SICK Flexi Classic series, UE410-GU, UE410-MU, UE410-8DI, UE410-XU Operating Instructions Manual
...
Flexi Classic
Modular Safety Controller
OPERATING INSTRUCTIONS
en
Operating instructions
Flexi Classic
This document is protected by the law of copyright, whereby all right s established therein remain with the
company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits
of the legal det ermination of Copyright Law. Alteration or abridgement of the document is not permitted without
the explicit written approval of the company SICK AG.
2 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions
Flexi Classic
Contents
Contents
1 About this document.................................................................................................... 6
1.1 Function of this document................................................................................6
1.2 Target group .....................................................................................................6
1.3 Information depth.............................................................................................6
1.4 Scope................................................................................................................7
1.5 Abbreviations....................................................................................................7
1.6 Symbols used ................................................................................................... 7
2 On safety.....................................................................................................................11
2.1 Qualified safety personnel..............................................................................11
2.2 Applications of the device...............................................................................11
2.3 Correct use .....................................................................................................12
2.4 General safety notes and protective measures..............................................12
2.5 Environmental protection ...............................................................................14
2.5.1 Disposal.........................................................................................14
2.5.2 Separation of materials.................................................................14
3 Product description....................................................................................................15
3.1 Special features..............................................................................................15
3.2 Structure.........................................................................................................16
3.2.1 UE410-MU main module...............................................................16
3.2.2 UE410-GU main module................................................................17
3.2.3 UE410-8DI input extension module ..............................................18
3.2.4 UE410-XU input/output extension ................................................18
3.2.5 UE410-2RO/UE410-4RO output modules.....................................18
3.2.6 Gateways.......................................................................................18
3.2.7 Module overview, adjustments and facilities for connecting
sensors..........................................................................................19
3.3 UE410-MU main module ................................................................................22
3.3.1 Controls and status indicators ......................................................24
3.3.2 Terminal assignment.....................................................................25
3.3.3 Outputs..........................................................................................26
3.4 UE410-GU main module.................................................................................27
3.4.1 Controls and status indicators ......................................................28
3.4.2 Terminal assignment.....................................................................29
3.4.3 Global emergency stop with the UE410-GU ..................................29
3.4.4 Local emergency stop on the UE410-GU.......................................31
3.4.5 Inputs............................................................................................32
3.4.6 Outputs..........................................................................................32
3.4.7 Connection of a UE410-8DI...........................................................33
3.4.8 Power-up delay and response time of the UE410-GU ...................33
3.4.9 Diagnostics and troubleshooting for the UE410-GU......................33
3.5 UE410-XU module ..........................................................................................35
3.5.1 Controls and status indicators ......................................................35
3.6 UE410-MU/UE410-XU programs....................................................................36
3.6.1 Program 1......................................................................................37
3.6.2 Program 2......................................................................................38
3.6.3 Programs 3.1 and 3.2 ...................................................................39
3.6.4 Program 4......................................................................................40
3.6.5 Programs 5.1 and 5.2 ...................................................................41
3.6.6 Program 6......................................................................................42
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Contents
3.6.7 Program 7..................................................................................... 43
3.6.8 Program 8..................................................................................... 44
3.6.9 Program 9..................................................................................... 45
3.6.10 Connection of sensors to the UE410-MU/UE410-XU.................... 46
3.7 UE410-GU programs...................................................................................... 49
3.8 UE410-8DI input extension module............................................................... 51
3.8.1 AND link........................................................................................ 52
3.8.2 OR link.......................................................................................... 53
3.8.3 Bypass .......................................................................................... 53
3.8.4 Reciprocal assignment — Mirror mode ......................................... 54
3.8.5 Connection of sensors to the UE410-8DI ..................................... 54
3.8.6 Controls and status indicators...................................................... 56
3.8.7 Inputs and outputs ....................................................................... 57
3.9 UE410-2RO/UE410-4RO output modules ..................................................... 57
3.9.1 Output module UE410-2RO.......................................................... 57
3.9.2 Output module UE410-4RO.......................................................... 58
3.9.3 Controls and status indicators...................................................... 59
3.9.4 UE410-2RO inputs and outputs.................................................... 59
3.9.5 UE410-4RO inputs and outputs.................................................... 59
Operating instructions
Flexi Classic
4 Special applications and functions........................................................................... 60
4.1 RE300 magnetic safety switch....................................................................... 61
4.2 IN4000 inductive safety switch...................................................................... 62
4.3 Testable single-beam photoelectric safety switches...................................... 63
4.4 Two-hand operation/jog mode....................................................................... 66
4.5 OR function.................................................................................................... 67
4.6 Muting function.............................................................................................. 68
4.6.1 Muting with two sensors............................................................... 69
4.6.2 Muting cycle..................................................................................69
4.6.3 Muting sensors............................................................................. 69
4.7 Placement of muting sensors ........................................................................ 70
4.7.1 Muting with two sensors (a sensor pair), crossed placement....... 71
4.7.2 4-sensor muting, sequential layout .............................................. 72
4.7.3 Muting with UE410-MU/UE410-XU............................................... 72
4.8 SICK muting sensors...................................................................................... 73
4.9 Bypass............................................................................................................ 74
4.10 Connecting S1, S2, S3................................................................................... 75
