Flex is Oft Hardware OI GB UE80 R10

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

GB

Flexi Soft

Modular Safety ControllerHardware

Operating instructions

Flexi Soft Hardware

2 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8012478/UE80/2010-12-10Subject to change without notice

This document is protected by the law of copyright, whereby all rights established therein remain with thecompany SICK AG. Reproduction of this document or parts of this document is only permissible within the limitsof the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted withoutthe explicit written approval of the company SICK AG.


Flexi Soft Hardware

8012478/UE80/2010-12-10 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 3Subject to change without notice

Contents

Contents1 About this document.........................................................................................................6

1.1 Function of this document....................................................................................61.2 Target group ..........................................................................................................61.3 Depth of information.............................................................................................71.4 Scope .....................................................................................................................71.5 Abbreviations used ...............................................................................................71.6 Symbols used ........................................................................................................8

2 On safety.............................................................................................................................92.1 Qualified persons ..................................................................................................92.2 Application areas for the device...........................................................................92.3 Correct use ..........................................................................................................102.4 General protective notes and protective measures..........................................112.5 Environmental protection ...................................................................................12

2.5.1 Disposal .............................................................................................122.5.2 Material separation...........................................................................12

3 Product description.........................................................................................................133.1 System properties ...............................................................................................133.2 System configuration ..........................................................................................143.3 Version, compatibility and features ...................................................................163.4 System plug FX3MPL0.......................................................................................173.5 Main module FX3CPU0......................................................................................17

3.5.1 Description ........................................................................................173.5.2 Display elements, error codes and terminal description................17

3.6 Main module FX3CPU1......................................................................................193.6.1 Description ........................................................................................193.6.2 Display elements, error codes and terminal description................20

3.7 FX3XTIO input/output extension module..........................................................213.7.1 Description ........................................................................................213.7.2 Display elements, error codes and terminal description................223.7.3 Internal circuits .................................................................................233.7.4 Disabling the test pulses of XTIO outputs........................................243.7.5 Single channel usage of XTIO outputs .............................................24

3.8 FX3XTDI input extension module ......................................................................253.8.1 Description ........................................................................................253.8.2 Display elements, error codes and terminal description................263.8.3 Internal circuits .................................................................................26

3.9 UE4102RO/UE4104RO relay output modules................................................273.9.1 Description ........................................................................................273.9.2 Display elements and terminal description .....................................29


Flexi Soft Hardware


Contents

4 Connecting devices ........................................................................................................304.1 Safety command devices and electro-mechanical safety switches ................33

4.1.1 Emergency stop pushbuttons (e.g. ES21).......................................334.1.2 Electro-mechanical safety switches with and without

interlock (e.g. i10, i100 and i1000) ................................................344.1.3 Enabling switch E100.......................................................................354.1.4 Two-hand control ..............................................................................364.1.5 Safety mats and bumpers................................................................364.1.6 Diode module DM8-A4K...................................................................374.1.7 Operating mode selector switches ..................................................404.1.8 Potential-free contacts .....................................................................40

4.2 Non-contact safety sensors ...............................................................................414.2.1 Magnetic safety switches (e.g. RE) ..................................................414.2.2 Inductive safety switches IN4000 and IN4000 Direct ...................414.2.3 Transponder T4000 Compact and T4000 Direct ...........................42

4.3 Testable single-beam photoelectric safety switches ........................................424.3.1 Testable Type 2 single-beam photoelectric safety switches..........424.3.2 Testable Type 4 single-beam photoelectric safety switches..........434.3.3 Customized testable single beam photoelectric safety

switches ............................................................................................444.3.4 Information for mounting testable single-beam photoelectric

safety switches .................................................................................444.4 Electro-sensitive protective equipment (ESPE).................................................464.5 Safety outputs.....................................................................................................464.6 EFI devices ..........................................................................................................46

4.6.1 Connection of EFI devices ................................................................464.7 Flexi Link .............................................................................................................47

4.7.1 Flexi Link overview............................................................................474.7.2 System requirements .......................................................................484.7.3 Connection of a Flexi Link system ...................................................48

5 Special functions ............................................................................................................505.1 Enhanced Function Interface — EFI ...................................................................50

5.1.1 Definition...........................................................................................505.1.2 Properties..........................................................................................505.1.3 Functions...........................................................................................515.1.4 Benefits .............................................................................................51

5.2 Muting .................................................................................................................525.2.1 General description ..........................................................................525.2.2 SICK muting sensors ........................................................................52

6 Mounting/Dismantling...................................................................................................536.1 Steps for mounting the modules .......................................................................536.2 Steps for dismantling the modules....................................................................55

7 Electrical installation .....................................................................................................567.1 Electrical installation requirements...................................................................567.2 Internal circuit power supply..............................................................................58

8 Configuration...................................................................................................................59

9 Commissioning................................................................................................................609.1 Full approval of the application .........................................................................609.2 Tests before the initial commissioning..............................................................61


Flexi Soft Hardware


Contents

10 Diagnostics ......................................................................................................................6210.1 In the event of faults or errors............................................................................62

10.1.1 ERROR operating states ...................................................................6210.2 Error displays of the status LEDs, error messages and rectification

measures.............................................................................................................6310.3 Additional error displays of EFI-compatible devices .........................................6710.4 SICK support........................................................................................................6710.5 Extended diagnostics..........................................................................................67

11 Maintenance....................................................................................................................6811.1 Regular inspection of the protective device by qualified personnel ................6811.2 Device replacement ............................................................................................69

12 Technical data .................................................................................................................7012.1 Response times of the Flexi Soft system...........................................................70

12.1.1 Calculation of the response times ...................................................7112.1.2 Min. switch off time...........................................................................75

12.2 Data sheet ...........................................................................................................7612.2.1 Main modules FX3CPU0 and FX3CPU1 .........................................7612.2.2 FX3XTIO input/output extension module........................................7712.2.3 FX3XTDI input/output extension module........................................8012.2.4 UE4102RO/UE4104RO output modules.......................................82

12.3 Dimensional drawings ........................................................................................8612.3.1 Main modules FX3CPU0/1 with system plug .................................8612.3.2 Input/output extension FX3XTIO, input extension FX3XTDI,

relay output modules UE4102RO and UE4104RO .......................86

13 Ordering information.......................................................................................................8713.1 Available modules and accessories...................................................................8713.2 Devices ................................................................................................................89

13.2.1 Single-beam photoelectric safety switches (Type 2).......................8913.2.2 Non-contact safety switches.............................................................9013.2.3 Safety light curtains and multiple light beam safety devices .........9013.2.4 Safety laser scanners and safety camera system ..........................9013.2.5 Diode module ....................................................................................9113.2.6 Muting lamp and cable .....................................................................91

14 Annex ................................................................................................................................9214.1 EC declarations of conformity ............................................................................9214.2 Manufacturers checklist .....................................................................................9814.3 List of tables........................................................................................................9914.4 List of illustrations............................................................................................ 101

Chapter 1 Operating instructions

Flexi Soft Hardware


About this document

1 About this documentPlease read the chapters 1 and 2 carefully before working with this documentation andthe Flexi Soft modular safety controller.

1.1 Function of this documentFor the Flexi Soft system there are three operating instructions with clearly distinguishedfields of application as well as mounting instructions and brief instructions for eachmodule.

� The “Flexi Soft — Hardware” operating instructions describe all the Flexi Soft modulesand their functions in detail. Use the Hardware operating instructions in particular toconfigure Flexi Soft safety controllers.

These operating instructions instruct the technical staff of the machine manufacturerand/or of the machine operator on the safe mounting, electrical installation,commissioning as well as maintenance of the Flexi Soft modular safety controller.

These operating instructions do not provide instructions for operating the machine inwhich the safety controller is, or will be, integrated. Information of this kind will be foundin the operating instructions for the machine.

� The “Flexi Soft Modular Safety Controller — Software” operating instructions describethe software-supported configuration and parameterization of the Flexi Soft safetycontroller. In addition the software operating instructions contain the description of thediagnostics functions that are important for operation and detailed information for theidentification and elimination of errors. Use the Software operating instructions inparticular for the configuration, commissioning and operation of Flexi Soft safetycontrollers.

� The “Flexi Soft Gateways” operating instructions describe all Flexi Soft gateways andtheir functions in detail.

These operating instructions instruct the technical staff of the machine manufacturerand/or of the machine operator on the safe mounting, electrical installation,commissioning as well as maintenance of the Flexi Soft gateways.

Additionally the “Flexi Soft Gateways” operating instructions contain important informa-tion on the configuration of the gateways using the Flexi Soft Designer software, on thedata transfer to and from networks as well as information on status, planning and therelated mapping.

� The mounting instructions/brief instructions are enclosed with each Flexi Soft module.They inform on the basic technical specifications of the modules and contain simplemounting instructions. Use the mounting instructions/brief instructions when mountingthe Flexi Soft safety controller.

1.2 Target groupThese operating instructions are addressed to the planning engineers, designers andoperators of systems which are to be protected by a Flexi Soft modular safety controller.They also are addressed to people who integrate the Flexi Soft safety controller into amachine, commission it initially or who are in charge of servicing and maintaining the unit.

Operating instructions Chapter 1

Flexi Soft Hardware


About this document

1.3 Depth of informationThese operating instructions contain information on the Flexi Soft modular safetycontroller in the following subjects:

� mounting

� electrical installation

� hardware commissioning

� error diagnostics and remedying

� part numbers

� conformity and approval

Planning and using SICK protective devices also require specific technical skills which arenot detailed in this documentation.

When operating the Flexi Soft modular safety controller, the national, local and statutoryrules and regulations must be observed.

The “Safe Machinery” guidelines contain general information about the topic of safetytechnology.

We also refer you to the homepage on the Internet and the CD:

http://www.sens-control.comFlexi Soft CD (2045931)

Here you will find:

� product and application animations

� configuration aids

� these operating instructions in different languages for viewing and printing

� the Flexi Soft Designer configuration software

� the “Flexi Soft Designer Software” operating instructions

� the “Flexi Soft Gateways” operating instructions

� EDS, GSD and GSDML files

1.4 ScopeThese operating instructions are valid for all modules of the Flexi Soft safety controller withthe exception of the Flexi Soft gateways.

These operating instructions are original operating instructions.

1.5 Abbreviations usedExternal device monitoring

Enhanced Function Interface

Electro-sensitive protective equipment (e.g. C4000)

Normally closed

Normally open

Output signal switching device

Probability of dangerous failure per hour

Programmable Logic Controller

Safety Integrity Level (safety class)

Safety Integrity Level Claim Limit

Note

EDM

EFI

ESPE

NC

NO

OSSD

PFHd

PLC

SIL

SILCL


Flexi Soft Hardware


About this document

1.6 Symbols usedRecommendations are designed to give you some assistance in your decision-makingprocess with respect to a certain function or a technical measure.

Notes provide special information on the device.

LED symbols describe the state of a diagnostics LED. Examples:� Red The red LED is illuminated constantly.� Red The red LED is flashing.� Green The green LED is off.

Instructions for taking action are shown by an arrow. Read carefully and follow theinstructions for action.

Warning!

A warning indicates concrete or potential dangers. Warnings are intended to protect youfrom harm and help avoid damage to devices and systems.

Read warnings carefully and follow them!

Otherwise the safety function may be impaired and a dangerous state may occur.

Recommendation

Note

� Red,� Red, � Green

� Action

�WARNING


Flexi Soft Hardware


On safety

2 On safetyThis chapter deals with your own safety and the safety of the equipment operators.

� Please read this chapter carefully before working with the Flexi Soft modular safetycontroller or with the machine protected by the Flexi Soft modular safety controller.

2.1 Qualified personsThe Flexi Soft modular safety controller may only be installed, commissioned and servicedby qualified personnel.

Qualified persons are defined as persons who …

� have undergone the appropriate technical training

and

� have been instructed by the responsible machine operator in the operation of themachine and the current valid safety guidelines

and

� have access to the operating instructions of the Flexi Soft and have read andfamiliarised themselves with them

and

� have access to the operating instructions for the protective devices (e.g. C4000)connected to the safety controller and have read and familiarised themselves withthem.

2.2 Application areas for the deviceThe Flexi Soft modular safety controller is a configurable controller for safety applications.It can be used …

� in accordance with EN 61�508 to SIL3

� in accordance with EN 62�061 to SILCL3

� in accordance with EN ISO 13�8491 up to Performance Level e

The degree of safety actually attained depends on the external circuit, the realization ofthe wiring, the parameter configuration, the choice of the pick-ups and their location at themachine.

Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safetyswitches, sensors, emergency stop pushbuttons) are connected to the modular safetycontroller and are linked logically. The corresponding actuators of the machines orsystems can be switched off safely via the switching outputs of the safety controller.


Flexi Soft Hardware


On safety

2.3 Correct use

The Flexi Soft system fulfils the requirements of Class A (industrial applications) inaccordance with the “Interference emission” basic specifications.

The Flexi Soft system is therefore only suitable for use in an industrial environment andnot for private use.

The Flexi Soft modular safety controller may only be used within specific operating limits(voltage, temperature, etc., refer to the technical data in chapter 12) in the sense of sec-tion 2.2 “Application areas for the device” on page 9 and section 7.1 “Electricalinstallation requirements” on page 56. It may only be used by specialist personnel andonly at the machine at which it was mounted and initially commissioned by qualified per-sonnel in accordance with these operating instructions.

SICK AG accepts no claims for liability if the equipment is used in any other way or if modi-fications are made to the device, even in the context of mounting and installation.

� The external voltage supply of the device must be capable of buffering brief mains volt-age failures of 20 ms as specified in EN 60�204. Suitable PELV- and SELV-compatiblepower supply units are available as accessories from SICK.

� The modules of the Flexi Soft system conform to Class A, Group 1, in accordance withEN 55�011. Group 1 encompasses all ISM devices in which intentionally generatedand/or used conductor-bound RF energy that is required for the inner function of thedevice itself occurs.

UL/CSA applications

� Use 60°C/75°C conductors.

� The terminal tightening torque must be 5–7 lbs/in.

� To be used in a Pollution Degree 2 environment only.

� The modules shall be supplied by an isolating power source protected by an UL�248fuse, rated max. 100/V, where V is the DC supply voltage with the maximum value of42.4 V DC, such that the limited voltage/current requirements of UL�508 are met.

� Max. XTIO Q1 … Q4 total current Isum = 3.2 A

� The gateways FX0-GPNT, FX0-GMOD and FX0-GENT are intended to be used withClass 2. Therefore the main module must be supplied in this case with a Class 2 powersource or Class 2 transformer in accordance with UL�1310 or UL�1585.

The safety functions are not evaluated by UL. The approval is accomplished according toUL�508, general use applications.

�WARNING

Note


Flexi Soft Hardware


On safety

2.4 General protective notes and protective measures

Observe the protective notes and measures!

Please observe the following items in order to ensure proper use of the Flexi Soft safetycontroller.

� When mounting, installing and using the Flexi Soft safety controller, observe thestandards and directives applicable in your country.

� The national/international rules and regulations apply to the installation, use andperiodic technical inspection of the Flexi Soft safety controller, in particular:

– Machinery Directive 2006/42/EC

– EMC Directive 2004/108/EC

– Provision and Use of Work Equipment Directive 89/655/EC

– Low-Voltage Directive 2006/95/EC1)

– The work safety regulations/safety rules� Manufacturers and owners of the machine on which a Flexi Soft safety controller is used

are responsible for obtaining and observing all applicable safety regulations and rules.

� The notices, in particular the test notices (see chapter 9, “Commissioning” on page 60)of these operating instructions (e.g. on use, mounting, installation or integration into theexisting machine controller) must be observed.

� The tests must be carried out by specialised personnel or specially qualified and autho-rised personnel and must be recorded and documented to ensure that the tests can bereconstructed and retraced at any time by third parties.

� These operating instructions must be made available to the user of the machine wherethe Flexi Soft safety controller is used. The machine operator is to be instructed in theuse of the device by qualified personnel and must be instructed to read the operatinginstructions.

1) UE4102RO and UE410-4RO only.

�WARNING


Flexi Soft Hardware


On safety

2.5 Environmental protectionThe Flexi Soft modular safety controller has been designed to minimise environmentalimpact. It uses only a minimum of power and natural resources.

� At work, always act in an environmentally responsible manner.

2.5.1 Disposal

Disposal of unusable or irreparable devices should always occur in accordance with theapplicable country-specific waste-disposal regulations (e.g. European Waste Code16 02 14).

We would be pleased to be of assistance on the disposal of this device. Contact your localSICK representative.

2.5.2 Material separation

Material separation may only be performed by qualified personnel!

Exercise care when disassembling the devices. The danger of injury is present.

Before you can turn over the devices for environmental-friendly recycling, you mustseparate the different materials of the Flexi Soft from one another.

� Separate the housing from the remaining components (especially the PCB).

� Send the separated components to the corresponding recycling centres (see thefollowing table).

Component Disposal

Product

Housing

PCBs, cables, plugs and electrical connection pieces

Plastic recycling

Electronics recycling

Packaging

Cardboard, paper Paper/cardboard recycling

Note

�WARNING

Tab. 1: Overview of disposalby component


Flexi Soft Hardware


Product description

3 Product descriptionThis chapter provides information on the features and properties of the Flexi Soft systemand describes the structure and operating principle.

3.1 System properties

The Flexi Soft system is characterised by the following system properties:

� modular structure: 1 main module, up to 2 different gateways and up to 12input/output extension modules, each with 22.5 mm compact width

� 8 to 96 inputs and 4 to 48 outputs

� programmable

� use of up to 255 standard and application-specific logic blocks

� standard logic blocks, e.g. AND, OR, NOT, XNOR, XOR

� application-specific logic blocks, e.g. emergency stop, two-hand, muting, press, rampdown, operating mode selector switch, reset, restart

� integration in different networks via gateways possible (EtherNet/IP, Modbus TCP,PROFINET IO, PROFIBUS DP, DeviceNet and CANopen)

� 2 EFI interfaces on the FX3CPU1 main module, see section 3.6

The Flexi Soft Designer configuration software is available for configuring the control tasks.

