OPERATING INSTRUCTIONS Flexi Soft

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

Flexi SoftModular Safety Controller Hardware

Described product

Flexi Soft

Modular Safety Controller Hardware

Manufacturer

SICK AGErwin-Sick-Str. 179183 WaldkirchGermany

Legal information

This work is protected by copyright. Any rights derived from the copyright shall bereserved for SICK AG. Reproduction of this document or parts of this document is onlypermissible within the limits of the legal determination of Copyright Law. Any modifica‐tion, abridgment or translation of this document is prohibited without the express writ‐ten permission of SICK AG.

The trademarks stated in this document are the property of their respective owner.

© SICK AG. All rights reserved.

Original document

This document is an original document of SICK AG.

2 O P E R A T I N G I N S T R U C T I O N S | Flexi Soft 8012478/YWI3/2016-06-08 | SICKSubject to change without notice

Contents

1 About these operating instructions................................................ 71.1 Function of this document....................................................................... 71.2 Scope......................................................................................................... 81.3 Information depth..................................................................................... 81.4 Target group.............................................................................................. 91.5 Further information................................................................................... 91.6 Symbols and document conventions...................................................... 9

2 Safety information............................................................................ 102.1 Safety notes in these operating instructions.......................................... 102.2 General safety notes................................................................................. 102.3 Intended use............................................................................................. 112.4 Requirements for the qualification of personnel.................................... 12

3 Product description........................................................................... 133.1 System characteristics............................................................................. 133.2 Version, compatibility, and features........................................................ 133.3 Construction and function........................................................................ 153.4 Modules..................................................................................................... 17

3.4.1 FX3-CPU0 main module.......................................................... 173.4.2 FX3-CPU1 main module.......................................................... 183.4.3 FX3-CPU2 main module.......................................................... 193.4.4 FX3-CPU3 main module.......................................................... 203.4.5 FX3-MPL0 and FX3-MPL1 system plugs................................ 223.4.6 FX3-XTIO I/O module............................................................... 223.4.7 FX3-XTDI I/O module............................................................... 263.4.8 FX3-XTDS I/O module.............................................................. 273.4.9 FX0-STIO I/O module............................................................... 293.4.10 Drive Monitor FX3-MOC0......................................................... 313.4.11 UE410-2RO/UE410-4RO relay output modules.................... 34

3.5 Interfaces.................................................................................................. 363.5.1 RS-232..................................................................................... 363.5.2 USB........................................................................................... 363.5.3 Enhanced Function Interface (EFI)......................................... 36

3.6 Special functions...................................................................................... 383.6.1 Flexi Link................................................................................... 383.6.2 Flexi Line.................................................................................. 393.6.3 Muting...................................................................................... 403.6.4 Automatic configuration recovery (ACR)................................. 40

4 Mounting............................................................................................. 424.1 Steps for mounting the module............................................................... 42

5 Electrical installation........................................................................ 44

CONTENTS

8012478/YWI3/2016-06-08 | SICK O P E R A T I N G I N S T R U C T I O N S | Flexi Soft 3Subject to change without notice

5.1 Requirements to be met by the electrical installation........................... 445.2 Description of the terminals..................................................................... 46

5.2.1 FX3-CPU0 main module.......................................................... 465.2.2 FX3-CPU1 and FX3-CPU2 main modules............................... 475.2.3 FX3-CPU3 main module.......................................................... 485.2.4 FX3-XTIO I/O module............................................................... 495.2.5 FX3-XTDI I/O module............................................................... 505.2.6 FX3-XTDS I/O module.............................................................. 505.2.7 FX0-STIO I/O module............................................................... 515.2.8 Drive Monitor FX3-MOC0......................................................... 525.2.9 Encoder connection boxes FX3-EBX1, FX3-EBX3, and FX3-

EBX4......................................................................................... 535.2.10 UE410-2RO and UE410-4RO relay output modules............. 60

5.3 Wiring for the power supply to a Flexi Soft system................................. 615.4 Connection of devices.............................................................................. 62

5.4.1 Safety command devices and electro-mechanical safetyswitches.................................................................................... 63

5.4.2 Non-contact safety switches................................................... 695.4.3 Testable single-beam photoelectric safety switches............. 715.4.4 Electro-sensitive protective devices....................................... 745.4.5 Safe outputs Q1 to Q4............................................................. 745.4.6 Connection of EFI-enabled devices........................................ 755.4.7 Connection of a Pro-face HMI................................................. 765.4.8 Connection of encoders.......................................................... 765.4.9 Connection of a Flexi Link system.......................................... 795.4.10 Connecting a Flexi Line system.............................................. 815.4.11 EMC measures for Flexi Link and Flexi Line.......................... 82

6 Configuration..................................................................................... 83

7 Commissioning the hardware......................................................... 847.1 Overall acceptance of the application..................................................... 847.2 Checks before initial commissioning....................................................... 84

8 Operation............................................................................................ 868.1 Status messages on the FX3-CPUx main module.................................. 868.2 Status messages for the FX3-XTIO I/O module...................................... 878.3 Status messages for the FX3-XTDI I/O module...................................... 888.4 Status messages for the FX3-XTDS I/O module..................................... 898.5 Status messages for the FX0-STIO I/O module...................................... 908.6 Status messages for the Drive Monitor FX3-MOC0................................ 918.7 Status messages for the UE410-2RO and UE410-4RO relay output

modules..................................................................................................... 92

9 Maintenance...................................................................................... 939.1 Regular thorough check of the safety function by qualified safety per‐

sonnel........................................................................................................ 93

CONTENTS


9.2 Device replacement.................................................................................. 93

10 Diagnostics......................................................................................... 9510.1 Response to errors................................................................................... 9510.2 Error states................................................................................................ 9510.3 Error displays shown by status LEDs, error messages, and trouble‐

shooting measures................................................................................... 9610.4 Additional error displays for EFI-enabled devices................................... 10510.5 Error history............................................................................................... 10510.6 SICK support............................................................................................. 106

11 Decommissioning............................................................................. 10711.1 How to dismantle the modules................................................................ 10711.2 Disposal..................................................................................................... 10811.3 Separation of materials............................................................................ 108

12 Technical data.................................................................................... 10912.1 Response times of the Flexi Soft system................................................ 109

12.1.1 Calculation of the response time............................................ 11012.1.2 Minimum switch-off time........................................................ 119

12.2 Data sheet................................................................................................. 11912.2.1 Main modules FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-

CPU3......................................................................................... 11912.2.2 FX3-XTIO I/O module............................................................... 12112.2.3 FX3-XTDI I/O module............................................................... 12512.2.4 FX3-XTDS I/O module.............................................................. 12712.2.5 FX0-STIO I/O module............................................................... 13012.2.6 Drive Monitor FX3-MOC0......................................................... 13212.2.7 Encoder connection boxes for FX3-MOC0.............................. 13812.2.8 UE410-2RO/UE410-4RO relay output modules.................... 13912.2.9 Diode module DM8-A4K......................................................... 144

12.3 Dimensioned drawings............................................................................. 14512.3.1 FX3-CPUx main modules with system plug............................ 14512.3.2 I/O modules FX3-XTIO, FX3-XTDI, FX3-XTDS, and FX0-STIO,

relay output modules UE410-2RO and UE410-4RO............. 14612.3.3 Drive Monitor FX3-MOC0......................................................... 14612.3.4 Encoder connection boxes FX3-EBX1, FX3-EBX3, and

FX3-EBX4.................................................................................. 14712.3.5 Dimensioned drawing diode module DM8-A4K.................... 149

13 Ordering information........................................................................ 15113.1 System plugs and modules...................................................................... 15113.2 Accessories............................................................................................... 152

14 Appendix............................................................................................. 15414.1 Compliance with EU directives................................................................. 15414.2 Checklist for the manufacturer................................................................ 155

CONTENTS


15 List of abbreviations..........................................................................156

16 List of figures..................................................................................... 157

17 List of tables....................................................................................... 159

CONTENTS


1 About these operating instructions

These operating instructions contain the information needed during the life cycle of theFlexi Soft modular safety controller.

They must be made available to all those who work with the Flexi Soft modular safetycontroller.

Please read these operating instructions carefully and make sure that you understandthe content fully before working with the Flexi Soft modular safety controller.

1.1 Function of this document

There are six sets of operating instructions and two sets of mounting instructions for the Flexi Soft system, eachcovering clearly defined fields of application.

Document type Title Contents Purpose Part number

Operating instruc‐tions

Flexi Soft Modular SafetyControllerHardware

Description of the Flexi Softmodules and their functions

Instructions for technicalpersonnel working for themachine manufacturer oroperator on the safe mount‐ing, electrical installation,and maintenance of theFlexi Soft safety controller

8012999


Flexi Soft in the Flexi SoftDesignerConfiguration software

Description of the software-based configuration of theFlexi Soft safety controlleralong with important diag‐nostics functions anddetailed notes on identifyingand rectifying errors

Instructions for technicalpersonnel working for themachine manufacturer oroperator on the safe configu‐ration and commissioning,as well as the safe opera‐tion, of the Flexi Soft safetycontroller

8012998


Flexi Soft GatewaysHardware

Description of the Flexi Softgateways and their functions

To provide technical person‐nel working for the machinemanufacturer/operator withinstructions so that they cansafely carry out the mount‐ing, electrical installation,and maintenance work forthe Flexi Soft gateways

8012662


Flexi Soft Gateways in FlexiSoft DesignerConfiguration Software

Description of the software-based configuration of theFlexi Soft gateway, informa‐tion about data exchange innetworks as well as aboutthe status, planning, andassociated mapping

To provide technical person‐nel working for the machinemanufacturer/operator withinstructions so that they cansafely configure and com‐mission the Flexi Soft gate‐ways

8012483


Flexi Loop Safe Sensor Cas‐cadeHardware

Description of the Flexi Loopsafe sensor cascade and itsfunctions

To provide technical person‐nel working for the machinemanufacturer/operator withinstructions so that they cansafely carry out the mount‐ing, electrical installation,and maintenance work forthe Flexi Loop safe sensorcascade

8015834

Table 1: Overview of the Flexi Soft documentation

ABOUT THESE OPERATING INSTRUCTIONS 1


Document type Title Contents Purpose Part number


Flexi Loop Safe Sensor Cas‐cade in Flexi Soft DesignerConfiguration Software

Description of how to config‐ure and set the parametersfor the Flexi Loop safe sen‐sor cascade using software

To provide technical person‐nel working for the machinemanufacturer/operator withinstructions so that they cansafely configure and com‐mission the Flexi Loop safesensor cascade

8014521

Mounting instruc‐tions

Flexi Soft Encoder Connec‐tion Boxes FX3-EBX3 andFX3-EBX4

Description of Flexi Softencoder connection boxesFX3-EBX3 and FX3-EBX4

To provide technical person‐nel working for the machinemanufacturer/operator withinstructions so that they cansafely carry out the mount‐ing, electrical installation,commissioning, and mainte‐nance work for Flexi Softencoder connection boxesFX3-EBX3 and FX3-EBX4

8015600

Mounting instruc‐tions

Flexi Soft encoder connec‐tion box FX3-EBX1

Description of Flexi Softencoder connection box FX3-EBX1

Instructions for technicalpersonnel working for themachine manufacturer oroperator on the safe mount‐ing, electrical installation,commissioning, and mainte‐nance of the Flexi Softencoder connection box FX3-EBX1

8019030

Table 1: Overview of the Flexi Soft documentation

1.2 Scope

These operating instructions apply to all Flexi Soft safety controller modules with theexception of the Flexi Soft gateways.

This document forms part of SICK part number 8012999 (“Flexi Soft Modular SafetyController Hardware” operating instructions in all available languages).

These operating instructions are intended to give technical personnel working for themachine manufacturer or machine operator instructions on the safe mounting, electri‐cal installation, commissioning, and operation and maintenance of the Flexi Soft safetycontroller.

These operating instructions do not provide information on operating the machine inwhich the safety controller is integrated. For information about this, refer to the operat‐ing instructions for the particular machine.

1.3 Information depth

These operating instructions contain information about the Flexi Soft modular safetycontroller on the following topics:

• Mounting• Electrical installation• Hardware commissioning

• Fault diagnosis and troubleshooting• Ordering information• Conformity and approval

The planning and use of SICK protective devices requires technical skills that are notcovered by this document.

The official and legal regulations for operating the Flexi Soft modular safety controllermust always be complied with.

1 ABOUT THESE OPERATING INSTRUCTIONS


1.4 Target group

These operating instructions are intended for planning engineers, developers, andoperators of equipment and systems which are protected by a Flexi Soft modular safetycontroller. They are also intended for people who are integrating the Flexi Soft safetycontroller into a machine, putting it into operation for the first time, or carrying outmaintenance work.

1.5 Further information

www.sick.com

The following information is available via the Internet:

• The Flexi Soft operating instructions in various languages for viewing and printing• The Flexi Soft Designer configuration software• Configuration aids• Example applications• Data sheets• Product and application animations• CAD data for drawings and dimensional drawings• EDS, ESI, GSD, and GSDML files• Certificates (such as the EU declaration of conformity)• Guide for Safe Machinery (six steps to a safe machine)

1.6 Symbols and document conventions

The following symbols are used in these operating instructions:

Instructions to action

b The arrow denotes instructions to action. Read carefully and follow the instructionsfor action.

LED symbols

These symbols indicate the status of an LED:

The LED is off. The LED is flashing. The LED is illuminated continuously.

ABOUT THESE OPERATING INSTRUCTIONS 1


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2 Safety information

This chapter contains general safety information about the Flexi Soft modular safetycontroller.

More safety information about specific usage situations for the Flexi Soft modularsafety controller is available in the respective chapters.

2.1 Safety notes in these operating instructions

Warnings

Warnings refer to specific or potential hazards. They are designed to help you to preventaccidents. Read carefully and follow the warning notices!

The following types of warnings are used in these operating instructions:

CAUTIONMakes you aware of a hazardous situation that can result in minor to moderate injury ifit is not avoided.

WARNINGMakes you aware of a hazardous situation that can result in serious injury or fatality if itis not avoided.

DANGERMakes you aware of a hazardous situation that will result in serious injury or fatality if itis not avoided.

NOTEThe symbol “i” marks a note and makes you aware of possible damage and otherimportant information.

2.2 General safety notes

DANGERFollow the safety notes and protective measures.Observe the following to ensure that the Flexi Soft safety controller is used as intended.

2 SAFETY INFORMATION


NOTE

• Ensure compliance with the national standards and directives governing themounting, installation, and use of the Flexi Soft safety controller.

• The national and international legal specifications apply to the installation and useof the Flexi Soft safety controller, to its commissioning, and to technical inspec‐tions repeated at regular intervals.

• The manufacturer and operator of the machine on which the Flexi Soft safety con‐troller is used are responsible for coordinating and complying with all applicablesafety specifications and regulations, in close cooperation with the relevantauthorities.

• The notes in these operating instructions (e.g., regarding use, mounting, installa‐tion, or integration into the machine controller), and in particular the notes aboutchecks (see "Commissioning the hardware", page 84) must be observed.

• The inspections must be carried out by qualified safety personnel or speciallyqualified and authorized personnel, and must be recorded and documented toensure that the tests can be reconstructed and retraced by a third party at anytime.

2.3 Intended use

The modular Flexi Soft safety controller is a configurable controller for safety applica‐tions. It can be used ...

• In accordance with IEC 61508 up to SIL3• In accordance with EN 62061 up to SIL claim limit 3• In accordance with EN ISO 13849-1 up to Performance Level e

The safety level actually achieved is determined by the external wiring, how the wiring isimplemented, the configuration, the selection of command triggers, and how they arearranged on the machine.

DANGERThe Flexi Soft system is intended solely for use in industrial applications.The Flexi Soft system satisfies the requirements of the generic standard for radiatedemission associated with industrial applications. The Flexi Soft system is, therefore,suitable solely for use industrial applications.

The use of the Flexi Soft safety controller is only permitted within the specified operat‐ing limits (voltage, temperature, etc., see "Technical data", page 109) and in the senseof Requirements to be met by the electrical installation. It may only be used by qualifiedsafety personnel and only on the machine on which it was mounted and initially com‐missioned by qualified safety personnel in accordance with these operating instruc‐tions.

DANGERAny other use or of modification to the system or devices – including in the context ofmounting and installation – will render any claims against SICK AG under the warrantyvoid.

b Follow the instructions in the safety notes and implement the safety measuresdescribed in both the “Flexi Soft Modular Safety Controller Hardware” and “FlexiSoft in the Flexi Soft Designer Software” operating instructions.

b When using a safety-relevant control logic, check for compliance with the specifi‐cations described in national and international standards; in particular, check thecontroller strategies and risk reduction measures prescribed for your application.

SAFETY INFORMATION 2


The external power supply of the Flexi Soft modules must be capable of buffering briefpower failures of 20 ms as specified in EN 60204-1, for example. Suitable PELV andSELV power supply units are available as accessories from SICK.

UL/CSA applications:

If the product is being used in accordance with UL 508 or CSA 22.2 No. 142, the follow‐ing conditions must also be met:

• Use a fuse rated max. 4 A and min. 30 V DC to UL 248 to protect the 24 V powersupply to the device.

• Use only copper wires with a minimum temperature resistance of 60 °C/75 °C,wire cross-section AWG 30–12 for screw terminals and AWG 24–16 for spring ter‐minals.

• Tighten the screw terminals to a torque of 5 to 7 lb⋅in.• Use the devices only in an environment with a maximum contamination level of 2.

NOTEThe safety functions are not UL-assessed. The approval corresponds to UL 508, generalapplications

2.4 Requirements for the qualification of personnel

The Flexi Soft modular safety controller must only be configured, mounted, connected,commissioned, and serviced by suitably qualified safety personnel.

Project planning

A person who has expertise and experience in the selection and use of protective devi‐ces on machines and is familiar with the relevant technical rules and national worksafety regulations is considered qualified for project planning.

Mechanical mounting and commissioning

A person who has expertise and experience in the relevant field and is sufficientlyfamiliar with the application of the protective device on the machine to assess whetheror not it can be operated safely is considered qualified for mechanical installation andcommissioning.

Electrical installation

A person who has expertise and experience in the relevant field and is sufficientlyfamiliar with the application of the protective device on the machine to assess whetheror not it can be operated safely is considered qualified for electrical installation andcommissioning.

Configuration

A person who has expertise and experience in the relevant field and is sufficientlyfamiliar with the application of the protective device on the machine to assess whetheror not it can be operated safely is considered qualified for configuration.

Operation and maintenance

A person who has expertise and experience in the relevant field, is familiar with theapplication of the protective device on the machine, and has received instructions fromthe operator in how to operate the machine is considered qualified for operation andmaintenance.

2 SAFETY INFORMATION


3 Product description

This chapter provides information about the properties of the Flexi Soft system anddescribes its construction and operating principle.

3.1 System characteristics

Sensors and switching elements (e.g., light curtains, laser scanners, switches, sensors,encoders, emergency stop pushbuttons) are connected and logically interlinked to theFlexi Soft modular safety controller. Safe shutdown of the actuators on the associatedmachines or systems is achieved via the switching outputs of the safety controller.

The Flexi Soft system is distinguished by the following system characteristics:

• Modular design: 1 main module, up to 2 different gateways, and up to 12 expan‐sion modules (12 I/O modules or 6 Drive Monitor modules, or a combination ofthe two) 1)

• 8 to 96 safe digital inputs and 4 to 48 safe digital outputs or 6 to 96 non-safedigital outputs

• Configurable• .Use of up to 255 logic and application-specific function blocks• Logic function blocks, including, e.g., AND, OR, NOT, XNOR, XOR• Application-specific function blocks including, e.g., emergency stop, two-hand,

muting, presses, ramp-down detection, operating mode selector switch, reset,restart

• Gateways can be used for integration into a variety of networks (EtherNet/IP, Mod‐bus TCP, PROFINET IO, PROFIBUS DP, DeviceNet, CANopen, and EtherCAT)

• 2 EFI interfaces on main modules FX3-CPU1, FX3-CPU2, and FX3-CPU3 (see "FX3-CPU1 main module", page 18)

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

You will find the configuration software on the Internet: www.sick.com

3.2 Version, compatibility, and features

There are various firmware versions and function packages (known as steps) for theFlexi Soft product family, which support different functions. This section provides youwith an overview of which firmware version, which function package, and/or which ver‐sion of the Flexi Soft Designer configuration software you will need in order to be ableto use a specific function or a specific device.

Available as of version

Necessary module with firm‐ware

Flexi SoftDesigner

Function blocks and logic

Offline simulation of logic Unrestricted V1.2.0

Import and export of partial applications Unrestricted V1.3.0

Automatic circuit diagrams Unrestricted V1.3.0

Central tag name editor Unrestricted V1.3.0

Table 2: Modules, firmware versions, and software versions you will need

1) The number of expansion modules is limited by the capacity of the FLEXBUS+ backplane bus. A Drive Monitor (FX3-MOC0) requires twicethe bus capacity of an I/O module. Therefore, each FX3-MOC0 reduces the maximum possible number of I/O modules that can be usedby two.

PRODUCT DESCRIPTION 3


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Flexi SoftDesigner

Documentation for function blocks of mainmodules in logic editor

Unrestricted V1.3.0

Matrix of input and output connections Unrestricted V1.3.0

Invertable inputs for AND, OR, RS flip-flop, androuting N:N function blocks

FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0

Function block for ramp-down detection FX3-CPUx V1.11.0 (Step 1.xx) V1.3.0

Function blocks for configurable switch-ondelay and configurable switch-off delay


Function block for speed-to-bool FX3-MOC0 V1.10.0 V1.7.0

Function block for motion-status-to-bool FX3-MOC0 V1.10.0 V1.7.0

Verification possible even without identicalhardware


Status input data and status output data inlogic

FX3-CPUx V2.00.0 (Step 2.xx)and FX3-XTIO, FX3-XTDI, or FX3-XTDS, each V2.00.0 (Step 2.xx)

V1.3.0

Easy applications for FX3-MOC0 FX3-MOC0 V1.10.0 V1.7.1

Special functions

Two S3000 safety laser scanners at one EFIinterface

FX3-CPU1 V1.00.0 V1.2.2

Flexi Link FX3-CPU1 V2.00.0 (Step 2.xx) V1.3.0

Flexi Loop FX3-CPUx V3.00.0 (Step 3.xx)and FX3-XTIO, FX3-XTDI, or FX3-XTDS, each V3.00.0 (Step 3.xx)

V1.6.0

Flexi Line FX3-CPU3 V3.00.0 (Step 3.xx) V1.6.0

Automatic configuration of connected EFI-ena‐bled safety sensors (automatic configurationrecovery)

FX3-CPU2 V3.00.0 (Step 3.xx) V1.5.0(FX3-CPU2)V1.6.0(FX3-CPU3)

Deactivation of test signals Q1 to Q4 on theFX3-XTIO possible

FX3-XTIO V2.00.0 (Step 2.xx) V1.3.0

Fast shut-off with bypass at FX3-XTIO FX3-CPUx and FX3-XTIO, eachV2.00.0 (Step 2.xx)

V1.3.0

Multiple safety mats at FX3-XTIO/FX3-XTDI FX3-XTIO or FX3-XTDI, eachV1.13.0

V1.3.0

Data recorder FX3-CPUx V2.00.0 (Step 2.xx) V1.5.0

Extended cross-circuit detection time for theswitching of increased capacitive loads at FX3-XTIO

FX3-XTIO V3.00.0 (Step 3.xx) V1.6.0

Configurable filter time for in/out filters andout/in filters at inputs I1 to I8 at FX3-XTIO/FX3-XTDI/FX3-XTDS

FX3-XTIO, FX3-XTDI, or FX3-XTDS, each V3.00.0 (Step 3.xx)

V1.6.0

Optimization of logic execution time FX3-CPUx V4.00.0 (Step 4.xx) V1.7.1

Conformities

RoHS conformity FX3-XTIO FX3-XTIO V1.01.0 1) –

Devices

Gateways for PROFINET IO, Modbus TCP, andEtherNet/IP



3 PRODUCT DESCRIPTION




Flexi SoftDesigner

Gateways for CANopen and CC-Link FX3-CPUx V1.11.0 (Step 1.xx) V1.3.0

EtherCAT gateway FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0

Speed Monitor MOC3SA Unrestricted V1.3.0

FX3-MOC0 FX3-CPUx V2.50.0 V1.5.0

FX3-XTDS Unrestricted V1.6.0

FX0-STIO Unrestricted V1.6.0


1) All other modules as of date of market launch.

NOTE

• Newer modules are backward-compatible, so each module can be replaced by amodule with a more recent firmware version.

• With Flexi Soft Designer version ≥ V1.4.0, devices with more recent firmware canbe configured even if the Flexi Soft Designer does not yet recognize the new firm‐ware. However, in this case, only the function packages (Step 1.xx, Step 2.xx, orStep 3.xx) supported by the present version of the Flexi Soft Designer would beavailable.

• Accordingly, a new version of the Flexi Soft Designer is required in order to be ableto use the full functional scope of modules with a more recent firmware version.For example, Flexi Soft Designer ≥ V1.3.0 is required for FX3-CPU0/1 with firm‐ware ≥ V2.00.0 as well as for FX3-XTIO/FX3-XTDI with firmware ≥ V2.00.0.

• The configuration software is not upwards-compatible. In other words, a projectcreated with a more recent version of the configuration software cannot beopened with an older version.

• The function package (Step 1.xx, Step 2.xx, or Step 3.xx) must be selected in thehardware configuration of the configuration software. The table indicates thewhether or not a required function package is available in Flexi Soft Designer.

• In order to be able to use the Step N.xx function package, the corresponding mod‐ule must have at least firmware version VN.00.0. Otherwise, an error message willbe displayed when you attempt to transfer a configuration to a module with alower firmware version.

• The hardware version of the Flexi Soft modules can be found in the hardware con‐figuration of the Flexi Soft Designer configuration software in online mode or inthe report, if you were previously online.

• The firmware version of the Flexi Soft modules can be found on their type label inthe Firmware version field.

• You will find the date of manufacture of a device in the S/N field on the type labelin the format yywwnnnn (yy = year, ww = calendar week, nnnn = sequential serialnumber in the calendar week).

• The configuration software version can be found in the Options menu under Info.• The latest version of the configuration software can be found on the Internet at

www.sick.com.

3.3 Construction and function

System construction

A Flexi Soft system consists of the following modules:

• 1 Flexi Soft system plug• 1 Flexi Soft main module



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• Up to 2 Flexi Soft gateways• Up to 12 Flexi Soft expansion modules (12 I/O modules or 6 Drive Monitor mod‐

ules, or a combination of the two) 2)

• In addition, up to 8 UE410-2RO relay output modules and/or up to 4 UE410-4ROrelay output modules (i.e., a maximum of 16 safe relay outputs)

NOTEOnly those modules listed here can be connected to a Flexi Soft system; other modulesare not permitted.

Figure 1: Example minimum construction of the Flexi Soft system with FX3-CPU0 and FX3-XTDI orFX3-CPU1 and FX3-XTIO

Figure 2: Maximum construction of the Flexi Soft system (without relay modules)

Model Type Inputs Outputs Functionblocks

Max. number

Main modules

Table 3: Overview of modules

2) The number of expansion modules is limited by the capacity of the FLEXBUS+ backplane bus. A Drive Monitor (FX3-MOC0) requires twicethe bus capacity of an I/O module. Therefore, each FX3-MOC0 reduces the maximum possible number of I/O modules that can be usedby two.