4.10.1 Operation with restart interlock.................................................... 75
4.10.2 Operation without restart interlock............................................... 75
4.10.3 Operation with external device monitoring (EDM) ........................ 75
4.11 Retriggering of the delayed OSSDs................................................................ 76
4.12 Grouping of subsystems ................................................................................ 78
4.13 ENABLE input................................................................................................. 79
5 Mounting/dismantling .............................................................................................. 80
5.1 Steps for mounting the modules.................................................................... 80
5.2 Steps for dismantling the modules................................................................ 81
5.3 Removing the anti-manipulation cover .......................................................... 82
6 Electrical installation................................................................................................ 83
4 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions
Flexi Classic
Contents
7 Application examples and connection diagrams......................................................85
7.1 L21 on the UE410-MU/XU..............................................................................85
7.2 Emergency stop on the UE410-MU/XU...........................................................85
7.3 RE300 on the UE410-MU/XU.........................................................................86
7.4 Two-hand IIIC on the UE410-MU/XU...............................................................86
7.5 C2000 and emergency stop on the UE410-MU/XU, two hazardous
areas...............................................................................................................87
7.6 i11 on the UE410-MU/XU, two independent hazardous areas.......................87
7.7 IN4000 on the UE410-MU/XU........................................................................88
7.8 C4000 on the UE410-MU/XU, 2-sensor muting.............................................88
7.9 Global emergency stop with two UE410-GU...................................................89
8 Commissioning...........................................................................................................90
8.1 Validation of the application...........................................................................90
8.2 Test notes.......................................................................................................91
8.2.1 Tests before the first commissioning ............................................91
8.2.2 Regular testing..............................................................................91
8.2.3 Regular inspection of the protective device by qualified
safety personnel............................................................................91
9 Configuration..............................................................................................................92
9.1 Accepting the system configuration................................................................92
10 Diagnostics.................................................................................................................93
10.1 In the event of faults or errors........................................................................93
10.2 Replacement of a module ..............................................................................93
10.3 SICK support...................................................................................................94
10.4 Error indications of the ERR error LED............................................................94
10.5 Anti-manipulation measures...........................................................................95
11 Technical specifications ............................................................................................96
11.1 Data sheet......................................................................................................96
11.1.1 UE410-MU/UE410-XU modules ....................................................96
11.1.2 UE410-GU module...................................................................... 101
11.1.3 UE410-8DI input extension module ........................................... 105
11.1.4 UE410-2RO/UE410-4RO output modules.................................. 107
11.2 Dimensional drawings................................................................................. 111
11.2.1 UE410-MU and UE410-GU main modules.................................. 111
11.2.2 UE410-XU, UE410-8DI, UE410-2RO, UE410-4RO, UE410-
PRO, UE410-DEV, UE410-CAN modules..................................... 111
12 Ordering information............................................................................................... 112
12.1 Available modules ....................................................................................... 112
12.2 Accessories/spare parts.............................................................................. 115
12.2.1 Single-beam photoelectric safety switches ................................ 115
12.2.2 Non-contact safety switches....................................................... 116
12.2.3 Safety light curtains and multiple light beam safety devices ..... 117
12.2.4 Safety laser scanners and safety camera system...................... 117
12.2.5 Muting lamps and cables........................................................... 117
12.2.6 Anti-manipulation cover.............................................................. 117
13 Annex....................................................................................................................... 118
13.1 Compliance with EU directives..................................................................... 118
13.2 Manufacturer’s checklist............................................................................. 118
13.3 List of tables................................................................................................ 119
13.4 List of illustrations....................................................................................... 120
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Subject to change without notice
Chapter 1 Operating instructions
About this document
Flexi Classic
1 About this document
Please read this chapter carefully before working with this documentation and the Flexi
Classic modular safety controller.
1.1 Function of this document
These operating instructions are designed to address the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, configuration,
electrical installation, commissioning, operation and maintenance of the Flexi Classic
modular safety controller.
These operating instructions do not provide instructions for operating machines on which
the safety controller is, or will be, integrated. Information on this is to be found in the appropriate operating instructions for the machine.
1.2 Target group
These operating instructions are addressed to planning engineers, machine designers and
operators of plants and systems which are to be protected by a Flexi Classic modular safe-
ty controller. They are also addressed to people who integrate the Flexi Classic modular
safety controller into a machine, initialise its use, or who are in charge of servicing and
maintaining the device.
Note
1.3 Information depth
These operating instructions contain the following information on the Flexi Classic modular
safety controller:
• mounting
• electrical installation
• commissioning and configuration
• care and maintenance
Planning and using SICK protective devices also require specific technical skills which are
not detailed in this documentation.
When operating the Flexi Classic modular safety controller, the national, local and statutory rules and regulations must be observed.
General information on accident prevention using opto-electronic protective devices can
be found in the competence brochure “Guidelines Safe Machinery”.
We also refer you to the homepage on the Internet at www.sens-control.com.
Here you will find information on:
• product and application animations
• configuration aid
• these operating instructions in different languages for viewing and printing
• fault, error diagnosis and
troubleshooting
• part numbers
• conformity and approval
6 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 1
Flexi Classic
About this document
1.4 Scope
These operating instructions are original operating instructions.
These operating instructions apply to all Flexi Classic safety controller modules with the
following entry in the field Operating Instructions on the type label: “E-01” or higher. Take
into account the respectively applicable operating instructions (refer to the type label entry
on the modules).
1.5 Abbreviations
EDM
ESPE
OSSD
PLC
SIL
SILCL
Note
Ν, ∏, ν
= Take action …
WARNING
External device monitoring
Electro-sensitive protective equipment (e.g. C4000)
Output signal switching device
Programmable logic controller
Safety Integrity Level
SIL claim limit
1.6 Symbols used
Refer to notes for special features of the device.
