engaged, Air Released

RLSSB-S (Stand Alone)

RLSSB-C (Cylinder Mount)

RLSSB-C-MR (Cylinder Mount with Manual Release)

RLSSB-S-MR (Stand Alone with Manual Release)

LINEAR MOTION CONTROL PRODUCTS

User Manual

safe

™

Certiﬁed Safety Products

FORM NO. L-21699-B-1120

Nexen Group, Inc.

560 Oak Grove Parkway

Vadnais Heights, Minnesota 55127

ISO 9001 Certiﬁed

This document is the original, non-translated, version.

Conformity Declaration: In accordance with Appendix II B of CE Machinery Directive (2006/42/EC):

A Declaration of Incorporation of Partly Completed Machinery evaluation for the applicable EU directives was

carried out for this product in accordance with the Machinery Directive. The declaration of incorporation is set

out in writing in a separate document and can be requested if required.

This machinery is incomplete and must not be put into service until the machinery into which it is to be

incorporated has been declared in conformity with the applicable provisions of the Directive.

Read this manual carefully before installation and operation.

Follow Nexen’s instructions and integrate this unit into your

system with care. This unit should be installed, operated and

maintained by qualified personnel ONLY. Improper installation

can damage your system, cause injury or death. Comply with

all applicable codes.

DANGER

In accordance with Nexen’s established policy of constant product improvement, the speciﬁcations contained in this manual

are subject to change without notice. Technical data listed in this manual are based on the latest information available at

the time of printing and are also subject to change without notice.

Technical Support: 800-843-7445

(651) 484-5900

www.nexengroup.com

3FORM NO. L-21699-B-1120

Table of Contents

General Speciﬁcations ------------------------------------------------------------------------------------------------------------------------- 4

General Safety Precautions ------------------------------------------------------------------------------------------------------------------ 4

Product Description ------------------------------------------------------------------------------------------------------------------- 5

Safety Standard Compliance ----------------------------------------------------------------------------------------------------------------- 6

Transport, Handling & Storage --------------------------------------------------------------------------------------------------------------- 6

Installation ------------------------------------------------------------------------------------------------------------------------------------------- 7

Rod Material ---------------------------------------------------------------------------------------------------------------------------------------- 8

Lubrication ------------------------------------------------------------------------------------------------------------------------------------------- 8

Optional Operating Mode Sensor(s) ---------------------------------------------------------------------------------------------------------- 9

Rod Lock Air Connections ------------------------------------------------------------------------------------------------------------------- 10

Air Controls and Programming --------------------------------------------------------------------------------------------------------------- 11

Manual Release ------------------------------------------------------------------------------------------------------------------------------------ 12

Service ------------------------------------------------------------------------------------------------------------------------------------ 12

Troubleshooting ------------------------------------------------------------------------------------------------------------------------------------ 13

Warranty ------------------------------------------------------------------------------------------------------------------------------------------- 14

FORM NO. L-21699-B-1120

GENERAL SPECIFICATIONS

Speciﬁcations:

Holding Force Up to 22350 N (5026 lbs)

Actuation Pressure 1 - 5.5 bar (14.5 - 120 psi)

External Temp. Limits 4.5 - 65.5 C (40 - 150 F)

Approximate Weight Up to 29.5 kg (65 lbs)

GENERAL SAFETY PRECAUTIONS

CAUTION

Use lifting aids and proper lifting

techniques when installing, removing,

or placing this product in service.

CAUTION

Do not exceed the maximum holding force

of the unit. The locking function will be

overloaded, causing rod slip and possible

damage to the shaft and product.

CAUTION

Watch for sharp features when

interacting with this product. The

parts have complex shapes and

machined edges.

CAUTION

Do not use a Rod Lock to stop a rotating

shaft. This product is not intended for

torsional braking or frequent dynamic

braking.