Model Type Inputs Outputs Functionblocks

Max. number

FX3-CPU0 Main module – –

255 1FX3-CPU1 Main module with EFI 4 1) –

FX3-CPU2 Main module with EFI and ACR 4 1) –

FX3-CPU3 Main module with EFI and ACRand Flexi Line

8 2) –

Gateways

FX0-GENT EtherNet/IP gateway 2 3) – –

2

FX0-GMOD Modbus TCP gateway 2 3) – –

FX0-GPNT PROFINET IO gateway 2 3) – –

FX0-GETC EtherCAT gateway 2 3) – –

FX0-GPRO PROFIBUS DP gateway 1 4) – –

FX0-GCAN CANopen gateway 1 4) – –

FX0-GDEV DeviceNet gateway 1 4) – –

Expansion modules

FX3-XTIO I/O module 8 4 –

12FX3-XTDI I/O module 8 – –

FX3-XTDS I/O module 8 4–6 5) –

FX0-STIO I/O module 6–8 6) 6–8 6) –

FX3-MOC0 Drive Monitor – – 10 6 7)

Relay modules

UE410-2RO Relay module – 2 – 8 8)

UE410-4RO Relay module – 4 – 4 8)

Table 3: Overview of modules

1) EFI connections.2) EFI and Flexi Line connections.3) RJ-45 female connectors.4) RS-485 female connector.5) Non-safe outputs. Test outputs XY1 and XY2 can be used as additional non-safe outputs.6) The FX0-STIO has 6 non-safe inputs and 6 non-safe outputs. Connections IY7 and IY8 can be used both

as additional non-safe inputs and additional non-safe outputs.7) Each FX3-MOC0 module reduces the maximum possible number of I/O modules that can be used by two.8) Maximum 16 safe relay outputs.

3.4 Modules

This chapter provides information about the properties and functions of the availablemodules and system components.

3.4.1 FX3-CPU0 main module

Description

The FX3-CPU0 main module is the CPU for the entire system. It is where all signals aremonitored and their logic is processed on the basis of the configuration stored in thesystem plug. The system outputs are switched further to the processing of the signals.The FLEXBUS+ internal bus provides the data interface.

NOTEThe FX3-CPU0 main module can only be operated together with the FX3-MPL0 systemplug.



Figure 3: FX3-CPU0 main module

1 FX3-MPL0 system plug2 RS-232 interface3 MS LED (Module Status)4 CV LED (Configuration Verified)


Description

The functions of the FX3-CPU1 main module are the same as those of the FX3-CPU0main module.

Additionally, this module has 2 EFI interfaces. When EFI-enabled devices are con‐nected, the following functions are supported:

• Transfer configuration to the connected EFI-enabled devices• Import configuration from the connected EFI-enabled devices• Diagnose the connected EFI-enabled devices• Exchange process data between main module and EFI-enabled devices• Connect up to four FX3-CPU1 main modules to one Flexi-Link system (see "Flexi

Link", page 38)

More information about the EFI interfaces: see "Enhanced Function Interface (EFI)",page 36





1 Systemstecker FX3-MPL02 RS-232-Schnittstelle3 EFI1_A4 EFI1_B5 LED MS (Modul-Status)6 LED CV (Configuration Verified)7 LED EFI18 LED EFI29 EFI2_B EFI2_A


Description


In addition, the FX3-CPU2 main module supports a function for the automatic configu‐ration of connected EFI-enabled devices (ACR). More information: see "Automatic con‐figuration recovery (ACR)", page 40 as well as the “Flexi Soft in the Flexi Soft DesignerSoftware” operating instructions.





1 FX3-MPL1 system plug2 RS-232 interface3 EFI1_A4 EFI1_B5 MS LED (Module Status)6 CV LED (Configuration Verified)7 EFI1 LED8 EFI2 LED9 EFI2_B EFI2_A


Description


This module also has a Flexi Line interface to support the safe networking of up to 32Flexi Soft stations (see "Flexi Line", page 39).





1 FX3-MPL1 system plug2 RS-232 interface3 USB interface4 Line_PRE_A (previous)5 Line_PRE_B (previous)6 EFI1_A7 EFI1_B8 MS LED (Module Status)9 CV LED (Configuration Verified) LINE LED EFI1 and EFI2 LEDs Line_NEXT_B (next) Line_NEXT_A (next) EFI2_B EFI2_A

USB interface

The FX3-CPU3 main module has a USB interface which supports the following func‐tions:• Transfer of the configuration from the configuration software to the system plug• Import of the configuration into the configuration software from the system plug• Diagnosis of the Flexi Soft safety controller in conjunction with the configuration

software

USB version Connection type

2.0 Mini-B

Table 4: USB interface on the FX3-CPU3 main module



3.4.5 FX3-MPL0 and FX3-MPL1 system plugs

There is a system plug at each main module. The system configuration for the entireFlexi Soft system is stored only in the system plug. This is beneficial when replacingmodules, because it means that a full reconfiguration of the Flexi Soft system is notrequired.

System plug variants

There are two system plug variants, each of which can only be used in conjunction withcertain main modules.

System plug Terminal color Compatible mainmodules

Functions

FX3-MPL0 Black • FX3-CPU0

• FX3-CPU1• Flexi Soft system power supply

• Storage of system configuration(without EFI-enabled devices)

FX3-MPL1 Yellow • FX3-CPU2

• FX3-CPU3• Flexi Soft system power supply

• Storage of system configuration(with EFI-enabled devices)

• Automatic configuration of con‐nected EFI-enabled safety sen‐sors (automatic configurationrecovery)

Table 5: System plug variants

NOTE

• The electrical power supply for the main module, the internal logic of all expansionmodules and gateways on the FLEXBUS+, and its inputs (I1 to I8) and test outputs(X1 to X8 plus XY1 and XY2) is provided exclusively via the system plug. The powerfor the outputs (Q1 to Q4, Y1 to Y6, and IY7 and IY8), on the other hand, is sup‐plied separately.

• The data saved in the system plug is retained even in the event of a power supplyfailure.

• Clearly label all connections (connecting cables and plug connectors) on the safetycontroller to avoid confusion. Since the Flexi Soft system has more than one con‐nector of the same type, you must be sure that once connecting cables or plugconnectors have been unplugged, they are not reconnected in the wrong position.

3.4.6 FX3-XTIO I/O module

Description

The FX3-XTIO module is an expansion module with 8 safe inputs and 4 safe outputs. Ithas 2 test signal generators: one for test output X1 and one for test output X2.

The FX3-XTIO module supports the following functions:• Monitoring of the connected safety devices (see "Connection of devices",

page 62)• Forwarding of information at inputs I1 to I8 to the main module• Receipt of control signals from the main module and corresponding switching of

outputs• Fast shut-off: direct shutdown of the actuators connected to the module.

This slows down the response of the overall system. The response times of thedevices at the inputs and outputs are extended by 8 ms in order to shut down theoutputs. Run times on the FLEXBUS+ internal bus and the logic execution time arenot relevant in this case (see "Response times of the Flexi Soft system",page 109).

• Activation or deactivation of the test signals at outputs Q1 to Q4



The FX3-XTIO module cannot be operated alone; an FX3-CPUx main module is alwaysnecessary.

Multiple FX3-XTIO modules can be used at the same time (see "Construction and func‐tion", page 15).

The power supply to the internal logic and the test outputs is provided via the systemplug and the FLEXBUS+ internal bus.

The power supply to outputs Q1 to Q4 on the FX3-XTIO must be provided directly viaA1/A2 at the corresponding module.

NOTE

• Short-circuits between any of the test signal generators for Flexi Soft expansionmodules, including between test signal generators for different modules, aredetected if test gaps of ≤ 4 ms and a test period of ≥ 200 ms have been set forthe relevant test outputs.

• Short-circuits to 24 V DC (to high) at inputs that are connected to test outputs aredetected regardless of the length of the test gaps and the test period.

Figure 7: FX3-XTIO I/O module

1 LED MS (Modul-Status)2 8 Eingangs-LEDs3 4 Ausgangs-LEDs

3.4.6.1 Internal structure

Figure 8: Internal structure of the FX3-XTIO – safe inputs and test outputs

1 Interne Logik



Figure 9: Internal structure of the FX3-XTIO – safe outputs

1 Internal logic

3.4.6.2 Deactivation of test signals at outputs Q1 to Q4 on the FX3-XTIO

With the FX3-XTIO Step ≥ 2.xx (firmware version V2.00.0), it is possible to deactivatethe test signals at one or more outputs of FX3-XTIO modules.

DANGERDeactivating the test signals at any output reduces the safety parameters of all out‐puts!Deactivating the test signals at one or more of outputs Q1 to Q4 of an FX3-XTIO modulereduces the safety parameters of all outputs Q1 to Q4 of this module. Do bear this inmind in order to ensure that your application meets the necessary requirements for areasonable risk analysis and risk reduction strategy.Detailed information about safety parameters: see "Technical data", page 109.Use protected or separate cabling.If you deactivate the test signals at one or more of outputs Q1 to Q4, then you must useprotected or separate cabling for these outputs, in order to avoid impairing the safetyfunction of the other safe outputs. A short-circuit to 24 V cannot be detected if the out‐put input is set to High. It is for this reason that when an internal hardware error isdetected, the ability of the other outputs to shut down can be impaired due to 24 Vreverse current flowing through this output.Perform tests cyclically whenever the test signals at one or more safe outputs aredeactivated.If you deactivate the test signals at one or more of outputs Q1 to Q4, then the followingtests must be performed at least once annually:

• All outputs without test signals must be shut down simultaneously for one secondby the logic program of the main module.Or:

• Restart the Flexi Soft system by switching off the power supply.



3.4.6.3 Extended error detection time for cross-circuits at outputs Q1 to Q4 on the FX3-XTIO for the switchingof increased capacitive loads

With the FX3-XTIO Step ≥ 3.xx (firmware version V3.00.0), it is possible to configure anextended error detection time for cross-circuits for outputs Q1 to Q4 of FX3-XTIO mod‐ules.

This may be necessary to switch loads where the voltage at the load does not drop tothe Low level as quickly as expected, with the result that if the standard error detectiontime is set, a cross-circuit error occurs immediately after switching off (change fromHigh to Low). Examples of such instances include:

• Loads with a higher capacitance than is permitted for the output by default, includ‐ing, e.g., the supply voltage for PLC output cards, which need to be connected withsafety technology.For this application, the test signal for the input must also be deactivated (see"Deactivation of test signals at outputs Q1 to Q4 on the FX3-XTIO", page 24).

• Inductive loads which cause an overshoot in the positive voltage range after theinduction voltage has died down.

FX3-XTIO firmwareversion

Switching of increased capacitiveloads

Error detection time(maximum permitted time to Lowlevel (≤ 3.5 V) after the output hasbeen switched off (Q1 to Q4)

≤ V2.11.0 Not possible 3 ms

≥ V3.00.0 Deactivated 3 ms

Activated 43 ms

Table 6: Maximum extended error detection times for cross-circuits on the FX3-XTIO

The capacitance which exceeds the value that is permitted by default for the outputmust be discharged to Low level at the customer's end once the output has beenswitched off. If this is not done within the maximum permitted time, a cross-circuit errorwill occur at the output, regardless of whether the test signals at this output are acti‐vated or deactivated.

DANGERYou must make sure that the PLC output card is compatible with safety-related shut‐down of the outputs as a result of the switching of the supply voltage.Ability to shut down safely can be impaired or even prevented by the following errors:

• Failure to detect a cross-circuit at an output of the PLC output card leading toreverse infeed to the PLC card power supply. In some cases this error can beexcluded by wiring inside a zone with sufficient protection.

• Failure to detect an error on the PLC output card leading to infeed of an externalsupply to the PLC card power supply from another live signal.

• Extension of the response time by a buffer capacitor in the PLC output card powersupply.Please note that the outputs of the FX3-XTIO modules cannot discharge this buffercapacitor as it is usually located downstream of a reverse polarity protectiondiode.

DANGERPlease note the extended error detection time.Switching loads with increased capacitance also extends the error detection time. Thisapplies primarily in the case of single-channel outputs.



For more information, see the “Flexi Soft in the Flexi Soft Designer Software” operatinginstructions.

3.4.6.4 Use of single-channel outputs on the FX3-XTIO

DANGERNote the possibility of brief switching to High with single-channel outputs.In the event of a hardware error, outputs (Q1 to Q4), which would normally be at Low,switch off subject to a delay or briefly switch to High until the error is detected and hasbeen responded to. The error detection time plus the error response time is determinedby the selected configuration for the output.

FX3-XTIO firmwareversion

Switching of increased capacitiveloads

Error detection time + errorresponse time

≤ V2.11.0 Not possible ≤ 10 ms

≥ V3.00.0 Deactivated ≤ 10 ms

Activated ≤ 50 ms

Table 7: Error detection time and error response time on the FX3-XTIO

Take this into account in your risk analysis and strategy for risk reduction, primarily forsingle-channel outputs. Failure to do this will put the machine operator at risk.

3.4.7 FX3-XTDI I/O module

Description

The FX3-XTDI module is an expansion module with 8 safe inputs. It has 2 test signalgenerators: one for test outputs X1, X3, X5, and X7 and one for test outputs X2, X4, X6,and X8.

The FX3-XTDI module supports the following functions:• Monitoring of the connected safety devices (see "Connection of devices",

page 62)• Forwarding of information at inputs I1 to I8 to the main module

The FX3-XTDI module cannot be operated alone; an FX3-CPUx main module is alwaysnecessary.

Multiple FX3-XTDI modules can be used at the same time (see "Construction and func‐tion", page 15).


NOTEAn FX3-XTDI has two test signal generators. One test signal generator is for the oddnumber test outputs X1, X3, X5, and X7; the other is for the even number test outputsX2, X4, X6, and X8.





DANGERRestricted short-circuit detection!Short-circuits between the odd number test outputs X1, X3, X5, and X7 cannot bedetected if they are assigned to the same test signal generator. The same is true of theeven number test outputs X2, X4, X6, and X8.

b Take this into account in the wiring (e.g., lay cables separately, use cable protec‐tion).

Figure 10: FX3-XTDI I/O module

1 LED MS (Modul-Status)2 8 Eingangs-LEDs


Figure 11: Internal structure of the FX3-XTDI – safe inputs and test outputs

1 Internal logic

3.4.8 FX3-XTDS I/O module

Description

The FX3-XTDS module is an expansion module with 8 safe inputs and 4 non-safe out‐puts. It has 2 optional test signal generators: one for test output XY1 and one for testoutput XY2.

The FX3-XTDS module supports the following functions:



• Monitoring of the connected safety devices (see "Connection of devices",page 62)

• Forwarding of information at inputs I1 to I8 to the main module• Receipt of control signals from the main module and corresponding switching of

outputs• Outputs XY1 and XY2 can be used as either test outputs or non-safe outputs.

DANGERDo not use the outputs of the FX3-XTDS for safety functions.The non-safe outputs XY1, XY2, and Y3 through Y6 of the FX3-XTDS must not be usedwithout additional measures to achieve the required safety for non-safety-relevant func‐tions. Not taking these additional measures will put the operator at risk.

The FX3-XTDS module cannot be operated alone; an FX3-CPUx main module is alwaysnecessary.

Multiple FX3-XTDS modules can be used at the same time (see "Construction and func‐tion", page 15).


The power supply to outputs Y3 to Y6 on the FX3-XTDS must be provided directly viaA1/A2 at the corresponding module.

NOTE



• If both outputs XY1 and XY2 are already being used as non-safe outputs, you canstill connect a tested element to one of the inputs I1 to I8. However, a warning willbe output nevertheless (i.e., this element will be displayed in read in the hardwareconfiguration).

Figure 12: FX3-XTDS I/O module

1 2 LEDs für Testausgänge oder nicht sichere Ausgänge2 LED MS (Modul-Status)3 8 Eingangs-LEDs4 4 Ausgangs-LEDs




Figure 13: Internal structure of the FX3-XTDS – safe inputs and test outputs

1 Internal logic

Figure 14: Internal structure of the FX3-XTDS – non-safe outputs

1 Internal logic

3.4.9 FX0-STIO I/O module

Description

The FX0-STIO module is an expansion module with 6 non-safe inputs, 6 non-safe out‐puts, and 2 connections which can be used as either non-safe inputs or as non-safeoutputs.

The FX0-STIO module supports the following functions:• Forwarding of information at inputs I1 to I6 to the main module• Receipt of control signals from the main module and corresponding switching of

outputs

DANGERDo not use the FX0-STIO for safety functions.The FX0-STIO must not be used for safety-relevant functions. To do so would be to putthe machine operator at risk.



The FX0-STIO module cannot be operated alone; an FX3-CPUx main module is alwaysnecessary.

Multiple FX0-STIO modules can be used at the same time (see "Construction and func‐tion", page 15).

The power supply to the internal logic is provided via the system plug and the FLEXBUS+ internal bus.

The power supply to outputs Y1 to Y6 as well as to connections IY7 and IY8 on the FX0-STIO must be provided directly via A1/A2 at the corresponding module.

Figure 15: FX0-STIO I/O module

1 2 Ausgangs-LEDs2 LED MS (Modul-Status)3 2 Eingangs-LEDs4 4 Ausgangs-LEDs5 4 Eingangs-LEDs6 2 LEDs für konfigurierbare Ein- oder Ausgänge

Use of connections IY7 and IY8 on the FX0-STIO

Connections IY7 and IY8 on an FX0-STIO module can be used as either additional non-safe inputs or additional non-safe outputs.


Figure 16: Internal structure of the FX0-STIO – non-safe inputs

1 Internal logic



Figure 17: Internal structure of the FX0-STIO – non-safe outputs

1 Internal logic

3.4.10 Drive Monitor FX3-MOC0

Description

The FX3-MOC0 module is an expansion module for the safe monitoring of the move‐ments of drive systems. In this context, movement means speed level, speed ramp, andposition. The module features an interface for the connection of two encoders (e.g.,incremental encoders, linear encoders, motor feedback systems, or linear distancemeasuring systems).

The FX3-MOC0 module supports the following functions:• Connection of two encoders for one or two axes

° Incremental encoders HTL 24 V, MTL 12 V, TTL, max. 300 kHz

° RS-422 incremental encoder, max. 1 MHz 3)

° Sine-cosine encoder 1 VSS, max. 120 kHz

° SSI encoder, RS-422, max. 1 MBaud• Standstill monitoring• Speed monitoring• Direction monitoring• Processing of information from the encoders and control signals from the main

module in the internal logic of the FX3-MOC0. A dedicated logic editor with a num‐ber of function blocks is available for this purpose.

• Forwarding of information from the internal logic to the main module

DANGERThe SIL and PL that can be achieved will vary depending on the encoders used andtheir electrical and mechanical properties.

3) Only possible for encoder 1 (ENC1).



Use of encoders Possible axesfor each FX3-MOC0 module

Available functions for detectingencoder errors

Achievable SIL(IEC 61508), SILCL(EN 62061) or PL(EN ISO 13849-1)1)

Two encoders forone axis; any typeof encoder canbe selected andthe two can bethe same or dif‐ferent types

1 • Monitoring of the ID code ofthe encoder connection boxin order to detect a break inthe FX3-MOCx connectingcable 2)

• Function block speed com‐parison 3)

SIL3, SILCL3, PL e

One sine-cosineencoder for oneaxis

2 • Monitoring of the ID code ofthe encoder connection boxin order to detect a break inthe FX3-MOCx connectingcable 2)

• Sine-cosine analog voltagemonitoring 4)

SIL2, SILCL2, PL d

Table 8: Achievable SIL and PL

1) Actual values: see table 132, page 132.2) Can be used by any type of encoder supported in the hardware configuration of the configuration soft‐

ware.3) Can be used in the FX3-MOC logic. For detailed information, see the “Flexi Soft in the Flexi Soft Designer

Software” operating instructions.4) Can be configured for sine-cosine encoders in the hardware configuration of the configuration software.

NOTEIt is essential to select the right encoder if the required level of safety is to be achieved.As systematic errors and common cause failures (CCF) often occur in this context, it isessential to be familiar with them/know how to handle them.



DANGERSuitable measures must be taken to counter common cause failures for encoders.

This applies in particular if both encoders are used for the redundant monitoring of oneaxis. The following possibilities are among those that must be taken into consideration:• The common GND connection due to the common connecting cable on the FX3-

MOC0 for both encoders as a common reference potential for both encoders maybe lost.

• The power supply for the encoders may be too low or lost completely.• The common power supply for both encoders may be too high. This could damage

both encoders. When PELV/SELV voltage supplies are used without additional pro‐tective measures, an increase in voltage to 60 V usually has to be assumed.

• The entire encoder connection to the FX3-MOC0 may be lost.

The Flexi Soft safety controller supports the following options for detecting errors in theencoder system:• Use at least one encoder connection box. This function is described in the “Flexi

Soft in the Flexi Soft Designer Software” operating instructions, section “Encoderconnection type and ID code monitoring”.

• Use a sine-cosine encoder with sine-cosine analog voltage monitoring activated. 4)

This function is described in the “Flexi Soft in the Flexi Soft Designer Software”operating instructions, section “Sine-cosine analog voltage monitoring”.

• Use an SSI encoder with evaluation of error bits. For this purpose you need a bit inthe SSI data which adopts an inverted state whenever the error under considera‐tion occurs, e.g., because the supply voltage to the encoders is too low or one ormore of the cables running from the encoder to the FX3-MOC0 has been discon‐nected. This function is described in the “Flexi Soft in the Flexi Soft Designer Soft‐ware” operating instructions, section “SSI encoders”.

• When A/B incremental encoders are used, there is no way of detecting errorsdirectly based on the encoder signals.

• Moreover, in conjunction with the logic from the Drive Monitor and the main mod‐ule, in some cases it is possible to use another signal from the process to checkthe plausibility of the encoder's motion signal, e.g., with a “Drive running/not run‐ning” signal.

The following options are available to keep the increase in voltage within the limits of aPELV/SELV power supply, as long as the prevailing error is not being managed by one ofthe selected monitoring methods:b Use isolated voltage supplies for the two encoders.b Use encoders which are designed and dimensioned for the prevailing supply volt‐

age.b Use the power supply for the encoders of the FX3-MOC0 module (ENC1_24V and

ENC2_24V) either directly or via the encoder connection box. If the supply voltagefor the Flexi Soft system at the main module's system plug exceeds 35 V, the sys‐tem switches to safe state, i.e., the safe outputs are switched off. This ensuressafe shutdown in the application in the event of an increase in voltage. However,there is a risk of damage to the encoders under these circumstances.

The FX0-MOC0 cannot be operated alone; an FX3-CPUx main module is always neces‐sary.

• FX3-CPU0 and FX3-CPU1: ≥ V2.50.0• All other FX3-CPUx modules (FX3-CPU2, etc): all firmware versions

Up to 6 FX3-MOC0 modules can be used at the same time (see "Construction and func‐tion", page 15). Each FX3-MOC0 module reduces the maximum possible number ofother expansion modules (i.e., I/O modules) by two.

4) Can be configured for sine-cosine encoders in the hardware configuration of the configuration software.



The power supply to the internal logic is provided via the system plug and the FLEXBUS+ internal bus.

Figure 18: Drive Monitor FX3-MOC0

1 LED MS (Modul-Status)

3.4.11 UE410-2RO/UE410-4RO relay output modules

Description

The UE410-2RO/UE410-4RO relay output modules provide dual-channel outputs withcontacts and “positively guided relay contacts”.

Figure 19: UE410-2RO relay output module

1 PWR LED (power)2 K1/2 LED


1 PWR LED (power)2 K1/2 LED3 K3/4 LED

NOTEThe relay output modules do not take part in communication via FLEXBUS+ internalbus. Therefore, they cannot receive control signals from the main module.

Up to a maximum of 4 UE410-4RO relay output modules or 8 UE410-2RO relay outputmodules can be connected to a Flexi Soft system, i.e., up to a maximum of 16 saferelay outputs can be available.

Other modules from the Flexi Classic product family cannot be integrated into the FlexiSoft system.




UE410-2RO

The UE410-2RO has one control input (B1). This input actuates two internal relays andprovides a redundant cut-off path consisting of:

• Two safe enabling current paths (13/14, 23/24), dual-channel and volt-free• One signaling current path (Y14), dual-channel and connected internally to 24 V

DC• One feedback circuit external device monitoring (Y1/Y2), dual-channel and volt-

free

Figure 21: Internal structure of the UE410-2RO

UE410-4RO

The UE410-4RO has two control inputs (B1, B2). Each of these inputs controls twointernal relays, thus making available two independent, redundant cut-off paths.

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



free

Control input (B2) actuates two internal relays and provides a redundant cut-off pathconsisting of:



free

The UE410-4RO module thus has double the functionality of a UE410-2RO.



Figure 22: Internal structure of the UE410-4RO

3.5 Interfaces

3.5.1 RS-232

Each main module has an RS-232 interface with the following functions:

• Transfer configuration from the configuration software to the system plug• Import configuration from the system plug into the configuration software• Diagnose the Flexi Soft system with the configuration software• Continuous diagnostics of the Flexi Soft system via a connected PLC As such the

RS-232 interface can provide an alternative to a gateway.

Male connector/Female connector

Pin Signal Color Pin assignment onPC side RS-232D-Sub (9-pin)

1 Reserved Brown –

2 RxD White Pin 3

3 GND (connected electricallyinternally to connection A2on the main module)

Blue Pin 5

4 TxD Black Pin 2

Table 9: Pin assignment of the RS-232 interface on the FX3-CPUx

NOTE

• If the RS-232 interface of the main module is to be connected permanently as analternative to using a gateway, the maximum permissible cable length is 3 m.

• The GND of the RS-232 interface is connected internally to the GND of the mainmodule's power supply (A2). Avoid ground loops between the GND connection ofthe RS-232 interface and connection A2 on the main module, e.g., by using opto‐couplers.

3.5.2 USB

The FX3-CPU3 main module has a USB interface with the following functions:

• Transfer configuration from the configuration software to the system plug• Import configuration from the system plug into the configuration software• Diagnose the Flexi Soft system with the configuration software

3.5.3 Enhanced Function Interface (EFI)

The FX3-CPU1, FX3-CPU2, and FX3-CPU3 main modules each have 2 EFI interfaces.The properties, the functions, and the benefits of these interfaces are described in thissection.



The general description of operation for EFI and the possible combinations of SICKproducts involving EFI are listed in the technical information document entitled “EFI -Enhanced Function Interface” (part no. 8012621).

Definition

An EFI interface is safe communication interface between SICK devices. Informationcan be read from EFI-enabled devices and commands can be sent to EFI-enabled devi‐ces.

Properties

• Each EFI interface can support up to 4 SICK devices, as long as the EFI-enableddevices support this number.

• Device connection via 2-wire cable• Various possible device combinations

° Sensor with sensor in same product family

° Sensor with safety controllers and gateways

° Connection of up to four FX3-CPU1, FX3-CPU2, or FX3-CPU3 main modules toone Flexi Link system (see "Flexi Link", page 38)

• Transfer of status information (process data) between SICK devices with EFI inter‐face

• Transfer of configuration from the configuration software to EFI-enabled devices• Import of configuration from EFI-enabled devices into the configuration software• Activation/use of advanced software functions

Functions

Alongside the product-specific functions of each of the EFI-enabled devices, the follow‐ing functions are available:

General functions• Status information (process data) from the EFI-enabled devices is available in the

controller and at the sensor.• Diagnostic information from all EFI-enabled devices is available in the controller.• Transfer of configuration information

Special functions• Simultaneous protective field evaluation• Protective field switching• Function switching• Operating mode selection• Signal routing• Remote diagnostic information via Ethernet• Information about the location of an interruption in a protective field in the case of

host-guest applications.• Expansion of signals and forwarding of results

Benefits

• Installation is quicker and less expensive (only 2 conductors) when signals frommultiple sensors are used

• Materials cost less as fewer function blocks and inputs/outputs are required• Higher availability thanks to the provision of diagnostic information with high infor‐

mation content for quick and accurate possible actions



3.6 Special functions

3.6.1 Flexi Link

Overview

Flexi Link allows you to combine up to four Flexi Soft stations via EFI for safe dataexchange. Only main modules FX3-CPU1 and higher can be used in a Flexi Link system.FX3-CPU0 main modules cannot be connected.

The process data of each station (inputs and outputs, logic results, etc.) can be madeavailable to all other stations in the Flexi Link system. The teach function can be usedto deactivate individual stations temporarily without impairing the operation of the over‐all system.

Features• Safe connection of up to four Flexi Soft stations via EFI• Connection via EFI1 or EFI1+2• Transmission/receipt of up to 52 bits of information per station (26 bits per EFI

interface)• A tag name that is valid globally can be assigned to each bit.• Teaching simulates the presence of stations that have been temporarily sus‐

pended (switched off).• Any station can be used for access in order to address and configure the entire

system with the configuration software.• The configuration of the entire Flexi Link system is saved in a unique project file.