LED symbols describe the state of a diagnostics LED. Examples:
Ν The LED is illuminated constantly.
∏ The LED is flashing.
ν The LED is off.
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
Warning!
A warning notice indicates an actual or potential risk or health hazard. They are designed
to help you to prevent accidents.
Read carefully and follow the warning notices!
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Chapter 1 Operating instructions
Tab.1:
Sensor symbols
About this document
Flexi Classic
Symbol Sensors
Electro-mechanical safety switches
Emergency stop button
Electro-sensitive protective equipment (ESPE)
Sensors that can be tested (e.g. photoelectric switches)
Inductive safety sensors (e.g. IN4000)
Two-hand operating panel (IIIA)
Two-hand operating panel (IIIC)
Jog mode via two-hand operating panel (IIIA) (time limit 5 s)
Muting lamp and Reset required lamp (not monitored)
Lamp permanently ON: Muting active
Lamp flashing 1 Hz: Reset required
Pressure sensitive mats (4-wire system)
Reset button
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Flexi Loop
Subject to change without notice
Operating instructions Chapter 1
Tab.2:
Module function
Flexi Classic
About this document
symbols
Symbol Module functions
Bypass function with electro-mechanical dual-channel equivalent switch
(e.g. enabling switch),
Bypass function limited to 60 s
Muting station with two inputs for muting sensors
Retriggering
Monitored semiconductor output
Off delay
ENABLE (EN)
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Chapter 1 Operating instructions
Tab.3:
Input assignment
Tab.4:
Logic symbols
About this document
Flexi Classic
symbols
Symbol Input assignment
Single-channel N/C contact
Single-channel N/C contact, cross-circuit detecting
Single-channel N/C contact at two inputs
Dual-channel N/C contact, equivalent, cross-circuit detecting, with
monitoring of synchronisation (1500 ms)
Dual-channel N/C contact, equivalent, cross-circuit detecting
Dual-channel N/C contact, equivalent
Dual-channel N/C / N/O contact, complementary, cross-circuit detecting
Dual-channel N/C / N/O contact, complementary, cross-circuit detecting,
with monitoring of synchronisation (1500 ms), (e.g. magnetically coded
switch RE300)
Dual-channel semiconductor input, monitored (ESPE)
Single-channel N/C contact/semiconductor input (e.g. sensors that can be
tested)
Switching mats, pressure-sensitive (4-wire system)
Symbol Logic
OR link
AND link
10 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 2
Flexi Classic
On safety
2 On safety
This chapter deals with your own safety and the safety of the equipment operators.
= Please read this chapter carefully before working with the Flexi Classic modular safety
controller or with the machine protected by the Flexi Classic modular safety controller.
2.1 Qualified safety personnel
The Flexi Classic modular safety controller must be mounted, commissioned and serviced
only by qualified safety personnel.
Qualified safety personnel are defined as persons who …
• have undergone the appropriate technical training
and
• who have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
• have access to the operating instructions of the Flexi Classic and those of the particular
modules and have read and familiarised themselves with them
and
• have access to the operating instructions for the protective devices (e.g. C4000)
connected to the safety controller and have read and familiarised themselves with
them.
2.2 Applications of the device
The Flexi Classic modular safety controller is a configurable control system for safety
applications.
The category in accordance with EN ISO 13 849-1 or the SIL in accordance with IEC 61 508
and the SILCL in accordance with EN 62 061 depend on the external circuit, the realisation
of the wiring, the choice of the sensors and their location at the machine.
The device corresponds to up to category 4 in accordance with EN ISO 13 849-1; applications can reach up to SIL3 in accordance with IEC 61 508, up to SILCL3 in accordance
with EN 62 061 or PL e in accordance with EN ISO 13 849-1. The emergency stop function
in the device corresponds to stop category 0 or 1 in accordance with EN 60 204-1.
In order to reach the SIL3 safety level (see chapter 11 “Technical specifications” on
page 96) in accordance with IEC 61 508, the following test must be made at least every
365 days:
• The Flexi Classic system must be powered down.
• The Flexi Classic system must be powered up.
• All safety functions of the connected safety sensors must be verified.
The type of safety sensors as well as the method of wiring must be chosen according to
the category which is to be achieved.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safety switches, sensors, emergency stop pushbuttons) are connected to the modular safety controller
and are linked logically. The corresponding actuators of the machines or systems can be
switched off safely via the switching outputs of the safety controller.
The Flexi Classic safety controller has been tested in accordance with UL 508.
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Chapter 2 Operating instructions
On safety
Flexi Classic
2.3 Correct use
The Flexi Classic modular safety controller may only be used as intended in section 2.2
“Applications of the device”. It may only be used by specialist personnel and only at the
machine at which it was mounted and initially commissioned by qualified safety personnel
in accordance with these operating instructions.
If the device is used for any other purposes or modified in any way — also during mounting
and installation — any warranty claim against SICK AG shall become void.
2.4 General safety notes and protective measures
Observe the safety notes and protective measures!
WARNING
Please observe the following items in order to ensure correct use of the Flexi Classic
modular safety controller.
• When mounting, installing and using the Flexi Classic, observe the standards and
directives applicable in your country.