The configuration software is available on the Internet or on the CD:

http://www.sens-control.com orFlexi Soft CD (2045931)

Fig. 1: Flexi Soft modularsafety controller

http://www.sens-control.com/


Flexi Soft Hardware


Product description

3.2 System configurationA Flexi Soft system consists of the following modules:

� an FX3MPL0 system plug

� an FX3CPU0 or FX3CPU1 main module

� up to 2 gateways

� up to 12 additional extension modules, e.g. FX3XTIO and FX3XTDI,

� in addition up to 8 UE4102RO relay output modules and/or 4 UE4104RO relay outputmodules (meaning a max. of 16 safe relay outputs).

Other modules of the Flexi Classic series may not be connected to the Flexi Soft system.Note

Fig. 2: Examples for theminimum configuration of aFlexi Soft system with CPU0and XTDI or CPU1 and XTIO

Fig. 3: Maximum configura-tion of the Flexi Soft system(without relay output exten-sions)


Flexi Soft Hardware


Product description

Type Kind Inputs OutputsLogic

blocksMax.

occurrence

FX3CPU0 – –

FX3CPU1Main module

42) –255 1×

FX0GENT EtherNet/IP gateway 23) – –

FX0GMOD Modbus TCP gateway 23) – –

FX0GPNT PROFINET IO gateway 23) – –

FX0-GETC EtherCAT gateway 23) – –

FX0GPRO PROFIBUS DP gateway 14) – –

FX0GDEV DeviceNet gateway 14) – –

FX0GCAN CANopen gateway 14) – –

2×

FX3XTIO Input/output extension 8 4 –

FX3XTDI Input extension 8 – –12×

UE4102RO Relay output extension – 2 – 8×5)

UE4104RO Relay output extension – 4 – 4×5)

2) EFI terminals.3) RJ45 sockets.4) RS485 socket.5) Max. of 16 safe relay outputs.

Tab. 2: Overview of themodules


Flexi Soft Hardware


Product description

3.3 Version, compatibility and featuresFor the Flexi Soft product family several firmware versions and function packages existthat allow different functions. This section gives an overview which firmware version, whichfunction package and/or which version of the Flexi Soft Designer software is required touse a certain function or device.

Minimum required version

Feature CPU XTIO/XTDI Flexi Soft DesignerLogic offline simulation –6) – V1.2.0Logic import/export – – V1.3.0Two S3000 on one EFI interface V1.00 – V1.2.2Automatic wiring diagrams – – V1.3.0Central tag name editor – – V1.3.0Flexi Link (only with CPU1) V2.00 (Step 2.xx) – V1.3.0Logic block documentation within theDesigner

– – V1.3.0

Input/output relation matrix – – V1.3.0Invertable inputs for the AND, OR,RS Flip-Flop and Routing N:N functionblocks

V2.00 (Step 2.xx) – V1.3.0

New function blocks (e.g. Ramp down,Fast Shut Off with Bypass, Adjustabledelays)

V2.00 (Step 2.xx) – V1.3.0

Verification without identical hardwarepossible

V2.00 (Step 2.xx) – V1.0.0

Test pulses on XTIO can be disabled – V2.00 (Step 2.xx) V1.3.0Status input data and Status outputdata in logic

V1.11 (Step 1.xx) V2.00 (Step 2.xx) V1.3.0

Several safety mats per XTIO/XTDI – V1.13 V1.3.0

Device CPU XTIO/XTDI Flexi Soft DesignerProfiNET, Modbus TCP, Ethernet/IPgateways

V1.11 (Step 1.xx) – V1.2.0

CANopen, DeviceNet, CC-Link gateways V1.11 (Step 1.xx) – V1.3.0EtherCAT gateway V1.11 (Step 1.xx) – V1.3.10-Speed Monitor MOC3SA – – V1.3.0ROHS conformity XTIO – V1.017) –

� You can find the firmware version on the type label of the Flexi Soft modules in the field“Software version”.

� In order to use modules with a newer firmware version, a new Flexi Soft Designerversion is required.

� The version of the Flexi Soft Designer can be found in the Extras menu under Info.� The newest version of the Flexi Soft Designer can be obtained on the Internet under

www.sens-control.com.� The function package (Step 1.xx or Step 2.xx) must be selected in the Flexi Soft

Designer hardware configuration. Function package Step 2xx is available with Flexi SoftDesigner 1.3.0 and higher.

� In order to use function package Step 2.xx, the respective module must have at leastfirmware version V2.00.0. Otherwise you will receive an error message when you try toupload a configuration using Step 2.xx to a module with a lower firmware version.

� Newer modules are downward compatible so that any module can be replaced by amodule with a higher firmware version.

� You will find the device’s date of manufacture on the type label in the S/N field in theformat yywwnnnn (yy = year, ww = calendar week, nnnn = continuos serial number inthe calendar week).

6) “–” means “any” or “not applicable”.7) All other modules from product launch onwards.

Tab. 3: Required firmwareand software versions

Notes

http://www.sens-control.com/


Flexi Soft Hardware


Product description

3.4 System plug FX3MPL0The system configuration of the complete Flexi Soft system is only stored in the systemplug. This offers the advantage when extension modules are replaced that the Flexi Softsystem does not have to be reconfigured.

� Connected EFI-compatible devices have to be configured again when they are replaced.

� The data stored in the system plug are retained when the voltage supply is interrupted.

� The main module, the internal logic of all modules and the inputs (e.g. I1…I8) and testoutputs (e.g. X1…X8) of extension modules are supplied with electricity exclusivelythrough the system plug. The outputs (e.g. Q1…Q4), on the other hand, are suppliedseparately.

� If modules are replaced, ensure that the system plug is plugged into the designatedmain module. Uniquely mark all the connection cables and connectors at the Flexi Softsystem in order to avoid confusion.

3.5 Main module FX3CPU0

3.5.1 Description

The main module FX3CPU0 is the central process unit of the entire system in which all thesignals are monitored and processed logically in accordance with the configuration storedin the system plug. The outputs of the system are switched as a result of the processing,whereby the FLEXBUS+ internal bus serves as the data interface.

3.5.2 Display elements, error codes and terminal description

Notes

Fig. 4: Display elementsFX3CPU0

RS-232 interfaceLED MS (Module Status)

LED CV (Configuration Verified)

System plug


Flexi Soft Hardware


Product description

MS LED Meaning Notes

� Supply voltage isoutside range

Switch on the supply voltage and check itat the terminals A1 and A2.

� Red/green(1 Hz)

A self test is beingcarried out or thesystem is beinginitialized

Please wait …

� Green (1 Hz) System is in Stop state Start the application in the Flexi SoftDesigner.

� Green (2 Hz) Identify (e.g. for FlexiLink)

� Green System is in Run state

� Red (1 Hz) Invalid configuration Check the module type and version of themain module and extension moduleswhose MS LED flashes red/green.

If appropriate, adapt the configurationusing the Flexi Soft Designer.

For detailed diagnostics information referto the Flexi Soft Designer.

� Red (2 Hz) Critical error in the sys-tem, possibly in thismodule. Application isstopped. All outputsare switched off.

Switch the supply voltage off and on again.If the error is not eliminated after multiplerepetition, replace this module.


� Red Critical error in thesystem, possibly inanother module.Application is stopped.All outputs areswitched off.

Switch the supply voltage off and on again.

If the error is not eliminated after multiplerepetition, replace the module whichdisplays � Red (2 Hz). If this is not thecase, use the diagnostic functions of theFlexi Soft Designer to narrow down therespective module.

CV LED Meaning Note

� Configuration inprogress

� Yellow (2 Hz) Storing of configura-tion data in the non-volatile memory

Supply voltage may not be interrupted untilthe storage process has been completed.

� Yellow (1 Hz) Unverifiedconfiguration

Verify configuration with the Flexi SoftDesigner software.

� Yellow Verified configuration

Tab. 4: Displays of theMS LED

Tab. 5: Displays of theCV LED


Flexi Soft Hardware


Product description

Pin Assignment

A1 24 V voltage supply for all the modules, with the exception of the outputs(Q1 … Q4)

A2 GND of the voltage supply

RS-232 interface

The main module furthermore has an RS232 interface with the following functions:

� Transferring the configuration from the Flexi Soft Designer to the system plug

� Uploading the configuration from the system plug to the Flexi Soft Designer

� Diagnostics of the Flexi Soft system with the Flexi Soft Designer

� Continuous diagnosis of the Flexi Soft system via the connected PLC, making theRS232 interface an alternative for a gateway.

Plug/socket Pin Signal Colour Assignment PC-sidedRS232 SubD (9 pins)

1 Reserved Brown –

2 RxD White Pin 3

3 GND (Internally electricallyconnected with connectionA2 of the main module)

Blue Pin 5

4 TxD Black Pin 2

� If the RS232 interface at the main module is connected permenantly for usage as analternative to a gateway, the maximum permissible cable length is 3 m.

� Avoid ground loops between the GND of the RS232 interface and the connection A2 ofthe main module, e.g. by using optocouplers.

3.6 Main module FX3CPU1

3.6.1 Description

The main module FX3CPU1 has the same functions as the FX3CPU0. Please observe thenotes in chapter 3.5.

In addition this module has 2 EFI interfaces. If EFI-compatible devices are connected, thefollowing additional functions can be used:

� Transferring the configuration from the Flexi Soft Designer to the system plug and to theconnected EFI-compatible devices

� Uploading the configuration from the system plug and the connected EFI-compatibledevices to the Flexi Soft Designer

� Diagnostics of the Flexi Soft system and the connected EFI-compatible devices with theFlexi Soft Designer

� Process data exchange between main module and EFI-compatible devices.

� Connection of up to four FX3-CPU1 main modules as a Flexi Link system (see section4.7 “Flexi Link” on page 47).

For further information about EFI interfaces refer to section 5.1.

Tab. 6: System plug pinassignment

Tab. 7: Pin assignment of theRS232 interface

Notes


Flexi Soft Hardware


Product description


The displays of the MS and CV LEDs as well as the pin assignment of the RS232 interfaceare identical with those of the FX3CPU0, see section 3.5.2.

EFI LED(EFI1 or EFI2)

Meaning Note

� OK –

� Red Waiting for integration of any EFI compatibledevice or Flexi Link station after power up

–

� Red (1 Hz) Error, e.g.:

� Any expected EFI compatible device or FlexiLink station not found within 3 minutes

� Integration check failed

� Communication interruption

� EFI device address conflict

� Flexi Link ID conflict

Check the wiring.

Later integration isstill possible.

� Red (2 Hz,alternating)

Identify, (e.g. for Flexi Link)

Fig. 5: Display elementsFX3CPU1

Tab. 8: Displays of the EFILEDs

RS-232 interfaceLED MS (Module Status)

LED CV (Configuration Verified)

LED EFI1

LED EFI2

EFI2_B

System plug

EFI2_A

EFI1_A

EFI1_B


Flexi Soft Hardware


Product description

3.7 FX3XTIO input/output extension module

3.7.1 Description

The FX3XTIO module is an input/output extension with 8 safety inputs and 4 safety out-puts. It has two test signal generators: One for test output X1 and one for test output X2.

The FX3XTIO module offers the following functions:

� Monitoring of the connected safety devices, also refer to chapter 4.

� Passing on the input information to the main module

� Receiving the control signals from the main module and corresponding switching of theoutputs

� Fast Shut Off: Direct switching off of the actuators connected to the module possiblewith main module CPU0 or CPU1 firmware version V1.10.0 or higher and Flexi SoftDesigner version V1.1.0 or higher.

This leads to a considerable reduction of the response time of the overall system. Forswitching off outputs, only 8 ms have to be added to the response times of the devicesconnected to the inputs and outputs. The response time on the internal FLEXBUS+ busas well as the logic execution time are irrelevant in this case. See also section 12.1“Response times of the Flexi Soft system” on page 70.

� Enabling or disabling of test pulses for outputs (Q1–Q4) with firmware version V2.00.0or higher and Flexi Soft Designer version V1.3.0 or higher.

The FX3XTIO module cannot be used alone and always requires a main moduleFX3CPU0/1, see the Flexi Soft Designer configuration software.

The simultaneous use of several FX3XTIO modules is possible, see section 3.2 “Systemconfiguration”.

Voltage for the internal logic and the test outputs is supplied from the system plug via theFLEXBUS+ internal bus.

Voltage for the FX3-XTIOs outputs Q1 … Q4 must be supplied directly via A1/A2 on therespective module.

� Short-circuits can be detected between any test signal generator of FX3-XTDI or FX3-XTIO extension modules, even between different modules, provided that the test gaptimes are < 4 ms. Short circuits to 24 V DC (stuck at high) at inputs connected to testoutputs are detected independently of the test gap time.

� The input I1…I8 LEDs display the input states with a refresh rate of approx. 64 ms.

Notes


Flexi Soft Hardware


Product description


Terminal Assignment

X1/X2 Test outputs 1 and 2

I1 … I4 Inputs 1 to 4

A1 24 V

A2 GND


Q1 … Q4 Outputs 1 to 4

MS LED Meaning Notes

� Supply voltage isoutside range

Switch on the supply voltage and check itat the terminals A1 and A2.

� Red/green(1 Hz)

Recoverable externalerror

Check the wiring of the flashing inputs andoutputs.

If all output LEDs flash, check the supplyvoltage at terminals A1 and A2 of thismodule.

� Green (1 Hz) System is in Stop state Start the application in the Flexi SoftDesigner.

� Green System is in Run state

� Red (1 Hz) Invalid configuration

� Red (2 Hz) Critical error in thesystem, possibly in thismodule. Application isstopped. All outputsare switched off.

Switch the supply voltage off and on again.If the error is not eliminated after multiplerepetition, replace this module.


� Red Critical error in thesystem, possibly inanother module.Application is stopped.All outputs areswitched off.

Switch the supply voltage off and on again.

If the error is not eliminated after multiplerepetition, replace the module whichdisplays � Red (2 Hz). If this is not thecase, use the diagnostic functions of theFlexi Soft Designer to narrow down therespective module.

Fig. 6: Display elementsFX3XTIO

Tab. 9: Terminal assignmentFX3XTIO

Tab. 10: Displays of theMS LED

LED MS (Module Status)8 input LEDs

4 output LEDs


Flexi Soft Hardware


Product description

Input LEDs (I1 … I8)Output LEDs (Q1 … Q4)

Meaning

� Input/output is inactive.

� Green Input/output is active.

� Green (1 Hz) synchronous with the redMS LED

Input/output is inactive and there is acorrectable error.

� Green (1 Hz) alternating with the redMS LED

Input/output is active and there is acorrectable error.

3.7.3 Internal circuits

Tab. 11: Displays of theinput/output LEDs

Fig. 7: Internal circuits FX3-XTIO – safety inputs and testoutputs

Fig. 8: Internal circuits FX3-XTIO – safety outputs

Appl

icat

ion

Appl

icat

ion


Flexi Soft Hardware


Product description

3.7.4 Disabling the test pulses of XTIO outputs

It is possible to disable the test pulses on one or several outputs of XTIO modules withfirmware version V2.00.0 and higher.

Disabling the test pulses of any output reduces the safety parameters of all outputs!

Disabling the test pulses of one or more safety outputs of an XTIO module will reduce thesafety parameters for all safety outputs Q1…Q4 of this module. Consider this to ensurethat your application conforms to an appropriate risk analysis and avoidance strategy!

For detailed information on the safety parameters see chapter 12 “Technical data” onpage 70.

Use protected or separate cabling!

If you disable the test pulses of one or more safety outputs, you have to use protected orseparate cabling for the safety outputs with disabled test pulses, because a short circuit to24 V can not be detected if the output is High. This could inhibit the switch-off capabilityfor the other outputs in case of an internal detected hardware failure due to reversepowering.

Perform cyclic tests if the test pulses of any safety output are disabled!

If you disable the test pulses of one or more safety outputs, at least once per year eitherall safety outputs without test pulses have to be switched off at the same time for at leastone second as a result of the logic program of the main module. Alternatively a powerreset of the Flexi Soft system has to be performed.

How to disable the test pulses of an XTIO output:

� Connect an output element to the XTIO module.

� Right click the output element and select Edit... from the context menu.

� Deactivate the option Enable test pulses of this output. The test pulses of this outputare switched off. A notice will be displayed in the hardware configuration area under therespective XTIO module.

3.7.5 Single channel usage of XTIO outputs

Consider a possible brief High switching of single channel safety outputs!

In case of an internal hardware error, single channel safety outputs (Q1…Q4) can switchtemporarily to High once for 10 ms after the error has been detected. Consider this foryour risk analysis and reduction strategy. Otherwise the operator of the machine will be indanger.

�WARNING

�WARNING


Flexi Soft Hardware


Product description

3.8 FX3XTDI input extension module

3.8.1 Description

The FX3XTDI module is the input extension with 8 safe inputs. It offers the followingfunctions:

� Monitoring of the connected sensor equipment, also refer to chapter 4.

� Passing the input information to the main module

The FX3XTDI module cannot be used alone and always requires a main moduleFX3CPU0/1, see the Flexi Soft Designer configuration software.

The simultaneous use of several FX3XTIO modules is possible, see chapter 3.2 “Systemconfiguration”.

Voltage for the internal logic and the test outputs is supplied from the system plug via theFLEXBUS+ internal bus.

Limited short-circuit recognition!

An FX3XTDI has two test signal generators. One test signal generator is responsible for theodd-numbered test outputs X1, X3, X5 and X7, the other for the even-numbered testoutputs X2, X4, X6 and X8.

