Baumuller SI4000 User manual

Operating Instructions
Read the Operating Instructions before beginning
Language English
Translation
Document-No. 5.08009.05
Part No. 422585
Status 11.03.2015


b maXX®Systems
Safety I/O Terminals

SI4000 / SO4000
E5.08009.05

Baumüller Nürnberg GmbH
Ostendstr. 80 - 90 
90482 Nürnberg
Germany
Tel. [phone] - 0 
Fax: [phone] - 1 30
E-Mail: [email protected]
Internet: www.baumueller.de

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Table of Contents
1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Information on the Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Preliminary information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Further applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.10 Customer service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.11 Terms used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.12.1 Approvals, directives and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Use of this handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Contents of the Operation Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Alterations and rebuilding of the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Operator responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6 Personnel training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Special dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Firefighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.10 Electric safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.10.1 Notice on power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.11 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.12 Conduct in the event of danger and accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.13 Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Functional Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Safety-related parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Lifetime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Using of the terminals with b maXX safe PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Description of the Safety I/O Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.1 SI4000 4-channel safety digital input terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.2 SO4000 4-channel safety digital output terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.1 SI4000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4.2 SO4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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6.2 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Installation of Bus Terminals on C mounting rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.1 Control cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3.2 Mounting rail installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4 Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.1 Connections within a bus terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.4.2 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.5 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.2 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.3 Mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.5 SI4000 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1.6 SO4000 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1.7 Address settings on the safety terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1.8 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2 Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.1 Diagnostic LEDs SI4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.2.2 Diagnostic LEDs SO4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.4.2 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8 System validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.1 Function test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9 Dismantling, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2 Requirements of the personnel carrying out work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.5 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Appendix A - Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix B - Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
B.1 List of all accessory items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix C - Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
C.1 Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
C.2 Commissioning and validation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Appendix D - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D.1 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D.2 Connection values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D.3 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Appendix E - Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
E.1 What is an EC directive? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
E.2 What the CE symbol indicates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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E.3 Definition of the term Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
E.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05
1PREFACE
1.1 Information on the Operation Manual
This Operation Manual provides important information on handling the device. Compli-
ance with all safety instructions operation instructions specified is a prerequisite for work
safety.
Furthermore, it is also necessary to comply with the local accident prevention legislation
and general safety regulations applying to the device’s field of application.
Read the Operation Manual completely, in particular the chapter on safety instructions,
before beginning any work on the device. The Operation Manual is a component of the
product and must be kept accessible to personnel in the immediate vicinity of the device
at all times.

Legend
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1.2
1.2 Legend
Warning notices
Warning notices are indicated by symbols in this Operation Manual. The notices are in-
troduced by signal words which express the extent of the hazard.
Comply with the notices under all circumstances and act with caution in order to avoid
accidents, personal injury and property damage.
DANGER!
....notifies of an imminent dangerous situation which will lead to death or serious in-
juries if not avoided.
WARNING!
....notifies of a potentially dangerous situation which can lead to death or serious in-
juries if not avoided.
CAUTION!
....notifies of a potentially dangerous situation which can lead to minor or slight inju-
ries if not avoided.
NOTE!
....notifies of a potentially dangerous situation which can lead to property damage if
not avoided.
Recommenda-
tions
NOTICE!
....draws attention to useful tips and recommendations as well as information for effi-
cient and trouble-free operation.