System requirements and restrictions

The following minimum system requirements must be met for Flexi Link:

System component Version

Hardware FX3-CPU1, FX3-CPU2, or FX3-CPU3 with firmware version ≥ V2.00.0

Software Flexi Soft Designer version ≥ V1.3.0

Table 10: System requirements for Flexi Link

The Flexi Link system can be only be connected via either EFI1 or EFI1+2 The data vol‐ume per station which can be made available to the other stations in a Flexi Link sys‐tem is determined by the connection method.

Connection method Data availability per station

EFI1 26 bits

EFI1+2 52 bits

Table 11: Data availability dependent on the connection method

NOTE

• You cannot use Flexi Link and EFI communication at the same time, i.e., it is notpossible to connect other EFI-enabled devices to EFI2 if you are using EFI1 forFlexi Link.

• The process data sent from any station is received by all other stations at virtuallythe same time. However, the data is not necessarily processed (logic) at the sametime, because the stations are not synchronized.

• The data is consistent within EFI1 and consistent within EFI2. However, the datafrom EFI1 and the data from EFI2 may be inconsistent for a short period of timebecause it is transmitted separately.



3.6.2 Flexi Line

Overview

Flexi Line allows you to network up to 32 Flexi Soft stations safely. Only main modulesFX3-CPU3 and higher can be used in a Flexi Line system. It is not possible to connectany of the other main modules (FX3-CPU0, FX3-CPU1, FX3-CPU2).

A single process image is defined for the entire Flexi Line system. Each byte in this proc‐ess image is valid either globally, i.e., in the entire system, or locally, i.e., only for thecorresponding station and its neighbor stations. Each Flexi Line station uses this proc‐ess image to communicate with its neighbor stations. Thanks to the topology,addresses are not required in order for communication to take place.

Features• Safe connection of up to 32 Flexi Soft stations via the Flexi Line interface• Topology without addresses: If the sequence of the stations changes, simply con‐

firm the new arrangement by performing a teach-in operation.• The EFI interface remains available without restrictions:

° EFI-enabled devices can be connected.

° A Flexi Link system can be connected.• A global process image is defined for all stations.• Bytes that are valid globally or locally can be defined in the process image.• The process image can contain up to 12 bytes or 96 bits.• The maximum cable length between 2 stations is 1,000 meters. The possible total

length of a system with 32 stations is, therefore, 31 kilometers.

System requirements and restrictions

The following minimum system requirements must be met for Flexi Line:

System component Version

Hardware FX3-CPU3, every firmware version

Software Flexi Soft Designer version ≥ V1.6.0

Table 12: System requirements for Flexi Line

NOTE

• You can even use Flexi Link or EFI communication simultaneously with Flexi Line,i.e., it is possible to connect either EFI-enabled devices or Flexi Link stations.

• The process image is transferred from station to station at a fixed update rate.However, the data is not necessarily processed (logic) at the same time, becausethe stations are not synchronized.

• The update rate of the Flexi Line system is determined by the maximum cablelength between two stations and the size of the process image.

Max. cable length 32 bits 64 bits 96 bits

125 m 2 ms 2 ms 4 ms

250 m 2 ms 4 ms 8 ms

500 m 4 ms 8 ms 12 ms

1,000 m 8 ms 12 ms 20 ms

Table 13: Update rate of a Flexi Line system dependent on the maximum cable length and thesize of the process image



3.6.3 Muting

General description

Muting automatically and temporarily overrides the safety-related functions provided bya control system or a safety device. Muting is used to move specific objects (palletsloaded with goods, for example) through an electro-sensitive protective device such asa safety light curtain and into a hazardous area. During this transport operation, themuting function overrides monitoring by the electro-sensitive protective device.

For more information about the process, read the notes in the “Flexi Soft in the FlexiSoft Designer Software” operating instructions.

SICK muting sensors

A selection of optical muting sensors are presented below. You can use these sensorsby type (light or dark switching).

Model Function

W9-3 Light/dark switching, complementary

W12-3

W18-3

W27-3

W24-3 Light/dark switching, switchable

Table 14: Selection and settings of optical SICK muting sensors in muting applications

NOTEThe following criteria apply when selecting and setting optical SICK muting sensors inmuting applications:

• Outputs must be PNP-switching.• Note the output level in the table below.

Output level of muting sensors State

High Activated, material detected

Low Deactivated, no material detected

Table 15: Output level of muting sensors

3.6.4 Automatic configuration recovery (ACR)

When an FX3-MPL1 system plug is used, EFI-enabled devices of the same type can bedetected and automatically reconfigured further to a replacement (automatic configura‐tion recovery). Advantages:

• Configuration backup of EFI sensors in FX3-CPU2 and FX3-CPU3• Rapid device replacement without reconfiguration with the corresponding configu‐

ration software• Quick and easy duplication of equipment in series machine manufacture

ACR can be used to restore the configuration of the following device families:

• S3000 firmware version ≥ B02.41, not in compatibility mode. For detailed infor‐mation, see the “Compatibility mode” chapter of the S3000 operating instructions(SICK part no. 8009937).

• S300 firmware version ≥ 02.10, not in compatibility mode. For detailed informa‐tion, see the “Compatibility mode” chapter of the S300 operating instructions(SICK part no. 8010947).

• S300 Mini



• M4000• C4000

ACR cannot be used to restore the configuration of the following devices:

• UE product family (UE402/UE403, UE44xx, UE41xx, UExx40)• Devices in the Flexi Soft product family (FX3-CPUx)

Please also refer to the information in the operating instructions for the EFI-enableddevices you are using.

You can find more information about using ACR in the “Flexi Soft in the Flexi SoftDesigner Software” operating instructions.



4 Mounting

4.1 Steps for mounting the module

DANGERThe Flexi Soft system must be mounted in an environment corresponding to enclosurerating IP 54 (EN 60529), e.g., inside a control cabinet with enclosure rating IP 54.You are not permitted to unplug modules from or connect modules to the Flexi Soft sys‐tem while the supply voltage is switched on.

• Mount the modules according to EN 50274.• Appropriate ESD protective measures must be taken during mounting. Failure to

do this can damage the devices.• Take suitable measures to ensure that foreign bodies cannot get into the openings

of the connectors, in particular the system plug.• The modules are housed inside a 22.5 mm wide housing for 35 mm standard rails

compliant with EN 60715 (DIN mounting rail).• The modules are interconnected via a FLEXBUS+ plug connector that is integrated

into the housing. Please note that the Flexi Soft modules must be pushed apart bya width of approximately 10 mm before a module can be removed from the DINmounting rail.

• Modules with ventilation slots (such as the EtherCAT gateway, for example) mustbe mounted so that vertical air circulation is possible. The ventilation slots mustbe positioned at the top and bottom.

• In a Flexi Soft system, the FX3-CPUx main module is positioned on the far left.• The two optional gateways are positioned next, immediately to the right of the

main module.• Mount all additional Flexi Soft expansion modules (e.g., FX3-XTIO, FX3-XTDI, or

FX3-MOC0) to the right of the gateways or to the right of the main module if youare not using a gateway. The expansion modules can be mounted in any order.

• Mount additional relay output modules (UE410-2RO or UE410-4RO) on the farright in the Flexi Soft system.

1

3

2

Figure 23: Mounting the module on the DIN mounting rail

b Make sure that the power supply to the Flexi Soft system is switched off.b Attach the device to the DIN mounting rail (1).b Make sure that the grounding spring 2) is sitting securely on the DIN mounting

rail, making good contact in order to ensure good electrical conduction.b Press the module down onto the DIN mounting rail by applying slight pressure in

the direction of the arrow (3).

4 MOUNTING


Figure 24: Attaching end clamps

b If multiple modules are present, slide each of the modules together in the direc‐tion of the arrow until the side-mounted plug connector engages.

b Install end pieces on the left and right sides.

The following steps are necessary after mounting and installation:

• Establish the electrical connections (see "Electrical installation", page 44)• Configuration (“Flexi Soft in the Flexi Soft Designer Software” operating instruc‐

tions)• Check the installation (see "Checks before initial commissioning", page 84)

NOTEFor information about mounting and removing the encoder connection boxes, see themounting instructions for the encoder boxes at www.sick.com.

MOUNTING 4


http://www.sick.com

5 Electrical installation

NOTEThis chapter deals with the electrical installation of the Flexi Soft system inside the con‐trol cabinet. You will find additional information about the electrical connection of otherdevices to the Flexi Soft system in the section about the corresponding device: see"Connection of devices", page 62.

5.1 Requirements to be met by the electrical installation

DANGERAll work to connect the system/machine must be carried out with the power supplydisconnected.The system could inadvertently start while you are connecting the devices.Ensure compliance with applicable safety standards.All safety-related parts of the system (wiring, connected sensors and command triggers,configuration, external device monitoring) must meet the requirements of the relevantsafety standards (e.g., EN 62061 or EN ISO 13849-1). This can mean that safety-related signals have to be set up with redundancy or that single-channel signals mustbe installed with protection or require short-circuit detection achieved by using test out‐puts and/or regular function tests.

b Please note that short-circuits between test outputs and the corresponding inputcannot be detected.

b Check whether these signals require protected or separate cables.

5 ELECTRICAL INSTALLATION


NOTE

• The Flexi Soft safety controller meets the EMC requirements set out in the genericstandard EN 61000-6-2 for industrial applications.

• Industrial safety devices by SICK are only suitable for local direct current applica‐tions. If the device is being used on power supply networks, e.g., in accordancewith IEC 61326-3-1, additional protective measures must be taken.

• Machines on which safety devices are being used must be installed and dimen‐sioned as appropriate for the lightning zone in accordance with EN 62305-1. Therequired level can be achieved by using external protective devices. The devicesused to provide protection against overvoltage must meet the requirements setout in EN 61643-11.

• The equipment must prevent common-mode disturbance as set out inIEC 61000-4-16 in the frequency range from 0 Hz to 150 kHz.

• To establish full EMC safety, you must connect the DIN mounting rail to functionalearth (FE).

• All electrical equipment must be installed in accordance with EN 60204-1.• The external voltage supply of the Flexi Soft modules must be capable of buffering

brief power failures of 20 ms as specified in EN 60204-1, for example.• The power supply and all connected signals must meet the requirements for low

voltages with safe isolation (SELV, PELV) as set out in EN 60664 and EN 50178(electronic equipment for use in power installations).

• Make sure that all of the modules in the Flexi Soft system, the connected protec‐tive devices (e.g., the EFI-enabled devices) and actuators, as well as the powersupplies, are connected to the same GND connection.

• Establish a star connection between the GND connections for the actuators at out‐puts Q1 to Q4 and the GND connection for the power supply. If you do not do this,an actuator (e.g., a relay) may pick up unexpectedly if there is a break in the com‐mon GND cable, at least one output is set to High, and at least one output for theactuators is set to Low.

• If the RS-232 interface on the main module is used as an alternative to a gateway,the maximum permissible cable length will be 3 m.

• The GND for the RS-232 interface is connected internally to the GND connectionfor the power supply to the main module (A2). Avoid ground loops between theGND connection of the RS-232 interface and connection A2 on the main module,e.g., by using optocouplers.

• Depending on the external loads and in particular in the case of inductive loads,additional external safety measures such as varistors or RC elements may be nec‐essary in order to protect the outputs. For information on limitations in operation:see "Technical data", page 109. It should be noted that the response times maybe extended depending on the type of suppressor.

• When a module is replaced, the terminals must be assigned correctly; this can beensured, for example, by labeling or laying the cables accordingly.

ELECTRICAL INSTALLATION 5


DANGERRestricted short-circuit detection on the FX3-XTDShort-circuits between the odd number test outputs X1, X3, X5, and X7 cannot bedetected if they are assigned to the same test signal generator. The same is true of theeven number test outputs X2, X4, X6, and X8.Take this into account in the wiring (e.g., lay cables separately, use cable protection).Reverse current at inputs on the FX3-XTIO, FX3-XTDI, and FX3-XTDS when the groundconnection is lostThe loss of the internal or external ground connection may result in a reverse currentflowing from the voltage supply of the main module (terminal A2 on the system plug) tothe safe inputs I1 through I8 of FX3-XTIO, FX3-XTDI, or FX3-XTDS modules. If you areconnecting multiple safe inputs in parallel, check whether this reverse current mightlead to an unintentional high state. For information on reverse current in the event ofthe loss of a ground connection: see "Data sheet", page 119.

5.2 Description of the terminals



1 FX3-MPL0 system plug2 RS-232 interface3 MS LED (Module Status)4 CV LED (Configuration Verified)

Terminal Pin assignment

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

A2 Power supply GND

Table 16: Pin assignment on the FX3-CPU0 main module with FX3-MLP0 system plug



5.2.2 FX3-CPU1 and FX3-CPU2 main modules


1 Systemstecker FX3-MPL02 RS-232-Schnittstelle3 EFI1_A4 EFI1_B5 LED MS (Modul-Status)6 LED CV (Configuration Verified)7 LED EFI18 LED EFI29 EFI2_B EFI2_A


1 FX3-MPL1 system plug2 RS-232 interface3 EFI1_A4 EFI1_B



5 MS LED (Module Status)6 CV LED (Configuration Verified)7 EFI1 LED8 EFI2 LED9 EFI2_B EFI2_A



A2 Power supply GND

EFI1_A Connections for EFI or for Flexi Link

EFI1_B

EFI2_A

EFI2_B

Table 17: Pin assignment at FX3-CPU1 main module with FX3-MPL0 system plug and at FX3-CPU2 main module with FX3-MPL1 system plug



1 FX3-MPL1 system plug2 RS-232 interface3 USB interface4 Line_PRE_A (previous)5 Line_PRE_B (previous)6 EFI1_A7 EFI1_B8 MS LED (Module Status)9 CV LED (Configuration Verified) LINE LED EFI1 and EFI2 LEDs Line_NEXT_B (next)



Line_NEXT_A (next) EFI2_B EFI2_A



A2 Power supply GND

EFI1_A Connections for EFI or for Flexi Link

EFI1_B

EFI2_B

EFI2_A

Line_PRE_A Connections for Flexi Line

Line_PRE_B

Line_NEXT_A

Line_NEXT_B

Table 18: Pin assignment on the FX3-CPU3 main module with FX3-MLP1 system plug


Figure 29: FX3-XTIO I/O module

1 LED MS (Modul-Status)2 8 Eingangs-LEDs3 4 Ausgangs-LEDs


A1 24 V

A2 GND

I1 … I8 Safe inputs 1 to 8

Q1 … Q4 Safe outputs 1 to 4

X1/X2 Test output 1/Test output 2

Table 19: Pin assignment for the FX3-XTIO I/O module




Figure 30: FX3-XTDI I/O module

1 LED MS (Modul-Status)2 8 Eingangs-LEDs



X1/X3/X5/X7 Test output 1 (test signal generator 1)

X2/X4/X6/X8 Test output 2 (test signal generator 2)

Table 20: Pin assignment for the FX3-XTDI I/O module


Figure 31: FX3-XTDS I/O module

1 2 LEDs für Testausgänge oder nicht sichere Ausgänge2 LED MS (Modul-Status)3 8 Eingangs-LEDs4 4 Ausgangs-LEDs




A1 24 V

A2 GND


Y3 … Y6 Non-safe outputs 3 to 6

XY1/XY2 Test output 1/Test output 2 ornon-safe output 1/non-safe output 2

Table 21: Pin assignment for the FX3-XTDS I/O module


Figure 32: FX0-STIO I/O module

1 2 Ausgangs-LEDs2 LED MS (Modul-Status)3 2 Eingangs-LEDs4 4 Ausgangs-LEDs5 4 Eingangs-LEDs6 2 LEDs für konfigurierbare Ein- oder Ausgänge


A1 24 V

A2 GND

I1 … I6 Non-safe inputs 1 to 6

IY7, IY8 Non-safe inputs 7 and 8 or non-safe outputs 7 and 8 (configurable)

Y1 … Y6 Non-safe inputs 1 to 6

Table 22: Pin assignment for the FX0-STIO I/O module




Figure 33: Drive Monitor FX3-MOC0

1 LED MS (Modul-Status)

There is a 15-pin micro D-SUB connector on the front of the FX3-MOC0 for connectingup to two encoders.

NOTE

• To make installation easier, we recommend using the connecting cables and con‐nection boxes that are available as accessories (see "Accessories", page 152).

• The signals are assigned based on the type of encoder used (see "Connection ofencoders", page 76).

Male connector Pin Signal Connecting cable colorcoding 1)

1 ENC1_A+ White

2 ENC1_B+ Green

3 ENC1_C+ Gray

4 ENC1_24V Blue

5 ENC2_24V Red

6 ENC2_C+ White/green

7 ENC2_B+ Gray/pink

8 ENC2_A+ Black

9 ENC1_A– Brown

10 ENC1_B– Yellow

11 ENC1_C– Pink

12 ENC_0V White/yellow

13 ENC2_C– Brown/green

14 ENC2_B– Red/blue

15 ENC2_A– Purple

Table 23: Pin assignment of the micro D-SUB male connector for the FX3-MOC0

1) Ordering data for connecting cable for direct encoder connection: see "Accessories", page 152.



5.2.9 Encoder connection boxes FX3-EBX1, FX3-EBX3, and FX3-EBX4

The encoder connection boxes that are available to purchase as accessories facilitatethe connection of encoders to the encoder interface of FX3-MOC0 modules. They areparticularly useful for encoders which are being used not only for an FX3-MOC0 butalso for motor feedback in a drive system.

There are additional terminals on all encoder connection boxes for the routing of sig‐nals which are not required for the FX3-MOC0 module but can still be transmitted in theencoder cable, e.g., brake actuation, temperature sensor, etc.

The following encoder connection boxes are available:

• Optimized motor feedback splitter box FX3-EBX1: facility for connecting twoencoders, two additional terminals for each encoder for the routing of signals.

• Motor feedback splitter box FX3-EBX3: facility for connecting one encoder, tenadditional terminals for the routing of signals. Usually used in a motor feedbacksystem.

• Dual encoder connection box FX3-EBX4: facility for connecting two encoders, twoadditional terminals for encoder 1 for the routing of signals.

For information on recommended connection types: see "Connection of encoders",page 76.

The FX3-EBX3 and FX3-EBX4 encoder connection boxes have a shielding hood for theplug-in spring terminals C1 and C2 to provide protection against electromagnetic inter‐ference.

Optimized motor feedbacksplitter box FX3-EBX1

Motor feedback splitter boxFX3-EBX3

Dual encoder connectionbox FX3-EBX4

Table 24: Connections on the encoder connection boxes (front view)



Description

Optimized motor feedbacksplitter box FX3-EBX1

Motor feedback splitterbox FX3-EBX3

Dual encoder connectionbox FX3-EBX4

C1 • Spring terminals forthe connection ofencoder signals froman encoder

• 2 terminals for rout‐ing other signals

• Plug-in spring terminals for the connection ofencoder signals from an encoder

• 2 terminals for routing other signals

C2 • Spring terminals forthe connection ofencoder signals froma second encoder

• 2 terminals for rout‐ing other signals

• Plug-in spring termi‐nals with 8 terminalsfor routing other sig‐nals

• Plug-in spring termi‐nals for the connec‐tion of encoder sig‐nals from a secondencoder

C3 • 15-pin HD D-SUB female connector with M3 screws for the connection of theconnection cable to the FX3-MOC0

C4 – • 9-pin D-Sub femaleconnector with M3screws for the con‐nection of a secondFX3-EBX3 motor feed‐back splitter box (toforward theENC2_x signals fromthe 15-pin HD D-Subfemale connector)

–

Uout – • Selector switch for the on-board power supply forencoders, infeed from the FX3-MOC0

• Terminals for shielding the two cables from the encoder and to the motor con‐troller for a low-resistance connection of the cable shields

• ID code in combination with the power supply, for evaluation by the FX3-MOC0

Table 25: Description of the connections on encoder connection boxes

DANGERThe encoder connection boxes must be mounted in an environment corresponding toenclosure rating IP 54 (EN 60529), e.g., inside a control cabinet with enclosure ratingIP 54.



Optimized motor feedback splitter box FX3-EBX1

Terminal strip Terminal Signal Description

1 NC2 Not connected to the encoder connection box, usedonly to route a signal, e.g., for an external power sup‐ply

2 NC1

3 ENC1_24V Encoder power supply

4 ENC1_0V Encoder GND connection

5 ENC1_C– Encoder 1, channel C, negative signal

6 ENC1_C+ Encoder 1, channel C, positive signal

7 ENC1_B– Encoder 1, channel B, negative signal

8 ENC1_B+ Encoder 1, channel B, positive signal

9 ENC1_A– Encoder 1, channel A, negative signal

10 ENC1_A+ Encoder 1, channel A, positive signal

Table 26: Pin assignment for encoder connection C1 on the FX3-EBX1


1 NC2 Not connected to the encoder connection box, usedonly to route a signal, e.g., for an external power sup‐ply

2 NC1

3 ENC2_24V Encoder power supply











Female connector Pin Signal

1 ENC1_A+

2 ENC1_A–

3 ENC1_24V

4 ENC2_A+

5 ENC2_A–

6 ENC1_B+

7 ENC1_B–

8 ENC_0V

9 ENC2_B+

10 ENC2_B–

11 ENC1_C+

12 ENC1_C–

13 ENC2_24V

14 ENC2_C+

15 ENC2_C–

Table 28: Pin assignment HD D-SUB female connector C3 on the FX3-EBX1 for connection to theFX3-MOC0

Motor feedback splitter box FX3-EBX3


1 NC2 Not connected to the encoder connection box, usedonly to route a signal, e.g., for an external power sup‐ply (instead of using Uout)

2 NC1

3 Uout Encoder power supply from the on-board power sup‐ply for this encoder connection box

4 ENCx_0V1 Encoder GND connection

5 ENCx_C–1 Encoder x, channel C, negative signal

6 ENCx_C+1 Encoder x, channel C, positive signal

7 ENCx_B–1 Encoder x, channel B, negative signal

8 ENCx_B+1 Encoder x, channel B, positive signal

9 ENCx_A–1 Encoder x, channel A, negative signal

10 ENCx_A+1 Encoder x, channel A, positive signal


1 x = 1 if it is the first encoder connection box, i.e., if plug connector C3 is connected directly to the FX3-MOC0.x = 2 if it is the second encoder connection box, i.e., if plug connector C3 is connected directly to anotherconnection box.




1 NC Not connected to the encoder connection box, usedonly to route signals2 NC

3 NC

4 NC

5 NC

6 NC

7 NC

8 NC

Table 30: Pin assignment for terminals C2 on the FX3-EBX3


1 ENC1_A+

2 ENC1_A–

3 ENC1_24V

4 ENC2_A+

5 ENC2_A–

6 ENC1_B+

7 ENC1_B–

8 ENC_0V

9 ENC2_B+

10 ENC2_B–

11 ENC1_C+

12 ENC1_C–

13 ENC2_24V

14 ENC2_C+

15 ENC2_C–


The FX3-EBX3 motor feedback splitter box also has a 9-pin D-SUB female connector forthe connection of a second motor feedback splitter box FX3-EBX3.

NOTE

• It is not permitted to connect an FX3-EBX4 dual encoder connection box here.• A maximum of two FX3-EBX3 motor feedback splitter boxes are permitted for each

FX3-MOCx module.




1 ENC_A+

2 ENC_B+

3 ENC_C+

4 ENC_24V

5 ENC_ID

6 ENC_A–

7 ENC_B–

8 ENC_C–

9 ENC_0V

Table 32: Pin assignment for D-SUB female connector C4 on the FX3-EBX3

Dual encoder connection box FX3-EBX4


1 NC2 Not connected to the encoder connection box, usedonly to route a signal, e.g., for an external power sup‐ply (instead of using Uout)

2 NC1

3 Uout Encoder power supply from the on-board power sup‐ply for this encoder connection box










1 Uout Power supply to the encoder from the voltage regula‐tor for this encoder connection box

2 ENC_0V Encoder GND connection











1 ENC1_A+

2 ENC1_A–

3 ENC1_24V

4 ENC2_A+

5 ENC2_A–

6 ENC1_B+

7 ENC1_B–

8 ENC_0V

9 ENC2_B+

10 ENC2_B–

11 ENC1_C+

12 ENC1_C–

13 ENC2_24V

14 ENC2_C+

15 ENC2_C–


On-board power supply Uout (FX3-EBX3 and FX3-EBX4 only)

On-board power supply which can be used as an option for the encoders, infeed fromFX3-MOC0 (C3.ENC1_24V and C3.ENC2_24V). The output voltage Uout can be switchedbetween 5 V, 7 V, 12 V, and 24 V (nominal) via a rotary switch.

Switch setting Supply voltageUout

Max. current Notes

0 5 V 240 mA Tolerance: 5%

1 7 V 170 mA

2 12 V 100 mA

3 24 V nominal 75 mA The supply voltage for the encoder can beup to 2 V below the supply voltage at thesystem plug (terminal A1).

Table 36: Setting of the supply voltage for the encoders at the FX3-EBX3 motor feedback splitterbox and at the FX3-EBX4 dual encoder connection box

DANGEROnly turn the rotary switch for the supply voltage on the connection box if the powersupply is switched off. Otherwise, the connected encoder may be damaged by the volt‐age peaks that occur during switching.



5.2.10 UE410-2RO and UE410-4RO relay output modules


1 PWR LED (power)2 K1/2 LED


1 PWR LED (power)2 K1/2 LED3 K3/4 LED


B1 Wiring of relay K1/K2

13/14 and 23/24 Safety contacts for cutoff circuit K1/K2

Y1/Y2 Feedback circuit external device monitoring (EDM), normally closed

Y14 Safety contact K1/K2, current-limited, normally open (see "Technicaldata", page 109)

Table 37: Pin assignment of the UE410-2RO relay output module




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

33/34 and 43/44 Safety contacts for cut-off circuit outputs K1/K2

Y1/Y2 Feedback circuit external device monitoring K1/K2, normally closed

Y3/Y4 Feedback circuit external device monitoring K3/K4, normally closed



Table 38: Pin assignment of the UE410-4RO relay output module

The UE410-2RO/UE410-4RO relay output modules cannot be used independently; theymust be connected via an FX3-XTIO module. £A control output from the FX3-XTIO mod‐ule (Q1 to Q4) must be bypassed with a control input from the relay output module (B1,B2); see the figure below.



Figure 36: Example integration of a relay output module into the Flexi Soft system

DANGERUse an EDM (external device monitoring) function block to monitor the feedback con‐tacts.It is not sufficient to connect control outputs B1 or B1/B2. In addition, feedback con‐tacts Y1/Y2 on the UE410-2RO or feedback contacts Y1/Y2 and Y3/Y4 on theUE410-4RO relay output module must be monitored with an EDM (external device mon‐itoring) function block in the Flexi Soft logic editor.

5.3 Wiring for the power supply to a Flexi Soft system

Figure 37: Wiring for the power supply to a Flexi Soft system

1 24 V DC2 System plug3 Logic



4 FLEXBUS+5 Application6 Main module7 Gateway 18 Gateway 29 Expansion module 1 Expansion module 2 Expansion module n A1 (24 V) A2 (GND) Test outputs (X1 … X8) Outputs (Q1 … Q4) Actuator

5.4 Connection of devices

This section describes the connection of safe and non-safe sensors, actuators, andswitching elements to the Flexi Soft system and provides instructions for setting upselected functions.

The Flexi Soft system supports applications up to SIL3 (in accordance with IEC 61508)or SILCL3 (in accordance with EN 62061) and performance level PL e (in accordancewith EN ISO 13849-1). The level of safety actually achieved is determined by the exter‐nal wiring, how the wiring is implemented, the configuration, the selection of devices,and how they are arranged on the machine. Take all necessary boundary conditionsinto account and assess them, for example in a failure mode and effects analysis(FMEA).

Other points to be considered during electrical installation: see "Electrical installation",page 44.

DANGERLoss of safety function due to incorrect configuration

b Take great care when planning and executing the configuration.

