Sick Flexi io xtdo1 User manual

OPERATING INSTRUCTIONS

Flexi IO XTDO1

Expansion module - IO

Described product

Flexi IO XTDO1

Manufacturer

SICK AG

Erwin-Sick-Str. 1

79183 Waldkirch

Germany

Legal information

This work is protected by copyright. Any rights derived from the copyright shall be

reserved for SICK AG. Reproduction of this document or parts of this document is

only permissible within the limits of the legal determination of Copyright Law. Any modi‐

fication, abridgment or translation of this document is prohibited without the express

written permission of SICK AG.

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

Original document

This document is an original document of SICK AG.

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Contents

1 About this document........................................................................ 5

1.1 Purpose of this document........................................................................ 5

1.2 Scope......................................................................................................... 5

1.3 Target groups and structure of these operating instructions................ 6

1.4 Further information................................................................................... 6

1.5 Symbols and document conventions...................................................... 6

2 Safety information............................................................................ 8

2.1 General safety notes................................................................................ 8

2.2 Intended use............................................................................................. 8

2.3 Improper use............................................................................................. 8

2.4 Cybersecurity............................................................................................ 9

2.5 Requirements for the qualification of personnel.................................... 9

3 Product description........................................................................... 10

3.1 Configuration of the safety controller...................................................... 10

3.2 Overview of the module............................................................................ 11

3.3 Design and function of the module......................................................... 11

3.4 Status indicators....................................................................................... 12

4 Project planning................................................................................ 13

4.1 Manufacturer of the machine.................................................................. 13

4.2 Operating entity of the machine.............................................................. 13

4.3 Design........................................................................................................ 13

4.4 Electrical integration................................................................................. 15

4.4.1 Internal circuitry....................................................................... 15

4.4.2 Safety outputs.......................................................................... 15

4.4.3 Single-channel use of safety inputs....................................... 16

4.5 Testing plan............................................................................................... 16

5 Mounting............................................................................................. 18

5.1 Mounting procedure................................................................................. 18

5.2 Module exchange...................................................................................... 18

6 Electrical installation........................................................................ 20

6.1 Connecting................................................................................................ 20

6.1.1 Front connector........................................................................ 20

6.2 Coding........................................................................................................ 21

6.2.1 Coding front connector and module....................................... 22

7 Commissioning.................................................................................. 24

7.1 Check during commissioning and modifications.................................... 24

8 Operation............................................................................................ 25

8.1 Status indicators....................................................................................... 25

CONTENTS

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8.2 Regular thorough check........................................................................... 26

9 Maintenance...................................................................................... 27

9.1 Regular thorough check........................................................................... 27

10 Troubleshooting................................................................................. 28

10.1 Possible faults........................................................................................... 28

11 Decommissioning............................................................................. 31

11.1 Disposal..................................................................................................... 31

12 Technical data.................................................................................... 32

12.1 Data sheet................................................................................................. 32

12.2 Dimensional drawings.............................................................................. 36

13 Ordering information........................................................................ 37

13.1 Scope of delivery....................................................................................... 37

13.2 Ordering information for main module.................................................... 37

13.3 Ordering information for expansion module........................................... 37

13.4 Ordering information for accessories...................................................... 37

14 Annex.................................................................................................. 39

14.1 Conformities and certificates................................................................... 39

14.1.1 EU declaration of conformity................................................... 39

14.1.2 UK declaration of conformity.................................................. 39

15 List of figures..................................................................................... 40

16 List of tables....................................................................................... 41

CONTENTS

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1 About this document

1.1 Purpose of this document

These operating instructions contain the information required during the life cycle of the

safety controller.

Operating instructions of the safety controller must be made available to all people who

work with the device.

1.2 Scope

Product

This document applies to the following products:

•Product code: Flexi IO XTDO1

•“Operating instructions” type label entry: 8024570

Document identification

Document part number:

•This document: 8024583

•Available language versions of this document: 8024570

You can find the current version of all documents at www.sick.com.

