Sick Flexi Soft - Hardware Operating Instructions PDF

OPERATING INSTRUCTIONS
Flexi Soft
Modular Safety Controller

Hardware
GB
Operating instructions
Flexi Soft: Hardware
This document is protected by the law of copyright, whereby all rights 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 determination of Copyright Law. Alteration or abridgement of the document is not permitted without
the explicit written approval of the company SICK AG.
SICK AG Industrial Safety Systems Germany All rights reserved
8012478/SC96/2008-11-28
Contents
Contents
8012478/SC96/2008-11-28
About this document ......................................................................................................6

1.1
Function of this document....................................................................................6
1.2
Target group ..........................................................................................................6
1.3
Depth of information.............................................................................................7
1.4
Scope .....................................................................................................................7
1.5
Abbreviations used ...............................................................................................7
1.6
Symbols used ........................................................................................................8
On safety..........................................................................................................................9
2.1
Qualified persons ..................................................................................................9
2.2
Application areas for the device...........................................................................9
2.3
Correct use ......................................................................................................... 10
2.4
General protective notes and protective measures......................................... 10
2.5
Environmental protection .................................................................................. 11
2.5.1
Disposal ............................................................................................ 11
2.5.2
Material separation.......................................................................... 11
Product description ..................................................................................................... 12

3.1
System properties .............................................................................................. 12
3.2
System configuration ......................................................................................... 13
3.3
System plug FX3-MPL0...................................................................................... 14
3.4
Main module FX3-CPU0..................................................................................... 15
3.4.1
Description ....................................................................................... 15
3.4.2
Display elements, error codes and terminal description ............... 15
3.5
Main module FX3-CPU1..................................................................................... 17
3.5.1
Description ....................................................................................... 17
3.5.2
3.6
FX3-XTIO input/output extension module......................................................... 19
3.6.1
Description ....................................................................................... 19
3.6.2
3.7
FX3-XTDI input extension module ..................................................................... 21
3.7.1
Description ....................................................................................... 21
3.7.2
3.8
UE410-2RO/UE410-4RO relay output modules............................................... 22
3.8.1
Description ....................................................................................... 22
3.8.2
Display elements and terminal description .................................... 24
Connecting devices ..................................................................................................... 25

4.1
Safety command devices and electro-mechanical safety switches................ 27
4.1.1
Emergency stop pushbuttons (e.g. ES21) ...................................... 27
4.1.2
Electro-mechanical safety switches with and without
interlock (e.g. I10, I100 and I1000) ............................................... 28
4.1.3
Enabling switch E100 ...................................................................... 29
4.1.4
Two-hand control.............................................................................. 29
4.1.5
Safety mats....................................................................................... 30
4.1.6
Operating mode selector switch...................................................... 30
4.1.7
Floating contacts.............................................................................. 30
4.2
Non-contact safety sensors ............................................................................... 31
4.2.1
Magnetic safety switches (e.g. RE) ................................................. 31
4.2.2
Inductive safety switches IN4000 and IN40 Direct ....................... 31
4.2.3
Transponder T4000 Compact and T40 Direct ............................... 32
Contents
4.3
4.4
4.5
4.6
Testable single-beam photoelectric safety switches........................................ 32

4.3.1
Testable Type 2 single-beam photoelectric safety switches.......... 32
4.3.2
Testable Type 4 single-beam photoelectric safety switches.......... 33
4.3.3
Information for mounting testable single-beam photoelectric
safety switches ................................................................................. 33
Electro-sensitive protective equipment (ESPE)................................................. 35
Outputs................................................................................................................ 35
EFI devices .......................................................................................................... 35
Special functions.......................................................................................................... 36
5.1
Enhanced Function Interface EFI ................................................................... 36
5.1.1
Definition........................................................................................... 36
5.1.2
Properties.......................................................................................... 36
5.1.3
Functions........................................................................................... 37
5.1.4
Benefits ............................................................................................. 37
5.2
Muting ................................................................................................................. 38
5.2.1
General description .......................................................................... 38
5.2.2
SICK muting sensors ........................................................................ 38
Mounting/Dismantling ................................................................................................ 39
6.1
Steps for mounting the modules ....................................................................... 39
6.2
Steps for dismantling the modules.................................................................... 40
Electrical installation................................................................................................... 42
Configuration................................................................................................................ 44
Commissioning ............................................................................................................. 45
9.1
Full approval of the application ......................................................................... 45
9.2
Tests before the initial commissioning.............................................................. 46
10 Diagnostics ................................................................................................................... 47
10.1 In the event of faults or errors ........................................................................... 47
10.2 SICK support ....................................................................................................... 47
10.3 Error display of the MS and CV status LEDs ..................................................... 47
10.4 Additional error displays of EFI-compatible devices......................................... 47
10.5 Extended diagnostics ......................................................................................... 47
11 Maintenance................................................................................................................. 48
11.1 Regular inspection of the protective device by qualified personnel................ 48
11.2 Cyclic testing ....................................................................................................... 48
11.3 Device replacement............................................................................................ 49
12 Technical data .............................................................................................................. 50
12.1 Data sheet........................................................................................................... 50
12.1.1
General system data ........................................................................ 50
12.1.2
Modules FX3-CPU0 and FX3-CPU1.................................................. 54
12.1.3
FX3-XTIO input/output extension module ....................................... 55
12.1.4
Input/Output extension module FX3-XTDI ...................................... 57
12.1.5
UE410-2RO/UE410-4RO output modules ...................................... 58
12.2 Dimensional drawings ........................................................................................ 61
12.2.1
Main modules FX3-CPU0/1 with system plug................................. 61
12.2.2
Input/output extension FX3-XTIO / input extension FX3-XTDI
/ relay output modules UE410-2RO and UE410-4RO.................... 61
8012478/SC96/2008-11-28
Contents
13 Ordering information ................................................................................................... 62

13.1 Available modules and accessories.................................................................. 62
13.2 Devices ............................................................................................................... 63
13.2.1
Single-beam photoelectric safety switches (Type 2)...................... 63
13.2.2
Non-contact safety switches............................................................ 64
13.2.3
Safety light curtains and multiple light beam safety devices ........ 64
13.2.4
Safety laser scanners and safety camera system ......................... 65
13.2.5
Muting lamp and cable .................................................................... 65
14 Annex
14.1
14.2
14.3
8012478/SC96/2008-11-28
......................................................................................................................... 66
Manufacturers checklist .................................................................................... 66
List of tables ....................................................................................................... 67
List of illustrations.............................................................................................. 69
Chapter 1
About this document
About this document

Please read the chapters 1 and 2 carefully before working with this documentation and the
Flexi Soft modular safety controller.
1.1
Function of this document
For the Flexi Soft system there are 3 operating instructions with clearly distinguished fields
of application as well as mounting instructions and brief instructions for each module.
The "Flexi Soft Hardware" operating instructions describe all the Flexi Soft modules
and their functions in detail. Use the Hardware operating instructions in particular to
configure Flexi Soft safety controllers.
These mounting instructions instruct the technical staff of the machine manufacturer
and/or of the machine operator on the safe mounting, electrical installation,
commissioning as well as maintenance of the Flexi Soft modular safety controller.
These operating instructions do not provide instructions for operating the machine in
which the safety controller is, or will be, integrated. Information of this kind will be found
in the operating instructions for the machine.
The "Flexi Soft Modular Safety Controller Software" operating instructions describe the
software-supported configuration and parameterization of the Flexi Soft safety controller.
In addition the software operating instructions contain the description of the diagnostics
functions that are important for operation and detailed information for the identification
and elimination of errors. Use the Software operating instructions in particular for the
configuration, commissioning and operation of Flexi Soft safety controllers.
The mounting instructions/brief instructions are enclosed with each Flexi Soft module.
They inform on the basic technical specifications of the modules and contain simple
mounting instructions. Use the mounting instructions/brief instructions when mounting
the Flexi Soft safety controller.
1.2
Target group
These operating instructions are addressed to the planning engineers, designers and
operators of systems which are to be protected by a Flexi Soft modular safety controller. It
also addresses people who integrate the Flexi Soft safety controller into a machine,
commission it initially or who are in charge of servicing and maintaining the unit.
8012478/SC96/2008-11-28
About this document
Chapter 1
1.3
Depth of information
These operating instructions contain information on the Flexi Soft modular safety
controller in the following subjects:
Mounting
Error diagnostics and remedying
Electrical installation
Part numbers
Hardware commissioning
Conformity and approval
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 Soft modular safety controller, the national, local and statutory
rules and regulations must be observed.
The "Safe Machinery" guidelines contain general information about the topic of safety
technology.
Note
We also refer you to the homepage on the Internet and the CD:
http://www.sens-control.com
Flexi Soft CD (2045931)
Here you will find:
Product and application animations
Configuration aids
These operating instructions in different languages for viewing and printing
Designer configuration software Flexi Soft
"Flexi Soft Modular Safety Controller Software" operating instructions
1.4
Scope
These operating instructions are valid for all modules of the Flexi Soft safety controller.
1.5
Abbreviations used
ESPE
Electro-sensitive protective equipment (e.g. C4000)
EDM
External device monitoring
EFI
Enhanced Function Interface
PFHD
Probability of dangerous failure per hour
OSSD
Output signal switching device
SIL
PLC
8012478/SC96/2008-11-28
Safety Integrity Level (safety class)

Programmable Logic Controller
About this document
Chapter 1
1.6
Recommendation
Note
O Red, Red, o Green
> Action
a
ATTENTION
Logo for Flexi Soft
Designer
Symbols used
Recommendations are designed to give you some assistance in your decision-making

process with respect to a certain function or a technical measure.
Notes provide special information on the device.
LED symbols describe the state of a diagnostics LED. Examples:
O Red
The red LED is illuminated constantly.
Red
The red LED is flashing.
o Green
The green LED is off.
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
Warning!
A warning indicates concrete or potential dangers. They save you from harm.
Read warnings carefully and abide by them!
References and notes for the Flexi Soft Designer configuration software are identified by
this symbol.
8012478/SC96/2008-11-28
On safety
Chapter 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 Soft modular safety
controller or with the machine protected by the Flexi Soft modular safety controller.
2.1
Qualified persons
The Flexi Soft modular safety controller may only be installed, commissioned and serviced
by qualified personnel.
Qualified persons are defined as persons who
have undergone the appropriate technical training
and
have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
have access to the operating instructions of the Flexi Soft 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
Application areas for the device
The Flexi Soft modular safety controller is a configurable controller for safety applications.
It can be used
in accordance with EN 61508 to SIL3
in accordance with EN 62061 to SILCL3
in accordance with EN ISO 13849-1:2006 up to Performance Level e
in accordance with EN 954-1 up to Category 4
The degree of safety actually attained depends on the external circuit, the realization of
the wiring, the parameter configuration, the choice of the pick-ups and their location at the
machine.
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.
8012478/SC96/2008-11-28
On safety
Chapter 2
2.3
Correct use
The Flexi Soft modular safety controller may only be used within specific operating limits
(voltage, temperature, etc., refer to the technical data in Chapter 12) in the sense of
Section 2.2 "Application areas for 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
personnel in accordance with these operating instructions.
SICK AG accepts no claims for liability if the equipment is used in any other way or if
modifications are made to the device, even in the context of mounting and installation.
The external voltage supply of the device must be capable of buffering brief mains
voltage failures of 20 ms as specified in EN 60204. Suitable PELV- and SELV-compatible
power supply units are available as accessories from SICK.
The modules of the Flexi Soft system conform to Class A, Group 1, in accordance with
EN 55011.
Group 1 encompasses all the 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.
a
ATTENTION
The Flexi Soft system fulfils the requirements of Class A (industrial applications) in
accordance with the "Interference emission" basic specifications.
The Flexi Soft system is therefore only suitable for use in an industrial environment and
not for private use.
2.4
a
ATTENTION
General protective notes and protective measures
Observe the protective notes and measures!