WARNING

Ensure proper guarding of the product is

used. Nexen recommends the machine builder

design guarding in compliance with OSHA 29

CFR 1910 “Occupational Safety and Health

Hazards”.

Do not engage the Rod Lock without

a properly sized rod in place or

damage to the internal components

may result.

CAUTIONCAUTION

Do not attempt to disassemble this

product. Product components are

spring-loaded and can cause serious

injury.

Figure 1 Caution

WARNING

Keep indoors. This product is

intended for indoor environments

only. Use of the brake outdoors will

damage components. No Excessive

Dust or humidity permitted.

5FORM NO. L-21699-B-1120

PRODUCT DESCRIPTION

The Rod Lock has been developed for locking and holding on the shaft of an air cylinder or guide rod. These spring engaged,

air released units are designed to hold in a safe position by default. Brakes are intended for static holding applications

and Emergency Stop situations.

The proper installation and maintenance of these rod locks must be observed to prevent damage to unit or improper use of unit.

Engaged State: In the engaged state, several compression springs push on the piston causing the clamping collar to lock

onto the rod. If air pressure is lost the unit will default to the brake engaged state.

Disengaged State: When air pressure is applied, the piston will push back against the springs, releasing the clamping

collar from the rod. Manual release units are also equipped with a cam operated manual release

feature to mechanically disengage the rod lock

A series of equally spaced compression springs provide the rod lock actuating force. Dozens

of ball bearings separate a split, tapered collar and piston. The piston travels up the ramp on

the collar under spring force and causes the split collar to constrict on the rod. Air pressure

applied to the opposite side of the piston compress the springs to release the grip on the rod.

Select models have a manual release feature to disengage the rod lock without air pressure.

The mechanism is cam operated, turned with a wrench and is a “default-to-lock” function. As

long as a force is applied to the wrench the rod lock is disengaged. With no force applied the

rod lock “defaults” to the engaged position.

NOTE

PISTON

COMPRESSION

SPRINGS

BREATHER VENT

AIR INLET

BALL BEARINGS

SPLIT COLLAR

MANUAL

RELEASE

HEX NUT

MANUAL

RELEASE CAM

Figure 2 Principle of Operation

FORM NO. L-21699-B-1120

SAFETY STANDARD COMPLIANCE

ISO 13849 is a Safety Standard which applies to machines and systems, and aims to reduce risk, in event of machine

failure. This section clariﬁes our Rod Lock’s intended use as a part of a system or machine that must comply with this

standard.

Rod Locks intended for safety related applications are to be installed in accordance with the required performance level/

category level per ISO 13849-1:2015. The category rating of safety channels and performance level of the machine is

the responsibility of the system manufacturer. For fulﬁllment of the safety function, the Rod Lock is to be viewed as an

individual component.

Braking Function: All safety rated Rod Locks use multiple Compression springs to provide the necessary spring force

over the life of the unit. The use of multiple springs ensures that a reduced locking force will be

available in the event of spring failure.

Safety Guidelines: Adhere to the guidelines for safe and reliable locking and error-free operation:

• Rod Lock is required to be installed and maintained per this literature

• Observe intended use of the Rod Lock

• Rod Lock sized and applied correctly per system requirements

• Rod Locks are to be selected and integrated into the safety machine

in accordance with ISO 13849-1:2015 by the system manufacturer.

TRANSPORT, HANDLING & STORAGE

During transport, the product will be in the default (engaged) position with a dummy rod inserted, eliminating the possibility

of parts shifting. Rod Locks can be handled without the use of special equipment.

Nexen products have a shelf life of 7 years beginning on the date of packaging serialization located on the original shipping

container of the item.

