SICK Intelliface Flexi Controllers [ UE410 Series ] Quick Start Guide

Transcription

1 SICK Intelliface Flexi Controllers [ UE40 Series ] Quick Start Guide 8 October 2006 IMPORTANT NOTE: The information provided in this document may be used to gain a basic understanding of the Intelliface Flexi Controller system. It is not intended to replace the Operating Instructions - UE40 Flexi, or the Brief Instructions that accompany each module. Please consult these documents for additional information and requirements for using Intelliface Flexi Controller products.

2 SICK Intelliface Flexi Controllers Quick Start Page of 20 Table of Contents PRODUCT OVERVIEW... INTELLIFACE FLEXI CONTROLLER CONFIGURATION PLANNER...2 IMPLEMENTING INTELLIFACE FLEXI CONTROLLER SYSTEMS...3 BASIC RULES...3 DIAGNOSTIC MODULES...4 ENABLE INPUT REQUIREMENTS...4 RESET FUNCTIONALITY...4 RETRIGGERING FUNCTIONALITY...5 TEACHING THE CONFIGURATION...5 SYSTEM VALIDATION...6 TROUBLESHOOTING THE INTELLIFACE FLEXI CONTROLLER SYSTEM...7 ERROR (ERR) LED...7 INPUT AND OUTPUT LED INFORMATION...7 REPLACING INTELLIFACE FLEXI CONTROLLER SYSTEM MODULES...8 REMOVING MODULES FROM THE SYSTEM...8 INSERTING MODULES BACK INTO THE SYSTEM...9 APPENDIX... APPLICATION EXAMPLE: E-STOP, ESPE X 3 AND INTERLOCK X2... WIRING EXAMPLE: INTEGRATING SAFETY STOP AND EMERGENCY STOP SIGNALS ACROSS MULTIPLE SYSTEMS...3 UE40-MU AND UE40-XU ROTARY SWITCH SETTINGS...4 UE40-8DI ROTARY SWITCH SETTINGS...5 INTELLIFACE FLEXI CONTROLLER DIMENSIONAL INFORMATION...5 INTELLIFACE FLEXI CONTROLLER INTERNAL CONNECTIONS...6 INTELLIFACE FLEXI CONTROLLER TECHNICAL SPECIFICATIONS...7 INTELLIFACE FLEXI CONTROLLER ORDERING INFORMATION...20 Author Information: James O Laughlin Safety Interface Solutions Product Manager SICK, Incorporated 6900 West 0 th Street Bloomington, MN USA i 8 October 2006

3 SICK Intelliface Flexi Controllers Quick Start Page of 20 Product Overview The Intelliface Flexi Controller provides unique solutions for safety-relevant controls applications up to Safety Category 4 (accord. EN954-; ISO 3849) and up to Safety Integrity Level (SIL) 3 (accord. IEC 6508). Historically, safety logic has been implemented using either hardwire techniques with safety relays, or via expensive safety programmable logical controllers (safety PLCs). Intelliface Flexi Controllers take advantage of the benefits of both technologies. When you connect safety input devices to the Intelliface Flexi Controller system, the logic is implemented using rotary switches. No software is required. Solid state safety outputs, rated up to.6 Amps each, provide sufficient current capability to drive a variety of actuator loads. Intelliface Flexi Controller series electro-mechanical relays are also available to accommodate higher current or voltage requirements, and provide mechanical means, which supports the requirements for Category 0 emergency stop circuits in accordance with ANSI / NFPA 79 and EN 48 requirements. Diagnostic modules are available that provide valuable diagnostic and status information regarding the Intelliface Flexi Controller system. Data includes: current state of safety inputs, current state of safety outputs, individual module status and fault-specific information. Information from the safety control system may be displayed on an operator interface without having to connect hardwire auxiliary contacts back to the main control cabinet. Unlike having separate safety contacts for the safety control system and monitoring contacts for the standard control system, the data from the Intelliface Flexi Controller system reflects the current state of the safety system discrepancies due to delays between the safety system and the standard control system are avoided. The Intelliface Flexi Controller system is composed of the following modules: UE40-MU Main Unit UE40-XU Expansion Unit for additional logic or output requirements UE40-8DI Input Expansion Unit UE40-2RO/4RO Relay Modules UE40-PRO Profibus DP Diagnostic Module UE40-DEV DeviceNet Diagnostic Module UE40-CAN CANopen Diagnostic Module (In Preparation) UE40-ETH EtherNet Module (In Preparation) Logic is implemented with rotary switches on the front of each module. Logical combinations with multiple modules are easily set based on how the modules are combined. Inputs into the system, including reset and other functionality may be monitored using test pulses from terminals X X8 (module dependent) on the UE40-MU, UE40-XU and UE40-8DI modules. These test pulse outputs allow users to monitor signals for short circuits (i.e. stuck at Active (HIGH) conditions) and crossed-circuits caused by miswiring of signals. 8 October 2006