Please observe the following items in order to ensure proper use of the Flexi Soft safety
controller.
When mounting, installing and using the Flexi Soft safety controller, 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 Soft safety controller, in particular:
Machinery Directive 98/37/EC
EMC Directive 2004/108/EC
Use of Work Equipment Directive 89/655/EC
Low-Voltage Directive 2006/95/EC
The work safety regulations/safety rules
Manufacturers and owners of the machine on which a Flexi Soft safety controller is used
are responsible for obtaining and observing all applicable safety regulations and rules.
The notices, in particular the test notices (see Chapter 9, "Commissioning") of these
operating instructions (e.g. on use, mounting, installation or integration into the existing
machine controller) must be observed.
10
8012478/SC96/2008-11-28
On safety
Chapter 2
The tests must be carried out by specialised 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 user of the machine where
the Flexi Soft safety controller is used. The machine operator is to be instructed in the
use of the device by qualified personnel and must be instructed to read the operating
instructions.
2.5
Environmental protection
The Flexi Soft 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
We would be pleased to be of assistance on the disposal of this device. Contact your local
SICK representative.
2.5.2
Material separation
Material separation may only be performed by qualified personnel!

Exercise care when disassembling the devices. The danger of injury is present.
ATTENTION
Before you can turn over the devices for environmental-friendly recycling, you must
separate the different materials of the Flexi Soft from one another.
> Separate the housing from the remaining components (especially the PCB).
> Send the separated components to the corresponding recycling centres (see the
following table).
Table 1: Overview of disposal
by component
Component
Disposal
Product
Housing
Plastic recycling
PCBs, cables, plugs and electrical

connection pieces
Electronics recycling
Packaging
Cardboard, paper
8012478/SC96/2008-11-28
Paper/cardboard recycling
11
Product description
Chapter 3
Product description
This chapter provides information on the features and properties of the Flexi Soft system
and describes the structure and operating principle.
3.1
System properties
Fig. 1: Flexi Soft modular

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

Modular structure: 1 main module and up to 12 input/output extension modules, each
with 22.5 mm compact width
8 to 96 inputs and 4 to 48 outputs
Programmable
Use of up to 255 standard and application-specific logic blocks
Standard logic blocks: AND, OR, NOT, XNOR, XOR
Application-specific logic blocks: Emergency stop, two-handed, muting, pressing,
operating mode selector switch, reset, restart
2 EFI interfaces at the FX3-CPU1 main module, see Section 3.5
Logo for Flexi Soft
Designer
The Flexi Soft Designer configuration software is available for configuring the control tasks.
The configuration software is available on the Internet or on the CD:
http://www.sens-control.com or
12
8012478/SC96/2008-11-28
Product description
Chapter 3
3.2
System configuration
A Flexi Soft system consists of the following modules:

an FX3-MPL0 system plug
an FX3-CPU0 or FX3-CPU1 main module
up to 12 additional FX3-XTIO and FX3-XTDI input/output extension modules,
in addition up to 8 UE410-2RO relay output modules and/or 4 UE410-4RO relay output
modules (meaning a max. of 16 safe relay outputs).
Note
Further modules of the UE410 series may not be connected to the Flexi Soft system.
Fig. 2: Examples for the

minimum configuration of a
Flexi Soft system with CPU0
and XTDI or CPU1 and XTIO
Fig. 3: Maximum
configuration of the Flexi Soft
system (without relay output
extensions and gateways)
8012478/SC96/2008-11-28
13
Product description
Chapter 3
Table 2: Overview of the

modules
Type
Kind
FX3-CPU0
FX3-CPU1
Main module
Inputs
(1)
Outputs
Logic
Max.
blocks
occurrence
255
1x
FX3-XTIO
Input/output extension
FX3-XTDI
Input extension
UE410-2RO
Relay output extension
8 x (2)
UE410-4RO
Relay output extension
4 x (2)
(1)
EFI terminals
(2)
Max. of 16 safe relay outputs
3.3
12 x
System plug FX3-MPL0
The system configuration of the complete Flexi Soft system is only stored in the system
plug. This offers the advantage when terminal modules are replaced that the Flexi Soft
system does not have to be reconfigured.
Note
Connected EFI-compatible devices have to be configured again when they are replaced.
The data stored in the system plug are retained when the voltage supply is interrupted.
The main module and the inputs of the system are supplied with electricity exclusively
through the system plug. The outputs, on the other hand, are supplied separately.
14
Note
The current of the power supply unit that supplies the main module has to be limited to a
maximum of 4 A either by the power supply unit itself or by a fuse.
Note
If modules are replaced, ensure that the system plug is plugged into the suitable main
module. Uniquely mark all the connection cables and connectors at the Flexi Soft system
in order to avoid confusion.
8012478/SC96/2008-11-28
Product description
Chapter 3
3.4
Main module FX3-CPU0
3.4.1
Description
The main module FX3-CPU0 is the central process unit of the entire system in which all the
signals are monitored and processed logically in accordance with the configuration stored
in the system plug. The outputs of the system are switched as a result of the processing,
whereby the FLEX BUS+ internal bus serves as the data interface.
The main module furthermore has an RS-232 interface with the following functions:
Transferring the configuration from the Flexi Soft Designer to the system plug
Downloading the configuration from the system plug to the Flexi Soft Designer
Diagnostics of the Flexi Soft system with the Flexi Soft Designer
Continuous diagnosis of the Flexi Soft system via the connected PLC, making the RS-232
interface an alternative for a gateway.
Note
The maximum permissible cable length is 3 m. The screen has to be shielded and
connected at suitable points to the FE.
Avoid ground loops between the GND of the RS-232 interface and the connection A2 of
the main module, e.g. by using optocouplers.
Note
When the system plug is not plugged in, ensure that no debris can enter the corresponding
opening.
3.4.2
Display elements, error codes and terminal description
Fig. 4: Display elements

FX3-CPU0
System plug
RS-232 interface
Table 3: System plug pin

assignment
8012478/SC96/2008-11-28
LED MS (Module Status)

LED CV (Configuration Verified)
Pin
Assignment
A1
24 V voltage supply for all the modules, with the exception of the outputs
A2
GND of the voltage supply
15
Product description
Chapter 3
Table 4: Displays of the

MS LED
MS LED
Meaning
Notes
Supply voltage is off or

outside of tolerance
Switch on the supply voltage and check it

at the terminals A1 and A2
Red/green
(1 Hz)
A self test is being

carried out or the
system is being
initialized
Please wait ...
Green (1 Hz)
System is ready for

operation
In order to start the application press the

Start button in the Flexi Soft Designer
O Green
Application is being
carried out
Red (1 Hz)
Invalid configuration
Check the module type and version of the

main module and extension modules
whose MS LED flashes red/green
If appropriate, adapt the configuration
using the Flexi Soft Designer
For detailed diagnostics information refer
to the Flexi Soft Designer
O Red
Critical error in the

system
Switch the supply voltage off and on again

If the error is not eliminated after multiple
repetition, replace the module
In order to narrow down the respective
module use the diagnostics display in the
Flexi Soft Designer

CV LED
CV LED
Meaning
Note
Configuration process
is running
Yellow (2 Hz)
Storing of configuration data in the nonvolatile memory
Supply voltage may not be interrupted until

the storage process has been completed
Yellow (1 Hz),
synchronous with
red MS LED
Invalid configuration
Check the module type and version of the

main module and extension modules
whose MS LED flashes red/green
If appropriate, adapt the configuration
using the Flexi Soft Designer
For detailed diagnostics information refer
to the Flexi Soft Designer
16
Yellow (1 Hz)
Valid but unverified

configuration
O Yellow
Valid and verified

configuration
Verify configuration with the Flexi Soft

Designer software
8012478/SC96/2008-11-28
Product description
Chapter 3

Table 6: Pin assignment of
RS-232 interface
Plug/socket
Pin
Signal
Colour
Assignment PC-sided
RS.232 SubD (9 pins)
3
4
Reserved
Brown
RxD
White
Pin 3
GND (Internally electrically

connected with connection
A2 of the main module)
Blue
Pin 5
TxD
Black
Pin 2
3.5
Main module FX3-CPU1
3.5.1
Description
The main module FX3-CPU1 has the same functions as the FX3-CPU0. Please observe the
notes in Chapter 3.4.
In addition this module has 2 EFI interfaces. If intelligent SICK sensor equipment is
connected, a functional extension at the sensors is then possible by simple means, see
the following table. For further information about EFI interfaces refer to Chapter 5.1.
Transferring the configuration from the Flexi Soft Designer to the system plug and to the
connected EFI-compatible devices
Downloading the configuration from the system plug and the connected EFI-compatible
devices to the Flexi Soft Designer
Diagnostics of the Flexi Soft system with the Flexi Soft Designer
Continuous diagnosis of the Flexi Soft system via the connected PLC, making the RS-232
interface an alternative for a gateway.
Note
The maximum permissible cable length is 3 m. The screen has to be shielded and
connected at suitable points to the FE.
Avoid ground loops between the GND of the RS-232 interface and the connection A2 of
the main module, e.g. by using optocouplers.
8012478/SC96/2008-11-28
17
Product description
Chapter 3
3.5.2
The displays of the MS and CV LEDs as well as the RS-232 interface are identical with
those of the FX3-CPU0, see Section 3.4.2.
FX3-CPU1
System plug
RS-232 interface
LED CV (Configuration Verified)

LED EFI1
LED EFI2
Table 7: Displays of the EFI

LEDs
18
EFI 1_A
EFI 2_B
EFI 1_B
EFI 2_A
EFI LED (EFI1 or EFI2)
Meaning
Note
OK
Red (1 Hz)
Communication error
Check the wiring
8012478/SC96/2008-11-28
Product description
Chapter 3
3.6
FX3-XTIO input/output extension module
3.6.1
Description
The FX3-XTIO module is an input/output extension with 8 safety inputs and 4 safety
outputs. It has two test signal generators: One for text output X1 and one for test output
X2.
The FX3-XTIO module fulfills the following tasks:
Monitoring of the connected sensor equipment, also refer to Chapter 4.
Passing on the input information to the main module
Receiving the control signals from the main module and corresponding switching of the
outputs
The FX3-XTIO module cannot be used alone and always requires a main module
FX3-CPU0/1, see the Flexi Soft Designer configuration software.
The simultaneous use of several FX3-XTIO modules is possible, see Chapter 3.2 "System
configuration".
Voltage supply is effected via the FLEX BUS+ internal bus.
Voltage supply of the outputs Q1 Q4 is effected directly at the FX3-XTIO module.
3.6.2

FX3-XTIO
8 input LEDs
4 output LEDs
Table 8: Terminal
assignment FX3-XTIO
8012478/SC96/2008-11-28
Terminal
Assignment
X1/X2
Test output 1 / Test output 2
I1 ... I4
Inputs 1 to 4
A1
24 V
A2
GND
I5 ... I8
Inputs 5 to 8
Q1 ... Q4
Outputs 1 to 4
19
Product description
Chapter 3
Table 9: Displays of the MS

LED
MS LED
Meaning
Notes
Supply voltage is off or

outside of tolerance
Check the supply voltage at

terminals A1 and A2
Red/green
alternatively (1 Hz)
A self test is being carried

out or the system is being
initialized
Check the module type and version.