Other documents relevant for the product

Table 1: Available documents

Document Title Part number

Operating instructions Flexi Compact safety control‐

ler

8024573

Operating instructions FLX3-XTDI1

Expansion module for safety

controllers

8024571

Operating instructions FLX3-XTDO1

Expansion module for safety

controllers

8024570

Operating instructions FLX0-GPNT1

Expansion module for safety

controllers

8024567

Operating instructions FLX0-GETC1

Expansion module for safety

controllers

8024566

Operating instructions FLX0-GCAN1

Expansion module for safety

controllers

8024572

Operating instructions Flexi Loop Safe Series Con‐

nection Hardware

8015834

Operating instructions Flexi Loop in the Safety

Designer Software

8018174

Competence brochure Guide for Safe Machinery 8008007

ABOUT THIS DOCUMENT 1

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1.3 Target groups and structure of these operating instructions

These operating instructions are intended for the following target groups:project devel‐

opers (planners, developers, designers), installers, electricians, safety experts (such as

CE authorized representatives, compliance officers, people who test and approve the

application), operators, and maintenance personnel.

These operating instructions are organized by the life phases of the device: project

planning, mounting, electrical installation, commissioning, operation and maintenance.

The table below shows the target groups and how – for many applications – these are

typically divided up between the manufacturer and the entity operating the machine in

which the device is to be integrated:

Area of responsibility Target group Specific chapters of these operating instruc‐

tions 1)

Manufacturer Project developers

(planners, developers,

designers)

Project planning, page 13

Technical data, page 32

Installers Mounting, page 18

Electricians Electrical installation, page 20

Safety experts Project planning, page 13

Commissioning, page 24

Technical data, page 32

Operating entity Operators Troubleshooting, page 28

Maintenance staff Troubleshooting, page 28

Ordering information, page 37

1) Chapters not listed here are intended for all target groups. All target groups must follow all of the safety

and warning instructions in all chapters of the operating instructions!

In other applications, the operating organization is also the manufacturer of the equip‐

ment with the corresponding allocation of the target groups.

1.4 Further information

www.sick.com

The following information is available via the Internet:

•Data sheets and application examples

•CAD files and dimensional drawings

•Certificates (such as the EU declaration of conformity)

•Guide for Safe Machinery. Six steps to a safe machine

•Safety Designer (software for configuring safety solutions made by SICK AG)

1.5 Symbols and document conventions

The following symbols and conventions are used in this document:

Safety notes and other notes

DANGER

Indicates a situation presenting imminent danger, which will lead to death or serious

injuries if not prevented.

1 ABOUT THIS DOCUMENT

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WARNING

Indicates a situation presenting possible danger, which may lead to death or serious

injuries if not prevented.

CAUTION

Indicates a situation presenting possible danger, which may lead to moderate or minor

injuries if not prevented.

NOTICE

Indicates a situation presenting possible danger, which may lead to property damage if

not prevented.

NOTE

Indicates useful tips and recommendations.

Instructions to action

bThe arrow denotes instructions to action.

1. The sequence of instructions for action is numbered.

2. Follow the order in which the numbered instructions are given.

✓The check mark denotes the result of an instruction.

ABOUT THIS DOCUMENT 1

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2 Safety information

2.1 General safety notes

Product integration

DANGER

The product can not offer the expected protection if it is integrated incorrectly.

bPlan the integration of the product in accordance with the machine requirements

(project planning).

bImplement the integration of the product in accordance with the project planning.

Mounting and electrical installation

DANGER

Death or severe injury due to electrical voltage and/or an unexpected startup of the

machine

bMake sure that the machine is (and remains) disconnected from the voltage

supply during mounting and electrical installation.

bMake sure that the dangerous state of the machine is and remains switched off.

Repairs and modifications

DANGER

Improper work on the product

A modified product may not offer the expected protection if it is integrated incorrectly.

bApart from the procedures described in this document, do not repair, open, manip‐

ulate or otherwise modify the product.