4 SICK Intelliface Flexi Controllers Quick Start Page 2 of 20 Intelliface Flexi Controller Configuration Planner A visualization tool has been developed to help simplify module selection and to understand the logic configuration possibilities associated with the Intelliface Flexi Controller system. This visualization tool is known as the Intelliface Flexi Controller Configuration Planner and is available at Intelliface Flexi Controller Configuration Planner is an ingenius tool that helps users select the right modules for their safety control system. Users may connect a variety of safety relevant devices and display the logic associated with the rotary switch settings they have configured. Intelliface Flexi Controller Configuration Planner software is not required to configure the logic in the Intelliface Flexi Controller system, but rather to help understand how the rotary switch settings affect the logical connection of safety-relevant sensor devices. For assistance in working with Intelliface Flexi Controller Configuration Planner, contact your local SICK sales representative. Assistance in locating a local representative can be obtained at 8 October 2006

5 SICK Intelliface Flexi Controllers Quick Start Page 3 of 20 Implementing Intelliface Flexi Controller Systems The Intelliface Flexi Controller system consists of the following Module types: Logic (UE40-MU, UE40-XU); I/O Extension Modules (UE40-8DI); Electro-mechanical Relay Modules (UE40-2RO, UE40-4RO); and Diagnostic Communications Modules (UE40-CAN, UE40-PRO, UE40-DEV and UE40-ETH). Basic Rules Implementation of the Intelliface Flexi Controller modules follows a few basic rules:. The left-most module must always be a UE40-MU. This module stores the system configuration information. Logic is set using a rotary switch on the front of the unit and a time delay setting for one or more outputs may also be configured. Each Intelliface Flexi Controller system has only one UE40-MU module. 2. When additional logic is required, the Intelliface Flexi Controller system can be extended using the UE40-XU unit. These modules behave very similarly to the UE40-MU module with the following differences: UE40-XU modules do not store system configuration information Multiple UE40-XU modules may exist in the system. 3. Additional inputs may be incorporated into the logic of the UE40-MU module or subsequent UE40-XU module(s) by adding one or more UE40-8DI modules to the right of the respective module. When this is done, the rotary switch settings on the UE40-8DI module define how these inputs are evaluated by the logic of both the UE40-8DI module and the UE40-MU or UE40-XU module. Logical operations include: Logical AND Logical OR Logical Bypass Furthermore, since the MU may be configured for two separate logical paths (dependent or independent), these additional inputs (two input groups per UE40-8DI) can be utilized as part of either safety logic chain. When UE40-8DI modules are used in the Intelliface Flexi Controller system, they are logically combined with either the UE40-MU module or UE40-XU that is located immediately to the left of the UE40-8DI module(s). 4. The total number of UE40-MU, UE40-XU and UE40-8DI modules cannot exceed 3 within a single Intelliface Flexi Controller system. 5. Relay modules utilize outputs from UE40-MU or UE40-XU devices. The UE40-2RO contains two (2) relay outputs and the UE40-4RO contacts four (4) relay outputs. A total of up to 6 relay outputs may be used in a single Intelliface Flexi Controller system. These modules may be located anywhere in the overall system. 8 October 2006

6 SICK Intelliface Flexi Controllers Quick Start Page 4 of 20 Diagnostic Modules 6. One diagnostic module may be used to communicate the individual input status, dual-channel output status and module status information via a standard fieldbus interface. The diagnostic modules are passive devices on the safety system and do affect the safety control system. When used, this module must be the right-most module in the system. Several different communication protocols are supported. These include: CANOpen (UE40-CAN) [in preparation]; DeviceNet (UE40-DEV); Profibus DP (UE40-PRO); and Various Ethernet Protocols (UE40-ETH) for: EtherNet/IP / Modbus TCP / TCP/IP / Profinet Real Time [RT] I/O [the UE40-ETH modules are currently in preparation please consult factory for availability] Enable Input Requirements 7. The Enable (EN) input on both the UE40-MU and UE40-XU modules provides means for logically connecting: Logical connection from a UE40-MU output to a UE40-XU unit in the same system; Logical connection from one UE40-XU output to a second UE40-XU unit in the same system; Logical connection from one Intelliface Flexi Controller system to a second Intelliface Flexi Controller system The Enable (EN) input provides a method for controlling the safety outputs of the UE40-MU and UE40-XU modules. When the Enable (EN) input is Inactive (LOW), then the safety outputs associated with the module are also Inactive (LOW). This provides the equivalent of a series, hardwired logic circuit. Reset functions are not affected by the state of the Enable (EN) input and must be handled elsewhere within the overall system. Reset Functionality 8. Reset and External Device Monitoring (EDM) functions are managed by Input S and Input S2 on both the UE40-MU and UE40-XU module(s) within the Intelliface Flexi Controller system. Input S is used for reset functionality and EDM for safety outputs Q and Q2. Input S2 is used for reset functionality and EDM for safety outputs Q3 and Q4. Reset and EDM functionality are accomplished in the following manner: Connection Functionality Manual Reset, Without External Device Monitoring Manual Reset, With External Device Monitoring Automatic Reset, Without External Device Monitoring Automatic Reset, With External Device Monitoring 8 October 2006

