SICK Flexi Soft in Flexi Soft Designer Configuration Software Operating instructions

O P E R A T I N G I N S T R U C T I O N S

Flexi Soft in Flexi Soft Designer

Configuration software

Described product

F

lexi Soft in Flexi Soft Designer

Configuration software

Manufacturer

SIC

K AG

Erwin-Sick-Str. 1

79183 Waldkirch

Germany

Legal information

T

his 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 modifica‐

tion, abridgment or translation of this document is prohibited without the express writ‐

ten permission of SICK AG.

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

Original document

T

his document is an original document of SICK AG.

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Contents

1 About this document........................................................................ 11

1.1 Purpose of this document........................................................................ 11

1.2 Scope of application and modification level........................................... 13

1.3 Information depth..................................................................................... 13

1.4 Target groups............................................................................................ 13

1.5 Further information................................................................................... 13

1.6 Symbols and document conventions...................................................... 14

2 On safety............................................................................................. 15

2.1 General safety notes................................................................................ 15

2.2 Intended use............................................................................................. 15

2.3 Requirements for the qualification of personnel.................................... 15

3 Version, compatibility, and features............................................... 17

4 Installation.......................................................................................... 20

4.1 System requirements............................................................................... 20

4.2 Installing and updating the software....................................................... 20

4.3 Unsupervised installation......................................................................... 21

4.4 Licensing and activation of additional functions.................................... 21

5 Connecting the computer to the Flexi Soft system...................... 22

5.1 Initial steps for setting up a connection.................................................. 22

5.1.1 Connecting the computer to the Flexi Soft system via

R

S-232..................................................................................... 22

5.1.2 Connecting the computer to the Flexi Soft system via USB.. 24

5.1.3 Status and background color.................................................. 25

5.2 Editing communication settings.............................................................. 25

5.2.1 Adding a COM connection profile (serial interface)............... 26

5.2.2 Add USB connection profile.................................................... 27

5.2.3 Add TCP/IP connection profile................................................ 27

5.2.4 Checking the connection profile............................................. 29

5.2.5 Changing the network settings for a Flexi Soft gateway........ 30

5.3 Establishing a connection to the Flexi Soft system................................ 30

5.4 Detecting a project................................................................................... 31

5.5 User groups in Flexi Soft Designer.......................................................... 31

6 The user interface............................................................................. 34

6.1 Home screen............................................................................................. 34

6.2 Language selection................................................................................... 34

6.3 Standard views......................................................................................... 34

6.4 Arranging windows.................................................................................... 35

6.5 Hardware configuration............................................................................ 36

6.5.1 Configuring the Flexi Soft modules......................................... 39

6.5.2 Module status bits in the Hardware configuration view........ 40

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6.5.3 Connecting elements............................................................... 41

6.5.4 Safe and non-safe elements in the hardware configuration 41

6.5.5 Expanding elements................................................................ 42

6.5.6 Configuring connected elements............................................ 42

6.5.7 Customized elements.............................................................. 44

6.5.8 Connecting EFI-enabled devices............................................. 48

6.5.9 Exporting and importing a partial application and replacing

module

s.................................................................................... 50

6.5.10 RS-232 routing......................................................................... 53

6.5.11 Optimization of the logic execution time................................ 57

6.6 Logic editor................................................................................................ 58

6.6.1 Using the Logic editor.............................................................. 59

6.6.2 CPU markers............................................................................ 60

6.6.3 Jump addresses....................................................................... 61

6.6.4 Validating the configuration.................................................... 62

6.6.5 I/O matrix................................................................................. 62

6.6.6 Logic access levels.................................................................. 65

6.7 Tag name editor........................................................................................ 67

6.7.1 Importing and exporting tag names....................................... 68

6.7.2 Exporting tag names for use in Pro-face GP-Pro EX.............. 69

6.7.3 Coding Pro-face prefixes and postfixes.................................. 70

6.8 Report........................................................................................................ 71

6.8.1 Comparing projects................................................................. 72

6.9 Diagnostics................................................................................................ 73

6.10 Data recorder............................................................................................ 75

6.10.1 Toolbar...................................................................................... 76

6.10.2 Status and control................................................................... 77

6.10.3 Configuring the data recorder................................................. 77

6.10.4 Recording data......................................................................... 80

6.10.5 Exporting, importing, and deleting data................................. 80

6.10.6 Visualizing data........................................................................ 80

7 Logic programming in the main module....................................... 83

7.1 General description.................................................................................. 83

7.2 Safety notes for logic programming......................................................... 83

7.3 Overview of the function blocks in the main module............................. 85

7.4 Configuring the function blocks............................................................... 86

7.4.1 Inputs of the function blocks.................................................. 87

7.4.2 Inverting inputs........................................................................ 87

7.4.3 Outputs of the function blocks............................................... 88

7.4.4 The Fault present output......................................................... 88

7.4.5 Changing the execution sequence.......................................... 89

7.5 Module data in the Logic editor............................................................... 89

7.5.1 Inputs........................................................................................ 89

7.5.2 Outputs..................................................................................... 90

7.5.3 Module status bits................................................................... 90

CONTENTS

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7.5.4 EFI I/O error status bits in the logic editor............................. 95