• The national/international rules and regulations apply to the installation, use and
periodic technical inspection of the Flexi Classic modular safety controller, in particular:
– Machinery Directive 2006/42/EC
– EMC Directive 2004/108/EC (valid until 19.04.2016)
EMC Directive 2014/30/EU (valid from 20.04.2016)
– Provision and Use of Work Equipment Directive 2009/104/EC
– Low Voltage Directive 2006/95/EC (valid until 19.04.2016)
Low Voltage Directive 2014/35/EU (valid from 20.04.2016)
– The work safety regulations/safety rules
• Manufacturers and owners of the machine on which a Flexi Classic is used are
responsible for obtaining and observing all applicable safety regulations and rules.
• The notes, in particular the test notes (see chapter 8 “Commissioning” on page 90) of
these operating instructions (e.g. on use, mounting, installation or integration into the
existing machine controller) must be observed.
• The tests must be carried out by qualified safety personnel or specially qualified and
authorised personnel and must be recorded and documented to ensure that the tests
can be reconstructed and retraced at any time by third parties.
• These operating instructions must be made available to the operator of the machine
where the Flexi Classic is used. The machine operator is to be instructed in the use of
the device by qualified safety personnel and must be instructed to read the operating
instructions.
• To meet the requirements of the relevant product standards (e.g. EN 61 496-1), the
external voltage supply for the devices (SELV) must, among other aspects, be able to
bridge a power failure lasting 20 ms. Suitable power supplies are available as accessories from SICK.
• The modules of the Flexi Classic family conform to Class A, Group 1, in accordance with
EN 55 011. Group 1 encompasses all ISM devices in which intentionally generated
and/or used conductor-bound RF energy that is required for the inner function of the
device itself occurs.
12 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
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Operating instructions Chapter 2
Flexi Classic
WARNING
WARNING
On safety
The Flexi Classic system complies, as per the “radiated emissions” generic standard,
with the requirements of class A (industrial applications).
The Flexi Classic system is therefore only suitable for use in an industrial environment.
Loss of the safety function through an incorrect configuration!
Plan and carry out configuration carefully!
The configuration of safety applications must be carried out with the greatest accuracy and
must match the status and the condition of the machine or system to be monitored.
= Check whether the configured safety application monitors the machine or system as
planned and whether the safety of a configured application is ensured at all times. This
must be ensured in each operating mode and partial application. Document the result
of this check!
= In each case, observe the instructions for commissioning and daily checking in the
operating instructions of the protective devices integrated into the safety application!
= Note the warnings and function descriptions of protective devices connected to the
safety controller! Contact the respective manufacturer of the protective device if in
doubt!
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Subject to change without notice
Chapter 2 Operating instructions
Tab.5:
Overview on
disposal
On safety
Flexi Classic
2.5 Environmental protection
The Flexi Classic modular safety controller has been designed to minimise environmental
impact. It uses only a minimum of power and natural resources.
= At work, always act in an environmentally responsible manner.
2.5.1 Disposal
Disposal of unusable or irreparable devices should always occur in accordance with the
applicable country-specific waste-disposal regulations (e.g. European Waste Code
16 02 14).
Note
WARNING
We would be pleased to be of assistance to you on the disposal of these devices.
Contact us.
2.5.2 Separation of materials
Material separation may only be performed by qualified safety personnel!
Caution is required when dismantling devices. There is a risk of injuries.
Before you send the devices for appropriate recycling, it is necessary to separate the
different materials in the Flexi Classic.
= Separate the housing from the rest of the parts (in particular the circuit board).
= Send the separated components for recycling as appropriate (see Tab. 5).
by components
Components Disposal
Product
Housing, circuit boards, cables,
connectors and electrical connecting
pieces
Packaging
Cardboard, paper
Electronic recycling
Paper/cardboard recycling
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Subject to change without notice
Operating instructions Chapter 3
Fig.1:
Flexi Classic
modular
Flexi Classic
Product description
3 Product description
This chapter provides information on the special features and properties of the Flexi
Classic modular safety controller. It describes the construction and the operating principle
of the device.
= Please read this chapter before mounting, installing and commissioning the device.
3.1 Special features
safety controller
The Flexi Classic series is a safety controller concept comprising different modules that
can be interconnected individually. This allows the system to be extended to up to 104
inputs or outputs.
Each of these modules has a compact width of 22.5 mm. The units are of plug-in style with
communication between the individual units over an internal bus.
The required logic and function is specified by means of rotary switches on the modules.
An exception thereof are the relay modules and the fieldbus modules that are used for
integration in a higher level controller without a safety function. These modules are output
units and have no effect on the logic set or the function of the upstream units.
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Subject to change without notice
Chapter 3 Operating instructions
Fig.2:
Safety controller
Product description
Flexi Classic
The Flexi Classic series consists of the following modules:
• main module UE410-MU
• main module UE410-GU
• input/output extension module UE410-XU
• input extension module UE410-8DI
• output modules UE410-2RO and UE410-4RO
• gateways, e.g.
– UE410-PRO (PROFIBUS-DP)
– UE410-CAN (CANopen)
– UE410-DEV (DeviceNet)
– UE410-EN1 (EtherNet/IP)
– UE410-EN3 (Modbus TCP)
– UE410-EN4 (PROFINET IO)
3.2 Structure
A Flexi Classic system always consists of a single main module (UE410-MU or UE410-GU)
and, if necessary, additional input and output extensions as well as a corresponding bus
module.
structure Flexi Classic
(example with UE410-MU)
Main module
4 inputs /4 outputs
Input/output extension module
4 in puts/4 o utputs
Input extension module
8 in puts
UE410-8DIUE410-XUUE410-MU
Output module
2/4 outputs
UE410-2RO/
UE410-4RO
Gateway
E.g. UE410 -PRO, UE410-DEV,
UE410-CAN (see operating
instructions Flexi Classic
Gateways )
3.2.1 UE410-MU main module
The UE410-MU is the main module in which the system configuration of the entire Flexi
Classic system is stored.