7 SICK Intelliface Flexi Controllers Quick Start Page 5 of 20 For reset and EDM management using S2 (i.e. for Q3 and Q4 safety outputs), U B and X2 are used in conjunction with the S2 input in lieu of U B, X and S respectively. U B is supply voltage for the Intelliface Flexi Controller system (i.e. 24 V DC) and X X2 are test pulse outputs on the module. Retriggering Functionality 9. A special function called Retriggering is configured at Input S3 on both the UE40-MU and UE40-XU modules within the Intelliface Flexi Controller system. Retriggering is used in conjunction with a delayed output (i.e. Q3 and/or Q4, program dependent). If a delayed output begins to time down after the internal logic indicates an Inactive (LOW) state (i.e. OFF-Delay Timer), but returns to an Active (HIGH) state before the timer expires, the Retriggering configuration determines how the output will behave. Connection Functionality Retriggering ON: If the OFF-delay timer has not expired and the logic associated with Q3/Q4 returns to Active (HIGH) after becoming Inactive (LOW), the delayed output circuit(s) do not become Inactive (LOW) and the delay timer will be reset. Retriggering OFF: The delayed output circuits open after the OFF-Delay time has expired regardless of the state of the logic of the safety input evaluation. When automatic reset is configured, and the logic associated with the safety inputs returns to an Active (HIGH) state before the delay time has expired, the delayed OSSDs will be de-activated for 400 ms, and then re-activated Important Note: All UE40-MU and UE40-XU modules within the Intelliface Flexi Controller system must specify whether Retriggering is ON or OFF (i.e. S3 must be connected to either X2 or U B ). If the Retriggering connection is not wired (e.g. for either ON or OFF), the Intelliface Flexi Controller system will not become Active (HIGH). Teaching the Configuration 0. When all wiring connections have been completed, the next step in implementing the Intelliface Flexi Controller system is to set the rotary switches to the configuration required and then teach in the system configuration. We recommend that the rotary switch setting(s) be well documented. It may also be useful to mark the rotary switch setting on the front of each module for clarity with a permanent marker. The teach process is accomplished by: Powering down the Intelliface Flexi Controller system. Holding down the Enter pushbutton. Applying power to the Intelliface Flexi Controller system; and then Releasing the Enter pushbutton while the Red Error LED is flashing. Any modification to any switch setting in the Intelliface Flexi Controller system after the teach process has been completed will generate a fault condition. 8 October 2006

8 SICK Intelliface Flexi Controllers Quick Start Page 6 of 20 System Validation. The final step in the implementation of the Intelliface Flexi Controller system is to verify that the system performs as expected. Verify that the configuration settings match system requirements in accordance with the risk assessment of the machine. Verify that the safety input LEDs correspond with the actuation of the associated safeguard or emergency stop device. Verify that the reset LEDs (S, S2) correspond with the actuation of the reset pushbutton(s). Verify that the Enable (EN) and Retriggering Input (S3) are Active (HIGH) when expected. Verify that the safety output LEDs and signals correspond with the actuators (e.g. motors, drives, etc.) and that the actuators stop according to the logic configured in the system. Verify that the safety system and machine functions are as intended. 8 October 2006

9 SICK Intelliface Flexi Controllers Quick Start Page 7 of 20 Troubleshooting the Intelliface Flexi Controller System A variety of LED information is available on each module to assist in troubleshooting the Intelliface Flexi Controller System. Error (ERR) LED Display Potential Cause Possible Remedies Solid Red Red Flashing x 2 Red Flashing x 3 An error has been detected in the system. Configuration error at the module Rotary Switch value has changed (manipulation) Remedy problem at module with flashing Error LED Repeat the configuration Turn the rotary switch back to original position Cycle power Repeat teach process. Red Flashing x 4 Module type not recognized Replace module and repeat teach process Red Flashing x 5 Issue with Supply Voltage Remedy supply voltage issue (e.g. The supply voltage is outside of specifications) Red Flashing x 6 Self-Diagnosis, Internal Error Cycle power When one of the above fault conditions has occurred, the power must be cycled in order to clear the fault condition. Input and Output LED Information LEDs are available for the following, as applicable: Inputs: I... I8 Inputs for Reset Function: S (Reset Q/Q2), S2 (Reset Q3/Q4), S3 (Retrigger) Inputs for Enable Function: EN Outputs: Q/Q2, Q3/Q4, QA and QB The following LED states are possible: LED is OFF, the corresponding Input or Output is Inactive (LOW). LED is Green ON, the corresponding Input or Output is Active (HIGH). LED is Green Flashing, the corresponding Input or Output is Inactive (LOW) / Fault Detected. Faults may include short-circuits, crossed-circuits or signals that do not match configuration. For dual channel evaluation in which a fault has been detected, both input LEDs for the defined dual channel will be Green Flashing Alternately. When an input or output error has been corrected in the Intelliface Flexi Controller System, the corresponding input may become Active (HIGH) without any further action (e.g. the system does not require a power cycle in this case to clear a fault condition). Important Note: Both the Enable (EN) and Retriggering (S3) inputs must be Active (HIGH) in order for any safety outputs to be Active (HIGH). 8 October 2006