If appropriate, adapt the
configuration using the Flexi Soft
Designer
Green (1 Hz)
Module is ready for

operation
Start the application in the Flexi Soft

Designer
O Green
Application is being carried

out
Red (1 Hz)
Correctable external error
Check the wiring of the flashing

inputs and outputs
If all the output LEDs flash, check
the supply voltage at terminals A1
and A2 of this module
O Red
Critical error in the system
Switch off the voltage supply of the

main module and switch it on again
If the error is not eliminated after
multiple repetition, replace the
module
In order to narrow down the
respective module use the
diagnostics display in the Flexi Soft
Designer

input/output LEDs
Input LEDs (I1 ... I8)
Meaning
Output LEDs (Q1 ... Q4)
Input/output is inactive
O Green
Input/output is active
Green (1 Hz) synchronous with the red MS

LED
Input/output is inactive and there is

a correctable error
Green (1 Hz) alternatively with the red MS LED Input/output is active and there is a
correctable error
20
8012478/SC96/2008-11-28
Product description
Chapter 3
3.7
FX3-XTDI input extension module
3.7.1
Description
The FX3-XTDI module is the input extension with 8 safe inputs. It fulfills the following tasks:
Monitoring of the connected sensor equipment, also refer to Chapter 4.
Passing on the input information to the main module
The FX3-XTDI module cannot be used alone and always requires a main module
FX3-CPU0/1, see the Flexi Soft Designer configuration software.
The simultaneous use of several FX3-XTIO modules is possible, see Chapter 3.2 "System
configuration".
Voltage supply is effected via the FLEX BUS+ internal bus.
An FX3-XTDI has two test signal generators. One test signal generator is responsible for the
odd-numbered test outputs X1, X3, X5 and X7, the other for the even-numbered test
outputs X2, X4, X6 and X8.
Attention
Take the following points into account for the wiring:

FX3-XTDI recognises short-circuits between odd-numbered (X1, X3, X5, X7) and evennumbered (X2, X4, X6, X8) test outputs.
Short-circuits under the odd-numbered (X1, X3, X5, X7) or under the even-numbered
(X2, X4, X6, X8) test outputs are not recognised.
3.7.2
The displays of the MS and CV LEDs as well as the input LEDs I1 ... I8 are identical with
those of the FX3-XTIO, see Section 3.6.2.
FX3-XTDI
Table 11: Terminal

assignment FX3-XTDI
8012478/SC96/2008-11-28
Terminal
Assignment
X1/X3
Test signal 1
X2/X4
Test signal 2
I1 ... I4
Inputs 1 to 4
I5 ... I8
Inputs 5 to 8
X5/X7
Test signal 1
X6/X8
Test signal 2
21
Product description
Chapter 3
3.8
UE410-2RO/UE410-4RO relay output modules
3.8.1
Description
The UE410-2RO/UE410-4RO relay output modules make dual-channel contact-based

outputs with "positively driven relay contacts" available.
The UE410-2RO/UE410-4RO relay output modules cannot be used independently, but are
switched via an FRX3-XTIO module. To this purpose a control output of the FX3-XTIO
module (Q1 ... Q4) has to be jumpered to a control input of the relay output module (B1,
B2), see the following figure.
Fig. 8: Example of the
inclusion of a relay module in
the Flexi Soft system
Note
The relay output modules are not nodes on the internal FLEX BUS+ bus. Control signals
cannot therefore be received from the main module.
A max. of 4 UE410-4RO relay output modules or 8 UE410-2RO modules can be connected
to a Flexi Soft system, i.e. a maximum of 16 safe relay outputs are available.
UE410-2RO
The UE410-2RO has a control input (B1). This controls two internal relays and forms a
redundant switch-off path consisting of:
two safe enabling circuits (13/14, 23/24), dual-channel and floating,
a signaling circuit (Y14), dual-channel and non-isolated,
a feedback EDM (Y1/Y2), dual-channel and floating.
22
8012478/SC96/2008-11-28
Product description
Chapter 3

Fig. 9: Internal
configuration UE410-2RO
UE410-4RO
The UE410-4RO has two control inputs (B1, B2). These control two times two internal
relays that form two independently redundant switch-off paths.
Control input (B1) controls two internal relays and forms a redundant switch-off path
consisting of:
Control input (B2) controls two internal relays and forms a redundant switch-off path
consisting of:
The UE410-4RO module thus has double the functionality of an UE410-2RO.
Fig. 10: Internal configuration

UE410-4RO
8012478/SC96/2008-11-28
23
Product description
Chapter 3
3.8.2
Display elements and terminal description
Fig. 11: UE410-2RO/

UE410-4RO display elements
Table 12: UE410-2RO/

UE410-4RO displays
Table 13: UE410-2RO

terminals
Table 14: UE410-4RO

terminals
24
Display
Meaning
PWR (green)
Supply voltage via safety bus is applied
K1/2 (green)
Relay K1/K2 safety contacts closed
K3/4 (green)
Relay K3/K4 safety contacts closed
Assignment
Description
B1
Circuiting relay K1/K2
13/14 and 23/24
Safety contacts for switch-off circuit K1/K2
Y1/Y2
Feedback circuit external device monitoring (EDM) (NC contact)
Y14
NO contact safety contact K1/K2, current-limited

(see Chapter 12 "Technical data" on Page 50)
Assignment
Description
B1
B2
13/14 and 23/24
Safety contacts for switch-off circuit outputs K1/K2
33/34 and 43/44
Safety contacts for switch-off circuit outputs K3/K4
Y1/Y2
Feedback EDM K1/K2 NC contact
Y3/Y4
Feedback EDM K3/K4 NC contact
Y14

Y24

8012478/SC96/2008-11-28
Connecting devices
Chapter 4
Connecting devices
This section describes the connection of safety sensors and actuators to the Flexi Soft
system and provides configuration information for the selected functions.
The Flexi Soft system supports applications up to Performance Level (PL) e (in accordance
with EN ISO 13849-1) and up to Safety Integrity Level SILCL3 (in accordance with
EN 62061).
To this purpose take all the required marginal conditions and evaluate these, for example,
in a failure analysis (FMEA).
For further information that has to be taken into consideration during the electrical
installation see Chapter 7, Electrical installation.
Loss of the safety function through an incorrect configuration!
ATTENTION
a
ATTENTION
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!
Take into account that the minimum switch-off time of the connected sensors must be
greater than the execution time of the logic (see Chapter 4.6 "Logic editor" in the
"Flexi Soft Modular Safety Controller Software" operating instructions and logic editor
of the Flexi Soft Designer) so that it is ensured that the Flexi Soft system can detect the
switching of the sensors. The minimum switch-off time of sensors is usually specified in
the technical data of the sensors.
Note
If an odd-numbered test output is used, odd-numbered inputs have to be used. If an evennumbered test output is used, even-numbered inputs have to be used.
You have to use the test outputs of the module to which the device to be tested is
connected.
After the configuration you obtain the following documentations in the Flexi Soft Designer
under "Info -> Report":
Logic report
Parts list
Information on wiring
8012478/SC96/2008-11-28
25
Connecting devices
Chapter 4
Fig. 12: Example extract of

the documentation in the
Flexi Soft Designer
26
8012478/SC96/2008-11-28
Connecting devices
Chapter 4
Table 15: Connection ES21
4.1
Safety command devices and electro-mechanical

safety switches
4.1.1
Emergency stop pushbuttons (e.g. ES21)
Electrical connection: Example from Flexi Soft Designer with FX3-XTIO
Singlechannel,
without testing
Contact between 24 V and I1
Singlechannel, with
testing
Contact between X2 and I2
Dual-channel,
without testing
Channel 1: Contact between 24 V and I3
Dual-channel,
with testing
Channel 1: Contact between X1 and I5

The dual-channel emergency stop pushbuttons preconfigured in the Flexi Soft Designer
have equivalent switching contacts. Corresponding elements for implementing dualchannel antivalent switching contacts are available in the element window under the group
of floating contacts.
Table 16: Functions with
ES21
Function
Notes
Testing
Possible
Series connection / Max. number of emergency stop pushbuttons connected in series:

Cascading
Take the max. line resistance of 100 W into account (see Chapter
12 "Technical data" on Page 50)
Discrepancy times
Notes
8012478/SC96/2008-11-28
4 ms ... 30 s
Further information is available in the operating instructions for the emergency stop
pushbutton ES21.
27
Connecting devices
Chapter 4
4.1.2
Table 17: Connection of
electro-mechanical safety
switches

interlocks
Electro-mechanical safety switches with and without interlock (e.g. I10, I100
and I1000)
Singlechannel,
without testing
Contact between Ub and I1
Singlechannel, with
testing
Dual-channel,
without testing
Channel 1: Contact between Ub and I3
Dual-channel,
with testing

Single-channel,
without testing
Contact between Ub and I1
Single-channel,
with testing
Dual-channel,
without testing
Coil at Q1
Coil at Q2

Coil at Q3
Dual-channel,
with testing

Coil at Q1

electro-mechanical safety
switches and interlocks
Function
Notes
Testing
Possible
Series connection / The max. number of series-connected emergency stop

Cascading
pushbuttons is determined by the max. line resistance of 100
W (see Chapter 12 "Technical data" on Page 50).
Discrepancy times
Notes
28
4 ms ... 30 s
Further information is available in the operating instructions of the electro-mechanical

safety switches.
8012478/SC96/2008-11-28
Connecting devices
Chapter 4
4.1.3
Table 20: Connection E100
Enabling switch E100
2 positions,
without testing
Channel 1: Contact E31 between Ub and I1
2 positions,
with testing
Channel 1: Contact E31 between X1 and I3
3 positions,
without testing

3 positions,
with testing


E100
Notes
Function
Notes
Testing
Possible
Series connection
Not possible
Discrepancy times
4 ms ... 30 s
Further information is available in the E100 operating instructions.

