operating instructions flexi loop

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

Flexi LoopSafe sensor cascade

Product described

Flexi Loop safe sensor cascade

Manufacturer

SICK AGErwin-Sick-Str. 179183 WaldkirchGermany

Legal notes

This document is protected by the law of copyright, whereby all rights established there‐in remain with the company SICK AG. Reproduction of this document or parts of thisdocument is only permissible within the limits of the legal determination of CopyrightLaw. Any alteration, abridgement, shortening or translation of this work is forbiddenwithout the express written approval of SICK AG.

The brands mentioned in this document are the property of the respective owners.

© SICK AG. All rights reserved.

Original document

This document is an original document from SICK AG.

2 O P E R A T I N G I N S T R U C T I O N S | Flexi Loop 8015836/YA87/2014-08-12 | SICKSubject to change without notice

Contents1 About these operating instructions......................................................7

1.1 Scope............................................................................................................... 71.2 Target groups and structure of these operating instructions.......................71.3 Additional information.....................................................................................81.4 Symbols and document conventions.............................................................8

2 Safety........................................................................................................92.1 Safety notes in these operating instructions.................................................92.2 General safety notes....................................................................................... 92.3 Correct use.......................................................................................................92.4 Requirements on the qualification of the personnel..................................10

3 Product description..............................................................................123.1 Structure and function..................................................................................12

3.1.1 System requirements...................................................................133.1.2 Safety by means of Flexi Loop.................................................... 133.1.3 Subdivision of the safe sensor cascade.....................................143.1.4 Supply of power............................................................................15

3.2 Principle of operation....................................................................................163.2.1 Operating principle on Flexi Soft.................................................163.2.2 Operating principle on Flexi Classic............................................183.2.3 Protection against tampering......................................................22

3.3 Device components...................................................................................... 223.3.1 Flexi Loop node............................................................................ 223.3.2 Flexi Loop accessories.................................................................243.3.3 Status indicators.......................................................................... 25

3.4 Examples of range of use.............................................................................27

4 Design.................................................................................................... 284.1 Total current.................................................................................................. 28

4.1.1 Permissible total current of a section.........................................284.1.2 Other limits................................................................................... 284.1.3 Connection facilities.................................................................... 294.1.4 Division into sections...................................................................31

4.2 Voltage drop via cables, Flexi Loop nodes and Flexi Loop accessories.... 324.2.1 Examples for the voltage drop.................................................... 324.2.2 Possible solutions........................................................................ 35

4.3 Energy balance in Flexi Soft Designer......................................................... 354.4 Supply of OSSD devices................................................................................374.5 Integration in the electrical control..............................................................37

4.5.1 Implementation of reset.............................................................. 374.5.2 Implementation of a safety locking device.................................40

5 Installation and mounting...................................................................445.1 Mounting in a cable channel........................................................................44

CONTENTS

8015836/YA87/2014-08-12 | SICKSubject to change without notice

O P E R A T I N G I N S T R U C T I O N S | Flexi Loop 3

5.2 Mounting with cable tie................................................................................ 445.3 Mounting with C-Fix bracket.........................................................................44

6 Electrical installation........................................................................... 466.1 Safety.............................................................................................................466.2 Connections...................................................................................................46

6.2.1 Connection to Flexi Soft...............................................................466.2.2 Connection to Flexi Classic..........................................................476.2.3 Connections of the Flexi Loop nodes..........................................486.2.4 Connection of the Flexi Loop nodes........................................... 496.2.5 Connections of the EMSS Flexi Loop node................................ 496.2.6 Connections of the OSSD Flexi Loop node.................................506.2.7 Connections of the PWRI power supply accessory.................... 526.2.8 Connections of the MSTR1 Flexi Loop accessory......................526.2.9 Connections of the MSTR2 Flexi Loop accessory......................536.2.10 Connections of the DIAG Flexi Loop accessory..........................54

7 Configuration........................................................................................ 557.1 Safety.............................................................................................................557.2 Configuration in the Flexi Soft Designer......................................................55

7.2.1 Starting the configuration............................................................557.2.2 Hardware configuration............................................................... 557.2.3 Flexi Loop configuration.............................................................. 587.2.4 Connecting sensors and switches.............................................. 647.2.5 Configuration in the logic editor..................................................667.2.6 The safe sensor cascade in operation....................................... 707.2.7 Connection to gateways.............................................................. 717.2.8 Report........................................................................................... 71

7.3 Configuration of protection against tampering with the MSTR Flexi Loopaccessory.......................................................................................................72

7.4 Configuration with the aid of a standard controller....................................737.4.1 Prerequisites................................................................................ 747.4.2 Configuration of the hardware.................................................... 747.4.3 Options for application design in the PLC.................................. 78

8 Commissioning.....................................................................................838.1 Display sequence during switching on........................................................ 838.2 Commissioning using the DIAG Flexi Loop accessory or the MSTR Flexi

Loop accessory..............................................................................................838.3 Test notes...................................................................................................... 83

8.3.1 Thorough checks before the initial commissioning...................838.3.2 Regular thorough check of the protective device by qualified

safety personnel...........................................................................848.3.3 Daily functional checks of the protective device....................... 84

9 Troubleshooting....................................................................................859.1 In the event of faults or errors..................................................................... 85

CONTENTS


9.2 SICK support..................................................................................................859.3 Indications of the LEDs.................................................................................85

9.3.1 MS LED......................................................................................... 859.3.2 LEDs of the EMSS Flexi Loop nodes...........................................879.3.3 LEDs of the OSSD Flexi Loop nodes........................................... 889.3.4 LEDs of the PWRI power supply accessory................................ 889.3.5 LEDs of the MSTR1 Flexi Loop accessory.................................. 899.3.6 LEDs of the MSTR2 Flexi Loop accessory.................................. 909.3.7 LEDs of the DIAG Flexi Loop accessory...................................... 92

9.4 Extended diagnostics....................................................................................939.4.1 Diagnostics using Flexi Soft........................................................ 939.4.2 Diagnostics using the MSTR2 Flexi Loop accessory..................939.4.3 Test tools for the configuration...................................................95

10 Technical data...................................................................................... 9710.1 Data sheet..................................................................................................... 97

10.1.1 Overall system..............................................................................9710.1.2 All Flexi Loop nodes and Flexi Loop accessories....................... 9710.1.3 EMSS Flexi Loop node (FLN-EMSS0000105 and FLN-

EMSS1100108)...........................................................................9910.1.4 OSSD Flexi Loop node (FLN-OSSD1000105 and FLN-

OSSD1100108).........................................................................10010.1.5 Terminator..................................................................................10110.1.6 PWRI power supply accessory.................................................. 10110.1.7 MSTR Flexi Loop accessory.......................................................102

10.2 Dimensional drawings................................................................................10310.2.1 Dimensional drawing Flexi Loop node..................................... 10310.2.2 Dimensional drawing PWRI power supply accessory.............. 10310.2.3 Dimensional drawing terminator.............................................. 10410.2.4 Dimensional drawing C-Fix bracket.......................................... 10410.2.5 Dimensional drawing MSTR Flexi Loop accessory.................. 10510.2.6 Dimensional drawing DIAG Flexi Loop accessory....................10610.2.7 Dimensional drawing YCON Flexi Loop accessory...................106

11 Ordering information.........................................................................10711.1 Scope of delivery.........................................................................................10711.2 Flexi Loop node...........................................................................................10711.3 Flexi Loop accessories............................................................................... 10711.4 Accessories................................................................................................. 108

11.4.1 Plug connectors......................................................................... 10811.4.2 Pre-assembled cables............................................................... 10811.4.3 Mounting accessories............................................................... 109

12 List of figures......................................................................................110

13 List of tables....................................................................................... 113

CONTENTS



14 Appendix............................................................................................. 11514.1 Conformity with EU directives.................................................................... 11514.2 Checklist for the manufacturer..................................................................117

CONTENTS


1 About these operating instructionsThese operating instructions contain the information that is required during the life cy‐cle of the safe sensor cascade.

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

1.1 Scope

These operating instructions only apply to the Flexi Loop safe sensor cascade with oneof the following type label entries in the Operating Instructions field: 8015834,8015834/XR04, 8015834/YA87.

These operating instructions form part of SICK part number 8015834 (all available lan‐guage versions of this document).

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

Document Title Part number

Operating instructions Flexi Soft Modular safety con‐troller Hardware

8012477

Operating instructions Flexi Soft Designer Software 8012479

Operating instructions Flexi Classic Modular safetycontroller

8011737

Additional information IO-Link FLA-MSTR00002 8017450

Supplementary operating in‐structions

Safety controllers network sol‐utions

8013368

Competence brochure Guide for Safe Machinery 8008007

Table 1: Available documents

1.2 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 thesafe sensor cascade: design, mounting, electrical installation, commissioning, opera‐tion and maintenance.

In many applications the target groups are assigned as follows to the manufacturer andorganization operating the machine in which the safe sensor cascade is integrated:

Area of responsibility Target group Specific chapter in these operating instruc‐tions 1)

Manufacturer Project engineers(planners, developers,designers)

"Design", Page 28"Technical data", Page 97"Accessories", Page 108

Fitters "Installation and mounting", Page 44"Commissioning", Page 83"Checklist for the manufacturer", Page 117

Electricians "Electrical installation", Page 46

ABOUT THESE OPERATING INSTRUCTIONS 1



Area of responsibility Target group Specific chapter in these operating instruc‐tions 1)

Operators Operator "Troubleshooting", 5

Maintenance person‐nel

"Troubleshooting", Page 85"Ordering information", Page 107

1) Chapters listed here are aimed at all target groups. All target groups must follow the safety notes andwarnings in the entire operating instructions!

In other applications the operating organization is at the same time the manufacturerof the machine — with the corresponding assignment of the target groups.

1.3 Additional information

www.sick.com

The following information is available on the Internet:

• versions 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)

1.4 Symbols and document conventions

In this operating instructions the following symbols are used:

Instructions for action

b Instructions for taking action are shown by an arrow. Read carefully and follow theinstructions for action.

LED symbols

These symbols indicate the status of an LED:

The LED is off. The LED is flashing. The LED is illuminated constantly.

1 ABOUT THESE OPERATING INSTRUCTIONS


2 SafetyThis chapter contains general safety information on the safe sensor cascade.

You will find additional safety information on specific usage situations for the safe sen‐sor cascade in the related chapters.

2.1 Safety notes in these operating instructions

Warnings

Warnings refer to specific or potential hazards. They are designed to help you to pre‐vent accidents. Read carefully and follow the warning notices!

The following types of warnings are used in these operating instructions:

CAUTIONMakes you aware of a hazardous situation that can result in minor to moderate injury ifit is not avoided.

WARNINGMakes you aware of a hazardous situation that can result in serious injury or fatality if itis not avoided.

DANGERMakes you aware of a hazardous situation that will result in serious injury or fatality if itis not avoided.

NOTEThe symbol “i” marks a note and makes you aware of possible damage and other im‐portant information.

2.2 General safety notes

DANGERRisk of ineffectiveness of the protective devicePersons or parts of the body to be protected are not recognized in case of non-observance.

b Pay particular attention to all warnings in these operating instructions.

2.3 Correct use

The Flexi Loop safe sensor cascade is an expansion for the Flexi Soft and Flexi Classicsafety controllers. It can be used …

• in accordance with IEC 61 508 up to SIL3• in accordance with EN 62 061 up to SILCL3• in accordance with EN ISO 13 849-1 up to category 4 and Performance Level e

The degree of safety actually attained depends on the external circuit, the design of thewiring, the parameter configuration, the selection of the safety sensors and their place‐ment on the machine.

SAFETY 2



Dual-channel, equivalent switching, electro-mechanical safety switches are connectedto the FLN-EMSS0000105 and FLN-EMSS1100108 Flexi Loop nodes, e.g. magneticsafety switches, emergency stop pushbuttons as well as safety switches with non-safeactuators on the FLN-EMSS1100108.

Safety sensors with monitored semiconductor output (OSSD) are connected to the FLN-OSSD1000105 and FLN-OSSD1100108 Flexi Loop nodes, e.g. safety light curtains ortransponder safety switches as well as safety sensors with non-safe actuators on theFLN-OSSD1100108.

The FLA-PWRI00001 power supply accessory is used to connect a power supply with+24 V, for the electrical isolation of individual Flexi Loop sections and for overcurrentshutdown.

The FLA-MSTR00001 and FLA-MSTR00002 Flexi Loop accessories connect a safe sen‐sor cascade to a Flexi Classic safety controller. The FLA-MSTR00002 Flexi Loop acces‐sory also has a non-safe input and a non-safe output. The non-safe output is used alter‐natively as an IO-Link interface.

