SICK UE4421 IP20 Safety Remote I/O for DeviceNet Safety Operating instructions

OPERATING INSTRUCTIONS

UE4421

IP20 Safety Remote I/O

for DeviceNet Safety

GB

Operating Instructions

UE4421

Subject to change without notice

This document is protected by copyright. The rights established in this way reside with the SICK AG. Any dupli-

cation of this document or of parts thereof is only permitted within the bounds of the statutory provisions of the

German Copyright Law. Any modification or abridging of this document without the express prior written permis-

sion of SICK AG is prohibited.

Operating Instructions

UE4421

Subject to change without notice

Contents

1 About this document.........................................................................................................7

1

.1 Function of this document....................................................................................7

1.2 Target group ..........................................................................................................7

1.3 Scope .....................................................................................................................8

1.4 Depth of information............................................................................................. 8

1.5 Abbreviations.........................................................................................................8

1.6 Symbols used ......................................................................................................10

2 On safety...........................................................................................................................11

2.1 Qualified safety personnel..................................................................................11

2.2 Safety concept.....................................................................................................11

2.2.1 Functional safety per IEC 61508.....................................................12

2.2.2 Risk assessment...............................................................................12

2.2.3 Hardware configuration ....................................................................13

2.2.4 Programming requirements..............................................................13

2.2.5 Communication .................................................................................13

2.2.6 Response time ..................................................................................13

2.3 Applications of the device...................................................................................14

2.3.1 Additional precautions according to UL 1604.................................14

2.4 General safety notes and protective measures ................................................15

2.4.1 General requirements:......................................................................17

2.4.2 Compliance with EMC directive........................................................18

2.4.3 Compliance with Low Voltage Directive ...........................................18

2.4.4 Compliance with EC directives .........................................................18

2.4.5 Reducing noise..................................................................................18

2.5 Environmental protection ...................................................................................19

2.5.1 Disposal.............................................................................................19

2.5.2 Separation of materials ....................................................................19

2.6 Correct use ..........................................................................................................19

2.7 Specification changes, errors and omissions....................................................21

2.8 Performance data ...............................................................................................21

3 Product description.........................................................................................................22

3.1 Device construction ............................................................................................22

3.2 Module designation overview.............................................................................23

3.3 Operating principle of the device .......................................................................23

3.3.1 DeviceNet overview...........................................................................23

3.3.2 DeviceNet Safety overview ...............................................................24

3.3.3 The operating principle of the UE4421............................................24

3.4 Properties of the UE4421...................................................................................28

3.4.1 Properties of the UE4421@22EE900................................................28

3.4.2 Properties of the UE4421@22EE490................................................29

3.4.3 Properties of the UE4421@22EE330................................................29

3.5 Examples of range of use ...................................................................................29

Operating Instructions

UE4421

Subject to change without notice

Contents

3.6 Configurable functions ....................................................................................... 30

3.6.1 Self-diagnosis.................................................................................... 30

3.6.2 Configuration lock............................................................................. 31

3.6.3 Automatic baud rate detection ........................................................ 31

3.6.4 Configuration of safety capable inputs............................................ 32

3

.6.5 Configuration of test/signal (standard) outputs ............................. 41

3.6.6 Configuration of safety capable outputs .........................................42

3.6.7 DeviceNet configuration................................................................... 43

3

.7 Selection principles ............................................................................................ 44

3.7.1 Safety-capable input field signal connections ................................ 44

3.7.2 Functions of the safety capable output field signal

connections....................................................................................... 46

3.8 Status indicators................................................................................................. 46

4 Installation, mounting and maintenance.....................................................................49

4.1 Mounting the UE4421........................................................................................ 50

4.1.1 Installation environment .................................................................. 50

4.1.2 Mounting ........................................................................................... 51

4.2 Maintenance considerations .............................................................................51

4.2.1 Cleaning ............................................................................................ 51

4.2.2 Inspection.......................................................................................... 52

4.2.3 Replacing units ................................................................................. 53

5 Electrical installation and hardware settings .............................................................54

5.1 Connecting input and output power and signal cables .................................... 54

5.2 Power supply requirements ............................................................................... 57

5.3 UE4421-22EE900 terminals ............................................................................. 58

5.4 UE4421-22EE490 terminals ............................................................................. 60

5.5 UE4421-22EE330 terminals ............................................................................. 62

5.6 Connecting DeviceNet communication cables ................................................. 65

5.7 MAC ID node address setting ............................................................................ 66

6 Circuit examples .............................................................................................................67

6.1 Wiring examples ................................................................................................. 67

6.2 Emergency stop pushbutton with dual channel input and manual reset ....... 69

6.2.1 Wiring ................................................................................................ 69

6.2.2 Parameter configuration .................................................................. 69

6.3 Two-hand input ................................................................................................... 70

