SICK 8023204 Operating instructions

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

Flexi Loop

Safe sensor cascade hardware

SC-FLN-OSSD5, SC-FLN-OSSD8, SC-FLN-EMSS5, SC-FLN-EMSS8

Described product

F

lexi Loop safe sensor cascade

SC-FLN-OSSD5, SC-FLN-OSSD8, SC-FLN-EMSS5, SC-FLN-EMSS8

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 Ordering information........................................................................ 6

1.1 Scope of delivery....................................................................................... 6

1.2 Flexi Loop node......................................................................................... 6

1.3 Flexi Loop accessories............................................................................. 6

2 About this document........................................................................ 7

2.1 Function of this document....................................................................... 7

2.2 Scope......................................................................................................... 7

2.3 Target groups and structure of these operating instructions................ 7

2.4 Additional information.............................................................................. 8

2.5 Symbols and document conventions...................................................... 8

3 Safety information............................................................................ 10

3.1 General safety notes................................................................................ 10

3.2 Correct use................................................................................................ 10

3.3 Requirements for the qualification of personnel.................................... 10

4 Product description........................................................................... 12

4.1 Structure and function............................................................................. 12

4.1.1 System requirements.............................................................. 13

4.1.2 Safety by means of Flexi Loop................................................ 13

4.1.3 Subdivision of the safe sensor cascade................................ 14

4.1.4 Supply of power....................................................................... 15

4.2 Principle of operation............................................................................... 16

4.2.1 Operating principle of Flexi Soft.............................................. 16

4.2.2 Protection against tampering.................................................. 18

4.3 Device components.................................................................................. 18

4.3.1 Flexi Loop node........................................................................ 18

4.3.2 Flexi Loop terminator............................................................... 19

4.3.3 Flexi Loop accessories............................................................ 20

4.3.4 Status indicators...................................................................... 20

5 Project planning................................................................................ 23

5.1 Total current and power failure................................................................ 23

5.2 Total current.............................................................................................. 23

5.2.1 Permissible total current of a section.................................... 23

5.2.2 Permissible inrush current...................................................... 23

5.2.3 Other limits............................................................................... 24

5.2.4 Connection facilities................................................................ 24

5.2.5 Division into sections............................................................... 25

5.3 Voltage drop via cables, Flexi Loop nodes and Flexi Loop accessories 26

5.3.1 Examples for the voltage drop................................................ 26

5.3.2 Possible solutions.................................................................... 28

5.4 Supply of OSSD devices........................................................................... 29

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5.5 Integration in the electrical control.......................................................... 29

5.5.1 Implementation of reset.......................................................... 29

5.5.2 Implementation of a safety locking device............................ 30

6 Mounting............................................................................................. 32

6.1 Mounting in a cable channel.................................................................... 32

6.2 Mounting with cable tie............................................................................ 32

6.3 Mounting with C-Fix bracket..................................................................... 32

7 Electrical installation........................................................................ 34

7.1 Safety......................................................................................................... 34

7.2 Connections.............................................................................................. 35

7.2.1 Connection to Flexi Soft.......................................................... 35

7.2.2 Connections of the Flexi Loop nodes..................................... 36

7.2.3 Connection of the Flexi Loop nodes within a safe sensor

c

ascade.................................................................................... 37

7.2.4 Connections of the EMSS Flexi Loop node............................ 38

7.2.5 Connections of the OSSD Flexi Loop node............................ 39

7.2.6 Connections of the PWRI power supply accessory................ 40

8 Commissioning.................................................................................. 41

8.1 Safety......................................................................................................... 41

8.2 Display sequence during switching on.................................................... 41

8.3 Test notes.................................................................................................. 41

8.3.1 Thorough checks before the initial commissioning............... 41

8.3.2 Regular thorough check of the protective device by quali‐

fied safety personnel............................................................... 41