The MSTR00001 Flexi Loop accessory, the FLA-MSTR00002 Flexi Loop accessory andthe DIAG00001 Flexi Loop accessory are used for system monitoring during commis‐sioning and in operation.

At any time the safe sensor cascade is only allowed to be used within the limits stipula‐ted and stated in the technical data and operating conditions.

The requirements stated in the technical data, e.g. power supplies, cables and ambientconditions, must be observed and met so that the safe sensor cascade provides it as‐sured function.

All warranty claims against SICK AG are forfeited in the case of any other use, or altera‐tions being made to the product.

Foreseeable misuse

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

• outdoors• under water• in explosive environments

2.4 Requirements on the qualification of the personnel

The safe sensor cascade is only allowed to be planned, mounted, connected, placed inoperation and maintained by qualified safety personnel.

Design

For design a person is considered qualified if the person has specialist knowledge andexperience in the selection and usage of protective devices on machines and is familiarwith the applicable technical regulations and national health and safety regulations.

Mechanical mounting and commissioning

For mechanical mounting and commissioning a persons is considered qualified if theperson has specialist knowledge and experience in the related area and is sufficientlyfamiliar with the usage of the protective device on the machine that the person canevaluate the operational safety status.

2 SAFETY


Electrical installation

For electrical installation and commissioning a persons is considered qualified if theperson has specialist knowledge and experience in the related area and is sufficientlyfamiliar with the usage of the protective device on the machine that the person canevaluate the operational safety status.

Configuration

For configuration a persons is considered qualified if the person has specialist knowl‐edge and experience in the related area and is sufficiently familiar with the usage ofthe protective device on the machine that the person can evaluate the operationalsafety status.

Operation and maintenance

For operation and maintenance a person is considered qualified if the person has spe‐cialist knowledge and experience in the related area and is sufficiently familiar with theusage of the protective device on the machine and the machine operator has been in‐structed on operation.

SAFETY 2



3 Product descriptionThis chapter provides information on the principle of operation of the safe sensor cas‐cade and provides application examples.

3.1 Structure and function

The Flexi Loop safe sensor cascade is an expansion for the Flexi Soft or Flexi Classicsystem. A safe sensor cascade comprises individual Flexi Loop nodes that are connec‐ted to the safety controller. The Flexi Loop nodes make it possible to collect informationfrom physically distributed safety sensors and safety switches.

Figure 1: Flexi Loop safe sensor cascade

1 Flexi Soft2 Flexi Classic with MSTR Flexi Loop accessory3 Safety sensors with monitored semiconductor output (OSSD)4 Electro-mechanical safety switches5 Flexi Loop

Dual-channel, equivalent switching, electro-mechanical safety switches (e.g. reedswitches) or safety sensors with monitored semiconductor output (OSSD) (e.g. safetylight 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 theswitches and sensors connected so as to provide a common shutdown criterion to thesafety controller.

Diagnostic functions make it possible to locate which safety sensor or safety switch hasshut down for which reason. Discrepancy or sequence errors are detected by means oftesting, 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.contamination) on the monitored system or to trigger functions (e.g. illumination oflamps and activation of door locking devices).

3 PRODUCT DESCRIPTION


Special features

• up to 32 Flexi Loop nodes per safe sensor cascade• up to 30 m between the Flexi Loop nodes and up to 960 m total length of the safe

sensor cascade• up to 10 m cable length between the Flexi Loop nodes and the devices connected• optional status indication via DIAG Flexi Loop accessory• optional power supply by means of PWRI power supply accessory• enclosure rating IP 65 and IP 67 according to EN 60 529

Connection to safety controllers• Flexi Soft safety controller• Flexi Classic safety controller• up to 8 safe sensor cascades on one Flexi Soft safety controller• up to 48 safe sensor cascades on one Flexi Classic safety controller

3.1.1 System requirements

Flexi Soft safety controller

The safe sensor cascade is connected to an expansion module. For this reason the fol‐lowing prerequisites apply for the Flexi Soft safety controller:

• one main module

° FX3-CPUx with firmware V3.xx or higher• one or more expansion modules

° FX3-XTIO with firmware V3.xx or higher

° FX3-XTDI with firmware V3.xx or higher

° FX3-XTDS with firmware V3.xx or higher

Flexi Classic safety controller

The safe sensor cascade is connected to the main module or an expansion module. Forthis reason the following prerequisites apply for the Flexi Classic safety controller:

• one main module

° UE410-MU version 13.45 or higher• optionally one or more expansion modules

° UE410-XU version 13.45 or higher

° UE410-8DI version 13.45 or higher

3.1.2 Safety by means of Flexi Loop

• Performance level up to PL e

° independent of the number of Flexi Loop nodes and therefore the number ofsensors/switches

° dependent of the performance level of the sensors/switches connected• 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 tested dual-channel equivalent safety switches are connected in series, errors cannotbe detected reliably. The following example shows such a situation.

PRODUCT DESCRIPTION 3



Figure 2: Error masking

If the switch S2 is opened correctly, e.g. the system is shut down. If the switch S3 isnow also opened, the error on S3 cannot be detected (error masking). If the switch S3is closed before S2, the error remains undetected.

3.1.3 Subdivision of the safe sensor cascade

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

• segmentA segment extends from the safety controller or the FL_OUT female connector onthe previous Flexi Loop node, including the connection cable, to the FL_OUT fe‐male connector on the Flexi Loop node (see "Connections of the Flexi Loop no‐des", Page 48), including the supply cables to the devices connected to the FlexiLoop node.

• sectionA section extends from a supply of power to the next accessory for the supply ofpower or to the terminator.

• stringA string covers the complete safe sensor cascade from the connection on thesafety controller to the terminator.



Figure 3: Subdivision of the safe sensor cascade

1 Segment2 Section3 String4 Safety controller

The Flexi Loop safe sensor cascade has a line topology. After the last Flexi Loop nodethe cascade must always be terminated using a FLT-TERM00001 terminator.

NOTEThe terminator must be connected directly to the Flexi Loop node, it is not allowed tobe connected via a cable.

Accessories for the supply of power and diagnostics can be connected between theFlexi Loop nodes (see "Supply of power", ).

The connection within Flexi Loop is made via commercially available 5-pin unshieldedcables with A-coded M12 male connectors and M12 female connectors. Cables up to30 m long can be laid between the individual Flexi Loop nodes.

Sensors or switches are connected using 5-pin or 8-pin unshielded cables with M12male connectors (see "Pre-assembled cables", Page 108). A series of SICK sensors orswitches can be connected using 1:1 cables (male/female connector).

• The cables for the sensors or switches must not exceed a length of 10 m.• During connection it is imperative you pay attention to the pin assignment on the

individual Flexi Loop nodes and the accessories (see "Connections", Page 46).

3.1.4 Supply of power

DANGERAlways supply the OSSD devices connected with power via the OSSD female connectoron the Flexi Loop node!Never supply an OSSD device connected with power directly from a separate powersupply. If several power supplies in a Flexi Loop section are connected in parallel, incase of a ground fault overcurrent and a cable fire may occur.Always use the power supply accessory to connect additional power supplies.

The power supply accessory is characterized by:

• power supply for the safe sensor cascade and connection of additional power sup‐plies (see "Connection facilities", Page 29)

• 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 powerconsumption of the sensors or actuators connected, the supply of power from a singlepower supply may be insufficient. In this case further power supplies can be connectedwith the aid of the power supply accessory.

Figure 4: Supply of power

1 Section 12 Section 23 Supply of power for section 2

3.2 Principle of operation

3.2.1 Operating principle on Flexi Soft

The data traffic in the safe sensor cascade is integrated into the data traffic on theFlexi Soft safety controller. The Flexi Soft I/O modules form the interface.

Safe cut-off path

The safety information on the switches and sensors connected is combined and trans‐mitted quickly and safely to the Flexi Soft.

This status is represented in the Flexi Soft Designer logic editor by a single safe inputbit (yellow). Downstream cut-off paths for the machines and systems to be monitoredare only allowed to be realized with the aid of this bit.



Figure 5: The Flexi Loop safe input bit in the Flexi Soft Designer logic editor

1 Safe bit

Diagnostics information on the safe sensor cascade

In addition non-safe diagnostics information on the states in the safe sensor cascade issent to the Flexi Soft safety controller.

Figure 6: Diagnostics information in the Flexi Soft Designer logic editor

1 Non-safe diagnostics information

The information is represented using the following bits (blue) in the logic:

• Sensor testing: indicates whether the test on the switches and sensors connectedis error-free.

• Loop Online: indicates whether the communication in the safe sensor cascade isactive.

DANGERNever use the diagnostics information for safety-related applications!Only the single safety-related bit for the cut-off path is allowed to be used for safety-related applications.

Diagnostics information on the Flexi Loop nodes

The following non-safe diagnostics information is also made available by each FlexiLoop node.




Figure 7: Diagnostics information on the individual Flexi Loop nodes in the Flexi Soft Designerlogic editor


• Tag name of the element connected: The bit indicates the status of the sensors orswitches connected. It is used to evaluate which Flexi Loop node has shut down.

• Dynamic testing: The bit indicates discrepancy or sequence errors on the sensorsor switches connected.

• Statictesting: The bit indicates electrical faults such as a cross-circuit or short-cir‐cuit on the sensors or switches connected.

• Online: The bit indicates whether the Flexi Loop node is physically present.


The safety information and the non-safe information can be further processed in theFlexi Soft safety controller logic or forwarded, e.g., via a gateway to a PLC (see "Configu‐ration in the logic editor", Page 66).

3.2.2 Operating principle on Flexi Classic

MSTR1 Flexi Loop accessory

The safe sensor cascade is connected to the Flexi Classic safety controller with theMSTR1 Flexi Loop accessory. The safe sensor cascade acts through the MSTR1 FlexiLoop accessory like a dual-channel, equivalent opening safety switch. The safety infor‐mation on the switches and sensors connected is combined and transmitted quicklyand safely to the inputs of the Flexi Classic safety controller.

In the example Flexi Loop is connected to the input control circuit A. Program 1 is selec‐ted.



Figure 8: MSTR1 Flexi Loop accessor on the Flexi Classic safety controller

1 Program in Flexi Classic2 MSTR1 Flexi Loop accessory3 Safety sensors with monitored semiconductor output (OSSD)4 Electro-mechanical safety switches

If a safety sensor or a safety switch on a Flexi Loop node changes to the Off status,then the MSTR1 Flexi Loop accessory shuts down safely.

In the example program 1 shuts down the OSSDs Q1 and Q2 on the safety controller.You will find detailed information on the programs of the safety controller in the “FlexiClassic Modular safety controller” operating instructions (SICK part No. 8011737).

IO functions of the MSTR2 Flexi Loop accessory

In addition to the functions of the MSTR1 Flexi Loop accessory, the MSTR2 Flexi Loopaccessory provides non-safe IO functions.




Figure 9: IO functions of the MSTR2 Flexi Loop accessory

1 Program in Flexi Classic2 IO functions3 Emergency stop pushbutton with reset button and Reset required lamp

In the configuration from the factory the AUX_IN of the MSTR2 Flexi Loop accessoryswitches all AUX_OUT of the Flexi Loop nodes. The AUX_IN of the Flexi Loop nodesswitch the AUX_OUT of the MSTR2 Flexi Loop accessory.

The non-safe input of the MSTR2 Flexi-Loop accessory switches the non-safe outputs ofthe Flexi Loop nodes. You can use this function, for example, to control lamps or to im‐plement a locking device.

The non-safe output of the MSTR2 Flexi Loop accessory collects the states of the non-safe inputs of the Flexi Loop nodes. The states are linked together using an OR opera‐tor. You can use this function, for example, for a common reset signal.

The factory settings for the MSTR2 Flexi Loop accessory can be configured via IO-Link.

IO-Link functions of the MSTR2 Flexi Loop accessory

If the IO-Link is connected, for example, to a PLC, then the MSTR2 Flexi Loop accessoryand the PLC exchange data via this interface.



Figure 10: IO-Link functions of the MSTR2 Flexi Loop accessory

1 Program in Flexi Classic2 LED display3 Diagnostics information on the PLC

The parameter list with all data that can be read and written is available as a separatedocument (SICK part number 8017450).

Process data

The PLC and the MSTR2 Flexi Loop accessory communicate cyclically in a data framefor process data:

• Flexi Loop transmits 4 bytes of input data to the PLC. These bytes contain the sta‐tus of the non-safe inputs AUX_IN of the Flexi Loop nodes.