The configuration of the safety application must be precisely adapted to the prevailingconditions in the system or machine to be monitored.

b Check whether the configured safety application monitors the machine or systemas you have planned and if the safety of a configured application is maintained atall times. This must be ensured in every operating mode and secondary applica‐tion. The results of this check must be documented!

b You must always follow the instructions on commissioning and daily checks descri‐bed in the operating instructions for the protective devices integrated into thesafety application.

b Note the warnings and descriptions of operation for the protective devices that areconnected to the safety controller. If you are in any doubt, contact the manufac‐turer of the protective device concerned.

b Please note that the minimum switch-off time of the connected sensors must belonger than the logic execution time (see the chapter on the logic editor in the“Flexi Soft in the Flexi Soft Designer Software” operating instructions and theinformation in the logic editor about the logic execution time) in order to ensurethat the Flexi Soft system can detect the sensors switching. The minimum switch-off time of the sensors is usually listed in the technical data for the sensors.



NOTE

• If you are using a test output with an odd number (X1, X3, X5, X7, XY1), inputs withodd numbers (I1, I3, I5, I7) must be used; if you are using a test output with aneven number (X2, X4, X6, X8, XY2), inputs with even numbers (I2, I4, I6, I8) mustbe used.

• You must use the test outputs of the modules to which the device to be tested isconnected.

DANGERProtect the single-channel inputs against short-circuits and cross-circuits.At a single-channel input with test signals which was previously Low, a short-circuit toHigh can look like a pulse for the logic due to the error detection. The short-circuit tohigh causes the signal to switch to High first and then back to Low after the error detec‐tion time. Therefore, single-channel signals with test signals require special attention.

• If the short-circuit to High occurs at a single-channel input with test signals thatwas previously High, this signal will look like a delayed falling edge (High-Low) tothe logic.

• If an unexpected signal or a delayed falling edge (High-Low) at a single-channelinput can lead to a dangerous state, you must take the following action:

° Use protected cables for the corresponding signal (to prevent cross-circuits toother signals)

° Do not use cross-circuit detection, i.e., no connection to a test output (seesection “Configuration of connected elements” in the “Flexi Soft in the FlexiSoft Designer Software” operating instructions)

This must be actioned in particular for the following inputs:

° Reset input at Reset function block

° Restart input at Restart function block

° Restart input at the function block for press applications (contact monitor foreccentric press, contact monitor for universal presses, PSDI mode, set uppress, press single stroke, press automatic)

° Override input at a function block for muting

° Reset input at a valve monitoring function block

° Reset to zero input at a counter function block

° Set to starting value input at a counter function block

Once the configuration is complete, you can use the configuration software to generatea report. This report includes the following information:

• Logic report• Bill of materials• Internal circuitry

5.4.1 Safety command devices and electro-mechanical safety switches

5.4.1.1 Emergency stop pushbutton (e.g., ES21)

Electrical connection: example with FX3-XTIO

Single-channel, at 24 V Contact between 24 V and I1

Single-channel, at test output Contact between X2 and I2

Dual-channel, at 24 V Channel 1: contact between 24 V and I3Channel 2: contact between 24 V and I4

Dual-channel, at test output Channel 1: contact between X1 and I5Channel 2: contact between X2 and I6

Table 39: Connection for emergency stop pushbutton



The dual-channel emergency stop pushbuttons preconfigured in the configuration soft‐ware have equivalent switching contacts. You will find suitable elements among thevolt-free contacts for the implementation of dual-channel complementary switchingcontacts.

Function Notes

Tested Possible

Series connection/cascading

If emergency stop pushbuttons are connected in series, the maximumconductor resistance must not exceed 100 Ω (see "Technical data",page 109).

Discrepancy time See the Flexi Soft Designer configuration software

Table 40: Functions with ES21

NOTEYou will find more information in the operating instructions for the ES21 emergencystop pushbutton.

5.4.1.2 Electro-mechanical safety switches and locking devices


Single-channel, at 24 V Contact between 24 V and I1

Single-channel, at test output Contact between X2 and I2

Dual-channel, at 24 V Channel 1: contact between 24 V and I3Channel 2: contact between 24 V and I4

Dual-channel, at test output Channel 1: contact between X1 and I5Channel 2: contact between X2 and I6

Table 41: Connection of electro-mechanical safety switches


Single-channel, at 24 V Contact between 24 V and I1Coil at Q1

Single-channel, at test output Contact between X1 and I1Coil at Q1

Dual-channel, at 24 V Channel 1: contact between 24 V and I1Channel 2: contact between 24 V and I2Coil at Q1

Dual-channel, at test output Channel 1: contact between X1 and I1Channel 2: contact between X2 and I2Coil at Q1

Table 42: Connection of locking devices

Function Notes

Tested Possible


If safety switches are connected in series, the maximum conductorresistance must not exceed 100 Ω (see "Technical data", page 109).


Table 43: Functions with electro-mechanical safety switches and locking devices

NOTEYou will find more information in the operating instructions for the electro-mechanicalsafety switches.



5.4.1.3 Enabling switch E100


2 positions, at 24 V Channel 1: contact E31 between 24 V and I1Channel 2: contact E41 between 24 V and I2

2 positions, at test output Channel 1: contact E31 between X1 and I3Channel 2: contact E41 between X2 and I4

3 positions, at 24 V Channel 1: contact E13 between 24 V and I5Channel 2: contact E23 between 24 V and I6Channel 3: contact E31 between 24 V and I7Channel 4: contact E41 between 24 V and I8

3 positions, at test output Channel 1: contact E13 between 24 V and I1Channel 2: contact E23 between 24 V and I2Channel 3: contact E31 between X1 and I3Channel 4: contact E41 between X2 and I4

Table 44: Connection of the E100

Function Notes

Tested Possible

Series connection Not possible


Table 45: Functions with the E100

NOTEYou will find more information in the operating instructions for the enabling switchE100.

5.4.1.4 Two-hand control


Type IIIA, at 24 V Channel 1: contact between 24 V and I1Channel 2: contact between 24 V and I2

Type IIIC, at 24 V Channel 1: left-hand normally open between24 V and I1Channel 2: left-hand normally closed between24 V and I2Channel 3: right-hand normally open between24 V and I3Channel 4: right-hand normally closed between24 V and I4

Table 46: Connection of the two-hand control

Type IIIA

With type IIIA, two equivalent inputs (N/O contacts for the 2 two-hand switches) aremonitored.

A valid input signal is only generated if the ON state (High level) is present at bothinputs within a period of 0.5 s (synchronous changeover, both two-hand switches actu‐ated) and both were previously in the OFF state (Low level).



Function Notes

Tested Possible


Not possible

Discrepancy time Fixed preset value: 500 msSee function block for type IIIA two-hand in the logic of the main mod‐ule, with which these outputs are to be evaluated.

Table 47: Functions with type IIIA two-hand control

Type IIIC

With type IIIC, two pairs of complementary inputs (N/O contact / N/C contact pair) aremonitored.

A valid input signal is only generated if the ON state (High/Low level) is present at bothinputs within a period of 0.5 s (synchronous changeover, both two-hand switches actu‐ated) and both were previously in the OFF state (Low/High level).

Function Notes

Tested Possible


Not possible

Discrepancy time Possible: 0–500 msSee function block for type IIIC two-hand in the logic of the main mod‐ule, with which these outputs are to be evaluated.

Synchronization time Fixed preset value: 500 msSee function block for type IIIC two-hand in the logic of the main mod‐ule, with which these outputs are to be evaluated.

Table 48: Functions with type IIIC two-hand control

5.4.1.5 Pressure-sensitive safety mats and bumpers


Pressure-sensitive safety mat which triggers ashort-circuit in 4-conductor technology, at testoutput

Channel 1: Connection between X1 and I1Channel 2: Connection between X2 and I2

Table 49: Connection of pressure-sensitive safety mats and bumpers

Function Notes

Parallel wiring Possible

Number of pressure-sensitive safety matsor bumpers per FX3-XTIO, FX3-XTDI, orFX3-XTDS module

Max. 1 without diode moduleMax. 4 without diode module

Table 50: Function of pressure-sensitive safety mats and bumpers

DANGERMake sure that the switch-off condition is sufficient.The duration of the switch-off condition for pressure-sensitive safety mats and bumpersmust be at least at long as the highest value for the “test period” in order to ensurethat the switch-off condition is detected and that no sequence errors occur.



5.4.1.6 Diode module DM8-A4K

The diode module DM8-A4K serves as a connection adapter when multiple pressure-sensitive safety mats that trigger short-circuits are connected to an FX3-XTIO or FX3-XTDI module. It decouples test outputs X1 and X2, thus increasing them fourfold.

NOTEThe diode module DM8-A4K does not constitute a safety component according to theMachinery Directive. Therefore, it does not have to be taken into account when calculat‐ing the safety integrity level (SIL according to IEC 61508 and SILCL according to EN62061) and the performance level (PL according to EN ISO 13849-1).

Electrical connection

Electrical connection: example with FX3-XTIO or FX3-XTDI

Pressure-sensitive safety mat which triggers ashort-circuit in 4-conductor technology, at testoutput and with diode module DM8-A4K con‐nected upstream

Channel 1: Contact from X1 to I1 via diodeChannel 2: Contact from X2 to I2 via diodeChannels 3 to 8 as shown in thecircuit diagram: see figure 38, page 67

Table 51: Connection of multiple pressure-sensitive safety mats with diode module DM8-A4Kconnected upstream

Circuit diagrams

Figure 38: Circuit diagram for multiple pressure-sensitive safety mats with diode module DM8-A4K connected to the FX3-XTIO upstream



Figure 39: Circuit diagram for multiple pressure-sensitive safety mats with diode module DM8-A4K connected to the FX3-XTDI upstream

NOTEInstead of a pressure-sensitive safety mat, you can also connect a safety switch or anemergency stop pushbutton, for example (see figure 39, page 68).

Internal circuitry for diode module DM8-A4K

Figure 40: Internal circuitry for diode module DM8-A4K

5.4.1.7 Operating mode selector switch


Operating mode selector switch (1 of 2), at 24V

Channel 1: contact between 24 V and I1Channel 2: contact between 24 V and I2

Operating mode selector switch (1 of 2), at testoutput

Channel 1: contact between X1 and I1Channel 2: contact between X1 and I3

Table 52: Connection of operating mode selector switch

Function Notes

Tested Possible

Table 53: Function with operating mode selector switch



NOTE

• Operating mode selector switches without test signals support between 2 and 8operating modes; operating mode selector switches with test signals supportbetween 2 and 4 operating modes.

• When wiring the tested operating mode selector switch, please remember that ifyou are using a test output with an odd number (X1, X3, X5, X7), inputs with oddnumbers (I1, I3, I5, I7) must be used; if you are using a test output with an evennumber (X2, X4, X6, X8), inputs with even numbers (I2, I4, I6, I8) must be used.

• You will find more information in the operating instructions for the operating modeselector switches.

5.4.1.8 Volt-free contacts

The configuration software provides a range of volt-free contacts for “free” arrangementof contact elements. This enables a variety of N/C / N/O combinations to be imple‐mented with and without testing. There are also start and stop button, reset button,and external device monitoring (EDM) elements available.

Function Notes

Tested Possible

Series connection Possible


Table 54: Functions with volt-free contacts

5.4.2 Non-contact safety switches

5.4.2.1 Magnetic safety switches (e.g., RE)


At test output Channel 1: contact between X1 and I1Channel 2: contact between X2 and I2

Table 55: Connection of magnetic safety switches with equivalent inputs (RE13, RE27)


At test output N/C contact between X1 and I3N/O contact between X2 and I4

Table 56: Connection of magnetic safety switches with complementary inputs (e.g., RE11, RE21,RE31, RE300)

Function Notes

Tested Possible


Possible; note max. conductor resistance of 100 Ω and ensure test sig‐nal time is set correctly

Discrepancy time Default setting: 1.5 s, see Flexi Soft Designer configuration software

Table 57: Functions with magnetic safety switches

NOTEYou will find more information in the operating instructions for the magnetic safetyswitches.



5.4.2.2 Inductive safety switches IN4000 and IN4000 Direct


IN4000 Test input TI (IN4000) at X1Output Q (IN4000) at I1

IN4000 Direct (with OSSD) OSSD1 (IN4000) at I3OSSD2 (IN4000) at I4

Table 58: Connection of inductive safety switches

Function Notes

Tested Necessary on the IN4000


IN4000 Direct cannot be cascadedIN4000: up to 6 sensors per inputMaximum OFF-ON delay for cascade: 10 ms (otherwise the test gap willtrigger a shutdown).Note max. conductor resistance of 100 Ω and ensure test signal time isset correctly

Table 59: Functions with inductive safety switches

NOTEYou will find more information in the operating instructions for the inductive safetyswitches.

5.4.2.3 Transponders T4000 Compact and T4000 Direct


T4000 Compact (at 24 V) 24 V at +LA, I1 at LA24 V at +LB, I2 at LB

T4000 Compact (at test output) X1 at +LA, I3 at LAX2 at +LB, I4 at LB

T4000 Direct (with OSSD) 24 V at UB (T4000), I5 at OA24 V at UB (T4000), I6 at OB

Table 60: Connection of the transponders

Function Notes

Tested Possible for T4000 CompactNot necessary for the T4000 Direct, as self-monitoring


T4000 Compact cannot be cascadedT4000 Direct: Note the maximum conductor resistance of 100 Ω (see"Technical data", page 109).

Table 61: Functions with transponders

NOTEYou will find more information in the operating instructions for the T4000 Compact andT4000 Direct transponders.



5.4.3 Testable single-beam photoelectric safety switches

5.4.3.1 Type 2 testable single-beam photoelectric safety switches


Wx12/24/27, Vx18 Test input TI (sender) at X1Output Q (receiver) at I1

L21, L27/L28 Test input TI (sender) at X2Output Q (receiver) at I2

Table 62: Connection of type 2 testable single-beam photoelectric safety switches

NOTEUse protected or separate cabling for the connections from the test output of the mod‐ule (X1 to X8) to the test input of the sender and from the output of the receiver to thesafe input of the module (I1 to I8). Otherwise, a cross-circuit between these signals mayprevent the error detection achieved with this test.

Function Notes

Tested Possible


Wx12/24/27, Vx18:

• Maximum 2 pairs per input can be cascaded with test gap = 4 ms(standard element in the configuration software)

• Maximum 5 pairs per input can be cascaded with test gap =12 ms (user-defined element required in the configuration soft‐ware)

L21:

• Maximum 10 pairs per input can be cascaded with test gap =4 ms (standard element in the configuration software)


L27/L28:

• Maximum 7 pairs per input can be cascaded with test gap = 4 ms(standard element in the configuration software)


Note the maximum conductor resistance of 100 Ω.

Table 63: Functions with type 2 testable single-beam photoelectric safety switches

NOTEYou will find more information in the operating instructions for the type 2 testable sin‐gle-beam photoelectric safety switches.

5.4.3.2 Type 4 testable single-beam photoelectric safety switches


L41 Test input TI (sender) at X1Output Q (receiver) at I1

Table 64: Connection of type 4 testable single-beam photoelectric safety switches



NOTEUse protected or separate cabling for the connections from the test output of the mod‐ule (X1 to X8) to the test input of the sender and from the output of the receiver to thesafe input of the module (I1 to I8). Otherwise, a cross-circuit between these signals mayprevent the error detection achieved with this test.

Function Notes

Tested Necessary


L41:

• Maximum 10 pairs per input can be cascaded with test gap =4 ms (standard element in the configuration software)


Note the maximum conductor resistance of 100 Ω.

Table 65: Functions with type 4 testable single-beam photoelectric safety switches

NOTEYou will find more information in the operating instructions for the type 4 testable sin‐gle-beam photoelectric safety switches.

5.4.3.3 User-defined testable single-beam photoelectric safety switches

For information about creating user-defined elements, see the “Flexi Soft in the FlexiSoft Designer Software” operating instructions.

NOTE

• Configure the user-defined element in the Flexi Soft Designer with the minimumvalue for the required test gap.

• Regardless of the test gap, the total OFF-ON delay for the cascade must be shorterthan the maximum OFF-ON delay for the corresponding test output (as shown inthe configuration software report) –2 ms. If it is not, the test gap will lead to shut‐down. For FX3-XTIO or FX3-XTDI modules, this value is = 12 ms – 2 ms = 10 ms.

• Use protected or separate cabling for the connections from the test output of themodule (X1 to X8) to the test input of the sender and from the output of thereceiver to the safe input of the module (I1 to I8). Otherwise, a cross-circuitbetween these signals may prevent the error detection achieved with this test.

5.4.3.4 Mounting instructions for testable single-beam photoelectric safety switches

NOTEFollow the mounting instructions in the operating instructions for the correspondingsensors and in particular the following points:

• Single-beam photoelectric safety switches must only be used to provide accessprotection in accordance with EN ISO 13855. The use of finger and hand protec‐tion is not permitted.

• Maintain a minimum distance from reflective surfaces• The safety distance between the light beam and the hazardous point MUST be

maintained for access protection.



Figure 41: Minimum distance a to reflective surfaces, correct mounting and alignment

S: SenderR: ReceiverD: Distance between sender and receivera: Minimum distance to reflective surface1: Limit to hazardous area2: Reflective surface3: Entry direction to hazardous area4: Optical axis

Figure 42: Minimum distance a based on distance D for testable single-beam photoelectricsafety switches with aperture angle of 10° (e.g., Wx12/24/27, Vx18)

NOTEYou will find diagrams for L21, L27/L28, and L41 in the corresponding operatinginstructions.



Avoid mutual interference between single-beam photoelectric safety switches andbetween cascades

• If several pairs of single-beam photoelectric safety switches are being used, theaperture angle of the sensors MUST be taken into account to exclude mutual inter‐ference.

• When receivers are mounted on only one side, the light beams on the receiverside must not overlap so that the light beam from one sender reaches two receiv‐ers.

• When senders and receivers are mounted on alternate sides, you must ensurethat the light beam from sender S1 cannot be received by receiver R3 and thelight beam from sender S3 cannot be received by receiver R1.

Figure 43: Mounting to avoid mutual optical interference

5.4.4 Electro-sensitive protective devices


C2000, C4000, M2000, M4000, S300,S3000, V300, miniTwin

OSSD1 (receiver) at I1OSSD2 (receiver) at I2

Table 66: Connection of electro-sensitive protective devices

NOTEYou will find more information in the operating instructions for the corresponding elec‐tro-sensitive protective devices.

5.4.5 Safe outputs Q1 to Q4

DANGERSafety-related devices must be suitable for safety-relevant signals.A function interruption affecting outputs Q1 to Q4 will lead to the loss of the safetyfunctions, introducing a risk of serious injury.

• Do not connect any loads which exceed the rated values of outputs Q1 to Q4.• Establish a star connection between the GND connections for the actuators at out‐

puts Q1 to Q4 and the GND connection for the power supply. If you do not do this,an actuator (e.g., a relay) could switch on inadvertently if the entire GND cablebreaks off when at least one output is at High and at least one output for theactuators is at Low.



Example for the connection of an FX3-XTIO I/O module to a UE10-3OS safety relay

The following example shows how a single-channel output and protected cable layingcan be used to achieve SIL3.

Figure 44: Example for the connection of an FX3-XTIO I/O module to a UE10-3OS safety relay

1 Required for SIL3 protected cable laying

5.4.6 Connection of EFI-enabled devices

If your Flexi Soft system contains a main module that is FX3-CPU1 or higher, you canconnect EFI-enabled devices and sensors by SICK to it.

If shielding is required for the connection of the EFI-enabled devices (e.g., for reasonsrelating to EMC), use a grounding terminal that is positioned near to the Flexi Soft mainmodule in the control cabinet. Connect this grounding terminal to the shielding.

NOTE

• An external terminator is not required for the EFI connections on the main module.• The main module and all EFI-enabled devices connected to it must be connected

to the same power supply GND connection.• The maximum permissible voltage at the EFI inputs is ±30 V (for terminal A2 =

GND).• You will find information about the connection of EFI-enabled devices, incl. the pin

assignment, in the operating instructions for the corresponding devices.

Cables

SICK offers two different EFI cables for the connection of EFI devices (see "Accesso‐ries", page 152). You will find more information in the operating instructions for the cor‐responding EFI-enabled device.



EMC measures

To increase the EMC immunity of EFI communication, it is important to connect theshielding for the EFI cable to functional earth at one or both ends.

To avoid interference on the EFI cable, connect the shielding to the same DIN mountingrail to which the functional earth (FE) of the Flexi Soft system is connected. The shield‐ing ground should be connected near to the cable entry inside the control cabinet.

NOTE

• The FE terminal of the Flexi Soft system is located on the rear of the housing. It isconnected automatically when mounted on the DIN mounting rail.

• To avoid further interference, the functional earth for the SICK sensors (e.g.,M4000, S3000) must also be connected to the shielding of the EFI cable.

• If other cables, including cables possibly affected by interference, are laid in thesame cable channel as the EFI cable (cables for drives or motors, for example),this can lead to availability problems. Therefore, we recommend laying the EFIcable in a separate cable channel.

5.4.7 Connection of a Pro-face HMI

You can connect an HMI manufactured by Pro-face to the RS-232 interface of the FlexiSoft main module. Suitable cables: see "Accessories", page 152.

NOTETo facilitate communication between the Flexi Soft station and the Pro-face HMI, youmust activate RS-232 routing for the main module (see the “Flexi Soft in the Flexi SoftDesigner Software” operating instructions).

You will find information about the configuration of the data exchanged via the RS-232interface, as well as about exporting tag names from the configuration software for usewith a Pro-face HMI, in the “Flexi Soft in the Flexi Soft Designer Software” operatinginstructions.

You will find information about replacing a suitable device, about connection, and aboutprogramming, in the “GP-Pro EX Device/PLC Connection Manual” operating instructionswhich are both available directly from Pro-face and can be downloaded from www.pro-face.com.

You can download the driver for the Pro-face devices for connection to the Flexi Softmain modules from www.pro-face.com.

You will find more information about communicating with the Flexi Soft system via theRS-232 interface in the “Flexi Soft RK512 Telegram Listing” online help (SICK part no.8015053).

5.4.8 Connection of encoders

Various options are available to you for connecting encoders to the FX3-MOC0 module.

DANGERThe SIL and PL that can be achieved will vary depending on the encoders used andtheir electrical and mechanical properties.Additional information: see "Drive Monitor FX3-MOC0", page 31.

NOTEYou will find the wiring plan for your selected encoder configurations in the configura‐tion software report.



Please also refer to the selection options for the encoder connection type in the config‐uration software.

Connection with 1motor feedback split‐ter box FX3-EBX1

A Encoder 1B Encoder 2C PLC/drive controller

Connection with 2motor feedback split‐ter boxes FX3-EBX3


Connection with 1motor feedback split‐ter box FX3-EBX3 andencoder cable pro‐vided by the customer


Table 67: Facilities for connecting encoders



Connection with 1dual encoder connec‐tion box FX3-EBX4

A Encoder 1B Encoder 2

Connection with con‐necting cable fordirect encoder con‐nection

A Encoder 1B Encoder 2

Table 67: Facilities for connecting encoders

Designation Variant Part number

1 Connection cable with female and male con‐nector, primary connecting cable

2 m 2067798

10 m 2067799

2 Connection cable with male and male connec‐tor, extension cable

2 m 2067800

10 m 2067801

3 Connecting cable with female connector fordirect encoder connection

2 m 2067893

4 Encoder cable provided by the customer – –

5 Motor feedback splitter box FX3-EBX3 – 2068728

6 Dual encoder connection box FX3-EBX4 – 2068729

7 Optimized motor feedback splitter boxFX3-EBX1

– 2079867

Table 68: Cables and connection boxes for encoders

NOTEWe recommend using the connecting cables and connection boxes that are availableas accessories (see "Accessories", page 152).

Wire the signals as listed in the table below as appropriate for the type of encoder:



Signal 5) Incrementalencoder, 2pairs of out‐puts(HTL 24 V,TTL)

Incrementalencoder, 2outputs(HTL 24 V,TTL)

Incrementalencoder, 2pairs of out‐puts(RS-422)

Sine-cosine encoder SSI encoder

ENCx_C– – B– – – Clock–

ENCx_C+ – B+ – – Clock+

ENCx_B– B– GND – Sin_Ref Sin– –

ENCx_B+ B+ B – Sin Sin+ –

ENCx_A– A– GND A– Cos_Ref Cos– Data–

ENCx_A+ A+ A A+ Cos Cos+ Data+

ENC_0V GND connection for encoder

ENCx_24V 24 V power supply for encoder, available at FX3-MOC0 module

Uout On-board voltage output, can be switched between 5 V, 7 V, 12 V, and 24 V,available at FX3-EBX3 and FX3-EBX4 encoder connection boxes

Table 69: Wiring of encoder signals

5.4.9 Connection of a Flexi Link system

DANGERDo not use any buffering elements in a Flexi Link system.The use of buffering elements such as CAN bridges, CAN repeaters, or CAN-enabledoptical single-beam photoelectric safety switches is not permitted in a Flexi Link sys‐tem. Components other than Flexi Link stations are not generally allowed. Using compo‐nents other than Flexi Link stations would put the machine operator at risk.

There are two cabling options for a Flexi Link system:

• Connection via EFI1 (26 bits)• Connection via EFI1+2 (52 bits)

In both cases, the identically named terminals must be connected (e.g., EFI1_A at sta‐tion A to EFI1_B on station B, etc.).

5) “ENCx_” = “ENC_”, “ENC1_” or “ENC2_”



Figure 45: Connection of Flexi Link stations via EFI1+2

NOTE

• An external terminator is not required for the EFI connections at the main module.• Stub cables or star wiring are not permitted.• The maximum permissible total length of the cables for EFI1 and EFI2 (all sta‐

tions) is 100 m in each case.• Cables that are not in use must be connected to FE at both ends.• All connected Flexi Link stations must be connected to the same GND connection

of the power supply (terminal A2 at the system plug).• The maximum permissible voltage at the EFI inputs is ±30 V (to terminal A2 =

GND)

Flexi Link cables

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

Length of cable Type of cable

Up to 40 m 2 × 2 × 0.25 mm² (AWG 23)

Up to 100 m 2 × 2 × 0.34 mm² (AWG 22)

Table 70: Possible cable lengths and types for Flexi Link connections

SICK offers a suitable cable for connections up to 100 m (SICK part no. 6034249, soldby the meter, see "Accessories", page 152).

EMC measures

Important notes: see "EMC measures for Flexi Link and Flexi Line", page 82.



5.4.10 Connecting a Flexi Line system

DANGERDo not use any buffering elements in a Flexi Line system.The use of buffering elements such as CAN bridges, CAN repeaters, or CAN-enabledoptical single-beam photoelectric safety switches is not permitted in a Flexi Line sys‐tem. Components other than Flexi Line stations are not generally allowed. Using compo‐nents other than Flexi Link stations would put the machine operator at risk.

The stations in a Flexi Line system are interconnected as follows:

b Connect the NEXT connection on each station with the PRE connection on thenext station.

b Connect each of the identically named terminals, i.e., A to A and B to B.

Figure 46: Connection of a Flexi Line system

NOTE

• An external terminator is not required for the Flexi Line connections at the mainmodule.

• Stub cables or star wiring are not permitted.• Cables that are not in use must be connected to FE at both ends.• The maximum permissible voltage at the Flexi Line inputs is ±30 V (to terminal A2

= GND)

Flexi Line cables

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

Length of cable Type of cable

Up to 125 m 2 × 0.34 mm² (AWG 22)

Up to 1,000 m 2 × 0.75 mm² (AWG 18)

Table 71: Possible cable lengths and types for Flexi Line connections

SICK offers a suitable cable for connections up to 40 m (SICK part no. 6029448, soldby the meter, see "Accessories", page 152).

EMC measures

Important notes: see "EMC measures for Flexi Link and Flexi Line", page 82.



5.4.11 EMC measures for Flexi Link and Flexi Line

Flexi Link and Flexi Line cables are used for the transmission of communication signals.Electromagnetic interference can disrupt signal transmission and interrupt communica‐tion. The following measures are necessary to minimize electromagnetic interference:

b Ensure sufficient equipotential bonding of the connection points for the shielding.Ensure compliance with the applicable standards and directives.

b Connect all inactive metal parts (doors and housing of the control cabinet, DINmounting rails, etc.) to the ground potential.

b Always connect the cable shielding to the ground connection across a large areaat both ends.

b Use suitable cable clamps to connect the shielding of the shielded cables directlyto the ground potential direct at the access to the system (control cabinet, frame,DIN mounting rail). The cable clamps must reach all the way around the cableshielding.

b Use suitable cable clamps to connect the cable shielding to the ground potentialonce again as close as possible to the main module (e.g., on the DIN mountingrail). The cable clamps must reach all the way around the cable shielding.