8.3.3 Daily functional checks of the protective device................... 41

9 Troubleshooting................................................................................. 42

9.1 In the event of faults or errors................................................................. 42

9.2 SICK support............................................................................................. 42

9.3 Indications of the LEDs............................................................................ 42

9.3.1 MS LED..................................................................................... 42

9.3.2 LEDs of the EMSS Flexi Loop nodes....................................... 44

9.3.3 LEDs of the OSSD Flexi Loop nodes....................................... 45

9.3.4 LEDs of the PWRI power supply accessory............................ 45

9.4 Extended diagnostics............................................................................... 46

10 Technical data.................................................................................... 47

10.1 Data sheet................................................................................................. 47

10.1.1 Overall system.......................................................................... 47

10.1.2 All Flexi Loop nodes and Flexi Loop accessories................... 47

10.1.3 EMSS Flexi Loop nodes (SC-FLN-EMSS5 and SC-FLN-

EMSS8)..................................................................................... 49

10.1.4 OSSD Flexi Loop nodes (SC-FLN-OSSD5 and SC-FLN-

OSSD8)..................................................................................... 49

CONTENTS

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10.1.5 Terminator................................................................................ 50

10.1.6 PWRI power supply accessory................................................ 50

10.2 Dimensional drawings.............................................................................. 52

10.2.1 Dimensional drawing Flexi Loop node.................................... 52

10.2.2 Dimensional drawing PWRI power supply accessory............ 53

10.2.3 Dimensional drawing terminator............................................ 53

11 Accessories........................................................................................ 54

11.1 Mounting accessories.............................................................................. 54

12 Annex.................................................................................................. 55

12.1 Compliance with EU directives................................................................. 55

12.2 Checklist for the manufacturer................................................................ 56

13 List of figures..................................................................................... 57

14 List of tables....................................................................................... 58

CONTENTS

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1 Ordering information

1.1 Scope of delivery

The following is included with delivery of the Flexi Loop node and the Flexi Loop acces‐

sor

ies:

•

Flexi Loop node or Flexi Loop accessory depending on order

•

general safety notes

1.2 Flexi Loop node

Table 1: Part numbers Flexi Loop nodes

Part Description Part number

SC-FLN-OSSD5 Flexi Loop node

f

or a safety sensor with monitored semiconductor

output (OSSD)

with one non-safe input

1096455

SC-FLN-OSSD8 Flexi Loop node

f

or a safety sensor with monitored semiconductor

output (OSSD)

with one non-safe input

with one non-safe output

1096456

SC-FLN-EMSS5 Flexi Loop node

f

or a dual-channel, equivalent switching, electro-

mechanical safety switch

1096457

SC-FLN-EMSS8 Flexi Loop node

f

or a dual-channel, equivalent switching, electro-

mechanical safety switch

with one non-safe input

with one non-safe output

1096458

1.3 Flexi Loop accessories

Table 2: Part numbers Flexi Loop accessories

Part Description Part number

SC-FLA-PWRI Flexi Loop accessories

f

or supply of power

for electrical isolation

for overcurrent shutdown

1096459

SC-FLT-TERM Flexi Loop termination element 1096460

1 ORDERING INFORMATION

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2 About this document

2.1 Function of this document

These operating instructions contain the information that is required during the life

c

ycle of the safe sensor cascade.

These operating instructions are to be made accessible to all persons who work with

the safe sensor cascade.

Read these operating instructions carefully and make sure you have completely under‐

stood the contents before you work with the safe sensor cascade.

2.2 Scope

These operating instructions only apply to the Flexi Loop safe series connection with

one of t

he following part numbers:

•

1096455

•

1096456

•

1096457

•

1096458

These operating instructions are included with SICK part number 8023204 (all avail‐

able languages of this document).

In addition, the following documents contain information on the safe sensor cascade:

T

able 3: Available documents

Document Title Part number

Operating instructions Flexi Loop in the Flexi Soft

D

esigner Software

8023208

Operating instructions Flexi Soft Modular safety con‐

t

roller Hardware

8022462

Operating instructions Flexi Soft in the Flexi Soft

Designer Configuration Soft‐

ware

8022491

Competence brochure Guide for Safe Machinery 8008007

2.3 Target groups and structure of these operating instructions

These operating instructions are aimed at the following target groups: project engineers

(planners, developers, designers), fitters, electricians, operators and maintenance per‐

sonnel.