• Flexi Loop receives 4 byte of output data from the PLC. These bytes contain thecommands for the non-safe outputs AUX_OUT of the Flexi Loop nodes.

Service data

The PLC communicates acyclically with the MSTR2 Flexi Loop accessory for service da‐ta. The service data offer the following options:

• execution of commands• configuration of the parameters for the Flexi-Loop string and the individual Flexi

Loop nodes• reading the parameter values and statuses of the Flexi Loop string and the Flexi

Loop nodes

Events

While in operation you can follow occurrences in the system via so-called events. Thefollowing events are available:

• state of the cut-off path• synchronization safety controller• Flexi Loop not in operation• cable connection• dynamic error




• static error• critical error• configuration difference

3.2.3 Protection against tampering

DANGERHazard due to disabling the protection against tampering!If you disable the protection against tampering, then a Flexi Loop node can be removedor jumpered. In this situation the safe sensor cascade switches on despite the change.Only disable the tamper protection if imperative for the implementation of the applica‐tion. In this case prevent possible tampering by other measures (e.g. protected cablelaying).

Flexi Soft safety controller

The Flexi Soft safety controller saves the node type and the number of nodes in a safesensor cascade.

In this way it is ensured Flexi Loop nodes are not replaced with other types, Flexi Loopnodes removed or added, or Flexi Loop nodes jumpered. In special cases this protec‐tion against tampering can be disabled (see "Disabling tamper protection", Page 63).

MSTR Flexi Loop accessory

The MSTR Flexi Loop accessory saves the number of nodes in a safe sensor cascade.

In this way it is ensured Flexi Loop nodes are not removed or added, or Flexi Loop no‐des jumpered.

Using IO-Link you can configure, if required, that the MSTR2 Flexi Loop accessory alsosaves the node type. In this way the MSTR2 Flexi Loop accessory prevents the replace‐ment of Flexi Loop nodes with other types.

3.3 Device components

3.3.1 Flexi Loop node

FLN-EMSS0000105 — 5-pin

Figure 11: FLN-EMSS0000105 Flexi Loop node — 5-pin

The 5-pin EMSS Flexi Loop node is suitable for connecting dual-channel, equivalentswitching electro-mechanical safety switches, e.g. magnetic safety switches or emer‐gency stop pushbuttons. The safety switches connected are tested for cross-circuit andshort-circuit as well as discrepancy and sequence errors.



FLN-EMSS1100108 — 8-pin

Figure 12: FLN-EMSS1100108 Flexi Loop node — 8-pin

The 8-pin EMSS Flexi Loop node also has a non-safe input and a non-safe output. Con‐trol switches (e.g. pushbuttons) or actuators (e.g. lamps or locking devices) can be con‐nected to these inputs and outputs.

FLN-OSSD1000105 — 5-pin

Figure 13: FLN-OSSD1000105 Flexi Loop node — 5-pin

The 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 safetyswitches). In addition it has a non-safe input. Signal outputs from the sensors (e.g. forsignaling contamination) can be connected to this input. The safety sensors connectedare tested for discrepancy and sequence errors.

FLN-OSSD1100108 — 8-pin

Figure 14: FLN-OSSD1100108 Flexi Loop node — 8-pin

The 8-pin OSSD Flexi Loop node has a non-safe input and also a non-safe output. Sig‐nal outputs from sensors (e.g. for signaling contamination) or LEDs (e.g. for Reset re‐quired) can be connected to this input and output.




3.3.2 Flexi Loop accessories

FLA-PWRI00001

Figure 15: FLA-PWRI00001 power supply accessory

The 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.

FLT-TERM00001

Figure 16: FLT-TERM00001 terminator

The terminator is used to terminate the safe sensor cascade on the last Flexi Loopnode. The terminator must be connected directly to the connection FL_OUT on the lastFlexi Loop node (see "Connections of the Flexi Loop nodes", Page 48).

FLA-MSTR00001

Figure 17: FLA-MSTR00001 Flexi Loop accessory

The MSTR1 Flexi Loop accessory connects a safe sensor cascade to a Flexi Classicsafety controller. It requires two test signal outputs (X) and two safe inputs (I) on a FlexiClassic module. In addition the MSTR1 Flexi Loop accessory is used to monitor the sys‐tem during commissioning and in operation.



FLA-MSTR00002

Figure 18: FLA-MSTR00002 Flexi Loop accessory

The MSTR2 Flexi Loop accessory connects a safe sensor cascade to a Flexi Classicsafety controller. It requires two test signal outputs (X) and two safe inputs (I) on a FlexiClassic module. In addition the MSTR2 Flexi Loop accessory is used to monitor the sys‐tem during commissioning and in operation.

The MSTR2 Flexi Loop accessory also has a non-safe input and a non-safe output. Thenon-safe output is used alternatively as an IO-Link interface.

Actuators on the Flexi Loop node are operated via the non-safe input.

Switching signals are transmitted from the Flexi Loop nodes to a standard controller viathe non-safe output.

The MSTR2 Flexi Loop accessory exchanges process data and service data with a PLCvia the IO-Link interface.

FLA-DIAG00001

Figure 19: FLA-DIAG00001 Flexi Loop accessory

The DIAG Flexi Loop accessory is used to monitor the system during commissioning andin operation.

3.3.3 Status indicators

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

For a detailed overview of the error messages see "Indications of the LEDs", Page 85.




MS LED

Figure 20: MS LED

The Flexi Loop nodes and the Flexi Loop accessories have an LED that indicates thecommunication status and the Flexi Loop node status. The designation MS = ModuleStatus is based on the Flexi Soft safety controller.

EMSS LEDs, AUX_IN-LED, AUX_OUT-LED

Figure 21: LEDs of the EMSS Flexi Loop nodes

The EMSS LEDs indicate the status of switching contact 1 or 2 on the safety switchconnected.

The AUX_IN and AUX_OUT LEDs indicate the status of the non-safe input and the non-safe output respectively.

OSSD LEDs, AUX_IN-LED, AUX_OUT-LED

Figure 22: LEDs of the OSSD Flexi Loop nodes

The OSSD LEDs indicate the status of the OSSDs connected.



The AUX_IN and AUX_OUT LEDs indicate the status of the non-safe input and the non-safe output respectively.

PWR LEDs, Overload LED

Figure 23: LEDs of the PWRI power supply accessory

The PWR LEDs indicate the status of the input voltage on the right and left side of thePWRI power supply accessory.

The Overload LED indicates an output overload.

Node LEDs of the MSTR and DIAG Flexi Loop accessory

Figure 24: Node LEDs 1 to 32

The node LEDs 1 to 32 indicate the status of the Flexi Loop nodes connected.

3.4 Examples of range of use

Figure 25: Application example




4 DesignThe safe sensor cascade makes it possible to cover a large distance. On the other handa large number of switches, sensors, actuators and LEDs can be connected.

Due to the cable lengths and the power consumption, it is imperative you pay attentionto two things:

• The total current in the safe sensor cascade must not exceed 4 A at any point! 1)

• The voltage VDC must be present at each input on a Flexi Loop node in the rangefrom 16.8 … 30 V DC!

4.1 Total current

DANGERWarning: Limit the total current in a safe sensor cascade to 4 A!The safe sensor cascade permits a maximum total current of 4 A. Use a suitable pro‐tection device or current limiters so that the input current does not exceed 4 A.

The magnitude of the total current is dependent on the following factors:

• number of nodes• current consumption of the sensors and actuators connected

4.1.1 Permissible total current of a section

The permissible total current within a section depends on the ambient temperature(see "Division into sections", Page 31).

Ambient temperature Permissible total current 1)

40 °C 4.0 A

55 °C 3.19 A

Table 2: Permissible total current within a section

1) At UL/CSA applications only 3.2 A.

4.1.2 Other limits

It is possible to connect sensors with a maximum current consumption of 3.9 A to theOSSD device connection on the FLN-OSSD1000105 Flexi Loop node.

A maximum current of 2 A is allowed to flow through the 8-pin M12 female connectorson the Flexi Loop nodes (AUX_OUT + VDC). 2)

It is possible to connect loads with a maximum current consumption of 0.5 A in relationto ground to the non-safe outputs (AUX_OUT) on the FLN-OSSD1100108 and FLN-EMSS1100108 Flexi Loop nodes.

A maximum total current of 2 A is allowed to flow through the VDC pins (1 and 2) of the8-pin M12 female connector on the MSTR Flexi Loop accessory. Use both power supplypins (1 and 2) and both GND pins (5 and 6) on the MSTR Flexi Loop accessory for thepower supply.

1) At an ambient temperature of 40 °C.2) Make sure the current drawn via VDC and AUX_OUT flows back via the GND pin.

4 DESIGN


4.1.3 Connection facilities

DANGERNever cut into the connection cables between the Flexi Loop nodes!If the cables for the safe sensor cascade are cut into, e.g. to supply the cascade direct‐ly using a separate power supply, then several power supplies will be connected in par‐allel. This situation can result in overcurrent and a cable fire in case of a ground fault.

To the power source for the Flexi Soft safety controller

Figure 26: Direct connection to the power source for the Flexi Soft safety controller

1 Power flow2 Data flow

NOTELimit the current that flows in the safe sensor cascade to a maximum of 4 A!If you connect a safe sensor cascade directly to the power source for the safety control‐ler, then you must limit the current to 4 A by means of suitable measures.The power supply must then either shut down automatically at currents above 4 A, oryou must insert a 4 A slow-blow fuse in-line.

DESIGN 4



Via PWRI power supply accessory (recommended)

Figure 27: Connection via PWRI power supply accessory

1 Power flow2 Data flow3 Power supply4 Max. 4 A

If you supply a safe sensor cascade via the PWRI power supply accessory, this accesso‐ry will monitor the current and shut down in case of overcurrent. In addition the operat‐ing voltage in each section is monitored.

To the power source for the Flexi Classic safety controller

Figure 28: Direct connection to the power source for the Flexi Classic safety controller

1 Power flow

4 DESIGN


NOTELimit the current that flows in the safe sensor cascade to a maximum of 4 A!If you connect a safe sensor cascade directly to the power source for the safety control‐ler, then you must limit the current to 4 A by means of suitable measures.The power supply must then either shut down automatically at currents above 4 A, oryou must insert a 4 A slow-blow fuse in-line.

Via PWRI power supply accessory (recommended)

Figure 29: Connection via PWRI power supply accessory

1 Flexi Loop power flow2 MSTR power supply3 Power supply

If you supply a safe sensor cascade via the PWRI power supply accessory, this accesso‐ry will monitor the current and shut down in case of overcurrent. In addition the operat‐ing voltage in each section is monitored.

4.1.4 Division into sections

If higher currents are required, the safe sensor cascade can be divided into separatesections (see "Subdivision of the safe sensor cascade", Page 14).

DESIGN 4



Figure 30: Division into sections

1 Power flow2 Data flow3 Power supplies4 Section 1 max. 4 A5 Section 2 max. 4 A

The PWRI power supply accessory monitors the current in the individual Flexi Loop sec‐tions and shuts down in case of overcurrent. In addition the operating voltage in eachsection is monitored.

The power supply for the next Flexi Loop node and the sensors connected to the nodeis electrically isolated from the previous Flexi Loop node by the power supply accessory.

4.2 Voltage drop via cables, Flexi Loop nodes and Flexi Loop accessories

The voltage VDC must be present at each input on a Flexi Loop node and a Flexi Loopaccessory in the range from 16.8 … 30 V DC!

The voltage drop over the safe sensor cascade is dependent on the following factors:

• number of Flexi Loop nodes (internal power consumption)• current consumption of the sensors and actuators connected• length of the cables• cross-section of the wire• ambient temperature

4.2.1 Examples for the voltage drop

In the following examples an input voltage of 24 V DC is assumed.

Number of nodes

The first examples show how the voltage drop behaves in relation to the number ofFlexi Loop nodes. The examples assume that there are no devices connected to theFlexi Loop nodes, instead that power only flows due to internal consumption of the no‐des (e.g. on exclusive operation with Flexi Loop nodes of type FLN-EMSS0000105).

The following table shows that although the voltage reduces at the individual Flexi Loopnodes due to the voltage drop, it is still high enough at the 10th Flexi Loop node.

4 DESIGN


Segment Wire cross-section[mm²]

Cable length[m]

Voltage VDC[V]

Current consumption ofconnected devices [A]

1 0.34 15.00 23.10 0.00

2 0.34 15.00 22.29 0.00

…

9 0.34 15.00 18.98 0.00

10 0.34 15.00 18.85 0.00

Table 3: Example voltage drop on 10 Flexi Loop nodes

However, if 15 Flexi Loop nodes are used in the same conditions, the input voltagedrops below the permissible value from the 7th Flexi Loop node.


