Product Information

• General Information
  • Safety Signal Words
  • Warranty
  • Website
  • ServAid
  • Safety Data Sheets MSDS/SDS
  • Signs and Stickers
  • Country of Origin
  • Dimensional Drawings
• Overview
  • Overview
  • Average power consumption
  • Normal Environmental Conditions
  • Technical Product Data
  • Accessories
    • Optional Accessories
      • Power cable, left entry (LE)
      • Power cable, straight entry (SE)
      • Power cable, straight to right entry (SRE)
      • Power cable, right entry to straight (RES)
      • Power cable, open end (OE)
      • Control cable
      • Power cable, right entry (RE)
      • FlexFan module
  • Bypass plug
  • E-stop entry plug
  • 24 VDC connector
  • ASM plug
  • E-stop configuration plug

General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

• Read all Safety Information delivered together with the different parts of the system.

• Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

• Read all locally legislated safety regulations regarding the system and parts thereof.

• Save all Safety Information and instructions for future reference.

Safety Signal Words

Warranty

• Product warranty will expire 12+1 months after dispatch from Atlas Copco's Distribution Center.

• Normal wear and tear on parts is not included within the warranty.

  • Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

• The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

• Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

• To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

• Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

For electrical motors:

• Warranty will only apply when the electric motor has not been opened.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

• Regulatory and Safety Information

• Technical Data

• Installation, Operation and Service Instructions

• Spare Parts Lists

• Accessories

• Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Signs and Stickers

The product is fitted with signs and stickers containing important information about personal safety and product maintenance. The signs and stickers shall always be easy to read. New signs and stickers can be ordered by using the spare parts list.

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

• Overview
• Average power consumption
• Normal Environmental Conditions
• Technical Product Data
• Accessories
  • Optional Accessories
    • Power cable, left entry (LE)
    • Power cable, straight entry (SE)
    • Power cable, straight to right entry (SRE)
    • Power cable, right entry to straight (RES)
    • Power cable, open end (OE)
    • Control cable
    • Power cable, right entry (RE)
    • FlexFan module
• Bypass plug
• E-stop entry plug
• 24 VDC connector
• ASM plug
• E-stop configuration plug

Overview

The FlexCarrier is available in two versions: 3 slot and 6 slot. The FlexController and the FlexDrives connect into slots on the FlexCarrier.

The FlexCarrier distributes power, interconnection, emergency stop (e-stop) and cooling. The FlexCarrier also connects to accessories.

It is possible to connect one FlexCarrier to other FlexCarriers in a daisy chain.

Average power consumption

Normal Environmental Conditions

This product is designed to be safe under the following conditions:

• Indoor use

• Altitude up to 2 000 m

• Operating temperature +5 °C / +41 °F to +50 °C / +122 °F

• Storage temperature +5 °C / +41 °F to +50 °C / +122 °F

• Maximum relative humidity 80 % for temperatures up to 31 °C / 89 °F decreasing linearly to 50 % relative humidity at 40 °C / 104 °F

• Mains supply voltage fluctuations up to ±10 % of the nominal voltage

• Transient overvoltages up to the levels of overvoltage category II

• Temporary overvoltages occurring on the mains supply

• Pollution degree 2

• Ingress protection rating: IP54

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Accessories

• Optional Accessories
  • Power cable, left entry (LE)
  • Power cable, straight entry (SE)
  • Power cable, straight to right entry (SRE)
  • Power cable, right entry to straight (RES)
  • Power cable, open end (OE)
  • Control cable
  • Power cable, right entry (RE)
  • FlexFan module

Optional Accessories

• Power cable, left entry (LE)
• Power cable, straight entry (SE)
• Power cable, straight to right entry (SRE)
• Power cable, right entry to straight (RES)
• Power cable, open end (OE)
• Control cable
• Power cable, right entry (RE)
• FlexFan module

Power cable, left entry (LE)

Left entry (LE) power cables are used when the FlexCarriers are mounted horizontally.