Short-circuits can be detected between any test signal generator of FX3-XTDI or FX3-XTIOextension modules, even between different modules, provided that the test gap times are< 4 ms. Short circuits to 24 V DC (stuck at high) at inputs connected to test outputs aredetected independently of the test gap time.

Please be aware that at the FX3-XTDI the odd-numbered test outputs X1, X3, X5 and X7are connected to one common test signal generator and that the even-numbered test out-puts X2, X4, X6 and X8 are connected to another common test signal generator. Thereforeshort circuits between test outputs X1, X3, X5 and X7 cannot be detected. The sameapplies respectively for test outputs X2, X4, X6 and X8.

� Take this into consideration during the wiring (e.g. separate routing, sheathed cables)!

�WARNING


Flexi Soft Hardware


Product description


The displays of the MS LED as well as the input LEDs I1 … I8 are identical with those of theFX3XTIO, see section 3.7.2.

Terminal Assignment

X1/X3 Test output 1 (test signal generator 1)






3.8.3 Internal circuits

Fig. 9: Display elementsFX3XTDI

Tab. 12: Terminalassignment FX3XTDI

Fig. 10: Internal circuits FX3-XTDI – safety inputs and testoutputs

LED MS (Module Status)8 input LEDs

Appl

icat

ion


Flexi Soft Hardware


Product description

3.9 UE4102RO/UE4104RO relay output modules

3.9.1 Description

The UE4102RO/UE4104RO relay output modules provide dual-channel contact-basedoutputs with positively guided relay contacts.

The UE4102RO/UE4104RO relay output modules cannot be used independently, butneed to be switched via an FX3XTIO module. To this purpose a control output of theFX3XTIO module (Q1 … Q4) has to be jumpered to a control input of the relay outputmodule (B1, B2), see the following figure.

Monitor the feedback contacts using an EDM function block!

It is not sufficient to connect the control outputs B1 or B1/B2. Additionally, the feedbackcontacts Y1/Y2 on the UE410-2RO or the feedback contacts Y1/Y2 and Y3/Y4 on theUE410-4RO relais module must be monitored using an EDM function block in the Flexi Softlogic editor.

The relay output modules are not participating at the internal FLEXBUS+ bus communica-tion. Control signals can therefore not be received from the main module.

A max. of four UE4104RO relay output modules or eight UE4102RO modules can be con-nected to a Flexi Soft system, i.e. a maximum of 16 safe relay outputs are available.

Other modules of the UE410 series can not be integrated into the Flexi Soft system.

UE4102RO

The UE4102RO has one control input (B1). This controls two internal relays and providesa redundant switch-off path consisting of:

� two safe enabling circuits (13/14, 23/24), dual-channel and potential-free,

� a signaling circuit (Y14), dual-channel and connected to internal 24 V DC,

� a feedback EDM (Y1/Y2), dual-channel and potential-free.

Fig. 11: Example of the inclu-sion of a relay module in theFlexi Soft system

�WARNING

Note


Flexi Soft Hardware


Product description

UE4104RO

The UE4104RO has two control inputs (B1, B2). These control two times two internalrelays that provide two independently redundant switch-off paths.

Control input (B1) controls two internal relays and provides a redundant switch-off pathconsisting of:




Control input (B2) controls two internal relays and forms a redundant switch-off pathconsisting of:




The UE4104RO module thus has twice the functionality of a UE4102RO.

Fig. 12: Internal configurationUE4102RO

Fig. 13: Internal configurationUE4104RO


Flexi Soft Hardware


Product description

3.9.2 Display elements and terminal description

Display Meaning

PWR (green) Supply voltage via safety bus is applied

K1/2 (green) Relay K1/K2 — safety contacts closed

K3/4 (green) Relay K3/K4 — safety contacts closed

Assignment Description

B1 Connecting relay K1/K2

13/14 and 23/24 Safety contacts for switch-off circuit K1/K2

Y1/Y2 Feedback circuit external device monitoring (EDM), NC contact

Y14NO safety contact K1/K2, current-limited(see chapter 12 “Technical data” on page 70)

Assignment Description



13/14 and 23/24 Safety contacts for switch-off circuit outputs K1/K2

33/34 and 43/44 Safety contacts for switch-off circuit outputs K3/K4

Y1/Y2 Feedback EDM K1/K2, NC contact

Y3/Y4 Feedback EDM K3/K4, NC contact



Fig. 14: UE4102RO/UE410-4RO display elements

Tab. 13: UE4102RO/UE410-4RO displays

Tab. 14: UE4102ROterminals

Tab. 15: UE4104ROterminals


Flexi Soft Hardware


Connecting devices

4 Connecting devicesThis section describes the connection of safety sensors and actuators to the Flexi Softsystem and provides configuration information for the selected functions.

The Flexi Soft system supports applications up to Performance Level (PL) e (in accordancewith EN ISO 13�8491) and up to Safety Integrity Level SILCL3 (in accordance withEN 62�061).

The degree of safety actually attained depends on the external circuitry, the realisation ofthe wiring, the parameter configuration, the choice of the safety sensors and how they aremounted on the machine. Take and evaluate these using e.g. a failure analysis (FMEA).

For further information that has to be taken into consideration during the electricalinstallation see chapter 7 “Electrical installation” on page 56.

Loss of the safety function through an incorrect configuration!

� Plan and carry out configuration carefully!

The configuration of safety applications must be carried out with the greatest accuracyand must match the status and the condition of the machine or system to bemonitored.

� Check whether the configured safety application monitors the machine or system asplanned and whether the safety of a configured application is ensured at all times. Thismust be ensured in each operating mode and partial application. Document the resultof this check!

� In each case, observe the instructions for commissioning and daily checking in theoperating instructions of the protective devices integrated into the safety application!

� Note the warnings and function descriptions of protective devices connected to thesafety controller! Contact the respective manufacturer of the protective device if indoubt!

� Take into account that the minimum switch-off time of the connected sensors must begreater than the execution time of the logic (see the chapter about the logic editor in the“Flexi Soft Designer software” operating instructions and the logic editor in the Flexi SoftDesigner) so that it is ensured that the Flexi Soft system can detect the switching of thesensors. The minimum switch-off time of sensors is usually specified in the technicaldata of the sensors.

� If an odd-numbered test output is used, odd-numbered inputs have to be used. If aneven-numbered test output is used, even-numbered inputs have to be used.

� You have to use the test outputs of the module to which the device to be tested isconnected.

Protect single channel inputs against short circuits and cross circuits!

If a stuck-at-high error occurs on a single channel input with test pulses that was previous-ly inactive, the logic may see a pulse for this signal. The stuck-at-high first causes the sig-nal to become Active (High) and then after the error detection time back to Inactive (Low)again. Due to the error detection a pulse may be generated. Therefore single channel sig-nals with test pulses need special attention:

� If the stuck-at-high occurs on a single channel signal input with test pulses that waspreviously Active (High), the logic will see a delayed Active (High) to Inactive (Low)transition.

�WARNING

Notes

�WARNING


Flexi Soft Hardware


Connecting devices

� If a single channel input is used and an unexpected pulse or a delayed falling edge atthis input may lead to a dangerous situation, the following measures have to be taken:

– Protected cabling of the related signal (to exclude cross circuits to other signals)– No cross circuit detection, i.e. no connection to test output (see the section

“Parameterization of connected elements” in the Flexi Soft Designer Softwareoperating instructions.

This needs especially to be considered for the following inputs:

– Reset input on the Reset function block– Restart input on the Restart function block– Restart input on the Press function blocks (Eccentric Press Contact, Universal Press

Contact, N-break, Press Setup, Press Single Stroke, Press Automatic)– Override input on a Muting function block– Reset input on a Valve function block– Reset input and Reload input on a Counter function block

After the configuration you obtain the following documentations in the Flexi Soft Designerunder “Report”:

� Logic report

� Parts list

� Wiring diagrams


Flexi Soft Hardware


Connecting devices

Fig. 15: Example extract ofthe documentation in theFlexi Soft Designer


Flexi Soft Hardware


Connecting devices

4.1 Safety command devices and electro-mechanicalsafety switches

4.1.1 Emergency stop pushbuttons (e.g. ES21)

Electrical connection: Example from Flexi Soft Designer with FX3XTIO

Single-channel,connected to24 V

Contact between 24 V and I1

Single-channel,connected totest output

Contact between X2 and I2

Dual-channel,connected to24 V

Channel 1: Contact between 24 V and I3


Dual-channel,connected totest output

Channel 1: Contact between X1 and I5


The dual-channel emergency stop pushbuttons preconfigured in the Flexi Soft Designerhave equivalent switching contacts. Corresponding elements for implementing dual-chan-nel complementary switching contacts are available in the element window under thegroup named “Potential-free contacts and restart”.

Function Notes

Testing Possible

Series connection/cascading

If emergency stop pushbuttons are connected in series, the max.line resistance shall not exceed 100 � (see chapter 12 “Technicaldata” on page 70)

Discrepancy times see Flexi Soft Designer software

Further information is available in the operating instructions for the emergency stoppushbutton ES21.

Tab. 16: Connection ES21

Tab. 17: Functions with ES21

Note


Flexi Soft Hardware


Connecting devices

4.1.2 Electro-mechanical safety switches with and without interlock (e.g. i10, i100and i1000)



Contact between Ub and I1




Channel 1: Contact between Ub and I3







Contact between Ub and I1

Coil at Q1



Coil at Q2




Coil at Q3




Coil at Q1

Function Notes

Testing Possible


If safety switches are connected in series, the max. line resistanceshall not exceed 100 � (see chapter 12 “Technical data” onpage 70).

Discrepancy times See Flexi Soft Designer software

Further information is available in the operating instructions of the electro-mechanicalsafety switches.

Tab. 18: Connection ofelectro-mechanical safetyswitches

Tab. 19: Connection ofinterlocks

Tab. 20: Functions withelectro-mechanical safetyswitches and interlocks

Note


Flexi Soft Hardware


Connecting devices

4.1.3 Enabling switch E100


2 positions,connected to24 V

Channel 1: Contact E31 between Ub and I1


2 positions,connected totest output

Channel 1: Contact E31 between X1 and I3


3 positions,connected to24 V





3 positions,connected totest output





Function Notes

Testing Possible

Series connection Not possible

Discrepancy times See Flexi Soft Designer software

Further information is available in the E100 operating instructions.

Tab. 21: Connection E100

Tab. 22: Functions with E100

Note


Flexi Soft Hardware


Connecting devices

4.1.4 Two-hand control


Type IIIA connected to24 V



Type IIIC connected to24 V

NC contact between 24 V and I1(I3)

NO contact between 24 V and I2(I4)

Type IIIA

At Type IIIA two equivalent inputs (NO contacts of the two two-hand buttons) aremonitored.

A valid input signal is only generated if the ON state (H level) exists at both inputs within aperiod of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were inthe OFF state (L level) beforehand.

Type IIIC

At Type IIIC two pairs of antivalent inputs (NO/NC contact pairs of the two two-handbuttons) are monitored.

A valid input signal is only generated if the ON state (H/L level) exists at both inputs withina period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were inthe OFF state (L/H level) beforehand.

Further information is available in the operating instructions of the two-hand control.

4.1.5 Safety mats and bumpers


Pressure-sensitive short-circuiting switching mats in4wire technology, connectedto test output

Channel 1: Contact between X1and I1

Channel 2: Contact between X2and I2

Function Notes

Parallel connection Possible

Ensure that the switch off condition is sufficient!

The switch off condition of safety mats and bumpers must be at least as high as thegreatest value for the “test period” of both used test outputs to ensure that the switch offcondition is detected and that no sequence error occurs.

Further information is available in the operating instructions of the safety mats.

Tab. 23: Connection of two-hand control

Note

Tab. 24: Connection of safetymats

Tab. 25: Function safetymats

�WARNING

Note


Flexi Soft Hardware


Connecting devices

4.1.6 Diode module DM8-A4K

The DM8-A4K diode module serves as a connecting adapter when several short-circuitingswitching mats are connected to a Flexi Soft XTDI or XTIO module. It de-couples and thusmultiplies the test outputs X1 and X2 by four.

The DM8-A4K diode module is not a safety component as per the machine directive2006/42/EC. Therefore it must not be taken into consideration when determining thesafety integrity level (SIL according to IEC 61�508 and SILCL according to EN 62�061) aswell as the Performance Level (PL according to EN ISO 13�849-1).

Electrical connection

Electrical connection: Example from Flexi Soft Designer with FX3XTIO or FX3-XTDI

Pressure-sensitive short-circuiting switching matsin 4wire technology,connected to test outputand DM8-A4K diodemodule connected inseries

Channel 1: Contact from X1 to I1via diode

Channel 2: Contact from X2 to I2via diode

Channel 3 to 8 corresponding

See connection diagram in Fig. 16.

Connection diagrams

Note

Tab. 26: Connection ofmultiple safety mats withdiode module DM8-A4Kconnected in series

Fig. 16: Connection diagrammultiple safety mats withdiode module DM8-A4Kconnected in series onFX3XTIO


Flexi Soft Hardware


Connecting devices

As shown in Fig. 17, instead of a safety mat it is possible to connect e.g. a safety switch oran emergency stop pushbutton as well.

Data sheet DM8-A4K diode module

General system data

Dimensions (H × W × D) 87 × 32 × 72 mm

Weight 59 g

Operating temperature -25 … +55 °C

Storage temperature -25 … +70 °C

Stripping length 7 mm

Connection cross section 0.2 … 2.5 mm²

Screw type terminal AWG 22–14

Protection class IP 00

Protection grade Pollution degree 2

Input data

Input voltage (max.) 25 V AC/60 V DC

Return voltage 1000 V

Return current 5 µA

Forward voltage 0.8 V

Input current per channel (1/2) 400 mA

Fig. 17: Connection diagrammultiple safety mats withdiode module DM8-A4Kconnected in series onFX3XTDI

Note

Tab. 27: Data sheet DM8-A4K diode module


Flexi Soft Hardware


Connecting devices

Circuit diagram DM8-A4K diode module

Dimensional drawing DM8-A4K diode module

Fig. 18: Circuit diagramDM8A4K diode module

Fig. 19: Dimensional drawingDM8-A4K diode module

32 mm87

mm

Inputs

Outputs

8 × 1N4007


Flexi Soft Hardware


Connecting devices

4.1.7 Operating mode selector switches


Operating modeselector switch (1 of 2)connected to 24 V



Operating modeselector switch (1 of 2)connected to testoutput



Function Notes

Testing Possible

� Operating mode selector switches without test pulses allow 2 to 8 operating modes;operating mode selector switches with test pulses allow 2 to 4 operating modes.

� When wiring the tested operating mode selector switches it should be noted that odd-numbered inputs (I1, I3, I5, I7) have to be used if an odd-numbered test output (X1, X3,X5, X7) is used, and even-numbered inputs (I2, I4, I6, I8) have to be used if an even-numbered test output (X2, X4, X6, X8) is used.

� Further information is available in the operating instructions of the operating modeselector switch.

4.1.8 Potential-free contacts

The Flexi Soft Designer software makes a series of potential-free contacts available for“free” configuration of contact elements. This allows different NC-/NO-contact combina-tions with and without testing to be implemented. In addition elements are available forthe start and stop button, reset button and external device monitoring (EDM).

Function Notes

Testing Possible

Series connection Possible

Discrepancy time See Flexi Soft Designer software

Tab. 28: Connection ofoperating mode selectorswitches

Tab. 29: Function ofoperating mode selectorswitches

Notes

Tab. 30: Function ofpotential-free contacts


Flexi Soft Hardware


Connecting devices

4.2 Non-contact safety sensors

4.2.1 Magnetic safety switches (e.g. RE)

Magnetic safety switches with equivalent inputs (RE13, RE27)


Connected totest output



Magnetic safety switches with complementary inputs (e.g. RE11, RE21, RE31, RE300)


Connected totest output

NC contact between X1 and I1

NO contact between X2 and I2

Function Notes

Testing Possible


Possible; observe the max. line resistance of 100 � and thecorrect setting of the test impulse time

Discrepancy time Default: 1.5 s. See Flexi Soft Designer software

Further information is available in the operating instructions of the magnetic safetyswitches.

4.2.2 Inductive safety switches IN4000 and IN4000 Direct


IN4000 Test input TE (IN4000) at X1

Output A (IN4000) at I1

IN4000 Direct(with OSSD)

OSSD1 (IN4000) at I3

OSSD2 (IN4000) at I4

Function Notes

Testing Necessary on IN4000


IN4000 direct cannot be cascaded

IN4000: up to 6 sensors per input

Max. off-on delay of the cascade 10 ms (otherwise the test gap willlead to switching off)

Observe the max. line resistance of 100 � and the correct settingof the test pulse time

Further information is available in the operating instructions of the inductive safetyswitches.

Tab. 31: Connection ofmagnetic safety switcheswith equivalent inputs

Tab. 32: Connection ofmagnetic safety switcheswith complementary inputs

Tab. 33: Functions withmagnetic safety switches

Note

Tab. 34: Connection ofinductive safety switches

Tab. 35: Functions withinductive safety switches

Note


Flexi Soft Hardware


Connecting devices

4.2.3 Transponder T4000 Compact and T4000 Direct


T4000 Compact(connected to 24 V)

Ub at +LA, I1 at LA

Ub at +LB, I2 at LB

T4000 Compact(connected to testoutput)

X1 at +LA, I3 at LA

X2 at +LB, I4 at LB

T4000 Direct(with OSSD)

Ub at UB (T4000), I5 at OA

Ub at UB (T4000), I6 at OB

Function Notes

Testing Possible for T4000 Compact

Not necessary for T4000 Direct, since self monitored


T4000 Compact is not cascadable;

Take the max. line resistance of 100 � into account at the T4000(see chapter 12 “Technical data” on page 70)

For further information refer to the operating instructions of the Transponder T4000Compact or T4000 Direct.