The following criteria must be maintained to achieve full shelf life of the product:

1. Original packaging must remain unopened and intact.

2. Product must have been stored in a temperature and humidity controlled environment.

• Temperature range of 65°F ±15°F (18.3°C ±8.3°C)

• Relative humidity range of 35%-55%

Speciﬁcation Deviation Effect on Safety Function

Air pressure too high Unit will leak, not hold force

Air pressure too low Fail to disengage

Apply too much force Will not hold applied force and will slip

Exceed environmental specs Not operate as intended

Refer to table below for effects on safety if Rod Lock is used outside of Nexen speciﬁcation range.

safe

™

Certiﬁed Safety Products

7FORM NO. L-21699-B-1120

1. Apply a constant supply of air, with a minimum of 4.1

bar (60 psi) air pressure to open (release) the Rod

Lock. Manual release option; apply the appropriate

amount of torque to the manual override mechanism

to open (release) the Rod Lock.

INSTALLATION

2. Remove the supplied rod from the inside of the Rod

Lock and keep for future use.

3. Carefully slide the Rod Lock over the cylinder rod

or guide rod, past the seal(s) and through the entire

assembly. Note: Cylinder (“C”) mounts, skip to

instruction #5.

4. “S” (stand-alone) series: Remove the air pressure to

engage the Rod Lock on the guide rod when it is in the

desired position.

5. “C” (cylinder mount) series: Carefully slide the Rod

Lock onto the cylinder rod toward the cylinder end cap.

The Rod Lock is piloted and sealed to the gland O.D.,

so some force is required. Press the Rod Lock onto

the end cap face as close as possible.

6. Using a corner-to-corner sequence, install and tighten

the mounting screws or tie rod nuts to approximately

75% of the ﬁnal tightening torque. (See Table 1)

7. Using a calibrated torque wrench, tighten the fasteners

or nuts to the ﬁnal torque speciﬁcation using the same

corner-to-corner sequence. Ensure all fasteners are

fully tightened.

8. Remove the air pressure to engage the Rod Lock on

the cylinder rod.

NOTE: “Rod” and “Shaft” refer to the same feature and

are used interchangeably.

The “S” (stand-alone) series Rod Locks are designed to

mount on round guide rods and are typically mounted in

accordance with the design of the machine.

The “C” (cylinder) series Rod Locks are designed to

mount directly to NFPA or ISO ﬂush-mount air cylinders.

The “C” -mounted Rod Locks come with (4) mounting

screws. These screws are used to attach the Rod Lock

to cylinders with tapped holes in the interface or with

socket head, sleeve nuts. The mounting screws are not

necessary on cylinders equipped with threaded tie rods

/ nuts. Cylinders should be prepared with enough rod

length and tie rod length (if appropriate) to accommodate

the rod lock length.

NOTE: Eight inch Rod Locks do not come with

mounting screw assemblies. Fasten the rod lock to

the cylinder with longer threaded tie rods and nuts.

See Figure 3.

32MM to 6” Bores

8” Bores

Figure 3

Rod Lock Inch-Pounds Nm

RLSSB 150-063 32-36 3.6-4.1

RLSSB 200-063 72-82 8-9

RLSSB 200-100 72-82 8-9

RLSSB 250-063 72-82 8-9

RLSSB 325-100 216-228 24-25.3

RLSSB 400-100 216-228 24-25.3

RLSSB 400-138 216-228 24-25.3

RLSSB 500-100 360-372 41-42

RLSSB 500-138 360-372 41-42

RLSSB 600-138 420-432 48-49

RLSSB 600-175 420-432 48-49

RLSSB 032-012 30-38 3.4-4.3

RLSSB 040-016 30-38 3.4-4.3

RLSSB 050-020 66-100 7.5-11.3

RLSSB 063-020 66-100 7.5-11.3

RLSSB 080-025 156-230 18-26

RLSSB 100-025 156-230 18-26

RLSSB 125-032 400 45

Table 1 Fastener or Tie Rod Torque

CAUTION

Do not engage the Rod Lock without a

properly sized rod in place or damage to

the internal components may result. Refer

to the Rod Material section.

FORM NO. L-21699-B-1120

NOTE

Nexen pneumatically actuated devices require clean, pressure regulated air for maximum performance and life.