Figure 47: Connect the cable shielding to the DIN mounting rail

1 DIN-Hutschiene2 Leitung3 Schrumpfschlauch

b Keep the cable ends from which the insulation has been stripped as short as pos‐sible.

b Use a suitable heat-shrinkable sleeve, for example, to insulate the end of theshielding braid.

NOTE

• All connections must be good conductors of electricity with low electrical impe‐dance. Stub cables or star EFI wiring are not permitted.

• Load cables (e.g., for frequency inverters, electronic speed controllers, contactors,brakes, etc.) and small-signal cables (e.g., measuring cables, analog sensors,fieldbus cables, etc.) must be laid separately and with low-induction coupling.



6 Configuration

DANGERCheck the safety function every time you make a change.If you change the configuration, you must subsequently check the effectiveness of thesafety function again. Follow the test instructions in the operating instructions for theconnected protective devices.

NOTETo configure the Flexi Soft system, you need the Flexi Soft Designer software and anFX3-MPL0 or FX3-MPL1 system plug.

• The system configuration for the entire Flexi Soft system (with the exception of theEFI-enabled devices) is stored in the system plug. This is beneficial when replacingexpansion modules, because it means that a full reconfiguration of the system isnot required.

• The Automatic Configuration Recovery (ACR) function can be used to detect andautomatically configure EFI-enabled devices of the same type following a replace‐ment, see "Automatic configuration recovery (ACR)", page 40

• The data saved in the system plug is retained even in the event of a power supplyfailure.

• Configuration information can be transmitted via the EFI interface.

NOTEIf two PCs set up TCP/IP connections via port 9000 of a Flexi Soft Ethernet gatewaywith one Flexi Soft main module in parallel, the Flexi Soft main module will only commu‐nicate via the connection set up most recently. As a result, the other PC sets up a fur‐ther connection without closing the connections established previously. There comes apoint in time at which there are too many open connections established via the gatewayto the PCs and only messages to maintain these open connections (known as keep-alive messages) are being exchanged on those PCs. This causes the Flexi Soft stationto switch to the lock-out state.

Configuration of connected devices

Devices which are connected to the safety controller are not generally configured andverified with the Flexi Soft safety controller configuration software. These devices havetheir own configuration and verification mechanisms.

For more information, see the operating instructions for the corresponding device.

Configuration of EFI-enabled devices

Devices connected to the Flexi Soft main module via EFI can be configured both locallyon the corresponding device and via the Flexi Soft system.

The following options are available:• Via the RS-232 interface of the Flexi Soft main module• Via the USB interface of the Flexi Soft main module (FX3-CPU3 and higher)• Via Ethernet (Flexi Soft EtherNet/IP gateway required, e.g., FX0-GENT)

You need the SICK CDS configuration and diagnostic software to configure and verifyEFI-enabled devices.

For more information, see the “Flexi Soft in the Flexi Soft Designer Software” operatinginstructions and the operating instructions for the corresponding device.

CONFIGURATION 6


7 Commissioning the hardware

DANGERThe hardware must not be commissioned unless it has been checked by qualifiedsafety personnel.Before the system in which you are using a Flexi Soft safety controller is put into opera‐tion for the first time, it must first be checked and approved by qualified safety person‐nel (this inspection and approval process must be recorded in writing).Check the hazardous area!Prior to commissioning, check that there is nobody inside the hazardous area.

b Check and secure the hazardous area to prevent entry (e.g., put up warning signs,erect barriers, etc.). Ensure compliance with statutory legislation and local regula‐tions.

7.1 Overall acceptance of the application

You are only permitted to put the system into operation if the overall acceptance proc‐ess was successful. Only trained specialists are permitted to deal with overall accept‐ance.

Overall acceptance comprises the following steps:

b Check that all safety-related parts of the system (wiring, connected sensors andcommand triggers, configuration) conform to the applicable safety standards (e.g.,EN 62061 or EN ISO 13849-1).

b Check the devices connected to the safety controller against the test instructionsin the corresponding operating instructions.

NOTESee the “Check prior to initial commissioning” section in each of the operating instruc‐tions for the electro-sensitive protective devices from SICK AG for more information.

b Clearly label all connections (connecting cables and plug connectors) on the safetycontroller to avoid confusion. Since the Flexi Soft system has more than one con‐nector of the same type, you must be sure that once connecting cables or plugconnectors have been unplugged, they are not reconnected in the wrong position.

b Check the signal paths and check for correct integration into higher-level control‐lers.

b Check for correct data transmission from and to the Flexi Soft safety controller.b Check the logic program for the safety controller.b Run a full validation of the safety function of the system in each operating mode

and simulate at least one error. Pay particular attention to the response times ofthe individual applications.

b Record the entire configuration process for the system and the individual devices,as well as the result of the safety inspection, in writing.

b To make it difficult to inadvertently overwrite the configuration, you can activatewrite protection for the configuration of the Flexi Soft system. Changes can thenonly be made if write protection has first been deactivated.

7.2 Checks before initial commissioning

Check the protective device as described below and in accordance with the applicablestandards and regulations.

7 COMMISSIONING THE HARDWARE


b Check the effectiveness of the safety function on the machine in all operatingmodes and functions in which the machine can be set.

b Ensure that all operators have been instructed by qualified safety personnelemployed by the machine user before they start working on a machine protectedby the safety controller. Instruction is the responsibility of the machine user.

COMMISSIONING THE HARDWARE 7


8 Operation

8.1 Status messages on the FX3-CPUx main module

Information about the positions of the LEDs on the FX3-CPU0 main module see figure25, page 46.

Information about the positions of the LEDs on the FX3-CPU1 and FX3-CPU2 main mod‐ules see figure 27, page 47.

Information about the positions of the LEDs on the FX3-CPU3 main module see figure28, page 48.

MS LED (all main modules)

MS LED Meaning Notes

Supply voltage out of range Switch on power supply and check at terminalsA1 and A2

Red/green (1 Hz)

Self-test in progress or sys‐tem initializing.

Please wait ...

Green(1 Hz)

System in Stop The application can be started from within theconfiguration software.

Green(2 Hz)

Identify (e.g., for Flexi Link) –

Green System in Run –

Red(1 Hz)

Invalid configuration Check module type and module version of mainmodule and expansion modules on which the MSLED is flashing red/green.Modify the configuration if necessary.Please use the diagnostic function in the configu‐ration software.

Red(2 Hz)

Serious error in the system,presumably in this module.The application was stopped.All outputs are switched off.

Switch the power supply off and then on again.If the problem still has not been remedied aftermultiple repetitions, replace this module.Please use the diagnostic function in the configu‐ration software.

Red Serious error in the system,presumably in a differentmodule. The application wasstopped. All outputs areswitched off.

Switch the power supply off and then on again.If the problem still has not been remedied afterrepeating this process multiple times, replace themodule showing red (2 Hz). If applicable, alsouse the diagnostic function in the configurationsoftware to isolate the affected module.

Table 72: MS LED

CV LED (all main modules)

CV LED Meaning Note

Configuration in progress. –

Yellow(2 Hz)

Saving configuration data inthe system plug (non-volatilememory)

Do not disconnect from power supply until saveprocess has been completed.

Yellow(1 Hz)

Unverified configuration Verify the configuration with the configurationsoftware.

Yellow Verified configuration –

Table 73: CV LED

8 OPERATION


EFI LEDs (FX3-CPU1 main module and higher)

LED EFI(EFI1 orEFI2)

Meaning Note

OK –

Red • Waiting for integration of EFI-enabled devi‐ces or Flexi Link station following power-up

• ACR execution (FX3-CPU2 and higher)

–

Red(1 Hz)

Error, e.g.,

• Expected EFI-enabled device or Flexi Linkstation not found within 3 minutes.

• Integration check failed

• Communication interrupted

• EFI device address conflict

• Flexi Link ID conflict

• ACR execution error, e. g., ACR integrationcheck failed, ACR transmission error (FX3-CPU2 and higher)

Check the wiring.Integration at a later dateremains possible at all times.

Red(2 Hz, EFI1and EFI2alternating)

Identify (e.g., for Flexi Link) –

Table 74: EFI LEDs

LINE LED (FX3-CPU3 main module and higher)

LINE LED Meaning

Flexi Line is not configured and not in operation.

Green Flexi Line in operation

Green (1 Hz) Flexi Line started, waiting for next station, orteach-in possible, e.g., after system modification

Green (2 Hz) Teach-in necessary

Red/green (2 Hz) Flexi Line configuration necessary

Red (1 Hz) Error on the Flexi Line bus, e.g., communication interrupted

Red Serious error, Flexi Line stopped

Table 75: LINE LED

8.2 Status messages for the FX3-XTIO I/O module

Information about the positions of the LEDs on the FX3-XTIO I/O module see figure 29,page 49.

OPERATION 8




Red/green (1 Hz)

With firmware V1.xx.0: invalidconfiguration

With firmware ≥ V2.00.0:remediable external error

Check cabling of the flashing inputs and outputs.If all output LEDs are flashing, check the supplyvoltage at terminals A1 and A2 of this module.

Green(1 Hz)


Green System in Run

Red(1 Hz)

With firmware V1.xx.0: reme‐diable external error

Check cabling of the flashing inputs and outputs.If all output LEDs are flashing, check the supplyvoltage at terminals A1 and A2 of this module.

With firmware ≥ V2.00.0:invalid configuration

Red(2 Hz)





Table 76: MS LED on the FX3-XTIO I/O module

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

Meaning

Input/output is deactivated.

Green Input/output is active.

Green (1 Hz) synchronized with the redMS LED

Input/output is deactivated and there is a remedi‐able error.

Green (1 Hz) alternating with the red MSLED

Input/output is active and there is a remediableerror.

Table 77: Input and output LEDs on the FX3-XTIO I/O module

NOTEThe LEDs indicate the state and are updated approx. every 64 ms.

8.3 Status messages for the FX3-XTDI I/O module

Information about the positions of the LEDs on the FX3-XTDI I/O module see figure 30,page 50.

8 OPERATION




Red/green (1 Hz)

With firmware V1.xx.0: invalidconfiguration

With firmware ≥ V2.00.0:remediable external error

Check cabling of the flashing inputs.If all output LEDs are flashing, check the supplyvoltage at terminals A1 and A2 of this module.

Green(1 Hz)


Green System in Run

Red(1 Hz)

With firmware V1.xx.0: reme‐diable external error

Check cabling of the flashing inputs

With firmware ≥ V2.00.0:invalid configuration

Red(2 Hz)

Serious error in the system,presumably in this module.The application was stopped.


Red Serious error in the system,presumably in a differentmodule. The application wasstopped.


Table 78: MS LED on the FX3-XTDI I/O module

Input LEDs (I1 … I8) Meaning

Input is deactivated.

Green Input is active.

Green (1 Hz) synchronized with the redMS LED

Input is deactivated and there is a remediableerror.


Input is active and there is a remediable error.

Table 79: Input LEDs on the FX3-XTDI I/O module


8.4 Status messages for the FX3-XTDS I/O module

Information about the positions of the LEDs on the FX3-XTDS I/O module see figure 31,page 50.

OPERATION 8




Red/green (1 Hz)

Remediable external error Check cabling of the flashing inputs and outputs.If all output LEDs are flashing, check the supplyvoltage at terminals A1 and A2 of this module.

Green(1 Hz)


Green System in Run

Red(1 Hz)

Invalid configuration

Red(2 Hz)





Table 80: MS LED on the FX3-XTDS I/O module

Input LEDs (I1 … I8)Output LEDs (XY1, XY2, and Y3 … Y6)

Meaning



Green (1 Hz) synchronized with the red MSLED

Input/output is deactivated and there is aremediable error.


Input/output is active and there is a remedia‐ble error.

Table 81: Input and output LEDs on the FX3-XTDS I/O module


8.5 Status messages for the FX0-STIO I/O module

Information about the positions of the LEDs on the FX0-STIO I/O module see figure 32,page 51.

8 OPERATION




Red/green (1 Hz)

Remediable external error Check cabling of the flashing inputs and outputs.If all output LEDs are flashing, check the supplyvoltage at terminals A1 and A2 of this module.

Green(1 Hz)


Green System in Run

Red(1 Hz)


Red(2 Hz)





Table 82: MS LED on the FX0-STIO I/O module

Input LEDs (I1 … I6)Output LEDs (Y1 … Y6)Input/output LEDs (IY7, IY8)

Meaning



Green (1 Hz) synchronized with the red MSLED

Input/output is deactivated and there is aremediable error.


Input/output is active and there is a remedia‐ble error.

Table 83: Input/output LEDs on the FX0-STIO I/O module


8.6 Status messages for the Drive Monitor FX3-MOC0

Information on the position of the LEDs on the Drive Monitor FX3-MOC0 see figure 33,page 52.

OPERATION 8



Supply voltage out of range Switch on power supply at main module andcheck at terminals A1 and A2

Red/green (1 Hz)

Remediable external error Check the encoder signals.Please use the diagnostic function in the configu‐ration software.

Green(1 Hz)


Green System in Run

Red(1 Hz)


Red(2 Hz)





Table 84: MS LED on the Drive Monitor FX3-MOC0

8.7 Status messages for the UE410-2RO and UE410-4RO relay output modules

Information about the positions of the LEDs on the UE410-2RO and UE410-4RO relayoutput modules see figure 34, page 60 and see figure 35, page 60.

LED display Meaning

PWR (green) Supply voltage via safety bus on.

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

K3/4 (green) Relay K1/K2 – safety contacts closed (on the UE410-4RO only)

Table 85: LEDs on the UE410-2RO and UE410-4RO relay output modules

8 OPERATION


9 Maintenance

This section provides information about regular checks and the replacement of FlexiSoft modules.

Do not attempt to remove, repair, or modify the Flexi Soft modules. This can lead to theloss of the safety function(s). It will also invalidate any warranty claims against SICK AG.

9.1 Regular thorough check of the safety function by qualified safety personnel

b Check the system following the inspection intervals specified in the national rulesand regulations. This procedure ensures that any changes to the machine or tam‐pering with the protective device are detected after initial commissioning.

b Every safety application must be checked at fixed intervals you define. The effec‐tiveness of the safety function must be checked by qualified and authorized per‐sonnel.

b If changes have been made to the machine or safety function or if the safety con‐troller has undergone retrofitting or repair work, e.g., if a module has beenreplaced, re-inspect the system using the checklist in the Appendix.

b Carry out regular inspections in order to keep the Flexi Soft modules in perfectworking order.

b Check that the implementation of the Flexi Soft modules complies with all techni‐cal data.

b Check the mounting conditions and check that the Flexi Soft module wiring is cor‐rect.

b To ensure their reliability, check at regular intervals that the safety functions aremeeting the requirements of the application as well as all applicable regulationsand standards (e.g., regular thorough check).

9.2 Device replacement

A serious error in a Flexi Soft module will affect the entire network. Therefore, devicesaffected by serious errors must be repaired or replaced quickly. We recommend keep‐ing a stock of spare Flexi Soft modules so that network operation can be restored asquickly as possible.

Follow the instructions for mounting and removing the Flexi Soft modules, see "Mount‐ing", page 42 and see "How to dismantle the modules", page 107.

Safety measures for device replacement

Please note the following safety measures when replacing Flexi Soft modules:

• Do not attempt to break up or repair the Flexi Soft modules. In addition to invalid‐ating any warranty claims against SICK AG, this is also dangerous, since there isno way of checking the original safety function.

• Restore the device to a safe state.• Before replacing a device, always disconnect the power supply in order to prevent

electric shock or unexpected device behavior.• To continue to be able to use the system configuration, check:

° Is the new module of the same type (same part number) and are there noerrors affecting the module following replacement?

° Has the new module been plugged in in the same position as the modulethat has been replaced?

° Have all plug connectors been reconnected in the correct positions?• Otherwise you will have to completely reconfigure and commission the new sys‐

tem, including carrying out all necessary thorough checks (see "Commissioningthe hardware", page 84).

MAINTENANCE 9


NOTE

• Following replacement, check that no errors are occurring with the new Flexi Softmodules.

• Always carry out a function test before commissioning a replacement module.• EFI-enabled devices do not have to be reconfigured once a Flexi Soft module has

been replaced.• If you want to send in a Flexi Soft module for repair, start by generating a report for

your project in the configuration software which includes the diagnostic messagesfor the Flexi Soft system. Send this report, along with the Flexi Soft module con‐cerned and a detailed description of the problem, to SICK, including all availableinformation.

• If you send in an FX3-MPL0 or FX3-MPL1 system plug for repair or analysis, it willbe sent back to you in its original state on delivery, i.e., with a blank configuration.Therefore, you should save your configuration as project files (use the configura‐tion software to do this).

9 MAINTENANCE


10 Diagnostics

10.1 Response to errors

DANGERCease operation if the cause of the malfunction has not been clearly identified.Immediately stop machine operation if you cannot clearly identify the fault and if youcannot safely remedy the problem.Check after troubleshootingAfter remedying an error, analyze the effect(s) and check all affected safety functions.

10.2 Error states

The Flexi Soft safety controller will respond to certain malfunctions or configurationerrors by switching to the safe state. The LEDs on the individual modules of the safetycontroller indicate the corresponding error state.

The error state will vary depending on the nature of the error:

Configuration error

• The system is in the Configuration required state (MS LED red (1 Hz)).• The applications in all modules are in the Stop state.• All safe outputs of the system are switched off.• All safe process data is set to zero. The non-safety-related process data is typically

also set to zero.

Remediable error

• The applications in all modules remain in the Run state (MS LED on the affectedmodules = alternate red/green (1 Hz), MS LED on modules that are notaffected = green).

• If safe outputs of the system are affected, they are switched off as a minimum.• If safe inputs are affected, the process data of these safe inputs is set to zero as a

minimum.

Serious error

• The system is in the Serious error state (MS LED on the module that has detectedthe serious error = red (2 Hz). MS LED on the modules on which the cause ofthe error is unknown = red).

• The applications in all modules are in the Stop state.• All safe outputs of the system are switched off.• All safe process data is set to zero. The non-safety-related process data is typically

also set to zero.

To put the device back into operation:b Remedy the cause of the error based on the MS, CV, and EFI LED displays.b In the event of serious errors, switch the power supply to the Flexi Soft system off

for at least 3 seconds and then switch it back on again.

DIAGNOSTICS 10


10.3 Error displays shown by status LEDs, error messages, and troubleshooting meas‐ures

The most important error codes, possible causes, and possible troubleshooting meas‐ures are listed in this chapter. These error messages can be displayed with the diagnos‐tics function of the configuration software if you have established a connection to theFlexi Soft system.

NOTE

• You will find information about how to carry out diagnostics in the “Diagnosticsview” chapter of the “Flexi Soft in the Flexi Soft Designer Software” operatinginstructions.

• Error displays and troubleshooting for the individual modules are described in thesections on the corresponding modules (see "Status messages on the FX3-CPUxmain module", page 86 to see "Status messages for the UE410-2RO andUE410-4RO relay output modules", page 92).

10 DIAGNOSTICS


LED display on the module Possible errorcodes

Possible causes Possible measures

Main module(FX3-CPUx)

Expansionmodule (FX3-XTIO, -XTDI, -XTDS, -MOC0,FX0-STIO)

MS = red(1 Hz)

All expansionmodules:MS = red(1 Hz) (firm‐ware≥ V2.00.0)orMS = red/green (1 Hz)(firmwareV1.xx.0)

Main module:0x000E4006,0x00160005,0x000F0013

The configuration in the system plugis incompatible, because it isintended for a different type of mainmodule:

• The system plug has been pre‐viously used in a system with adifferent type of main module(e.g., FX3-CPU0 instead ofFX3-CPU1, or vice versa).

• An incorrect main module hasbeen used in the hardwareinstallation.

• Transfer a configuration withthe same type of main moduleas in the hardware installation.

• Replace the main module inthe hardware installation witha main module of the sametype as in the project file.

Main module:0x00170005,0x000F0013

The configuration in the system plugis incompatible, because it isintended for more recent firmwareversion of the main module:

• The system plug has been con‐figured for an incompatiblemore recent firmware versionof the main module (e.g.,V2.00.0 instead of V1.11.0).

• An older firmware version ofthe main module has beenused in the hardware installa‐tion.

• Transfer a configuration withthe same or an older firmwareversion (e.g, V1.xx.0 instead ofV2.xx.0).

• Replace the main module inthe hardware installation witha module with a more recentor identical firmware versionas in the project file.

Main module:0x000E4013,0x00274006

The configuration in the system plugis incompatible with at least oneexpansion module:

• An expansion module is miss‐ing in the hardware installa‐tion.

• Transfer a configuration with asuitable number of expansionmodules.

• Add the missing expansionmodule to the hardware instal‐lation.

Main module:0x000E0006,0x0005000DFX3-XTIO/-XTDI:0x4901,0x4904

The configuration in the system plugis invalid:

• The last configuration opera‐tion was not completed suc‐cessfully, e.g., because thepower supply was switched offbefore the write operation tothe system plug was com‐pleted.

• Hardware error in system plug

• The system plug is empty (con‐dition on delivery).

• Transfer the configurationagain and make sure that thepower supply at the main mod‐ule remains switched on untilthe transfer operation is com‐plete.

• Replace the system plug andtransfer the configurationagain.

Table 86: Error codes and error messages in the Flexi Soft system and possible troubleshooting measures

DIAGNOSTICS 10






MS = red(1 Hz)EFI = red(1 Hz)

One or moreexpansionmodules:MS = red(1 Hz) (firm‐ware≥ V2.00.0)orMS = red/green (1 Hz)(firmwareV1.xx.0)

Main module:0x0014000A

If FX3-CPU1: EFI device addressconflict:

• At least 2 main modules withthe same EFI address are con‐nected.

• Change the EFI address of themain module or the connecteddevice in the configurationsoftware.

Main module:0x0015000A

If FX3-CPU1 and Flexi Link: incorrectFlexi Link ID:

• EFI1 and EFI2 were mixed upduring wiring.

• At least 1 main module withan incorrect Flexi Link ID isconnected.

• Check the wiring between theFlexi Link stations: EFI1 mustbe connected to EFI1 and, ifapplicable, EFI2 to EFI2.

• Connect Flexi Link stationswith correct IDs.

• Transfer the configuration toall Flexi Link stations with thesame Flexi Link IDs.

Main module:0x001F0006,0x00230006,0x00234006,0x001F4006

The configuration in the system plugis incompatible with at least oneexpansion module:

• Incorrect module type or incor‐rect module version (MS LEDon module is flashing red orred/green).

• Too many expansion modulesare connected. (MS LED onmodule is flashing red or red/green.)

• Expansion modules are miss‐ing. (MS LEDs on all othermodules are flashing red orred/green.)

• Transfer a configuration withthe same module type and thesame or an older firmware ver‐sion of all expansion modules.

• Replace the expansion moduleaffected in the hardwareinstallation with a module ofthe same type and a firmwareversion that is older than oridentical to the one in theproject file.

MS = green (1 Hz)CV = yel‐low (1 Hz)

MS = green (1 Hz)

– The system is in the Stop state(ready for operation).

The application can be started fromwithin the configuration software.For automatic starting followingpower-up, the project must be veri‐fied with the configuration software.

MS = green (1 Hz)CV = yel‐low

MS = green (1 Hz)

– The system is in the Stop state(ready for operation).

The application can be started fromwithin the configuration software.

MS = green

MS = green

– The system is in operation. Noerrors detected.

–


10 DIAGNOSTICS






MS = green

One or moreexpansionmodules:MS = red/green (1 Hz)(firmware≥ V2.00.0)orMS = red(1 Hz) (firm‐ware V1.xx.0)andQ1 + Q2 + Q3+ Q4 = green (1 Hz)

FX3-XTIO:0x4804,0x4806,0x4807

The supply voltage of an FX3-XTIOmodule is too low or is missing.

Check the power supply at terminalsA1 (24 V) and A2 (GND) on the FX3-XTIO module, including under worst-case conditions.The error is reset automatically afterapprox. 8 seconds if its cause is nolonger present.

MS = green One or moreexpansionmodules:MS = red/green (1 Hz)(firmware≥ V2.00.0)orMS = red(1 Hz) (firm‐ware V1.xx.0)andQ1 or Q2 orQ3 or Q4 = green (1 Hz)

FX3-XTIO:0x4701,0x4702,0x4704.0x4705

• Short-circuit to 24 V or cross-circuit in the wiring of the safeoutput Q1 to Q4 (associatedLED is flashing)

• Capacitive load exceeds per‐missible maximum value (e.g.,due to spark quenching capac‐itor).

• Inductive load exceeds permis‐sible maximum value.

• Internal hardware in FX3-XTIOmodule

• Short-circuit to GND in the wir‐ing of the safe output Q1 to Q4(associated LED is flashing)

• Power supply at FX3-XTIO mod‐ule interrupted briefly

• Check the wiring of theaffected output.

• Check the capacitive load.

• Check the inductive load.

• Replace the FX3-XTIO module.

To reset the error, all outputs of theaffected module must be switchedoff by the logic of the main moduleby switching off the associated inputsignals (e.g., emergency stop). It cantake up to 8 seconds to reset theerror. Alternatively, reset the voltageat the main module.


DIAGNOSTICS 10






MS = green One or moreexpansionmodules:MS = red/green (1 Hz)(firmware≥ V2.00.0)orMS = red(1 Hz) (firm‐ware V1.xx.0)andI1 or I2 or I3or I4 or I5 orI6 or I7 or I8 = green(1 Hz)

FX3-XTIO/-XTDI:0x4601

Inputs connected to a test output:

• Short-circuit to 24 V or cross-circuit in the wiring of testedsensors:

° a) Short-circuit to 24 V orcross-circuit in the wiringof X1, X2, … or X8 to atactile switch or to a testinput of a testable input

° b) Short-circuit to 24 V orcross-circuit in the wiringof a tactile switch or anoutput of a testable sen‐sor to I1, I2, … or I8

• Defective testable sensor

• Cable break in the wiring of apressure-sensitive safety mat:

° a) Cable break in the wir‐ing of X1, X2, … or X8 tothe pressure-sensitivesafety mat

° b) Cable break in the wir‐ing from the pressure-sensitive safety mat toI1, I2, … or I8

• Defective pressure-sensitivesafety mat

• Check the wiring of theaffected input.

• Replace the testable sensor.

To reset the error, switch off theaffected input (input state Low/Lowfor equivalent dual-channel inputs,Low/High for complementary dual-channel inputs) or reset the voltageat the main module.


10 DIAGNOSTICS






MS = green One or moreexpansionmodules:MS = red/green (1 Hz)(firmware≥ V2.00.0)orMS = red(1 Hz) (firm‐ware V1.xx.0)andI1 + I2 or I3 +I4 or I5 + I6 orI7 + I8 = green (1 Hz)

FX3-XTIO/-XTDI:0x4429 or0x442A

Discrepancy error or sequence errorat dual-channel inputs (associatedLEDs flashing green):

• Cable break or short-circuit toGND at one of the two inputsignals of the input pair

• Sensor hardware error (e.g., isone of the two contacts/outputs permanently closed(High) or open (Low)).

• Defective sensor (one of thetwo signals is not switching toa state corresponding to theother input within the config‐ured discrepancy time).

• The safety door opened orclosed too slowly; as a result,both contact switches (e.g.,reed contacts) did not switchwithin the configured discrep‐ancy time.

• Only one of the two inputs trig‐gered the switch-off conditionand then switched back to theON state, while the value ofthe other input did not changeat all (sequence error).

• Check the wiring of theaffected input and check theswitching capacity of the twocontacts/outputs of the con‐nected sensor.

• Check the mechanical depend‐ence of the two switches.

• Replace the switch/sensor inthe hardware installation.