6.3.1 Wiring ................................................................................................ 70

6.3.2 Parameter configuration .................................................................. 70

6.4 User mode switch input...................................................................................... 71

6.4.1 Wiring ................................................................................................ 71

6.4.2 Parameter configuration .................................................................. 71

6.5 Muting lamp output ............................................................................................ 72

6.5.1 Wiring ................................................................................................ 72

6.5.2 Parameter configuration .................................................................. 72

6.6 Dual channel limit switch input with manual reset .......................................... 73

6.6.1 Wiring ................................................................................................ 73

6.6.2 Parameter configuration .................................................................. 73

6.7 Dual channel solid-state outputs....................................................................... 74

6.7.1 Wiring ................................................................................................ 74

6.7.2 Parameter configuration .................................................................. 74

6.8 Dual channel relay outputs with EDM input...................................................... 75

6.8.1 Wiring ................................................................................................ 75

6.8.2 Parameter configuration .................................................................. 75

Operating Instructions

UE4421

Subject to change without notice

Contents

7 General procedure and configuration ...........................................................................76

7.1 Delivery status.....................................................................................................76

7.2 Overview ..............................................................................................................76

7.3 Planning...............................................................................................................77

7.4 UE4421 configuration.........................................................................................78

7.4.1 Configuration tools............................................................................78

7.4.2 Setting a password............................................................................78

7.4.3 Setting device parameters ...............................................................79

7.4.4 Transfer the configuration ................................................................80

7.4.5 Verify UE4421 device behavior........................................................80

7.5 Safety network requirements .............................................................................81

8 Commissioning ................................................................................................................82

8.1 Technical commissioning ...................................................................................82

8.1.1 Commissioning UE4421 devices .....................................................82

8.1.2 System self-test after switching on ..................................................83

8.1.3 General acceptance of the UE4421 ................................................83

9 Fault diagnosis ................................................................................................................84

9.1 What to do in case of faults................................................................................84

9.2 SICK support........................................................................................................84

9.3 System performance in the case of malfunctions in connected devices ........84

9.3.1 Effect on the UE4421 .......................................................................84

9.3.2 Effect on the safety-rated inputs......................................................84

9.3.3 Effect on the safety-rated outputs ...................................................85

9.3.4 Effect on the safety-rated controller/the process image................85

9.4 Error displays of the MS and NS LEDs...............................................................86

9.5 Error displays of the input and output LEDs......................................................87

9.6 Troubleshooting using network communication ...............................................87

9.6.1 Safety capable input errors ..............................................................88

9.6.2 Test/signal output errors..................................................................89

9.6.3 Safety capable output errors............................................................90

9.6.4 Error history information...................................................................91

10 Allocating remote inputs and outputs ..........................................................................93

10.1 DeviceNet/DeviceNet Safety connection types ................................................93

10.2 Data nomenclature .............................................................................................94

10.3 Input and output data assembly overview.........................................................95

10.4 UE4421@22EE900 I/O assembly summary.......................................................96

10.5 UE4421@22EE490 I/O assembly summary.......................................................97

10.6 UE4421@22EE330 I/O assembly summary.......................................................98

11 Technical specifications.................................................................................................99

11.1 Data sheet ...........................................................................................................99

11.2 Response time ................................................................................................. 104

11.2.1 Input reaction time......................................................................... 105

11.2.2 Output reaction time ...................................................................... 105

12 Dimensional drawings ................................................................................................. 106

12.1 Dimensional drawing UE4421-22EE900 ....................................................... 106

12.2 Dimensional drawing UE4421-22EE490 ....................................................... 106

12.3 Dimensional drawing UE4421-22EE330 ....................................................... 106

Operating Instructions

UE4421

Subject to change without notice

Contents

13 Ordering information ....................................................................................................107

13.1 UE4421 series bus nodes................................................................................107

13.2 UE4421 series bus node accessories.............................................................108

14 Annex..............................................................................................................................110

14.1 Planning table for the configuration ................................................................110

14.2 Explicit messaging ............................................................................................112

14.3 I/O assembly details.........................................................................................115

14.3.1 Input assemblies ............................................................................115

14.3.2 Output assemblies..........................................................................120

14.4 .EDS File Information........................................................................................120

14.4.1 General parameters .......................................................................121

14.4.2 Safety input parameters.................................................................121

14.4.3 Test output parameters..................................................................122

14.4.4 Safety output parameters ..............................................................123

14.4.5 Operation time parameters............................................................123

14.5 EC declaration of conformity............................................................................124

14.6 Checklist for the manufacturer........................................................................126

14.7 Glossary.............................................................................................................127

14.8 List of tables .....................................................................................................130

14.9 List of illustrations ............................................................................................132

Operating Instructions Chapter 1

UE4421

Subject to change without notice

About this document

1 About this document

Thank you for purchasing the UE4421 IP20 Remote I/O bus node for DeviceNet Safety.