All seals in Nexen pneumatically operated devices are lubricated for life, and do not require additional lubrication.

However, some customers prefer to use an air line lubricator, which injects oil into the pressurized air, forcing

an oil mist into the air chamber. This is acceptable, but care must be taken to ensure once an air mist lubrication

system is used, it is continually used over the life of the product as the oil mist may wash free the factory

installed lubrication.

Locate the lubricator above and within ten feet of the product, and use low viscosity oil such as SAE-10.

Synthetic lubricants are not recommended.

Nexen product’s bearings are shielded and pre-lubricated, and require no further lubrication.

ROD MATERIAL

• Nexen strongly recommends the following rod material

for cylinder rods and guide rods. Deviations from these

speciﬁcations will result in poor rod lock performance

and shaft damage.

Hardness Speciﬁcation Hard Chrome

Plating Thickness

Less than 52 HRC 20 microns

[0.0008 inch]

Greater than 52 HRC 8-3 microns

[0.0003- 0.0005 inch]

• The diameter should lie in the h8 tolerance range.

Reference: USAS B4.1 - 1967(1974)

ISO 286-1 - 1988

ISO 286-2 - 1988

• The rod must be clean and dry to maintain optimum

holding forces.

• The surface roughness Rmax should be 1.6 microns

[63 micro-inch] or better.

• The rated holding force corresponds to static load

conditions. If the rated value is exceeded, slippage may

occur. Operating dynamic forces must not exceed the

static holding force.

CAUTION

Nexen’s Static Rod Lock is suitable for

infrequent dynamic braking (emergency stops)

when used with hardened shaft material

Repeated dynamic stops may cause rod and/

or collar wear, reducing holding forces.

1. Close and disconnect the air line from the unit.

2. Turn the Lubricator Adjustment Knob counterclockwise

three complete turns.

3. Open the air line.

4. Close the air line to the unit when a drop of oil forms

in the Lubricator Sight Gage.

5. Connect the air line to the unit.

6. Turn the Lubricator Adjustment Knob clockwise until

closed.

7. Turn the Lubricator Adjustment Knob counterclockwise

one-third turn.

8. Open the air line to the unit.

LUBRICATION

CAUTION

These settings are for Nexen supplied

lubricators. If you are not using a Nexen

lubricator, calibration must follow the

manufacturer's suggested procedure.

LUBRICATOR DRIP RATE SETTINGS

9FORM NO. L-21699-B-1120

OPTIONAL OPERATING MODE SENSOR(S)

Nexen’s Magnetic Proximity Sensors are available to

gather operational data from the Rod Lock. The Safety

Rated RLSSB can be equipped with one or two T-slots

for sensor mounting.

These sensors may be used by system manufacturers

to gain higher safety category ratings per ISO 13849-1.

Rating of the safety function is the responsibility of the

system manufacturer.

Each Proximity sensor can be set up to sense one of the

following functions of the Rod Lock:

Disengagement Sensor Deﬁnition:

Sensor is activated when the rated air pressure is applied

and the piston moves to a disengaged position.

Engagement Sensor Deﬁnition:

Sensor is activated when the piston moves out of the

disengaged position into a position in which the clamp

collar constricts on the rod.

SENSOR WIRING

Nexen’s Magnetic Proximity Sensor is available in two

modes, see Table 2. System manufacturer is responsible

for selecting appropriate sensor type for speciﬁed safety

application.

PNP Mode (Sourcing)

Normally Open (N.O.) or Normally Closed (N.C.) PNP

type Sourcing Output available, see Figure 5. Typically

matched with a PLC Sinking Input.

NPN Mode (Sinking)

Normally Open (N.O.) or Normally Closed (N.C.) NPN type

Sinking Output available, see Figure 5. Typically matched

with a PLC Sourcing Input.