To reset the error, the affected inputpair must be Low/Low in the case ofequivalent dual-channel inputs andLow/High in the case of complemen‐tary dual-channel inputs.

MS = red MS = red Main module:0xXXXCXXXXExpansion mod‐ules: 0xCXXX(X = randomvalue)

• Power supply GND at the FX3-XTIO module is missing (onlywith firmware V1.xx.0).

• Internal error in the expansionmodule

• Internal error in the main mod‐ule

• Check the connection from ter‐minal A2 on the FX3-XTIO mod‐ules to the power supply GND.

• Check the system for electro‐magnetic interference (ground‐ing of the DIN mounting rail,etc.).

• To reset the error, reset thevoltage at the main module.

• If the error persists, replacethe modules.

MS = red MS = red(2 Hz) (firm‐ware≥ V2.00.0)

Main module:0xXXXCXXXXExpansion mod‐ules: 0xCXXX(X = randomvalue)

Internal error in the expansion mod‐ule (associated MS LED flashing)



• If the error persists, replacethe module on which the MSLED is flashing.


DIAGNOSTICS 10






MS = red(2 Hz) (firm‐ware≥ V2.00.0)

MS = red Main module:0xXXXCXXXXExpansion mod‐ules: 0xCXXX(X = randomvalue)

Internal error in the main module orin the system



• If the error persists, replacethe main module followed bythe expansion modules.

MS = red or red (2 Hz)

MS = red or red (2 Hz)

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

• Consequential error further toanother serious error

• Fault affecting the internal sig‐nals of the main modulecaused by significant electro‐magnetic interference

• Hardware error in the mainmodule or in an expansionmodule

• Check the other diagnosticmessages for serious errorswith a very similar time stamp.


• If the error persists, replacethe main module followed bythe expansion modules.

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

• FLEXBUS+ communication(backplane bus communica‐tion with I/O modules andgateways) faulty due to electro‐magnetic interference

• FLEXBUS+ communication(backplane bus communica‐tion with I/O modules andgateways) faulty due to a seri‐ous error in I/O modules. Thisis a consequential error andthere are other messagesrelating to serious errors with avery similar time stamp (±1 s)in the diagnostic history.


• Check the system with regardto electromagnetic interfer‐ence (FE connection for DINmounting rail and control cabi‐net, star wiring of the 24 Vpower supply, local isolation ofload and control elements,etc.).

• Check the other diagnosticmessages with a very similartime stamp.

Main module:0x002AC006

Incompatible input data from theexpansion module:

• A dual-channel input at anFX3-XTIO or FX3-XTDI modulehas two signal dips (High toLow) within 2 s (e.g., test gapsof an OSSD output or bouncingrelay contacts).

• A signal input at an FX3-XTIOor FX3-XTDI module changesits state in 4 ms intervals dur‐ing a period of 40 ms or more(e.g., proximity switch at a gearwheel).


• Change the configuration byactivating the on-off filter andthe on-off filter for the inputsof the FX3-XTIO or FX3-XTDImodule concerned. Pleasenote that this extends theresponse time for this signalby at least 8 ms.


10 DIAGNOSTICS






MS = red or red (2 Hz)(continued)

MS = red or red (2 Hz)(continued)

FX3-XTIO/-XTDI:0xC306Main module:0x0029C006

• Internal hardware in FX3-XTIOor FX3-XTDI module

• Consequential error on mainmodule: 0x0029C006


• Replace the FX3-XTIO or FX3-XTDI module in the hardwareinstallation.


• Power supply at terminal A2(GND) of the FX3-XTIO moduleinterrupted

• Internal hardware in FX3-XTIOor FX3-XTDI module


• Check the supply voltage atterminals A1 (24 V) and A2(GND) on the FX3-XTIO mod‐ule, including under worst-case conditions.


• If the error persists, replacethe FX3-XTIO or FX3-XTDI mod‐ule in the hardware installa‐tion.


• Short-circuit to 24 V or cross-circuit in the wiring of the safeoutput Q1 to Q4 (associatedLED is flashing)

• Capacitive load exceeds per‐missible maximum value (e.g.,due to spark quenching capac‐itor).

• Inductive load exceeds permis‐sible maximum value.

• Internal hardware in FX3-XTIOmodule


• Check the wiring of theaffected output.

• Check the capacitive load.

• Check the inductive load.


• If the error persists, replacethe FX3-XTIO module in thehardware installation.


DIAGNOSTICS 10






MS = green All expansionmodules:MS = green

Main module:0x000A0011

• Function block error duringdual-channel input evaluation(e.g., emergency stop, solenoidswitch): discrepancy error atinput pair 1 of the functionblock

• Cable break or short-circuit toGND at one of the two inputsignals of the input pair

• Sensor hardware error (e.g., isone of the two contacts/outputs permanently closed(High) or open (Low)).

• Defective sensor (one of thetwo signals is not switching toa state corresponding to theother input within the config‐ured discrepancy time).

• The safety door opened orclosed too slowly; as a result,both contact switches (e.g.,reed contacts) did not switchwithin the configured discrep‐ancy time.

• Check the wiring of theaffected input and check theswitching capacity of the twocontacts/outputs of the con‐nected sensor.

• Check the mechanical depend‐ence of the two switches.

• Replace the switch/sensor inthe hardware installation.

To reset the error, the affected inputpair must switch from Low/Low toHigh/High in the case of equivalentdual-channel inputs and from Low/High to High/Low in the case ofcomplementary dual-channel inputswithin the configured discrepancytime.

Main module0x00100011

• Function block error (externaldevice monitoring or valvemonitoring): The feedback sig‐nal was not sent in responseto the control signal within themaximum feedback delaytime.

• Hardware error affecting theconnected relay/valve or errorin the wiring

• The relay/valve used has alonger switching delay at themonitoring contact.

• Increase the maximum feed‐back delay time for the func‐tion block if this is compatiblewith your application.

• Replace the relay/valve in thehardware installation.


10 DIAGNOSTICS






All LEDs brieflyoff, then LEDtest sequence

All LEDs brieflyoff, then LEDtest sequence

Main module:0x002D4006

• The power supply to the mainmodule was affected by a briefvoltage dip (almost to 0 V).

• The voltage of the voltage sup‐ply to the main module drop‐ped (to between approx. 6 Vand 16 V) and then rose backinto the operating range.

• Ensure that the power supplyunit is able to jumper an inter‐ruption in the power supplylasting up to 20 ms.

• Ensure that the power supplyunit is able to operate the loadso that load switching cannotcause the voltage to drop.

• Check the wiring of the powersupply to the main module.Use separate cables to otherheavy loads in order to avoid avoltage dip on the supply cablecaused by other load currents.

Main module:0x003E4006

The system has performed a restartdue to faults occurring on the FLEX‐BUS+:

• FLEXBUS+ communication(backplane bus communica‐tion with I/O modules andgateways) faulty due to electro‐magnetic interference

• FLEXBUS+ communication(backplane bus communica‐tion with I/O modules andgateways) faulty due to a seri‐ous error in an expansion mod‐ule (I/O module or gateway).This is a consequential errorand there are other messagesrelating to serious errors with avery similar time stamp (±1 s)in the diagnostic history.

• Check the system with regardto electromagnetic interfer‐ence (FE connection for DINmounting rail and control cabi‐net, star wiring of the powersupply (24 V and GND), localisolation of load and controlelements, etc.).

• Check the other diagnosticmessages with a very similartime stamp.


10.4 Additional error displays for EFI-enabled devices

EFI-enabled devices (see "Enhanced Function Interface (EFI)", page 36) supportadvanced functions in conjunction with the FX3-CPU1, FX3-CPU2, or FX3-CPU3 mainmodule. Error displays and troubleshooting are described in the operating instructionsfor the corresponding devices.

10.5 Error history

The diagnostic function in the configuration software enables you export the error his‐tory from the Flexi Soft system for subsequent saving or printing in a report in PDF for‐mat. For more detailed information, see the “Flexi Soft in the Flexi Soft Designer Soft‐ware” operating instructions.

DIAGNOSTICS 10


10.6 SICK support

If you cannot remedy an error with the help of the information in the relevant Flexi Softoperating instructions, please contact your SICK subsidiary.

10 DIAGNOSTICS


11 Decommissioning

11.1 How to dismantle the modules

Figure 48: Unplug the plug-in terminals.

b Remove the plug-in terminals including the wiring and the end pieces.

Figure 49: Disconnect the plug connectors.

b If multiple modules are present, slide each of the modules apart in the direction ofthe arrow until the side-mounted plug connector unlocks.

DECOMMISSIONING 11


Figure 50: Remove the modules from the DIN mounting rail

b Press the module down at the rear (1) and remove it from the mounting rail (2)in the direction of the arrow while keeping it pressed down.

NOTEFor information about mounting and removing the encoder connection boxes, see themounting instructions for the encoder boxes at www.sick.com.

11.2 Disposal

Always dispose of unusable or irreparable devices in accordance with the applicablewaste disposal regulations specific to your country (e.g., European waste disposal code16 02 14).

NOTEWe will be glad to help you dispose of these devices. Please contact us.

11.3 Separation of materials

DANGEROnly qualified safety personnel are permitted to separate materials.Exercise caution when dismantling devices. There is a risk of injury.

Before the devices can be submitted for environmentally-friendly recycling, the variousmaterials of which the Flexi Soft safety controller is comprised must be separated.

b Separate the housing from the rest of the components (in particular from theprinted circuit board).

b Submit the separated components for recycling as appropriate (see the tablebelow).

Components Disposal

Housing Plastics recycling

Printed circuit boards, cables, male connec‐tors, and electrical connectors

Electronics recycling

Packaging Paper/cardboard recycling

Table 87: Overview of component disposal

11 DECOMMISSIONING


http://www.sick.com

12 Technical data

12.1 Response times of the Flexi Soft system

All paths must be taken into account when calculating the response times in a FlexiSoft system.

Figure 51: Response times within a Flexi Soft system

Fast shut-off

The fast shut-off function is supported on FX3-XTIO I/O modules. This function enablesa response time of 8 ms to be achieved.

NOTEThe fast shut-off function can only be applied to inputs and outputs on the same FX3-XTIO I/O module.

Flexi Link

In a Flexi Link system, the response time for a remote input compared to a local inputincreases by 4.5 ms + 2 × logic execution time of the Flexi Link station on which theremote input is located.

Flexi Line

In the case of an input on a remote station, the response time in a Flexi Line systemincreases by

• The input time of the remote station (see table 89, page 111 to see table 96,page 114),

• The response time of the logic of the station processing this input (see table 88,page 111: point 2.a)

TECHNICAL DATA 12


and

• N × (10 ms + 2 × send cycle time)where N = the number of connection paths between the stations.

Using the Flexi Line solution within a station increases the response time by one logicexecution time of this station.

Optimization of logic execution time

Flexi Soft main modules with firmware ≥ V4.00.0 have firmware optimizations whichcan affect the logic execution time. For compatibility with older models, these optimiza‐tions can be activated and/or deactivated by the user.

Activate the Optimization of logic execution time option in Flexi Soft Designer and deactivatefunctions you are not using (Flexi Line, Flexi Loop, EFI including Flexi Link) to use thehigher performance capability of this firmware.

When optimization is activated, the logic program is executed more quickly in the mainmodule. This can reduce the logic execution time. In complex applications in particular,this reduces the processing time and thus also the response time.

NOTEThe minimum logic execution time of a Flexi Soft system is always 4 ms. It cannot bereduced further by means of optimization.Changes to the logic execution time can mean that changes have to be made to theconfiguration of the function blocks that are based on the logic execution time.In order to be able to use the optimization of the logic execution time, you need an FX3-CPUx main module with firmware ≥ V4.00.0 (Step 4.xx) and the Flexi Soft Designer ver‐sion ≥ V1.7.1.

For more information about optimizing the logic execution time, see the “Flexi Soft inthe Flexi Soft Designer Software” operating instructions.

12.1.1 Calculation of the response time

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

12 TECHNICAL DATA


1. Inputs Response time of the inputunder consideration on thesignal path

E1 or E2 or E3 or E4 (fromtable below)

2. Logic a) Response time of thelogic of the main module(FX3-CPUx logic)

2 × logic execution time 1)

Delay due to logic applica‐tion 2) (e.g., function blockswitch-on delay or switch-offdelay)

b) Response time for rout‐ing (only affects A3 outputto gateway)

No delay 0 ms

c) Response time of thefast shut-off logic (onlyapplicable for FX3-XTIOmodules)

No delay 0 ms

3. Outputs Response time of the outputunder consideration on thesignal path

A1 or A2 or A3 or A4 (fromtable below)

Total response time

Table 88: Calculation of the response time of the Flexi Soft system in ms

1) Take the values from the report in the configuration software.2) Time values have a tolerance of 10 ms in addition to the logic execution time; i.e., 10 ms must be added

to each selected value in order to calculate the response time. For example, in the case of a switch-offdelay of 10 ms and a logic execution time of 12 ms, 32 ms must be used for the calculation.

Digital inputs (E1)

General informa‐tion

Sensor response time 1)


Input processing time 6.5 ms

If on/off filteractive

+ min. filter time 2)

If I1 … I8 con‐nected to testinput X1 … X8

+ max. OFF-ON delay 3) of the test input used

a) Pressure-sensitive safetymats andbumpers

+ test period 3) of the test output, higher value of the twotest outputs

b) Type 4 test‐able sensors(e.g., L41)

+ test period 3) of the test output

c) All other sen‐sors

+ test gap 3) of the test output(if test gap 3) > 1 ms)

Total E1

Table 89: Calculation of the response time for the digital inputs (E1) in ms

1) Take the values from the corresponding operating instructions.2) Switching off is delayed until the signal has been at Low for at least the selected filter time. For FX3-XTIO

and FX3-XTDI firmware version < V3.00.0, the filter time is set to a fixed value of 8 ms.3) Take the values from the report in the configuration software.

TECHNICAL DATA 12


Digital outputs (A1)


Response time of the actuator 1)


Output processing timea) From the logic (via FLEXBUS+): + 4.5 msb) From fast shut-off: + 1.5 ms

If you are usingsingle-channeloutputs

Potential switch-off delay in the event of an internal error,depending on whether an extended error detection time hasbeen configured for the switching of capacitive loads:+ 10 ms or + 50 ms 2)

Total A1

Table 90: Calculation of the response time for the digital outputs (A1) in ms

1) Take the values from the corresponding operating instructions.2) see "Extended error detection time for cross-circuits at outputs Q1 to Q4 on the FX3-XTIO for the switch‐

ing of increased capacitive loads", page 25 and see "Use of single-channel outputs on the FX3-XTIO",page 26.

Input from an EFI-enabled device (E2)

If EFI functionsare used via EFI-enabled devices

Response time of the EFI data source (usually a sensor) forexternal OSSDs via EFI 1) or remote Flexi Link station

Constant:

a) Scanner(e.g., S3000)

+ 3.5 ms

b) Light curtain(e.g., C4000)

+ 1.5 ms

c) Flexi Link + 0.5 ms

Total E2

Table 91: Calculation of the response time for the input from an EFI-enabled device (E2) in ms

1) Take the values from the corresponding operating instructions.

Output to an EFI-enabled device (A2)


Response time of the EFI data receiver (e.g., scanner withprotective field switching via EFI) 1)

Constant: EFI cycle time of the EFI data receiver1)

a) Scanner(e.g., S3000)

+ 24 ms

b) Light curtain(e.g., C4000)

+ 4 ms

c) Flexi Link + 4 ms

Total A2

Table 92: Calculation of the response time for the output of an EFI-enabled device (A2) in ms

1) Take the values from the corresponding operating instructions.

12 TECHNICAL DATA


Input from a gateway (E3)


Fieldbus response time for data to the gateway(e.g., from PLC) 1)


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

a) With Ether‐CAT gateway

– 3 ms

b) With anothergateway

+ 5 ms

With 2 gateways – 4 ms

Total E3

Table 93: Calculation of the response time for the input from a gateway (E3) in ms

1) Take the values from the corresponding operating instructions.2) The update interval between the main module and a Flexi Soft gateway depends on the volume of data to

be transmitted and the number of gateways in the system. Take the values from the report in the configu‐ration software. The update interval is a multiple of 4 ms for every 10 bytes to be transmitted to or fromthe gateway, if the system has a gateway. If you are using two gateways, the update interval is a multipleof 8 ms.

Output to a gateway (A3)


Fieldbus response time for data from the gateway(e.g., to the PLC) 1)


2 × internal update interval for data from the main moduleto the gateway 2)

a) With Ether‐CAT gateway

0 ms

b) With anothergateway

+ 8 ms

With 2 gateways – 4 ms

Total A3

Table 94: Calculation of the response time for the output to a gateway (A3) in ms

1) Take the values from the corresponding operating instructions.2) The update interval between the main module and a Flexi Soft gateway depends on the volume of data to

be transmitted and the number of gateways in the system. Take the values from the report in the configu‐ration software. The update interval is a multiple of 4 ms for every 10 bytes to be transmitted to or fromthe gateway, if the system has a gateway. If you are using two gateways, the update interval is a multipleof 8 ms.

TECHNICAL DATA 12


Input from an FX3-MOCx (E4)


FX3-MOCx logic to FX3-CPUx logic 0 ms

Encoder to FX3-MOCx logic

a) Incrementalencoder, sine-cosine encoder(speed valueand directionstatus)

Max. 8 ms 1)

b) Incrementalencoder, sine-cosine encoder(position value)

Max. 6 ms

c) SSI master(speed valueand directionstatus)

Max. 4 ms + 1.5 x max. data receive interval 1) 2)

d) SSI master(position value)

Max. 4 ms + max. data receive interval 2)

e) SSI listener(speed valueand directionstatus)

Max. 9 ms + 1.5 x max. data receive interval 1) 2)

f) SSI listener(position value)

Max. 9 ms + max. data receive interval 2)

Total E4

Table 95: Calculation of the response time for the input from an FX3-MOCx (E4) in ms

1) Since the speed is calculated from the position difference between two detected position values, thespeed value is an average of the actual speed within the time interval for position detection. In the caseof a hypothetical linear speed change, therefore, the response time time for the speed value is greaterthan the response time for the position value by ½ the time interval for position detection. In the case ofincremental encoders and sine-cosine encoders, the time interval for position detection is 4 ms; for SSIencoders in the worst-case scenario it is the selected maximum data receive interval.

2) This is the selected value in the dialog box for the SSI encoder. Take the value from the report in theconfiguration software.

Output to an FX3-MOCx (A4)


FX3-CPUx logic to FX3-MOCx logic Max. 4 ms

Total A4

Table 96: Calculation of the response time for the output to an FX3-MOCx (A4) in ms

12.1.1.1 Example 1: Calculation of the response time for a Flexi Soft system consisting of an FX3-CPU1 andan FX3-XTIO

Digital inputs (E1): C4000 safety light curtain at FX3-XTIO (e.g., at I5/I6)

Digital outputs (A1): Robot, dual-channel, at FX3-XTIO (e.g., at Q3/Q4)

Input of EFI-enabled device(E2):

C4000 receiver (stand-alone) at FX3-CPU1 (e.g., at EFI1_A)

Two paths must be considered and calculated separately:

12 TECHNICAL DATA


Figure 52: Response times within a Flexi Soft system

Digital inputs (E1)


C4000 response time 14.0 ms



If on-off filteractive

+ min. filter time 1) –


+ max. OFF-ON delay 2) of the test input used –

a) Pressure-sensitive safetymats andbumpers

+ test period 2) of the test output, higher value of the twotest outputs

–

b) Type 4 test‐able sensors(e.g., L41)

+ test period 2) of the test output –

c) All other sen‐sors

+ test gap 2) of the test output(if test gap 2) > 1 ms)

–


–

Total E1 20.5 ms

Table 97: Example for the calculation of the response time for the digital inputs (E1)

1) Switching off is delayed until the signal has been at Low for at least the selected filter time. For FX3-XTIOand FX3-XTDI firmware version < V3.00.0, the filter time is set to a fixed value of 8 ms.

2) Take the values from the report in the configuration software.

TECHNICAL DATA 12


Digital outputs (A1) on path 1


Robot response time 40.0 ms


Output processing time 4.5 ms


Potential switch-off delay in the event of an internal error,depending on whether an extended error detection time hasbeen configured for the switching of capacitive loads: + 10ms or + 50 ms 1)

–

Total A1 44.5 ms

Table 98: Example for the calculation of the response time for the digital outputs (A1) on path 1

1) see "Extended error detection time for cross-circuits at outputs Q1 to Q4 on the FX3-XTIO for the switch‐ing of increased capacitive loads", page 25 and see "Use of single-channel outputs on the FX3-XTIO",page 26.

Response time of path 1

1. Inputs Response time of the inputunder consideration onpath 1

E1 20.5 ms

2. Logic Logic response time 2 × logic execution time 8.0 ms

Delay due to logic application –

3. Outputs Response time of the outputunder consideration onpath 1

A1 44.5 ms

Total response time of path 1 73.0 ms

Table 99: Example for the calculation of the response time of path 1 of a Flexi Soft system

Input from an EFI-enabled device (E2)


Response time of the EFI data source (C4000 receiver(stand-alone))

12.0 ms

Constant (C4000) 1.5 ms

Total E2 13.5 ms

Table 100: Example for the calculation of the response time for the input from an EFI-enableddevice (E2)

Digital outputs (A1) on path 2


Robot response time 40.0 ms



Total A1 44.5 ms

Table 101: Example for the calculation of the response time for the digital outputs (A1) on path 2

12 TECHNICAL DATA


Response time of path 2

1. Inputs Response time of the inputunder consideration onpath 2

E2 13.5 ms



3. Outputs Response time of the outputunder consideration onpath 2

A1 44.5 ms

Total response time of path 2 66.0 ms

Table 102: Example for the calculation of the response time of path 2 of a Flexi Soft system

12.1.1.2 Example 2: Calculation of the response time for a Flexi Link system

Figure 53: Response times within a Flexi Link system

Flexi Link station A

Logic execution time = 4 ms

Flexi Link station B

Logic execution time = 8 ms

Digital inputs (E1) from station A


Tactile sensor 0 ms



If on-off filteractive

+ min. filter time 1) –


–

Total E1 6.5 ms

Table 103: Example for the calculation of the response time for the digital inputs (E1) from sta‐tion A


TECHNICAL DATA 12


Output to an EFI-enabled device (A2) from station A


Response time of the EFI data receiver (see table below forFlexi Link station B)

–

Constant (Flexi Link) 4 ms

Total A2 4 ms

Table 104: Example for the calculation of the response time for the output to an EFI-enableddevice (A2) from station A


Total response time of station A


E1 6.5 ms




A2 4.0 ms

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

Table 105: Example for the calculation of the total response time of station A (from remote inputto EFI) in a Flexi Link system

Input from an EFI-enabled device (E2) from station B


Response time of the EFI data receiver (see table above forFlexi Link station A)

18.5 ms

Constant (Flexi Link) 0.5 ms

Total E2 19.0 ms

Table 106: Example for the calculation of the response time for the input from an EFI-enableddevice (E2) from station B

Digital outputs (A1) from station B


Response time of the actuator 40.0 ms



Total A1 44.5 ms

Table 107: Example for the calculation of the response time for the digital inputs (E1) from sta‐tion B

12 TECHNICAL DATA


Total response time of station B


E2 19.0 ms




A1 44.5 ms

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

Table 108: Example for the calculation of the total response time of station B (remote input tolocal output) in a Flexi Link system

12.1.2 Minimum switch-off time

The minimum switch-off time (e.g., of connected sensors) is the minimum time forwhich a switch-off condition must prevail in order to be detected by the Flexi Soft sys‐tem so that error-free switching is possible. The minimum switch-off time must be ...

• Greater than the logic execution time + 1 ms and• Greater than the test gap + the maximum OFF-ON delay, if the input is connected

at test output X1 to X8 and the test gap is > 1 ms and• Greater than the test period (i.e., the higher value of the two test outputs used) +

the maximum OFF-ON delay if pressure-sensitive safety mats or bumpers arebeing used 6)

The minimum switch-off time of the sensors is usually listed in the technical data forthe sensors.

12.2 Data sheet

12.2.1 Main modules FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3

Safety technology parameters FX3-CPUx

NOTEThe data for the safety technology parameters is based on an ambient temperature of+40 °C (the temperature usually used for the static calculation of the values).

FX3-CPU0 FX3-CPU1/2/3

Safety integrity level 1) SIL3 (IEC 61508)

SIL claim limit 1) SILCL3 (EN 62061)

Category Category 4 (EN ISO 13849-1)

Performance level 1) PL e (EN ISO 13849-1)

PFHd 1.07 × 10–9 1.69 × 10–9

PFHd for Flexi Line station 2) – 0.40 × 10–9

TM (mission time) 20 years (EN ISO 13849-1)

Table 109: Safety technology parameters FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3

1) For more detailed information about the safety design and dimensioning of your machine/system, pleasecontact your SICK subsidiary.

2) Valid for an FX3-CPU3 main module used exclusively to route information via Flexi Line.

6) Take the values from the report in the configuration software.

TECHNICAL DATA 12


General data FX3-CPUx

FX3-CPU0 FX3-CPU1/2/3

Conformity/approvals CE, cULus, CCC, EAC

Protection class III (EN 61140)

Enclosure rating IP 20 (EN 60529)

Ambient operating temperature(UL/CSA: surrounding air tempera‐ture)

–25 … +55 °C

Storage temperature –25 … +70 °C

Air humidity 10 … 95%, non-condensing

Operating altitude Max. 2,000 m above sea level (80 kPa)

Vibration resistance 5–150 Hz/1 G (EN 60068-2-6)10–500 Hz/3 Grms (EN 60068-2-64)

Shock resistance

Continuous shock 15 g, 11 ms (EN 60068-2-27)

Single shock 30 g, 11 ms (EN 60068-2-27)

Interference immunity EN 61000-6-2

Radiated emission EN 61000-6-4

Number of EFI interfaces 0 2

Number of Flexi Line interfaces 0 FX3-CPU1/2: 0FX3-CPU3: 1

Data interface Internal bus (FLEXBUS+)

Configuration interface RS-232 FX3-CPU1/2: RS-232FX3-CPU3: RS-232, USB

RS-232 connectivity M8, 4-pin

USB connectivity–

FX3-CPU1/2: –FX3-CPU3: USB Mini-B,5-pin

EFI and Flexi Line connectivity – Dual level spring terminals

Wire cross-section EFI

–

Single-wire or fine-wire: 0.2… 1.5 mm²Stranded wire with ferrule:a) With plastic ferrule max.0.75 mm²b) With plastic ferrule max.1.5 mm²AWG to UL/CUL: 24 … 16

Dimensions (W × H × D) 22.5 × 96.5 × 120.6 mm

Weight 111 g (±5%) FX3-CPU1/2: 119 g (±5%)FX3-CPU3: 133 g (±5%)

Table 110: General data FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3

Power supply unit (A1, A2) for FX3-CPUx via system plug

FX3-CPU0/1/2/3

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

Supply voltage UL/CSA applications 24 V DC

Table 111: Power supply unit (A1, A2) for FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3 (viaFX3-MPL0 or FX3-MPL1 system plug)

12 TECHNICAL DATA


FX3-CPU0/1/2/3

Type of supply voltage PELV or SELVThe supply current for the module must be limited exter‐nally to max. 4 A – either by the power supply unit usedor using a fuse.

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

Overvoltage category II (EN 61131-2)

Power consumption Max. 2.5 W

Power-up delay Max. 18 s

Connectivity Screw terminals

Wire cross-section Single-wire or stranded: 0.14 … 2.5 mm²AWG to UL/CUL: 26 … 14

Table 111: Power supply unit (A1, A2) for FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3 (viaFX3-MPL0 or FX3-MPL1 system plug)


Safety technology parameters FX3-XTIO


TECHNICAL DATA 12


FX3-XTIO



Category 2)

For single-channel outputs withactivated test signals at all safeoutputs (Q1 … Q4)

Category 4 (EN ISO 13849-1) 3)

For single-channel outputs withdeactivated test signals at this orany other safe output (Q1 … Q4)

Category 3 (EN ISO 13849-1) 3) 4)

For dual-channel outputs with orwithout deactivated test signals atthis or any other safe output(Q1 … Q4)

Category 4 (EN ISO 13849-1) 4) 5)


PFHd 2)

For single-channel outputs 4.8 × 10–9

For dual-channel outputs 0.9 × 10–9

TM (mission time) 20 years (EN ISO 13849-1) 4)

Table 112: Safety technology parameters FX3-XTIO


2) Valid for single-channel inputs and for dual-channel inputs.3) If single-channel outputs are being used: Use protected or separate cabling for these safe outputs,

because although a short-circuit to 24 V can be detected, no other option is available for switching off.4) If safe outputs without test signals are being used, at least once a year either all safe outputs with test

signals must be switched off at the same time for at least one second or the Flexi Soft system must berestarted by switching off the voltage supply.