The UE410-MU has 4 safety inputs, 4 semiconductor outputs and 2 test outputs. The
9 programs that are available can be set by means of rotary switches that ensure the
connection of a large number of safety components. Functions such as EDM, resetting,
etc. are selected by means of the wiring of S1, S2 and S3. The UE410-MU can control two
applications acting independently as well as two applications that are dependent on each
other.
Fieldbus
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Operating instructions Chapter 3
Flexi Classic
Product description
The devices listed in the following can be connected to the UE410-MU and the modules
connected to it:
• emergency stop pushbuttons
• pressure sensitive mats
• two-hand controllers
• safety switches
• non-contact safety switches (e.g. RE300, T4000 Compact, IN4000)
• single-beam photoelectric safety switches (e.g. L21, L41)
• safety light curtains and multiple light beam safety devices (e.g. MSL, miniTwin,
C/M2000, C/M4000)
• safety laser scanners and safety camera systems (e.g. S300, V300, S3000)
Typical applications such as muting and OR links can be implemented simply, depending
on the setting of the program switch. If additional inputs or outputs are required, the
UE410-MU can be supplemented with a UE410-XU input/output extension module and/or
one or several UE410-8DI input extension modules.
If relay outputs are required, these can be implemented with the UE410-2RO/UE410-4RO
output modules.
Note
3.2.2 UE410-GU main module
The UE410-GU is a main module that can be used as an alternative to the UE410-MU. As
in the UE410-MU, the system configuration for the entire Flexi Classic system is saved in
the UE410-GU. The UE410-GU makes possible a global emergency stop function for several stations connected together that must each be equipped with a UE410-GU. A local
emergency stop is also possible on each UE410-GU.
The UE410-GU has 4 safety inputs (I1-I4), 1 semiconductor output (Q1), 1 output for a
lamp for “Global emergency stop status” and “Reset required” (Q2), 2 test outputs (X1, X2)
and 2 inputs and 2 outputs for the global emergency stop function (IP, IN, OP and ON). The
safe control inputs I5 and I6 are used to connect external device monitoring and a reset
button. The 9 available programs can be set using a rotary switch and make it possible to
connect a variety of safety components.
The following devices can be connected to the UE410-GU:
• emergency stop pushbutton
• safety switch
• non-contact safety switches (e.g. RE300, T4000 Compact)
• single-beam photoelectric safety switches (e.g. L21, L41)
• safety light curtains and multiple light beam safety devices (e.g. MSL, miniTwin,
C/M2000, C/M4000)
• safety laser scanners and safety camera systems (e.g. S300, V300, S3000)
If additional inputs are required, the UE410-GU can be expanded with one or more input
extension modules UE410-8DI.
The UE410-GU can also be expanded with a UE410-XU. This module does not act on the
global emergency stop.
If relay outputs are required, these can be implemented with the UE410-2RO/UE410-4RO
output modules.
The UE410-GU does not support all data sets from all gateways.
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Chapter 3 Operating instructions
Notes
Product description
Flexi Classic
3.2.3 UE410-8DI input extension module
The UE410-8DI module is an input extension with 8 inputs that can be linked using the OR,
AND or Bypass logic function to the respectively upstream UE410-MU, UE410-GU or
UE410-XU module. The 9 switch positions of the UE410-8DI rotary switch determine which
safety components can be connected to the UE410-MU/GU/XU and which type of logic is
used. The input extension module UE410-8DI acts exclusively on the next UE410-MU,
UE410-GU or UE410-XU module positioned to the left in the module structure, thus forming a function group. It is allowed to connect a maximum of 8 UE410-8DI modules to a
UE410-MU, UE410-GU or UE410-XU.
For more informationen on this topic see section 4.12 “Grouping of subsystems” on
page 78.
3.2.4 UE410-XU input/output extension
The UE410-XU module is an input/output extension with 4 safety inputs, 4 semiconductor
outputs and 2 test outputs. It has the same switch positions, logic functions and facilities
for connecting sensors as the UE410-MU. In contrast to the UE410-MU and UE410-GU, the
UE410-XU cannot store the system configuration.
• A UE410-XU can only be operated in combination with a UE410-MU or UE410-GU main
module.
• A main module and a UE410-XU can be linked logically with each other, thus forming a
subsystem (for further information please refer to section 4.12 “Grouping of subsystems” on page 78).
Note
3.2.5 UE410-2RO/UE410-4RO output modules
The UE410-2RO/UE410-4RO output extensions make one or two dual-channel, contactbased outputs available. They do not have any influence on the specified logic instructions
of a system structure and are controlled by the UE410-MU, UE410-GU or UE410-XU outputs.
3.2.6 Gateways
Gateways (fieldbus modules) can be added to the Flexi Classic modular system for diagnostic purposes. They output the system configuration and the input/output states as well
as the error and status information of all the modules.
Several gateways are available, e.g.:
• UE410-PRO for PROFIBUS-DP
• UE410-DEV for DeviceNet
• UE410-EN1 for EtherNet/IP
The UE410-GU does not support all data sets from all gateways.
You will find a complete list of all gateways and the data sets supported in the operating
instructions “Flexi Classic Gateways” or in the Internet on our homepage www.senscontrol.com.
All gateways have 4 non-safe application diagnostic outputs. The outputs are short-circuit
protected (see also the Flexi Classic Gateways operating instructions).