Please read this chapter carefully before working with this documentation and the

UE4421.

1.1 Function of this document

These operating instructions are designed to address the technical personnel of the ma-

chine manufacturer or the machine operator with regard to the safe mounting, installation,

configuration, electrical installation, commissioning, operation and maintenance of the

UE4421.

These operating instructions do not provide instructions for operating machines on which

the UE4421 has been, or could be, integrated. Information on this is to be found in the

appropriate operating instructions of the machine provided by the machine manufacturer.

The following documents should also be read and understood before installing and

commissioning the UE4421:

Document name Information covered Available from Part number

UE4421 IP20

Remote I/O bus

node operating

instructions (this

manual)

Operating instructions for the

UE4421 series

SICK 8011213

UE4421 IP20

Remote I/O bus

node instruction

sheet

Installation and wiring notes for

the UE4421 series

SICK 8011257

SICK DeviceNet

Safety Configurator

system manual

Information on using SICK

DeviceNet Safety Configurator

for configuration of a DeviceNet/

DeviceNet Safety network

SICK 8011293

ODVA Planning and

Installation Manual

– DeviceNet cable

system

Provides details regarding the

connection methods (e.g. cables,

connectors, etc.), specifications

and power supply methods for

the installation of a DeviceNet/

DeviceNet Safety network

Open

DeviceNet

Vendor

Association

(ODVA)

PUB 00027R1

1.2 Target group

These operating instructions are intended to be used by planning engineers, developers

and the operators of plant and systems which are to be protected by one or several safety

systems in connection with the UE4421. These operating instructions should also be refe-

renced by people who integrate the UE4421 into a machine/system, initialize its use, or

who are in charge of servicing and maintaining the device.

Tab.

1

:

Related documents

Chapter 1 Operating Instructions

UE4421

Subject to change without notice

About this document

1.3 Scope

T

hese operating instructions are original operating instructions.

These operating instructions are applicable to the UE4421 IP20 bus nodes with one of the

following entries on the type label in the field Operating Instructions:



8011216



8011216/QI50

 8011216/TF86

This document is part of SICK part number 8011216 (Installation and Operation Manual

for the “UE4421 – IP20 Remote I/O Bus Node for DeviceNet Safety” in all available

languages).

1.4 Depth of information

These operating instructions contain the following information about UE4421:

 Installation and mounting

 Electrical installation

 putting into operation and configuration

 integration into other safety systems

(examples of circuits)

 care and maintenance

 fault, error diagnosis and trouble-

shooting

 part numbers

 conformity and approval

Planning and using protective devices connected to the UE4421 also requires specific

technical skills which may not be detailed in this documentation. When operating the

UE4421, the national, local and statutory rules and regulations must be observed.

General information on health and safety using active optical-electronic protective devices

(AOPDs) is contained in the brochure “Safe Machines with Opto-Electronic Protective

Devices” from SICK.

We also refer you to the SICK homepage on the Internet at www.sick.com.

Here you will find information on:

 sample applications

 a list of frequently asked questions about the UE4421

 these operating instructions for viewing and printing

1.5 Abbreviations

Application Diagnostic Output = configurable signal output that indicates a specific device

status (e.g. SICK C4000 safety light curtain).

Active Optical-Electronic Protective Device, e.g. SICK C4000 safety light curtain (see ESPE).

Active Optical-Electronic Protective Device with Diffuse Reflection, e.g. SICK S3000 safety

laser scanner (see ESPE).

C4000 series safety light curtain from SICK.

SICK Configuration & Diagnostic Software = software for the configuration of SICK intelli-

gent safety sensors (e.g. C4000 series safety light curtains and S3000 series safety laser

scanners).

A device configured to produce change-of-state (COS) message will produce data when-

ever the data changes, or at a base heartbeat rate. This adjustable heartbeat rate provides

a way for the consuming device to know that the producer is still alive and active.

Note

ADO

AOPD

AOPDDR

C4000

CDS

Change of State (COS)

Operating Instructions Chapter 1

UE4421

Subject to change without notice

About this document

Electronic Data Sheet. An electronic file that provides device specific information used for

integration of the device on to the DeviceNet/DeviceNet Safety network.

Expected Packet Interval. A parameter in DeviceNet and DeviceNet Safety that defines the

frequency of data transmission between two network connections, e.g. devices.

Electro-sensitive protective equipment, e.g. SICK C4000 safety light curtain.

M4000 series multiple light beam safety devices (perimeter guards).

Media Access Code Identifier. The address of a device on DeviceNet or DeviceNet Safety.

Available MAC IDs range from 0963. Each node on the network must have a unique MAC ID

in order for the network to function properly.

Mean Time Between Failure. The average time between failure occurrences.

Normally Closed Contact (e.g. 2NC = 2 Normally Closed Contacts).

Normally Open Contact (e.g. 2NO = 2 Normally Open Contacts).