7.6 Time values and logic execution time..................................................... 96

7.7 Logical function blocks............................................................................. 96

7.7.1 NOT........................................................................................... 96

7.7.2 AND........................................................................................... 97

7.7.3 OR............................................................................................. 98

7.7.4 XOR (exclusive OR)................................................................... 99

7.7.5 XNOR (exclusive NOR)............................................................. 99

7.7.6 Multiple release....................................................................... 100

7.7.7 RS Flip-Flop.............................................................................. 101

7.7.8 JK Flip-Flop............................................................................... 101

7.7.9 Multiple memory...................................................................... 103

7.7.10 Clock generator........................................................................ 104

7.7.11 Event counter (up, down, and up and down)......................... 105

7.7.12 Fast shut off and Fast shut off with bypass........................... 108

7.7.13 Edge detection......................................................................... 113

7.7.14 Binary encoder......................................................................... 113

7.7.15 Binary decoder......................................................................... 116

7.7.16 Message generator.................................................................. 119

7.7.17 Routing 1:n............................................................................... 122

7.7.18 Routing n:n............................................................................... 123

7.8 Application-specific function blocks........................................................ 123

7.8.1 Reset........................................................................................ 123

7.8.2 Restart...................................................................................... 125

7.8.3 Off-delay timer.......................................................................... 126

7.8.4 Adjustable off-delay timer....................................................... 127

7.8.5 On-delay timer.......................................................................... 128

7.8.6 Adjustable on-delay timer........................................................ 129

7.8.7 External device monitoring...................................................... 130

7.8.8 Valve monitoring...................................................................... 133

7.8.9 User mode switch.................................................................... 136

7.8.10 Switch synchronization............................................................ 138

7.8.11 Error output combination........................................................ 142

7.8.12 Ramp down detection.............................................................. 143

7.8.13 Frequency monitoring.............................................................. 149

7.8.14 Start warning............................................................................ 154

7.9 Function blocks for dual-channel evaluation.......................................... 159

7.9.1 Single-channel evaluation....................................................... 160

7.9.2 Dual-channel evaluation (1 pair) and discrepancy time....... 160

7.9.3 Double dual-channel evaluation and synchronization time.. 162

7.9.4 Emergency stop....................................................................... 164

7.9.5 Magnetic switch....................................................................... 165

7.9.6 Light curtain monitoring.......................................................... 166

7.9.7 Safety gate monitoring............................................................ 167

7.9.8 Tolerant dual-channel evaluation........................................... 168

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7.9.9 Two hand control type IIIA....................................................... 173

7.9.10 Two hand control type IIIC....................................................... 174

7.9.11 Multi operator.......................................................................... 175

7.10 Parallel muting, Sequential muting, and Cross muting function

bloc

ks........................................................................................................ 177

7.10.1 Overview and general description.......................................... 177

7.10.2 Safety notes for muting applications...................................... 179

7.10.3 Inputs, outputs and parameters of function blocks.............. 182

7.10.4 Notes on wiring........................................................................ 190

7.10.5 Transition from Stop status to Run status.............................. 191

7.10.6 Error statuses and reset information..................................... 191

7.10.7 Parallel muting......................................................................... 191

7.10.8 Sequential muting................................................................... 193

7.10.9 Cross muting............................................................................ 195

7.11 Function blocks for press contact monitoring........................................ 197

7.11.1 Overview and general description.......................................... 197

7.11.2 Eccentric press contact........................................................... 198

7.11.3 Universal press contact........................................................... 204

7.12 Function blocks for press cycle control................................................... 212

7.12.1 Press setup.............................................................................. 212

7.12.2 Press single stroke.................................................................. 215

7.12.3 Press automatic....................................................................... 220

7.12.4 PSDI mode............................................................................... 224

7.13 Grouped and customized function blocks............................................... 232

7.13.1 Grouped function blocks......................................................... 232

7.13.2 Customized function blocks.................................................... 233

7.14 Simulating the configuration.................................................................... 235

7.15 Force mode............................................................................................... 237

8 I/O modules....................................................................................... 242

8.1 Dual-channel evaluation and discrepancy time monitoring................... 242

8.2 ON-OFF filter and OFF-ON filter................................................................ 243

8.3 Deactivating test pulses at FX3-XTIO outputs......................................... 244

8.4 Extended fault detection time for cross-circuits at outputs Q1 to Q4

of the FX3-XTIO for switching higher capacitive loads............................ 245