SENSOR INSTALLATION AND SETUP

Note: Validate sensor functionality in application, including

possible temperature range.

The Rod Lock can be equipped with one or two magnetic

proximity sensors. If two sensors are used, they can be

conﬁgured to detect redundant or individual engaged and

/ or disengaged states. If sensors are setup for redundant

detection, the sensor states should always match. If

sensors are setup for individual, opposing detection, the

sensor states should always be opposite. To ensure proper

operation, compare the expected state to the measured

state. Once installed on the rod, Nexen recommends

checking the positioning of the sensor for proper switching

location.

Wire magnetic sensor and insert cable clip into t-slot per

the instructions included with the sensor(s). Provide power

to sensor, and complete the following:

Sensing Disengagement Position:

1. With rod lock on rod, supply air pressure to the rod

lock so it is disengaged.

2. Install sensor as shown in Figure 6. Start with sensor

positioned closest to the back of the rod lock, past the

sensing target. Slide the sensor towards the front end

of the rod lock until LED is lit. Once the LED is lit, move

sensor a small amount further into sensing target.

3. Use a standard ﬂat-head screwdriver or 1.5mm allen

wrench to turn the screw and ﬁx the sensor in the t-slot.

4. Cycle air pressure to ensure the LED is lit only when

release air pressure is supplied to the rod lock.

LOAD

NPN Mode (Sinking)

PNP Mode (Sourcing)

LOAD

PNP Mode (Sourcing)

LOAD

0 VDC

10-30 VDC

0 VDC

10-30 VDC

0 VDC

10-30 VDC

0 VDC

10-30 VDC

Figure 5

Sensor Wiring

Figure 4

Locking

Mode

Sensor(s)

Sensing

Magnet

Note: Safety Rated Units may have

one or two sensor slots.

Sensing Engagement Position:

1. With rod lock on rod, remove air pressure to the rod

lock so it is engaged.

2. Install sensor as shown in Figure 6. Start with sensor

positioned closest to the front of the rod lock, before

the sensing target is reached. Slide the sensor

towards the back end of the rod lock until LED is

lit. Once the LED is lit, move sensor a small amount

further into sensing target.

3. Use a standard ﬂat-head screwdriver or 1.5mm allen

wrench to turn the screw and ﬁx the sensor in the t-slot.

4. Cycle air pressure to ensure the LED is lit only when

air pressure is removed from the brake.

Figure 66

(Engagement)

(Disengagement)

Sensor Adjustment Direction

Back End of

Rod Lock

Front End of

Rod Lock

LED LightLED Light

on Sensoron Sensor

Note: Ferrous Materials in Close Proximity

may interfere with sensor function.

Normally Open: Normally Closed:

FORM NO. L-21699-B-1120

NOTE

For quick response, Nexen recommends a quick

exhaust valve and short air lines between the

Control Valves and the unit. Align the air inlet

ports to a down position to allow condensation

to drain out of the air chambers of the product.

CAUTION

Low air pressure will cause slippage

and damage.

All Nexen pneumatically actuated devices require clean

and dry air, which meet or exceeds ISO 8573.1:2001

Class 4.4.3 quality.

1. Basic Conﬁguration:

Attach a Standard Air Fitting to the Rod Lock. Use

Teﬂon tape and/or pipe sealant on the threads. This

conﬁguration will have slower response times.

Standard Conﬁguration:

Attach the Quick Exhaust Valve to the Rod Lock. Use

Teﬂon tape and/or pipe sealant on the threads.

Cable Wire

Color

Valve

24 VDC Valve Pin

DIN Connector

for 964650 (Inch

NFPA Units)

Brown + 1

White - 2

Green Ground Ground

DIN Connector for

964651 (Metric

ISO Units)

Black,Labeled + + 1

Black,Labeled - - 2

Green Ground Ground

Table 3

Optional Solenoid Valve Speciﬁcations

Ports Part # Voltage Power Resistance Current Cv

English 964650 24 VDC 4 W 145 ohms .17 A .25

Metric 964651 24 VDC 4.8 W 120 ohms .20 A .915

DANGER

Support the load before disengaging the

Rod Lock. Failure to support the load

could result in serious bodily injury.