Open DeviceNet Vendor Association. A non-profit association of vendors established for

the promotion of DeviceNet/DeviceNet Safety.

Output signal switching device (e.g. PNP Semiconductor-based safety output).

Originator Unique Identifier.

The Probability of Failure on Demand in accordance with the functional safety testing

requirements outlined in IEC 61508.

The Probability of Failure per Hour in accordance with the functional safety testing

requirements outlined in IEC 61508.

(Safety) Programmable Logic Controller.

S3000 series safety laser scanners from SICK

Safety Configuration Identifier. Also known as a configuration signature. The value of the

SCID is a concatenation of the configuration CRC and a Time Stamp. The SCID is used to

ensure that a DeviceNet Safety device has the expected configuration.

Safety data link = SICK safety interface (connection of OSSDs and EFI) using devices such

as SICK C4000 series safety light curtains or S3000 series safety laser scanners.

Refers to the manufacturer of this device SICK AG, and all SICK AG subsidiary companies.

Safety Integrity Level in accordance with IEC 61508 standard.

Safety Network Configuration Tool used for the configuration of DeviceNet Safety–capable

devices (i.e. SICK DeviceNet Safety Configuration Tool with Safety Extensions).

Safety Network Number. A DeviceNet Safety attribute that uniquely identifies a network or

sub-network in a single or multiple network system.

Target Unique Identifier.

Unconnected Message Manager.

All IP20 Remote I/O bus nodes of the UE4421 family. In the context of this document, the

UE4421 definition does not include the DeviceNet Safety IP67 bus nodes that utilize a

similar naming convention (e.g. UE4420 or UE4450).

Uninterrupted supply voltage for use by device logic and safety capable input circuitry

(including test/signal outputs).

Interruptible (switchable) supply voltage for use by safety capable output circuitry.

EDS

E

PI

ESPE

M4000

M

AC ID

MTBF

NC

NO

ODVA

OSSD

OUNID

PFD

PFH

PLC (SPLC)

S3000

SCID

SDL

SICK

SIL

SNCT

SNN

TUNID

UCMM

UE4421

U

L

, U

L1

, U

L2

U

S

Chapter 1 Operating Instructions

UE4421

Subject to change without notice

About this document

1.6 Symbols used

R

ecommendations are designed to give users assistance in their decision-making process

with respect to a certain function or a technical measure.

Refer to notes for special features of the device.

L

ED symbols indicate the status of an LED on the UE4421:

The LED is off.

The LED turns red.

The LED flashes red.

Instructions for taking action are shown by an arrow. Carefully read and follow the instruc-

tions for action.

Warning!

A warning notice indicates an actual or potential risk or health hazard. They are designed

to help users prevent accidents. Carefully read and follow the warning notices!

DeviceNet and DeviceNet Safety are registered trademarks of the Open DeviceNet Ven-

dor Association, Inc. (ODVA). Other product names and company names referenced in this

manual are trademarks or registered trademarks of their respective companies.

Recommendation

Notes

,  Red,  Red



 Red

 Red

 Take action …



WARNING

Trademark

Operating Instructions Chapter 2

UE4421

Subject to change without notice

On safety

2 On safety

This chapter deals with your own safety and the safety of the equipment operators.

Please read this chapter carefully before starting to work with the UE4421 or with

machinery that utilizes the UE4421 as part of the machine safeguarding strategy.

2.1 Qualified safety personnel

The UE4421 and the components connected to it may only be assembled, operated and

maintained by qualified safety personnel. Qualified safety personnel are defined as

persons who …

 have undergone the appropriate technical training

and

 have been instructed by the responsible machine operator in the operation of the

machine and the current valid safety guidelines

and

 are sufficiently familiar with the applicable official health and work safety regulations,

directives and generally recognized engineering practice (e.g. DIN standards, VDE

stipulations, engineering regulations from other EC member states) that they can assess

the work safety aspects of the power-driven equipment

and

 have access to the operating instructions for the UE4421 Remote I/O bus node for

DeviceNet Safety (8011213) and have read them

and

 have access to the user manual Configuration System DeviceNet Safety (8011293) and

have read them

and

 have access to the operating instructions “DeviceNet Planning and Installation Manual”

of the Open DeviceNet Vendor Association (ODVA) (www.odva.org) and have read them

and

 have access to the installation and operating instructions for protective devices (e.g.

C4000 or S3000) connected to the UE4421 and have read them.

Prior to the installation of a UE4421, qualified safety personnel should conduct a risk

assessment on the machine to determine its suitability for the application.

2.2 Safety concept

The UE4421 devices have been third party certified as safety-rated devices in accordance

with the standards and testing criteria current at the time of certification. The safety tests

consist of test routines that run during all operating phases of the device.

Applicable standards include, but are not limited to, the following:

 EN ISO 13849@1 (UE4421 supports applications to performance level e).