Cable length[m]

Voltage VDC[V]


1 0.34 15.00 22.68 0.00

2 0.34 15.00 21.44 0.00

…

6 0.34 15.00 17.33 0.00

7 0.34 15.00 16.52 0.00

…

15 0.34 15.00 13.08 0.00

Table 4: Example voltage drop on 15 Flexi Loop nodes

Solution example with PWRI power supply accessory

By using a PWRI power supply accessory after the 11th Flexi Loop node, the input volt‐age is adequate at all Flexi Loop nodes.

Segment Wire cross-sec‐tion [mm²]

Cable length[m]

Voltage VDC[V]

Current consumption of con‐nected devices [A]

1 0.34 15.00 23.02 0.00

2 0.34 15.00 22.12 0.00

…

11 0.34 15.00 17.86 0.00

FLA-PWRI

1 0.34 15.00 23.02 0.00

…

4 0.34 15.00 20.58 0.00

Table 5: Example voltage drop on 15 Flexi Loop nodes with PWRI

Solution example with increased wire cross-section

With the aid of a wire cross-section of 0.75 mm² it is ensured that there is an adequateinput voltage even at the 15th Flexi Loop node.


Cable length[m]

Voltage VDC[V]


1 0.75 15.00 23.38 0.00

2 0.75 15.00 22.80 0.00

…

Table 6: Example voltage drop on 15 Flexi Loop nodes with wire cross-section 0.75 mm²

DESIGN 4




Cable length[m]

Voltage VDC[V]


14 0.75 15.00 18.96 0.00

15 0.75 15.00 18.89 0.00


Devices with current consumption

If devices with a current consumption are connected to the Flexi Loop node (in the ex‐ample with 0.5 A and with 1.5 A), the input voltage drops below the permissible valuefrom the 2nd Flexi Loop node.


Cable length[m]

Voltage VDC[V]


1 0.34 15.00 20.00 0.50

2 0.34 15.00 16.86 1.50

3 0.34 15.00 16.14 0.00

…

10 0.34 15.00 13.42 0.00

Table 7: Example voltage drop due to current consumption of connected devices

Solution example with PWRI power supply accessory

By using a PWRI power supply accessory after the 5th Flexi Loop node, the input voltageis adequate at all 10 Flexi Loop nodes.

Segment Wire cross-sec‐tion [mm²]

Cable length[m]

Voltage VDC[V]

Current consumption of con‐nected devices [A]

1 0.34 15.00 23.02 0.50

2 0.34 15.00 22.12 1.50

…

5 0.34 15.00 17.07 0.00

FLA-PWRI

1 0.34 15.00 23.97 0.00

…

5 0.34 15.00 22.93 0.00

Table 8: Example voltage drop on 10 Flexi Loop nodes with PWRI

Solution example with increased wire cross-section

With the aid of a wire cross-section of 0.75 mm² it is ensured that there is an adequateinput voltage even at the 10th Flexi Loop node.


Cable length[m]

VoltageVDC[V]


1 0.75 15.00 23.84 0.50

2 0.75 15.00 22.37 1.50

…

9 0.75 15.00 20.82 0.00

10 0.75 15.00 20.76 0.00


4 DESIGN


4.2.2 Possible solutions

If the voltage drop over a Flexi Loop segment or Flexi Loop section is too high, i.e. thereis an excessively low input voltage at a node, then …

• increase the wire cross-section.• if possible shorten the cables.• install the PWRI power supply accessory.

If you require additional information and support during planning, please contact yourlocal SICK subsidiary.

4.3 Energy balance in Flexi Soft Designer

Flexi Soft Designer has a feature for calculating the voltage drop offline and measuringit online.

Configuring Flexi Loop modules

Figure 31: Configuring Flexi Loop modules

1 Select module cable2 Define customer-specific cable

For the PWRI power supply accessory define the module cable used and the power sup‐ply cable used:

b Select or define module cable.b Select or define power supply cable.

For the EMSS or OSSD Flexi Loop nodes define the module cable used and the sensor/actuator cable used:

b Select or define module cable.b Select or define power supply cable.

DESIGN 4



You can select stipulated cables or define customer-specific cables:

b Select cable.b Alternatively define customer-specific cable.b Enter cable length in m.b Enter core cross-section in mm².

Figure 32: Switching to design

1 Switching to design

b To switch to design click the button 1.✓ Flexi Soft Designer displays the energy balance.

Calculating voltage drop and power consumption

Figure 33: Calculating voltage drop and power consumption

1 Maximum ambient temperature and input voltage2 Open detailed view of the Flexi Loop module3 Data on the module cable4 Data of the power supply cable and sensor/actuator cable5 Voltage range of the sensor or actuator6 Calculate button

4 DESIGN


b Select ambient temperature and enter input voltage.b Open detailed view of the modules.b If necessary, modify data on the module cables and sensor/actuator cables.b Enter permitted input voltage range for the sensor or actuator.b Enter current consumption of the sensor or actuator.b Click on CALCULATE.✓ Flexi Soft Designer calculates the voltage drop and the power consumption.

Figure 34: Calculated energy balance

1 Total input current and length of the Flexi Loop string2 Module current3 Module voltage4 Current consumption sensor and actuator5 Voltage on the sensor6 Element with critical value

The sum of all currents that flow directly or via the power supply accessory into theFlexi Loop string is displayed by Flexi Soft Designer in the input current field.

4.4 Supply of OSSD devices

DANGERAlways supply the OSSD devices connected with power via the OSSD female connectoron the Flexi Loop node!Never supply an OSSD device connected with power directly from a separate powersupply. If several power supplies in a Flexi Loop section are connected in parallel, incase of a ground fault overcurrent and a cable fire may occur.Always use the power supply accessory to connect additional power supplies.

4.5 Integration in the electrical control

4.5.1 Implementation of reset

4.5.1.1 Reset with the Flexi Soft safety controller

To implement reset and restart, pay attention to the following notes:

DESIGN 4



b In Flexi Soft Designer use a RESET function block to reset the protective devices.b Connect, e.g., one or more reset buttons to the non-safe inputs (AUX_IN) on the

FLN-EMSS1100108 or FLN-OSSD1100108 Flexi Loop nodes.b If you use further non-safe inputs (AUX_IN) on the Flexi Loop nodes for purposes

other than reset, make sure these do not fulfill any reset condition. 3)

b Use a RESTART function block downstream to restart the machine.b Connect the control switch for restart to a separate input that must not be on the

same safe sensor cascade.Signal propagation times for Flexi Loop communication always result in longer sig‐nal times (pulse durations) in the Flexi Soft logic.Note that due to the signal propagation times, a Flexi Loop input signal may belonger in the Flexi Soft logic (longer pulse duration) than the original signal. Thesame applies for the Flexi Loop output signals on AUX_OUT.

b Set the minimum reset duration for the function blocks RESET and RESTART to100 ms.

Figure 35: Implementation of reset and restart as well as the flashing mode in the logic editor

1 Reset and restart2 Flashing mode

Flashing on Reset required

Due to the signal propagation times you cannot use the RESET REQUIRED output of theRESET function block to make the lamps on the non-safe outputs of the Flexi Loop nodesflash. The Flexi Loop nodes provide the output options FLASHING MODE 1 and FLASHING MODE2 for this purpose.

In the previous example the FLASHING MODE 1 on all three Flexi Loop nodes is switched onby input bit STATIC 1 and the ROUTING function block.

The actual condition RESET REQUIRED is realized by the AND operation on the ENABLE andthe ENABLE CONDITION.

3) Reset is realized by pressing and releasing the reset button. This action generates an active high pulse last‐ing at least 100 ms and maximum 30 s.

4 DESIGN


4.5.1.2 Reset with the Flexi Classic safety controller

Prerequisites

b If you connect the reset pushbutton to a safe sensor cascade and want to inte‐grate this button into a Flexi Classic safety controller, then use the MSTR2 FlexiLoop accessory.

b Use its standard IO functions with the factory default settings without data com‐munication via IO-Link (see "Operating principle on Flexi Classic", Page 18).

b Connect one or more reset buttons to the non-safe inputs on the FLN-EMSS1100108 or FLN-OSSD1100108 Flexi Loop nodes. All non-safe inputs(AUX_IN) act on the non-safe output (AUX_OUT) of the MSTR2 Flexi Loop accesso‐ry.

b Integrate this signal into the reset function on the Flexi Classic safety controller.b If you use further non-safe inputs (AUX_IN) on the Flexi Loop nodes for purposes

other than reset, make sure these do not fulfill any reset condition. Mask thesenodes with the aid of IO-Link, for example, by switching off the parameter AUX_IN TOMSTR AUX_OUT (see "Configuration of the Flexi Loop nodes", Page 75).

Figure 36: Reset with the Flexi Classic safety controller

1 Safe cut-off path2 MSTR2 Flexi Loop accessory3 Flexi Classic safety controller4 Application (e.g. in a PLC)5 Reset signal6 Reset with Flexi Classic7 Operation of the lamps

Signal propagation times via the Flexi-Loop communication always result in longerpulse durations during signal transmission. For this reason an input signal from thenon-safe input (AUX_IN) on a Flexi Loop node has a longer pulse duration on the output(AUX_OUT) of the MSTR2 Flexi Loop accessory.

NOTETo restart the machine use an additional control switch downstream and outside thesystem configuration comprising Flexi Loop and Flexi Classic safety controller.

DESIGN 4



4.5.2 Implementation of a safety locking device

4.5.2.1 Connection

The safety-related switch contacts on a spring-locked safety locking device are connec‐ted to EMSS connections on the Flexi Loop node. The position monitoring for the pro‐tective device and for the interlocking must use the same switching element. If the out‐put monitoring in the Flexi Loop node is deactivated (see "Output options", Page 69and see "Configuration of the Flexi Loop nodes", Page 75), the actuator signal for thelocking device can be connected to the input AUX_IN. The interlocking for the safetylocking device is connected to the output AUX_OUT.

Figure 37: Connection of a safety locking device to the EMSS node

1 EMSS node2 Connecting cable M12, 8-pin, male/female connector3 Safety locking device i10 Lock, i10-M0454

Pin assignmentEMSS 8-pin (female connector)

Signal Pin assignmenti10 Lock, i10-M0454 (male

connector)

1 VDC 1

2 AUX_IN 2

3 EMSS1_A 3

4 EMSS1_B 4

5 AUX_OUT 5

6 GND 6

7 EMSS2_A 7

8 EMSS2_B 8

Table 10: Pin assignment safety locking device to EMSS node

4.5.2.2 Implementation in the Flexi Soft safety controller

In Flexi Soft Designer the elements SWITCH WITH DUAL-CHANNEL LOCKING DEVICE and SINGLE-CHANNEL N/O CONTACT are connected to the Flexi Loop node.

4 DESIGN


Figure 38: Elements on the EMSS node

1 In = safety switch2 Out = locking device3 In = single-channel N/O contact

In the logic editor the input bits SAFE CASCADE (for the safety contacts) and SINGLE-CHANNELN/O CONTACT (for the actuator) must be processed in the application. The diagnostics bitSAFETY SWITCH can also be processed.

Figure 39: Locking device in the logic editor

The output bit INTERLOCK WITH LOCKING must be controlled by the application to lock thelocking device.

The output monitoring must be deactivated with the aid of an input bit STATIC 1 (see"Output options", Page 69).

4.5.2.3 Implementation with the Flexi Classic safety controller

Prerequisites

If you connect locking devices to the safe sensor cascade and want to integrate theseinto a Flexi Classic safety controller, then use the MSTR2 Flexi Loop accessory. Use itsstandard IO functions with the factory default settings without data communication viaIO-Link (see "Operating principle on Flexi Classic", Page 18).

DESIGN 4



Figure 40: Locking device with the Flexi Classic safety controller

1 Safe cut-off path (position monitoring for the protective device and the interlocking)2 MSTR2 Flexi Loop accessory3 Flexi Classic safety controller4 Locking device application (e.g. in a PLC)5 Signal for interlocking6 Connection to GND7 Optional: actuator signal

Connect the signal for interlocking your application to the non-safe input AUX_IN on theMSTR2 Flexi Loop accessory. The safe sensor cascade feeds the signal to the non-safeoutputs of the Flexi Loop nodes. There the signal activates the interlocking connectedfor the locking device.