10 SICK Intelliface Flexi Controllers Quick Start Page 8 of 20 Replacing Intelliface Flexi Controller System Modules Removing Modules from the System In the event that a module must be replaced (see troubleshooting section), the following process should be followed:. Power down the Intelliface Flexi Controller System. Remove the terminal blocks from the top and bottom of the module. Remove the end stop, or move the end stop at least 0mm from the Intelliface Flexi Controller System, so that the modules may be moved left or right on the DIN mounting rail. 2. When there is more than one module in the system, slide the modules apart individually until the slide plug connection between the modules is separated on either side of the module to be replaced. 8 October 2006

11 SICK Intelliface Flexi Controllers Quick Start Page 9 of Press the module that will be replaced downward () and remove it from the DIN mounting rail in the direction of the arrow while keeping it pressed down (2). Inserting Modules Back into the System 4. Insert the replacement module on to the DIN mounting rail () in the same location as the module that was removed. Ensure that the functional earth contact located on the back of the module (2) makes adequate contact with the DIN mounting rail. Latch the module on the DIN mounting rail by pressing gently downward (3). 8 October 2006

12 SICK Intelliface Flexi Controllers Quick Start Page 0 of Once the module is re-mounted on the DIN mounting rail. Slide the modules individually back together until all modules have returned to their original position. Replace the end stop to secure the modules in place. 6. If the replacement module also includes replacement terminal blocks, remove the terminal blocks and discard. Reinsert the original terminal blocks (previously removed). The terminal blocks are keyed make sure that the correct terminal blocks are inserted properly. Do not force the terminal blocks into the incorrect location. 7. Set the rotary switches to match the settings on the module that was replaced and then cycle power. If the module that was replaced was the UE40-MU, follow the Teach process outlined earlier in this document. This will ensure that the configuration is stored in the device. 8. Follow the normal reset procedure and then validate proper system operation. 8 October 2006

13 SICK Intelliface Flexi Controllers Quick Start Page of 20 Appendix Application Example: E-Stop, ESPE x 3 and Interlock x2 The application presented below provides an example of how the Intelliface Flexi Controller System may be used to provide safety relevant control. The application presented below includes one () emergency stop pushbutton, two (2) safety interlock switches and three (3) S3000 safety laser scanners. The following diagram from SICK s Intelliface Flexi Controller Configuration Planner (available at shows how this system could be implemented. Outputs Q and Q2 are based on a logical AND of the emergency stop and two (2) safety interlock switches (blue logic path). Outputs Q3 and Q4 are based on a logical AND of the three (3) S3000 safety laser scanners (green logic path) followed by a logical AND with the blue logic path. The result is a logical AND of all safety input signals. Output Q3 is then connected to input B of the UE40-2RO relay module to provide a control signal (K) for safety-relevant control of the actuator. A reset switch that incorporates external device monitoring is connected to input S2 for implementation of a manual reset associated with safety output Q3. Since safety outputs Q and Q2 are not used, automatic reset without external device monitoring is connected to input S. Retriggering is configured as OFF as a delayed output is not used. The enable (EN) input is also connected to 24 V DC since no logical cascading is required. 8 October 2006

14 SICK Intelliface Flexi Controllers Quick Start Page 2 of 20 The following electrical schematic provides additional detail regarding the implementation of the application. 24 VDC Safety Interlocks X X2 A A2 EN S S2 S3 X X2 X3 X4 I I2 I3 I Y4 Y 7 FUNCTION 3 FUNCTION INPUT A Reset MU 8DI 2RO 0 DELAY 6 FUNCTION INPUT B I I2 I3 I4 Q Q2 Q3 Q4 I5 I6 I7 I8 X5 X6 X7 X8 B Y E-Stop PB OSSD OSSD 2 OSSD OSSD 2 OSSD OSSD 2 K COM 8 October 2006