5) If safe outputs without test signals are being used: Use protected or separate cabling for the safe outputswhose test signals are deactivated, because a short-circuit to 24 V cannot be detected if the safe outputis High. In the event of an internal hardware error being detected, the ability of the other safe outputs toshut down could be impaired by reverse current.

General data for the FX3-XTIO

FX3-XTIO





–25 … +55 °C





Shock resistance




Table 113: General data for the FX3-XTIO

12 TECHNICAL DATA


FX3-XTIO


Connectivity Dual level spring terminals

Wire cross-section Single-wire or stranded: 0.2 … 1.5 mm²Stranded wire with ferrule:a) With plastic ferrule max. 0.75 mm²b) With plastic ferrule max. 1.5 mm²AWG to UL/CUL: 24 … 16


Power consumption via FLEXBUS+,no current at X1, X2

Max. 2.2 W


Weight 164 g (±5%)

Table 113: General data for the FX3-XTIO

Power supply unit (A1, A2) for FX3-XTIO

FX3-XTIO





Power consumption Maximum 120 W (30 V x 4 A) determined by the load atoutputs Q1 to Q4, plus maximum 1 W power consump‐tion through the internal circuit


Table 114: Power supply unit (A1, A2) for FX3-XTIO

Safe inputs (I1 … I8) of the FX3-XTIO

FX3-XTIO

Number of inputs 8

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

Reverse current at input in the event of the loss of the ground connection 1)

Hardware version < V1.10(FX3-XTIO Step 1.xx) 2)

Max. 20 mA1.5 kΩ effective resistance of the power supply to theinput

Hardware version ≥ V1.10(FX3-XTIO Step 2.xx) 2)

Max. 2 mA

Switching current (for the connectionof mechanical contacts)

14.4 mA at 5 V3 mA at 24 V

Input pulse filter (pulses within these limits do not have any effect)

Pulse width Max. 0.9 ms

Table 115: Safe inputs (I1 … I8) of the FX3-XTIO

TECHNICAL DATA 12


FX3-XTIO

Pulse period Min. 4 ms

Input capacity Max. 10 nF + 10%

Discrepancy time 4 ms … 30 s, configurable

Table 115: Safe inputs (I1 … I8) of the FX3-XTIO

1) Do not connect any other safe inputs in parallel if the reverse current could lead to a High state at theother input.

2) The hardware version of the Flexi Soft modules can be found in the hardware configuration of the FlexiSoft Designer configuration software in online mode or in the report, if you were previously online.

Test outputs (X1, X2) of the FX3-XTIO

FX3-XTIO

Number of outputs 2 (with 2 test signal generators)

Type of output PNP semiconductor, short-circuit protected, cross-circuitmonitored

Output voltage High 15 … 30 V DC (max. 1.8 V dip to terminal A1 of the mainmodule)

Output resistance Low ≤ 33 Ω + 10%, current limited at approx. 10 mA

Output current Max. 120 mA at every test output (X1 or X2).A maximum of 8 testable sensor cascades are thus pos‐sible per module, each with up to 30 mA, maximum.The total current of the Flexi Soft system for all outputs(X1 … X8 and XY1 … XY2) must not exceed 1.28 A. Thiscorresponds, for example, to a maximum of 32 testablesensor cascades each with 30 mA plus 64 tactile sen‐sors at inputs of expansion modules, each with 5 mA.

Test signal rate (test period) 40 … 1,000 ms, 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 Ω

Table 116: Test outputs (X1, X2) of the FX3-XTIO

Safe outputs (Q1 … Q4) of the FX3-XTIO

FX3-XTIO

Number of outputs 4

Type of output PNP semiconductors, short-circuit protected


Leakage current Low

Normal operation Max. 0.1 mA

Error 1), hardware version < V1.10(FX3-XTIO Step 1.xx)

Max. 1.6 mA

Error 1), hardware version < V1.10(FX3-XTIO Step 2.xx)

Max. 2.0 mA

Output current Max. 2.0 A

Sum current Isum

TU ≤ 45 °C Max. 4.0 A

Table 117: Safe outputs (Q1 … Q4) of the FX3-XTIO

12 TECHNICAL DATA


FX3-XTIO

TU ≤ 55 °C Max. 3.2 A

UL/CSA applications Max. 3.2 A

Test signal duration (test gap) 2) < 650 µs or deactivated

Test signal rate (test period) Min. 200 ms

Load capacity ≤ 0.5 µF

Cable resistance 3) Max. 5 Ω (e.g., 100 m × 1.5 mm² = 1.2 Ω)

Maximum permissible coil energy without external controllers 4)

Hardware version V1.00 0.22 J

Hardware version ≥ V1.01 0.37 J

Response time Dependent on logic configuration, details: see table 88,page 111

Synchronicity of outputs Qx within aFlexi Soft station (time delay)5)

Max. 1 ms

Possible switching to High in theevent of an internal hardware error

10 ms or 50 msDetails: see "Use of single-channel outputs on the FX3-XTIO", page 26

Table 117: Safe outputs (Q1 … Q4) of the FX3-XTIO

1) In the event of an error (interruption of the GND cable) with a minimum load resistance of 2.5 kΩ, theleakage current will flow as a maximum at the safe output. With lower load resistances, the leakage cur‐rent may be higher, but in this case the output voltage is < 5 V. A downstream device such as a relay oran FPLC (fail-safe programmable logic controller), for example, must detect this state as Low.

2) When activated, the outputs are tested regularly (short Low switching). When selecting the downstreamcontrollers, make sure that the test signals with the parameters listed above do not result in switchingoff, or deactivate the test signals at the outputs.

3) Limit the resistance of the individual cables to the downstream controller to this value to ensure that ashort-circuit between the outputs is safely detected. (See also EN 60204 Electrical equipment ofmachines, Part 1: General requirements.)

4) Examples for the resulting maximum coil induction based on the coil current:

• Hardware version V1.00: 1760 mH @ 0.5 A, 440 mH @ 1 A, 110 mH @ 2 A

• Hardware version V1.01: 2960 mH @ 0.5 A, 740 mH @ 1 A, 185 mH @ 2 AExternal controllers are not required for inductive loads (e.g., contactors, relays, and valves) if this maxi‐mum coil energy is not exceeded.RC elements parallel to the inductive load should not be used, because they form an oscillating circuitwhich can cause an overshoot in the positive voltage range after the induction voltage has died down,leading to a cross-circuit error. The tolerated time for the overshoot (> 3.5 V) must be observed:

• Firmware version ≤ V2.10.0: < 1 ms

• Firmware version V2.11.0: < 3 ms

• • Firmware version ≥ V3.00.0: < 3 ms or < 43 ms, if an extended error detection time has beenconfigured for the switching of capacitive loads

An external parallel resistor can be used to reduce the overshoot if necessary.5) This includes switching off in the event of an error: In the case of a dual-channel output, both channels

switch off within this time in the event of an error.


Safety technology parameters FX3-XTDI


FX3-XTDI



Table 118: Safety technology parameters FX3-XTDI

TECHNICAL DATA 12


FX3-XTDI



PFHd 0.4 × 10–9


Table 118: Safety technology parameters FX3-XTDI


General data for the FX3-XTDI

FX3-XTDI




Ambient operating temperature –25 … +55 °C





Shock resistance








Power consumption via FLEXBUS+,no current at X1 … X8

Max. 2 W


Weight 139 g (±5%)

Table 119: General data for the FX3-XTDI

Safe inputs (I1 … I8) of the FX3-XTDI

FX3-XTDI

Number of inputs 8





Table 120: Safe inputs (I1 … I8) of the FX3-XTDI

12 TECHNICAL DATA


FX3-XTDI

Reverse current at input in the event of the loss of the ground connection 1)

Hardware version < V1.10(FX3-XTIO Step 1.xx) 2)

Max. 20 mA1.5 kΩ effective resistance of the power supply to theinput

Hardware version ≥ V1.10(FX3-XTDI Step 2.xx) 2)

Max. 2 mA


14.4 mA at 5 V3 mA at 24 V



Table 120: Safe inputs (I1 … I8) of the FX3-XTDI


2) The hardware version of the Flexi Soft modules can be found in the hardware configuration of the FlexiSoft Designer configuration software in online mode or in the report, if you were previously online.

Test outputs (X1, X2) of the FX3-XTDI

FX3-XTDI


Type of output PNP semiconductors, short-circuit protected, cross-cir‐cuit monitored



Output current Max. 120 mA at each of the two test signal generators(X1/X3/X5/X7 or X2/X4/X6/X8).A maximum of 8 testable sensor cascades are thus pos‐sible per module, each with up to 30 mA, maximum.The total current of the Flexi Soft system for all outputs(X1 … X8 and XY1 … XY2) must not exceed 1.28 A. Thiscorresponds, for example, to a maximum of 32 testablesensor cascades each with 30 mA plus 64 tactile sen‐sors at inputs of expansion modules, each with 5 mA.





Table 121: Test outputs (X1, X2) of the FX3-XTDI


Safety technology parameters FX3-XTDS

NOTEThe data for the safety technology parameters is based on an ambient temperature of+40 °C (the temperature usually used for the static calculation of the values).The safety technology parameters do not apply for outputs XY1, XY2, and Y3–Y6.

TECHNICAL DATA 12


FX3-XTDS





PFHd 0.4 × 10–9


Table 122: Safety technology parameters FX3-XTDS


General data for the FX3-XTDS

FX3-XTDS





–25 … +55 °C





Shock resistance








Power consumption via FLEXBUS+,no current at XY1 and XY2

Max. 1.5 W


Weight 139 g (±5%)

Table 123: General data for the FX3-XTDS

Power supply unit (A1, A2) for FX3-XTDS

FX3-XTDS



Table 124: Power supply unit (A1, A2) for FX3-XTDS

12 TECHNICAL DATA


FX3-XTDS



Power consumption Max. 60 W (30 V × 2 A), determined by the load at out‐puts Y3 to Y6


Table 124: Power supply unit (A1, A2) for FX3-XTDS

Safe inputs of the FX3-XTDS

FX3-XTDS

Number of inputs 8



Input current high 2.4 … 3.8 mA


Reverse current at input in the eventof the loss of the ground connec‐tion 1)

Max. 2 mA


14.4 mA at 5 V3 mA at 24 V



Table 125: Safe inputs (I1 … I8) of the FX3-XTDS


Outputs of the FX3-XTDS as test outputs

FX3-XTDS





Output current Max. 120 mA at each of the two test signal generators(XY1 or XY2).A maximum of 8 testable sensor cascades are thus pos‐sible per module, each with up to 30 mA, maximum.The total current of the Flexi Soft system for all outputs(X1 … X8 and XY1 … XY2) must not exceed 1.28 A. Thiscorresponds, for example, to a maximum of 32 testablesensor cascades each with 30 mA plus 64 tactile sen‐sors at inputs of expansion modules, each with 5 mA.



Table 126: Outputs XY1 … XY2 of the FX3-XTDS when used as test outputs

TECHNICAL DATA 12


FX3-XTDS



Table 126: Outputs XY1 … XY2 of the FX3-XTDS when used as test outputs

Non-safe outputs of the FX3-XTDS

FX3-XTDS

Number of non-safe outputs 4 (6)



Leakage current Low


Error 1) Max. 1.0 mA

Output current

XY1, XY2 Max. 120 mA

Y3 … Y6 Max. 0.5 A

Maximum permissible coil energywithout external controllers 2)

0.37 J


Table 127: Non-safe outputs (Y3 … Y6 plus XY1 and XY2 when used as non-safe outputs) of theFX3-XTDS

1) In the event of an error (interruption of the GND cable) with a minimum load resistance of 2.5 kΩ, theleakage current will flow as a maximum at the output. With lower load resistances, the leakage currentmay be higher, but in this case the output voltage is < 5 V. A downstream device such as a relay or anFPLC (fail-safe programmable logic controller), for example, must detect this state as Low.

2) Examples for the resulting maximum coil induction: 2960 mH @ 0.5 A.


General data for the FX0-STIO

FX0-STIO





–25 … +55 °C





Shock resistance



Table 128: General data for the FX0-STIO

12 TECHNICAL DATA


FX0-STIO






Power consumption via FLEXBUS+ Max. 1.5 W


Weight 139 g (±5%)

Table 128: General data for the FX0-STIO

Power supply unit (A1, A2) for FX0-STIO

FX0-STIO





Power consumption Max. 120 W (30 V × 4 A), determined by the load at out‐puts Y1 to IY8


Table 129: Power supply unit (A1, A2) for FX0-STIO

Input circuit of the FX0-STIO

FX0-STIO

Number of safe inputs 6 (8)






14.4 mA at 5 V3 mA at 24 V



Table 130: Input circuit (I1 … IY8) of the FX0-STIO

Non-safe outputs of the FX0-STIO

FX0-STIO

Number of non-safe outputs 6 (8)


Table 131: Non-safe outputs (Y1 … Y6 plus IY7 and IY8) of the FX0-STIO

TECHNICAL DATA 12


FX0-STIO


Leakage current Low


Error 1) Max. 1.0 mA

Output current Max. 0.5 A

Maximum permissible coil energywithout external controllers 2)

0.37 J


Table 131: Non-safe outputs (Y1 … Y6 plus IY7 and IY8) of the FX0-STIO

1) In the event of an error (interruption of the GND cable) with a minimum load resistance of 2.5 kΩ, theleakage current will flow as a maximum at the output. With lower load resistances, the leakage currentmay be higher, but in this case the output voltage is < 5 V. A downstream device such as a relay or anFPLC (fail-safe programmable logic controller), for example, must detect this state as Low.

2) Examples for the resulting maximum coil induction: 2960 mH @ 0.5 A.


Safety technology parameters FX3-MOC0


FX3-MOC0

Safety technology parameters for axes with two encoders (any combination of sine-cosine,TTL, HTL 24 V, MTL 12 V, RS-422, SSI, same or different types)





PFHd 5 × 10–9

Minimum movement for error detec‐tion 2)

≥ Selected tolerance limit of the function block to beused for the cross-comparison, e.g., speed comparison,at least 1 x within 24 hours

Safety technology parameters for axes with a sine-cosine encoder and sin/cos analog voltagemonitoring activated




Performance level 1) PL d (EN ISO 13849-1)

PFHd 6 × 10–9

Minimum movement for error detec‐tion 2)

≥ 1 sine-cosine period,at least 1 x within 24 hours

Supplementary troubleshooting measures

For encoders with Sin/Sin_Ref andCos/Cos_Ref 3)

Required, see the “Limits of sin/cos analog voltage mon‐itoring” section of the “Flexi Soft in the Flexi SoftDesigner Software” operating instructions 4)

Table 132: Safety technology parameters FX3-MOC0

12 TECHNICAL DATA


FX3-MOC0

For encoders with Sin+/Sin– andCos+/Cos– 5)

Not required

General safety technology parameters


Table 132: Safety technology parameters FX3-MOC0


2) Typically, in accordance with generally accepted test principles set out by testing authorities, the require‐ment here is that provision must be made in the application to ensure that the unit to be monitored exe‐cutes a movement at least once within 24 hours. This movement must trigger a signal change at theencoder system on the basis of which the errors to be considered are detected.

3) Sin_Ref and Cos_Ref are DC voltage, typically 2.5 V DC.4) E.g., joint use of the encoder signals for the electronic switching of the drive system.5) Sin– and Cos– are the inverted voltage of Sin+ and Cos+ respectively.

General data for the FX3-MOC0

FX3-MOC0





–25 … +55 °C





Shock resistance





Connectivity Micro-D-Sub male connector, 15-pin


Power consumption via FLEXBUS+,no encoder power supply(ENC1_24V, ENC2_24V, ENC_0V)

Max. 2.5 W


Weight 120 g

Table 133: General data for the FX3-MOC0

Encoder connection at the FX3-MOC0

Minimum Typical Maximum

General values(ENCx_A+, ENCx_B+, ENCx_C+, ENCx_A–, ENCx_B–, ENCx_C–, ENC_0V)

Table 134: Encoder connection at the FX3-MOC0

TECHNICAL DATA 12



Input resistance for configuration forSSI encoders or A/B incrementalencoders 1)

35 kΩ – –

Input resistance for configuration forsine-cosine encoders 2)

0.9 kΩ 1 kΩ 1.1 kΩ

Differential resistance for configura‐tion for SSI encoders or RS-422 A/Bincremental encoders 3)

100 Ω 120 Ω 150 Ω

Encoder power supply (ENC1_24V, ENC2_24V, ENC_0V)

Voltage drop, output voltage 4) – – 1.8 V

Output current ENC1_24V – – 0.1 A

Output current ENC2_24V – – 0.1 A

Error detection time ID code monitor‐ing with encoder connection box 5)

Max. 10 ms

TTL, 2 outputs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–)

Input voltage difference High 6) 2 V 5 V 5.3 V

Input voltage difference Low 6) –0.3 V 0 V 0.8 V

Input voltage 7) –5 V – 10 V

TTL, 2 output pairs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–, ENC_0V)

Input voltage difference High 6) 1.2 V 5 V 5.6 V

Input voltage difference Low 6) –5.6 V –5 V –1.2 V


HTL 24 V, 2 outputs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–)

Input voltage difference High 6) 13 V 24 V 30 V

Input voltage difference Low 6) –3 V 0 V 5 V


HTL 24 V, 2 output pairs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–, ENC_0V)


Input voltage difference Low 6) –30 V –24 V –8 V


MTL 12 V, 2 outputs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–)

Input voltage difference High 6) 6.5 V 12 V 15 V

Input voltage difference Low 6) –1 V 0 V 2.5 V


MTL 12 V, 2 pairs of outputs (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–, ENC_0V)


Input voltage difference Low 6) –15 V –12 V –4 V


SSI encoders (ENCx_A+, ENCx_A–, ENCx_C+, ENCx_C–, ENC_0V)

Input voltage difference High forClock, if SSI listener, and Data 6)

0.2 V – 5 V

Input voltage difference Low forClock, if SSI listener, and Data 6)

–5 V – –0.2 V



12 TECHNICAL DATA



Output voltage difference High forClock, if SSI master 8)

2 V – –

Output voltage difference Low forClock, if SSI master 8)

– – –2 V

Incremental encoder with HTL 24 V, MTL 12 V, TTL (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–,ENC_0V)

Input frequency – – 300 kHz

Pulse duration High 1.5 µs – –

Pulse duration Low 1.5 µs – –

Edge distance A/B (phase shift) 70° 90° 110°

Accuracy error affecting speed detec‐tion 9)

Max. 5% incl. the internal resolution of the speed infor‐mation

Accuracy error affecting positiondetection 10)

Max. 1 increment of the internal resolution of the posi‐tion information

Counting direction

S = position information

Incremental encoder with RS-422 (ENC1_A+, ENC1_A–, ENC1_C+, ENC1_C–, ENC_0V)

Input voltage difference High 6) 0.2 V – 5 V

Input voltage difference Low 6) –5 V – –0.2 V


Output voltage difference High 8) 2 V – –

Output voltage difference Low 8) – – –2 V

Input frequency – – 1 MHz

Pulse duration High 0.4 µs – –

Pulse duration Low 0.4 µs – –

Edge distance A/B (phase shift) 70° 90° 110°





SSI encoders (ENCx_A+, ENCx_A–, ENCx_C+, ENCx_C–, ENC_0V)

Baud rate 11)14) 100 kHz – 1 MHz

Clock gap between data packages(mono flop time) 12)

100 µs – –

Number of position data bits 13)14)

Firmware < V2.00(FX3-MOC0 Step 1.xx)

16 – 16

Firmware ≥ V2.00(FX3-MOC0 Step 2.xx)

8 – 16


TECHNICAL DATA 12



Number of bits in the entire SSI pro‐tocol frame 13)14)

8 – 62

Change in position information (speed)

≤ 16 position data bits 14) Max. 2 (data bits/frame – 1) – 1 increments per max. datareceive interval 14)

≤ 17 position data bits 14) Max. 65,535 increments per max. data receive interval14)





DANGERNote the maximum speed.Noncompliance with the maximum permissible change in position information can lead to theoutput of an inverted direction of rotation and too low a speed, since the position data bits willoverflow without being detected.

Sine-cosine encoders (ENCx_A+, ENCx_A–, ENCx_B+, ENCx_B–, ENC_0V)

Input voltage difference 17) 0.8 VPP 1 VPP 1.2 VPP

Input voltage 18) 0 V – 5 V

Input frequency 0 Hz – 120 Hz

Phase shift 80° 90° 100°

Sin/cos analog voltage monitor‐ing 19), lower limit for vector lengthmonitoring 17)

0.5 VPP 0.55 VPP –

Sin/cos analog voltage monitor‐ing 19), upper limit for vector lengthmonitoring 17)

– 1.26 VPP 1.5 VPP

Error detection time for sin/cos analog voltage monitoring

Vector length monitoring Max. 20 ms, but at least ¼ sine-cosine period

Monitoring of the signal hub Max. 1 sine-cosine period, but at least 8 ms





Counting direction

S = position information


1) Resistance between ENCx_y+/– and ENC_0V.2) Resistance between ENCx_y+/– and ENC_0V. An input voltage of 30 V between ENCx_y+/– and ENC_0V

will not damage the module, e.g., in the event of voltage limiting, if the voltage exceeds 5 V.3) Resistance between between ENCx_y+ and ENCx_y– with series capacitor to block direct current load. An

input voltage of 30 V will not damage the module.

12 TECHNICAL DATA


4) Voltage between A1 of the main module and ENCx_24V at 0.1 A load current.5) See the “Flexi Soft in the Flexi Soft Designer Software” operating instructions, section “Encoder connec‐

tion type and monitoring the ID code”.6) Voltage between ENCx_y+ and ENCx_y–.7) Voltage between ENCx_y+ and ENC_0V as well as between ENCx_y– and ENC_0V.8) Voltage between ENCx_y+ and ENCx_y– with a terminator of ≥ 60 Ω.9) Plus the resolution of the speed information limited by the resolution of the encoder system:

a) Rotational movement in rpm = 15,000/(4 × number of A/B periods per revolution)b) Linear movement in mm/s = 250/(4 × number of A/B periods per revolution)

10) Plus the resolution of the position information limited by the resolution of the encoder system:1 rev./(4 × number of A/B periods per revolution).

11) Master and listener mode.12) Time between the falling edges of the clock.13) Without start bit. If repeat transmission is used (clock continues without clock gap so that the same data

can be transmitted again), the entire stream is viewed as a frame.14) These are parameters of the SSI encoder that can be set in Flexi Soft Designer.15) Plus the resolution of the speed information limited by the resolution of the encoder system:

a) Rotational movement in rpm = 15,000/(increments per revolution) b) Linear movement in mm/s =250/(increments per revolution).

16) Plus the resolution of the position information limited by the resolution of the encoder system:1 rev./(increments per revolution).

17) Peak-to-peak voltage between ENCx_y+ and ENCx_y–.18) Voltage between ENCx_y+ and ENC_0V as well as between ENCx_y– and ENC_0V.19) This function is described in the “Flexi Soft in the Flexi Soft Designer Software” operating instructions,

section “Sin/cos analog voltage monitoring”.20) Plus the resolution of the speed information limited by the resolution of the encoder system a) Rotational

movement in rpm = 15,000/(4 × number of sine-cosine periods per revolution)b) Linear movement in mm/s = 250/(4 × number of sine-cosine periods per revolution)

21) Plus the resolution of the position information limited by the resolution of the encoder system:1 rev./(4 × number of sine-cosine periods per revolution).

TECHNICAL DATA 12


12.2.7 Encoder connection boxes for FX3-MOC0

General data, encoder connection boxes for the FX3-MOC0

Encoder connection boxes for FX3-MOC0




–25 … +55 °C





Shock resistance






Dimensions (W × H × D) 45 × 142.3 × 73.1 mm

Weight

Optimized motor feedback splitterbox FX3-EBX1

119 g

Motor feedback splitter boxFX3-EBX3

170 g

Dual encoder connection boxFX3-EBX4

163 g

Table 135: General data, encoder connection boxes for the FX3-MOC0

On-board power supply on the FX3-MOC0 (FX3-EBX3, FX3-EBX4)

The technical data in this section is only valid for the following devices:

Motor feedback splitter box FX3-EBX3 Dual encoder connection box FX3-EBX4

12 TECHNICAL DATA





Type of supply voltage PELV or SELVThe supply current for the encoder connection box mustbe limited externally to max. 1 A – either by the connec‐tion to the power supply at the encoder connection ofthe FX3-MOC0, or by the power supply voltage used, orusing a fuse.

Output voltage at Uout

Rotary switch Uout = 0 4.75 V 5 V 5.25 V



Rotary switch Uout = 3 – 24 V 1) –

Permissible output current at Uout

Rotary switch Uout = 0 – – 240 mA




Table 136: On-board power supply Uout (from the FX3-MOC0)

1) The supply voltage for the encoder can be up to 2 V below the supply voltage at the system plug (terminalA1).

12.2.8 UE410-2RO/UE410-4RO relay output modules

Safety technology parameters UE410-2RO/UE410-4R0


UE410-2RO/UE410-4R0





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

(see table 144, page 143)

1.2 × 10–9

B10d value 0.75 A (AC 15)/4,150,000 (see table 144, page 143)

Safe Failure Fraction (SFF) 99.6%

Diagnostic coverage (DC) 99%

TM (mission time) Depending on PFHd value, ambient temperature, loadcase, and switching operations (see table 144,page 143)

Table 137: Safety technology parameters UE410-2RO/UE410-4R0

TECHNICAL DATA 12


UE410-2RO/UE410-4R0

Number of mechanical switchingoperations

Min. 200,000

Table 137: Safety technology parameters UE410-2RO/UE410-4R0


General data UE410-2RO/UE410-4R0

UE410-2RO/UE410-4R0




–25 °C … +55 °C

Storage temperature –25 °C … +70 °C




Shock resistance





Rated impulse voltage (Uimp) 4 kV

Overvoltage category II (EN 61131-2)

Contamination rating 2 inside, 3 outside

Rated voltage 300 V AC

Galvanic separation

Supply circuit–input circuit No

Supply circuit–output circuit Yes

Input circuit–output circuit Yes


Weight (without packaging)

UE410-2RO 160 g (±5%)

UE410-4RO 186 g (±5%)

Table 138: General data UE410-2RO/UE410-4R0

Supply circuit of the UE410-2RO/UE410-4R0 (via FX3-CPUx)


Power consumption

UE410-2RO – – 1.6 W

UE410-4RO – – 3.2 W

Table 139: Supply circuit of the UE410-2RO/UE410-4R0 (via FX3-CPUx)

12 TECHNICAL DATA


Input circuit (B1, B2) of the UE410-2RO/UE410-4R0


Input voltage ON 18 V DC – 30 V DC

Table 140: Input circuit (B1, B2) of the UE410-2RO/UE410-4R0

Output circuit (13-14, 23-24, 33-34, 43-44) of the UE410-2RO/UE410-4R0


No. of normally open

UE410-2RO 2

UE410-4RO 4

No. of normally closed

UE410-2RO 1

UE410-4RO 2

AC switching voltage 5 V AC 230 V AC 1) 253 V AC

DC switching voltage 5 V DC 230 V DC 1) 253 V DC

Switching current 10 mA – 6 A

Mechanical service life Min. 10 × 106

Electrical endurance see figure 55, page 142

Minimum contact load atUn = 24 V DC

50 mW – –

Sum current – – 8 A

Response time 2) – – 30 ms

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

Contact material AgSnO2

Output circuit fuse 6 A gG, each current path

Usage category AC-15: Ue 250 V, Ie 3 A

DC-13: Ue 24 V, Ie 3 A

Table 141: Output circuit (13-14, 23-24, 33-34, 43-44) of the UE410-2RO/UE410-4R0

1) see figure 54, page 142 or see figure 55, page 142.2) Time from Low at B1/B2 until relay drops out.