In the configuration from the factory the non-safe input AUX_IN of the Flexi Loop acces‐sory MSTR2 does not act on all non-safe outputs AUX_OUT of the Flexi Loop nodes. Ifyou use the non-safe outputs AUX_OUT of individual Flexi Loop nodes for purposes oth‐er than the connection of a locking device, then switch off the parameter AUX_OUT FROMMSTR AUX_IN for this Flexi Loop node via IO-Link (see "Configuration of the Flexi Loop no‐des", Page 75).

NOTEOn all Flexi Loop nodes FLN-EMSS1100108 with locking device connected, leave thenon-safe input AUX_IN unused or make a connection to GND 6. Otherwise the outputmonitoring activated in the factory configuration on all Flexi Loop nodes will intervenein the switching behavior of the non-safe outputs AUX_OUT.

Actuator signals

You can forward the locking device actuator signals to your application.

Deactivate the output monitoring for all Flexi Loop nodes with a locking device connec‐ted with the aid of IO-Link (see "Configuration of the Flexi Loop nodes", Page 75).

Use the parameter MSTR AUX_OUT LOGIC to select the logical operator for the signals on thenon-safe output of the MSTR2 Flexi Loop accessory with the aid of IO-Link (see "Config‐uration of the Flexi Loop string", Page 77).

4 DESIGN


Connect actuator signal to the non-safe input AUX_IN of the Flexi Loop nodes. The safesensor cascade forwards the signal to the non-safe output on the MSTR2 Flexi-Loop ac‐cessory. Connect this signal with your application 7.

DESIGN 4



5 Installation and mountingThis chapter describes the preparation and completion of the mounting of the safe sen‐sor cascade.

5.1 Mounting in a cable channel

Due to its size, the Flexi Loop node can be mounted in a cable channel with a width³40 mm.

Figure 41: Mounting in a cable channel

1 Cable channel

5.2 Mounting with cable tie

Figure 42: Mounting with cable tie

1 Slot for cable tie

The Flexi Loop nodes have a slot on the top and bottom 1. These slots are used formounting using a cable tie.

5.3 Mounting with C-Fix bracket

The Flexi Loop nodes can be mounted with the aid of a so-called C-Fix bracket.

5 INSTALLATION AND MOUNTING


Figure 43: C-Fix bracket

1 Washer2 Fixing screws M5 (not included)

How to mount the Flexi Loop node with a C-Fix bracket:

Figure 44: Mounting the Flexi Loop node with C-Fix bracket

b Mount the C-Fix bracket (1) on a flat surface.b Fasten the M5 screws to a torque approx. 3 Nm. Higher torques can damage the

bracket, lower torques provide inadequate protection against displacement.b Fit the Flexi Loop node in the C-Fix brackets and press it down gently (2).b Rotate the Flexi Loop node to the rear (3) until the C-Fix bracket engages in the

slot on the housing of the Flexi Loop node (4).b Fasten the M3 screws for the C-Fix brackets to a torque of approx. 1.5 Nm to fix

the Flexi Loop node (5).

Mounting on mounting profiles with T-slots

The C-Fix brackets are suitable for mounting the Flexi Loop nodes on mounting profileswith T-slots.

INSTALLATION AND MOUNTING 5



6 Electrical installation6.1 Safety

DANGERHazard due to electrical voltageHazard due to unexpected starting of the machine

b Make sure the machine is and remains in the electrically unpowered status duringthe electrical installation.

b Ensure that the dangerous state of the machine is (and remains) switched off.b Always use a suitable power supply.b Make sure that the outputs of the safety controller do not have any effect on the

machine during the electrical installation.

NOTE

• The safe sensor cascade meets the interference suppression requirements (EMC)for industrial use (interference suppression class A). When used in residentialareas it can cause interference.

• Undertake the electrical installation in accordance with EN 60 204-1.• The voltage supply of the devices must be capable, among others, of buffering

brief mains voltage failures of 20 ms as specified in EN 60 204-1.• The voltage supply as well as all signals connected have to fulfil the regulations for

extra-low voltages with safe separation (SELV/PELV) in accordance withEN 60 664.

• All safety sensors and actuators connected as well as wiring and installation haveto fulfil the required safety characteristics.

• On the replacement of a Flexi Loop node, it must be ensured the pin assignmentis made correctly, e.g. by marking or laying in a suitable manner.

6.2 Connections

6.2.1 Connection to Flexi Soft

Figure 45: Terminals on the Flexi Soft expansion modules

1 Terminals for inputs and outputs

The figure shows the terminals for inputs and outputs based on the example of the ex‐pansion module FX3-XTDI. For the pin assignments please see the “Flexi Soft ModularSafety Controller Hardware” operating instructions“.

The safe sensor cascade is connected to one output (X) and to two safe inputs (I) on anI/O module.

6 ELECTRICAL INSTALLATION


Which inputs and outputs depends on the configuration of the Flexi Soft in Flexi SoftDesigner (see "Selection of the Flexi Loop string", Page 56).

The safe sensor cascade can be connected to the same voltage supply as the safetycontroller. However, the current must be limited to 4 A.

Figure 46: Connection to Flexi Soft

Use 5-pin cables with M12 female connectors and flying leads to connect the safe sen‐sor cascade (see "Pre-assembled cables", Page 108).

6.2.2 Connection to Flexi Classic

Figure 47: Terminals on the Flexi Classic main module

1 Terminals for inputs and outputs

The figure shows the terminals for inputs and outputs based on the example of themain module UE410-MU. For the pin assignments please see the „Flexi Classic Modu‐lar safety controller“ operating instructions“.

ELECTRICAL INSTALLATION 6



Connect the MSTR Flexi Loop accessory to two outputs (X) and to two safe inputs (I) onthe safety controller. Use 8-pin cables with M12 female connectors and flying leads toconnect the safe sensor cascade (see "Pre-assembled cables", Page 108).

NOTEIf you connect the safe sensor cascade to the same power supply as the safety control‐ler, then limit the current to 4 A.Use both power supply pins (1 and 2) and both GND pins (5 and 6) on the MSTR FlexiLoop accessory for the power supply.

Figure 48: Connection to Flexi Classic

1 FC_A12 FC_B13 VDC4 GND5 FC_A26 FC_B2

6.2.3 Connections of the Flexi Loop nodes

Figure 49: Connections of the Flexi Loop nodes

1 FL_IN (male connector)2 FL_OUT (female connector)



FL_IN 5-pin

Male connector Pin Signal Meaning Color 1)

1 VDC 24 V supply voltage Brown

2 DATA_OUT Output to the Flexi Soft inputIn + 1

White

3 GND GND supply voltage Blue

4 SAFE_OUT Safe shutdown signalOutput to the Flexi Soft input In

Black

5 DATA_IN Input from the Flexi Soft output Xn Gray

Table 11: Pin assignment FL_IN (male connector)

1) The stated colors apply on the usage of pre-assembled cables (should be checked).

6.2.4 Connection of the Flexi Loop nodes

Within the safe sensor cascade the individual Flexi Loop nodes are connected using1:1 cables (male/female connector) via FL_OUT and FL_IN.

Figure 50: Connection FL_OUT to FL_IN

1 FL_OUT (female connector)2 FL_IN (male connector)

DANGERNever cut into the connection cables between the Flexi Loop nodes!If the cables for the safe sensor cascade are cut into, e.g. to supply the cascade direct‐ly using a separate power supply, then several power supplies will be connected in par‐allel.This situation can result in overcurrent and a cable fire in case of a ground fault.

6.2.5 Connections of the EMSS Flexi Loop node

Figure 51: Connections of the EMSS Flexi Loop node

1 EMSS (female connector)




EMSS 5-pin

Female connector Pin Signal Meaning Color 1)

1 EMSS1_A Switch 1, connection A Brown

2 EMSS1_B Switch 1, connection B White

3 EMSS2_A Switch 2, connection A Blue

4 EMSS2_B Switch 2, connection B Black

5 EMSS2_A Switch 2, connection A Gray

Table 12: Pin assignment EMSS 5-pin (female connector)


EMSS 8-pin


1 VDC 24 V supply voltage White

2 AUX_IN Non-safe input Brown

3 EMSS1_A Switch 1, connection A Green

4 EMSS1_B Switch 1, connection B Yellow

5 AUX_OUT Non-safe output Gray

6 GND GND supply voltage Pink

7 EMSS2_A Switch 2, connection A Blue

8 EMSS2_B Switch 2, connection B Red

Table 13: Pin assignment EMSS 8-pin (female connector)


Figure 52: Connection sketch dual-channel equivalent switch

An application example for the connection of a locking device: see "Implementation ofa safety locking device", Page 40.

6.2.6 Connections of the OSSD Flexi Loop node

Figure 53: Connections of the OSSD Flexi Loop node

1 OSSD (female connector)



OSSD 5-pin


1 VDC 24 V supply voltage for safety de‐vice

Brown

2 OSSD1 Input OSSD1 White

3 GND GND supply voltagefor safety device

Blue

4 OSSD2 Input OSSD2 Black

5 AUX_IN Non-safe input Gray

Table 14: Pin assignment OSSD 5-pin (female connector)


OSSD 8-pin


1 AUX_IN Non-safe input White


Brown

3 AUX_OUT Non-safe output Green


Yellow

5 OSSD1 Input OSSD1 Gray

6 OSSD2 Input OSSD2 Pink

7 GND GND supply voltage for safety de‐vice

Blue


Red

Table 15: Pin assignment OSSD 8-pin (female connector)


DANGERAlways supply the OSSD devices connected with power via the OSSD female connectoron the FLN-OSSD1000105 or FLN-OSSD1100108 Flexi Loop node!Never supply an OSSD device connected with power directly from a separate powersupply. If several power supplies are connected in parallel, in case of a ground faultovercurrent and a cable fire may occur.The OSSD devices must be connected to the same voltage supply as the Flexi Loop no‐des to which the OSSDs are connected.




6.2.7 Connections of the PWRI power supply accessory

Figure 54: Connections of the PWRI power supply accessory

1 PWRI (male connector)

PWRI 5-pin


1 VDC 24 V supply voltageof the power supply connec‐ted

Brown

2 VDC White

3 GND GND from the power supplyconnected

Blue

4 GND Black

5 Do not use Gray

Table 16: Pin assignment PWRI 5-pin (male connector)


6.2.8 Connections of the MSTR1 Flexi Loop accessory

Figure 55: Connections of the MSTR1 Flexi Loop accessory

1 FC_IN (male connector)



FC_IN 8-pin




3 FC_A1 Test input 1 Green

4 FC_A2 Safe output 1 Yellow

5 GND GND supply voltage Gray


7 FC_B1 Test input 2 Blue

8 FC_B2 Safe output 2 Red

Table 17: Pin assignment FC_IN 8-pin (male connector)


6.2.9 Connections of the MSTR2 Flexi Loop accessory

Figure 56: Connections of the MSTR2 Flexi Loop accessory

1 FC_IN (male connector)2 IO-Link (male connector)

FC_IN 8-pin




3 FC_A1 Test input 1 Green

4 FC_A2 Safe output 1 Yellow

5 GND GND supply voltage Gray


7 FC_B1 Test input 2 Blue

8 FC_B2 Safe output 2 Red

Table 18: Pin assignment FC_IN 8-pin (male connector)


IO-Link 5-pin





1 VDC 24 V IO-Link supply voltage Brown

2 AUX_IN Non-safe input White


4 C/Q orAUX_OUT

IO-Link interface/non-safe output Black

5 nc Not assigned Gray

Table 19: Pin assignment IO-Link 5-pin (male connector)


6.2.10 Connections of the DIAG Flexi Loop accessory

Figure 57: Connections of the DIAG Flexi Loop accessory

1 FL_IN (male connector)2 FL_OUT (female connector)

FL_IN 5-pin



2 DATA_OUT Output to the Flexi Soft input In +1

White


4 SAFE_OUT Safe shutdown signalOutput to the Flexi Soft input In

Black

5 DATA_IN Input from the Flexi Soft output Xn Gray

Table 20: Pin assignment FL_IN (male connector)




7 Configuration7.1 Safety

DANGERTest the protective device after any changes!The entire protective device must be tested for correct operation after each change ofthe configuration.

7.2 Configuration in the Flexi Soft Designer

This chapter describes the functions on the safe sensor cascade that can be set viasoftware. Some of the functions can be combined.

You will find detailed information on the usage of the Flexi Soft Designer in the “FlexiSoft Designer Software“ operating instructions.

7.2.1 Starting the configuration

To configure, there are two possible procedures:

• create a new project,e.g. to configure from scratch a Flexi Soft safety controller with a safe sensor cas‐cade connected.

• open an existing project file,e.g. to add a safe sensor cascade.