The structure of these operating instructions is orientated on the phases of life of the

safe sensor cascade: design, mounting, electrical installation, commissioning, opera‐

tion and maintenance.

In many applications the target groups are assigned as follows to the manufacturer and

organization operating the machine in which the safe sensor cascade is integrated:

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Table 4: Assignment of target groups

Area of responsibility Target group Specific chapter in these operating instruc‐

t

ions

1)

Manufacturer Project engineers

(

planners, developers,

designers)

"Total current and power failure", page 23

"Technical data", page 47

"Accessories", page 54

Fitters "Mounting", page 32

"C

ommissioning", page 41

"Checklist for the manufacturer", page 56

Electricians "Electrical installation", page 34

Operators Operator "Troubleshooting", page 42

Maintenance person‐

ne

l

"Troubleshooting", page 42

"Ordering information", page 6

1)

Chapters listed here are aimed at all target groups. All target groups must follow the safety notes and

warnings in the entire operating instructions!

In other applications the operating organization is at the same time the manufacturer of

t

he machine — with the corresponding assignment of the target groups.

2.4 Additional information

www.sick.com

T

he following information is available on the Internet:

•

This document in other languages

•

Data sheets and application examples

•

CAD data of drawings and dimensional drawings

•

Certificates (e.g. EU declaration of conformity)

•

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

2.5 Symbols and document conventions

The following symbols are used in these operating instructions:

Safety notes and other notes

DANGER

Indicates 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

Indic

ates 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.

2 ABOUT THIS DOCUMENT

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NOTE

Indic

ates useful tips and recommendations.

Instructions to action

b

T

he arrow denotes instructions to action. Read carefully and follow the instructions

for action.

LED symbols

These symbols indicate the status of an LED:

o

The LED is off.

O

The LED is illuminated continuously.

ôFõ

The LED is flashing.

ôFõôGõ

Two LEDs are flashing alternately.

ôFõôFõ

Two LEDs are flashing in synchronism.

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3 Safety information

3.1 General safety notes

This chapter contains general safety information about the safe sensor cascade.

Mor

e safety information about specific usage situations of the safe sensor cascade is

available in the respective chapters.

DANGER

H

azard due to lack of effectiveness of the protective device

In the case of non-compliance, it is possible that the dangerous state of the machine

may not be stopped or not stopped in a timely manner.

b

Read this document carefully and ensure that you have fully understood the con‐

tents before you work with the device.

b

Pay particular attention to all safety notes in this document.

3.2 Correct use

The Flexi Loop safe sensor cascade is an expansion for the Flexi Soft and Flexi Classic

s

afety controllers. It can be used …

•

To IEC 61508 up to SIL3

•

To EN 62061 up to SIL claim limit 3

•

To EN ISO 13849-1 up to category 4 and performance level e

The degree of safety actually attained depends on the external circuit, the design of the

wiring, the parameter configuration, the selection of the safety sensors and their place‐

ment on the machine.

The safe sensor cascade must only be used within the limits of the prescribed and

specified technical data and operating conditions at all times.

Incorrect use, improper modification, or tampering with the safe sensor cascade will

invalidate any warranty offered by SICK AG; in addition, any responsibility and liability

on the part of SICK AG for damage and secondary damage caused by such use, modifi‐

cation, or tampering shall be excluded.

Foreseeable misuse

T

he Flexi Loop safe sensor cascade is not suitable for the following usage, among oth‐

ers:

•

outdoors

•

under water

•

in explosive environments

3.3 Requirements for the qualification of personnel

Only qualified safety personnel are permitted to configure, install, connect, commis‐

sion, and maint

ain the safe sensor cascade.

Project planning

For project planning, a person is considered competent when he/she has expertise and

experience in the selection and use of protective devices on machines and is familiar

with the relevant technical rules and national work safety regulations.