4.1.4
Table 22: Connection of twohand control
Two-hand control
Type IIIA
without testing

NC contact between 24 V and I1(I3)
Type IIIC
without testing
NO contact between 24 V and I2(I4)
Type IIIA
At Type IIIA two equivalent inputs (NO contacts of the two two-hand buttons) are
monitored.
A valid input signal is only generated if the ON state (H level) exists at both inputs within a
period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were in
the OFF state (L level) beforehand.
Type IIIC
At Type IIIC two pairs of antivalent inputs (NO/NC contact pairs of the two two-hand
buttons) are monitored.
A valid input signal is only generated if the ON state (H/L level) exists at both inputs within
a period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both were in
the OFF state (L/H level) beforehand.
8012478/SC96/2008-11-28
29
Connecting devices
Chapter 4
Note
Further information is available in the operating instructions of the two-hand control.

4.1.5

safety mats
Safety mats
Pressure-sensitive shortcircuiting switching mats in

4-wire technology, with testing
Table 24: Function safety

mats
Note
Function
Notes
Testing
Possible
Series connection
Possible
Table 26: Function of

operating mode selector
switch
Note
Channel 2: Contact between X2

and I2
Further information is available in the operating instructions of the safety mats.

4.1.6

operating mode selector
switch
Channel 1: Contact between X1

and I1
Operating mode selector switch
Operating mode
selector switch (1 of 2)
with testing
Operating mode
selector switch (1 of 2)
without testing
Function
Notes
Testing
Possible
Untested variant switches can be used that allow selections between 2 and 8 operating
modes, test variant switches between 2 and 4.
When wiring the tested operating mode selector switches it should be noted that oddnumbered inputs (I1, I3, I5, I7) have to be used if an odd-numbered test output (X1, X3,
X5, X7) is used, and even-numbered inputs (I2, I4, I6, I8) have to be used if an evennumbered test output (X2, X4, X6, X8) is used.
Further information is available in the operating instructions of the operating mode
selector switch.
4.1.7
Floating contacts
The Flexi Soft Designer software makes a series of floating contacts available for "free"
configuration of contact elements. This allows different NC-/NO-contact combinations with
and without testing to be implemented. In addition elements are available for the start and
stop button, reset button and external device monitoring (EDM).
Table 27: Function of floating
contacts
30
Function
Notes
Testing
Possible
Series connection
Possible
Discrepancy times
Possible, 4 ms ... 30 s
8012478/SC96/2008-11-28
Connecting devices
Chapter 4
4.2
Non-contact safety sensors
4.2.1
Magnetic safety switches (e.g. RE)
Magnetic safety switches with equivalent inputs (RE13, RE27)

magnetic safety switches
with equivalent inputs

With testing

Magnetic safety switches with complimentary inputs (e.g. RE11, RE21, RE31, RE300)
with complimentary inputs
With testing
NC contact between X1 and I1

NO contact between X2 and I2

Function
Notes
Testing
Possible
Series connection / Possible; observe max. line resistance of 100 W and correct
Cascading
setting of the test impulse time
Discrepancy times
Notes
Further information is available in the operating instructions of the magnetic safety

switches.
4.2.2

inductive safety switches
1500 ms preset (800 ms at RE300)
Inductive safety switches IN4000 and IN40 Direct
IN4000
Test input TE (IN4000) at X1

Output A (IN4000) at I1
IN40 Direct
(with OSSD)
inductive safety switches
OSSD1 (IN4000) at I3
OSSD2 (IN4000) at I4
Function
Notes
Testing
Necessary on IN4000!
Series connection / IN40 direct cannot be cascaded

Cascading
IN4000: up to 6 sensors per input
Observe max. line resistance of 100 W and correct setting of the
test impulse time
Max. off-on delay through a complete chain may not exceed a maximum of 10 ms.
Notes
8012478/SC96/2008-11-28
Further information is available in the operating instructions of the inductive safety

switches.
31
Connecting devices
Chapter 4
4.2.3
transponders
Transponder T4000 Compact and T40 Direct

transponders
T4000 Compact
(without testing)
Ub at +LA, I1 at LA
T4000 Compact
(with testing)
X1 at +LA, I3 at LA
T40 Direct
(with OSSD)
Ub at UB (T40), I5 at OA
Ub at +LB, I2 at LB
X2 at +LB, I4 at LB
Ub at UB (T40), I6 at OB
Function
Notes
Testing
Possible for T4000 Compact

Not necessary for T40 Direct, since self monitored
Series connection / T4000 Compact not cascadable;

Cascading
take the max. line resistance of 100 W into account at the T40
Notes

testable Type 2 single-beam
photoelectric safety switches
For further information refer to the operating instructions of the Transponder T4000
Compact or T40 Direct.
4.3
Testable single-beam photoelectric safety switches
4.3.1
Testable Type 2 single-beam photoelectric safety switches
Wx12/18/24/27,
Vx18
Test input TE (transmitter) at X1
L21/27/28
Output Q (receiver) at I1
Attention

Route the transmitter and receiver lines outside the control cabinet in such a manner that
cross-circuiting between these lines can be excluded, for example in separate sheathed
cables or in protected areas.
Function
Notes
Testing
Possible
Series connection / Wx12/18/24/27, Vx18: max. 5 pairs per input can be cascaded
Cascading
L21: max. 35 pairs per input can be cascaded
L27/28: max. 4 pairs per input can be cascaded
Take the max. line resistance of 100 W into account.
Note
32
For further information refer to the operating instructions of the testable Type 2 singlebeam photoelectric safety switches.
8012478/SC96/2008-11-28
Connecting devices
Chapter 4
4.3.2
Testable Type 4 single-beam photoelectric safety switches
L41

Attention

Route the transmitter and receiver lines outside the control cabinet in such a manner that
cross-circuiting between these lines can be excluded, for example in separate sheathed
cables or in protected areas.
Function
Notes
Testing
Necessary
Series connection / Max. 10 pairs per input

Cascading
Take the max. line resistance of 100 W into account
Note
For further information refer to the operating instructions of the testable Type 4 singlebeam photoelectric safety switches.
4.3.3
Notes
Information for mounting testable single-beam photoelectric safety switches
Observe the information for mounting in the operating instructions of the respective
sensors and in particular the following points:
Single-beam photoelectric safety switches may only be used as access protection in
accordance with EN 999. Usage as finger and hand protection is not permissible.
Observe the minimum distance to reflective surfaces.
It is imperative that the safety distance between the light beam and hazardous point be
observed at access protection.
Fig. 13: Minimum distance

"a" to reflective surfaces,
correct mounting and
alignment
S = Sender
R = Receiver
D = Distance between sender and receiver
1 = Limit to hazardous area

3 = Direction of access to hazardous area
2 = Reflective surface
4 = Optical axis
a = Minimum distance from reflective surfaces
8012478/SC96/2008-11-28
33
Connecting devices
Chapter 4
Fig. 14: Minimum distance

"a" as a factor of the distance
"D" for testable single-beam
with a field of view of 10
(e.g. Wx12/18/24/27, Vx18)
Note
Diagrams for L21 and L41 are available in the respective operating instructions.
Avoiding mutual influence at single-beam photoelectric safety switches and between

cascades
If several single-beam photoelectric safety switch pairs are used, the field of view of the
sensors has to be observed in order to prevent mutual influence.
If the senders are only mounted on one side, the light beams may not overlap on the
receiver side so that the light beam of one sender does not reach two receivers.
If the senders and receivers are mounted alternatively, ensure that the light beam of
Sender S1 cannot be received by Receiver R3 and that the light beam of Sender S3
cannot be received by Receiver R1.
Fig. 15: Mounting to avoid
mutual optical influence
34
S1
R1
R2
S2
S3
R3
8012478/SC96/2008-11-28
Connecting devices
Chapter 4
4.4
Table 39: Connection ESPE
Electro-sensitive protective equipment (ESPE)
C20, C40,
M20, M40,
S300, S3000,
V300
Note
ATTENTION
OSSD2 (receiver) at I2
Further information is available in the operating instructions of the corresponding ESPE.
4.5
OSSD1 (receiver) at I1
Outputs
Safety-oriented devices must be suitable for safety related signals!

A function interruption of safety outputs results in a loss of the safety functions so that the
risk of serious injury exists.
Do not connect any loads that exceed the rated values of the safety outputs.
Wire the Flexi Soft system so that 24 V DC signals cannot unintentionally contact 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 sheathed cables.
4.6
EFI devices
If shielding is required, for example for EMC reasons, when connecting the EFI devices,
use an earth terminal that is placed in the control cabinet near the Flexi Soft main module
for this purpose. Connect this earth terminal with the shielding.
8012478/SC96/2008-11-28
35
Chapter 5
Special functions
Special functions
5.1
Enhanced Function Interface EFI
The FX3-CPU1 main module has 2 EFI interfaces. This chapter describes the properties,
the functions and the benefits of these interfaces.
The general EFI function description and the possibilities for combining SICK products with
regard to EFI is available in the EFI operating instructions 8012621.
Information about the status information at the EFI connection is available in the
configuration help 8011150.
5.1.1
Definition
An EFI interface is a safe communication interface between SICK devices. With it

information from the sensor equipment can be read out, as well as commands transferred
to the sensor equipment.
5.1.2
Properties
Up to 4 SICK devices are possible per EFI line, in as far as the EFI-compatible devices
support this number.
Connection of the devices using a 2-wire cable
Various device combination possibilities
Sensor with sensor within the same product family
Sensor with safety controllers and gateways
Transferring of status information between SICK devices using an EFI interface
Activation/utilisation of sensor functions
36
8012478/SC96/2008-11-28
Special functions
Chapter 5
5.1.3
Functions
In addition to the product-specific functions of the respective EFI-compatible devices the

following functions are available:
General functions
Status information of the sensors are available in the controller and at the sensor
Diagnostics information of all the EFI nodes is available in the controller
Transfer of configuration information
Special functions
Simultaneous protective field evaluation
Protective field switching
Function changeover
Operating mode selection
Signal routing
Decentralized diagnostics information via Ethernet
Information on the location of the protective field interruption at host-guest applications
Evaluation of signals and forwarding of the results
5.1.4
Benefits
Reduction of the installation work (only 2 wires) when signals from several sensors are
used
Reduction of the required material through possibility of saving function blocks and
I/Os
High availability through provision of the diagnostics information with high information
contents for rapid and correct handling options
8012478/SC96/2008-11-28
37
Special functions
Chapter 5
5.2
Muting
5.2.1
General description
Muting is the automatic temporary bypassing of all the safety-oriented functions of the
control system or of the safety device. Muting is used when certain objects, such as pallets
with material, may be moved into the hazardous area. During this transportation through
electro-sensitive protective equipment (ESPE), such as a safety light curtain, the muting
function suppresses monitoring by the ESPE.
Observe the information in the "Flexi Soft Modular Safety Controller Software" operating
instructions for the further procedure.
5.2.2
Table 40: Selection of the
SICK optical muting sensors
SICK muting sensors
Sensor
Type
Switching output Q
Photoelectric proximity switch
WT24
Light switching
WT27-2
Photoelectric reflex switch
WT260
Light switching
WL23
Dark switching
WL27
Through-beam photoelectric
switch
WL260
Dark switching
WL12
Dark switching
WL14
Dark switching
WL18-2
Dark switching
WS24/WE24
Dark switching
WS27/WE27
WS260/WE260
38
8012478/SC96/2008-11-28
Mounting/Dismantling
Chapter 6
This chapter describes the mounting of the modules of the Flexi Soft safety controller.
6.1
a
ATTENTION
Steps for mounting the modules
The Flexi Soft system is only suitable for mounting in a control cabinet with at least IP 54
degree of protection.
In a Flexi Soft system the main module FX3-CPU0 or FX3-CPU1 is positioned at the
extreme left, the two optional gateways follow directly.
Ensure that suitable ESD protective measures are also taken during mounting.
Otherwise the FLEX BUS+ bus may be damaged.
The connection between the modules is effected by means of the plug connection
integrated in the housing. Take into account that, when replacing a module, the Flexi
Soft modules have to be pushed approx. 10 mm apart before the corresponding module
can be removed from the DIN rail.
Take suitable measures to ensure that foreign matter does not penetrate the connector
openings, in particular that of the system plug.
Mounting in accordance with EN 50274
The modules are located in a 22.5-mm wide modular system for 35 mm DIN rails to
EN 60715.
Fig. 16: Mounting the module

onto the DIN rail
> Hang the device onto the DIN rail (1).