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1.3 Limitation of liability
All statements and instructions in this Operation Manual have been compiled in compli-
ance with the applicable standards and legislation while taking the current level of tech-
nology and our long-term experience and findings into account.
The manufacturer assumes no liability for damages resulting from:
mfailure to observe the Operation Manual
mapplication for purposes other than those intended
muse by untrained personnel
The actual scope of materials delivered may vary from the explanations and illustrations
described here in cases involving custom designs or the use of additional ordering op-
tions, or as a result of the most recent changes in technology.
The user assumes the responsibility of conducting maintenance and commissioning in
accordance with the safety regulations of the applicable standards and all other relevant
national or regional legislation relating to conductor dimensioning and protection, ground-
ing, circuit breakers, overvoltage protection, etc.
The person who conducted the assembly or installation shall be accountable for damages
occurring during assembly or connection.
1.4 Preliminary information
CAUTION!
The following shall apply if the document you are reading is designated as preliminary
information:
This version pertains to preliminary technical information which the user of the de-
scribed devices and functions should receive ahead of time, in order to be able to ad-
just to potential changes and/or functional expansions.
This information is to be considered preliminary since it has not yet been subjected
to the Baumüller internal review process. In particular, this information is still subject
to changes, meaning that this preliminary information cannot be construed as legally
binding. Baumüller assumes no liability for damages resulting from this potentially in-
correct or incomplete version. 
Should you detect or suspect content-related and/or serious formal errors in this pre-
liminary information, please contact the contact person assigned to you and inform
us of your findings and comments, so that they can be taken into account and poten-
tially incorporated during the transition from the preliminary information to the final
(reviewed by Baumüller) information. The obligations specified in the following sec-
tion under “Obligations” do not apply to preliminary information.

Copyright
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1.5
1.5 Copyright
Treat the Operation Manual as confidential. It is intended exclusively for those working
with the device. It is not permissible to transfer the Operation Manual to third parties with-
out the written approval of the manufacturer.
NOTICE!
The content-related statements, texts, diagrams, images and other illustrations are
copyright protected and subject to industrial property rights. Any improper use is lia-
ble to prosecution.
b maXX®is a registered trademark of Baumüller Nürnberg GmbH
1.6 Further applicable documents
Components from other manufacturers are built into the device. Hazard evaluations for
these bought-in parts have been conducted by the applicable manufacturers. The confor-
mity of the designs with the applicable European and national legislation has been de-
clared by the respective component manufacturers.
1.7 Replacement parts
WARNING!
Improper or defective replacement parts canlead to damage, malfunctions or total
failure as well as jeopardize safety.
Therefore:
mOnly use original replacement parts from the manufacturer
Procure replacement parts from authorized dealers or directly from the manufacturer.
See also ZAppendix B - Accessories– from page 65 onward.
1.8 Disposal
If no return or disposal agreement has been made, dismantled components can be taken
for recycling after proper disassembly.
See also ZDisposal – on page 62.

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1.9 Warranty conditions
The warranty conditions can be found as a separate document in the sales documenta-
tion.
The operation of the devices described here in accordance with the specified methods/
procedures/requirements is permissible. Everything else, even the operation of devices
in installation positions not depicted here, for instance, is not permissible and must be
clarified with the factor on a case-by-case basis. The warranty will be rendered null and
void if the devices are operated differently than described here.
1.10 Customer service
Our customer service is available for technical support.
Information on the contact person responsible can be found at any time via telephone,
fax, E-mail or over the internet (www.baumueller.de).
1.11 Terms used
The terms “SI4000” (for input terminal) or “SO4000” (for output terminal) are also used for
the product “Safety I/O Terminals.”
A list of the abbreviations used can be found in ZAppendix A - Abbreviations– from page
63 onward.
1.12 Certification
The safety I/O Terminals are a component part of a system composed of b maXX safe
PLC, power supply and other system modules.
The safety I/O Terminals have been developed in accordance with the standards speci-
fied in ZChapter 1.12.1– and certified by TÜV Süd.
SI4000:
Approval no. Z10 15 03 75013 001
Test report: BV82168T
SO4000:
Approval no. Z10 15 03 75013 003
Test report: BV82168T

Certification
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1.12
1.12.1 Approvals, directives and standards
Safety engineering stan-
dards and directives Area of application Approvals
EN 61508, Parts 1-3 Functional safety of security-
related electric, electronic and
programmable electronic sys-
tems
up to SIL 3
DIN EN ISO 13849-1 Safety-related components of
control units
up to performance
level e (category 4)
Additional standards Area of application
2006/42/EC machinery directive
DIN EN 81-1 to the extent to which
they may be applica-
ble
EN 13243 to the extent to which
they may be applica-
ble
DIN EN 61000-6-2
DIN EN 61000-6-4