CAUTION

24 VDC valve connector has a

suppression diode installed across the

coil. Observe proper voltage polarity or

connector damage will result.

FIGURE 7 Optional Solenoid Valve #964651 (Metric Units)

Exhaust

Silencer

To Quick Exhaust, Brake

Air Supply

Tube Fitting

Manual Override*

(English Units)

DIN

Connector Lead Wires

1/8 NPT (English Units)

1/8 BSPT (Metric Units)

- 1/4” O.D. Tube

(English Units)

- 6mm O.D. Tube

(Metric Units)

Manual Override*

(Metric Units)

CAUTION

The Rod Lock will disengage if you

depress the domed button at the top

of the Solenoid Valve (if air pressure

is applied). The LED will illuminate

when the Solenoid Valve is actuated

and the Rod Lock is disengaged.

With Optional Solenoid:

Mount the optional Solenoid Valve directly to the Rod

Lock using supplied ﬁttings. Use Teﬂon tape and/or pipe

sealant on the threads. If the optional Solenoid Valve isn't

mounted directly to the Rod Lock, it is recommended

to mount a Quick Exhaust Valve near the Rod Lock

for better brake response times. Refer to Figure 7.

Table 2

NOTE: Align the air inlet ports in the down position to

allow condensation to drain out of the air chamber.

2. Attach the air supply line to the air inlet, the quick

exhaust valve, or the solenoid valve, depending on

conﬁguration selected in Step 1.

3. If using optional solenoid valve, attach DIN Connector

cable to valve by pressing DIN Connector onto valve

power pins and tightening DIN Connector fastener.

Then connect DIN Connector cable wires, using Table

2, to the appropriate power supply, see Table 3.

Optional Solenoid Valve #964650 (English Units)

Quick Exhaust Valves Air Pressure Ratings:

8 Bar [120 PSIG] Max (All Q.E. Valves)

0 Bar [0 PSIG] Min (English Q.E. Valve)

3 Bar [44 PSIG] Min (Metric Q.E. Valve)

Fittings are

conﬁgured

differently

on Metric

Solenoid

Valve.

See Sales

Drawing.

Rod Lock Unit Size Quick Exhaust Valve

Part Number

Size 150-, 200- & 250-

NFPA Inch Units 945100 (.125-27 NPT)

Size 032-, 040-, 050- & 063-

Metric ISO Units 945127 (.125-28 BSPP)

Size 325-, 400-, 500-, 600- & 800-

NFPA Inch Units 945125 (.250-18 NPT)

Size 080-, 100- & 125-

Metric ISO Units 945128 (.250-19 BSPP)

BSPP ports accept BSPP or BSPT ﬁttings of the same size.

ISO-G and BSPP are the same thing.

ROD LOCK AIR CONNECTIONS (Does not apply to customer cylinder)

The Nexen Rod Lock is equipped with a NPTF or BSPP

(ISO-G) port for the air inlet. Route clean air, using soft or

hard lines, supplying at least 4.1 bar [60 psi] to facilitate

full disengagement.

NOTE: Install the valve in close proximity to the Rod

Lock unit for faster engagement and disengagement.

Higher air pressures will also speed the disengagement

time, but do not exceed 8.0 bar [120 psi] air pressure.

The Nexen Rod Lock is equipped with a port for the internal

vent (ﬁlters are included with most models). If the air quality

around the application is poor, route the vent of the Rod

Lock to a more suitable area, or use a ﬁltered breather.

Contact Nexen for available components.

NOTE: Clean air is important for proper Rod Lock

functioning. Debris inside the Rod Lock may inhibit

performance and/or shorten the life of the product.

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