15 TM TM TM SICK Intelliface Flexi Controllers Quick Start Page 3 of 20 Wiring Example: Integrating Safety Stop and Emergency Stop Signals Across Multiple Systems XP Controller XP!C Part of XPC +V +24V Unused switch locations must be jumpered out. +24V Unused switch locations must be jumpered out. +24V Unused switch locations must be jumpered out. DIR I/O START_BTN START K K K(y) +24V +24V K2 Diagnostic Bus to local zone controller +24V K3 Diagnostic Bus to local zone controller +24V K(x) Diagnostic Bus to local zone controller RUN_ENABLE +24V START X I X2 I2 I3 I4 S S3 A I I2 I3 I4 S3 X S S2 X I X2 I2 X3 I3 X4 I4 A I I2 I3 I4 S3 X S S2 A I I2 I3 I4 S3 X S S2 SS_REQUEST START K SSE RELAY K FUNCTION 7 FUNCTION PROG A SW 0 ADDR X0 7 FUNCTION PROG A SW 0 ADDR X0 7 FUNCTION PROG A SW 0 ADDR X0 +24V MU XU 8DI Flexi Diagnostic Module MU 8DI Flexi Diagnostic Module MU 8DI Flexi Diagnostic Module EN 0 DELAY EN DELAY PROG B SW ADDR X EN DELAY PROG B SW ADDR X EN DELAY PROG B SW ADDR X Q A2 Q A2 Q3 Q4 X5 I5 X6 I6 X7 I7 X8 I8 Q A2 Q3 Q4 Q A2 Q3 Q4 Motor K2 Power Contactor Motor K3 Power Contactor Motor K(x) Power Contactor SYSTEM RESET OK To local Zone Controller I/O SAFETY_OK Interlock Switches Unused switch locations must be jumpered out. To local Zone Controller I/O Interlock Switches Unused switch locations must be jumpered out. K(y) To local Zone Controller I/O Interlock Switches Unused switch locations must be jumpered out. RUN_ENABLE SSE(y) RELAY CONNECTION OF SICK FLEXI MODULES FOR ZONE ONE OF X (Other zones can be added to the middle of the string.) Emergency stop signal integrity is maintained by monitoring Safety Output Q from the UE40-MU located in the right-most subsystem. This signal is fed back to the left-most subsystem UE40-MU and is monitored as a safety input signal. In order for Safety Output Q on the left-most subsystem to be Active (HIGH), either the Safety Output Q from the right-most subsystem must be Active (HIGH) or a Reset Request is made by the control system. The Reset Request may only be Active (HIGH) when: An emergency stop signal has been generated (i.e. the normally closed K(y) contact is Active (HIGH)); A reset request signal has been generated by the primary control system (e.g. SS_REQUEST on far left of the diagram); A reset pushbutton is pressed. In the event that any one of these conditions is not met, the system will not restart. Only after satisfying all three conditions will each subsystem restart according to the connection of S/S2. In the event that any emergency stop is pressed in the system, the stop condition will cause the subsequent Enable (EN) signals to become Inactive (LOW) until the entire system reflects an Inactive (LOW) condition and the reset sequence is successfully completed again. IMPORTANT NOTE: When cascading multiple systems together using the EN (Enable) Input, an additional Response Time of 3 ms must be added to the overall system response time for each cascaded system implemented into the safety chain. 6 October 2006

16 SICK Intelliface Flexi Controllers Quick Start Page 4 of 20 UE40-MU and UE40-XU Rotary Switch Settings Each UE40-MU and UE40-XU has two rotary switches. The top rotary switch corresponds to Inputs I I4 and the corresponding logic outlined below. The lower rotary switch allows users to set an OFF-Delay timer (program dependent). There are different timer ranges available. Consult the ordering information for specific model designations and part number information. Program OR Logic (e.g. Contact Mat OR OSSD) Program 2 OR Logic (e.g. RE300 OR OSSD) Program 3. Simple Muting (e.g. C4000 Muted with Optical Sensors) Program 3.2 Simple Muting (e.g. IN4000 Muted with Optical Sensors) Program 4 Two Hand Control (Type IIIC) Program 5 AND Logic (e.g. Safety Interlock AND Type IIIA THC) Program 6 AND Logic (e.g. Safety Interlock AND E-Stop) Program 7 AND Logic (e.g. C4000 AND S3000) Program 8 Independent Outputs (e.g. C4000 Independent of S3000) Input Description Inputs I/I2 Dual-channel Equivalent Device with Test Outputs X, X2 Inputs I3/I4 Dual-channel Equivalent Device with External Test Pulses Response Time Q/Q2 Response Time Q3/Q4 I/I2 with Contact Mat 30 ms I/I2 with Other Devices 29 ms I3/I4 3 ms 6 October 2006 Input Description Same as Q/Q2 plus the Adjustable Delay Time Setting Inputs I/I2 Dual-channel Complementary Device with Test Outputs X, X2 Synchronization Monitoring of 800ms (e.g. RE300 Non-contact Sensor) Inputs I3/I4 Dual-channel Equivalent Device with External Test Pulses Response Time Q/Q2 Response Time Q3/Q4 I/I2 29 ms Same as Q/Q2 plus the I3/I4 3 ms Adjustable Delay Time Setting Input Description Inputs I/I2 Dual-channel Equivalent Device with External Test Pulses Inputs I3/I4 Two Single-channel Muting Sensors Time Between Muting Condition & Valid Muting State is 6 ms. Typical Switch OFF Time at Muting Sensors 6 ms. Maximum Switch OFF Time at Muting Sensors 65 ms. Muting Gap Suppression of Inputs I3 / I4 allowed for up to 00ms. Response Time Q/Q2/Q3 Response Time Q4 Same as Q/Q2/Q3 plus the 3 ms Adjustable Delay Time Setting Input Description Inputs I/I2 IN4000 Inductive Proximity Sensor (I-X) or Type 2 Testable Sensor (I2-X2) Inputs I3/I4 Two Single-channel Muting Sensors Time Between Muting Condition & Valid Muting State is 6 ms. Typical Switch OFF Time at Muting Sensors 6 ms. Maximum Switch OFF Time at Muting Sensors 65 ms. Muting Gap Suppression of Inputs I3 / I4 allowed for up to 00ms. Response Time Q/Q2/Q3 Response Time Q4 I-X to Q/Q2 79 ms I2-X2 to Q/Q2 29 ms Same as Q/Q2/Q3 plus the Adjustable Delay Time Setting Input Description Inputs I/I2/I3/I4 Type IIIC Two Hand Control (Two Dual Channel Complementary Inputs) Synchronization Monitoring of 500 ms Response Time Q/Q2 Response Time Q3/Q4 29 ms 29 ms Input Description Inputs I/I2 Dual-channel Equivalent Device with Test Outputs X, X2 Inputs I3/I4 Two Single-channel N.O. Contacts with Test Outputs X, X2 (Type IIIA THC) Response Time Q/Q2 Response Time Q3/Q4 29 ms 29 ms Input Description Inputs I/I2 Dual-channel Equivalent Device with Test Outputs X, X2 Inputs I3/I4 Dual-channel Equivalent Device with Test Outputs X, X2 Response Time Q/Q2/Q3 Response Time Q4 Same as Q/Q2/Q3 plus the 29 ms Adjustable Delay Time Setting Input Description Inputs I/I2 Dual-channel Equivalent Device with External Test Pulses Inputs I3/I4 Dual-channel Equivalent Device with External Test Pulses Response Time Q/Q2/Q3 Response Time Q4 Same as Q/Q2/Q3 plus the 3 ms Adjustable Delay Time Setting Input Description Inputs I/I2 Dual-channel Equivalent Device with External Test Pulses Inputs I3/I4 Dual-channel Equivalent Device with External Test Pulses Response Time Q/Q2/Q3 Response Time Q4 Same as Q3 plus the 3 ms Adjustable Delay Time Setting