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Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05
2USE OF THIS HANDBOOK
This safety handbook contains information on the intended use of the Baumüller safety
I/O terminals.
Knowledge of regulations and proper technical implementation of the safety instructions
in this handbook by qualified personnel are prerequisites for the safe installation, commis-
sioning and safety during the operation and maintenance of the Baumüller safety I/O ter-
minals. Unqualified interventions in the devices, during shutdown or use of the safety
functions or failure to comply with the instructions of this handbook can lead to serious
personal injury, property damage or environmental harm, for which Baumüller assumes
no liability.
Baumüller control devices are developed, manufactured and tested in compliance with
the applicable safety standards. They may only be used under the specified environmen-
tal conductions and only in connection with approved external devices.
The Operation Manual contains safety instructions, descriptions of the interfaces and in-
formation on the phases of the product’s life cycle:
nInstallation/Assembly
nCommissioning
nOperation
nTroubleshooting
nMaintenance/repair
nDisassembly

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Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05
3SAFETY
This section provides an overview of all important safety aspects for the optimum protec-
tion of the personnel as well as for safe and trouble-free operation.
3.1 Contents of the Operation Manual
All persons assigned to work on or with the device must have read and understood that
Operation Manual before beginning work with the device. This also applies if the person
concerned has already worked with such a device or similar device or has been trained
by the manufacturer.
3.2 Alterations and rebuilding of the device
In order to avoid hazards and ensure optimum performance, neither alterations, additions
nor rebuilding work may be conducted on the device unless explicitly authorized by the
manufacturer.
3.3 Appropriate use
WARNING!
Caution - Risk of injury
Safety terminals may only be used for the purposes described below!
The safety terminals expand the application range of Baumüller bus terminals with func-
tions that enable them to be used for machine safety applications. The safety terminals
are designed for machine safety functions and directly associated industrial automation
tasks. They are therefore only approved for applications with a defined fail-safe state.This
safe state is the wattless state. Fail-safety according to the relevant standards is required.

Appropriate use
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3.3
The safety terminals enable connection of:
m24 VDC sensors (SI4000) such as
emergency stop push buttons, pull cord switches, position switches, two-hand
switches, safety mats, light curtains, light barriers, laser scanners etc.
m24 VDC actuators (SO4000) such as
contactors, protection door switches with tumbler, signal lamps, servo drives etc.
NOTICE!
Test pulses
When selecting actuators please ensure that the SO4000 test pulses do not lead to
actuator switching or diagnostic message from the SO4000. The test pulses of the
SO4000 terminal outputs are not configurable and cannot be switched off.
The following modules were developed for these tasks:
mThe SI4000 terminal is an input module with digital inputs.
mThe SO4000 terminal is an output module with digital outputs.
These modules are suitable for operation with
mBaumüller b maXX safe PLC
mBaumüller ECK000 series bus coupler
Your use of the device is considered to be compliant with its intended use if you have read
all instructions and information in this Operation Manual.
WARNING!
Follow the machinery directive
The safety terminals may only be used in machines according to the Machinery Di-
rective.
WARNING!
Ensure traceability
The buyer has to ensure the traceability of the device via the serial number.

WARNING!
Danger due to use other than intended!
Any use of the device different from and/or exceeding beyond the scope of the intend-
ed use can lead to dangerous situations.
Therefore:
mOnly use the device as intended.
mFollow all specifications of this Operation Manual.
mEnsure that exclusively qualified personnel work on or with this device.
mTake care in project planning to see that the device is always used within its spec-
ifications.
mThe device and/or mounting rail is mounted on a wall which is sufficiently sturdy.
mEnsure that the power supply meets the required specifications.
mOnly operate the device if it is in technically faultless condition.
mOnly use the device in combination with components approved by Baumüller Nürn-
berg GmbH.
Safety
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3.4 Operator responsibility
The device is implemented in an industrial zone. The operator of the device is thus sub-
ject to the legal work safety obligations.
In addition to the work safety instructions in this Operation Manual, the safety, accident
prevention and environmental protection regulations applicable to the area of application
of this device must also be complied with. In doing so, the following applies in particular:
mThe operator must inform himself of the applicable work safety regulations and addi-
tionally ascertain hazards arise through the special work conditions at the place of use
of the device in a risk assessment. The operator must implement this in the form of op-
eration instructions for the operation of the device.
mThis Operation Manual must be kept in theimmediate vicinity of the device and be ac-
cessible to persons working on and with the device at all times.
mThe statements of the Operation Manual are to be followed completely and absolutely!
mThe device may only be operated in technically faultless condition and must be safe for
operation.
3.5 Protective equipment
Protection category
SI4000 IP 20
SO4000 IP 20
All SI4000 and SO4000 devices with the couple stations (b maXX safe PLC or bus cou-
pler) must be built into a suitable electrical cabinet in order to comply with the protective
categories (IP54) required in EN 60529.