4.3 Testable single-beam photoelectric safety switches

4.3.1 Testable Type 2 single-beam photoelectric safety switches


Wx12/18/24/27,Vx18

Test input TE (transmitter) at X1

Output Q (receiver) at I1

L21, L27/L28 Test input TE (transmitter) at X2


Use protected or separate cabling for the test output of the module (X1...X8) to the testinput of the transmitter and for the output of the receiver to the safety input of the module(I1..I8). Otherwise a cross circuit between these signals can inhibit the error detection bythis test.

Tab. 36: Connection oftransponders

Tab. 37: Functions withtransponders

Note

Tab. 38: Connection oftestable Type 2 single-beamphotoelectric safety switches

Note


Flexi Soft Hardware


Connecting devices

Function Notes

Testing Possible


Wx12/18/24/27, Vx18:

� max. 2 pairs per input can be cascaded with test gap = 4 ms(standard element)

� max. 5 pairs per input can be cascaded with test gap = 12 ms(customized element required)

L21:



L27/L28:



Take the max. line resistance of 100 � into account.

For further information refer to the operating instructions of the testable Type 2 single-beam photoelectric safety switches.

4.3.2 Testable Type 4 single-beam photoelectric safety switches


L41 Test input TE (transmitter) at X1


Use protected or separate cabling for the test output of the module (X1...X8) to the testinput of the transmitter and for the output of the receiver to the safety input of the module(I1..I8). Otherwise a cross circuit between these signals can inhibit the error detection bythis test.

Function Notes

Testing Necessary


L41:



Take the max. line resistance of 100 � into account

For further information refer to the operating instructions of the testable Type 4 single-beam photoelectric safety switches.

Tab. 39: Functions withtestable Type 2 single-beamphotoelectric safety switches

Note

Tab. 40: Connection oftestable Type 4 single-beamphotoelectric safety switches

Note

Tab. 41: Functions withtestable Type 4 single-beamphotoelectric safety switches

Note


Flexi Soft Hardware


Connecting devices

4.3.3 Customized testable single beam photoelectric safety switches

For information on how to create customized elements please see the Flexi Soft Softwareoperating instructions (SICK part no. 8012480).

� In the Settings dialog for the customized element, select the minimum value for thedesired test gap.

� Regardless of the test gap, the overall off-on-delay of the cascade must be smaller thanthe Max. off-on delay of the respective test output (as shown in the Flexi Soft Designerreport) –2 ms. Otherwise the test gap will lead to switching off. For XTIO or XTDImodules this value is = 12 ms – 2 ms = 10 ms.

� Use protected or separate cabling for the test output of the module (X1...X8) to the testinput of the transmitter and for the output of the receiver to the safety input of themodule (I1..I8). Otherwise a cross circuit between these signals can inhibit the errordetection by this test.

4.3.4 Information for mounting testable single-beam photoelectric safety switches

Observe the information for mounting in the operating instructions of the respectivesensors and in particular the following points:

� Single-beam photoelectric safety switches may only be used as access protection inaccordance with prEN ISO 13�855. Usage as finger and hand protection is notpermissible.

� Observe the minimum distance to reflective surfaces.

� It is imperative that the safety distance between the light beam and hazardous point beobserved at access protection.

S = Sender

R = Receiver

D = Distance between sender and receiver

a = Minimum distance from reflectivesurfaces

1 = Limit to hazardous area

2 = Reflective surface

3 = Direction of access to hazardous area

4 = Optical axis

Notes

Notes

Fig. 20: Minimum distance“a” to reflective surfaces, cor-rect mounting and alignment


Flexi Soft Hardware


Connecting devices

Diagrams for L21 and L41 are available in the respective operating instructions.

Avoiding mutual influence at single-beam photoelectric safety switches and betweencascades

� If several single-beam photoelectric safety switch pairs are used, the field of view of thesensors has to be observed in order to prevent mutual influence.

� If the senders are only mounted on one side, the light beams may not overlap on thereceiver side so that the light beam of one sender does not reach two receivers.

� If the senders and receivers are mounted alternatively, ensure that the light beam ofSender S1 cannot be received by Receiver R3 and that the light beam of Sender S3cannot be received by Receiver R1.

Fig. 21: Minimum distance“a” as a factor of the distance“D” for testable single-beamphotoelectric safety switcheswith a field of view of 10°(e.g. Wx12/18/24/27, Vx18)

Note

Fig. 22: Mounting to avoidmutual optical influence


Flexi Soft Hardware


Connecting devices

4.4 Electro-sensitive protective equipment (ESPE)Electrical connection: Example from Flexi Soft Designer with FX3XTIO

C20, C40, M20, M40, S300,S3000, V300, miniTwin

OSSD1 (receiver) at I1

OSSD2 (receiver) at I2

Further information is available in the operating instructions of the corresponding ESPE.

4.5 Safety outputs

Safety-oriented devices must be suitable for safety related signals!

A function interruption of safety outputs results in a loss of the safety functions so that therisk of serious injury exists.

� Do not connect any loads that exceed the rated values of the safety outputs.

� Connect the GND wires of the power supply to earth so that the devices do not switchon when the safety output line is applied to frame potential.

4.6 EFI devicesIf your Flexi Soft system contains a CPU1, you can connect intelligent SICK EFI compatibledevices and sensors to your main module.

4.6.1 Connection of EFI devices

If shielding is required, for example for EMC reasons, when connecting the EFI devices,use an earth terminal that is placed in the control cabinet near the Flexi Soft main modulefor this purpose. Connect this earth terminal with the shielding.

� No external termination resistor is required for EFI connections on the main module.

� The main module and all connected EFI-compatible devices must have the same 0 V DCof the power supply.

� The maximum permitted voltage at EFI inputs is +/– 30 V (to terminal A2 = 0 V DC)

� You will find information on connecting EFI-compatible devices incl. pin assignments inthe operating instructions for the corresponding devices.

Cables

SICK offers two different cables for the connection of EFI-compatible devices (see section13.1 “Available modules and accessories” on page 87). Further information can be foundin the operating instructions for the related EFI-compatible device.

Tab. 42: Connection ESPE

Note

�WARNING

Notes


Flexi Soft Hardware


Connecting devices

EMC measures

To increase the EMC resistance of the EFI communication, it is recommended to connectthe EFI cable shield on one or both sides to functional earth.

Connect this shield to the same DIN rail to which the functional earth (FE) of the Flexi Softsystem is connected in order to minimize interferences on the EFI cable. The connection ofthe shield to FE should be close to the cable inlet of the control cabinet.

� The FE terminal of the Flexi Soft system is located at the bottom of the housing andconnects automatically to the DIN rail when the module is mounted.

� To avoid further interferences, the functional earth of the SICK sensors (e.g. M4000,S3000) must be connected to the EFI shield as well.

� If other cables are present within the same cable duct where the EFI cable is routed andthese cables emit a high degree of EMC interference (drives or motor related), this canlead to availability problems in the application. In this case, it is recommended to installthe EFI cable in a separate duct.

4.7 Flexi Link

4.7.1 Flexi Link overview

Flexi Link allows you to combine up to four Flexi Soft stations via EFI for safe data commu-nication. Only FX3-CPU1 main modules can be used in a Flexi Link system, the connectionof FX3-CPU0 modules is not possible.The process data of each station (inputs and outputs, logic results etc.) can be made avai-lable to all other stations in the Flexi Link system. The Teach function allows to temporarilydeactivate single stations without impairing the function of the overall system.

Features

� Safe connection of up to four Flexi Soft stations via EFI.

� Connection via EFI1 or EFI1 and EFI2.

� Transfer/receive up to 52 bit of information per station (26 bit per EFI channel).

� Each bit can be assigned a global tag name.

� Teaching simulates the presence of temporarily suspended (switched off) stations.

� Any station can be used as access point to address and configure the entire systemwith the Flexi Soft Designer.

� The configuration of the entire Flexi Link system is stored in a single project file.

The Flexi Link system can be connected using only EFI1 or using both EFI1 and EFI2. Theoverall number of process data bits per station that can be made available to the otherstations in the Flexi Link system depends on the connection method:

Connection method Available process data bits per station

EFI1 26

EFI1/EFI2 52

You can not use Flexi Link and EFI communication at the same time, i.e. it is not possibleto connect other EFI compatible devices on the EFI2 connection while EFI1 is used for FlexiLink.

Notes

Tab. 43: Available processdata bits depending on theconnection method

Note


Flexi Soft Hardware


Connecting devices

4.7.2 System requirements

The minimum system requirements for Flexi Link are as follows:

System component Minimum version

Hardware FX3-CPU1 with firmware version V2.00.0 or higher

Software Flexi Soft Designer version 1.3.0 or higher

4.7.3 Connection of a Flexi Link system

Do not use buffering elements in a Flexi Link system!

It is not allowed to use buffering elements such as e.g. CAN bridges, CAN repeaters or CANoptical light barriers in a Flexi Link system. As a general rule, no components other thanFlexi Soft stations are allowed. Otherwise the operator of the machine will be in danger.

There are two possibilities for wiring a Flexi Link system:

� Connection via EFI1 (26 bits)

� Connection via EFI1 and EFI2 (52 bits)

Either way, always the identically named terminals have to be connected (e.g. EFI1 A onstation A with EFI1 A on station B etc.).

� No external termination resistor is required for EFI connections on the CPU.

� Stub lines or star-shaped wiring are not permitted.

� The max. permitted overall cable length (all stations) for EFI1 and EFI2 is 100 m each.

� Unused conductors must be connected to FE on both ends.

� All connected Flexi Link stations must have the same 0 V DC of the power supply(terminal A2 of system plug).

� The max permitted voltage at EFI inputs is +/– 30 V (to terminal A2 = 0 V DC)

Tab. 44: Minimum systemrequirements for Flexi Link

�WARNING

Fig. 23: Connection of FlexiLink stations via EFI1 andEFI2

Notes

0 V DC

Max. 100 m


Flexi Soft Hardware


Connecting devices

Flexi Link cable

The Flexi Link stations can be connected using CAN cables (shielded, twisted pair).

Cable length Type

Up to 40 m 2 × 2 × 0.25 mm²

Up to 100 m 2 × 2 × 0.34 mm²

SICK offers a suitable cable for connection lengths up to 100 m (SICK part no. 6034249,ordered per meter). Please also see section 13.1 “Available modules and accessories” onpage 87.

EMC measures

Flexi Link cables are used for transferring communication signals. Electromagneticalinfluences may disturb the signal transfer and interrupt the Flexi Link communication. Inorder to minimize electromagnetical interference, the following measures are required:

� Connect all inactive metallic parts (control cabinet doors and housing, mounting railsetc.) to the same reference potential.

� Connect the reference potential to the protective earth conductor.

� Connect the protective earth conductor to the external earth potential.

� Connect the shield of the shielded cables to the reference potential directly at theentrance to the system (control cabinet, frame, mounting rail) using suitable cableclamps. The cable clamps must completely enclose the cable shield.

� Connect the cable shield again to the reference potential as close as possible to theFX3-CPU1 (e.g. on the mounting rail) using suitable cable clamps. The cable clampsmust completely enclose the cable shield.

� Keep the stripped cable ends as short as possible.

� Isolate the screening braiding end e.g. with a suitable shrink tube.

� All connections must be made electrically well conducting with low impedance.

� Stub lines or star-shaped EFI wiring are not permitted.

� Load cables (e.g. for frequency changers, electronic speed controllers, contactors,brakes etc.) and small-signal cables (e.g. measuring lines, analog sensors, field buslines etc.) must be layed separately and with low inductive coupling.

Potential equalisation

� Always connect the cable screen on both sides to earth potential. Be aware that theearth potential may differ on the earth connections. If this is the case, you must installan additional potential equalisation. Follow the relevant standards and regulations.

Tab. 45: Possible cablelengths and types for FlexiLink connections

Fig. 24: Connection of theFlexi Link cable shield to themounting rail

Notes

Shrink tube

Mounting rail

Flexi Link cable


Flexi Soft Hardware


Special functions

5 Special functions

5.1 Enhanced Function Interface — EFIThe FX3CPU1 main module has 2 EFI interfaces. This chapter describes the properties,the functions and the benefits of these interfaces.

The general EFI function description and the possibilities for combining SICK products withregard to EFI is available in the EFI operating instructions 8012621.

5.1.1 Definition

An EFI interface is a safe communication interface between SICK devices. With it informa-tion from the sensor equipment can be read out, as well as commands transferred to thesensor equipment.

5.1.2 Properties

� Up to 4 SICK devices are possible per EFI line, in as far as the EFI-compatible devicessupport this number.

� Connection of the devices using a 2wire cable

� Various device combination possibilities

– Sensor with sensor within the same product family

– Sensor with safety controllers and gateways

– Connection of up to four Flexi Soft FX3-CPU1 main modules in a Flexi Link system(see section 4.7 “Flexi Link” on page 47).

� Transferring of status information (process data) between SICK devices using an EFIinterface

� Transferring the configuration from the Flexi Soft Designer to the EFI-compatible devices

� Uploading the configuration from the EFI-compatible devices to the Flexi Soft Designer

� Activation/utilisation of sensor functions


Flexi Soft Hardware


Special functions

5.1.3 Functions

In addition to the product-specific functions of the respective EFI-compatible devices thefollowing functions are available:

General functions

� Status information (process data) of the EFI-compatible devices are available in thecontroller and at the sensor

� Diagnostics information of all the EFI-compatible devices is available in the controller

� Transfer of configuration information

Special functions

� Simultaneous protective field evaluation

� Protective field switching

� Function changeover

� Operating mode selection

� Signal routing

� Decentralized diagnostics information via Ethernet

� Information on the location of the protective field interruption at host-guest applications

� Evaluation of signals and forwarding of the results

5.1.4 Benefits

� Reduction of the installation work (only 2 wires) when signals from several sensors areused

� Reduction of the required material through possibility of saving function blocks andI/Os

� High availability through provision of the diagnostics information with high informationcontents for rapid and correct handling options


Flexi Soft Hardware


Special functions

5.2 Muting

5.2.1 General description

Muting is the automatic temporary bypassing of safety-oriented functions of the controlsystem or of the safety device. Muting is used when certain objects, such as pallets withmaterial, may be moved into the hazardous area. During this transportation throughelectro-sensitive protective equipment (ESPE), such as a safety light curtain, the mutingfunction inhibits monitoring by the ESPE.

Observe the information in the “Flexi Soft Modular Safety Controller — Software” operatinginstructions for the further procedure.

5.2.2 SICK muting sensors

Sensor Type Switching output Q

WT24

WT272

Light switchingPhotoelectric proximity switch

WT260 Light switching

WL23

WL27

Dark switching

WL260 Dark switching

WL12 Dark switching

WL14 Dark switching

Photoelectric reflex switch

WL182 Dark switching

WS24/WE24

WS27/WE27

Through-beam photoelectricswitch

WS260/WE260

Dark switching

Tab. 46: Selection of theSICK optical muting sensors


Flexi Soft Hardware


Mounting/Dismantling

6 Mounting/DismantlingThis chapter describes the mounting of the modules of the Flexi Soft safety controller.

6.1 Steps for mounting the modules

The Flexi Soft system must be mounted in a control cabinet with at least IP 54enclosure rating!

� In a Flexi Soft system the main module FX3CPU0 or FX3CPU1 is positioned at the farleft.

� The two optional gateways follow directly to the right of the main module.

� Connect further Flexi Soft extension modules (e.g. FX3XTIO or FX3XTDI) on the rightside of the gateways or on the right side of the main module, if no gateway is used.

� Connect any additional relay modules (UE4102RO or UE4104RO) on the far right ofthe entire Flexi Soft system.

� The modules are located in a 22.5 mm wide modular system for 35 mm DIN rails toEN 60�715.

� The modules are connected to each other via the FLEXBUS+ plug connection integratedin the housing. Take into account that, when replacing a module, the Flexi Soft moduleshave to be pushed approx. 10 mm apart before the corresponding module can beremoved from the DIN rail.

� Mount the modules in accordance with EN 50�274

� Ensure that suitable ESD protective measures are taken during mounting. Otherwise theFLEXBUS+ bus may be damaged.

� Take suitable measures to ensure that foreign matter does not enter the connectoropenings, in particular that of the system plug.

� Make sure that the voltage supply of the Flexi Soft system is switched off.

� Hang the device onto the DIN rail ().

� Ensure that the earthing spring contact is positioned correctly (�). The earthing springcontact of the module must contact the DIN rail securely to allow electrical conductivity.

� Snap the module onto the DIN rail by pressing it lightly in the direction of the arrow (�).

�WARNING

Fig. 25: Mounting the moduleonto the DIN rail


Flexi Soft Hardware



� If there are several modules, slide the modules together individually in the direction ofthe arrow until the side plug connection latches in.

� Install end clips on the left and right.

The following steps are necessary after mounting:

� completing the electrical connections (chapter 7)

� configuration (“Flexi Soft Modular Safety Controller — Software” operating instructions)

� checking the installation (chapter 9.2)

Fig. 26: Installing end clips


Flexi Soft Hardware



6.2 Steps for dismantling the modules

� Remove the removable terminals with the wiring and the end clips.

� If there are several modules, slide the modules away from each other individually in thedirection of the arrow until the side plug connection is separated.

� Press the module downwards at the rear () and remove it from the DIN rail in thedirection of the arrow while keeping it pressed down (�).

Fig. 27: Removing theremovable terminals

Fig. 28: Disconnecting theplug connections

Fig. 29: Removing modulesfrom the DIN rail


Flexi Soft Hardware


Electrical installation

7 Electrical installation

7.1 Electrical installation requirementsThis chapter deals with the electrical installation of the Flexi Soft system in the controlcabinet. You will find additional information on the electrical connection of other devices tothe Flexi Soft system in the section on the respective device in chapter 4 “Connectingdevices” on page 30.