> Ensure that the earthing spring contact is positioned correctly (2). The earthing spring
contact of the module must contact the DIN rail securely to allow electrical conductivity.
> Latch the module onto the DIN rail by pressing it lightly in the direction of the arrow (3).
8012478/SC96/2008-11-28
39
Chapter 6
Fig. 17: Installing the end

clips
> If there are several modules, slide the modules together individually in the direction of
the arrow until the side plug connection latches in.
> Install the end clips on the right and left.
The following steps are necessary after mounting:
Completing the electrical connections (Chapter Fehler! Verweisquelle konnte nicht
gefunden werden.)
Configuration ("Flexi Soft Modular Safety Controller Software" operating instructions)
Checking the installation (Chapter 9.2)
6.2
Steps for dismantling the modules
Fig. 18: Removing the

removable terminals
> Remove the removable terminals with wiring and the end clips.
40
8012478/SC96/2008-11-28
Chapter 6

Fig. 19: Disconnecting the
plug connections
> If there are several modules, slide the modules away from each other individually in the
direction of the arrow until the side plug connection is separated.
Fig. 20: Removing modules
from the DIN rail
> Press the module downwards at the rear (1) and remove it from the DIN rail in the
direction of the arrow while keeping it pressed down (2).
8012478/SC96/2008-11-28
41
Chapter 7
Switch the entire machine/system off line!

The system could start up unexpectedly while you are connecting the devices.
ATTENTION
Notes
The Flexi Soft safety controller fulfils the EMC requirements in accordance with the basic
specification EN 61000-6-2 for industrial use.
To ensure full electromagnetic compatibility (EMC), the mounting rail has to be
connected to functional earth (FE).
The control cabinet or assembly casing of the Flexi Soft safety controller must comply at
least with enclosure rating IP 54.
Mounting in accordance with EN 50274
Electrical installation in accordance with EN 60204-1
The voltage supply of the devices must be capable of buffering brief mains voltage
failures of 20 ms as specified in EN 60204-1.
The voltage supply has to fulfil the regulations for extra-low voltages with safe separation
(SELV, PELV) in accordance with EN 60664 and DIN 50178 (equipment of electrical
power installation with electronic devices).
All connected pick-ups and downstream controllers as well as wiring and installation
must correspond to the required category in accordance with EN 954-1 and in
accordance with SIL3 to EN 62061 and conform to the required safety level in
accordance with EN 954-1, EN62061 or EN 13489-1, etc. For further information refer
to Chapter 12, "Technical data".
Ensure that all the modules of the Flexi Soft safety controller, the connected protective
devices as well as the voltage supply/ies are connected with the same earth (GND). The
GND of the RS-232 interface is connected internally to the GND of the supply of the
main module (A2).
If the RS-232 interface at the main module is used as an alternative to a gateway,
observe the limitation of the cable length (max. 3 m). In addition, the line at least has to
be earthed in the control cabinet and connected to the main module in which the main
module is connected.
Route the lines outside the control cabinet in such a manner that cross-circuiting
between these lines can be excluded, e.g. in separate sheathed cables or in protected
areas.
In order to protect the safety outputs and to increase the service life, the external loads
have to be equipped with, for example, varistors or RC elements. Take into account that
the response times may increase, depending on the type of protective circuiting.
The safety outputs and the contactor monitoring (EDM) have to be wired inside the
control cabinet.
If a module is replaced the terminal assignment has to be guaranteed, for example by
labelling or corresponding cable routing.
Mount the reset button so that it cannot be actuated by a person located in the
hazardous area. When operating the control device of the reset button, the operator
must have full visual command of the hazardous area.
42
8012478/SC96/2008-11-28
Chapter 7
a
ATTENTION
Note
8012478/SC96/2008-11-28
Limited short-circuit recognition!

An FX3-XTDI has two test signal generators. One test signal generator is responsible for the
odd-numbered test outputs X1, X3, X5 and X7, the other for the even-numbered test
outputs X2, X4, X6 and X8.
This means that short-circuits between odd-numbered and even-numbered test pulse
outputs are recognised when the test gaps < 4 ms. If the test gaps 4 ms, the shortcircuits are not always recognised in every case. Similarly short-circuits amongst the evennumbered test pulse outputs and odd-numbered test pulse outputs are not recognised,
Take this into consideration during the wiring (e.g. separate routing, sheathed cables)!
43
Configuration
Chapter 8
Configuration
a
ATTENTION
Notes
Check the configuration for the protective device before commissioning and after every
change!
If you change the configuration, you must check the effectiveness of the protective device.
Please observe the test notes in the operating instructions of the connected protective
device.
The Flexi Soft Designer software and the FX3-MPL0 system plug are required to configure
the Flexi Soft system.
Configuration and verification of devices that are connected to the safety controller is
generally not carried out by using the Flexi Soft Designer software, even if they can be
addressed via an RS-232 interface of a Flexi Soft module. These devices have their own
mechanisms for configuration and verification. The exception is formed by the EFI sensors
connected to the Flexi Soft main module CPU1 (EFI elements from the elements window).
These sensors can be configured directly in the Flexi Soft Designer by double-clicking the
icon, or alternatively configured and verified locally at the sensor via the RS-232 interface.
The SICK configuration and diagnostics software CDS is used to this purpose.
The system configuration of the complete Flexi Soft system (with the exception of the
EFI-compatible devices) is only stored in the system plug. This offers the advantage
when terminal modules are replaced that the system does not have to be reconfigured.
The data stored in the system plug are retained when the voltage supply is interrupted.
Transfer of configuration information via the EFI interface possible.
44
8012478/SC96/2008-11-28
Commissioning
Chapter 9
Commissioning
Do not commission without a check by qualified personnel!
ATTENTION
Before initial commissioning of a system using a Flexi Soft safety controller, it must be
checked and released by qualified personnel.
Check the hazardous area!

Ensure that no one is located in the hazardous area before commissioning.
ATTENTION
> Check the hazardous area and secure it against being entered by people (e.g. set up
warning signs, attach blocking ropes or similar). Observe the relevant laws and local
regulations.
9.1
Full approval of the application
System commission may only be carried out if full approval was successful. Full approval
may only be performed by professionals trained accordingly.
The full approval includes the following items to be checked:
> Check whether the attachment of components to the connections corresponds to the
required Safety Integrity Level in accordance with EN 954-1 or EN 62061 and/or
EN 13849-1.
> Check the devices connected to the safety controller in accordance with the test notes
from the accompanying operating instructions.
Note
The "Test before the first commissioning" chapter can be found for this in the operating
instructions of the ESPE from SICK AG.
> Clearly mark all the connection cables and plugs at the safety controller in order to avoid
confusion. Since the Flexi Soft system has several connections of the same design,
ensure that loosened connection cables are not connected back to the wrong
connection.
> Check the signal paths and the correct inclusion in higher-level controllers.
> Check the correct data transfer from and to the Flexi Soft safety controller.
> Check the logic program of the safety controller.
> Perform a complete validation of the safety functions of the system in each operating
mode and an error simulation. Observe the response times of the individual applications
in particular.
> Completely document the configuration of the system, the individual devices and the
result of the safety check.
> In order to prevent unintentional overwriting of the configuration, activate the write
protection of the configuration parameters of the Flexi Soft system. Modifications are
only possible if the write protection has been deactivated.
Note
The software for the configuration documentation is available on the Internet under
http://www.sens-control.com
8012478/SC96/2008-11-28
45
Chapter 9
Commissioning
9.2
Tests before the initial commissioning
The purpose of the initial commissioning tests is to confirm the safety requirements
specified in the national/international rules and regulations, especially in the Machine and
Work Equipment Directive (EC Conformity).
> Check the effectiveness of the protective device at the machine, using all the selectable
operating modes and functions.
> Ensure that the operating personnel of the machine fitted with the safety controller
become instructed by the qualified personnel of the machine owner before beginning
work. Arranging the instruction is the responsibility of the machine owner.
46
8012478/SC96/2008-11-28
Diagnostics
Chapter 10
10
Diagnostics
10.1
In the event of faults or errors
Cease operation if the cause of the malfunction has not been clearly identified!
ATTENTION
Stop the machine if you cannot clearly identify or allocate the error and if you cannot safely
remedy the malfunction.
Complete functional test after remedying malfunction!

Carry out a full functional test after a malfunction has been remedied.
ATTENTION
ERROR operating mode
With certain malfunctions or a faulty configuration, the Flexi Soft safety controller enters
the safe status. The MS and CV LEDs of the individual modules of the safety controller
indicate the corresponding type of error.
To place the device back in operation:
> Rectify the cause of the malfunction in accordance with the display of the MS and CV
LEDs.
> Switch the voltage supply of the Flexi Soft off and back on again.
10.2
SICK support
If you cannot remedy a malfunction using the information in this chapter, please contact
your local SICK branch.
Note
When you send in a FX3-MPL0 system plug for repair or analysis, it is returned in the state
of delivery. Therefore store the configuration(s) of your devices in the Flexi Soft Designer.
10.3
Error display of the MS and CV status LEDs
Error displays and error elimination are described in the individual modules, see Chapters
3.4 to 3.8.
10.4
Additional error displays of EFI-compatible devices
EFI-compatible devices (see Chapter 5.1) have extended functions in connection with the
CPU1 main module.
Error displays and error elimination are described in the operating instructions of the
corresponding devices.
10.5
Extended diagnostics
The Flexi Soft Designer contains extended diagnostic possibilities. If you cannot identify
what kind of error is occurring or if you have serviceability problems, it allows you to locate
the error more accurately.
For detailed information refer to the operating instructions of the Flexi Soft Designer
software.
8012478/SC96/2008-11-28
47
Maintenance
Chapter 11
11
Maintenance
The following section informs about regular tests and the exchange of Flexi Soft modules.
Do not try to dismantle, repair or modify the Flexi Soft modules. This can lead to a loss of
the safety function(s). In addition SICK AG accepts no claims for liability.
11.1
Regular inspection of the protective device by qualified

personnel
> Check the system at the inspection intervals specified in the national rules and
regulations. This procedure ensures that any changes on the machine or manipulations
of the protective device are detected before use/re-use.
> Each safety application must be checked at an interval specified by you. The
effectiveness of the protective device must be checked by authorised commissioned
persons.
> If any modifications have been made to the machine or the protective device, or if the
safety controller has been changed or repaired, the system must be checked again as
specified in the checklist in the Annex.
> Carry out regular or daily inspections in order to keep the Flexi Soft modules in an
optimal operating mode.
> Check whether the implementation of the Flexi Soft modules fulfills all the technical data
of the device.
> Check the mounting conditions and whether the wiring of the Flexi Soft modules has
been carried out correctly.
> Regularly verify that the safety functions fulfil the requirements of the application as well
as all the regulations and standards (e.g. regular checking) in order to ensure the
reliability of the safety functions.
> If you use single-channel safety outputs for applications up to Category 3, the internal
self-tests have to be carried out regularly during switching on (regular testing). The
regular check can be carried out by means of a regular switching off and back on of the
voltage supply, followed by a status change of the single-channel output. The regular
check has to be carried out at least once a month.
11.2
a
ATTENTION
Cyclic testing
The Flexi Soft system has to be tested cyclically!