18 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 3
Tab.6:
Module overview
Tab.7:
Overview of setting
Flexi Classic
Product description
3.2.7 Module overview, adjustments and facilities for connecting sensors
Module Description
UE410-MU
• Main unit of the Flexi Classic modular safety
controller
• 4 safe inputs and 4 safe outputs
• Storage of the system configuration
UE410-GU
• Central function block of the Flexi Classic
modular safety controller
• Global emergency stop can be realized
• 4 safe inputs
• 1 safe output
• Storage of the system configuration
UE410-XU • Input/output extension/subsystem
• 4 safe inputs and 4 safe outputs
• Identical functionality as UE410-MU
UE410-8DI • Input extension
• 8 safe inputs
• Information coupling to the upstream UE410-
MU, UE410-GU or UE410-XU module
UE410-2RO 2 contacts (N/O), 1 signal contact (N/C)
possibilities
UE410-4RO 4 contacts (N/O), 2 signal contacts (N/C)
Flexi Classic gateways
e.g. UE410-PRO, UE410-DEV,
UE410-CAN
Setting possibility Can be set at the module Comment
ENTER button UE410-MU/UE410-GU
Status and diagnostics (information that is not
safety relevant) of a Flexi Classic on a fieldbus
(see Flexi Classic Gateways operating instructions)
Saving of all Flexi Classic system
programs, settings and wiring
Program 1-9
UE410-MU/UE410GU/UE410-XU
Selection of the safety sensors
and of the logic elements to be
connected
Off delay
0-5 s, 0-50 s or
0-300 s
UE410-MU/UE410-XU
Delays 1 or 2 outputs on the
module
3 different variants available
(Not on UE410-xxxT0)
Switch position 0-9 UE410-8DI
Selection of the logic elements
and of the safety sensors to be
connected
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Subject to change without notice
Chapter 3 Operating instructions
Tab.8:
Connection of sen
-
Product description
Flexi Classic
sors to the UE410-MU,
UE410-XU and UE410-8DI
Sensor
Program
UE410-MU/UE410-XU UE410-8DI
A (I1/I2) B (I3/I4) A (I1-I4) B (I5-I8)
7, 8 1, 2, 7, 8, 9 1, 6, 7 1, 6, 7
7, 8 1, 2, 7, 8, 9 6, 7 6, 7
1, 5, 6, 9 5, 6 2, 3, 8 2, 3, 8
– – 4 4
2 – 5 5
1 – 2 2
3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7
3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7
3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7
20 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 3
Flexi Classic
Product description
Sensor
Program
UE410-MU/UE410-XU UE410-8DI
A (I1/I2) B (I3/I4) A (I1-I4) B (I5-I8)
4 4 – –
– 5.2 – –
– 5.1 – –
2 – 5 5
3 – – –
1, 5, 6, 7, 8
1, 2, 6, 7, 8,
2, 3, 6, 7, 8 2, 3, 6, 7, 8
9
3 – 1 1
3 3 – –
1, 5, 6, 9 5, 6 2, 3, 8 2, 3, 8
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Subject to change without notice
Chapter 3 Operating instructions
Fig.3:
Scheme programs 1
-3Fig.4:
Scheme program 4
Product description
Flexi Classic
3.3 UE410-MU main module
The UE410-MU main module is the main module of the Flexi Classic modular safety controller. Only one UE410-MU can be integrated for each Flexi Classic system. A UE410-MU
can control up to two applications acting independently or two applications that are dependent on each other.
In order to increase the number of inputs, one or more UE410-8DI extension modules can
be used additionally.
An additional UE410-XU module can be used in order to increase the number of outputs
(for further information refer to section 4.12 “Grouping of subsystems” on page 78).
The system configuration is stored in the UE410-MU main module (ENTER button to accept
the program settings and system configuration) (for further information refer to section 9.1
“Accepting the system configuration” on page 92).
9 programs that can be set with a screwdriver at the program switch are available.
22 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 3
Fig.5:
Scheme
Fig.6:
Scheme program 8
Flexi Classic
programs 5-7, 9
Product description
Note
WARNING
The following functions can be set by selecting the program and connecting the terminals
S1, S2, and S3 at the module:
• type of the logic and of the safety sensors to be connected
• restart interlock
• external device monitoring (EDM)
Q1 and Q2 always switch off within the response time.
Q31) and Q4 can be deactivated with off delay by using the lower rotary switch (depending
on the device variant 0-5 s/0-50 s/0-300 s/not on UE410-xxxT0).
The outputs are tested periodically in order to detect errors in the safety outputs Q1-Q4.
When using XU modules see section 4.12 “Grouping of subsystems” on page 78.
For further information see section 3.6 “UE410-MU/UE410-XU programs” on page 36.
Subsequent changes to the program or to the wiring (S1-S3) without saving will result in a
safety-related shutdown.
8011509/YPP0/2015-10-26 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 23
Subject to change without notice
1)
Q3 has various functions; see section 3.6 “UE410-MU/U E410-XU programs” on page 36.
Chapter 3 Operating instructions
Fig.7:
UE410
-
MU controls
Tab.9:
UE410
-
MU
Button for accepting the
Program switch
Switch for off delay
Product description
Flexi Classic
3.3.1 Controls and status indicators
and status indicators
system configuration
(not on UE410-xxxT0),
see Tab. 10
indications
LED indicators Meaning
PWR (green) Supply voltage present
Q1/Q2, Q3/Q4 (green) Switching state of the safety outputs (high level)
Q3/Q4 (green flashing) Q3/Q4 to high level during the course of the delay time
ERR (red flashing)
Indication for erroneous operational status on this
module, see chapter 10 “Diagnostics” on page 93
ERR (red)
Indication for erroneous operational status on the whole
system (the error is on another module), see chapter 10
“Diagnostics” on page 93
EN, S1-S3 (green) Voltage is present.