Switch off the entire machine/system!

The system could start up unexpectedly while you are connecting the devices.

Observe the relevant safety standards!

All safety related parts of the installation (cabling, connected sensors and actuators, con-figuration settings, EDM) must be according to the relevant safety standards (e.g.IEC 62�061 or ISO EN 13�8491). This may mean that safety related signals need to beredundant or that single channel signals need protected wiring or short circuit detection byusing test outputs and/or periodical function tests.

� Take into account that short circuits between test outputs and the corresponding inputcannot be detected.

� Consider if protected or separate cabling is required for these signals.

� The Flexi Soft safety controller fulfils the EMC requirements in accordance with thebasic specification EN 61�00062 for industrial use.

� SICK industrial safety devices are designed for local DC supply applications only. If thedevice is used in power supply networks, e.g. according to IEC 61�326-3-1, additionalprotective measures have to be taken.

� Machines where safety devices are used must be installed and designed according tothe Lightning Protection Zone (LPZ) according to EN 62�305-1. Required immunity levelscan be achieved through the use of external protective devices. The installed surgeprotective devices (SPD) should meet the requirements according to EN 61�643-11.

� The installation must prevent common mode disturbances according toIEC 61�000416 in the frequency range from 0 Hz to 150 kHz.

� To ensure full electromagnetic compatibility (EMC), the mounting rail has to be connec-ted to functional earth (FE).

� The Flexi Soft system must be mounted in a control cabinet with at least IP 54enclosure rating.

� Electrical installation in accordance with EN 60�2041

� The voltage supply of the devices must be capable of buffering brief mains voltage fail-ures of 20 ms as specified in EN 60�2041.

� The voltage supply has to fulfil the regulations for extra-low voltages with safe separa-tion (SELV, PELV) in accordance with EN 60�664 and EN 50�178 (equipment of electricalpower installation with electronic devices).

� You must connect all modules of the Flexi Soft system, the connected protective devices(e.g. the EFI devices) as well as the voltage supply/ies with the same 0 V DC (GND). TheGND of the RS232 interface is connected internally to the GND of the supply of themain module (A2).

Note

�WARNING

Notes


Flexi Soft Hardware



� If the RS232 interface at the main module is used as an alternative to a gateway, themaximum permissible cable length is 3 m.

� Avoid ground loops between the GND of the RS232 interface and the connection A2 ofthe main module, e.g. by using optocouplers.

� Depending on the external loads, especially for inductive loads, additional externalprotective elements, e.g. varistors or RC elements may be necessary in order to protectthe safety outputs. For operating limits see section 12 “Technical data” on page 70.Take into account that the response times may increase, depending on the type ofprotective element.

� If a module is replaced the correct terminal assignment has to be guaranteed, forexample by labelling or suitable cable routing.

� If standing behind the protective devices (e.g. safety light curtain) is possible, mount thereset button so that it cannot be actuated by a person located in the hazardous area.When operating the control device of the reset button, the operator must have fullvisual command of the hazardous area.

Limited short-circuit recognition!

An FX3XTDI has two test signal generators. One test signal generator is responsible for theodd-numbered test outputs X1, X3, X5 and X7, the other for the even-numbered testoutputs X2, X4, X6 and X8.

Short-circuits can be detected between any test signal generator of FX3-XTDI or FX3-XTIOextension modules, even between different modules, provided that the test gap times are< 4 ms. Short circuits to 24 V DC (stuck at high) at inputs connected to test outputs aredetected independently of the test gap time.

Please be aware that at the FX3-XTDI the odd-numbered test outputs X1, X3, X5 and X7are connected to one common test signal generator and that the even-numbered test out-puts X2, X4, X6 and X8 are connected to another common test signal generator. Thereforeshort circuits between test outputs X1, X3, X5 and X7 cannot be detected. The sameapplies respectively for test outputs X2, X4, X6 and X8.Take this into consideration during the wiring (e.g. separate routing, sheathed cables)!

Reverse current at XTIO/XTDI inputs in case of ground interruption

In case of an internal or external ground interruption there can be a reverse current fromthe power supply of the main module (system plug terminal A2) to the safety inputs I1…I8of XTIO/XTDI modules. This must be considered if other inputs are connected in parallel tothese inputs, so that this reverse current does not lead to an unintended High level at theparallel connected inputs.

�WARNING


Flexi Soft Hardware



7.2 Internal circuit power supply

Fig. 30: Flexi Soft power supply internal circuit

24V

DC

24V

DC

Syst

empl

ug

Logi

c

Appl

.

Appl

.

Appl

.

Appl

.

Appl

.

Main module Gateway 1 Gateway 2Extensionmodule 1

Extensionmodule 2

Extensionmodule n

Load Load Load

A2(0 V)

A2(0 V)

A2(0 V)

Outputs(Q1…Q4)

Outputs(Q1…Q4)

Outputs(Q1…Q4)

A1(24 V)

Test outputs(X1…X8)

A1(24 V)

A1(24 V)

A1(24 V)

A2(0 V)


Flexi Soft Hardware


Configuration

8 Configuration

Check the safety function before commissioning and after every change!

If you change the configuration, you must check the effectiveness of the safety function.Please observe the test notes in the operating instructions of the connected protectivedevices.

The Flexi Soft Designer software and the FX3MPL0 system plug are required to configurethe Flexi Soft system.

Configuration and verification of devices that are connected to the safety controller is ge-nerally not carried out via the Flexi Soft Designer software. These devices have their ownmechanisms for configuration and verification. One exception are EFI-compatible devicesconnected to the Flexi Soft main module CPU1 (the EFI compatible devices can be foundunder “EFI elements” in the elements window). These devices can be configured directly inthe Flexi Soft Designer by double-clicking the icon, or alternatively configured and verifiedlocally at the device via its RS232 interface. The SICK configuration and diagnostics soft-ware CDS is required for the configuration of the EFI-compatible devices.

� The system configuration of the complete Flexi Soft system (with exception of the EFI-compatible devices) is stored in the system plug. This offers the advantage whenextension modules or gateways are replaced that the system does not have to bereconfigured.

� The data stored in the system plug is retained when the voltage supply is interrupted.

� The transfer of configuration information via the EFI interface is possible.

�WARNING

Notes


Flexi Soft Hardware


Commissioning

9 Commissioning

Do not commission without a check by qualified personnel!

Before initial commissioning of a system using a Flexi Soft safety controller, it must bechecked and released by qualified personnel.

Check the hazardous area!

Ensure that no one is located in the hazardous area before commissioning.

� Check the hazardous area and secure it against being entered by people (e.g. set upwarning signs, attach blocking ropes or similar). Observe the relevant laws and localregulations.

9.1 Full approval of the applicationSystem commission may only be carried out if full approval was successful. Full approvalmay only be performed by professionals trained accordingly.

The full approval includes the following items to be checked:

� Check whether all safety related parts of the installation (cabling, connected sensorsand actuators, configuration settings) are according to the relevant safety standards(e.g. EN ISO 13�8491 or EN 62�061).

� Check the devices connected to the safety controller in accordance with the test notesin the accompanying operating instructions.

The “Test before the first commissioning” chapter can be found for this in the operatinginstructions of the ESPE from SICK AG.

� Label all connections (connection cables and plugs) at the safety controller clearly andwithout ambiguity to avoid confusion. Since the Flexi Soft system has several connec-tions of the same design, ensure that disconnected cables or plugs cannot be connec-ted back unintentionally to the wrong connection.

� Check the signal paths and the correct inclusion in higher-level controllers.

� Check the correct data transfer from and to the Flexi Soft safety controller.

� Check the logic program of the safety controller.

� Perform a complete validation of the safety functions of the system in each operatingmode and an error simulation. Observe the response times of the individualapplications in particular.

� Completely document the configuration of the system, the individual devices and theresult of the safety check.

� In order to prevent unintentional overwriting of the configuration, activate the writeprotection of the configuration parameters of the Flexi Soft system. Modifications areonly possible if the write protection has been deactivated.

The software for the configuration documentation is available on the Internet under

http://www.sens-control.comFlexi Soft CD (2045931)

�WARNING

Note

Note


Flexi Soft Hardware


Commissioning

9.2 Tests before the initial commissioningThe purpose of the initial commissioning tests is to confirm the safety requirementsspecified in the national/international rules and regulations, especially in the Machine andWork Equipment Directive (EC Conformity).

� Check the effectiveness of the protective device at the machine, using all the selectableoperating modes and functions.

� Ensure that the operating personnel of the machine fitted with the safety controllerbecome instructed by the qualified personnel of the machine owner before beginningwork. Arranging the instruction is the responsibility of the machine owner.


Flexi Soft Hardware


Diagnostics

10 Diagnostics10.1 In the event of faults or errors

Cease operation if the cause of the malfunction has not been clearly identified!

Stop the machine if you cannot clearly identify or allocate the error and if you cannot safelyremedy the malfunction.

Complete functional test after remedying malfunction!

Carry out a full functional test after a malfunction has been remedied.

10.1.1 ERROR operating states

With certain malfunctions or a faulty configuration, the Flexi Soft safety controller entersthe safe status. The LEDs of the individual modules of the safety controller indicate thecorresponding error level.

Depending on the error there are different error levels:

Configuration error

� The system will be in state Configuration required (MS LED � Red (1Hz)).

� Applications in all modules are in operating state ’Stop’.

� All safety outputs in the system are switched off.

� All safety process data is set to zero. Typically also not safety related process data is setto zero.

Recoverable error

� Applications in all modules remain in operating state Run (MS LED of the effectedmodules = � Red/green alternating (1 Hz), MS LED of not effected modules =� Green).

� If safety outputs are effected, then at least these safety outputs in the system areswitched off.

� If safety inputs are effected, then at least the process data for these safety inputs areset to zero.

Critical fault

� The system will be in state Critical fault (MS LED of the module which detected thecritical fault = � Red (2 Hz). MS LED of the modules which are unclear about the errororigin = � Red).

� Applications in all modules are in operating state Stop.

� All safety outputs in the system are switched off.

� All safety process data is set to zero. Typically also not safety related process data is setto zero.

How to place the device back in operation:

� Rectify the cause of the malfunction in accordance with the display of the MS and CVLEDs.

� In the case of critical faults, switch the voltage supply of the Flexi Soft off for at least 3seconds and back on again.

�WARNING


Flexi Soft Hardware


Diagnostics

10.2 Error displays of the status LEDs, error messages andrectification measures

This section lists and describes the most important error codes, possible causes and po-tential rectification measures. These error messages can be displayed in the Diagnosticsstandard view of the Flexi Soft Designer if you are connected to the Flexi Soft system.

� For information on how to perform diagnostics see the “Flexi Soft Hardware” operatinginstructions, chapter “Diagnostics standard view”.

� Error displays for the individual modules and error elimination are described in thechapters on the individual modules, see chapters 3.5 to 3.9.

LED indication on module

Main module(CPU0 or CPU1)

Extension module(XTIO or XTDI)

Possibleerror codes

Possible reasons Possible measures

Main module:0x000E4006,0x00160005,0x000F0013

Configuration in system plug is incompa-tible because it is for a different mainmodule type:� System plug has been used before in

a system with different main moduletype (e.g. CPU0 instead of CPU1 orvice versa).

� Wrong main module type is used inthe hardware installation.

� Download a configuration with thesame main module type as in thehardware installation.

� Replace the main module in the hard-ware installation by a module with thesame module type as selected in theproject file.

Main module:0x00170005,0x000F0013

Configuration in system plug is incompa-tible because it is for a newer firmwareversion of the main module:� System plug has been configured for

an incompatible higher main modulefirmware version (e.g. V2.00.0instead of V1.11.0).

� An older main module firmwareversion is used in the hardwareinstallation.

� Download a configuration with thesame or a smaller CPU firmwareversion (e.g. V1.xx instead of V2.xx).

� Replace the main module in the hard-ware installation by a module with anequal or higher firmware versionselected in the project file.

Main module:0x000E4013,0x00274006

Configuration in system plug is incompa-tible for at least one extension module:� Extension module is missing in the

hardware installation.

� Download a configuration with amatching list of extension modules.

� Add missing extension module in thehardware installation.

MS = � Red(1 Hz)

All extensionmodules:MS = � Red (1 Hz)(firmware ≥ V2.00.0)orMS = � Red/green(1 Hz) (firmwareV1.xx.0)

Main module:0x000E0006,0x0005000D.XTIO/XTDI:0x4901,0x4904

Configuration in system plug is invalid:� The last configuration procedure has

not been completed successfully, e.g.because the power supply has beenturned off before writing to thesystem plug has been completed.

� System plug hardware failure.� The system plug is empty (out-of-the-

box value).

� Download the configuration again andensure that the power supply at themain module is on until the downloadprocedure has been completed.

� Replace the system plug anddownload configuration again.

Main module:0x0014000A

If CPU1: EFI device address conflict:� There are at least 2 main modules

with the same EFI address connected

� Change the EFI device address withFlexi Soft designer, either of the mainmodule or of the connected device..

MS = � Red(1 Hz)EFI = � Red(1 Hz)

All extensionmodules:MS = � Red (1 Hz)(firmware ≥ V2.00.0)orMS = � Red/green(1 Hz) (firmwareV1.xx.0)

Main module:0x0015000A

If CPU1 and Flexi Link: Wrong Flexi LinkID:� EFI1 and EFI2 is swapped in the

wiring.� There is at least 1 main module with

a different Flexi Link ID connected.

� Check wiring between the Flexi Linkstations: EFI1 connected with EFI1,and if applies EFI2 with EFI2.

� Connect Flexi Link stations withmatching Flexi Link IDs.

� Download configuration to all FlexiLink stations with same Flexi Link IDs.

Main module:0x001F0006,0x00230006

Configuration in system plug is incompa-tible for at least one extension module:� Wrong type or version of module

(whose MS LED is flashing red orred/green).

� Too many extension modules areconnected.

� Download a configuration with thesame module type and the same or asmaller firmware version for allextension modules.

� Replace the affected extension mod-ule in the hardware installation by amodule with the same module typeand the same or smaller firmwareversion as selected in the project file.

Notes


Flexi Soft Hardware


Diagnostics




Possibleerror codes


MS = � Green(1 Hz)CV = � Yellow(1 Hz)

MS = � Green(1 Hz)

-- System is in Stop state (ready to run). Start application in Flexi Soft Designer.For automatic start after power up averification of the project is necessarywith Flexi Soft Designer.

MS = � Green(1 Hz)CV = � Yellow

MS = � Green(1 Hz)

-- System is in Stop state (ready to run). Start application in Flexi Soft Designer.

MS = � Green MS = � Green -- System is in operation. No errordetected.

--

MS = � Green One or moreextension modules :MS = � Red/green(1 Hz) (firmware≥ V2.00.0)orMS = � Red (1 Hz)(firmware V1.xx.0)andQ1+Q2+Q3+Q4 =� Green (1 Hz)

XTIO: 0x4804,0x4806,0x4807

Module power supply of XTIO is too lowor missing.

Check supply voltage at terminals A1(24 V) and A2 (0 V) at the XTIO module,also under worst case load conditions.Error is reset automatically after approx.8 seconds, if the error reason no longerexists.

XTIO: 0x4701,0x4704.Main module:0x0029C006

Short circuit to 24 V or cross circuit inwiring of safety output Q1.. Q4 (whoseLED is flashing).� Capacitive load exceeded the

allowed maximum value (e.g. bycapacitor for spark quenching).

� Follow on error in main module(0x0029C006) in combination withXTIO firmware V1.xx.0.

� Hardware failure of XTIO module

� Check wiring of effected output.� Check capacitive load.To reset the error all outputs of theeffected module have to be turned offfrom logic of main module by turning offrelated input signals, e.g. E-stop. Errorreset can take up to 8 seconds.Alternatively power cycle the main module(required if 0x0029C006 occurred).� Replace XTIO module.

MS = � Green One or moreextension modules :MS = � Red/green(1 Hz) (firmware≥ V2.00.0)orMS = � Red (1 Hz)(firmware V1.xx.0)andQ1 or Q2 or Q3 or Q4=� Green (1 Hz) XTIO: 0x4702 Short circuit to 0 V in wiring of safety

output Q1.. Q4 (whose LED is flashing).� Check wiring of effected output.To reset the error the effected outputshave to be turned off from logic of mainmodule by turning off related inputsignals, e.g. E-stop.

MS = � Green One or moreextension modules :MS = � Red/green(1 Hz) (firmware≥ V2.00.0)orMS = � Red (1 Hz)(firmware V1.xx.0)andI1 or I2 or I3 or I4 orI5 or I6 or I7 or I8 =� Green (1 Hz)

XTIO/XTDI:0x4601

For inputs which are connected to testoutput:� Short circuit to 24 V or cross circuit in

wiring for tested sensors:� Short circuit to 24 V or cross circuit in

wiring from X1, X2, .. or X8 to tactileswitch or test input of testable input.

� Short circuit to 24 V or cross circuit inwiring from tactile switch or output oftestable sensor to I1, I2, …or I8.

� Defect testable sensor.� Cable interruption in wiring for safety

mat:� Cable interruption in wiring from X1,

X2, .. or X8 to safety mat.� Cable interruption in wiring from

safety mat to I1, I2, …or I8.� Defect safety mat.

� Check wiring of effected input.� Replace testable sensor.To reset the error turn off the effectedinput (input state Low/Low for equivalentdual channel inputs, Low/High forcomplementary dual channel inputs) orpower cycle the main module.


Flexi Soft Hardware


Diagnostics




Possibleerror codes


MS = � Green One or moreextension modules :MS = � Red/green(1 Hz) (firmware≥ V2.00.0)orMS = � Red (1 Hz)(firmware V1.xx.0)andI1+I2 or I3+I4 orI5+I6 or I7+I8 = �Green (1 Hz)

XTIO/XTDI:0x4429 or0x442A

Discrepancy error or sequence error atdual channel inputs (whose LEDs areflashing green):� Cable interruption or short circuit to

0 V at one of both input signals of theinput pair.

� Hardware failure of sensor, e.g. oneof both contacts/outputs is perma-nently closed (High) or opened (Low).