TECHNICAL DATA 12


Figure 54: Maximum switching voltage for direct current, relay output modules UE410-2RO/UE410-4RO

1 Gleichspannung [V DC]2 Gleichstrom [A]3 Ohmsche Last

Figure 55: Electrical endurance of relay output modules UE410-2RO/UE410-4RO

1 Schaltspiele2 Schaltstrom [A]3 250 V AC ohmsche Last bei 1 Schließerkontakt

Output circuit (Y14, Y24) of the UE410-2RO/UE410-4R0


Type of output N/O contact at internal 24 V DC, positively guided, cur‐rent-limited

No. of normally open Y14/24

UE410-2RO 1

UE410-4RO 2

Table 142: Output circuit (Y14, Y24) of the UE410-2RO/UE410-4R0

12 TECHNICAL DATA



Output voltage 16 V DC 24 V DC 30 V DC

Output current 1) – – 75 mA

Load capacity – – 200 nF

Table 142: Output circuit (Y14, Y24) of the UE410-2RO/UE410-4R0

1) The entire output current is limited. Maximum sum current of all relay modules at Y14 or Y24 is < 80 mA.

Terminals and connection data UE410-2RO/UE410-4R0



Stripping length – – 8 mm

Maximum tightening torque – – 0.6 Nm

For UL-508 and CSA applications

UE410-xx3…, UE410-xxx3…

Connection cross-section AWG 30–12(use 60/75 °C copper strands only)

Tightening torque 5–7 lb⋅in

UE410-xx4…, UE410-xxx4…

Connection cross-section AWG 30–12(use 60/75 °C copper strands only)

Table 143: Terminals and connection data UE410-2RO/UE410-4R0

PFHd values UE410-2RO/UE410-4R0

Loadtype I [A] Switching fre‐

quencySwitching opera‐

tions per year B10d PFHd

AC15

0.1 1/h 8760 10,000,000 5 × 10–10

0.75 1/h 8760 4,150,000 1.2 × 10–9

3 1/h 8760 400,000 1.2 × 10–8

5 1/h 8760 70,000 7.2 × 10–8

DC131 1/h 8760 2,000,000 2.5 × 10–9

3 1/h 8760 450,000 1.1 × 10–8

AC12 1/h 8760 1,000,000 5 × 10–9

4 1/h 8760 600,000 8.4 × 10–9

Table 144: PFHd values UE410-2RO/UE410-4R0

DANGERTo achieve SILCL3 to EN 62061 (see "Technical data", page 109), the following testmust be carried out every 365 days:

b Check the correct switching function for each safety-relevant output circuit of theUE410-xRO modules, e.g., by switching the machine or system off and then backon again, monitored by the EDM function.

TECHNICAL DATA 12


12.2.9 Diode module DM8-A4K

General system data for the DM8-A4K diode module

Diode module DM8-A4K

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

Weight 59 g

Ambient operating temperature –25 … +55 °C


Stripping length 7 mm

Wire cross-section 0.2 … 2.5 mm²

Screw connection AWG 22–14

Enclosure rating IP 00

Protection class III

Contamination rating 2

Table 145: General system data for the DM8-A4K diode module

Input data for diode module DM8-A4K

Diode module DM8-A4K

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

Reverse voltage 1,000 V

Reverse current 5 µA

Forward voltage 0.8 V

Input current per channel (1/2) 400 mA

Table 146: Input data for diode module DM8-A4K

12 TECHNICAL DATA


12.3 Dimensioned drawings

12.3.1 FX3-CPUx main modules with system plug

Figure 56: Dimensioned drawing FX3-CPUx (mm)

1 Steckbereich

TECHNICAL DATA 12


12.3.2 I/O modules FX3-XTIO, FX3-XTDI, FX3-XTDS, and FX0-STIO, relay output modules UE410-2RO andUE410-4RO

Figure 57: Dimensioned drawing FX3-XTIO, FX3-XTDS, FX0-STIO, FX3-XTDI, UE410-2RO, andUE410-4RO (mm)


Figure 58: Dimensioned drawing FX3-MOC0 (mm)

12 TECHNICAL DATA


12.3.4 Encoder connection boxes FX3-EBX1, FX3-EBX3, and FX3-EBX4

Optimized motor feedback splitter box FX3-EBX1

Figure 59: Dimensioned drawing optimized motor feedback splitter box FX3-EBX1 (mm/in)

TECHNICAL DATA 12


Motor feedback splitter box FX3-EBX3

Figure 60: Dimensioned drawing motor feedback splitter box FX3-EBX3 (mm/in)

12 TECHNICAL DATA


Dual encoder connection box FX3-EBX4

Figure 61: Dimensioned drawing dual encoder connection box FX3-EBX4 (mm/in)

12.3.5 Dimensioned drawing diode module DM8-A4K

Figure 62: Dimensioned drawing diode module DM8-A4K

1 Inputs

TECHNICAL DATA 12


2 8 × 1N40073 Outputs

12 TECHNICAL DATA


13 Ordering information

13.1 System plugs and modules

Part Description Part number

System plug

FX3-MPL000001 System plug for FX3-CPU0 or FX3-CPU1Screw terminals

1043700

FX3-MPL100001 System plug for FX3-CPU2 or FX3-CPU3Screw terminals

1047162

Main modules

FX3-CPU000000 Main module 1043783

FX3-CPU130002 Main module2 EFI connections, plug-in dual level spring ter‐minals

1043784

FX3-CPU230002 Main module2 EFI connections, plug-in dual level spring ter‐minals

1058999

FX3-CPU320002 Main module2 EFI connections, 1 Flexi Line connection,plug-in dual level spring terminals

1059305

Gateways

FX0-GENT00000 EtherNet/IP gateway 1044072

FX0-GMOD00000 Modbus TCP gateway 1044073

FX0-GPNT00000 PROFINET IO gateway 1044074

FX0-GETC00000 EtherCAT gateway 1051432

FX0-GPRO00000 PROFIBUS DP gateway 1044075

FX0-GCAN00000 CANopen gateway 1044076

FX0-GDEV00000 DeviceNet gateway 1044077

Expansion modules

FX3-XTIO84002 I/O module8 safe inputs, 4 safe outputs, plug-in dual levelspring terminals

1044125

FX3-XTDI80002 I/O module8 safe inputs, plug-in dual level spring termi‐nals

1044124

FX3-XTDS84002 I/O module8 safe inputs, 4 or 6 non-safe outputs, plug-indual level spring terminals

1061777

FX0-STIO68002 I/O module6 or 8 non-safe inputs, 8 or 6 non-safe out‐puts, plug-in dual level spring terminals

1061778

FX3-MOC000000 Drive MonitorConnection of two encoders

1062344

Relay modules

UE410-2RO4 Relay module2 normally open and 1 24 V DC signal output,plug-in spring terminals

6032677

Table 147: Part numbers for system plugs and modules, Flexi Soft safety controller

ORDERING INFORMATION 13



UE410-4RO4 Relay module4 normally open and 2 24 V DC signal outputs,plug-in spring terminals

6032676

UE10-2FG3D0 Safety relayPlug-in screw terminals

1043916

UE12-2FG3D0 Safety relay, can be cascadedPlug-in screw terminals

1043918

Table 147: Part numbers for system plugs and modules, Flexi Soft safety controller

13.2 Accessories


– Plug-in spring terminals 2045890

– Plug-in screw terminals 2045891

– EFI cable thick, 12.2 mm, PVC, sold by themeter

6030756

– EFI cable thin, 6.9 mm, PVC, sold by the meter 6030921

– Flexi Line cable, PVC, sold by the meter 6029448

– Flexi Link cable, shielded, twisted pair,2 × 2 × 0.34 mm² (AWG 22), sold by the meter

6034249

– Configuration cable2 m, M8, D-Sub

6021195

– Configuration cable3 m, USB-A, USB Mini-B

6042517

– Configuration cable3 m, M8, angled, open end

6036342

DSL-8U04G02M025KM1 Configuration cable, M8 on USB-A, 2 m 6034574

DSL-8U04G10M025KM1 Configuration cable, M8 on USB-A, 10 m 6034575

Table 148: Part numbers for accessories for the Flexi Soft safety controller


FX3-EBX1 Optimized motor feedback splitter box for theFX3-MOC0

2079867

FX3-EBX3 Motor feedback splitter box for the FX3-MOC0 2068728

FX3-EBX4 Dual encoder connection box for the FX3-MOC0

2068729

– Connecting cable for all encoder connectionboxes, shielded, twisted pair, 1 micro D-Sub15-pin, straight, 1 HD D-Sub 15-pin

– • Primary connecting cable 2 m 2067798


– Connecting cable for all encoder connectionboxes, shielded, twisted pair, 1 micro D-Sub15-pin, angled, 1 HD D-Sub 15-pin



Table 149: Part numbers for accessories for Drive Monitor FX3-MOC0

13 ORDERING INFORMATION



– Connecting cable for direct encoder connec‐tion, shielded, twisted pair, 1 HD D-Sub 15-pin,straight, open cable end, 2 m

2067893

– Connecting cable for direct encoder connec‐tion, shielded, twisted pair, 1 HD D-Sub 15-pin,angled, open cable end, 2 m

2077263

– Expansion cable for motor feedback splitterbox FX3-EBX3, shielded, twisted pair, 1 D-Sub9-pin, 1 HD D-Sub 15-pin

– • Expansion cable 0.3 m 2078260

– • Expansion cable 2 m 2067800

– • Expansion cable 10 m 2067801

– Connecting cable for direct encoder connec‐tion, shielded, twisted pair, 1 micro D-Sub15-pin, 2 × M12 8-pin

2071072

Table 149: Part numbers for accessories for Drive Monitor FX3-MOC0


DM8-A4K Diode module for the connection of multiplepressure-sensitive safety mats that triggershort-circuits

6026142

Table 150: Part numbers for DM8-A4K diode module


– Muting lamp with mounting kit 2020743

– LED muting lamp with cable 2 m 2019909

– LED muting lamp with cable 10 m 2019910

Table 151: Part numbers for muting lamp and cable

ORDERING INFORMATION 13


14 Appendix

14.1 Compliance with EU directives

EU declaration of conformity (excerpt)

The undersigned, representing the following manufacturer herewith declares that theproduct is in conformity with the provisions of the following EU directive(s) (including allapplicable amendments), and that the respective standards and/or technical specifica‐tions are taken as the basis.

Complete EU declaration of conformity for download

You can call up the EU declaration of conformity and the current operating instructionsfor the protective device by entering the part number in the search field atwww.sick.com (part number: see the type label entry in the “Ident. no.” field).

14 APPENDIX


http://www.sick.com

14.2 Checklist for the manufacturer

Checklist for the manufacturer/installer installing the Flexi Soft safety controller

The details on the items listed below must be available at the latest when the system iscommissioned for the first time. However, they are dependent upon the application, therequirement of which must be reviewed by the manufacturer/installer.

This checklist should be retained and kept with the machine documentation to serve asreference during recurring tests.

This checklist does not replace the initial commissioning, nor the regular inspection byqualified safety personnel.

Have the safety rules and regulations been observed in compliance with thedirectives/standards applicable to the machine?

Yes ⃞ No ⃞

Are the applied directives and standards listed in the declaration of con‐formity?

Yes ⃞ No ⃞

Does the protective device correspond to the required category? Yes ⃞ No ⃞Are the required protective measures against electric shock in effect (protec‐tion class)?

Yes ⃞ No ⃞

Has the safety function been checked in compliance with the test notes ofthis documentation? In particular:Function check of the control devices, sensors, and actuators connected tothe safety controllerCheck of all cut-off paths

Yes ⃞ No ⃞

Is there an assurance that a full thorough check of the safety function is car‐ried out after every change to the configuration of the safety function?

Yes ⃞ No ⃞

APPENDIX 14


15 List of abbreviations

ACR

Automatic configuration recovery = function for the automatic recovery or reproductionof the configuration of connected EFI-enabled safety sensors such as laser scanners orlight curtains

ESPE

Electro-sensitive protective device (e.g., C4000)

CDS

SICK Configuration and Diagnostic Software

EDM

External device monitoring

EFI

Enhanced function interface = safe SICK device communication

FPLC

Fail-safe programmable logic controller

HMI

Human machine interface

OSSD

Output signal switching device

PFHd

Probability of dangerous failure per hour

SIL

Safety integrity level

SILCL

Safety integrity level claim limit

PLC

Programmable logic controller

15 LIST OF ABBREVIATIONS


16 List of figures

1. Example minimum construction of the Flexi Soft system with FX3-CPU0 and FX3-XTDI or FX3-CPU1 and FX3-XTIO................................................................................16

2. Maximum construction of the Flexi Soft system (without relay modules).............. 163. FX3-CPU0 main module............................................................................................. 184. FX3-CPU1 main module............................................................................................. 195. FX3-CPU2 main module............................................................................................. 206. FX3-CPU3 main module............................................................................................. 217. FX3-XTIO I/O module.................................................................................................. 238. Internal structure of the FX3-XTIO – safe inputs and test outputs..........................239. Internal structure of the FX3-XTIO – safe outputs....................................................2410. FX3-XTDI I/O module.................................................................................................. 2711. Internal structure of the FX3-XTDI – safe inputs and test outputs..........................2712. FX3-XTDS I/O module.................................................................................................2813. Internal structure of the FX3-XTDS – safe inputs and test outputs........................ 2914. Internal structure of the FX3-XTDS – non-safe outputs........................................... 2915. FX0-STIO I/O module..................................................................................................3016. Internal structure of the FX0-STIO – non-safe inputs...............................................3017. Internal structure of the FX0-STIO – non-safe outputs............................................ 3118. Drive Monitor FX3-MOC0............................................................................................3419. UE410-2RO relay output module...............................................................................3420. UE410-4RO relay output module...............................................................................3421. Internal structure of the UE410-2RO........................................................................ 3522. Internal structure of the UE410-4RO........................................................................ 3623. Mounting the module on the DIN mounting rail.......................................................4224. Attaching end clamps.................................................................................................4325. FX3-CPU0 main module............................................................................................. 4626. FX3-CPU1 main module............................................................................................. 4727. FX3-CPU2 main module............................................................................................. 4728. FX3-CPU3 main module............................................................................................. 4829. FX3-XTIO I/O module.................................................................................................. 4930. FX3-XTDI I/O module.................................................................................................. 5031. FX3-XTDS I/O module.................................................................................................5032. FX0-STIO I/O module..................................................................................................5133. Drive Monitor FX3-MOC0............................................................................................5234. UE410-2RO relay output module...............................................................................6035. UE410-4RO relay output module...............................................................................6036. Example integration of a relay output module into the Flexi Soft system...............6137. Wiring for the power supply to a Flexi Soft system...................................................6138. Circuit diagram for multiple pressure-sensitive safety mats with diode module

DM8-A4K connected to the FX3-XTIO upstream...................................................... 6739. Circuit diagram for multiple pressure-sensitive safety mats with diode module

DM8-A4K connected to the FX3-XTDI upstream...................................................... 6840. Internal circuitry for diode module DM8-A4K...........................................................6841. Minimum distance a to reflective surfaces, correct mounting and alignment.......7342. Minimum distance a based on distance D for testable single-beam photoelectric

safety switches with aperture angle of 10° (e.g., Wx12/24/27, Vx18).................7343. Mounting to avoid mutual optical interference........................................................ 7444. Example for the connection of an FX3-XTIO I/O module to a UE10-3OS safety relay

..................................................................................................................................... 7545. Connection of Flexi Link stations via EFI1+2............................................................8046. Connection of a Flexi Line system............................................................................. 8147. Connect the cable shielding to the DIN mounting rail............................................. 8248. Unplug the plug-in terminals....................................................................................10749. Disconnect the plug connectors..............................................................................107

LIST OF FIGURES 16


50. Remove the modules from the DIN mounting rail..................................................10851. Response times within a Flexi Soft system............................................................ 10952. Response times within a Flexi Soft system............................................................ 11553. Response times within a Flexi Link system............................................................ 11754. Maximum switching voltage for direct current, relay output modules UE410-2RO/

UE410-4RO...............................................................................................................14255. Electrical endurance of relay output modules UE410-2RO/UE410-4RO.............14256. Dimensioned drawing FX3-CPUx (mm)................................................................... 14557. Dimensioned drawing FX3-XTIO, FX3-XTDS, FX0-STIO, FX3-XTDI, UE410-2RO, and

UE410-4RO (mm)..................................................................................................... 14658. Dimensioned drawing FX3-MOC0 (mm)..................................................................14659. Dimensioned drawing optimized motor feedback splitter box FX3-EBX1 (mm/in)....

14760. Dimensioned drawing motor feedback splitter box FX3-EBX3 (mm/in)............... 14861. Dimensioned drawing dual encoder connection box FX3-EBX4 (mm/in)............ 14962. Dimensioned drawing diode module DM8-A4K.....................................................149

16 LIST OF FIGURES


17 List of tables

1. Overview of the Flexi Soft documentation...................................................................72. Modules, firmware versions, and software versions you will need......................... 133. Overview of modules.................................................................................................. 164. USB interface on the FX3-CPU3 main module......................................................... 215. System plug variants.................................................................................................. 226. Maximum extended error detection times for cross-circuits on the FX3-XTIO........257. Error detection time and error response time on the FX3-XTIO...............................268. Achievable SIL and PL................................................................................................ 329. Pin assignment of the RS-232 interface on the FX3-CPUx......................................3610. System requirements for Flexi Link........................................................................... 3811. Data availability dependent on the connection method..........................................3812. System requirements for Flexi Line........................................................................... 3913. Update rate of a Flexi Line system dependent on the maximum cable length and

the size of the process image....................................................................................3914. Selection and settings of optical SICK muting sensors in muting applications.....4015. Output level of muting sensors..................................................................................4016. Pin assignment on the FX3-CPU0 main module with FX3-MLP0 system plug....... 4617. Pin assignment at FX3-CPU1 main module with FX3-MPL0 system plug and at

FX3-CPU2 main module with FX3-MPL1 system plug..............................................4818. Pin assignment on the FX3-CPU3 main module with FX3-MLP1 system plug....... 4919. Pin assignment for the FX3-XTIO I/O module........................................................... 4920. Pin assignment for the FX3-XTDI I/O module........................................................... 5021. Pin assignment for the FX3-XTDS I/O module..........................................................5122. Pin assignment for the FX0-STIO I/O module........................................................... 5123. Pin assignment of the micro D-SUB male connector for the FX3-MOC0................ 5224. Connections on the encoder connection boxes (front view)....................................5325. Description of the connections on encoder connection boxes............................... 5426. Pin assignment for encoder connection C1 on the FX3-EBX1................................ 5527. Pin assignment for encoder connection C2 on the FX3-EBX1................................ 5528. Pin assignment HD D-SUB female connector C3 on the FX3-EBX1 for connection

to the FX3-MOC0.........................................................................................................5629. Pin assignment for encoder connection C1 on the FX3-EBX3................................ 5630. Pin assignment for terminals C2 on the FX3-EBX3.................................................. 5731. Pin assignment HD D-SUB female connector C3 on the FX3-EBX3 for connection

to the FX3-MOC0.........................................................................................................5732. Pin assignment for D-SUB female connector C4 on the FX3-EBX3.........................5833. Pin assignment for encoder connection C1 on the FX3-EBX4................................ 5834. Pin assignment for encoder connection C2 on the FX3-EBX4................................ 5835. Pin assignment HD D-SUB female connector C3 on the FX3-EBX4 for connection

to the FX3-MOC0.........................................................................................................5936. Setting of the supply voltage for the encoders at the FX3-EBX3 motor feedback

splitter box and at the FX3-EBX4 dual encoder connection box............................. 5937. Pin assignment of the UE410-2RO relay output module.........................................6038. Pin assignment of the UE410-4RO relay output module.........................................6039. Connection for emergency stop pushbutton.............................................................6340. Functions with ES21...................................................................................................6441. Connection of electro-mechanical safety switches.................................................. 6442. Connection of locking devices................................................................................... 6443. Functions with electro-mechanical safety switches and locking devices............... 6444. Connection of the E100............................................................................................. 6545. Functions with the E100............................................................................................ 6546. Connection of the two-hand control.......................................................................... 6547. Functions with type IIIA two-hand control................................................................. 6648. Functions with type IIIC two-hand control................................................................. 66

LIST OF TABLES 17


49. Connection of pressure-sensitive safety mats and bumpers.................................. 6650. Function of pressure-sensitive safety mats and bumpers.......................................6651. Connection of multiple pressure-sensitive safety mats with diode module DM8-

A4K connected upstream.......................................................................................... 6752. Connection of operating mode selector switch........................................................ 6853. Function with operating mode selector switch......................................................... 6854. Functions with volt-free contacts...............................................................................6955. Connection of magnetic safety switches with equivalent inputs (RE13, RE27).....6956. Connection of magnetic safety switches with complementary inputs (e.g., RE11,

RE21, RE31, RE300)..................................................................................................6957. Functions with magnetic safety switches..................................................................6958. Connection of inductive safety switches...................................................................7059. Functions with inductive safety switches..................................................................7060. Connection of the transponders................................................................................7061. Functions with transponders..................................................................................... 7062. Connection of type 2 testable single-beam photoelectric safety switches.............7163. Functions with type 2 testable single-beam photoelectric safety switches............7164. Connection of type 4 testable single-beam photoelectric safety switches.............7165. Functions with type 4 testable single-beam photoelectric safety switches............7266. Connection of electro-sensitive protective devices.................................................. 7467. Facilities for connecting encoders.............................................................................7768. Cables and connection boxes for encoders..............................................................7869. Wiring of encoder signals...........................................................................................7970. Possible cable lengths and types for Flexi Link connections...................................8071. Possible cable lengths and types for Flexi Line connections.................................. 8172. MS LED........................................................................................................................8673. CV LED.........................................................................................................................8674. EFI LEDs...................................................................................................................... 8775. LINE LED......................................................................................................................8776. MS LED on the FX3-XTIO I/O module........................................................................ 8877. Input and output LEDs on the FX3-XTIO I/O module................................................8878. MS LED on the FX3-XTDI I/O module........................................................................ 8979. Input LEDs on the FX3-XTDI I/O module................................................................... 8980. MS LED on the FX3-XTDS I/O module.......................................................................9081. Input and output LEDs on the FX3-XTDS I/O module.............................................. 9082. MS LED on the FX0-STIO I/O module........................................................................ 9183. Input/output LEDs on the FX0-STIO I/O module...................................................... 9184. MS LED on the Drive Monitor FX3-MOC0..................................................................9285. LEDs on the UE410-2RO and UE410-4RO relay output modules........................... 9286. Error codes and error messages in the Flexi Soft system and possible trouble‐

shooting measures..................................................................................................... 9787. Overview of component disposal............................................................................ 10888. Calculation of the response time of the Flexi Soft system in ms..........................11189. Calculation of the response time for the digital inputs (E1) in ms........................11190. Calculation of the response time for the digital outputs (A1) in ms..................... 11291. Calculation of the response time for the input from an EFI-enabled device (E2) in

ms..............................................................................................................................11292. Calculation of the response time for the output of an EFI-enabled device (A2) in

ms..............................................................................................................................11293. Calculation of the response time for the input from a gateway (E3) in ms.......... 11394. Calculation of the response time for the output to a gateway (A3) in ms............ 11395. Calculation of the response time for the input from an FX3-MOCx (E4) in ms.... 11496. Calculation of the response time for the output to an FX3-MOCx (A4) in ms...... 11497. Example for the calculation of the response time for the digital inputs (E1).......11598. Example for the calculation of the response time for the digital outputs (A1) on

path 1........................................................................................................................116

17 LIST OF TABLES


99. Example for the calculation of the response time of path 1 of a Flexi Soft system...................................................................................................................................116

100. Example for the calculation of the response time for the input from an EFI-enableddevice (E2)................................................................................................................ 116

101. Example for the calculation of the response time for the digital outputs (A1) onpath 2........................................................................................................................116

102. Example for the calculation of the response time of path 2 of a Flexi Soft system...................................................................................................................................117

103. Example for the calculation of the response time for the digital inputs (E1) fromstation A....................................................................................................................117

104. Example for the calculation of the response time for the output to an EFI-enableddevice (A2) from station A....................................................................................... 118

105. Example for the calculation of the total response time of station A (from remoteinput to EFI) in a Flexi Link system..........................................................................118

106. Example for the calculation of the response time for the input from an EFI-enableddevice (E2) from station B....................................................................................... 118

107. Example for the calculation of the response time for the digital inputs (E1) fromstation B....................................................................................................................118

108. Example for the calculation of the total response time of station B (remote input tolocal output) in a Flexi Link system.........................................................................119

109. Safety technology parameters FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3....119

110. General data FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3........................... 120111. Power supply unit (A1, A2) for FX3-CPU0, FX3-CPU1, FX3-CPU2, and FX3-CPU3 (via

FX3-MPL0 or FX3-MPL1 system plug).....................................................................120112. Safety technology parameters FX3-XTIO.................................................................122113. General data for the FX3-XTIO.................................................................................122114. Power supply unit (A1, A2) for FX3-XTIO................................................................. 123115. Safe inputs (I1 … I8) of the FX3-XTIO...................................................................... 123116. Test outputs (X1, X2) of the FX3-XTIO..................................................................... 124117. Safe outputs (Q1 … Q4) of the FX3-XTIO................................................................ 124118. Safety technology parameters FX3-XTDI.................................................................125119. General data for the FX3-XTDI.................................................................................126120. Safe inputs (I1 … I8) of the FX3-XTDI......................................................................126121. Test outputs (X1, X2) of the FX3-XTDI..................................................................... 127122. Safety technology parameters FX3-XTDS............................................................... 128123. General data for the FX3-XTDS................................................................................128124. Power supply unit (A1, A2) for FX3-XTDS................................................................128125. Safe inputs (I1 … I8) of the FX3-XTDS.....................................................................129126. Outputs XY1 … XY2 of the FX3-XTDS when used as test outputs.........................129127. Non-safe outputs (Y3 … Y6 plus XY1 and XY2 when used as non-safe outputs) of

the FX3-XTDS............................................................................................................130128. General data for the FX0-STIO.................................................................................130129. Power supply unit (A1, A2) for FX0-STIO................................................................. 131130. Input circuit (I1 … IY8) of the FX0-STIO...................................................................131131. Non-safe outputs (Y1 … Y6 plus IY7 and IY8) of the FX0-STIO..............................131132. Safety technology parameters FX3-MOC0..............................................................132133. General data for the FX3-MOC0.............................................................................. 133134. Encoder connection at the FX3-MOC0....................................................................133135. General data, encoder connection boxes for the FX3-MOC0................................138136. On-board power supply Uout (from the FX3-MOC0).................................................139137. Safety technology parameters UE410-2RO/UE410-4R0...................................... 139138. General data UE410-2RO/UE410-4R0.................................................................. 140139. Supply circuit of the UE410-2RO/UE410-4R0 (via FX3-CPUx)..............................140140. Input circuit (B1, B2) of the UE410-2RO/UE410-4R0...........................................141141. Output circuit (13-14, 23-24, 33-34, 43-44) of the UE410-2RO/UE410-4R0....141142. Output circuit (Y14, Y24) of the UE410-2RO/UE410-4R0.................................... 142

LIST OF TABLES 17


143. Terminals and connection data UE410-2RO/UE410-4R0.................................... 143144. PFHd values UE410-2RO/UE410-4R0................................................................... 143145. General system data for the DM8-A4K diode module...........................................144146. Input data for diode module DM8-A4K...................................................................144147. Part numbers for system plugs and modules, Flexi Soft safety controller...........151148. Part numbers for accessories for the Flexi Soft safety controller.........................152149. Part numbers for accessories for Drive Monitor FX3-MOC0................................. 152150. Part numbers for DM8-A4K diode module.............................................................153151. Part numbers for muting lamp and cable...............................................................153

17 LIST OF TABLES


LIST OF TABLES 17


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