7.2.2 Hardware configuration

7.2.2.1 Configuration prerequisites

In the HARDWARE CONFIGURATION view in the Flexi Soft Designer there must be at least oneFX3-CPUx main module and one expansion module FX3-XTIO, FX3-XTDI or FX3-XTDS.

Make sure that you first select the correct firmware in the MODULES selection window.

7.2.2.2 System requirements Flexi Soft safety controller

To be able to use a safe sensor cascade on a Flexi Soft, you will need one main moduleand at least one expansion module. The following prerequisites apply for the modules:

Main modules

Figure 58: Selection of the firmware for the main module

• FX3-CPUx with firmware V3.xx or higher

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At least one expansion module

Figure 59: Selection of firmware for the I/O module

• FX3-XTIO with firmware V3.xx or higher• FX3-XTDI with firmware V3.xx or higher• FX3-XTDS with firmware V3.xx or higher

7.2.2.3 Selection of the Flexi Loop string

Up to eight safe sensor cascades can be connected to a safety controller. Each of thesesafe sensor cascades forms a Flexi Loop string in Flexi Soft Designer.

In the ELEMENTS selection window you can select these Flexi Loop strings. They are se‐quentially numbered from one to eight.

Figure 60: Flexi Loop strings 1 to 8

The number assignment is fixed. If you use the eighth Flexi Loop string, then in the fol‐lowing settings eight will always appear as the identification number.

7 CONFIGURATION


Figure 61: Identification via Flexi Loop number

1 Identification via Flexi Loop number

7.2.2.4 Selection of the connections on the I/O module

b On the left in Flexi Soft Designer change to the ELEMENTS selection window.b Choose FLEXI LOOP.b Choose a Flexi Loop string.✓ If you drag the Flexi Loop string over suitable free inputs or outputs in the configu‐

ration area using the mouse, the inputs or outputs will illuminate green.

Figure 62: Selection of the Flexi Loop string

1. The software automatically takes into account the necessary number of inputs oroutputs. Drop the Flexi Loop string on a suitable position.

✓ The device symbol is now integrated into the view at this position.

Figure 63: Connection symbols for a Flexi Loop string

A safe sensor cascade requires one output (X) and two inputs (I). The connections aremarked as follows:

CONFIGURATION 7



Output with Flexi Loop symbol

Safe input with the safe bit

Non-safe input with the data cable

By positioning a Flexi Loop element you can define on which terminals on an expansionmodule the Flexi Loop protocol is used for communication. The test output used Xn aswell as all safe inputs allocated to this test output are no longer available for the con‐nection of further tested input elements.

7.2.3 Flexi Loop configuration

b Change to the Flexi Loop configuration by changing to the FLEXI LOOP view.

Figure 64: Flexi Loop view

If there are additional interfaces (e.g. gateways) in your hardware configuration, then aselection list appears in INTERFACES. Select FLEXI LOOP here.

Figure 65: Selection of additional interfaces

7.2.3.1 Assembly of the safe sensor cascade

In the CONFIGURATION AREA, initially the expansion module to which the safe sensor cas‐cade is connected is shown on the right.

b On the left, select the required Flexi Loop node or the required Flexi Loop accesso‐ry.

7 CONFIGURATION


Figure 66: Selection of a Flexi Loop nodeb Drag the Flexi Loop node or the Flexi Loop accessory to the right beside the I/O

module.✓ The Flexi Loop node or the Flexi Loop accessory is shown enlarged there.

Figure 67: Flexi Loop node in the Flexi Loop configurationb Drag the other Flexi Loop nodes or Flexi Loop accessories to the right beside the

first Flexi Loop node.b Terminate the last Flexi Loop node using a terminator.

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A safe sensor cascade can contain up to 32 Flexi Loop nodes. Each Flexi Loop node isautomatically given a node number. The count starts at the first Flexi Loop node con‐nected to the I/O module and ends at the Flexi Loop node to which the terminator isconnected.

Figure 68: Flexi Loop in the Flexi Soft Designer

1 Logical numbering of the Flexi Loop nodes2 Physical numbering

Power supply and diagnostics accessories can be installed between the sensor nodes(see "Supply of power", Page 15). These accessories are not given a logical number. Forthis reason all Flexi Loop nodes and all Flexi Loop accessories are also given a physicalnumber that, however, has no effect on the maximum number of nodes.

7.2.3.2 Name of the Flexi Loop node or accessory

b Use the right mouse button to click the individual nodes and select EDIT... on thecontext menu.

✓ The MODULE PROPERTIES dialog box opens.

7 CONFIGURATION


Figure 69: Module properties

The dialog box contains the following information on the Flexi Loop node:

• type code• serial number• software version• module voltage• part number• description• manufacturer• module cable• sensor/actuator cable

b Type a name for the related node in the TAG NAME field.b Use meaningful names. The tag name is displayed in the logic editor and will aid

you in identifying the input or output signal.b In the MODULE CABLE field select a cable or select CUSTOM and enter the cable length

and wire cross-section.b In the SENSOR/ACTUATOR CABLE field select a cable or select CUSTOM and enter the ca‐

ble length and wire cross-section.

Pin assignment

b Click PIN ASSIGNMENT on the left.✓ The pin assignment for the related female connectors is displayed.

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Figure 70: Pin assignment

Flexi Loop error report

If errors have occurred, the Flexi Loop error report button appears on the left.

b Click FLEXI LOOP ERROR REPORT on the left.✓ The errors that have occurred are displayed.

7 CONFIGURATION


Figure 71: Flexi Loop error report

7.2.3.3 Disabling tamper protection


The node type used is saved for each position in a safe sensor cascade. In this way it isensured that Flexi Loop nodes cannot be replaced with other types.

If you select the ALLOW TYPES OTHER THAN CONFIGURED option, this tamper protection will beinactive. This option can be useful on setting up modular systems.

The number of Flexi Loop nodes configured in a safe sensor cascade is saved. In thisway it is ensured Flexi Loop nodes are not replaced with other types, Flexi Loop nodesremoved or added, or Flexi Loop nodes jumpered and the safe sensor cascade thenswitched back on again.

If you select the ALLOW LESS NODES THAN CONFIGURED option, this tamper protection will beinactive. You can then, for example, set up modular systems on which the maximumnumber of modules is configured, but a smaller number of modules is allowed.

How to disable the tamper protection:

b In the configuration area click the FLEXI LOOP SETTING button.✓ The following dialog box is opened:

CONFIGURATION 7



Figure 72: Disabling tamper protectionb Activate the desired option and click on OK.

7.2.4 Connecting sensors and switches

b At the bottom right in the Flexi Loop configuration change to the Elements selec‐tion window.

Figure 73: Changing to the elementsb Select an element.

Figure 74: Selection of the element✓ If you move the element over suitable free inputs or outputs, the inputs or outputs

7 CONFIGURATION


will illuminate green. The software automatically takes into account the necessarynumber of inputs or outputs.

Figure 75: Suitable free inputs or outputsb Drop the element at a suitable position.✓ The device symbol is now integrated into the view at this position.

Figure 76: Flexi Loop node with element

How to delete or move elements:

b Move the element to other inputs/outputs or back to the PARKING AREA using themouse.

b Delete the element by clicking the device symbol using the right mouse buttonand clicking DELETE on the context menu.

b Alternatively you can drag the element to the RECYCLE BIN at the bottom left of theconfiguration area.

7.2.4.1 Assigning tag names for the connected elements

If an element is in the configuration area, its parameters can be configured.

b Use the right mouse button to click the element and select EDIT... on the contextmenu or double-click an element using the left mouse button.

✓ The ELEMENT SETTINGS window opens.b Assign a TAG NAME (identifiable name for the element). Use meaningful names. The

tag names are displayed in the logic editor and are useful during configuration.

7.2.4.2 Export and Import of safe sensor cascades

You can export the configuration of a Flexi Loop string and, for instance, import it intoanother project. In this way you can copy a Flexi Loop string once configured.

CONFIGURATION 7



Figure 77: Button for exporting and importing the configuration

7.2.5 Configuration in the logic editor

Once the safe sensor cascade has been configured and the sensors, switches and ac‐tuators have been connected, then the safe sensor cascade can be used in the logiceditor.

Note that due to the signal propagation times, a Flexi Loop input signal may be longerin the Flexi Soft logic (longer pulse duration) than the original signal. The same appliesfor the Flexi Loop output signals on AUX_OUT.

7.2.5.1 Safe cut-off path

The safety information on the switches and sensors connected is combined and trans‐mitted quickly and safely to the Flexi Soft.

This status is represented in the Flexi Soft Designer logic editor by a single safe bit (yel‐low). Downstream cut-off paths for the machines and systems to be monitored are onlyallowed to be realized with the aid of this bit.

Figure 78: Flexi Loop in the logic editor of the Flexi Soft Designer

1 Safe bit

• The bit is only 1 as long as a shutdown or an error has not occurred in any of theFlexi Loop nodes.

• The bit changes to 0 within the response time stated in the technical data if ashutdown has occurred or an error has occurred on one of the sensors orswitches.

Recommendation

If you hold the mouse pointer over an element, the complete name and additional infor‐mation on the element are displayed.

7 CONFIGURATION


Figure 79: Tooltips in the logic editor

7.2.5.2 Non-safe inputs and outputs

The non-safe inputs AUX_IN and outputs AUX_OUT are polled or set cyclically. The inputor output signals are therefore available quickly in the logic or on the output. Exact re‐sponse times: see "All Flexi Loop nodes and Flexi Loop accessories", Page 97.

Figure 80: Non-safe inputs and outputs in the Flexi Soft Designer logic editor

1 Non-safe input2 Non-safe output

The non-safe inputs and outputs are represented using the following bits (gray) in thelogic:

• AUX_IN

° The bit is 1 if the non-safe input is active.

° The bit is 0 if the non-safe input is inactive.• AUX_OUT

° The bit is 1 if the non-safe output is active.

° The bit is 0 if the non-safe output is inactive.

7.2.5.3 Diagnostics information on the safe sensor cascade

In addition non-safe diagnostics information on the states in the safe sensor cascade issent to the Flexi Soft safety controller.

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Figure 81: Diagnostics information in the Flexi Soft Designer logic editor


The information is represented using the following bits (blue) in the logic:

• Sensor testing: indicates whether the test on the sensors and switches connectedis error-free.

° The bit is 1 as long as the sensor test is successful on all the sensors andswitches connected to the Flexi Loop nodes.

° The bit is 0 if a static or dynamic error has occurred on one of the sensors orswitches.

• Online: indicates whether the communication in the safe sensor cascade is active.

° The bit is 1 if the communication in the safe sensor cascade is running.

° The bit is 0 if the safe sensor cascade communication is interrupted.


7.2.5.4 Diagnostics information on the individual Flexi Loop nodes

The following non-safe diagnostics information is also made available by each FlexiLoop node.

Figure 82: Diagnostics information on the individual Flexi Loop nodes in the Flexi Soft Designerlogic editor


• Tag name of the element connected: The bit indicates the status of the sensors orswitches connected. It is used to evaluate which Flexi Loop node has shut down.

° The bit is 1 if there is no shutdown on the Flexi Loop node.

° The bit is 0 if there is a shutdown.• Dynamic testing: The bit indicates discrepancy or sequence errors on the sensors

or switches connected.

° The bit is 1 if no error occurred.

° The bit is 0 if there is a discrepancy or sequence error.• Static testing: The bit indicates electrical faults such as a cross-circuit or short-cir‐

cuit on the sensors or switches connected.

° The bit is 1 if no error occurred.

° The bit is 0 if there is a cross-circuit or short-circuit.

7 CONFIGURATION


• Online: The bit indicates whether the Flexi Loop node is physically present.

° The bit is 1 if the Flexi Loop node is present.

° The bit is 0 if the Flexi Loop node is missing.

The safety information and the non-safe information can be further processed in theFlexi Soft safety controller logic or forwarded, e.g., via a gateway to a PLC.


7.2.5.5 Output options

The following output options are available for the Flexi Loop node:

• flashing mode 1 and 2 for each node

° Flashing mode 1 causes lamps connected to AUX_OUT to flash at 1 Hz if theoutput is active.

° Flashing mode 2 causes lamps connected to AUX_OUT to flash at 2 Hz if theoutput is active.

Figure 83: Activation of the flashing mode

• output monitoringOn a Flexi Loop node with AUX_OUT and AUX_IN the output state is coupled to theinput state by default. This feature means that the state of the output cannotchange as long as the input is switched (in this way a flashing mode set is sup‐pressed).