� Defect sensor (one of both signalsdoes not change to the correspon-ding state to the other input withinthe configured discrepancy time.

� Opening or closing of safety door wastoo slow so that the 2 contacts swit-ches (e.g. reed contacts) did notswitch within the configureddiscrepancy time.

� Only one of both inputs has causedthe switch off condition and haschanged back to the on condition,without the other input havingchanged at all (sequence error).

� Check wiring of effected input andcheck switching capability of bothcontacts/outputs of the connectedsensor.

� Check mechanical dependency ofboth switches.

� Replace switch/sensor in hardwareinstallation

To reset the error the effected input pairhas to be Low/Low for equivalent dualchannel inputs and Low/High forcomplementary dual channel inputs.

MS = � Red MS = � Red Main module:0xXXXCXXXX.Extensionmodules:0xXXXXCXXX(X= any value)

� Power supply 0 V at XTIO modulemissing (firmware V1.xx.0 only).

� Internal error in extension module.� Internal error in main module.

� Check connection of terminal A2 ofXTIO modules to 0 V of power supply.

� Check installation for EMC influence(earthing of DIN rail, …).

� To reset the error power cycle themain module.

� If the error persists, then replacemodules.

MS = � Red MS = � Red (2 Hz)(with firmware ≥V2.00.0)

Main module:0xXXXCXXXX.Extensionmodules:0xXXXXCXXX(X= any value)

Internal error in extension module(whose MS LED is flashing).



� If the error persists, then replace themodule whose MS LED is flashing

MS = � Red(2 Hz) (withfirmware ≥V2.00.0)

MS = � Red Main module:0xXXXCXXXX.Extensionmodules:0xXXXXCXXX(X= any value)

Internal error in main module or in thesystem.



� If the error persists, then replacesubsequently main module andextension modules.

Main module:0x0006C002,0x0007C002,0x0001C005,0x0003C006,0x0005C006,0x0029C006,0x0003C013

� Follow on error for other criticalerrors.

� Disturbance of main module internalsignals due to heavy EMCdisturbance.

� Hardware failure in main module orany extension module.

� Check the other diagnosis messagesfor critical faults with almost the sametime stamp.


� If error persists, then replacesubsequently main module andextension modules.

MS = � Red or �Red (2 Hz)

MS = � Red or �Red (2 Hz)

Main module:0x0001C013,0x0004C013,0x0005C013,0x000CC013

� FLEXBUS+ communication(backplane communication to I/Omodules and to gateways) disturbeddue to EMC disturbance.

� FLEXBUS+ communication (back-plane communication to I/O modulesand to gateways) disturbed due tocritical fault in I/O modules. In thiscase this is a follow on error andthere will be also other critical faultswith almost the same time stamp(+/- 1 s) in the diagnosis history.


� Check installation for EMC aspects (FEconnection of DIN rail and controlcabinet, star wiring of 24 V powersupply, local separation of power partsand control parts, …)

� Check the other diagnosis messageswith almost same time stamp.


Flexi Soft Hardware


Diagnostics




Possibleerror codes


Main module:0x002AC006

Unequal input data from extensionmodule:� A dual channel input at XTIO module

or XTDI module has 2 signal dips(High to Low) with a time distance of2 ms (e.g. test gaps of an OSSDoutput or bouncing relay contacts).

� A signal channel input at XTIOmodule or XTDI module changesstate in intervals of 4 ms for aduration of 40 ms or more (e.g.proximity switch to a tooth wheel).


� Change the configuration by activatingthe ON-OFF filter and activating theOFF-ON filter for inputs of the effectedXTIO/XTDI module. Please be awarethat this increases the response timefor this signal by at least 8 ms.

XTIO/XTDI:0xC306

Internal hardware failure of XTIO or XTDImodule.


� Replace XTDI/XTIO module inhardware installation.

Possible measuresPossible measures

XTIO/XTDI:0xC307

� Power supply at terminal A2 (GND) ofXTIO module interrupted.

� Internal hardware failure of XTIO orXTDI module.

� Check supply voltage at terminals A1(24 V) and A2 (0 V) at the XTIOmodule, also under worst case loadconditions.


� If the error persists, replace XTDI/XTIOmodule in hardware installation.

Main module:0x000A0011

Function block error with dual channelinput evaluation (e.g. Emergency stop,Magnetic switch): Discrepancy error atpair 1 of function block:� Cable interruption or short circuit to

0 V at one of both input signals of theinput pair.

� Hardware failure of sensor, e.g. oneof both contacts/outputs is perma-nently closed (High) or opened (Low).

� Defect sensor (one of both signalsdoes not change to the correspon-ding state to the other input withinthe configured discrepancy time.

� Opening or closing of safety door wastoo slow, so that the 2 contacts swit-ches (e.g. reed contacts) did notswitch within the configureddiscrepancy time.

� Check the wiring of the effected inputand check switching capability of bothcontacts/outputs of the connectedsensor.

� Check mechanical dependency ofboth switches.

� Replace switch/sensor in hardwareinstallation

To reset the error the effected input pairhas to change within the configureddiscrepancy time from Low/Low toHigh/High for equivalent dual channelinputs, from Low/High to High/Low forcomplementary dual channel inputs.

MS = � Green All extensionmodules:MS = � Green

Main module0x00100011

� Function block error (EDM or Valvemonitor): Feedback signal did notfollow the control signal within themax. feedback delay time.

� Hardware failure of connectedrelay/valve or failure in the wiring.

� Used relay/valve has greaterswitching delay for monitor contact.

� Increase Max. feedback delay time ofthe function block, if acceptable forthe application.

� Replace relay/valve in the hardwareinstallation.

All LEDstemporarily offand then LED testsequence.

All LEDs temporarilyoff and then LED testsequence.

Main module:0x002D4006

� Power supply of main module hadshort voltage dip (to almost 0 V).

� Power supply of main module had avoltage drop (approx. down to

6 V…16 V) and increased back tooperating range.

� Ensure that power supply is capable tobuffer power interruption up to 20 ms.

� Ensure that power supply is capable todrive the load, so that switching ofloads does not cause a drop of thesupply voltage.

� Check power supply wiring of mainmodule. Use separate wires to otherheavy loads to avoid voltage drops onthe supply cable by other loadcurrents.


Flexi Soft Hardware


Diagnostics




Possibleerror codes

Possible reasons Possible measuresPossible measuresPossible measures

Main module:0x003E4006

The system has performed a restart be-cause interferences have been detectedin the FLEXBUS+ communication:� FLEXBUS+ communication (back-

plane communication to I/O modulesand to gateways) disturbed due toEMC disturbance.

� FLEXBUS+ communication (back-plane communication to I/O modulesand to gateways) disturbed due tocritical fault in any extension module(I/O modules or gateway). In thiscase this is a follow on error andthere will be also other critical faultswith almost the same time stamp(+/- 1 s) in the diagnosis history.

� Check installation for EMC aspects (FEconnection of DIN rail and controlcabinet, star wiring of power supply(24 V and 0 V), local separation ofpower parts and control parts, …)

� Check the other diagnosis messageswith almost the same time stamp.

Tab. 47: Error codes and error messages of the Flexi Soft system and possible rectificationmeasures

10.3 Additional error displays of EFI-compatible devicesEFI-compatible devices (see chapter 5.1) have extended functions in connection with theCPU1 main module.

Error displays and error elimination are described in the operating instructions of thecorresponding devices.

10.4 SICK supportIf you cannot remedy a malfunction using the information in this chapter, please contactyour local SICK branch.

When you send in a FX3MPL0 system plug for repair or analysis, it is returned in the stateof delivery, i.e. with an empty configuration. Therefore save your configuration(s) to projectfiles with the Flexi Soft Designer.

10.5 Extended diagnosticsThe Flexi Soft Designer contains extended diagnostic possibilities. If you cannot identifywhat kind of error is occurring or if you have serviceability problems, it allows you to locatethe error more accurately.

For detailed information refer to the operating instructions of the Flexi Soft Designersoftware.

Note


Flexi Soft Hardware


Maintenance

11 MaintenanceThe following section informs about regular tests and the exchange of Flexi Soft modules.

Do not try to dismantle, repair or modify the Flexi Soft modules. This can lead to a loss ofthe safety function(s). In addition SICK AG accepts no claims for liability.

11.1 Regular inspection of the protective device by qualifiedpersonnel

� Check the system at the inspection intervals specified in the national rules and regula-tions. This procedure ensures that any changes on the machine or manipulations of theprotective device are detected before use/re-use.

� Each safety application must be checked at an interval specified by you. The effective-ness of the protective device must be checked by authorised commissioned persons.

� If any modifications have been made to the machine or the protective device, or if thesafety controller has been changed or repaired, the system must be checked again asspecified in the checklist in the annex.

� Carry out regular or daily inspections in order to keep the Flexi Soft modules in anoptimal operating mode.

� Check whether the implementation of the Flexi Soft modules fulfills all the technicaldata of the device.

� Check the mounting conditions and whether the wiring of the Flexi Soft modules is stillcorrect.

� Regularly verify that the safety functions fulfil the requirements of the application aswell as all relevant regulations and standards (e.g. regular checking) in order to ensurethe reliability of the safety functions.


Flexi Soft Hardware


Maintenance

11.2 Device replacementA critical fault in a Flexi Soft module impairs the complete network. Devices that havecritical faults must therefore be repaired or replaced rapidly. We recommend keepingspare devices of the Flexi Soft modules at hand so that network operation can be re-established as fast as possible.

Safety measures for replacing devices

Observe the following safety measures when replacing Flexi Soft modules:

� Do not try to dismantle or repair the Flexi Soft modules. Not only does SICK accept noclaims for liability, but it is also dangerous as it makes verifying the original safetyfunctions impossible.

� Reset the device into a state in which safety is ensured.

� Carry out replacement only when the voltage supply is switched off in order to avoid anelectric shock or unexpected device behaviour.

� In order to continue using the system configuration check:

– Is the new module of the same type (same material number) and is there no error atthe new module after the replacement?

– Is the new module plugged in at the same position as the replaced module?

– Have all connectors been re-connected to the correct terminals?� Otherwise you have to completely reconfigure and commission the new system,

including all the necessary tests (see chapter 9, “Commissioning” on page 60).

� After the replacement ensure that no errors arise with the new Flexi Soft modules.

� Always carry out a function test before commissioning a replacement module.

� EFI-compatible devices do not have to be reconfigured after the replacement of a FlexiSoft module.

� If you send in Flexi Soft modules for repair, generate a report on your project and carryout diagnostics with the Flexi Soft Designer, enclose a detailed description of theproblem with the device and send the Flexi Soft modules with all available informationto SICK.

Note


Flexi Soft Hardware


Technical data

12 Technical data

12.1 Response times of the Flexi Soft systemIn order to calculate the response times of a Flexi Soft system, all paths have to be takeninto consideration.

Fast Shut Off

The Fast Shut Off function can be realised on a single FX3XTIO input/output extensionmodule. A response time of 8 ms can be reached this way.

The Fast Shut Off function has only an effect on the inputs and outputs of the sameFX3XTIO input/output extension module.

Flexi Link

The response time in a Flexi Link system is increased for a remote input compared to alocal input by 4.5 ms + 2 × logic execution time of the remote Flexi Link station.

Fig. 31: Response timeswithin a Flexi Soft system

Note

Fieldbus Fieldbus

FLEXBUS+ FLEXBUS+

FLEXBUS+ FLEXBUS+

EFI EFI

Digitalinputs

Digitaloutputs

Fastshut off

Input fromgateway

Output togateway

Logic/Routing

Input fromEFI device

Output toEFI device


Flexi Soft Hardware


Technical data

12.1.1 Calculation of the response times

The following table can be used to calculate the response times of corresponding pathswithin the Flexi Soft system.

Evaluation1.) Response time of the considered input in the signal path E1 or E2 or E3 (from table below)

2 × logic execution time8)

2a.) Response time of the logic Delay through logic application9)

(e.g. On- or Off-delay function block)2b.) Response time of the routing (applies only for output to gateway) No delay 03.) Response time of the considered output in the signal path A1 or A2 or A3 (from table below)

Total response time

Occurrence Digital inputs Digital outputsGeneral Response time of the sensor10) Response time of the actuatorGeneral Input processing time 6.5 Output processing time

a) from logic (via FLEXBUS+): + 4.5 msb) from Fast Shut Off: + 1.5 ms

If On/Off filter enabled + min. 8.0 ms11)

If I1 … I8 is connectedat the test outputX1 … X8

+ Max. off-on delay8) of used testoutput

a) Safety mats andbumpersb) Testable type 4sensors (e.g. L41)c) All other sensors iftest gap8) is > 1 ms

+ Additional response time(see Tab. 49)+ Test period8) of the test output

+ Test gap8) of the test output

Total E1 Total A1

Occurrence Input from EFI device Output to EFI deviceIf EFI functions areused via EFI-compatibledevices

Response time of the EFI data source(as a rule a sensor) for external OSSDsvia EFI10) or Flexi Link remote station

Response time of the message receiver (e.g.scanner with protective field switching viaEFI)10)

Constant:a) Scanner (e.g. S300,S3000)b) Light grid (e.g.C4000, M4000)c) Flexi Link

+ 3.5 ms

+ 1.5 ms

+ 0.5 ms

EFI cycle time of the EFI receiver10)

Constant:a) Scanner (e.g. S300, S3000): + 24 msb) Light grid (e.g. C4000, M4000): + 4 msc) Flexi Link: + 4 ms

Total E2 Total A2

Occurrence Gateway — data from the network Gateway — data to the networkGeneral Response time field bus for data input

to gateway (e.g. from PLC)10)Response time field bus for data from gateway(e.g. to PLC)10)

General 2 × internal update interval for datafrom the gateway to the mainmodule12)

2 × internal update interval for data from themain module to the gateway12)

a) If 1 gateway + 5 ms a) If 1 gateway: + 8 msb) If 2 gateways + 1 ms b) If 2 gateways: + 4 ms

Total E3

Logi

c/R

outin

g

Total A3

Tab. 48: Calculation of the response times of the Flexi Soft system in ms

8) Take the values from the Flexi Soft Designer report.9) Time values have a tolerance of 10 ms, i.e. for each selected value 10 ms must be considered additionally for

the response time. E.g. for a 10 ms Off delay, 20 ms must be used for the calculation.10) Take values from the corresponding operating instructions11) The switching off is delayed until the signal has been Low for 8 ms at least.12) The update interval between the CPU and a Flexi Soft gateway depends on the amount of data to be trans-

ferred and the number of gateways used in the system. Take the values from the Flexi Soft Designer report.The update interval amounts to a multiple of 4 ms for each 10 bytes to be transferred to or from the gatewayif the system contains one gateway. If 2 gateways are used the update rate amounts to a multiple of 8 ms.


Flexi Soft Hardware


Technical data

Test period of both test outputs (ms)13)

Test output #1 Test output #2

Additional response time

40 40 20 ms

40 200 … 1000 40 ms

200 200 100 ms

200 400 … 1000 200 ms

400 400 300 ms

400 600 … 1000 400 ms

600 600 500 ms

600 800 … 1000 600 ms

800 800 700 ms

800 1000 800 ms

1000 1000 900 ms

Example 1:

Calculation of the response time for a Flexi Soft system consisting of an FX3CPU1 and anFX3XTIO:

Configuration Logic

Digital inputs: XTIO[1].I5I6.C4000: One C4000 safety light curtain

Digital outputs: XTIO[1].Q3Q4.Robot: Robot, dual-channel

Input from EFI device: CPU1[0].EFI1.1.OSSD [OSSD]: one C4000 receiver (stand-alone) (safety light curtain with high resolution for hazardouspoint, hazardous area and access protection at machines)

2 paths have to be considered and calculated separately:

13) Take the values from the Flexi Soft Designer report.

Tab. 49: Additional responsetime for safety mats andbumpers if I1 … I8 is connec-ted to test output X1 … X8

Fig. 32: Example of a FlexiSoft system


Flexi Soft Hardware


Technical data

Occurrence Digital inputs Digital outputsGeneral C4000 response time 14.0 ms Robot response time 40.0 msGeneral Input processing time 6.5 ms Output processing time 4.5 msWhen On/Off filter 8.0 ms –When X1 … X8 isconnected at the testoutputa) Safety mats andswitching railsb) Testable sensorsType 4 (e.g. L41)c) All other sensors

–

–

–

–

Total E1 20.5 ms

Logic

Total A1 44.5 ms

Evaluation1.) Response time of the considered input in the signal path (path 1) E1 20.5 ms

2 × logic execution time 8.0 ms2.) Response time of the logic

Delay through logic application –3.) Response time of the considered output in the signal path (path 1) A1 44.5 ms

Total response time 73.0 ms

Tab. 50: Example for the calculation of the response time of Path 1 of a Flexi Soft system

Occurrence Input from EFI device Digital outputsResponse time of the EFI datasource (C4000 receiver (stand-alone))

12.0 ms Robot response time 40.0 msIf EFI functions areused via EFI-compatibledevices

Constant (C4000) 1.5 ms Output processing time 4.5 ms

Total E2 13.5 ms

Logic

Total A1 44.5 ms

Evaluation1.) Response time of the considered input in the signal path (path 2) E2 13.5 ms


Delay through logic application –3.) Response time of the considered output in the signal path (path 2) A2 44.5 ms

Total response time 66.0 ms

Tab. 51: Example for the calculation of the response time of Path 2 of a Flexi Soft system

Fig. 33: Response timeswithin a Flexi Soft system

C4000

Digitalinput Logic

Digitaloutput

Robot

Input fromEFI device

C4000stand-alone

receiver

Path 1Path 1Path 2

Path 2


Flexi Soft Hardware


Technical data

Example 2:

Calculation of the response time for a Flexi Link system:

Flexi Link Station A

Logic execution time = 4 ms

Flexi Link Station B

Logic execution time = 8 ms

Occurrence Digital inputs Output to EFI deviceGeneral Tactile sensor 0 ms Response time of the message receiver

(see Table below for Flexi Link station B)General Input processing time 6.5 msWhen On/Off filter 8.0 ms –When X1 … X8 isconnected at the testoutput...