In order to fulfil the safety-specific characteristics (see Chapter 12 "Technical data") SIL3 in
accordance with IEC 61508, the following proof test interval has to be carried out at least
every 365 days:
> The operating voltage of the Flexi Soft system has to be switched off.
> The operating voltage of the Flexi Soft system has to be switched on.
> All the safety functions of all the connected sensors have to be verified.
48
8012478/SC96/2008-11-28
Maintenance
Chapter 11
11.3
Device replacement
A fault in the Flexi Soft modules impairs the complete network. Devices that have faults
must therefore be repaired or replaced rapidly. We recommend keeping spare devices of
the Flexi Soft modules at hand so that network operation can be re-established as fast as
possible.
Safety measures for replacing devices
Observe the following safety measures when replacing the Flexi Soft modules:
Do not try to dismantle or repair the Flexi Soft modules. Not only does SICK accept no
claims for liability, but it is also dangerous because checking of the original safety
functions is not possible in this case.
Reset the device into a state in which safety is ensured.
Carry out replacement only when the voltage supply is switched off in order to avoid an
electric shock or unexpected device behaviour.
In order to continue using the system configuration check:
Whether the new module is of the same type (same material number) and whether
there is no error at the new module after the replacement and
That the new module is plugged at the same position as the replaced module.
Otherwise you have to completely reconfigure and commission the new system,
including all the necessary tests (see Chapter 9, "Commissioning" to this purpose).
Note
EFI-compatible devices have to be reconfigured after the replacement.

After the replacement ensure that no errors arise with the new Flexi Soft modules.
Always carry out a function test before commissioning a replacement module.
If you send in Flexi Soft modules for repair, enclose a brief detailed description of the
problem with the device and send the Flexi Soft modules to SICK.
8012478/SC96/2008-11-28
49
Technical data
Chapter 12
12
Technical data
12.1
Data sheet
12.1.1
General system data
Response times of the Flexi Soft system

All the controlled systems have to be taken into consideration in order to calculate the
response time of a Flexi Soft system.
Fig. 21: Response times
within a Flexi Soft system
> The following table can be used to calculate the response times of corresponding paths
within the Flexi Soft system.
50
8012478/SC96/2008-11-28
Technical data
Chapter 12
Table 41: Calculation of the response times of the Flexi Soft system in ms
Occurrence
Digital inputs
General
Response time of the sensor
General
Input processing time
When On/Off filter
8.0 ms
When X1 ... X8 is
connected at the test
output
a) Safety mats and
switching rails
b) Testable sensors
Type 4 (e.g. L41)
c) All other sensors
only when the gap
value of the test
output > 1ms
Digital outputs
1)
Response time of the actuator

6.5
Output processing time
4.5
Period value 2) of the test

output
Period value 2) of the test
output
12 ms + gap value of the test
output 2)
Logic
Total E1
Total A1
Occurrence
EFI message transmitter
EFI message receiver
If EFI functions are

used via EFIcompatible devices
Response time of the EFI data

source (as a rule a sensor) for
external OSSDs via EFI 1)
Response time of the message receiver

(e.g. scanner with protective field
switching via EFI) 1)
Constant:
a) Scanner (e.g. S300, S3000):
3.5 ms
b) Light grid (e.g. C4000,
M4000): 1.5 ms
EFI cycle time of the EFI receiver 1)

Constant:
a) Scanner (e.g. S300, S3000): 24 ms
b) Light grid (e.g. C4000, M4000): 2.5 ms
Total E2
Total A2
Evaluation
Response time of the considered input in the signal path
E1 or E2 (from above table)

2 x logic execution time 2)
Response time of logic
Delay through logic application

(e.g. On- or Off-delay function block
Response time of the considered output in the signal path
A1 or A2 (from above table)
Total response time
8012478/SC96/2008-11-28
1)
Take values from the corresponding operating instructions
2)
Take values from the Flexi Soft Designer-Report
51
Technical data
Chapter 12
Example
Calculation of the response time for a Flexi Soft system consisting of an FX3-CPU1 and an
FX3-XTIO
Fig. 22: Example of a Flexi
Soft system
Configuration
Logic
Digital inputs:
XTIO[1].I5I6.C4000: One C4000 safety light curtain
Digital outputs:
XTIO[1].Q3Q4.Robot: Robot, dual-channel
EFI message transmitter:
[EFI 1.1] OSSD [OSS: One C4000 receiver (stand-alone)

(safety light curtain with high resolution for hazardous point,
hazardous area and access protection at machines)
2 paths have to be considered and calculated separately:

Fig. 23: Response times
within a Flexi Soft system
52
8012478/SC96/2008-11-28
Technical data
Chapter 12
Table 42: Example for the calculation of the response time of Path 1 of a Flexi Soft system
Occurrence
Digital inputs
General
C4000 response time
14.0 ms
General
Input processing time
6.5 ms
When On/Off filter
8.0 ms
When X1 ... X8 is
connected at the test
output
a) Safety mats and
switching rails
b) Testable sensors
Type 4 (e.g. L41)
c) All other sensors
Digital outputs
Robot response time
40.0 ms
4.5 ms
Logic
Total E1
20.5 ms
Total A1
44.5 ms
Evaluation
Response time of the considered input in Path 1
E1
20.5 ms
2 x logic execution time
Response time of the considered output in Path 1
A1
8.0 ms
44.5 ms
Total response time
73.0 ms
Table 43: Example for the calculation of the response time of Path 2 of a Flexi Soft system
Occurrence
Message transmitter
If EFI functions are

used via EFIcompatible devices
Response time of the EFI

data source (C4000
receiver (stand-alone))
Constant (C4000)
Total E2
Digital outputs
12.0 ms
Robot response time
1.5 ms
13.5 ms
Total A2
40.0 ms
4.5 ms
44.5 ms
Evaluation
Response time of the considered input in Path 2
E2
2 x logic execution time
Response time of the considered output in Path 2
A2
Total response time
8012478/SC96/2008-11-28
13.5 ms
8.0 ms
44.5 ms
66.0 ms
53
Technical data
Chapter 12
12.1.2
Table 44: Data sheet
FX3-CPU0 and FX3-CPU1
Modules FX3-CPU0 and FX3-CPU1

FX3-CPU0
FX3-CPU1
Category to EN/ISO 13849
Category 4
Category to EN 954-1
Category 4
Safety Integrity Level
SIL3 (IEC 61508), SILCL3 (EN 62061)
Performance Level
PL e (EN/ISO 13849)
PFHd
1.07E-09 1/h
TM service life
20 years
Ambient temperature in operation
25 C ... +55 C
Storage temperature
40 C ... +70 C
Humidity
10% ... 95%, non-condensing
Climatic conditions
To EN 61131-2 (55 C, 95% rel. humidity)
Rigidity
5 Hz ... 500 Hz, tested to EN 61131-2
Enclosure rating to EN/IEC 60529
Terminals: IP 40
Housing: IP 20
Electromagnetic compatibility
EN 61131-2, EN 61000-6-2,
EN 55011 (Class A)
Protection class
III
Number of EFI interfaces
Data interface
Internal bus (FLEX BUS+)
Configuration interface
RS-232
Cross-circuit of connecting wires
Single-core or finely stranded:
1.69E-09 1/h
1 x 0.14 ... 2.5 mm2 or 2 x 0.14 ... 0.75 mm2

Finely stranded with ferrules to EN 46228:
1 x 0.25 ... 2.5 mm2 or 2 x 0.25 ... 0.5 mm2
EFI connection method
Dimensions (W x H x D)
22.5 x 93.7 x 120.8 mm
Weight
100 g
Two-tier spring
terminals
110 g
Power supply (A1, A2) via system plug FX3-MPL0

Supply voltage
24 V DC (16.8 ... 24 V DC ... 30 V DC)
Type of supply voltage
PELV or SELV
The current of the power supply unit that supplies
the main module has to be limited to a maximum of
4 A either by the power supply unit itself or by a
fuse
54
Power consumption
Max. 2.5 W
Switch-on time
Max. 18 s
Short-circuit protection
4 A gG (with tripping characteristic B or C)
8012478/SC96/2008-11-28
Technical data
Chapter 12
12.1.3
FX3-XTIO
FX3-XTIO input/output extension module
Category to EN 13849
Category 4
Category 4
SIL3 (IEC 61508)
Performance Level
PL e (EN 13849-1)
PFHd
7% PFH for SIL3: 7.1E-09 1/h
TM service life
20 years
25 C ... +55 C
Storage temperature
40 C ... +70 C
Humidity
Climatic conditions
To EN 61131-2 (55C, 95% rel. humidity)
Rigidity
5 Hz ... 500 Hz, tested to EN 61131-2
Terminals: IP 40
Housing: IP 20
EN 61131-2 (Zone B), EN 61000-6-2,

EN 55011 (Class A)
III
Protection class
Power input via FLEX BUS+
without currents to
X1, X2
Max. 1.1 W

1 x 0.14 ... 2.5 mm2 or 2 x 0.14 ... 0.75 mm2
1 x 0.25 ... 2.5 mm2 or 2 x 0.25 ... 0,5 mm2
Connection method
Two-tier spring terminals
Data interface
Internal bus (FLEX BUS+)
22.5 x 93.7 x 120.8 mm
Weight
180 g
Power supply unit (A1, A2)

Supply voltage
24 V DC (16.8 V DC ... 24 V DC ... 30 V DC)
Type of supply voltage
PELV or SELV
The current of the power supply unit that supplies
the main module has to be limited to a maximum of
4 A either by the power supply unit itself or by a
fuse.
8012478/SC96/2008-11-28
Power consumption
Max. 96 W, determined by the load at the outputs

Q1 to Q4
Switch-on time
Max. 18 s
Short-circuit protection
4 A gG (with tripping characteristic B or C)
55
Chapter 12
Technical data
Input circuit (I1 ... I8)

Input voltage HIGH
13 V DC ... 30 V DC
Input voltage LOW
5 V DC ... +5 V DC
Input current HIGH
2.4 mA ... 3.8 mA
Input current LOW
2.5 mA ... 2.1 mA
Discrepancy times
4 ms ... 30 s, configurable
Number of inputs
Control outputs (X1, X2)