DANGERIf you use the input AUX_IN for resetting, you must never deactivate output monitoring!By means of the output monitoring, for instance, the detection of an incorrect reset sig‐nal is prevented in the case of a cross-circuit between AUX_OUT and AUX_IN.

Set the bit if you want to use the output AUX_OUT independent of the state of the inputAUX_IN. This can be necessary, e.g., for safety locking devices (see "Implementation ofa safety locking device", Page 40).

Figure 84: Deactivate the output monitoring

CONFIGURATION 7



7.2.6 The safe sensor cascade in operation

Figure 85: Transfer of a configuration

Figure 86: Transfer and start of a configuration

Once you have transferred the configuration to the safety controller and started it, theFlexi Loop nodes and the Flexi Loop accessories are shown in Flexi Soft Designer.

Figure 87: The safe sensor cascade in operation

In the Flexi Loop window you can see the states of the LEDs on Flexi Loop nodes andthe Flexi Loop accessories. In the part on the left you can see the elements connectedin a table.

Restarting

7 CONFIGURATION


You can restart the safe sensor cascade using the button shown here.

Diagnostics

You can start the diagnostics on the safe sensor cascade using the button shown here.

Use the diagnostics if the Flexi Loop string is interrupted at a point. Flexi Soft Designerdetermines the number nodes still functioning.

If you start the diagnostics, the safe sensor cascade shuts down.

7.2.7 Connection to gateways

Using data set 1 the data can be transferred as usual via the related gateway to thehigher level controller.

In data set 1 you will find the bytes of the safe sensor cascade in AVAILABLE DATA.

Figure 88: Available bytes of the safe sensor cascade

Using data set 1 it is possible to transfer 50 bytes and map these bytes in the gate‐way’s data telegrams in the Flexi Soft Designer user interface.

7.2.8 Report

Complete information on the related project including all configuration settings and wir‐ing information is combined in the Report view.

NOTEThe report is an important part of the documentation of the safety-related validation ofa machine or a system.

The report contains the option FLEXI LOOP in the selection tree on the left in Configura‐tion.

If this option is selected, then the data on the safe sensor cascade, on the module towhich the safe sensor cascade is connected and on each individual Flexi Loop nodeand Flexi Loop accessory are prepared on opening the report.

CONFIGURATION 7



Figure 89: Report in the Flexi Soft Designer

Refer to the “Flexi Soft Designer Software” operating instructions for detailed informa‐tion concerning the use of the report.

7.3 Configuration of protection against tampering with the MSTR Flexi Loop accessory


If you use the safe sensor cascade on a Flexi Classic safety controller, then teach-in thenumber of Flexi Loop nodes in the MSTR Flexi Loop accessory.

If you also want to define the node types, then use the MSTR2 Flexi Loop accessoryand configure it with the aid of a standard controller (see "Configuration of the FlexiLoop nodes", Page 75).

Prerequisites:• The electrical installation of the Flexi Loop string is complete.• The output X1 on the Flexi Classic safety controller is connected to the connection

FC_A1 on the MSTR Flexi Loop accessory, the output X2 to the connection FC_B1.• There is no IO-Link connection established between the MSTR2 Flexi Loop acces‐

sory and the IO-Link master.• The voltage supply is switched on, the operating mode LED flashes red (1 Hz).

7 CONFIGURATION


Figure 90: MSTR Flexi Loop accessory with operating mode LED

1 Node LEDs 1 to 322 Operating mode LED3 IO-Link LED

How to teach-in the number of Flexi Loop nodes in the MSTR Flexi Loop accessory on:

b Switch off the power supply.b Remove wiring on the output X1 and wire the output X2 to the connections FC_A1

and FC_B1.b Switch on power supply.✓ The configuration is saved, the operating mode LED flashes red/green alternately.✓ Once the configuration has been saved the operating mode LED flashes green

(1 Hz).b Switch off the power supply.b Re-wire output X1 to the connection FC_A1 and output X2 only to connection

FC_B1 wiring.b Switch on power supply.✓ The Flexi Loop string starts to operate, from this point on the MSTR Flexi Loop ac‐

cessory checks whether the correct number of Flexi Loop nodes are connected oneach power up.

If you want to teach-in a new configuration, then undertake a new teach-in process. Theprevious configuration is irretrievably overwritten during this process.

If you want to delete a configuration, then undertake a new teach-in process without aterminator. On the conclusion of the teach-in process the operating mode LED flashesred at 1 Hz (configuration required).

If you want to disable the protection against tampering, connect the terminator directlyto the MSTR Flexi Loop accessory. Then undertake a new teach-in process. The MSTRFlexi Loop accessory then no longer checks the number of nodes or node types.

7.4 Configuration with the aid of a standard controller

DANGERTest the protective device after any changes!The entire protective device must be tested for correct operation after each change ofthe configuration.

This chapter describes the most functions on the safe sensor cascade that can be setvia IO-Link. The parameter list with all data that can be read and written is available asa separate document (SICK part number 8017450).

CONFIGURATION 7



7.4.1 Prerequisites

Hardware

To be able to use the safe sensor cascade on a standard controller you will need an IO-Link master that meets the following prerequisites:

• IO-Link V1.1• Communication mode COM1 (4.8 kBaud)• TimeStamp function on the IO-Link master deactivated 4)

Software

All configuration notes relate to the configuration tool TwinCAT™ from Beckhoff.

Integrate the MSTR2 Flexi Loop accessory with the aid of IO-Link Device DescriptionIODD or with the function block from the SICK library in the hardware configuration forthe project.

Connect the standard controller and the MSTR2 Flexi Loop accessory via an IO-Link ter‐minal or an IO-Link master (in the following always IO-Link master).

You can straightforwardly restore the configuration of a Flexi Loop string on the replace‐ment of the MSTR2 Flexi Loop accessory by using the Datastorage function (availablefrom firmware version V1.03.0 of the MSTR2 Flexi Loop accessory).

7.4.2 Configuration of the hardware

How to configure the safe sensor cascade in the standard controller:

b Log into the configuration software for the standard controller as SPECIALIST.b Change to PARAMETER on the IO-Link port used.b Open the PARAMETER MENU branch there.✓ The commands and parameters contained in the IODD are displayed.

Figure 91: Commands and parameters in the IODD

1 Parameter2 Parameter Menu

4) If supported by the PLC.

7 CONFIGURATION


7.4.2.1 Configuration of the Flexi Loop nodes

A safe sensor cascade can contain up to 32 Flexi Loop nodes. The logical numbering 2starts after the MSTR2 Flexi Loop accessory 1 at the first Flexi Loop node connectedand ends with the terminator 3.

Figure 92: Logical numbering of the Flexi Loop nodes

1 MSTR Flexi Loop accessory2 Logical numbering of the Flexi Loop nodes and the terminator3 Terminator4 Flexi Loop accessories (in the example PWRI)

Flexi Loop accessories (in the example PWRI) 4 can be connected between the FlexiLoop nodes. Flexi Loop accessories are not given a logical number.

Defining number and types

In the configuration from the factory the first position contains a Flexi Loop nodeFLN-EMSS1100108 and the second position a terminator. You define the actual num‐ber and the types of the Flexi Loop nodes.


b Open the EDIT CONFIG. DATA branch.✓ For each possible Flexi Loop node and the terminator there is a sub-branch (EDIT

CONFIGURATION DATA -NODE 01 … 33).b Expand the EDIT CONFIGURATION DATA -NODE 01 branch.✓ The system displays the configuration options for the Flexi Loop node.b On the NODE TYPE menu select the Flexi Loop node.b Undertake these steps for all Flexi Loop nodes in the Flexi Loop string.b Select the terminator as the last Flexi Loop node.b If necessary select on the NODE TYPE menu the type EMPTY for node positions that are

not used.b Save the configuration using Store 5).

Output monitoring

On a Flexi Loop node with AUX_OUT and AUX_IN the output state is coupled to the inputstate by default. This feature means that the state of the output cannot change as longas the input is switched (in this way a flashing mode set is suppressed).

Deactivate the output monitoring if you want to use the output AUX_OUT independentof the state of the input AUX_IN. This can be necessary, e.g., for safety locking devices.

5) Applies for TwinCAT™, alternatively Store all User Data (SystemCommand 03h ParamDownloadStart - IO-LinkInterface and System Specification V.1.1 Table B.9).

CONFIGURATION 7



DANGERIf you use the input AUX_IN for resetting, you must never deactivate output monitoring!The output monitoring prevents, for instance, the detection of an incorrect reset signalin the case of a cross-circuit between AUX_OUT and AUX_IN.

b Open the EDIT CONFIG. DATA branch.✓ For each possible Flexi Loop node and the terminator there is a sub-branch (EDIT

CONFIGURATION DATA -NODE 01 … 33).b Expand the EDIT CONFIGURATION DATA -NODE [N] branch for the required Flexi Loop node.✓ The system displays the configuration options for the Flexi Loop node.b Set the parameter OUTPUT MONITORING to DEACTIVATED.b Save the configuration using Store 6).✓ Output monitoring is inactive.

AUX_IN to MSTR AUX_OUT

If you use several inputs to reset the protective device, the hazardous area must bevisible from every reset button!

In the configuration from the factory the Flexi Loop links together all inputs of the FlexiLoop nodes using an OR operator. The result is output by the MSTR2 Flexi Loop acces‐sory on the output AUX_OUT. Use this function for example for a common reset signalin the standard IO mode.

b Set the parameter AUX_IN TO MSTR AUX_OUT to OFF.b Save the configuration using Store 6).✓ The Flexi Loop node no longer feeds the status on its AUX_IN to the output

AUX_OUT of the MSTR2 Flexi Loop accessory.

AUX_OUT from MSTR AUX_IN

Flexi Loop links the status of the input AUX_IN of the MSTR2 Flexi Loop accessory to alloutputs AUX_OUT of the Flexi Loop nodes. Use this function for example for the imple‐mentation of locking device applications.

An OR operator is applied to the process data for the outputs AUX_OUT of the individualFlexi Loop nodes and the logic states of the parameter AUX_OUT FROM MSTR AUX_IN.

b Set the parameter AUX_OUT FROM MSTR AUX_IN to OFF.b Save the configuration using Store 6).✓ The output AUX_OUT of the Flexi Loop node is no longer linked to the AUX_IN of

the MSTR2 Flexi Loop accessory.

Flashing mode 1 or 2

With the aid of flashing modes 1 and 2 lamps on the non-safe outputs of the Flexi Loopnodes can flash at 1 Hz or 2 Hz.

b Set the parameter FLASHING MODE 1 or FLASHING MODE 2 to ON.b Save the configuration using Store 6).✓ If the output AUX_OUT of the Flexi Loop node is activated, then it is operated at

1 Hz or 2 Hz.


7 CONFIGURATION


7.4.2.2 Configuration of the Flexi Loop string


Setting commissioning mode

If necessary, deactivate a taught-in configuration by setting the MSTR2 Flexi Loop ac‐cessory to commissioning mode.


b Open the EDIT CONFIG. DATA branch.b Expand the EDIT MSTR SETTINGS branch.✓ The system displays the configuration options for the MSTR2 Flexi Loop accessory.b On the COMMISSIONING MODE menu select the TRUE option.b Save the configuration using Store 7).✓ The MSTR2 Flexi Loop accessory changes to the WAITING FOR CONFIGURATION mode.

Disabling tamper protection

Define whether the number and types for the Flexi Loop nodes are to be checked onpower up.

b Open the EDIT CONFIG. DATA branch.b Expand the EDIT MSTR SETTINGS branch.✓ The system displays the configuration options for the MSTR2 Flexi Loop accessory.b On the IGNORE NODE COUNT menu select the TRUE option.b Save the configuration using Store 7).✓ With immediate effect the number of Flexi Loop nodes will not be checked.b On the IGNORE NODE TYPES menu select the TRUE option.b Save the configuration using Store 7).✓ With immediate effect the types of Flexi Loop node will not be checked.

Logic of the common input

In the configuration from the factory the Flexi Loop links together all inputs of the FlexiLoop nodes to one common input using an OR operator. The result is output by theMSTR2 Flexi Loop accessory on the output AUX_OUT. The operator can be changedfrom OR to AND.

b Open the EDIT CONFIG. DATA branch.b Expand the EDIT MSTR SETTINGS branch.✓ The system displays the configuration options for the MSTR2 Flexi Loop accessory.b On the MSTR AUX_OUT LOGIC menu select the TRUE option.b Save the configuration using Store 7).✓ These inputs are linked together using an AND operator.b On the MSTR AUX_OUT LOGIC menu select the FALSE option.b Save the configuration using Store 7).✓ These inputs are linked together using an OR operator.