9 Logic programming in Drive Monitor FX3-MOC0.......................... 247

9.1 General description.................................................................................. 247

9.2 Safety notes for logic programming......................................................... 247

9.3 Parameterization of function blocks........................................................ 249

9.4 Inputs and outputs in the logic editor..................................................... 249

9.4.1 General data sources.............................................................. 250

9.5 Time values and logic execution time..................................................... 250

9.6 Data types used in the logic of the FX3-MOC0....................................... 250

9.7 Exchange of process data between main module and FX3-MOC0....... 252

9.8 Module status bits of the FX3-MOC0...................................................... 253

CONTENTS

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9.9 Overview of the function blocks in the FX3-MOC0................................. 254

9.10 Function blocks for monitoring................................................................ 255

9.10.1 Speed cross check V1............................................................. 255

9.10.2 Speed monitor V1.................................................................... 266

9.10.3 Safe Stop V1............................................................................ 277

9.11 Function blocks for data conversion........................................................ 290

9.11.1 UI8 to Bool V1.......................................................................... 290

9.11.2 Bool to UI8 V1.......................................................................... 291

9.11.3 Motion status to Bool V1......................................................... 291

9.11.4 Speed to Bool V1..................................................................... 292

9.11.5 Speed to laser scanner V1...................................................... 293

9.12 Easy Applications...................................................................................... 294

9.12.1 Using Easy Applications........................................................... 295

9.12.2 Typical procedure for working with Easy Applications........... 298

10 Encoder connected to Drive Monitor FX3-MOC0.......................... 299

10.1 Functions for all encoder types................................................................ 299

10.1.1 General parameters of the encoder on the FX3-MOC0........ 299

10.1.2 Scaling of the measurement system...................................... 299

10.1.3 Encoder count direction.......................................................... 300

10.1.4 Encoder connection type and ID code monitoring................ 300

10.1.5 Monitoring of the maximum step change in speed............... 301

10.2 A/B incremental encoder......................................................................... 302

10.3 Sin/Cos encoders..................................................................................... 302

10.3.1 Special parameters for Sin/Cos encoders............................. 302

10.3.2 Sin/Cos analog voltage monitoring........................................ 302

10.3.3 Limits of Sin/Cos analog voltage monitoring......................... 307

10.3.4 Sin/Cos resolution enhancement........................................... 310

10.4 SSI encoder............................................................................................... 310

10.4.1 Special parameters for SSI encoders..................................... 310

10.4.2 Transmit position data twice................................................... 311

10.4.3 Error bit evaluation.................................................................. 312

10.4.4 Maximum data reception interval........................................... 312

11 Logic programming in Drive Monitor FX3-MOC1.......................... 313

11.1 General description.................................................................................. 313

11.2 Safety notes for logic programming......................................................... 313

11.3 Parameterization of function blocks........................................................ 315

11.4 Inputs and outputs in the logic editor..................................................... 315

11.4.1 General data sources.............................................................. 316

11.5 Time values and logic execution time..................................................... 316

11.6 Data types used in the logic of the FX3-MOC1....................................... 316

11.7 Exchange of process data between main module and FX3-MOC1....... 318

11.8 Module status bits of the FX3-MOC1...................................................... 319

11.9 Overview of the function blocks in the FX3-MOC1................................. 320

11.10 Function blocks for monitoring................................................................ 322

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11.10.1 General principles.................................................................... 322

11.10.2 Programming examples........................................................... 324

11.10.3 Position by reference V1......................................................... 329

11.10.4 Position cross check V1.......................................................... 339

11.10.5 Speed cross check V2............................................................. 348

11.10.6 Speed monitor V2.................................................................... 363

11.10.7 Position monitor V1................................................................. 375

11.10.8 Safe Stop V2............................................................................ 391

11.11 Function blocks for data conversion........................................................ 407

11.11.1 UI8 to Bool V1.......................................................................... 407

11.11.2 Bool to UI8 V1.......................................................................... 408

11.11.3 Motion status to Bool V2......................................................... 409

11.11.4 Speed to Bool V2..................................................................... 409

11.11.5 Speed to laser scanner V2...................................................... 411

11.12 Logical function blocks............................................................................. 413

11.12.1 NOT V1...................................................................................... 413

11.12.2 AND8 V1................................................................................... 413

11.12.3 OR8 V1..................................................................................... 414

12 Encoder connected to Drive Monitor FX3-MOC1.......................... 416

12.1 Functions for all encoder types................................................................ 416

12.1.1 General parameters of the encoder on the FX3-MOC1........ 416

12.1.2 Scaling of the measurement system...................................... 416

12.1.3 Encoder count direction.......................................................... 417

12.1.4 Encoder connection type and ID code monitoring................ 417

12.1.5 Inhibit Error Message.............................................................. 418

12.2 A/B incremental encoder......................................................................... 418

12.3 Sin/Cos encoders..................................................................................... 419

12.3.1 Special parameters for Sin/Cos encoders............................. 419

12.3.2 Sin/Cos analog voltage monitoring........................................ 419

12.3.3 Limits of Sin/Cos analog voltage monitoring......................... 424

12.3.4 Sin/Cos resolution enhancement........................................... 427

12.4 SSI encoder............................................................................................... 427

12.4.1 Special parameters for SSI encoders..................................... 427

12.4.2 Double data transmission....................................................... 428

12.4.3 Error bit evaluation.................................................................. 429

12.4.4 Filtering of speed jumps.......................................................... 429

12.4.5 Maximum position jump monitoring....................................... 430

12.4.6 Maximum data reception interval........................................... 431

12.4.7 Position range.......................................................................... 431

12.4.8 Teach position.......................................................................... 433

13 Analog input module FX3-ANA0..................................................... 434

13.1 Input signals.............................................................................................. 435

13.2 Process ranges......................................................................................... 439

13.3 Signal ranges............................................................................................ 441

CONTENTS

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13.4 Additional configuration........................................................................... 444