Number of outputs
2 (with 2 test pulse generators)
Output type
PNP semiconductor, short-circuit protected, cross

circuit monitoring
Output voltage
16 V DC ... 30 V DC
Output current
Max. 120 mA at a test output (X1 or X2)

This means that a maximum of 8 testable sensor
cascades per module with max. 30 mA each are
possible.
The total current of the Flexi Soft systems is limited
to a maximum of 1.28 A. This corresponds to e.g.
32 inputs of testable sensors with 30 mA each and
64 inputs of FX3-XTIO or FX3-XTDI modules.
Test pulse rate
1 Hz ... 25 Hz, configurable
Test pulse duration
1 ms ... 100 ms, configurable
Load capacity
1 F for test pulse duration 4 ms

0.5 F for test pulse duration 1 ms
< 100 W
Cable resistance
Safety outputs (Q1 ... Q4)
56
Number of outputs
Output type
PNP semiconductor, short-circuit protected, crosscircuit monitoring
Output voltage
24 V DC (16.8 V DC ... 30 V DC)
Output current
2A
Total current Isum
Max. 3.2 A
Test pulse width
< 650 s
Test pulse rate
Typ. 0.8 Hz
Load capacity
0.5 F
Cable length
100 m, 1.5 mm2
Response time
Depending on the logic configuration, for details

see Table 41
8012478/SC96/2008-11-28
Technical data
Chapter 12
12.1.4
FX3-XTDI
Input/Output extension module FX3-XTDI
Category to EN 13849
Category 4
Category 4
SIL3 (IEC 61508)
Performance Level
PL e (EN 13849-1)
PFHd
6% PFH for SIL3: 5.68E-09 1/h
TM service life
20 years
25 C ... +55 C
Storage temperature
40 C ... +70 C
Humidity
Climatic conditions
To EN 61131-2 (55 C, 95% rel. humidity)
Rigidity
5 Hz ... 500 Hz, tested to EN 61131-2
Terminals: IP 40
Housing: IP 20
EN 61131-2 (Zone B), EN 61000-6-2,

EN 55011 (Class A)
Protection class
III
Power input via FLEX BUS+

without currents to X1 ... X8
Max. 1.4 W

1 x 0.14 ... 2.5 mm2 or 2 x 0.14 ... 0.75 mm2
1 x 0.25 ... 2.5 mm2 or 2 x 0.25 ... 0.5 mm2
Connection method
22.5 x 93.7 x 120.8 mm
Weight
150 g
Input circuit (I1 ... I8)
8012478/SC96/2008-11-28
Input voltage HIGH
13 V DC ... 30 V DC
Input voltage LOW
5 V DC ... +5 V DC
Input current HIGH
2.4 mA ... 3.8 mA
Input current LOW
2.5 mA ... 2.1 mA
Discrepancy times
4 ms ... 30 s, configurable
Number of inputs
57
Technical data
Chapter 12
Control outputs (X1 ... X8)

Number of outputs
8 (with 2 test pulse generators)
Output type
PNP semiconductor, short-circuit protected, crosscircuit monitoring
Output voltage
16 V DC ... 30 V DC
Output current
Max. 120 mA at each of the two test signal

generators (X1/X3/X5/X7 or X2/X4/X6/X8)
This means that a maximum of 8 testable sensor
cascades per module with max. 30 mA each are
possible.
The total current of the Flexi Soft systems is limited
to a maximum of 1.28 mA. This corresponds to e.g.
32 inputs of testable sensors with 30 mA each and
64 inputs of FX3-XTIO or FX3-XTDI modules.
Test pulse rate
1 Hz ... 25 Hz, configurable
Load capacity
1 F for test pulse duration 4 ms

0.5 F for test pulse duration 1 ms
Cable resistance
< 100 W
12.1.5
UE410-2RO/UE410-4R0
UE410-2RO/UE410-4RO output modules
Supply circuit
Supply voltage
24 V DC (19.2 V DC ... 30 V DC)

If UE410-2RO/4RO is connected and loading of the
output current paths:
U > 25 V AC/60 V DC (PELV)
U < 25 V AC/60 V DC (SELV/PELV)
Power consumption
58
UE410-4RO
Max. 2 W
UE410-2RO
Max. 1 W
8012478/SC96/2008-11-28
Technical data
Chapter 12
Output circuit (1314, 23-24, 33-34, 43-44)

Number of NO contacts
UE410-2RO
UE410-4RO
Number of NC contacts
UE410-2RO
UE410-4RO
Switching voltage
250 V AC (5 V AC ... 275 V AC)

230 V DC (5 V DC ... 275 V DC)
Switching voltage
10 mA at 5 V
2 mA at 24 V
Max. 6 A
Total current
12 A
Response time (time from LOW at

B1/B2 to drop relay)
30 ms
Output type
Volt-free NO contacts, positively driven
Contact material
AgSnO2 with 1 m Au
Output circuit fusing
6 A (gG), per current path
Utilisation category
AC-15: Ue 250 V, Ie 3 A
DC-13: Ue 24 V, Ie 3 A
Output circuit (Y14, Y24)

Output type
Non-isolated NO contact, positively driven, currentlimited
Number of NO contacts Y14/24

UE410-2RO
UE410-4RO
Output voltage
24 V DC (18 V DC ... 30 V DC)
Output current
Max. 75 mA
The total output current is limited. The maximum
total current of all the relay modules at Y14 or Y24
is I<80 mA
Load capacity
200 nF
General data
Electrical isolation
Supply circuit input circuit
No
Supply circuit output circuit
Yes
Input circuit output circuit
Yes
Weight (without packaging)
8012478/SC96/2008-11-28
UE410-2RO
0.16 kg
UE410-4RO
0.19 kg
59
Chapter 12
Technical data
Operating data
Ambient operating temperature
25 C ... 55 C
Storage temperature
25 C ... 70C
Humidity
10% to 95%, non-condensing
Climatic conditions
EN 61131-2
Mechanical strength
Oscillation
EN 61131-2
Vibration stability
(EN 60068-2-64)
5500 Hz/5 grms
Electrical safety EN 50178

Rated impulse withstand voltage
(Vimp)
4 kV
Overvoltage category
III
Pollution degree
2 inside, 3 outside
Rated voltage
300 V AC
Enclosure rating to EN 60529

housing/terminals
IP 40/IP 20
EN 61131-2, EN 61000-6-2,
EN 55011 Class A
Terminal and connection data

Single-core or finely stranded
1 x 0.14 mm to 2.5 mm or
2 x 0.14 mm to 0.75 mm
Finely stranded with ferrules to

EN 46228
1 x 0.25 mm to 2.5 mm or
2 x 0.25 mm to 0.5 mm
Stripped length
8 mm
Maximum break-away torque
0,6 Nm
Functional safety in accordance

with EN 954
Cat. 4
Functional safety in accordance

with EN 61508
SIL3
Safety-specific characteristics
All these data are based on an ambient temperature of +55 C.
60
PFD
1.6 x 10-7
PFH
1 x 10-9 h-1
SFF
99.6%
DC
99%
8012478/SC96/2008-11-28
Technical data
Chapter 12
12.2
Dimensional drawings
12.2.1
Main modules FX3-CPU0/1 with system plug
12.2.2
Input/output extension FX3-XTIO / input extension FX3-XTDI / relay output

modules UE410-2RO and UE410-4RO
Fig. 24: Dimensional drawing

FX3-CPU0/1 (mm)
Fig. 25: Dimensional drawing

FX3-XTIO / FX3-XTDI,
UE410-2RO / UE410-4RO
(mm)
8012478/SC96/2008-11-28
61
Ordering information
Chapter 13
13
13.1
Table 48: Part numbers of

Flexi Soft safety controller
modules
Available modules and accessories
Device type
Part
Part no.
FX3-MPL000001
System plug
1043700
FX3-CPU000000
Main module
1043783
FX3-CPU130002
Main module
2 EFI inputs
1043784
FX3-XTIO84002
Input/output extension
8 inputs/4 outputs
1044125
FX3-XTDI80002
Input extension
8 inputs
1044124
UE410-2RO3
Output module
2 NO contacts and 1 24-V DC alarm signal
Removable terminals
6026144
UE410-4RO3
Output module
4 NO contacts and 2 24-V DC alarm signals
Removable terminals
6026143
Configuration cable
6021195
2 m, M8, Sub D
Configuration cable
6036342
3 m, M8, angled, open end

Converter UC-232A
62
RS-232 USB converter, RS-232 to USB
6035396
8012478/SC96/2008-11-28
Chapter 13
13.2
Devices
Our extensive range of products including further articles such as safety switches, safety
interlocks and emergency stop pushbuttons with the corresponding accessories is
available in our catalogue or on the Internet under www.sick.com.
The following sections contain a selection.
13.2.1
single-beam photoelectric
safety switches (Type 2)
8012478/SC96/2008-11-28
Single-beam photoelectric safety switches (Type 2)
Part
Description
Part no.
WS/WE12-2P460
Through-beam photoelectric switch

WS/WE12-2P460,
24 V DC, operating range 10 m, PNP, device
plug M12, 4-pin
1018047
WS/WE12-2P160

WS/WE12-2P160,
24 V DC, operating range 10 m, PNP,
connecting cable 2 m
1018046
WS/WE24-2P250

WS/WE24-2P250,
24 V DC, operating range 40 m, PNP, terminal
connection
1018049
WS/WE24-2P450

WS/WE24-2P450,
plug M12, 4-pin
1018051
WS/WE24-2P260

WS/WE24-2P260,
24 V DC, operating range 40 m, PNP, terminal
connection and heating
1018050
WS/WE24-2P460

WS/WE24-2P460,
plug M12, 4-pin, heating
1018052
WS/WE27-2F460

WS/WE27-2F460,
operating range 35 m, PNP, Q+Q, device plug
M12, 4-pin
1019561
WS/WE27-2F450S05

WS/WE27-2F450S05,
operating range 35 m, PNP, Q+Q, device plug
M12, 4-pin, heating
1016025
WS/WE27-2F730

WS/WE27-2F730 with device plug 7-pin
1015124
WS/WE27-2F750

WS/WE27-2F750 with device plug 7-pin,
heating
1015752
63
Chapter 13
Part
Description
Part no.
VS/VE18-2O4450
VS/VE18-2O4450 through-beam photoelectric

switch consisting of transmitter and receiver,
PNP, NPN, Q, Q, device plug M12, 4-pin,
operating range 16 m, metal housing
6011846
VS/VE18-204550
VS/VE18-2O4550 through-beam photoelectric

switch consisting of transmitter and receiver,
PNP, NPN, Q, Q, device plug M12, 4-pin,
angled, operating range 16 m, metal housing
6011845
L21
All variants
* See the catalogue "Industrial Safety Systems" 8010889 or under www.sick.com.