17 SICK Intelliface Flexi Controllers Quick Start Page 5 of 20 UE40-8DI Rotary Switch Settings Each UE40-8DI has two rotary DIP switches. The top rotary DIP switch corresponds to Inputs I I4 and intermediate logic value QA. The bottom rotary DIP switch corresponds to Inputs I5 I7 and intermediate logic value QB.. Each setting is independent of the other with the exception of Program 9. The input descriptions provided below apply to Inputs I I4 or Inputs I5 I7 when the corresponding rotary DIP switch setting is implemented to select the associated Program. Input Description Program 0 Logic Disabled Program AND Logic Program 2 AND Logic Program 3 AND Logic Program 4 AND Logic Program 5 AND Logic Program 6 AND Logic Program 7 OR Logic Program 8 BYPASS Program 9 MIRROR Mode Logic is disabled. The inputs associated with this program are ignored at the UE40-MU / UE40-XU. Single-channel Equivalent Device with Corresponding Test Outputs Dual-channel Equivalent Device with Corresponding Test Outputs Dual-channel Equivalent Device with Corresponding Test Outputs Synchronization is Monitored 800 ms Maximum Value. Dual-channel Complementary Device with Corresponding Test Outputs Dual-channel Complementary Device with Corresponding Test Outputs (e.g. RE300) Synchronization is Monitored 800 ms Maximum Value Single-channel Normally Closed Contact Externally Tested (Tied to two inputs); or Dual-channel Equivalent Device with Corresponding External Testing (e.g. Semiconductor OSSDs) Dual-channel Equivalent Device with Corresponding External Testing (e.g. Semiconductor OSSDs) ; or Single-channel Normally Closed Contact Externally Tested (e.g. safety interlock tied to 2 inputs) Dual-channel Equivalent Device with Corresponding Test Outputs and Synchronization Monitoring of 800ms (e.g. Enabling Switch or Key-Operated Switch). Maximum duration is 60 s. The inputs corresponding to this switch setting will mirror the configuration of the other rotary DIP switch, including which outputs will be affected on the UE40-MU or UE40-XU. Intelliface Flexi Controller Dimensional Information UE40-MU UE40-XU, UE40-8DI, UE40-2RO, UE40-4RO, UE40-DEV, UE40-PRO, UE40-CAN All units are in mm. 6 October 2006

18 SICK Intelliface Flexi Controllers Quick Start Page 6 of 20 Intelliface Flexi Controller Internal Connections UE40-MU UE40-XU UE40-8DI UE40-2RO UE40-4RO UE40-PRO; UE40-DEV 6 October 2006