13.5 The FX3-ANA0 in the logic editor............................................................. 445

13.6 The FX3-ANA0 in the data recorder......................................................... 448

14 Flexi Link............................................................................................. 449

14.1 Overview of Flexi Link............................................................................... 449

14.1.1 System requirements and restrictions for Flexi Link............. 449

14.2 Principle of operation............................................................................... 449

14.2.1 Flexi Link address.................................................................... 450

14.2.2 Flexi Link ID.............................................................................. 450

14.3 Setting up a new Flexi Link system.......................................................... 451

14.3.1 Connecting to an existing hardware system.......................... 451

14.3.2 Setting up a Flexi Link project when the hardware is not

a

vailable................................................................................... 454

14.3.3 Flexi Link configuration........................................................... 455

14.3.4 Transferring and verifying the Flexi Link configuration.......... 460

14.4 Flexi Link functions................................................................................... 462

14.4.1 Flexi Link system: System overview........................................ 465

14.4.2 Flexi Link system: Process image........................................... 466

14.4.3 Flexi Link system: Network settings....................................... 467

14.4.4 Flexi Link stations: Flexi Link data in the logic editor............ 469

14.4.5 Flexi Link stations: Station X view and process image.......... 471

14.4.6 Flexi Link stations: Teach function......................................... 473

14.4.7 Flexi Link status bits................................................................ 475

14.5 Flexi Link troubleshooting........................................................................ 477

14.5.1 Inconsistent Flexi Link ID........................................................ 477

15 Flexi Line............................................................................................. 478

15.1 Overview of Flexi Line............................................................................... 478

15.1.1 System requirements and restrictions for Flexi Line............. 478

15.2 Flexi Line principle of operation............................................................... 479

15.2.1 Topology................................................................................... 479

15.2.2 Flexi Line configuration........................................................... 479

15.2.3 Flexi Line checksum................................................................ 482

15.2.4 Flexi Line data in the logic editor............................................ 482

15.2.5 Flexi Line status bits................................................................ 483

15.2.6 Teach........................................................................................ 484

15.2.7 Status and diagnostics............................................................ 485

15.3 Setting up a new Flexi Line system.......................................................... 486

15.3.1 Configuring and commissioning a Flexi Line system............. 486

15.3.2 Modifying a Flexi Line system................................................. 487

15.3.3 Configuring the Flexi Line logic............................................... 488

16 Transferring and saving the configuration..................................... 490

16.1 Transferring project data to the safety controller................................... 490

16.2 Compatibility check.................................................................................. 490

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16.3 Verifying the configuration....................................................................... 491

16.4 Activating write protection for the configuration in the controller......... 492

16.5 Configuration checksums......................................................................... 492

16.6 Duplicating system plugs......................................................................... 493

16.7 Automatic configuration recovery (ACR).................................................. 494

16.7.1 Supported EFI-enabled devices.............................................. 494

16.7.2 Structure of the ACR dialog box.............................................. 494

16.7.3 Setting up ACR......................................................................... 496

16.7.4 Replacing devices.................................................................... 499

16.7.5 Troubleshooting....................................................................... 500

16.8 Automated download of a configuration................................................. 500

16.8.1 Creating a download script...................................................... 501

16.8.2 Performing automated download........................................... 503

16.8.3 Return values of the download tool........................................ 505

17 Device statuses in the Flexi Soft system....................................... 507

17.1 Changing the device status...................................................................... 507

17.2 Behavior on system startup..................................................................... 508

17.3 Software-controlled reset of the main module....................................... 508

18 Commissioning.................................................................................. 510

18.1 Wiring and voltage supply........................................................................ 510

18.2 Transferring the configuration.................................................................. 510

18.3 Thorough technical check and commissioning...................................... 510

19 Troubleshooting................................................................................. 512

20 Deinstallation..................................................................................... 513

21 Ordering information........................................................................ 514

21.1 Ordering information for Flexi Soft Designer additional functions........ 514

22 List of abbreviations.......................................................................... 515

23 List of figures..................................................................................... 516

24 List of tables....................................................................................... 524

CONTENTS

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1 About this document

1.1 Purpose of this document

For the Flexi Soft system, there are operating instructions and mounting instructions, each covering clearly defined

f

ields of application.