2.2 Intended use

The Flexi Compact safety controller is a freely configurable control for safety applica‐

tions.

The product may be used in safety functions.

Sensors and switching elements (e.g. light curtains, laser scanners, switches, sensors,

encoders, emergency stop pushbuttons) are connected to the 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.

Incorrect use, improper modification or manipulation of the product will invalidate any

warranty from SICK; in addition, any responsibility and liability of SICK for damage and

secondary damage caused by this is excluded.

The product is only suitable for use in industrial environments.

2.3 Improper use

Among others, the safety controller is not suitable for the following applications:

•Outdoors

•Underwater

•In explosion-hazardous areas

•In residential areas

2 SAFETY INFORMATION

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2.4 Cybersecurity

Overview

To protect against cybersecurity threats, it is necessary to continuously monitor and

maintain a comprehensive cybersecurity concept. A suitable concept consists of organi‐

zational, technical, procedural, electronic, and physical levels of defense and considers

suitable measures for different types of risks. The measures implemented in this

product can only support protection against cybersecurity threats if the product is used

as part of such a concept.

You will find further information at www.sick.com/psirt, e.g.:

•General information on cybersecurity

•Contact option for reporting vulnerabilities

•Information on known vulnerabilities (security advisories)

2.5 Requirements for the qualification of personnel

The product must be configured, installed, connected, commissioned, and serviced by

qualified safety personnel only.

Project planning

You need safety expertise to implement safety functions and select suitable products

for that purpose. You need expert knowledge of the applicable standards and regula‐

tions.

Mounting, electrical installation and commissioning

You need suitable expertise and experience. You must be able to assess if the machine

is operating safely.

Operation and maintenance

You need suitable expertise and experience. You must be instructed in machine oper‐

ation by the machine operator. For maintenance, you must be able to assess if the

machine is operating safely.

SAFETY INFORMATION 2

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3 Product description

3.1 Configuration of the safety controller

Configuration of the safety controller

A safety controller comprises the following components:

•A main module

•Up to 12 optional expansion modules (excluding maximum 1 gateway)

PWR

FLEXIcompact

I11

I10

I12

I15

I17

I16

I18

I19

I20

I14

PWR

I13

Figure 1: Example maximum configuration

1Main module

2Expansion module - gateway

3IO expansion module

Complementary information

•The gateway and IO expansion modules can be arranged arbitrarily.

3 PRODUCT DESCRIPTION

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3.2 Overview of the module

PWR

Figure 2: FLX3-XTDO1 IO expansion module

1Release element of the module

2Status indicators (LEDs)

3Front connector unlocking

4Front connector with terminals

5Backplane bus

3.3 Design and function of the module

Prerequisites

•The module can only be operated with a main module.

Configuration

Table 2: Interfaces of the module

Description Quantity

Safety capable inputs 8

Safety capable outputs 8

Function

The module is a safe digital input/output expansion module.

The module offers the following functions:

•Monitoring of the connected safety devices

•Switching of the connected safety devices

•Special IO functions (e.g., fast shut off)

Complementary information

•Safety outputs have test pulses for detecting short-circuits in the wiring.

•Voltage is supplied to the module via the backplane bus. Communication with the

main module of the safety controller also occurs via the backplane bus.

•Voltage is supplied directly to the safety outputs Q via A1/A2 on the module.

PRODUCT DESCRIPTION 3

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3.4 Status indicators

Status indicators

PWR

XTDO1

1085354

Q5 Q6

PWR

A1 A2

Figure 3: LEDs for indicating the status

The arrangement of the status indicators corresponds to the arrangement of the termi‐

nals.

Status indicator

Table 3: Status indicator

Labeling Color Function

PWR (power) Green/Red Device status 1)

I1…I8 Green Safety input 1 … 8

Q1…Q8 Green Safety output 1 … 8

1) Does not indicate whether the local auxiliary supply at A1 and A2 for the safety outputs is currently within

the supply voltage range.