19 SICK Intelliface Flexi Controllers Quick Start Page 7 of 20 Intelliface Flexi Controller Technical Specifications General Minimum Typical Maximum Operating Temperature -25 C +50 C Storage Temperature -25 C +70 C Air Humidity (non-condensing) 0 % 95% Protection Class (accord. EN 5078) III Enclosure Rating (accord. EN/IEC 60529) IP 20 Climatic Conditions In accordance with EN 63-2 Vibration (accord. EN ) Hz, 5 g Safety Category (accord. EN 954-) Safety Category 4 Safety Integrity Level (accord. IEC 6508) SIL 3 Supply Circuit (A, A2 on UE40-MU or UE40-XU) Voltage supply U B 9.2 V DC 24 V DC 30 V DC Residual Ripple U SS Power Consumption UE40-MU, UE40-XU UE40-8DI UE40-2RO UE40-4RO UE40-DEV UE40-PRO Short-circuit Protection Protection Class / Electrical Safety Electromagnetic Compatibility (EMC) Weights UE40-MU, UE40-XU UE40-8DI UE40-2RO UE40-4RO UE40-DEV UE40-PRO Note: If a UE40-2RO or UE40-4RO is used in the UE40 system, and the output current paths have voltages that are: U > 25 V AC / 60 V DC, then a PELV power supply should be used. U < 25 V AC / 60 V DC, then a PELV or SELV power supply should be used. 3 V DC 3 W.8 W W 2 W.6 W 2.2 W 4 A using fuse characteristic gg and tripping characteristic B or C III EN 63-2 (Zone B), EN , EN 550 Class A 80 g 50 g 60 g 90 g 60 g 60 g UE40-MU and UE40-XU Technical Specifications General Data Minimum Typical Maximum Maximum Switch-on Time 0 s Input Circuits (I-I4, EN, S-S3) Number of Safety Capable Inputs (I-I4) 2 Dual-channel resp. 4 Single-channel Number of Control Inputs (EN, S-S3) 4 Input Voltage HIGH 5 V DC 24 V DC 30 V DC Input Voltage LOW - 5 V DC 0 V DC 5 V DC Input Current HIGH 2.3 ma 3 ma 3.6 ma Input Current LOW ma 0 ma 0.5 ma Minimum Switch ON Time of Signal 70 ms Maximum LOW signal at Input Without Switching Safety Capable Outputs Q-Q4. ms Minimum Switch OFF Time of Signal See Response Time Teach-in Time of ENTER Button on UE40-MU at Power-up 3 s 6 October 2006

20 SICK Intelliface Flexi Controllers Quick Start Page 8 of 20 Test / Signal Outputs (Control Outputs) (X-X2) Number of Test / Signal Outputs (X, X2) 2 Output Type PNP Semiconductor, Short-circuit Protected, Cross-Circuit Monitored Output Voltage 8 V DC 24 V DC 30 V DC Output Current 50 ma Test Pulse Width Programs, 2, 4, 5, 6 2 ms Program ms at X, 2 ms at X2 Test Pulse Frequency 5 Hz Load Capacitance 000 nf Load Resistance 00 Ω Safety Capable Output Circuits (Q-Q4) Number of Safety Capable Outputs 4 Output Type PNP Semiconductor, Short-circuit Protected, Cross-Circuit Monitored Output Voltage 8 V DC 24 V DC 30 V DC Output Current per Channel.6 A Output Current per Module 3.2 A Test Pulse Width 300 µs Test Pulse Frequency 5 Hz Load Capacitance 500 nf Cable Length (single conductor,.5mm 2 ) 00 m Adjustable Delay Settings UE40-MU..T5 or UE40-XU..T5 0 / 0.5 / /.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 s UE40-MU..T50 or UE40-XU..T50 0 / 5 / 0 / 5 / 20 / 25 / 30 / 35 / 40 / 50 s UE40-MU..T300 or UE40-XU..T300 0 / 0.5 / /.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 min UE40-8DI Technical Specifications Input Circuits (I-I8) Minimum Typical Maximum Number of Safety Capable Inputs (I-I4) 4 Dual-channel resp. 8 Single-channel Input Voltage HIGH 5 V DC 24 V DC 30 V DC Input Voltage LOW - 5 V DC 0 V DC 5 V DC Input Current HIGH 2.3 ma 3 ma 3.6 ma Input Current LOW ma 0 ma 0.5 ma Minimum Switch ON Time of Signal 70 ms Maximum LOW signal at Input Without Switching Safety Capable Outputs Q-Q4. ms Minimum Switch OFF Time of Signal See Response Time Test / Signal Outputs (Control Outputs) (X-X8) Number of Test / Signal Outputs (X-X8) 8 Output Type PNP Semiconductor, Short-circuit Protected, Cross-Circuit Monitored Output Voltage 8 V DC 24 V DC 30 V DC Output Current 50 ma Test Pulse Frequency 5 Hz Load Capacitance 000 nf Load Resistance 00 Ω Response Time Information (Related to Q-Q4 of UE40-MU or UE40-XU) Response Time Programs, 3, 4, 5 Response Time Program 2 Response Time Programs 6, 7 Response Time Program 8 Response Time Program 9 34 ms Safety Mat = 34 ms Other Devices = 34 ms 7 ms N/A Bypass Mode Refer to corresponding program of the mirrored input channels. Response times shown do not account for any adjustable delay time setting. Make sure that the delay time (when configured) is taken into account for any response time calculations. 6 October 2006