–EFI cycle time of the EFI receivera) Scanner: 24 msb) Light grid: 4 msc) Flexi Link: 4 ms

4 ms

Total E1 6.5 ms

Logic

Total A2 4 ms

Evaluation1.) Response time of the considered input in the signal path E1 6.5 ms


Delay through logic application –3.) Response time of the considered output in the signal path A1 4.0 ms

Total response time (from remote input to EFI) 18.5 ms

Occurrence Input from EFI device Digital outputsResponse time of the EFI datasource (see table above forFlexi Link station A)

18.5 ms Response time of the actuator(Robot response time)

40.0 msIf EFI functions areused via EFI-compatibledevices

Constant (Flexi Link) 0.5 ms Output processing time 4.5 ms

Total E2 19.0 ms

Logic

Total A1 44.5 ms

EvaluationResponse time of the considered input in the signal path E2 19.0 ms

2 × logic execution time 16.0 msResponse time of logic

Delay through logic application –Response time of the considered output in Path 2 A2 44.5 ms

Total response time (remote input to local output) 79.5 ms

Tab. 52: Example for the calculation of the response time of a remote input in a Flexi Link system

Fig. 34: Response timeswithin a Flexi Link system

Digitalinput

DigitalinputLogic Logic

Digitaloutput

Outputto EFIdevice

Inputfrom EFIdevice

remote input local input

Flexi Link Station A Flexi Link Station B


Flexi Soft Hardware


Technical data

12.1.2 Min. switch off time

The minimum switch-off time (e.g. of connected sensors) is the minimum time for which aswitch-off condition must be present in order to be detected so that error-free switching ispossible. The min. switch-off time must be …

� greater than the logic execution time, and

� greater than the test gap + max. off-on delay, if the input is connected to test outputX1…X8 and the test gap is > 1 ms, and

� greater than the test period + max. off-on delay, if safety mats or bumpers are used.


Flexi Soft Hardware


Technical data

12.2 Data sheet

12.2.1 Main modules FX3CPU0 and FX3CPU1

FX3CPU0 FX3CPU1

Safety Integrity Level14) SIL3 (IEC 61�508)

SIL claim limit14) SILCL3 (EN 62�061)

Category Category 4 (EN ISO 13�8491)

Performance Level14) PL e (EN ISO 13�8491)

PFHd (mean probability of adangerous failure per hour)

1.07�×10–9 1.69�×10–9

TM (mission time) 20 years (EN ISO 13�849)

Protection class III (EN 61�140)

Enclosure rating Terminals: IP 20 (EN 60�529)

Housing: IP 40 (EN 60�529)

Ambient temperature in operation –25 … +55 °C

Storage temperature –25 … +70 °C

Humidity 10 … 95�%, non-condensing

Climatic conditions 55 °C, 95�% rel. humidity (EN 61�1312)

Vibration resistance 10-500 Hz/5 g (EN 60�06826)

Shock resistance

Continuous shock 10 g, 16 ms (EN 60�068-2-29)

Single shock 30 g, 11 ms (EN 60�068-2-27)

Electromagnetic compatibility Class A (EN 61�00062, EN 55�011)

Number of EFI interfaces 0 2

Data interface Internal bus (FLEXBUS+)

Configuration interface RS232

Cross-section of connecting wires Single-core or finely stranded:1 × 0.14 … 2.5 mm2 or 2 × 0.14 … 0.75 mm2

Finely stranded with ferrules to EN 46�228:1 × 0.25 … 2.5 mm2 or 2 × 0.25 … 0.5 mm2

EFI connection method–

Dual level springclamp terminals

Dimensions (W × H × D) 22.5 × 96.5 × 120.8 mm

Weight 111 g (+/- 5%) 119 g (+/- 5%)

14) For detailed information on the safety design of your machine/system, please contact your local SICKrepresentative.

Tab. 53: Data sheetFX3CPU0 and FX3CPU1


Flexi Soft Hardware


Technical data

FX3CPU0 FX3CPU1

Power supply (A1, A2) via system plug FX3MPL0

Supply voltage 24 V DC (16.8 … 24 … 30 V DC)

Type of supply voltage PELV or SELV

The current of the power supply unit for the mainmodule has to be limited to a maximum of 4 A —either by the power supply unit itself or by a fuse

Power consumption Max. 2.5 W

Switch-on time Max. 18 s

12.2.2 FX3XTIO input/output extension module

Safety specific characteristics

Input configuration (I1…I8) Single or dual channel input

Safety output configuration(Q1…Q4)

Dual channel output Single channeloutput with testpulses enabled forall outputs

Single channel out-put with test pulsesenabled for this out-put and disabled forany other output

Single channeloutput with testpulses disabled forthis output

Safety Integrity Level15)

(IEC 61�508)SIL3 SIL3 SIL3 SIL2

Category (EN ISO 13�8491) Category 4 Category 4 Category 3 Category 3

Performance Level15)

(EN ISO 13�8491)PLe PLe PLe PLd


2.5�×10–9 6.0�×10–9 6.0�×10–9 18�×10–9

TM (mission time) 20 years (EN ISO 13�849)16)









Shock resistance




16) If safety outputs are used without test pulses, at least once per year either all safety outputs without testpulses have to be switched off at the same time for at least 1 second or alternatively a power reset has to beperformed.

Tab. 54: Data sheet FX3XTIO


Flexi Soft Hardware


Technical data


System connection Dual level spring clamp terminals

Power input via FLEXBUS+ withoutcurrents to X1, X2

Max. 2.2 W

Cross-section of connecting wires Single-core or finely stranded:

1 × 0.14 … 2.5 mm2 or 2 × 0.14 … 0.75 mm2

Finely stranded with ferrules to EN 46�228:

1 × 0.25 … 2.5 mm2 or 2 × 0.25 … 0,5 mm2



Weight 164 g (+/- 5%)

Power supply unit (A1, A2)

Supply voltage 24 V DC (16.8 V DC … 24 … 30 V DC)

Type of supply voltage PELV or SELV

The current of the power supply unit for the mainmodule has to be limited to a maximum of 4 A —either by the power supply unit itself or by a fuse.

Power consumption Max. 120 W (30 V × 4 A), determined by the load atthe outputs Q1 to Q4

Switch-on time Max. 18 s

Short-circuit protection 4 A gG (with tripping characteristic B or C)

Input circuit (I1 … I8)

Input voltage HIGH 13 … 30 V DC

Input voltage LOW –5 … +5 V DC

Input current HIGH 2.4 … 3.8 mA

Input current LOW –2.5 … 2.1 mA

Input reverse current in case ofground interruption17)

Max. 20 mA1.5 kΩ effective reverse resistance to power supply

Switching current (with mechanicalcontacts)

14.4 mA at 5 V3 mA at 24 V

Input capacitance Max. 10 nF

Discrepancy times 4 ms … 30 s, configurable

Number of inputs 8

Test outputs (X1, X2)

Number of outputs 2 (with 2 test pulse generators)

Output type PNP semiconductor, short-circuit protected,short-circuit monitoring (selectable)

Output voltage High 15 … 30 V DC (max. 1.8 V drop to terminal A1 ofmain module)

Output resistance Low 22 Ω +/- 10�%, current limited at approx. 10 mA

17) Do not switch other safety inputs in parallel, if the reverse current could lead to a High state at the other input.


Flexi Soft Hardware


Technical data

Output current Max. 120 mA at a test output (X1 or X2)

This means that a maximum of 8 testable sensorcascades per module with max. 30 mA each arepossible.

The total current of the Flexi Soft system is limitedto a maximum of 1.28 A. This corresponds to e.g. amaximum of 32 testable sensor cascades with30 mA each plus 64 tactile sensors to inputs ofextension modules with max. 5 mA each.

Test pulse rate (test period) 1 … 25 Hz, configurable

Test pulse duration (test gap) 1 … 100 ms, configurable

Load capacity 1 μF for test gap ≥ 4 ms0.5 μF for test gap 1 ms

Cable resistance < 100 �

Safety outputs (Q1 … Q4)

Number of outputs 4

Output type PNP semiconductor, short-circuit protected, short-circuit monitoring (selectable)

Output voltage High 15.6 … 30 V DC (max. 0.8 V drop to terminal A1 ofthis module)

Leakage current Low18) Max. 0.1 mA

Output current Max. 2.0 A

Total current Isum

TA ≤ 45 °C

TA ≤ 55 °C

For UL/CSA applications

Max. 4.0 A

Max. 3.2 A

Max. 3.2 A

Test pulse width19) < 650 µs or disabled20)21)

Test pulse rate Max. 5 Hz

Capacitive load ≤ 0.5 µF

Cable resistance22) Max. 5 � (e.g. 100 m × 1.5 mm² = 1.2 �)

18) In the case of a fault (0 V cable open circuit), maximally the leakage current flows in the OSSD cable. Thedownstream controller must detect this status as Low. An FPLC (Fail-safe Programmable Logic Controller)must be able to identify this status.

19) When active, the outputs are tested cyclically (brief switching to Low). When selecting the downstreamcontrollers, make sure that the test pulses do not result in deactivation when using the above parameters ordisable the test pulses on the outputs.

20) If safety outputs are used without test pulses, at least once per year either all safety outputs without testpulses have to be switched off at the same time for at least 1 second or alternatively a power reset has to beperformed.

21) If safety outputs are used without test pulses: Use protected or separate cabling for the safety outputs withouttest pulses, because a short circuit to 24 V can not be detected if the output is High. This could inhibit theswitch-off capability for the other outputs in case of an internal detected hardware failure due to reversepowering.

22) Make sure to limit the individual line core resistance to the downstream controller to this value to ensure thata short-circuit between the outputs is safely detected. (Also note EN 60�204 Electrical Machine Equipment,Part 1: General Requirements.)


Flexi Soft Hardware


Technical data

Max. permitted coil energy withoutexternal protection elements23)

Hardware version V1.00

Hardware version V1.01

0.22 J

0.37 J

Response time Depending on the logic configuration, for detailssee Tab. 48


12.2.3 FX3XTDI input/output extension module

Safety Integrity Level24) SIL3 (IEC 61�508)




0.4�×10–9

TM (mission time) 20 years (EN ISO 13�849)









Shock resistance




System connection Dual level spring clamp terminals

Power input via FLEXBUS+ withoutcurrents to X1 … X8

Max. 2 W

Cross-section of connecting wires Single-core or finely stranded:

1 × 0.14 … 2.5 mm2 or 2 × 0.14 … 0.75 mm2

Finely stranded with ferrules to EN 46�228:

1 × 0.25 … 2.5 mm2 or 2 × 0.25 … 0.5 mm2


Weight 139 g (+/- 5%)

23) Examples for resulting max. coil inductivity:HW V1.00: 1760 mH @ 0.5A, 440 mH @ 1A, 110 mH @ 2AHW V1.01: 2960 mH @ 0.5A, 740 mH @ 1A, 185 mH @ 2A


Tab. 55: Data sheet FX3XTDI


Flexi Soft Hardware


Technical data

Input circuit (I1 … I8)

Input voltage HIGH 13 … 30 V DC

Input voltage LOW –5 … +5 V DC

Input current HIGH 2.4 … 3.8 mA

Input current LOW –2.5 … 2.1 mA

Input reverse current in case ofground interruption25)

Max. 20 mA1.5 kΩ effective reverse resistance to power supply

Switching current (with mechanicalcontacts)

14.4 mA at 5 V3 mA at 24 V

Input capacitance Max. 10 nF

Discrepancy times 4 ms … 30 s, configurable

Number of inputs 8

Test outputs (X1 … X8)

Number of outputs 8 (with 2 test pulse generators)

Output type PNP semiconductor, short-circuit protected, cross-circuit monitoring

Output voltage 16 … 30 V DC

Output current Max. 120 mA at each of the two test signalgenerators (X1/X3/X5/X7 or X2/X4/X6/X8)

This means that a maximum of 8 testable sensorcascades per module with max. 30 mA each arepossible.

The total current of the Flexi Soft systems is limitedto a maximum of 1.28 A. This corresponds to e.g.32 inputs of testable sensors with 30 mA each and64 inputs of FX3XTIO or FX3XTDI modules.

Test pulse rate (test period) 1 … 25 Hz, configurable

Test pulse duration (test gap) 1 … 100 ms, configurable

Load capacity 1 μF for test gap ≥ 4 ms0.5 μF for test gap 1 ms

Cable resistance < 100 �

25) Do not switch other safety inputs in parallel, if the reverse current could lead to a High state at the other input.


Flexi Soft Hardware


Technical data

12.2.4 UE4102RO/UE4104RO output modules

Minimum Typical Maximum

Supply circuit (via FX3CPUx)

Power consumption

UE4104RO – – 3.2 W

UE4102RO – – 1.6 W

Input circuit B1, B2

Input voltage ON 18 V DC – 30 V DC

Output circuit (13-14, 23-24, 33-34, 43-44)

Number of N/O contacts

UE4102RO – 2 –

UE4104RO – 4 –

Number of N/C contacts

UE4102RO – 1 –

UE4104RO – 2 –

5 V AC 230 V AC26) 253 V ACSwitching voltage

5 V DC 230 V DC26) 253 V DC

Switching current 10 mA – 6 A

Mechanical endurance Min. 10 × 106

Electrical endurance See Fig. 35

Minimum contact loadwith Un = 24 V DC

50 mW – –

Total current – – 8 A

Response time27) – – 30 ms

Type of output Potential-free N/O contacts, positively guided

Contact material AgSnO2 with 1µ Au

Output circuit fusing 6 A (gG), per current path

AC-15: Ue 250 V, Ie 3 AUsage category

DC-13: Ue 24 V, Ie 3 A

26) See Fig. 35 or Fig. 36.27) Time from LOW on B1/B2 to relay drop-out.

Tab. 56: Data sheetUE4102RO/UE4104R0


Flexi Soft Hardware


Technical data


Output circuit (Y14, Y24)

Type of output N/O contact, connected to internal 24 V DC,positively guided, current-limited

Number of N/O contacts Y14/24

UE4102RO – 1 –

UE4104RO – 2 –

Output voltage 16 V DC 24 V DC 30 V DC

Output current28) – – 75 mA

Load capacity – – 200 nF

28) The total output current is limited. Maximum total current for all relay modules on Y14 and Y24 is I�<80 mA.

Fig. 35: DC load breakingcapacity output modulesUE410-2RO/UE410-4RO

Fig. 36: Electrical enduranceoutput modules UE410-2RO/UE410-4RO

Max. DC load breaking capacity

Resistive load

DC current [A]

DC

volta

ge[V

DC]

Electrical endurance

250 V AC resistive loadon 1 N/O contact

Switching current [A]

Ope

ratio

ns


Flexi Soft Hardware


Technical data


General data

Electrical isolation

Supply circuit-input circuit No

Supply circuit-output circuit Yes

Input circuit-output circuit Yes

Weight (without packaging)

UE4102RO 160 g (+/- 5%)

UE4104RO 186 g (+/- 5%)

Operating data

Ambient operating temperature –25 °C – 55 °C

Storage temperature –25 °C – 70 °C

Air humidity 10�% to 95�%, non-condensing

Climatic conditions EN 61�1312

Mechanical strength

Vibration EN 61�1312

Vibration resistance 5-500 Hz/3 grms (EN 60�068264)

Electrical safety EN 61�131-2

Impulse voltage withstand level(Uimp)

4 kV

Overvoltage category II

Contamination level 2 inside, 3 outside

Rated voltage 300 V AC

Enclosure ratinghousing/terminals

IP 40/IP 20 (EN 60�529)

Electromagnetic compatibility EN 61�1312, EN 61�00062, EN 55�011 class A

Terminal and connection data

Single or fine stranded wire 1 × 0.14 mm² to 2.5 mm² or2 × 0.14 mm² to 0.75 mm²

Fine stranded wire with terminalcrimps to EN 46�228

1 × 0.25 mm² to 2.5 mm² or2 × 0.25 mm² to 0.5 mm²

Insulation stripping length – – 8 mm

Maximum break-away torque – – 0.6 Nm


Flexi Soft Hardware


Technical data


Safety specific characteristics

All these data are based on an ambient temperature of +40 °C.

Safety integrity level29) SIL3 (IEC 61�508)

SIL claim limit29) SILCL3 (EN 62�061)



PFD 1.6 × 10-7

PFHd at I = 0.75 A,switching frequency = h-1

(see also Tab. 57)

1.2 × 10–9

B10d value,switching frequency = h-1

0.75 A (AC 15)/4,150,000 (see also Tab. 57)

SFF 99.6�%

DC 99�%

TM (mission time) Depending on PFHd value, ambient temperature,load and switching operations (see Tab. 57)

No. of mechanical switchingoperations

Min. 200,000

Loadtype

I[A] Switching frequencySwitching operations

per annumB10d PFHd

0.1 1/h 8760 10,000,000 5.00 x 10-10

0.75 1/h 8760 4,150,000 1.20 x 10-09

3 1/h 8760 400,000 1.20 x 10-08AC15

5 1/h 8760 70,000 7.20 x 10-08

1 1/h 8760 2,000,000 2.50 x 10-09

DC133 1/h 8760 450,000 1.10 x 10-08

2 1/h 8760 1,000,000 5.00 x 10-09

AC14 1/h 8760 600,000 8.40 x 10-09


Tab. 57: PFHd valuesUE4102RO/UE4104R0


Flexi Soft Hardware


Technical data

12.3 Dimensional drawings

12.3.1 Main modules FX3CPU0/1 with system plug

12.3.2 Input/output extension FX3XTIO, input extension FX3XTDI, relay outputmodules UE4102RO and UE4104RO

Fig. 37: Dimensional drawingFX3CPU0 and FX3-CPU1(mm)

Fig. 38: Dimensional drawingFX3XTIO, FX3XTDI,UE4102RO, UE4104RO(mm)

22.5

20

20

8.75

8.5

96.5 93

.3

5.1

58 78

114.3

75.3 19.5

75.25 14.893.7

109

120.6

15.4

appr

ox.3

3co

nnec

torr

ange

22.529.1

2075.25

93.693.7

14.814.8

109

120.6114.3

93.3

96.5

5.1 5.