 IEC 61508 (UE4421 supports applications to SIL3).

In general, the UE4421 requires that all safety-relevant input devices indicate a normal

run condition as an “ON” state. The “OFF” state is considered to be the safe state.

All safety capable inputs and safety capable outputs should be in failsafe state (e.g. inac-

tive (LOW) state) during any fault or safety trip condition.

Chapter 2 Operating Instructions

UE4421

Subject to change without notice

On safety

2.2.1 Functional safety per IEC 61508

Functional safety of electrical/electronic/programmable electronic (E/E/PE) safety-related

devices is now guided by international standard IEC 61508. Use of these devices involves

identifying specific hazardous conditions that may lead to serious consequences and then

establishing the maximum tolerable frequency.

IEC 61508 defines functional safety integrity targets for the maximum tolerable failure

rate for each piece of equipment, based on that equipment’s relative contribution to the

hazard being considered. These “safety integrity levels” (SIL) fall into two classifications:

Low demand mode of operation and high demand mode of operation. The following table

defines the SIL levels for high demand mode of operation.

Safety Integrity Level High Demand Mode of Operation

(Probability of a dangerous failure per hour, e.g. PFH)

4  10

–9

to < 10

–8

3  10

–8

to < 10

–7

2  10

–

7

to < 10

–

6

1  10

–6

to < 10

–5

The UE4421 is certified as meeting SIL3 requirements in accordance with IEC 61508.

2.2.2 Risk assessment

A risk assessment must be completed in order to determine the tasks and hazards asso-

ciated with a machine and what methods are utilized to reduce or eliminate the hazards

associated with each task. Standards and technical reports that describe the process of

risk assessment include, but are not limited to, the following:

 EN ISO 14121@1

 ANSI/RIA R15.06

 ANSI B11.TR3

Risk assessment is an iterative process. Once tasks and hazards have been identified and

a risk has been determined, the process of risk reduction begins. This entails the selec-

tion, installation and integration of safeguards to mitigate the hazard. After installation and

integration of these safeguards, the next step is to perform a subsequent risk assessment

based on the changes. Additional risk reduction may be necessary for any residual risks

that may exist.

Performance of risk assessment is necessary!

Consult your local, regional and national regulations, standards and technical reports for

additional details regarding the performance of risk assessment and implementation of

risk reduction requirements.

The proper use of the safety device described in this operation manual as it relates to in-

stallation conditions and mechanical performance and functions is a prerequisite for its

use. When selecting or using this safety device, risk assessment must be conducted with

the aim of identifying potential danger factors in equipment or facilities in which the safety

device is to be applied, during the development stage of the equipment or facilities. Suit-

able safety devices must be selected under the guidance of a sufficient risk assessment

system. An insufficient risk assessment system may lead to the selection of unsuitable

safety devices.

Tab.

2

:

SIL definition for High

Demand Modes of Operation



WARNING

Operating Instructions Chapter 2

UE4421

Subject to change without notice

On safety

2.2.3 Hardware configuration

 To ensure safety-rated operation, use only SICK configuration files (.EDS files) in

conjunction with the corresponding SICK safety-rated device.

 Follow the specifications outlined in these operating instructions.

 Only equipment that can be isolated safely from the main power source should be

connected to the system.

Only use safety-relevant hardware and software for safety-relevant applications!

Hardware modules and software components that are not safety-rated may be used to

process non-safety-rated signals and monitor (only) safety-rated signals. However, these

devices cannot be used to carry out safety-related task processing.

2.2.4 Programming requirements

It is imperative that only safety-relevant signals from the UE4421 are utilized for safety-

relevant logic. Since the UE4421 cannot determine whether standard devices or safety-

relevant devices have been connected to the UE4421, the user of the device(s) (e.g. OEM,

integrator or end-user) must be sure that the signals used in any safety-relevant control

strategy are appropriate and correct.

For configuration of the UE4400, utilize the Electronic Data Sheet (EDS) file provided with

SICK DeviceNet Safety Configurator. If you do not have SICK DeviceNet Safety Configura-

tor, the latest .EDS file may be downloaded from the ODVA website at

http://www.odva.org

You are responsible for programming your control system correctly in accordance with

these instructions, applicable regulations and standards!

Since the UE4421 and associated components are programmable devices, the user is

responsible for assuring that the UE4421 and any associated device is programmed

properly and suitable for the application. SICK shall not be responsible for the user’s

programming of any programmable product, or any consequence thereof.

2.2.5 Communication

The UE4421 communicates via DeviceNet and DeviceNet Safety via the five-pole terminal

block located on the front of the unit. UE4421 is configured using a DeviceNet connection

via a Safety Network Configuration Tool (SNCT; e.g. SICK DeviceNet Safety Configurator

with Safety Extensions).