Table 1: Overview of the Flexi Soft documentation

Document type Title Contents Purpose Part number

Operating instruc‐

t

ions

Flexi Soft Modular

Safety Controller

Hardware

Description of the Flexi Soft

modules and their functions

Instructions for technical

personnel working for the

machine manufacturer or

operator on the safe mount‐

ing, electrical installation,

and maintenance of the

Flexi Soft safety controller

8012999

Operating instruc‐

tions

Flexi Soft in the

Flexi Soft Designer

Configuration software

Description of the software-

based configuration of the

Flexi Soft safety controller

along with important diag‐

nostics functions and

detailed notes on identifying

and rectifying errors

Instructions for technical

personnel working for the

machine manufacturer or

operator on the safe configu‐

ration and commissioning,

as well as the safe opera‐

tion, of the Flexi Soft safety

controller

8012998

Operating instruc‐

tions

Safety Designer

Configuration software

Description of the installa‐

tion and general basic princi‐

ples of operation

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

use the Safety Designer con‐

figuration software

8018178

Operating instruc‐

tions

Flexi Soft in the

Safety Designer

Configuration software

Description of the software-

based configuration of the

Flexi Soft safety controller

along with important diag‐

nostics functions and

detailed notes on identifying

and rectifying errors

Instructions for technical

personnel working for the

machine manufacturer or

operator on the safe configu‐

ration and commissioning,

as well as the safe opera‐

tion, of the Flexi Soft safety

controller

8013926

Operating instruc‐

tions

Flexi Soft Gateways

Hardware

Description of the Flexi Soft

gateways and their functions

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely carry out the mount‐

ing, electrical installation,

and maintenance work for

the Flexi Soft gateways

8012662

Operating instruc‐

t

ions

Flexi Soft Gateways in

Flexi Soft Designer

Configuration software

Description of the software-

based configuration of the

Flexi Soft gateway, informa‐

tion about data exchange in

networks as well as about

the status, planning, and

associated mapping

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely configure and com‐

mission the Flexi Soft gate‐

ways

8012483

ABOUT THIS DOCUMENT 1

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Document type Title Contents Purpose Part number

Operating instruc‐

t

ions

Flexi Soft Gateways in the

Safety Designer

Configuration software

Description of the software-

based configuration of the

Flexi Soft gateway, informa‐

tion about data exchange in

networks as well as about

the status, planning, and

associated mapping

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely configure and com‐

mission the Flexi Soft gate‐

ways

8018170

Operating instruc‐

tions

Flexi Loop

safe series connection

Hardware

Description of the Flexi Loop

safe series connection and

its functions

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely carry out the mount‐

ing, electrical installation,

and maintenance work for

the Flexi Loop safe series

connection

8015834

Operating instruc‐

tions

Flexi Loop in the

Flexi Soft Designer

configuration software

Description of how to config‐

ure and set the parameters

for the Flexi Loop safe series

connection using software

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely configure and com‐

mission the Flexi Loop safe

series connection

8014521

Operating instruc‐

tions

Flexi Loop in Safety Designer

Configuration software

Description of how to config‐

ure and set the parameters

for the Flexi Loop safe series

connection using software

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely configure and com‐

mission the Flexi Loop safe

series connection

8018174

Mounting instruc‐

tions

Flexi Soft FX3-EBX3 and

FX3-EBX4 Encoder/Motor

Feedback Connection Boxes

Description of FX3-EBX3 and

FX3-EBX4 encoder/motor

feedback connection boxes

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely carry out the mount‐

ing, electrical installation,

commissioning, and mainte‐

nance work for FX3-EBX3

and FX3-EBX4 encoder/

motor feedback connection

boxes

8015600

Mounting instruc‐

tions

Flexi Soft FX3-EBX1 Opti‐

mized Dual Encoder/Motor

Feedback Connection Box

Description of the FX3-EBX1

optimized dual encoder/

motor feedback connection

box

To provide technical person‐

nel working for the machine

manufacturer/operator with

instructions so that they can

safely carry out the mount‐

ing, electrical installation,

commissioning, and mainte‐

nance work for the FX3-

EBX1 optimized dual

encoder/motor feedback

connection box

8019030

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1.2 Scope of application and modification level

These operating instructions apply to version V1.9.2 of the Flexi Soft Designer configu‐

r

ation software when used in conjunction with the FX3-CPU0, FX3-CPU1, FX3-CPU2,

and FX3-CPU3 devices with firmware version V1.00.0–V4.04.0, and in conjunction with

the FX3-MOC0 (firmware version V1.00.0–V1.10.0), FX3-MOC1 (firmware version

V2.00.0–V3.00.0), and FX3-ANA0 (firmware version V1.01.0–V2.00.0) devices.

This document forms an integral part of SICK part number 8012998 (the “Flexi Soft in

Flexi Soft Designer Configuration Software” operating instructions in all available lan‐

guages).