DANGER!
Life-threatening danger through electric current!
Immediate life-threatening danger is present if contact with live parts is made.
Therefore:
mOperate the device in an electrical cabinet which provides protection from direct
contact with the devices and meets at least the protective categories (IP54) of
EN 60529.
Personnel training
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3.6
3.6 Personnel training
WARNING!
Risk of injury if operated by insufficiently qualified persons!
Improper handling can lead to severe personal injury and property damage.
Therefore:
mOnly allow certain activities to be conducted by persons specified in the respective
chapters of this Operation Manual.
The following qualifications for various areas of operation are specified in the Operation
Manual:
mOperating personnel
The drive system may only be operated by persons who have been trained, instructed
and authorized to do so.
Troubleshooting, repairs, cleaning, maintenance and exchange may only be conduct-
ed by trained or instructed personnel. These persons must be familiar with the Opera-
tion Manual and act according to it.
Commissioning and instruction may only be conducted by qualified personnel.
mQualified personnel
Electrical engineers and specialist electricians of the customer or a third party who are
authorized by Baumüller Anlagen-Systemtechnik GmbH & Co. KG, trained and certi-
fied in the installation and commissioning of Baumüller drive systems and commission-
ing, grounding and designating electrical systems and devices in accordance with the
safety engineering standards.
Qualified personnel is educated or trained in the maintenance and use of suitable safe-
ty equipment in accordance with the respective local safety engineering standards.

Safety
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3.7 Personnel protective equipment
Wearing the appropriate personal protective equipment when working is required in order
to minimize hazards to the health.
mAlways wear the respective protective equipment required for the respective task when
working.
mObserve signs on personal safety in the work area!
Protective work clothes
denotes tight-fitting work clothing with low tear resistance, tight sleeves and no pro-
truding parts. It primarily serves in protecting from...
Do not wear any rings and necklaces.
Protective helmet
for protection from falling and flying parts.
Safety shoes
for protection from heavy falling parts.
Safety gloves
to protect the hands from friction, abrasions, prick wounds or deeper injuries as well
as from contact with hot objects.
To be worn during
special work
Protective glasses
to protect the eyes from flying parts and spraying liquids

Special dangers
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3.8
3.8 Special dangers
The residual risks arising as a result of the hazard analysis will be specified in the follow-
ing section.
Observe the safety instructions described here and the warning notices in the following
chapters in order to reduce health hazards and avoid dangerous situations.
Electric current
DANGER!
Live-threatening danger from electric current!
Immediate life-threatening danger is present if contact with live parts is made. Dam-
age to the insulation or individual component can be life-threatening.
Therefore:
mShut down immediately if the insulation on the power supply is damaged.
mOnly allow the work to be conducted on the electrical system by qualified person-
nel.
mTurn the current off when conducting any work on the electrical system and secure
it before turning it back on.
Dangers from re-
sidual energy
DANGER!
Live-threatening danger from electric current!
After the device has been disconnected from the mains, live parts such as line con-
nectors may only be touched once the capacitors in the device have been dis-
charged.
Therefore:
mTake the capacitors’ discharge time into account and do not touch live parts be-
forehand.
mFollow commensurate instructions on the device.
mIf you have connected additional capacitors to the intermediate circuit, it can also
take considerably longer for the intermediate circuit to discharge. In such case, you
will have to establish the necessary waiting period yourself or measure whether
the device has been de-energized.