3 S

AFETY INFORMATION

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Mechanical mounting

F

or mechanical mounting, a person is considered competent when he/she has the

expertise and experience in the relevant field and is sufficiently familiar with the appli‐

cation of the protective device on the machine that he/she can assess its operational

safety status.

Electrical installation

For electrical installation, a person is considered competent when he/she has the

expertise and experience in the relevant field and is sufficiently familiar with the appli‐

cation of the protective device on the machine that he/she can assess its operational

safety status.

Configuration

For configuration, a person is considered competent when he/she has the expertise

and experience in the relevant field and is sufficiently familiar with the application of

the protective device on the machine that he/she can assess its work safety aspects.

Commissioning

For commissioning, a person is considered competent when he/she has the expertise

and experience in the relevant field and is sufficiently familiar with the application of

the protective device on the machine that he/she can assess its operational safety sta‐

tus.

Operation and maintenance

For operation and maintenance, a person is considered competent when he/she has

the expertise and experience in the relevant field and is sufficiently familiar with the

application of the protective device on the machine and has been instructed by the

machine operator in its operation.

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4 Product description

4.1 Structure and function

The Flexi Loop safe sensor cascade is an expansion for the Flexi Soft or Flexi Classic

s

ystem. A safe sensor cascade comprises individual Flexi Loop nodes that are con‐

nected to the safety controller. The Flexi Loop nodes make it possible to collect informa‐

tion from physically distributed safety sensors and safety switches.

Figure 1: Flexi Loop safe sensor cascade

1

Flexi Soft

2

Safety sensors with monitored semiconductor output (OSSD)

3

Electro-mechanical safety switches

4

Flexi Loop

Dual-channel, equivalent switching, electro-mechanical safety switches (e.g. reed

s

witches) or safety sensors with monitored semiconductor output (OSSD) (e.g. safety

light curtains or safety laser scanners) can be connected to the Flexi Loop nodes.

The main function of the Flexi Loop nodes is the safe and quick monitoring of the

switches and sensors connected so as to provide a common shutdown criterion to the

safety controller.

Diagnostic functions make it possible to locate which safety sensor or safety switch has

shut down for which reason. Discrepancy or sequence errors are detected by means of

testing, as are cross-circuits or short-circuits on the sensors or switches.

Unsafe inputs and outputs also make it possible to evaluate certain situations (e.g. con‐

tamination) on the monitored system or to trigger functions (e.g. illumination of lamps

and activation of door locking devices).

Special features

•

up t

o 32 Flexi Loop nodes per safe sensor cascade

•

up to 100 m between Flexi Loop nodes and up to 3,200 m total length of the safe

sensor cascade

•

up to 10 m cable length between the Flexi Loop nodes and the devices connected

•

Optional voltage supply with PWRI power supply accessory

•

enclosure rating IP 65 and IP 67 to EN 60529

Connection to safety controllers:

•

Flexi Soft safety controller

•

up to 8 safe sensor cascades on one Flexi Soft safety controller

4 P

RODUCT DESCRIPTION

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4.1.1 System requirements

Flexi Soft safety controller

T

he safe sensor cascade is connected directly to a Flexi Soft safety controller extension

module. The following prerequisites apply:

•

one main module

°

SC-FS-CPUx

•

one or more expansion modules

°

SC-FS-XTIO

°

SC-FS-XTDI

°

SC-FS-XTDS

4.1.2 Safety by means of Flexi Loop

•

P

erformance level up to PL e

°

dependent on the performance level of the overall application

°

independent of the number of Flexi Loop nodes and thus the number of sen‐

sors / switches

°

independent of whether the sensors / switches are directly connected to the

safety controller or to the safe sensor cascade

•

one cut-off path; the status of this path is represented in the Flexi Soft logic by

means of a single safe bit. This feature permits quick, safe shutdown.

•

no error masking

The problem of error masking

If t

ested dual-channel equivalent safety switches are connected in series, errors cannot

be detected reliably. The following example shows such a situation.