Further topics

•"Status indicators", page 25

•"Troubleshooting", page 28

3 PRODUCT DESCRIPTION

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4 Project planning

4.1 Manufacturer of the machine

The manufacturer of the machinery must carry out a risk assessment and apply appro‐

priate protective measures. Further protective measures may be required in addition to

the product.

The product must not be tampered with or changed, except for the procedures descri‐

bed in this document.

The product must only be repaired by the manufacturer of the product or by someone

authorized by the manufacturer. Improper repair can result in the product not providing

correct protection.

4.2 Operating entity of the machine

Changes to the electrical integration of the product in the machine controller and

changes to the mechanical mounting of the product necessitate a new risk assess‐

ment. The results of this risk assessment may require the entity operating the machine

to meet the obligations of a manufacturer.

After each change to the configuration, it is necessary to check whether the protective

measure provides the necessary protection. The person making the change is responsi‐

ble for ensuring that the protection measure provides the necessary protection.

The product must not be tampered with or changed, except for the procedures descri‐

bed in this document.

The product must only be repaired by the manufacturer of the product or by someone

authorized by the manufacturer. Improper repair can result in the product not providing

correct protection.

4.3 Design

Installation site

•The safety controller must be protected against condensation and conductive

contamination, e.g. in an IP54 control cabinet.

•Mounting on a 35mm × 7.5mm mounting rail in accordance with IEC60715.

•The mounting rail is connected to the functional earth.

•Mounting rail is mounted on a mounting plate.

•Mounting plate is connected to functional earth.

•Mounting in a vertical orientation (on a horizontal mounting rail).

•Take suitable ESD protection measures.

Air circulation

To ensure sufficient air circulation and cooling, sufficient distance must be kept in the

control cabinet above and below the module.

Provide an adequate clearance in front of the module (front side) for the connected

cables.

PROJECT PLANNING 4

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≥ 30≥ 30

≥ 25

Figure 4: Clearances for adequate air circulation

Required distance:

•Above and below the module: ≥30mm

•In front of the module: ≥25mm

4 PROJECT PLANNING

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4.4 Electrical integration

4.4.1 Internal circuitry

Figure 5: Internal circuitry XTDO

4.4.2 Safety outputs

Important information

WARNING

Ineffectiveness of the protective device

In the event of a fault, a single safety output (Q) can switch off after a delay or briefly

switch to High. The response time increases depending on the configuration of the

output. The dangerous state may not be stopped or not be stopped in a timely manner

in the event of non-compliance.

bTake the increased response time into consideration in the risk analysis.

bTake the possible reduced safety level into consideration in the risk analysis.

Fault detection by testing

The following faults can be detected by testing an element:

•Short-circuits between any of the safety outputs.

You can detect a cross-circuit between the safety outputs of 12 sequential mod‐

ules.

•Short circuits to 24VDC (to High) on safety outputs.

•Actuator wiring short-circuits to 24V.

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Further topics

•"Front connector", page 20

•"Configuring elements"

4.4.3 Single-channel use of safety inputs

Important information

WARNING

Unexpected pulses or delayed falling signal edges due to a short-circuit to High

Machine can start up unexpectedly or the dangerous state of the machine may not be

stopped or not stopped in a timely manner.

bProtect single-channel inputs against short-circuits and cross-circuits.

bMake sure the signal line is laid with protection (to prevent a cross-circuit with

other signal lines).

bDo not reference the test outputs.

Short-circuit to High for single-channel use of safe inputs

On a single-channel safety input with test pulses, which was previously in the low state,

a short-circuit to high may be interpreted as a pulse by the logic due to the fault

detection. The short-circuit to High causes the signal to switch to High and back to Low

at the end of the fault detection time.

If a short-circuit to High occurs on a single-channel safety input with test pulses and

this was already in the High state, the logic interprets the signal as a delayed falling

signal edge (High - Low).