2.2.6 Response time

It is imperative that all safeguarding devices be installed and integrated into the safety

control system to prevent access to all hazards. A key factor in determining device location

is the minimum safety distance.

Formulas that describe minimum safety distance vary based on device type, safeguard

orientation, resolution, system response time, and more. Consult applicable machine

regulations and standards for information regarding safeguarding device installation and

integration requirements.

The response time associated with the UE4421 is described later in this document.



WARNING



WARNING

Chapter 2 Operating Instructions

UE4421

Subject to change without notice

On safety

2.3 Applications of the device

T

he UE4421 is a decentralized safety capable input/safety capable output module that al-

lows for the integration of safety components using DeviceNet Safety via IP 20 connection

technology.

It can be used

 in accordance with IEC 61508 to SIL3

 in accordance with EN 62061 to SILCL3

 in accordance with EN ISO 13849@1 to category 4 or 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 control switches and their

placement on the machine.

The UE4421 may be used as a DeviceNet Safety target device in connection with a SICK

DeviceNet Safety UE4470 series safety network controller or other DeviceNet Safety safe-

ty-rated Originator. The UE4421 may also be used as a DeviceNet slave device in connec-

tion with a third-party DeviceNet master device/controller.

Signals generated by any device must be suitable for the application logic.

Since non-safety-rated devices can be connected to the safety capable inputs or safety

capable outputs of the UE4421, it is imperative that

 all input signals are suitable for the application, e.g. safety devices are connected to

safety capable input signals in safety relevant applications

and

 all output signals are suitable for the application e.g. safety devices are connected to

safety capable outputs in safety relevant applications

Control logic that utilizes information from the UE4421 must consider whether these

devices are suitable for the application. Safety devices should satisfy the rating required

for the application (e.g. a type 4 safety light curtain should be installed and integrated to

satisfy type 4 machine safeguarding requirements).

The installation and integration of devices on the UE4421 must meet regulatory

requirements!

The UE4421 supports applications up to SIL3 in accordance with IEC 61508 and up to

Performance Level e in accordance with EN ISO 13849@1.

However, the user is responsible for insuring that all devices connected to the UE4421 are

suitable for their intended purpose and that the logic, wiring, installation and integration

(including configuration, etc.) of these devices is in accordance with the application

requirements, regulations (including local, regional and national) and standards.

2.3.1 Additional precautions according to UL 1604

Models UE4421@22EE900 and UE4421@22EE490 are suitable for use in Class I, Div. 2,

Group A, B, C, D or non-hazardous location only.

Warning: Explosion hazard!

Substitution of components may impair suitability for Class I, Div. 2!

Do not disconnect equipment unless power has been switched off or the area is known

to be non-hazardous!



WARNING



WARNING



WARNING

Operating Instructions Chapter 2

UE4421

Subject to change without notice

On safety

2.4 General safety notes and protective measures

P

ay attention to the safety notes!

Please observe the following directives, regulations and standards to assure the correct

and safe use of the UE4421.

Failure to read and understand the information provided in this manual may result in

personal injury or death, damage to product or product failure!

Please read each section of this manual in its entirety and ensure that you understand the

information provided in the section and related sections before attempting any of the pro-

cedures or operations given.

The national and international legislative provisions apply to the installation and use of the

UE4421 and the safety components connected to it, e.g. a programmable safety-rated

device, a safety light curtain or components with a contact output; these legislative provi-

sions apply also to the commissioning and recurring technical examinations, in particular:

For North America:

 Regulations and requirements administrated by the Occupational Safety and Health

Administration (OSHA). These include those regulations outlined in Title 29 of the Code

of Federal Regulations Part 1910 Subpart O [29CFR1910 Subpart O].

 Ministry of Labor regulations (Canada)

 Other relevant health and safety regulations

For Europe:

 Machinery Directive 2006/42/EC

 Low Voltage Directive 2006/95/EC

 EMC Directive 2004/108/EC

 Work Equipment Directive 89/655/EEC

 Work safety regulations and safety rules

 Other relevant health and safety regulations

For Japan:

 Article 42 of the Industrial Safety and Health Law

 Article 44 of the Industrial Safety and Health Law

 Other relevant health and safety regulations

“Type Test” requirements are provided in Article 44 of the Industrial Safety and Health

Law. The requirements apply to complete systems and not specifically to a single compo-

nent within the system. Use of components as a “safety device for press machines or

shearing tool” in accordance with Article 42 of the Industrial Safety and Health Law

requires that the entire system be approved for that purpose.