13.2.2
non-contact safety switches
Non-contact safety switches
Part
Description
Part no.
RExx
All variants
RE300-DA03P
Set consisting of switch and actuator RE300,

sensor with 3 m cable
6025080
RE300-DA10P
Set consisting of switch and actuator RE300,

sensor with 10 m cable
6025079
T40-E0101
Sensor T40 Direct Multicode
6035041
T40-E0121
Sensor T40 Direct Unicode
6035042
T4000-2DRNAC
Sensor T4000 Compact
6022052
T4000-1KBA
Actuator
5306531
DOL-1208-G10MA
T4000 Compact connecting cable

M12 8-pin with 10 m cable
6022152
IN40-D0101K
IN4000 switch Q40
6027389
IN40-D0202K
IN4000 switch M30
6027392
IN40-D0303K
IN4000 switch M18
6027391
IN40-E-E0101K
IN 40 Direct
6027388
DOL-1204-G10M
IN4000 connecting cable

M12 8-pin with 10 m cable
6010543

13.2.3
Table 51: Safety light
curtains and multiple beam
systems
Safety light curtains and multiple light beam safety devices
Part
Description
Part no.
C4000
All variants
M4000
All variants
C2000
All variants
M2000
All variants
64
8012478/SC96/2008-11-28
Chapter 13
13.2.4
Table 52: Laser scanners
Safety laser scanners and safety camera system
Part
Description
Part no.
S3000
All variants
S300
All variants
V4000
All variants
V300
All variants

13.2.5
muting lamp and cable
8012478/SC96/2008-11-28
Muting lamp and cable
Part
Description
Part no.
Muting display lamp with mounting kit
2020743
LED muting lamp with cable 2 m
2019909
LED muting lamp with cable 10 m
2019910
65
Annex
Chapter 14
14
Annex
14.1
Manufacturers checklist
L
Checklist for the manufacturer/installer for installation of the Flexi Soft safety controller
The specifications for the following items listed must be available at least for the initial commissioning. They are
dependent on the application, whose requirement must be checked by the manufacturer/installer.
This checklist should be retained/stored with the machine documentation so that you can use it as a reference for
periodical tests.
1. Have the safety rules and regulations been observed in compliance with the
directives/standards applicable to the machine?
Yes
No
2. Are the applied directives and standards listed in the declaration of conformity?
Yes
No
3. Does the protective device comply with the required category?
Yes
No
4. Are the required protective measures against electric shock in effect (protection class)?
Yes
No
5. Has the protective function been checked in compliance with the test notes in this
documentation? Especially:
Yes
No
Yes
No
Functional check of the command devices, sensors and actuators connected to the safety
controller
Test of all switch-off paths
6. Are you sure that the safety controller was tested fully for safety functionality after each
configuration change?
This checklist does not replace initial commissioning and regular tests by qualified personnel.
66
8012478/SC96/2008-11-28
Annex
Chapter 14
14.2
List of tables
Table 1: Overview of disposal by component ...................................................................... 11

Table 2: Overview of the modules........................................................................................ 14
Table 3: System plug pin assignment.................................................................................. 15
Table 4: Displays of the MS LED ......................................................................................... 16
Table 5: Displays of the CV LED .......................................................................................... 16
Table 6: Pin assignment of RS-232 interface ..................................................................... 17
Table 7: Displays of the EFI LEDs......................................................................................... 18
Table 8: Terminal assignment FX3-XTIO .............................................................................. 19
Table 9: Displays of the MS LED .......................................................................................... 20
Table 10: Displays of the input/output LEDs ........................................................................ 20
Table 11: Terminal assignment FX3-XTDI.............................................................................. 21
Table 12: UE410-2RO/ UE410-4RO displays ........................................................................ 24
Table 13: UE410-2RO terminals ............................................................................................ 24
Table 14: UE410-4RO terminals ............................................................................................ 24
Table 15: Connection ES21.................................................................................................... 27
Table 16: Functions with ES21............................................................................................... 27
Table 17: Connection of electro-mechanical safety switches .............................................. 28
Table 18: Connection of interlocks ........................................................................................ 28
Table 19: Functions with electro-mechanical safety switches and interlocks..................... 28
Table 20: Connection E100.................................................................................................... 29
Table 21: Functions with E100 .............................................................................................. 29
Table 22: Connection of two-hand control............................................................................. 29
Table 23: Connection of safety mats ..................................................................................... 30
Table 24: Function safety mats.............................................................................................. 30
Table 25: Connection of operating mode selector switch .................................................... 30
Table 26: Function of operating mode selector switch......................................................... 30
Table 27: Function of floating contacts ................................................................................. 30
Table 28: Connection of magnetic safety switches with equivalent inputs......................... 31
Table 29: Connection of magnetic safety switches with complimentary inputs.................. 31
Table 30: Functions with magnetic safety switches.............................................................. 31
Table 31: Connection of inductive safety switches ............................................................... 31
Table 32: Functions with inductive safety switches.............................................................. 31
Table 33: Connection of transponders .................................................................................. 32
Table 34: Functions with transponders ................................................................................. 32
Table 35: Connection of testable Type 2 single-beam photoelectric safety switches ........ 32
Table 36: Functions with testable Type 2 single-beam photoelectric safety switches ....... 32
Table 37: Connection of testable Type 4 single-beam photoelectric safety switches ........ 33
Table 38: Functions with testable Type 4 single-beam photoelectric safety switches ....... 33
Table 39: Connection ESPE .................................................................................................... 35
Table 40: Selection of the SICK optical muting sensors....................................................... 38
Table 41: Calculation of the response times of the Flexi Soft system in ms....................... 51
8012478/SC96/2008-11-28
67
Chapter 14
Annex
Table 42: Example for the calculation of the response time of Path 1 of a Flexi Soft
system...................................................................................................................... 53
Table 43: Example for the calculation of the response time of Path 2 of a Flexi Soft
system...................................................................................................................... 53
Table 44: Data sheet FX3-CPU0 and FX3-CPU1 ................................................................... 54
Table 45: Data sheet FX3-XTIO .............................................................................................. 55
Table 46: Data sheet FX3-XTDI .............................................................................................. 57
Table 47: Data sheet UE410-2RO/UE410-4R0.................................................................... 58
Table 48: Part numbers of Flexi Soft safety controller modules........................................... 62
Table 49: Part numbers of single-beam photoelectric safety switches (Type 2) ................. 63
Table 50: Part numbers of non-contact safety switches ....................................................... 64
Table 51: Safety light curtains and multiple beam systems ................................................. 64
Table 52: Laser scanners........................................................................................................ 65
Table 53: Part numbers of muting lamp and cable ............................................................... 65
68
8012478/SC96/2008-11-28
Annex
Chapter 14
8012478/SC96/2008-11-28
14.3
List of illustrations
Fig. 1:
Flexi Soft modular safety controller....................................................................... 12
Fig. 2:
Examples for the minimum configuration of a Flexi Soft system with CPU0
and XTDI or CPU1 and XTIO ................................................................................... 13
Fig. 3:
Maximum configuration of the Flexi Soft system (without relay output

extensions and gateways)...................................................................................... 13
Fig. 4:
Display elements FX3-CPU0.................................................................................. 15
Fig. 5:
Display elements FX3-CPU1.................................................................................. 18
Fig. 6:
Display elements FX3-XTIO ................................................................................... 19
Fig. 7:
Display elements FX3-XTDI ................................................................................... 21
Fig. 8:
Example of the inclusion of a relay module in the Flexi Soft system .................. 22
Fig. 9:
Internal configuration UE410-2RO ........................................................................ 23
Fig. 10:
Internal configuration UE410-4RO ....................................................................... 23
Fig. 11:
UE410-2RO/ UE410-4RO display elements ......................................................... 24
Fig. 12:
Example extract of the documentation in the Flexi Soft Designer....................... 26
Fig. 13:
Minimum distance "a" to reflective surfaces, correct mounting and

alignment ................................................................................................................ 33
Fig. 14:
Minimum distance "a" as a factor of the distance "D" for testable singlebeam photoelectric safety switches with a field of view of 10
(e.g. Wx12/18/24/27, Vx18) ................................................................................ 34
Fig. 15:
Mounting to avoid mutual optical influence ......................................................... 34
Fig. 16:
Mounting the module onto the DIN rail................................................................. 39
Fig. 17:
Installing the end clips ........................................................................................... 40
Fig. 18:
Removing the removable terminals ...................................................................... 40
Fig. 19:
Disconnecting the plug connections ..................................................................... 41
Fig. 20:
Removing modules from the DIN rail .................................................................... 41
Fig. 21:
Response times within a Flexi Soft system........................................................... 50
Fig. 22:
Example of a Flexi Soft system .............................................................................. 52
Fig. 23:
Response times within a Flexi Soft system........................................................... 52
Fig. 24:
Dimensional drawing FX3-CPU0/1 (mm) .............................................................. 61
Fig. 25:
Dimensional drawing FX3-XTIO / FX3-XTDI,

UE410-2RO / UE410-4RO (mm)............................................................................ 61
69
8012478/SC96/2008-11-28 TL/VD Printed in Germany (2008-12) Subject to change without notice The specified product features and technical data do not represent any guarantee 02 A4 sw int32
Australia
Phone +61 3 9497 4100

1800 33 48 02 tollfree
E-Mail sales@sick.com.au
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Phone +32 (0)2 466 55 66
E-Mail info@sick.be
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Phone +55 11 3215-4900
E-Mail sac@sick.com.br
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Phone +420 2 57 91 18 50
E-Mail sick@sick.cz
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E-Mail ghk@sick.com.hk
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E-Mail sick@sick.dk
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E-Mail info@sick.fr
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OPERATING INSTRUCTIONS

Modular Safety Controller

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

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

Product description ..................................................................................................... 12

Connecting devices ..................................................................................................... 25

SICK AG Industrial Safety Systems Germany All rights reserved

Testable single-beam photoelectric safety switches........................................ 32

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

13 Ordering information ................................................................................................... 62

SICK AG Industrial Safety Systems Germany All rights reserved

About this document

About this document

Function of this document

SICK AG Industrial Safety Systems Germany All rights reserved

About this document

Flexi Soft: Hardware

Error diagnostics and remedying

Conformity and approval

Care and maintenance

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

External device monitoring

Enhanced Function Interface

Probability of dangerous failure per hour

Output signal switching device

Safety Integrity Level (safety class)

SICK AG Industrial Safety Systems Germany All rights reserved

About this document

Recommendations are designed to give you some assistance in your decision-making

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

Application areas for the device

SICK AG Industrial Safety Systems Germany All rights reserved

General protective notes and protective measures

Observe the protective notes and measures!

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

Material separation may only be performed by qualified personnel!

PCBs, cables, plugs and electrical

SICK AG Industrial Safety Systems Germany All rights reserved

Fig. 1: Flexi Soft modular

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

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

A Flexi Soft system consists of the following modules:

Fig. 2: Examples for the

SICK AG Industrial Safety Systems Germany All rights reserved

Table 2: Overview of the

Relay output extension

Relay output extension

Max. of 16 safe relay outputs

System plug FX3-MPL0

SICK AG Industrial Safety Systems Germany All rights reserved

Flexi Soft: Hardware

Main module FX3-CPU0

Display elements, error codes and terminal description

Fig. 4: Display elements