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

Operating Instructions Safety I/O Terminals SI4000 / SO4000
Dokument-Nr.: 5.08009.05 3
of 82
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

Operating Instructions Safety I/O Terminals SI4000 / SO4000
Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH
4
of 82
Inhaltsverzeichnis
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

Operating Instructions Safety I/O Terminals SI4000 / SO4000
Dokument-Nr.: 5.08009.05 5
of 82
Inhaltsverzeichnis
E.3 Definition of the term Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
E.4 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Operating Instructions Safety I/O Terminals SI4000 / SO4000
Dokument-Nr.: 5.08009.05 Baumüller Nürnberg GmbH
6
of 82

7
of 82
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
Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05 Baumüller Nürnberg GmbH
8
of 82
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.

Preface
Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05
9
of 82
1
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
Operation Manual Safety I/O Terminals SI4000 / SO4000
Document no.: 5.08009.05 Baumüller Nürnberg GmbH
10
of 82
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.