158 78


Flexi Soft Hardware


Ordering information

13 Ordering information

13.1 Available modules and accessoriesDevice type Part Part no.

FX3-MPL000001 System plug 1043700

FX3-CPU000000 Main moduleDual level spring clamp terminals

1043783

FX3-CPU130002 Main module2 EFI connections, dual level spring clampterminals

1043784

FX0-GENT00000 Ethernet gateway for EtherNet/IP 1044072

FX0-GMOD00000 Ethernet gateway for Modbus TCP 1044073

FX0-GPNT00000 Ethernet gateway for PROFINET IO 1044074

FX0-GETC00000 Ethernet gateway for EtherCAT 1051432

FX0-GPRO00000 PROFIBUS gateway 1044075

FX0-GCAN00000 CANopen gateway 1044076

FX3-XTIO84002 Input/output extension8 inputs/4 outputs, dual level spring clampterminals

1044125

FX3-XTDI80002 Input extension8 inputs, dual level spring clamp terminals

1044124

UE410-2RO3 Output module2 NO contacts and 1 24 V DC signal output,removable terminals

6026144

UE410-4RO3 Output module4 NO contacts and 2 24 V DC signal outputs,removable terminals

6026143

UE10-2FG2D0 Safety relayScrew terminals

1043915

UE10-2FG3D0 Safety relayRemovable screw terminals

1043916

UE12-2FG2D0 Cascadable safety relayScrew terminals

1043917

UE12-2FG3D0 Cascadable safety relayRemovable screw terminals

1043918

Tab. 58: Part numbers ofFlexi Soft safety controllermodules


Flexi Soft Hardware



Device type Part Part no.

EFI cable, thick, 12.2 mm, PVC, per meter 6030756

EFI cable, thin, 6.9 mm, PVC, per meter 6030921

Flexi Link cable, shielded, twisted pair,2 × 2 × 0.34 mm², per meter

6034249

Configuration cable

2 m, M8, Sub D

6021195

Configuration cable

3 m, M8, angled, open ends

6036342

Converter UC-232A RS232 USB converter, RS232 to USB 6035396


Flexi Soft Hardware



13.2 DevicesOur extensive range of products including further articles such as safety switches, safetyinterlocks and emergency stop pushbuttons with the corresponding accessories isavailable in our catalogue or on the Internet under www.sick.com.

The following sections contain a selection.

13.2.1 Single-beam photoelectric safety switches (Type 2)

Part Description Part no.

WS/WE12-2P460 Through-beam photoelectric switch, 24 V DC,operating range 10 m, PNP, device plug M12,4pin

1018047

WS/WE12-2P160 Through-beam photoelectric switch, 24 V DC,operating range 10 m, PNP, connecting cable 2 m

1018046

WS/WE24-2P250 Through-beam photoelectric switch, 24 V DC,operating range 40 m, PNP, terminal connection

1018049

WS/WE24-2P450 Through-beam photoelectric switch, 24 V DC,operating range 40 m, PNP, device plug M12,4pin

1018051

WS/WE24-2P260 Through-beam photoelectric switch, 24 V DC,operating range 40 m, PNP, terminal connectionand heating

1018050

WS/WE24-2P460 Through-beam photoelectric switch, 24 V DC,operating range 40 m, PNP, device plug M12,4pin, heating

1018052

WS/WE27-2F460 Through-beam photoelectric switch, operatingrange 35 m, PNP, Q+Q, device plug M12, 4pin

1019561

WS/WE27-2F450S05 Through-beam photoelectric switch, operatingrange 35 m, PNP, Q+Q, device plug M12, 4pin,heating

1016025

WS/WE27-2F730 Through-beam photoelectric switch with deviceplug 7pin

1015124

WS/WE27-2F750 Through-beam photoelectric switch with deviceplug 7pin, heating

1015752

VS/VE18-2O4450 Through-beam photoelectric switch consisting oftransmitter and receiver, PNP, NPN, Q, , deviceplug M12, 4pin, operating range 16 m, metalhousing

6011846

VS/VE18-204550 Through-beam photoelectric switch consisting oftransmitter and receiver, PNP, NPN, Q, , deviceplug M12, 4-pin, angled, operating range 16 m,metal housing

6011845

L21 All variants *

* See the catalogue “Industrial Safety Systems” 8010889 or under www.sick.com.

Tab. 59: Part numbers ofsingle-beam photoelectricsafety switches (Type 2)

http://www.sick.com/


Flexi Soft Hardware



13.2.2 Non-contact safety switches


RExx All variants *

T40-E0101 Sensor T4000 Direct Multicode 6035041

T40-E0121 Sensor T4000 Direct Unicode 6035042

T40-2DRNAC Sensor T4000 Compact 6022052

T40-1KBA Actuator 5306531

DOL-1208-G10MA T4000 Compact connecting cable

M12 8-pin with 10 m cable

6022152

IN40-D0101K IN4000 switch Q40 6027389

IN40-D0202K IN4000 switch M30 6027392

IN40-D0303K IN4000 switch M18 6027391

IN40-E-E0101K IN4000 Direct 6027388

DOL-1204-G10M IN4000 connecting cable

M12 8-pin with 10 m cable

6010543


13.2.3 Safety light curtains and multiple light beam safety devices


C4000 All variants *

M4000 All variants *

C2000 All variants *

M2000 All variants *

miniTwin All variants *


13.2.4 Safety laser scanners and safety camera system


S3000 All variants *

S300 All variants *

V4000 All variants *

V300 All variants *


Tab. 60: Part numbers ofnon-contact safety switches

Tab. 61: Safety light curtainsand multiple beam systems

Tab. 62: Laser scanners


Flexi Soft Hardware



13.2.5 Diode module


DM8-A4K Diode module for the connection of multipleshort-circuiting switching mats

6026142

13.2.6 Muting lamp and cable


– Muting display lamp with mounting kit 2020743

– LED muting lamp with cable 2 m 2019909

– LED muting lamp with cable 10 m 2019910

Tab. 63: Part number ofdiode module

Tab. 64: Part numbers ofmuting lamp and cable


Flexi Soft Hardware


Annex

14 Annex

14.1 EC declarations of conformityFig. 39: EC declaration ofconformity for the FX3-CPU1and FX3-CPU2 (page 1)


Flexi Soft Hardware


Annex

Fig. 40: EC declaration ofconformity for the FX3-CPU1and FX3-CPU2 (page 2)


Flexi Soft Hardware


Annex

Fig. 41: EC declaration ofconformity for the FX3-XTIOand FX3-XTDI (page 1)


Flexi Soft Hardware


Annex

Fig. 42: EC declaration ofconformity for the FX3-XTIOand FX3-XTDI (page 2)


Flexi Soft Hardware


Annex

Fig. 43: EC declaration ofconformity for the UE410-2RO and UE410-4RO(page 1)


Flexi Soft Hardware


Annex

Fig. 44: EC declaration ofconformity for the UE410-2RO and UE410-4RO(page 2)


Flexi Soft Hardware


Annex

14.2 Manufacturers checklist

�Checklist for the manufacturer/installer for installation of the Flexi Soft safety controller

The specifications for the following items listed must be available at least for the initial commissioning. They aredependent on the application, whose requirement must be checked by the manufacturer/installer.

This checklist should be retained/stored with the machine documentation so that you can use it as a reference forperiodical tests.

1. Have the safety rules and regulations been observed in compliance with the directives/standardsapplicable to the machine?

Yes � No �

2. Are the applied directives and standards listed in the declaration of conformity? Yes � No �

3. Does the protective device comply with the required category? Yes � No �

4. Are the required protective measures against electric shock in effect (protection class)? Yes � No �

5. Has the protective function been checked in compliance with the test notes in thisdocumentation? Especially:

� Functional check of the command devices, sensors and actuators connected to the safetycontroller

� Test of all switch-off paths

Yes � No �

6. Are you sure that the safety controller was tested fully for safety functionality after eachconfiguration change?

Yes � No �

This checklist does not replace initial commissioning and regular tests by qualified personnel.


Flexi Soft Hardware


Annex

14.3 List of tablesTab. 1: Overview of disposal by component .......................................................................12

Tab. 2: Overview of the modules.........................................................................................15

Tab. 3: Required firmware and software versions .............................................................16

Tab. 4: Displays of the MS LED ...........................................................................................18

Tab. 5: Displays of the CV LED ............................................................................................18

Tab. 6: System plug pin assignment...................................................................................19

Tab. 7: Pin assignment of the RS232 interface ................................................................19

Tab. 8: Displays of the EFI LEDs..........................................................................................20

Tab. 9: Terminal assignment FX3XTIO ...............................................................................22

Tab. 10: Displays of the MS LED ...........................................................................................22

Tab. 11: Displays of the input/output LEDs .........................................................................23

Tab. 12: Terminal assignment FX3XTDI...............................................................................26

Tab. 13: UE4102RO/UE410-4RO displays ..........................................................................29

Tab. 14: UE4102RO terminals .............................................................................................29

Tab. 15: UE4104RO terminals .............................................................................................29

Tab. 16: Connection ES21.....................................................................................................33

Tab. 17: Functions with ES21................................................................................................33

Tab. 18: Connection of electro-mechanical safety switches ...............................................34

Tab. 19: Connection of interlocks .........................................................................................34

Tab. 20: Functions with electro-mechanical safety switches and interlocks......................34

Tab. 21: Connection E100.....................................................................................................35

Tab. 22: Functions with E100 ...............................................................................................35

Tab. 23: Connection of two-hand control..............................................................................36

Tab. 24: Connection of safety mats ......................................................................................36

Tab. 25: Function safety mats...............................................................................................36

Tab. 26: Connection of multiple safety mats with diode module DM8-A4Kconnected in series .................................................................................................37

Tab. 27: Data sheet DM8-A4K diode module.......................................................................38

Tab. 28: Connection of operating mode selector switches..................................................40

Tab. 29: Function of operating mode selector switches ......................................................40

Tab. 30: Function of potential-free contacts ........................................................................40

Tab. 31: Connection of magnetic safety switches with equivalent inputs ..........................41

Tab. 32: Connection of magnetic safety switches with complementary inputs .................41

Tab. 33: Functions with magnetic safety switches...............................................................41

Tab. 34: Connection of inductive safety switches ................................................................41

Tab. 35: Functions with inductive safety switches...............................................................41

Tab. 36: Connection of transponders ...................................................................................42

Tab. 37: Functions with transponders ..................................................................................42

Tab. 38: Connection of testable Type 2 single-beam photoelectric safety switches .........42

Tab. 39: Functions with testable Type 2 single-beam photoelectric safety switches ........43

Tab. 40: Connection of testable Type 4 single-beam photoelectric safety switches .........43


Flexi Soft Hardware


Annex

Tab. 41: Functions with testable Type 4 single-beam photoelectric safety switches........43

Tab. 42: Connection ESPE.....................................................................................................46

Tab. 43: Available process data bits depending on the connection method.....................47

Tab. 44: Minimum system requirements for Flexi Link .......................................................48

Tab. 45: Possible cable lengths and types for Flexi Link connections ...............................49

Tab. 46: Selection of the SICK optical muting sensors .......................................................52

Tab. 47: Error codes and error messages of the Flexi Soft system and possiblerectification measures ............................................................................................67

Tab. 48: Calculation of the response times of the Flexi Soft system in ms .......................71

Tab. 49: Additional response time for safety mats and bumpers if I1 … I8 isconnected to test output X1 … X8..........................................................................72

Tab. 50: Example for the calculation of the response time of Path 1 of a Flexi Softsystem......................................................................................................................73

Tab. 51: Example for the calculation of the response time of Path 2 of a Flexi Softsystem......................................................................................................................73

Tab. 52: Example for the calculation of the response time of a remote input in aFlexi Link system .....................................................................................................74

Tab. 53: Data sheet FX3CPU0 and FX3CPU1 ....................................................................76

Tab. 54: Data sheet FX3XTIO ...............................................................................................77

Tab. 55: Data sheet FX3XTDI ...............................................................................................80

Tab. 56: Data sheet UE4102RO/UE4104R0.....................................................................82

Tab. 57: PFHd values UE4102RO/UE4104R0 ..................................................................85

Tab. 58: Part numbers of Flexi Soft safety controller modules...........................................87

Tab. 59: Part numbers of single-beam photoelectric safety switches (Type 2) .................89

Tab. 60: Part numbers of non-contact safety switches .......................................................90

Tab. 61: Safety light curtains and multiple beam systems .................................................90

Tab. 62: Laser scanners........................................................................................................90

Tab. 63: Part number of diode module ................................................................................91

Tab. 64: Part numbers of muting lamp and cable ...............................................................91


Flexi Soft Hardware


Annex

14.4 List of illustrationsFig. 1: Flexi Soft modular safety controller........................................................................13

Fig. 2: Examples for the minimum configuration of a Flexi Soft system with CPU0and XTDI or CPU1 and XTIO.....................................................................................14

Fig. 3: Maximum configuration of the Flexi Soft system (without relay outputextensions)...............................................................................................................14

Fig. 4: Display elements FX3CPU0....................................................................................17

Fig. 5: Display elements FX3CPU1....................................................................................20

Fig. 6: Display elements FX3XTIO .....................................................................................22

Fig. 7: Internal circuits FX3-XTIO – safety inputs and test outputs..................................23

Fig. 8: Internal circuits FX3-XTIO – safety outputs ............................................................23

Fig. 9: Display elements FX3XTDI .....................................................................................26

Fig. 10: Internal circuits FX3-XTDI – safety inputs and test outputs..................................26

Fig. 11: Example of the inclusion of a relay module in the Flexi Soft system ...................27

Fig. 12: Internal configuration UE4102RO .........................................................................28

Fig. 13: Internal configuration UE4104RO .........................................................................28

Fig. 14: UE4102RO/UE410-4RO display elements ...........................................................29

Fig. 15: Example extract of the documentation in the Flexi Soft Designer........................32

Fig. 16: Connection diagram multiple safety mats with diode module DM8-A4Kconnected in series on FX3XTIO ............................................................................37

Fig. 17: Connection diagram multiple safety mats with diode module DM8-A4Kconnected in series on FX3XTDI ............................................................................38

Fig. 18: Circuit diagram DM8A4K diode module................................................................39

Fig. 19: Dimensional drawing DM8-A4K diode module......................................................39

Fig. 20: Minimum distance “a” to reflective surfaces, correct mounting andalignment .................................................................................................................44

Fig. 21: Minimum distance “a” as a factor of the distance “D” for testable single-beam photoelectric safety switches with a field of view of 10° (e.g.Wx12/18/24/27, Vx18) .........................................................................................45

Fig. 22: Mounting to avoid mutual optical influence ..........................................................45

Fig. 23: Connection of Flexi Link stations via EFI1 and EFI2..............................................48

Fig. 24: Connection of the Flexi Link cable shield to the mounting rail .............................49

Fig. 25: Mounting the module onto the DIN rail..................................................................53

Fig. 26: Installing end clips...................................................................................................54

Fig. 27: Removing the removable terminals .......................................................................55

Fig. 28: Disconnecting the plug connections ......................................................................55

Fig. 29: Removing modules from the DIN rail .....................................................................55

Fig. 30: Flexi Soft power supply internal circuit...................................................................58

Fig. 31: Response times within a Flexi Soft system............................................................70

Fig. 32: Example of a Flexi Soft system ...............................................................................72

Fig. 33: Response times within a Flexi Soft system............................................................73

Fig. 34: Response times within a Flexi Link system............................................................74

Fig. 35: DC load breaking capacity output modules UE410-2RO/UE410-4RO.................83

Fig. 36: Electrical endurance output modules UE410-2RO/ UE410-4RO.........................83


Flexi Soft Hardware


Annex

Fig. 37: Dimensional drawing FX3CPU0 and FX3-CPU1 (mm)..........................................86

Fig. 38: Dimensional drawing FX3XTIO, FX3XTDI, UE4102RO, UE4104RO (mm) ........86

Fig. 39: EC declaration of conformity for the FX3-CPU1 and FX3-CPU2 (page 1).............92

Fig. 40: EC declaration of conformity for the FX3-CPU1 and FX3-CPU2 (page 2).............93

Fig. 41: EC declaration of conformity for the FX3-XTIO and FX3-XTDI (page 1) ................94

Fig. 42: EC declaration of conformity for the FX3-XTIO and FX3-XTDI (page 2) ................95

Fig. 43: EC declaration of conformity for the UE410-2RO and UE410-4RO (page 1) ......96

Fig. 44: EC declaration of conformity for the UE410-2RO and UE410-4RO (page 2) ......97


Flexi Soft Hardware


Annex

SICK AG | Waldkirch | Germany | www.sick.com

8012

478/

UE80

/201

0-12

-10

∙ RV/

XX (2

010-

12) ∙

A4

2c in

t35a Australia

Phone +61 3 9497 4100 1800 33 48 02 – tollfreeE-Mail [email protected]

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