Power cable, straight entry (SE)

Power cable, straight to right entry (SRE)

Use straight to entry (SRE) power cables when the FlexCarriers are mounted vertically top down, that is, the first FlexCarrier mounted above second the FlexCarrier.

Power cable, right entry to straight (RES)

Use straight to entry (RES) power cables when the FlexCarriers are mounted vertically bottom up, that is, the first FlexCarrier mounted below second the FlexCarrier.

Power cable, open end (OE)

Use 4222 1887 xx for fixed installations in EU.
Use 4222 3147 xx for fixed installations in the USA and Canada.
Use 4222 3189 xx for non-fixed installations.
All installations must follow local laws and regulations.

Control cable

The following cables are provided when the FlexCarriers are mounted far from each other:

Power cable, right entry (RE)

Right entry (RE) power cables are used when the FlexCarriers are mounted horizontally.

FlexFan module

As an option there is a possibility to use one fan module per three slots. The fan modules will increase the amount of power dissipation the system can tolerate without being overheated

The fan module consists of two redundant fans:

• 3 slot: One fan module.

• 6 slot: Two fan modules.

Bypass plug

The bypass plug is used in the second FlexCarrier and each of the following FlexCarriers in an e-stop chain. The bypass plug does not have any connections and the plug covers the 24 VDC IN.

E-stop entry plug

The e-stop entry plug is used in the first FlexCarrier in an e-stop chain. It has four connectors for the e-stop button and two connectors for the reset button

The reset button circuit is normally closed, when the e-stop button is pressed the reset circuit opens.

Wiring

24 VDC connector

The 24 VDC connector is ordered separately and must be the following:
Plug component, screw connection with tension sleeve, 2 connections
Type: MC 1,5/ 2-ST-3,5
Order No.: 1840366 from PHOENIX CONTACT.

ASM plug

If an external safety PLC will control the e-stop, an ASM plug is used in the first FlexCarrier in the e-stop chain. The safety PLC is connected to a PROFINET fieldbus module on the FlexController

E-stop configuration plug

Select a plug to connect in the e-stop configuration connector. Each plug will have a pre-configuration. The following plugs are available:

• E-stop entry plug

• Bypass plug

• ASM plug.

Installation

• Installation Requirements
  • Mounting FlexSystem
  • Cable planning
    • Recommended cables for minimum footprint
    • Recommended cables for general positioning
• Installation Instructions
  • Connection interfaces
  • Install first FlexCarrier
  • Route and install power- and control cables to FlexCarrier

Installation Requirements

• Mounting FlexSystem
• Cable planning
  • Recommended cables for minimum footprint
  • Recommended cables for general positioning

Mounting FlexSystem

For minimal footprint select power cables and mount the FlexSystem according to the specified distances.

The FlexCarrier should be mounted vertically for optimal system functionality. This will allow for best air flow and heat transfer. Mounting FlexCarrier horizontally can affect the lifetime of the system.

The FlexSystem and the main switch box can be mounted in any normal industrial environment without any extra enclosure, if local regulations do not require otherwise.

The FlexSystem should not be exposed to excessive amount of vibrations. The vibration should be less than 10 g (98 m/s²) and between 1000 to 2000 Hz.

Screw: M6, Torque: 9.8 Nm

Distances between FlexSystem parts for minimal footprint (with FlexFan)

Distances between FlexSystem parts for minimal footprint (without FlexFan)

Cable planning

• Recommended cables for minimum footprint

• Recommended cables for general positioning

Recommended cables for minimum footprint

For information of dimensions for minimal footprint installation, see Mounting FlexSystem.

Power cables

To connect a FlexCarrier to mains switch board, use the power cable:

To connect a FlexCarrier to a 3 slot FlexCarrier, use these power cables:

To connect a FlexCarrier to a 6 slot FlexCarrier, use these power cables:

Control cables

Use these control cables:

Recommended cables for general positioning

FlexCarriers can be positioned freely, with more spacing or with FlexCarriers not placed in the same plane.