If a dangerous state could potentially arise because of an unexpected pulse or a

delayed falling signal edge, then concrete measures must be implemented.

This is particularly important in the case of the following inputs:

•Reset input on the reset function block

•Restart input on the restart function block

•Override input on the muting function blocks

•Reset to zero input and Set to reload value input on a counter function block

4.5 Testing plan

Testing plan

The manufacturer of the machine and the operating entity must define all required

thorough checks. The definition must be based on the application conditions and the

risk assessment and must be documented in a traceable manner.

In addition, the device must be checked for correct functioning after each change to the

configuration.

bWhen defining the thorough check, please note the following:

°Define the type and execution of the thorough check.

°Define the frequency of the thorough check.

°Notify the machine operators of the thorough check and instruct them

accordingly.

The following thorough checks are often defined in connection with a protective

device:

•Thorough check during commissioning and modifications

•Regular thorough check

4 PROJECT PLANNING

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Thorough check during commissioning and modifications

Before commissioning the machine and after making changes, you must check whether

the safety functions are fulfilling their planned purpose and whether persons are being

adequately protected.

The following points are helpful when planning the thorough check:

•Does the thorough check have to be completed by qualified safety personnel?

•Can the thorough check be completed by personnel specially qualified and author‐

ized to do so?

•Does the thorough check have to be documented in a traceable manner?

•Can the thorough check be carried out according to a check list?

•Do the machine operators know the function of the protective device?

•Have the machine operators been trained to work on the machine?

•Have the machine operators been notified about modifications to the machine?

bDefine all guidelines for the thorough check.

Regular thorough check

The following points are helpful when planning the thorough check:

•Which thorough check must be carried out and how is it carried out?

•How often does the thorough check have to be carried out?

•Do the machine operators have to be notified of the thorough check and do they

need to be instructed accordingly?

bDefine all guidelines for the thorough check.

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5 Mounting

5.1 Mounting procedure

For information on the mounting process, please see the operating instructions:

•“Flexi Compact” (SICK part number 8024573)

5.2 Module exchange

Approach

1. Disconnect module and the connected components from all voltage sources.

2. Take front connector with connected cables off the defective device: Press the

unlocking mechanism of the front connector downwards and pull out the front

connector.

Figure 6: Dismantle front connector

3. Dismantle the defective module.

4. Mount new module.

5. Mount front connector with connected cables to the new module: First mount in

the module with bent hook and then engage in the housing.

5 MOUNTING

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Click

Figure 7: Mount the front connector

✓The front connector engages with an audible click.

MOUNTING 5

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6 Electrical installation

6.1 Connecting

Prerequisites

•Mounting is completed.

•Electrical installation is carried out according to the project planning.

•Dangerous condition of the machine is and remains off during the electrical instal‐

lation.

•The outputs of the safety controller do not affect the machine during electrical

installation.

6.1.1 Front connector

Prerequisites

Electrical connection requirement:

•Electrical installation is performed in accordance with EN60204-1.

•The mounting rail is connected to the functional earth.

•The voltage supply and connected signals meet the requirements for extra-low

voltages with safe separation (EN60664) or NECClass2 (UL1310).

•The external voltage supply must be capable of buffering brief power failures of

20ms as specified in EN60204-1. Suitable power supply units are available as

accessories from SICK.

•Galvanically isolate the battery-operated 24V power circuit from the circuit of the

safety controller using an enclosed DC-DC transducer in accordance with EN1175

(e.g., when using on an automated guided vehicle).

•The GND of all connected devices must have the same potential as A2 of the main

module. Exceptions are actuators which are connected to an expansion module

with its own voltage supply.

•The GND connections of the actuators to the safety outputs are in star formation

with the GND connection of the voltage supply.

Pin assignment

3 4

1 2

Figure 8: Terminals on front connector

6 ELECTRICAL INSTALLATION

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