1.3 Information depth

These operating instructions are intended to provide technical personnel working for

t

he machine manufacturer or machine operator with instructions so that they can con‐

figure, operate and perform diagnostics on a Flexi Soft system with the Flexi Soft

Designer software. They are only valid in conjunction with the “Flexi Soft Modular Safety

Controller Hardware” operating instructions.

Please note that technical skills not covered by this document are also required when

planning and using SICK protective devices.

General safety notes: see "On safety", page 15. Please make sure to read these

instructions.

The official and legal regulations for operating the Flexi Soft modular safety controller

must always be complied with.

1.4 Target groups

These operating instructions are intended for planning engineers, developers, and oper‐

a

tors of plants and systems that are to be protected by means of a Flexi Soft modular

safety controller. They are also intended for people who integrate the Flexi Soft safety

controller into a machine, carry out its commissioning, or who are in charge of mainte‐

nance.

These operating instructions do not provide information on operating the machine,

plant, or system in which the Flexi Soft safety controller is integrated. For information

about this, refer to the operating instructions of the machine, plant, or system con‐

cerned.

1.5 Further information

www.sick.com

T

he following information is available via the Internet:

•

The Flexi Soft operating instructions in various languages for viewing and printing

•

The Flexi Soft Designer configuration software

•

The Safety Designer configuration software

•

Configuration aids

•

Example applications

•

Data sheets

•

Product and application animations

•

CAD data for drawings and dimensional drawings

•

EDS, ESI, GSD, and GSDML files

•

Certificates (such as the EU declaration of conformity)

•

Guide for Safe Machinery (six steps to a safe machine)

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Subject to change without notice

1.6 Symbols and document conventions

The following symbols and conventions are used in this document:

Safety notes and other notes

DANGER

Indic

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

injuries if not prevented.

WARNING

Indic

ates 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

Indic

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

not prevented.

NOTE

Indic

ates useful tips and recommendations.

Instructions to action

b

T

he 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.

LED symbols

These symbols indicate the status of an LED:

o

The LED is off.

Ö

The LED is flashing.

O

The LED is illuminated continuously.

Menus and commands

T

he names of software menus, submenus, options and commands, selection boxes,

and windows are all emphasized. Example:

1. Go to the File menu and click on Edit.

The term “dangerous state”

The figures in this document always show the dangerous state (standard term) of the

machine as movement of a machine part. In practice, there are various types of danger‐

ous state:

•

Machine movements

•

Live electrical parts

•

Visible and invisible beams

•

A combination of multiple hazards

1 A

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2 On safety

This chapter contains general safety information about the Flexi Soft modular safety

cont

roller.

More safety information about specific usage situations for the Flexi Soft modular

safety controller is provided in the respective chapters.

2.1 General safety notes

WARNING

Im

proper mounting or use

The target safety-related level may not be achieved in the event of non-compliance.

b

When mounting, installing, and using the Flexi Soft safety controller, remember to

observe all applicable standards and directives.

b

Observe the relevant national and international legal provisions for the installation

and use of the Flexi Soft safety controller, its commissioning, and technical inspec‐

tions repeated at regular intervals.

b

The manufacturer and operator of the machine on which the Flexi Soft safety con‐

troller is used are responsible for liaising with the relevant authorities about all

applicable safety regulations/rules and for ensuring compliance with these.

b

The notes, in particular the test notes, in these operating instructions (e.g. regard‐

ing use, mounting, installation, or integration into the machine controller) must

always be observed.

b

The thorough checks must be carried out by qualified safety personnel or specially

qualified and authorized personnel, and must be recorded and documented by a

third party to ensure that the tests can be reconstructed and retraced at any time.

2.2 Intended use

The Flexi Soft Designer software is intended for configuring a modular Flexi Soft safety

c

ontroller.

The Flexi Soft system must only be used within the limits of the prescribed and speci‐

fied technical data and operating conditions at all times.

NOTICE

Incor

rect use, improper modification or manipulation of the Flexi Soft system will invali‐

date any warranty from SICK; in addition, any responsibility and liability of SICK for dam‐

age and secondary damage caused by this is excluded.

2.3 Requirements for the qualification of personnel

The Flexi Soft modular safety controller may only be mounted, commissioned, and

maint

ained by qualified safety personnel. A person is deemed properly qualified if they

meet all of the following conditions:

•

Appropriate technical training

•

A knowledge of operation and the applicable safety guidelines following instruction

by the machine operating company

•

Sufficient knowledge of the relevant national occupational safety regulations, work

safety regulations, directives, and generally accepted technical rules and stan‐

dards (e.g., DIN standards, VDE regulations, technical rules of other EU member

states) so that he/she is able to evaluate when the power-operated equipment is

safe

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•

A k

nowledge of the contents of the Flexi Soft operating instructions and access to

these instructions

•

A knowledge of the contents of the operating instructions for the protective

devices associated with the safety controller (e.g. deTec4) and access to these

instructions

2 ON S

AFETY

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3 Version, compatibility, and features

There are different firmware versions and function packages (so-called “Steps”) for the

F

lexi Soft product family that permit realization of the different functions. This section

provides an overview of which firmware version, which function package and/or which

version of the Flexi Soft Designer configuration software or Safety Designer configura‐

tion software is needed to use a certain function or a certain device.