Power cables

The selection is based on the routed length between cable ends from A to B. Select a FlexPower cable with the closest longer length to the measurement.

The minimum bending radius (0.12 m) must be followed.

Control cables

The selection is based on the routed length between cable ends from A to B. Select a FlexControl cable with the closest longer length to the measurement.

The minimum bending radius (0.1 m) must be followed.

Installation Instructions

• Connection interfaces
• Install first FlexCarrier
• Route and install power- and control cables to FlexCarrier

Connection interfaces

Pos
1.	Circuit breakers (16 A).
2.	Emergency stop (e-stop) configuration plug: Option 1; E-stop entry plug Option 2; Bypass plug Option 3; Advanced Security Module (ASM) plug
3.	24 VDC IN (Max 8 A) For (CPU) backup supply.
4.	Hex switch to set the FlexCarrier address.
5.	24 VDC OUT (1.8 A) For external devices
6.	Gasket for cable routing.
7.	Inter-Com Port, In (for daisy chain) (24VDC, ethernet, e-stop).
8.	Inter-Com Port, Out (24VDC, ethernet, e-stop).
9.	High voltage 400/480 VAC, Out (for daisy chain).
10	High voltage 400/480 VAC, In.
11.	Device slot, 400/480 VAC.
12	FlexFan connector.
13	Device slot, 24 VDC, ethernet, e-stop.

Install first FlexCarrier

Route and install power- and control cables to FlexCarrier

Make sure that the cables are in good condition before connecting them to the system. Check that

• Cables are not damaged

• Connectors are not damaged.

If these conditions are not fulfilled the system must not be connected to mains or switched on.

Systems where damages to connections or cables are found must be disconnected and repaired immediately.

WARNING

It is dangerous to use systems, cables or units that are not in good condition or not connected according to electrical regulations and system requirements, whether manufactured by Atlas Copco or third party.

Operation

• Ergonomic Guidelines

Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas for improvement in posture, component placement, or work environment.

• Take frequent breaks and change work positions frequently.

• Adapt the workstation area to your needs and the work task.

  • Adjust for a convenient reach range by determining where parts and tools need to be located to avoid static load.

  • Use workstation equipment such as tables and chairs appropriate for the work task.

• Avoid work positions above shoulder level or with static holding during assembly operations.

  • When working above shoulder level, reduce the load on the static muscles by lowering the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  • Take frequent breaks.

  • Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

• Adjust for a convenient field of vision that requires minimal eye and head movements.

• Use appropriate lighting for the work task.

• Select the appropriate tool for the work task.

• In noisy environments, use ear protection equipment.

• Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibration.

• Minimize exposure to reaction forces.

  • When cutting:

    A cut-off wheel can get stuck if the cut-off wheel is bent or not guided properly. Use the correct flange for the cut-off wheel and avoid bending the cut-off wheel during operation.

  • When drilling:

    The drill might stall when the drill bit breaks through. Use support handles if the stall torque is high. The safety standard ISO11148 part 3 recommends using a device to absorb a reaction torque above 10 Nm for pistol grip tools and 4 Nm for straight tools.

  • When using direct-driven screwdrivers or nutrunners:

    Reaction forces depend on the tool settings and joint characteristics. Strength and posture determine the amount of reaction force that an operator can tolerate. Adapt the torque setting to the operator's strength and posture and use a torque arm or reaction bar if the torque is too high.

• In dusty environments, use a dust extraction system or wear a mouth protection mask.

Service

• Preventing ESD Problems
• Maintenance Instructions
  • Service Recommendations

Preventing ESD Problems

The components inside the product and controller are sensitive to electrostatic discharge. To avoid future malfunction, make sure that service and maintenance is carried out in an ESD approved work environment. The figure below shows an example of an appropriate service work station.

Maintenance Instructions

• Service Recommendations

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

• Replace any defective or worn parts

Recycling

• Environmental Regulations
• Recycling information

Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.

Recycling information