I1-I4 (green) Signal is present.
I1/I2 flash in phase Cross-circuit between I1/I2
I3/I4 flash in phase Cross-circuit between I3/I4
I1/I2 flash out of phase Process error at I1/I2
I3/I4 flash out of phase Process error at I3/I4
I1 to I4 flashes
Synchronization time/concurrence error, expected signal
is not present at the respective input.
S1-S3 flashes Expected signal is not present (e.g. EDM or Reset).
24 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Other indicators Device error, see chapter 10 “Diagnostics” on page 93
Subject to change without notice
Operating instructions Chapter 3
Tab.10:
UE410
-MU
Tab.11:
UE410
-
MU terminal
Flexi Classic
Product description
operating elements
assignment
Switch/button Function
FUNCTION
10-step rotary switch (position 0 forbidden) for setting an input
circuit function (see section 3.6 “UE410-MU/UE410-XU programs”
on page 36)
X1s, X10s,
2)
X1min
10-step rotary switch for setting the off delay time (see section 3.6
“UE410-MU/UE410-XU programs” on page 36)
ENTER Button for accepting the system configuration (Teach-in).
See section 9.1 “Accepting the system configuration” on page 92.
3.3.2 Terminal assignment
Assignment Description
I1/I2 Input for logic path A
I3/I4 Input for logic path B
EN ENABLE input, activates the logic path(s)
S1
S2
Input for reset buttons (RESET), restart interlock (EDM), retriggering,
etc.
S3
A1 (+UB)
Voltage supply
A2 (GND)
X1
X2
Test outputs: cross-circuit detecting and short-circuit detecting control
signals for controlling safety sensors
3)
Q1-Q4 Monitored semiconductor outputs (OSSD)
Q3
Is used in Program 3 as the output for the muting lamp and Reset
required.
3)
2)
The maximum adjustable duration of the switch off delay is 5, 50 or 300 s depending on the device variant,
see section 12.1 “Available modules” on page 112.
3)
When using multiple modules see section 4.12 “Grouping of subsystems” on page 78.
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Subject to change without notice
Chapter 3 Operating instructions
WARNING
Product description
Flexi Classic
3.3.3 Outputs
You have two possibilities to reach SIL3 or Category 4 for your application:
• dual-channel wiring of the outputs, e.g. Q1/Q2 to K1/K2
or
• single-channel wiring only with routing within protected areas such as in a control
cabinet, e.g. Q1 to K1/K2.
Safety-oriented devices must be suitable for safety related signals!
A function interruption of safety outputs results in a loss of the safety functions so that the
risk of serious injury exists.
• Do not connect any loads that exceed the rated values of the safety outputs.
• Wire the Flexi Classic system so that 24 V DC signals cannot contact the safety outputs.
• Connect the GND wires of the power supply to earth so that the devices do not switch
on when the safety output line is applied to frame potential.
• Use suitable components or devices that fulfil all the applicable regulations and
standards.
Actuators at the outputs can be wired single-channeled. In order to maintain the respective
Safety Integrity Level the lines have to be routed in such a manner that cross circuits to
other live signals can be excluded, for example by routing them within protected areas
such as in a control cabinet or in separate plastic-sheathed cables.
26 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
Operating instructions Chapter 3
Flexi Classic
Product description
3.4 UE410-GU main module
The UE410-GU is a main module that can be used as an alternative to the UE410-MU. The
system configuration is stored in the main module (for further information please refer to
section 9.1 “Accepting the system configuration” on page 92).
Only one UE410-GU can be used per Flexi Classic system.
In order to increase the number of inputs, one or more UE410-8DI extension modules can
be used additionally.
To increase the number of outputs, an additional UE410-XU can be used (see section 4.12
“Grouping of subsystems” on page 78). A total of up to 12 Flexi Classic modules and one
gateway can be connected to the UE410-GU.
The UE410-GU makes possible a global emergency stop function for several stations connected together that must each be equipped with a UE410-GU. If the global emergency
stop on a module is operated, the safety outputs on all modules switch off. To reset a global emergency stop, the reset button must be operated on the same module on which the
global emergency stop was triggered.
Note
A global emergency stop must always be reset manually.
Along with the global emergency stop function, on each module it is also possible to select
a local emergency stop function with or without restart interlock. The local emergency stop
only acts on the safety output on the related module. A local emergency stop can be reset
either automatically or manually.
The safety output Q1 always switches within the response time. A switch off delay as on
the UE410-MU is not possible with the UE410-GU.
Different programs for the local inputs can be selected with the aid of a rotary switch.
9 programs are available using which the following functions can be set:
• type of the safety sensors to be connected
• global emergency stop or global and local emergency stop
• automatic or manual reset of a local emergency stop
For further information see section 3.7 “UE410-GU programs” on page 49.
WARNING
Subsequent changes to the program will result in a safety-related shutdown without
saving.
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Subject to change without notice
Chapter 3 Operating instructions
Fig.8:
UE410
-
GU controls
Tab.12:
UE410
-
GU
Tab.13:
UE410
-
GU
Program switch
Button for accepting the
Product description
Flexi Classic
3.4.1 Controls and status indicators
and status indicators
system configuration
indications
LED indicators Meaning
PWR (green) Supply voltage is present.