WARNING

Note

Chapter 2 Operating Instructions

UE4421

Subject to change without notice

On safety

The UE4421 has been third party certified by TÜV Rheinland as compliant with the

f

ollowing:

European standards:

 EN ISO 13849@1

 EN 60204-1



EN 61000@6@2



EN 61000@6@4

 EN ISO 13850

International standards:

 IEC 61508 part 1-7

 IEC 61131@2

North American standards:

 NFPA 79:2002

 ANSI/RIA R15.06:1999

 ANSI B11.19:2003

The UE4421 has been certified as follows by Underwriter’s Laboratory (UL) as

compliant with the following:

 UL 508

 UL 1998

 NFPA 79

 UL 1604 (for UE4421-22EE900 and UE4421-22EE490 only)

 CSA 22.1 No. 14

The UE4421 has been certified by the Open DeviceNet Vendor Association as compliant

with the following:

 DeviceNet conformance test

 DeviceNet Safety conformance test

You must ensure that the UE4421 and related control equipment satisfy regulations

and standards requirments!

The UE4421 is provided with safety functions and mechanisms as stipulated in relevant

standards, but suitable designs must be used to allow these functions and mechanisms to

operate properly inside system constructions containing safety-related components. Build

systems that enable these functions and mechanisms to perform properly, based on a full

understanding of their operation. Typical related standards include:

 ISO 14119, Safety of Machinery —- Interlocking Devices Associated with Guards —

Principles of Design and Selection

When the UE4421 to build systems containing safety-related components for equipment

or facilities, the system must be designed with the full understanding of and conformance

to local, national and international standards, such as those listed below, and/or

standards in related industries. Typical related standards include:

 EN ISO 12100, Safety of Machinery — Basic Concepts and General Principles for Design

 IEC 61508, Safety Standard for Safety Instrumented Systems (Functional Safety of

Electrical/Electronic/Programmable Electronic Safety-related Systems)



WARNING

Operating Instructions Chapter 2

UE4421

Subject to change without notice

On safety

2.4.1 General requirements:

 Manufacturers and operators of the machine in which the UE4421 is installed and

integrated are responsible for obtaining and observing all applicable safety regulations

and rules.

 The notes in these operating instructions (e.g. on use, mounting, installation or integra-

tion into the existing machine control system) must be observed. The test procedures in

the operating instructions of all connected components must also be observed.

 The tests must be carried out by qualified safety personnel or specially qualified and

authorised personnel and must be recorded and documented to ensure that the tests

can be reproduced and retraced at any time by third parties.

 Use only appropriate components or devices that comply with relevant safety standards

corresponding to the required performance level according to EN ISO 13849@1 and

safety integrity level (SIL). Conformity to the requirements of the required performance

level and safety integrity level must be determined for the entire system. It is

recommended to consult with a certification body regarding assessment of conformity to

the required safety integrity level.

 The user must confirm compliance with the applicable standards for the entire system.

 Disconnect the module from the power supply before wiring. Devices connected to the

module may operate unexpectedly if wiring is performed while power is supplied.

 Do not get your fingers caught when handling/inserting the terminal blocks.

 The life of the module depends on switching conditions. Verify that operating conditions

are in accordance with the technical specifications of the UE4421.

 The testing of the components and overall system must be carried out by qualified safety

personnel as defined in chapter 2.1 “Qualified safety personnel” on page 11 that have

been authorized to perform this function. Testing must be recorded and documented to

ensure that the tests can be reconstructed and retraced at any time by third parties.

 The operating instructions must be made available to the personnel operating the

machine in which the UE4421 has been installed and integrated.

Do not use the UE4421-22EE330 model in atmospheres subject to flammable or

explosive gases.

Arcs or relay heating accompanying switching may cause a fire or explosion.



WARNING

Chapter 2 Operating Instructions

UE4421

Subject to change without notice

On safety

2.4.2 Compliance with EMC directive

SICK industrial safety devices are designed for local DC supply applications only!

Machines where safety devices are used must be installed and designed according to the

Lightning Protection Zone (LPZ) EN 62305@1. Required immunity levels can be achieved

through the use of external protective devices. The installed surge protective devices (SPD)

should meet the requirements of EN 61643@11.

T

he installation must prevent disturbances according to IEC 61000@4@16 (common mode

disturbances in the frequency range of 0 Hz to 150 kHz).

The UE4421 complies with the relevant EMC standards so that it can be easily integrated

into the overall machine control system. The user, however, must confirm overall system

conformance. Conditions vary based on configuration, wiring and other conditions of the

equipment or control panel that the UE4421 is installed in. The user is therefore responsi-

ble for performance of the final check to confirm that devices and the overall machine

conform to EMC standards.

2.4.3 Compliance with Low Voltage Directive

Always ensure that devices operating at voltages of 50 V AC to 1000 V AC and 75 V DC to

1500 V DC meet the necessary safety standards for the Controller (EN 61131@2).

2.4.4 Compliance with EC directives

DeviceNet products that comply with EC directives must be installed as follows:

 All UE4421 devices must be installed within control panels rated IP 54 minimum.

 Satisfy the power supply requirements outlined in section 5.2 “Power supply

requirements” on page 57 of this manual.