Figure 2: Error masking

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If the switch S2 is opened correctly, e.g. the system is shut down. If the switch S3 is now

also opened

, the error on S3 cannot be detected (error masking). If the switch S3 is

closed before S2, the error remains undetected.

4.1.3 Subdivision of the safe sensor cascade

The safe sensor cascade is divided into segment, section and string:

•

S

egment

A segment starts at the safety controller or the FL_OUT female connector of the

upstream Flexi Loop node; it includes the connection cable as far as the FL_OUT

female connector of the Flexi Loop node (see "Connections of the Flexi Loop

nodes", page 36) and the supply lines to the devices connected to the Flexi Loop

node.

•

section

A section extends from a supply of power to the next accessory for the supply of

power or to the terminator.

•

string

A string covers the complete safe sensor cascade from the connection on the

safety controller to the terminator.

Figure 3: Subdivision of the safe sensor cascade

1

Segment

2

Section

3

Line

4

Safety controller

The Flexi Loop safe series connection is structured as a line topology. The series con‐

nec

tion must always be terminated with an SC-FLT-TERM terminator after the last Flexi

Loop node.

NOTE

T

he terminator must be connected directly to the Flexi Loop node, it is not allowed to be

connected via a cable.

Power supply accessories can be installed between the Flexi Loop nodes (see "Supply

of power", page 15).

Within Flexi Loop, the connection is made with standard 5-pin unshielded cables with A-

coded M12 male connectors and M12 female connectors. Cables up to 100 m in

length can be laid between the individual Flexi Loop nodes.

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Sensors or switches are connected using 5-pin or 8-pin unshielded cables with M12

male connec

tors. A series of SICK sensors or switches can be connected with 1:1

cables (male/female connector).

•

The cables for the sensors or switches must not exceed a length of 10 m .

•

You must consider the pin assignment of the individual Flexi Loop nodes and the

accessories when making the connection (see "Connections", page 35).

4.1.4 Supply of power

DANGER

D

anger due to overcurrent

Non-compliance can lead to cable fires.

If multiple power supply units in a Flexi Loop section are connected in parallel, the loss

of the GND connection can lead to overcurrent and cable fires.

b

Always supply connected OSSD devices with power via the OSSD female connector

of Flexi Loop node SC-FLN-OSSD5 or SC-FLN-OSSD8.

b

OSSD devices must always be connected to the same voltage supply as the Flexi

Loop node to which they are connected.

b

Always use the power supply accessory to connect additional power supply units.

b

Never use a separate power supply unit to supply power directly to a connected

OSSD device.

The power supply accessory is characterized by:

•

V

oltage supply to the safe series connection and connection of additional voltage

supply units (see "Connection facilities", page 24)

•

electrical isolation in individual sections

•

shutdown of the safe sensor cascade or the section in case of overload

Depending on the number of Flexi Loop nodes, the length of the cables, and the power

consumption of the connected sensors or actuators, a voltage supply from a single

power supply unit might not be sufficient. Should this be the case, additional power

supply units can be connected with the power supply accessory.

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Figure 4: Supply of power

1

Section 1

2

Section 2

3

Supply of power for section 2

4.2 Principle of operation

4.2.1 Operating principle of Flexi Soft

The Flexi Soft I/O modules provide the interface to the Flexi Soft safety controller.

Safe cut-off path

T

he safety information on the switches and sensors connected is combined and trans‐

mitted quickly and safely to the Flexi Soft.

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Figure 5: Safe cut-off path

1

Safe cut-off path

2

I/O module for the Flexi Soft safety controller

3

Safety sensors with monitored semiconductor output (OSSD)

4

Electro-mechanical safety switches

Diagnostic information

N

on-safe diagnostic information about the statuses inside the safe sensor cascade and

about the Flexi Loop nodes is also sent to the Flexi Soft safety controller.