Table 2: Modules, firmware versions, and software versions you will need

Necessary module with firmware

from version

Available from

Flexi Soft

Designer

Available from

Safety Designer

Function blocks and logic

Offline simulation of logic Unrestricted V1.2.0 V1.6.x

Import and export of partial applications Unrestricted V1.3.0 V1.6.x

Automatic circuit diagrams Unrestricted V1.3.0 V1.6.x

Central tag name editor Unrestricted V1.3.0 V1.6.x

Documentation for function blocks of main mod‐

ule

s in logic editor

Unrestricted V1.3.0 N. a.

1)

Matrix of input and output connections Unrestricted V1.3.0 V1.6.x

Invertible inputs for the function blocks AND, OR,

R

S Flip-Flop and Routing n:n

FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0 V1.6.x

Function block for ramp-down detection FX3-CPUx V1.11.0 (Step 1.xx) V1.3.0 V1.6.x

Function blocks for configurable switch-on delay

and configurable switch-off delay

FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0 V1.6.x

Speed to Bool function block FX3-MOC0 V1.10.0 V1.7.0 V1.6.x

Motion Status to Bool function block FX3-MOC0 V1.10.0 V1.7.0 V1.6.x

Verification possible even without identical hard‐

w

are

FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0 V1.6.x

Status input data and status output data in logic FX3-CPUx V2.00.0 (Step 2.xx)

and FX3-

XTIO, FX3-XTDI, or FX3-

XTDS, each V2.00.0 (Step 2.xx)

V1.3.0 V1.6.x

Easy applications for FX3-MOC0 FX3-MOC0 V1.10.0 V1.7.1 N. a.

Special functions

Two S3000 safety laser scanners at one EFI

int

erface

FX3-CPU1 V1.00.0 V1.2.2 N. a.

Flexi Link FX3-CPU1 V2.00.0 (Step 2.xx) V1.3.0 N. a.

Flexi Loop FX3-CPUx V3.00.0 (Step 3.xx)

and FX3-

XTIO, FX3-XTDI, or FX3-

XTDS, each V3.00.0 (Step 3.xx)

V1.6.0 V1.8.0

Flexi Line FX3-CPU3 V3.00.0 (Step 3.xx) V1.6.0 N. a.

Automatic configuration of connected EFI-

enabled s

afety sensors (automatic configuration

recovery)

FX3-CPU2 V3.00.0 (Step 3.xx) V1.5.0

(FX3-CPU2)

V1.6.0

(FX3-CPU3)

N. a.

Deactivation of test signals Q1 to Q4 on the FX3-

X

TIO possible

FX3-XTIO V2.00.0 (Step 2.xx) V1.3.0 V1.6.x

Fast shut-off with bypass at FX3-XTIO FX3-CPUx and FX3-XTIO, each

V2.00.0 (Step 2.xx)

V1.3.0 V1.6.x

Multiple safety mats at FX3-XTIO/FX3-XTDI FX3-XTIO or FX3-XTDI, each V1.13.0 V1.3.0 V1.6.x

Data recorder FX3-CPUx V2.00.0 (Step 2.xx) V1.5.0 V1.6.x

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Necessary module with firmware

fr

om version

Available from

Flexi Soft

Designer

Available from

Safety Designer

Extended cross-circuit detection time for the

switching of increased capacitive loads at FX3-

XTIO

FX3-XTIO V3.00.0 (Step 3.xx) V1.6.0 V1.6.x

Configurable filter time for in/out filters and

out/

in filters at inputs I1 to I8 at FX3-XTIO/FX3-

XTDI/FX3-XTDS

FX3-XTIO, FX3-XTDI, or FX3-XTDS,

each V3.00.0 (Step 3.xx)

V1.6.0 V1.6.x

Optimization of logic execution time FX3-CPUx V4.00.0 (Step 4.xx) V1.7.1 V1.6.x

Automated download No limitation V1.9.1 n.a.

Devices

FX3-CPU0 No limitation V1.2.0 V1.6.x

FX3-CPU1 No limitation V1.2.0 N. a.

FX3-CPU2 No limitation V1.2.0 N. a.

FX3-CPU3 No limitation V1.2.0 N. a.

FX3-XTIO No limitation V1.2.0 V1.6.x

FX3-XTDI No limitation V1.2.0 V1.6.x

Gateways for PROFINET IO, Modbus TCP and Eth‐

erN

et/IP™

FX3-CPUx V1.11.0 (Step 1.xx) V1.2.0 V1.6.x

CC-Link gateway FX3-CPUx V1.11.0 (Step 1.xx) V1.3.0 N. a.

CANopen gateway FX3-CPUx V1.11.0 (Step 1.xx) V1.3.0 V1.6.x

EtherCAT gateway FX3-CPUx V2.00.0 (Step 2.xx) V1.3.0 V1.6.x

EFI-pro gateway FX3-CPUx V4.00.0 (Step 4.xx) N. a. V1.6.x

SIM1000 FXG

2)

FX3-CPUx V1.11.0 (Step 1.xx) V1.9.2 n.a.