 The UE4421 also conforms to the Common Emission Standard (EN 50081@2). Radiated

emission characteristics (10-m regulations) may vary depending on the configuration of

the control panel used, other devices connected to the control panel, wiring and other

conditions. You are responsible for confirming that the overall machine or equipment

conforms to EC directives.

2.4.5 Reducing noise

The following examples show how to reduce noise.

 Reduce electrical noise from the communication cable by installing a ferrite core on the

communication cable within 10 cm (3.93 in) of the DeviceNet Master unit or the

DeviceNet Safety Originator unit. The following model is suitable:

– Ferrite Core (Data Line Filter) LF130B manufactured by Easy Magnet Company

 Wire the control panel with cables that are as short as possible and ground to 100  or

less.

 Keep DeviceNet communication cables as short as possible and ground to 100  or

less.



WARNING

Operating Instructions Chapter 2

UE4421

Subject to change without notice

On safety

2.5 Environmental protection

T

he UE4421 is constructed to minimize adverse effects on the environment as much as

possible. It uses only a minimum of power and natural resources. Always act in an environ-

mentally responsible manner.

2.5.1 Disposal

Unusable or irreparable devices should always be disposed as per the applicable national

regulations on waste disposal (e.g. European waste code 16 02 14). We would be pleased

to be of assistance on the disposal of this device. Contact your local SICK representative.

2.5.2 Separation of materials

Only qualified safety personnel are allowed to separate materials!

Caution is required when dismantling devices. There is a risk of injuries.

Before you send the devices for appropriate recycling, it is necessary to separate the

different materials in the UE4421. Separate the housing from the rest of the parts (in

particular the circuit board). Send the separated parts for recycling as appropriate (see

Tab. 3).

Components Recycling

Housing Circuit Boards, cable, connectors

Electrical connecting pieces

Electronic recycling

Cardboard, paper Paper/cardboard recyclingPackaging

Housing material Plastic recycling

2.6 Correct use

The UE4421 Safety Remote I/O for DeviceNet Safety must only be used within specified

operational limits (voltage, temperature etc., see chapter 11 „Technical specifications“ on

page 99 and section 2.3 “Applications of the device” on page 14). It must be used only by

qualified safety personnel and only on the machine where it has been installed and initia-

lized by qualified safety personnel in accordance with the operating instructions UE4421

Safety Remote I/O for DeviceNet Safety (8011213).

If the device is used for any other purposes or modified in any way — also during mounting

and installation — any warranty claim against SICK AG shall become void.

SICK shall not be responsible for conformity with any standards, codes or regulations that

apply to the combination of products for the application or use of the product. Take all

necessary steps to determine the suitability of the product for systems, machine and

equipment with which the UE4421 will be used. Know and observe all prohibitions of use

applicable to the UE4421.

You must ensure that the use of the UE4421 is suitable for the application!

Never use the UE4421 or any associated product(s) for an application involving serious

risk to life or property without ensuring that the system as a whole has been designed to

address the risks, and that the SICK products are properly rated and installed for the in-

tended use within the overall equipment or system.



WARNING

Tab.

3

:

Overview on

disposal

by components



WARNING

Chapter 2 Operating Instructions

UE4421

Subject to change without notice

On safety

The following are some examples of applications for which particular attention must be

g

iven. This is not intended to be an exhaustive list of all possible uses of the products.



Outdoor use, uses involving potential chemical contamination or electrical interference,

or conditions or uses not described in this document.

 Nuclear energy control systems, combustion systems, railroad systems, aviation

systems, medical equipment, amusement machines, vehicles, and installation subject to

separate industry or government regulations.

 Systems, machines and equipment that could present a risk to life or property.

You must operate the UE4421 in accordance with the performance specifications

described in this and other related device operating instructions!

Before using the UE4421 under conditions that are not described in these operating in-

structions or the UE4421 installation sheet or applying the UE4421 to nuclear control

systems, railroad systems, aviation systems, vehicles, combustion systems, medical equip-

ment, amusement machines, safety equipment and other systems, machines and equip-

ment that may have a serious influence on lives and property if used improperly, consult

your local SICK representative.

You must ensure that the related controller is suitable for your application!

It is extremely important that a programmable logic controller (PLC) and all PLC units be

used for the specified purpose under the specified conditions, especially in applications

that can directly or indirectly affect human life. You must ensure that the PLC system is

suitable for your application (e.g. with proper safety certifications and correct logic).

Before installing the UE4421, the user must ensure that

 The installation and integration is suitable for the application;

 The installation and integration addresses the hazards and risks associated with the

application;

 Units are properly rated and installed for the intended use within the overall equipment

or system;

and

 The devices that may be connected to this product comply with the product specifica-

tions and are in compliance with the applicable standards, rules and regulations of the

countries where the product is used.



WARNING

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SICK UE4421 IP20 Safety Remote I/O for DeviceNet Safety Operating instructions

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