Q1 (green) Safety output Q1 is high.
ERR (red flashing)
Indication for erroneous operational status on this module, see
chapter 10 “Diagnostics” on page 93
ERR (red)
Indication for erroneous operational status on the whole system
(the error is on another module), see chapter 10 “Diagnostics”
on page 93
I1/I2 (green) Global cut-off path closed
I3/I4 (green) Cut-off path closed
I1/I2 (green flashing
Cross-circuit between I1/I2
in phase)
I3/I4 (green flashing
Cross-circuit between I3/I4
in phase)
I1/I2 (green flashing
Process error at I1/I2
out of phase)
I3/I4 (green flashing
Process error at I3/I4
out of phase)
I5 (green) External device monitoring contact is closed.
operating elements
28 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
I6 (green) Reset button is closed.
IP (green) Input IP is high.
IN (green) Input IN is high.
Other indicators Device error, see chapter 10 “Diagnostics” on page 93
Switch/button Function
X
10-step rotary switch (position 0 forbidden) for setting an input
circuit function, see section 3.7 “UE410-GU programs” on
page 49
ENTER
Button for accepting the system configuration (Teach-in), see
section 9.1 “Accepting the system configuration” on page 92
Subject to change without notice
Operating instructions Chapter 3
Tab.14:
UE410
-
GU terminal
Flexi Classic
Product description
3.4.2 Terminal assignment
assignment
Assignment Description
I1/I2 Global emergency stop (equivalent switch with test pulses)
I3/I4
Local emergency stop (local input, depending on the program
set)
A1 (+UB)
Voltage supply
A2 (GND)
X1
X2
Q1 Single-channel safety output (OSSD)
Q2
Test outputs: cross-circuit detecting and short-circuit detecting
control signals for controlling safety sensors
4)
4)
Connection for the lamp for “Global emergency stop status” and
“Reset required”
I5 Connection for the external device monitoring (EDM)
I6 Connection for the reset button
I
P
I
N
O
P
O
N
Input signal from the previous module (PRE_IN)
Input signal from the next module (NEXT_IN)
Output signal to the previous module (PRE_OUT)
Output signal to the next module (NEXT_OUT)
Notes
3.4.3 Global emergency stop with the UE410-GU
The global emergency stop makes possible the simultaneous shut down of the safety outputs on several Flexi Classic stations connected together that are each equipped with a
UE410-GU as the main module.
• In theory as many UE410-GU modules as required can be connected together to form a
global emergency stop system. However, it is recommended not to exceed 32 modules,
because each module increases the response time of the overall system (see the information on the global response time in section 11.1.2 “UE410-GU module” of the technical data on page 101).
• The different UE410-GU modules that together form a global emergency stop circuit do
not need to be in the same protected area. Faults in the area OX and IX, e.g. a shortcircuit or cross circuit, are detected and will result in shutdown.
• All UE410-GU modules that are on a common global emergency stop cut-off path must
be connected to the same GND connection.
Principle of operation
As long as the system is enabled, each UE410-GU sends a signal to the previous UE410GU (PRE) and to the next UE410-GU (NEXT). If the global emergency stop is activated on a
module (falling edge on I1/I2), then this module sets its safety output Q1 as well as the
signals to its neighboring modules (outputs OP and ON) to low. The neighboring modules
now also set their safety output Q1 as well as their outputs OP and ON to low.
The status of the global emergency stop is also output via the output Q2. If the global
emergency stop is activated on this UE410-GU, this status is indicated with a signal
flashing at 2 Hz on output Q2. If the global emergency stop has been activated on another
UE410-GU, then this status is indicated with a continuous high on output Q2.
4)
When using multiple modules see section 4.12 “Grouping of subsystems” on page 78.
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Subject to change without notice
Chapter 3 Operating instructions
Fig.9:
Connecting several
First module
Last module
Module(s) in the middle
Product description
Flexi Classic
Once the cause of the global emergency stop has been rectified (inputs I1 and I2 are high
again, e.g. protective field clear), then the UE410-GU on which the global emergency stop
was originally triggered signals on output Q2 the status Reset required with a signal
flashing at 1 Hz.
Reset
A global emergency stop can only be reset manually. The reset must be undertaken on the
same module on which the global emergency stop was triggered.
Once the global cut-off path for this module is closed again (inputs I1 and I2 are high
again, e.g. protective field clear) and the reset button on this module is then operated, the
safety output Q1 on this module as well as the outputs OP and ON switch to high again.
The following conditions are to be noted for the reset:
• Only the falling edge is evaluated.
• The minimum actuation time for the reset button is ≥ 50 ms.
• The maximum actuation time for the reset button is ≤ 5 s.
If one of these criteria is not met, the emergency stop is not reset.
Wiring of the modules
To connect several UE410-GU modules together, the input IN on the previous UE410-GU
must be connected to the output OP on the next UE410-GU and the output ON on the previous UE410-GU must be connected to the input IP on the next UE410-GU.
For the specification of the connection cable please refer to the data sheet in section 11.1.2 “UE410-GU module” on page 101.
The first and last UE410-GU in an emergency stop system act as end modules. An end
module is a UE410-GU that has only one neighboring station. These modules are defined
by the wiring of the outputs X1 and X2.
• The end module without PRE is defined by wiring X1 to IP.
• The end module without NEXT is defined by wiring X2 to IN.
This wiring is saved with the configuration and checked each time on switching on.
UE410-GU modules
30 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YPP0/2015-10-26
Subject to change without notice
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