21 SICK Intelliface Flexi Controllers Quick Start Page 9 of 20 UE40-2RO / UE40-4RO Technical Specifications Minimum Typical Maximum General Electrical Isolation Supply Circuit to Input Circuit No Supply Circuit to Output Circuit Yes Input Circuit to Output Circuit Yes Electrical Safety EN 5078 Impulse Voltage Withstand Level (Uimp) 4 kv Overvoltage Category III Pollution Degree 2 Inside, 3 Outside Output Circuits (3-4, 23-24, 33-34, 43-44) Output Type Positively Guided, Floating Normally Open Contacts Number of Normally Open (NO) Contacts UE40-2RO (2 x Channel) 2 UE40-4RO (2 x 2 Channel) 4 Number of Normally Closed (NC) Contacts UE40-2RO UE40-4RO 2 Switching Voltage AC 5 V AC 250 V AC 275 V AC Switching Voltage DC 5 V DC 230 V DC 275 V DC Switching Current per Output Channel 0 ma 6 A Switching Current per Module 2 A Output Circuit Fusing 6 A using fuse characteristic gg Utilization Category AC-5: U e 250 V, I e 3A DC-3: U e 24 V, I e 3A Response Time (UE40-MU / UE40-XU Input to Relay Output) Response Time of Associated Q Q4 Output of UE40-MU or UE40-XU plus 30 ms Monitoring Output Circuit (Y4, Y24) Output Type Positively Guided, Non-isolated Normally Open Contact, Current Limited Number of Normally Open (NO) Contacts UE40-2RO UE40-4RO 2 Switching Voltage DC 8 V DC 24 V DC 30 V DC Switching Current per Output Channel 75 ma Load Capacitance 200 nf UE40-DEV / UE40-PRO Technical Specifications Minimum Typical Maximum Output Circuits (X-X4) Type of Output PNP Semiconductor, Short-circuit Protected Number of Outputs 4 Output Voltage 8 V DC 24 V DC 30 V DC Output Current 00 ma Load Capacitance 00 nf Cable Length (single conductor,.5mm 2 ) 50 m Interface - DeviceNet Fieldbus DeviceNet (Group 2 Only Server) Interface Level ISO-DIS 898 Connection Technology Open Style Connector, 5-pin Slave Address 0 63 Baud Rate 25 Kbit/s, 250 Kbit/s, 500 Kbit/s Interface PROFIBUS-DP Fieldbus PROFIBUS DP V0 Interface Level RS-485 Connection Technology D-Sub Socket, 9-pin Slave Address 0 99 Baud Rate Autodetect to 2 Mbit/s 6 October 2006

22 SICK Intelliface Flexi Controllers Quick Start Page 20 of 20 Intelliface Flexi Controller Ordering Information Main Unit (UE40-MU) Number of Inputs 2 Dual-Channel resp. 4 Single-Channel Number of Safety Capable Outputs 2 Dual-channel resp. 4 Single-channel Expansion Unit (UE40-XU) Number of Inputs 2 Dual-Channel resp. 4 Single-Channel Number of Safety Capable Outputs 2 Dual-channel resp. 4 Single-channel Delay Time (Adjustable) Connection Type Model Designation Part Number 0 s 5 s UE40-MU3T s 50 s Pluggable screw terminals UE40-MU3T s 300 s UE40-MU3T s 5 s Dual level UE40-MU4T s 50 s pluggable spring UE40-MU4T s 300 s clamp terminals UE40-MU4T Delay Time (Adjustable) Connection Type Model Designation Part Number 0 s 5 s UE40-XU3T s 50 s Pluggable screw terminals UE40-XU3T s 300 s UE40-XU3T s 5 s Dual level UE40-XU4T s 50 s pluggable spring UE40-XU4T s 300 s clamp terminals UE40-XU4T Input Expansion Unit (UE40-8DI) Number of Safety Capable Inputs 4 Dual-Channel resp. 8 Single-Channel Number of Safety Capable Outputs None Relay Modules (UE40-2RO/4RO) Number of Normally Open Contacts 2 x Channel (2 Channels Total) 2 x 2 Channel (4 Channels Total) Number of Normally Closed Contacts (Diagnostic Output) 2 Connection Type Model Designation Part Number Pluggable screw terminals UE40-8DI Dual level pluggable spring clamp terminals Connection Type UE40-8DI Model Designation Part Number Pluggable screw terminals UE40-2RO Dual level pluggable spring clamp terminals UE40-2RO Pluggable screw terminals UE40-4RO Dual level pluggable spring clamp terminals UE40-4RO Diagnostic Modules (UE40-PRO/DEV/CAN/ETH) Model Part Field bus Protocol Connection Type Designation Number PROFIBUS-DP UE40-PRO DeviceNet UE40-DEV Pluggable screw terminals CANopen - In Preparation UE40-CAN Ethernet - In Preparation UE40-ETH3 PROFIBUS-DP UE40-PRO DeviceNet Dual level pluggable spring UE40-DEV CANopen - In Preparation clamp terminals UE40-CAN Ethernet - In Preparation UE40-ETH4 Note: Contact factory for availability for modules with dual level pluggable spring clamp terminals. TBD TBD 6 October 2006