Further processing of information in the logic editor

The safety information and the non-safe diagnostic information can undergo further

processing in the logic of the Flexi Soft safety controller (see the “Flexi Loop in the Flexi

Soft Designer” operating instructions, part no. 8023208) or it can be forwarded to a

PLC, for example, via a gateway.

Figure 6: Further processing of information

1

Gateway

2

Diagnostic information

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4.2.2 Protection against tampering

DANGER

Hazard due to lack of effectiveness of the protective device

If the manipulation protection is switched off, a Flexi Loop node can be removed or

bridged. In this case, the safe sensor cascade switches back on despite the change.

b

Only deactivate manipulation protection when it is absolutely necessary to realize

the application.

b

In this case, take other steps (e.g. protected cable laying) to prevent possible

manipulation.

Flexi Soft safety controller

T

he Flexi Soft safety controller saves the node type and the number of nodes in a safe

sensor cascade.

This prevents Flexi Loop nodes from being replaced with other types of nodes as well as

preventing them from being removed, added, or jumpered. In specific cases, this pro‐

tection against manipulation can be disabled (see the “Flexi Loop in the Flexi Soft

Designer” operating instructions, part no. 8023208).

4.3 Device components

4.3.1 Flexi Loop node

SC-FLN-EMSS5 – 5-pin

Figure 7: SC-FLN-EMSS5 Flexi Loop node – 5-pin

T

he 5-pin EMSS Flexi Loop node is suitable for connecting dual-channel, equivalent

switching electro-mechanical safety switches, e.g. magnetic safety switches or emer‐

gency stop pushbuttons. The safety switches connected are tested for cross-circuit and

short-circuit as well as discrepancy and sequence errors.

SC-FLN-EMSS8 – 8-pin

Figure 8: SC-FLN-EMSS8 Flexi Loop node – 8-pin

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The 8-pin Flexi Loop EMSS node ha

s one more non-safe input and one more non-safe

output than the 5-pin Flexi Loop EMSS node. Control switches (e.g., pushbuttons) or

actuators (e.g., lamps or locks) can be connected here.

SC-FLN-OSSD5 – 5-pin

Figure 9: SC-FLN-OSSD5 Flexi Loop node – 5-pin

T

he 5-pin OSSD Flexi Loop node is suitable for connecting safety sensors with moni‐

tored semiconductor output (OSSD) (e.g. safety light curtains or transponder safety

switches). In addition it has a non-safe input. Signal outputs from the sensors (e.g. for

signaling contamination) can be connected to this input. The safety sensors connected

are tested for discrepancy and sequence errors.

SC-FLN-OSSD8 – 8-pin

Figure 10: SC-FLN-OSSD8 Flexi Loop node – 8-pin

T

he 8-pin Flexi Loop OSSD node has one more non-safe output than the 5-pin Flexi

Loop OSSD node. Sensor signal outputs (e.g., for weak signals) or LEDs (e.g., for reset

required) can be connected here.

4.3.2 Flexi Loop terminator

SC-FLT-TERM

Figure 11: SC-FLT-TERM terminator

T

he terminator is used to terminate the safe series connection at the last Flexi Loop

node. The terminator must be connected directly to the FL_OUT connection of the last

Flexi Loop node (see "Connections of the Flexi Loop nodes", page 36).

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4.3.3 Flexi Loop accessories

SC-FLA-PWRI

Figure 12: SC-FLA-PWRI power supply accessories

T

he power supply accessory is used to connect a power supply with +24 V, for the elec‐

trical isolation of individual Flexi Loop sections and for overcurrent shutdown.

4.3.4 Status indicators

The LEDs indicate the operating states of the Flexi Loop nodes.

F

or a detailed overview of the error messages see "Indications of the LEDs", page 42.

MS LED

Figure 13: MS LED

T

he Flexi Loop nodes and the Flexi Loop accessories have an LED which displays the

communication status and the status of the Flexi Loop node. The designation MS (=

module status) comes from the Flexi Soft safety controller.

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SICK 8023204 Operating instructions

SICK 8023204 Operating instructions

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