Speed Monitor MOC3SA Unrestricted V1.3.0 V1.6.x

FX3-MOC0 FX3-CPUx V2.50.0 V1.5.0 N. a.

FX3-MOC1 FX3-CPUx V2.50.0 V1.8.0 V1.6.x

FX3-XTDS Unrestricted V1.6.0 V1.6.x

FX0-STIO Unrestricted V1.6.0 V1.6.x

FX3-ANA0 FX3-CPUx V4.00.0 (Step 4.xx) V1.8.0 V1.7.0

Conformities

RoHS conformity FX3-XTIO FX3-XTIO V1.01.0 – –

1)

N. a. = Not available

2)

All other modules as from market introduction.

2)

You can find information on this gateway in the SIM1000 FXG operating instructions.

3 VERSION, COMPATIBILITY, AND FEATURES

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NOTE

•

Mor

e recent modules are backward compatible so that each module can be

replaced by one with a higher firmware version.

•

Flexi Soft Designer Version ≥ V1.4.0 can also be used to configure devices with a

later version of the firmware, even if Flexi Soft Designer does not yet recognize the

new firmware. In such cases, the user will only be able to access the function

packages (Step 1.xx, Step 2.xx, Step 3.xx, or Step 4.xx) that are supported by the

available version of Flexi Soft Designer.

•

A corresponding new version of the configuration software is needed in order to

use the full functional scope of modules with a later firmware version.

•

The configuration software is not upwards-compatible. In other words, a project

created with a more recent version of the configuration software cannot be

opened with an older version.

•

The function package (Step 1.xx, Step 2.xx, Step 3.xx, or Step 4.xx) must be

selected in the hardware configuration menu of the configuration software. The

availability of a desired function package in the configuration software is shown in

the table.

•

To use the Step N.xx function package, the relevant module must have a minimum

firmware version of VN.00.0. If you try to transfer a configuration in a module with

a lower firmware version, an error message is displayed.

•

The hardware version of the Flexi Soft modules can be seen in the hardware con‐

figuration of the configuration software in online status or in the report if the sys‐

tem was previously online.

•

You will find the firmware version of the Flexi Soft modules on the type label of the

Flexi Soft modules in the firmware version field.

•

The date of manufacture of a device can be found in the S/N field on the type

label in the format yywwnnnn (yy = year, ww = calendar week, nnnn = sequential

serial number in the calendar week).

•

The version of the configuration software can be found by selecting Info in the

Extras menu.

•

The latest version of the configuration software can be found on the Internet at

www.sick.com.

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4 Installation

4.1 System requirements

Recommended system configuration:

•

Oper

ating system: Microsoft Windows XP (32 bit/64 bit) (only with Flexi Soft

Designer < V1.7.1), Microsoft Windows Vista (32 bit/64 bit), Windows 7, or Win‐

dows 10

•

Microsoft .NET Framework 3.5

•

1 GHz processor

•

1 GB RAM

•

Screen resolution of 1024 × 768 pixels

•

300 MB of free memory on the hard drive

Flexi Soft Designer is a .NET Framework application. It requires installation of .NET

Framework version 3.5. Information about the latest .NET Framework versions and sup‐

ported operating systems can be found on the Internet at http://www.microsoft.com/.

Microsoft .NET Framework version 3.5 and any other necessary components can also

be downloaded from http://www.microsoft.com/downloads/.

4.2 Installing and updating the software

The latest version of the Flexi Soft Designer software can be found on the Internet at

www

.sick.com.

b

Download the installation program, launch it, then following the instructions in the

installation program.

NOTE

•

A

dministrator rights are required to install Flexi Soft Designer correctly.

•

Optional additional functions of the Flexi Soft Designer such as the automated

download of verified configurations must be explicitly selected at the beginning of

the installation.

New versions of the software may contain new functions and may support new Flexi

S

oft modules. The version of the Flexi Soft Designer can be found by selecting Info in

the Extras menu.

b

Before installing a new software version, deinstall the old version. The folder con‐

taining your project data will be retained during the deinstallation process.

Errors during installation

T

able 3: Troubleshooting during installation

Error/error message Possible cause Troubleshooting measures

When you start Flexi Soft

D

esigner, the following error

message (or a similar one)

appears: “Unable to locate

DLL – Dynamic Link Library

mscoree.dll could not be

found in the specified path.

Please set registry key HKLM

\Software\Microsoft\.NET‐

Framework\InstallRoot to

point to the .NET Framework

install location.”

Microsoft .NET Framework is

not installed on the computer.

Install the appropriate version

of Microsoft .NET Framework;

if necessary, ask your system

administrator.

.NET Framework is available

for download from Microsoft's

web pages.

Note:

Install .NET Framework 3.5.

4 INS

TALLATION

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