CONFIGURATION 7



7.4.3 Options for application design in the PLC

WARNINGNever use the IO-Link information for safety-related applications!Only the safe cut-off path on the Flexi Classic safety controller is allowed to be used forsafety-related applications.

If the safe sensor cascade is in operation and the sensors, switches and actuators areconnected, the safe sensor cascade can be used in the process image on the standardcontroller.

The following information is available:

• cut-off path as IO-Link event• non-safe inputs and outputs in the process data• diagnostics information to the Flexi Loop string in the service data• diagnostics information on the individual Flexi Loop nodes in the service data


7.4.3.1 Cut-off path

The status of the cut-off path is available to the standard controller as an IO-Link event(code 6144, 1800h).

• If there is no shutdown and no error has occurred on any of the Flexi Loop nodes,the event is not present.

• If there has been a shutdown or an error has occurred on one of the sensors orswitches, then the event is present.

7.4.3.2 Non-safe inputs and outputs

Process data

The non-safe inputs AUX_IN and outputs AUX_OUT are polled or set cyclically (IO-Linkprocess data). The input or output signals are therefore available quickly in the processimage or on the output.

The PLC and the MSTR2 Flexi Loop accessory communicate cyclically in a data framefor process data:

Flexi Loop transmits 4 bytes of input data to the PLC. These bytes contain the status ofthe non-safe inputs AUX_IN of the Flexi Loop nodes.

Flexi Loop receives 4 byte of output data from the PLC. These bytes contain the com‐mands for the non-safe outputs AUX_OUT of the Flexi Loop nodes.

• Flexi Loop transmits 4 bytes of input data to the PLC. The 32 bits contain the sta‐tus of the non-safe inputs AUX_IN of the Flexi Loop nodes.bit 0 = Flexi Loop node 32, bit 31 = Flexi Loop node 1bit = 1 = non-safe input active, bit = 0 = non-safe input inactive

• Flexi Loop receives 4 byte of output data from the PLC. The 32 bits contain thecommands for the non-safe outputs AUX_OUT of the Flexi Loop nodes.bit 0 = Flexi Loop node 32, bit 31 = Flexi Loop node 1bit = 1 = non-safe output becomes active, bit = 0 = non-safe output becomes inac‐tive

7 CONFIGURATION


Response times

The pulse durations of the input signals from AUX_IN and the output signals onAUX_OUT are longer than the original signals due to the signal propagation times in theprocess image. The response time for the inputs and outputs comprise the followingcomponents:

propagation times of the bits for the non-safe inputs and outputs (see "All FlexiLoop nodes and Flexi Loop accessories", Page 97).+ transfer time IO-Link (cycle time x 2)+ PLC process propagation time

7.4.3.3 Diagnostics information on the safe sensor cascade

The standard controller polls non-safe diagnostic information on the statuses within thesafe sensor cascade with the aid of service data.

Flexi Loop connection status

The value in the index 275 (113h) shows the status of the communication within thesafe sensor cascade.

The value is 0 if the safe sensor cascade communication is interrupted.

The value is 1 or 2 if the safe sensor cascade communication is initialized.

The value is 3 or 4 if the communication in the safe sensor cascade is running.

The value is 6 if the safe sensor cascade is not terminated (missing terminator, opensafe sensor cascade).

The value is 7 if there is a configuration error (e.g. incorrect number of nodes) in thesafe sensor cascade.

Overall number of nodes

The value in the index 276 (114h) corresponds to the number of Flexi Loop nodesfound.

Safety controller status

The value in the index 277 (115h) indicates whether the signal from the safety control‐ler connected is detected.

The value is 0 if there is no supply voltage on FC_IN.

The value is 1 if a safety controller has not been found on FC_IN.

The value is 2 if a safety controller has been found on FC_IN and the compatibility testis in progress.

The value is 3 if a compatible safety controller has been found on FC_IN and the safesensor cascade is operational.

7.4.3.4 Diagnostics information on the individual Flexi Loop nodes

The indices 285 (11Dh) to 288 (120h) contain diagnostics information on the individu‐al Flexi Loop nodes.

Each index is 4 bytes long. The 32 bits are each allocated to one of the Flexi Loop no‐des:

• bit 0 = Flexi Loop node 32• bit 31 = Flexi Loop node 1

CONFIGURATION 7



Shutdown information

The value in index 285 (11Dh) indicates the output state of the safety sensors or safetyswitches connected to the Flexi Loop nodes. Bit 0 to 31 correspond to the Flexi Loopnodes 32 to 1.

• The bit is 1 if there is no shutdown on the Flexi Loop node.• The bit is 0 if there is a shutdown.

Static testing

The value in index 286 (11Eh) indicates static errors (cross-circuit or short-circuit) onthe safety sensors or safety switches connected to the Flexi Loop nodes. Bit 0 to 31correspond to the Flexi Loop nodes 32 to 1.

• The bit is 1 if no error occurred.• The bit is 0 if there is a cross-circuit or short-circuit.

Dynamic testing

The value in index 287 (11Fh) indicates dynamic errors (discrepancy or sequence er‐ror) on the safety sensors or safety switches connected to the Flexi Loop nodes. Bit 0 to31 correspond to the Flexi Loop nodes 32 to 1.

• The bit is 1 if no error occurred.• The bit is 0 if there is a discrepancy or sequence error.

Node detected

The value in index 288 (120h) indicates which of the Flexi Loop nodes is physicallypresent. Bit 0 to 31 correspond to the Flexi Loop nodes 32 to 1.

• The bit is 1 if the Flexi Loop node is present.• The bit is 0 if the Flexi Loop node is missing.

7.4.3.5 Output options

The output options for the Flexi Loop nodes can be changed in a volatile manner usingthe service data. Volatile parameters can only be used if the corresponding parameterin the configuration has been set to the value logical 0.

Each index is 4 bytes long. The 32 bits are each allocated to one of the Flexi Loop no‐des:

• bit 0 = Flexi Loop node 32• bit 31 = Flexi Loop node 1

Flashing mode 1 or 2

The index 281 (119h) sets the flashing mode 1 (1 Hz flashing) for the related FlexiLoop node.

The index 282 (11Ah) sets the flashing mode 2 (2 Hz flashing) for the related FlexiLoop node.

Bit 0 to 31 of the index correspond to the Flexi Loop nodes 32 to 1.

• If the bit is set to 1, flashing mode 1 or 2 becomes active.• If the bit is set to 0, flashing mode 1 or 2 becomes inactive.

If the process data switch the output AUX_OUT on a Flexi Loop node, the output is oper‐ated at 1 Hz or 2 Hz (a lamp connected flashes).

7 CONFIGURATION


Deactivate output monitoring

The index 283 (11Bh) sets the output monitoring for the related Flexi Loop node. Bit 0to 31 of the index correspond to the Flexi Loop nodes 32 to 1.

• If the bit is set to 1, the output monitoring becomes inactive.• If the bit is set to 0, the output monitoring becomes active.

7.4.3.6 Standard commands

Using standard commands you can trigger the pre-defined functions.

Factory settings

Using the command RESTORE FACTORY SETTINGS you can reset the MSTR2 Flexi Loop acces‐sory to the default delivery status.

Read voltages

You can read the operating voltage at the individual Flexi Loop nodes using the com‐mand READ NODE VOLTAGE.

b Enter the number of the Flexi Loop node in the index 472 (1D8h).b Enter the value 192 in the index 2.✓ Depending on the node selection, the node voltage is then available in the indices

401 (191h) to 433 (1B1h). The operating voltage is also available for the MSTR2Flexi Loop accessory on the menu under Observation (see "Diagnostics using theMSTR2 Flexi Loop accessory", Page 93).

NOTEThe Flexi Loop communication is interrupted while the node voltage is read. It is notpossible to exchange process data during this time.

Restarting

You can restart the safe sensor cascade using the command APPLICATION RESET.

7.4.3.7 Events

On the occurrence of an event the safe sensor cascade signals to the IO-Link masterthat there is an event present. The IO-Link master then reads the event.

State of the cut-off path

The event 6144 (1800h) SAFETY CASCADE INTERRUPTED indicates whether the safe sensorcascade is shut down.

• If there is no shutdown and no error has occurred on any of the Flexi Loop nodes,the event is not present.

• If there has been a shutdown or an error has occurred on one of the sensors orswitches, then the event is present.

Synchronization safety controller

The event 6145 (1801h) SYNCHRONIZATION SAFETY CONTROLLER indicates whether a safetycontroller has been found.

• If a safety controller has been detected, then the event is not present.• If the connection to a safety controller is interrupted, then the event is present.

CONFIGURATION 7



Flexi Loop not in operation

The event 6152 (1808h) FLEXI LOOP NOT IN OPERATION indicates whether the communica‐tion within the safe sensor cascade is active.

• If the communication in the safe sensor cascade is running, then the event is notpresent.

• If the communication in the safe sensor cascade is interrupted, then the event ispresent.

Cable connection

The event 6153 (1809h) CABLE PROBLEM DETECTED indicates that the internal cable moni‐toring has detected a problem with the cabling for the safe sensor cascade.

• If the safe sensor cascade is correctly wired and terminated with a terminator,then the event is not present.

• If the cabling for the safe sensor cascade is interrupted or not terminated with aterminator, then the event is present.

Dynamic error

The event 6146 (1802h) DYNAMIC TESTING FAILED indicates whether the dynamic testing ofthe safety sensors and safety switches connected was free of errors.

• If the dynamic testing on all the safe sensors and safety switches connected tothe Flexi Loop nodes was successful, then the event is not present.

• If a dynamic error has occurred on one of the sensors or switches, then the eventis present.

Static error

The event 6147 (1803h) STATIC TESTING FAILED indicates whether the static testing of thesafety sensors and safety switches connected was free of errors.

• If the static testing on all the safety sensors and safety switches connected to theFlexi Loop nodes was successful, then the event is not present.

• If a static error has occurred on one of the sensors or switches, then the event ispresent.

Critical error

The event 6148 (1804h) CRITICAL ERROR (HARDWARE) indicates whether damage has beendetected on the hardware in the safe sensor cascade or the MSTR Flexi Loop accessory(damaged Flexi Loop nodes, short-circuits on connection cables, faulty safety switchesor safety sensors etc.).

• If the status of all hardware components in the safe sensor cascade is free offaults, then the event is not present.

• If a fault has been detected in the hardware in the safe sensor cascade, then theevent is present.

Configuration difference

The event 6149 (1805h) CONFIGURATION DIFFERENCE indicates whether the actual physicallayout of the safe sensor cascade corresponds to the expected configuration.

• If there is no difference between the actual layout of the safe sensor cascade andthe expected configuration, then the event is not present.

• If the actual layout of the safe sensor cascade is different to the expected configu‐ration, then the event is present.

7 CONFIGURATION


8 CommissioningDANGERHazard due to lack of effectiveness of the protective device

b Before you operate a machine protected by the devices for the first time, makesure that the system is first checked and released by qualified safety personnel.

b Only place the machine in operation with a correctly functioning protective device.

8.1 Display sequence during switching on

After switching on an LED test is undertaken. During this test each LED illuminatesbriefly in each available color. The LED test is displayed simultaneously on all FlexiLoop nodes.

The synchronization of the Flexi Loop nodes then starts. Then the LEDs indicate the re‐lated operational status (see "Status indicators", Page 25).

8.2 Commissioning using the DIAG Flexi Loop accessory or the MSTR Flexi Loop acces‐sory

The DIAG Flexi Loop accessory or the MSTR Flexi Loop accessory will assist your duringthe commissioning of a Flexi Loop string.

Commissioning mode

In the commissioning mode, the node LEDs 1 to 32 indicate the status of all Flexi Loopnodes connected to the right of the accessory.

The DIAG Flexi Loop accessory operates in the commissioning mode with one of the fol‐lowing prerequisites:

• The safety controller connected is not configured.• On the connection FL_IN, pin 5 (DATA_IN) is connected to pin 1 (VDC).

The MSTR Flexi Loop accessory operates in the commissioning mode with the followingprerequisite:

• There is no safety controller connected.

Transparent mode of the Flexi Loop accessory DIAG

Once the safety controller has been connected or placed in operation, then the DIAGFlexi Loop accessory operates in the transparent mode.

In the transparent mode the node LEDs 1 to 32 indicate the status of all Flexi Loop no‐des connected. This statement applies to nodes connected both the left and right ofthe DIAG Flexi Loop accessory.

8.3 Test notes

The purpose of the thorough checks described in the following is to confirm the safetyrequirements specified in the national/international rules and regulations, especiallythe safety requirements in the Machine and Work Equipment Directive (EU Conformity).

These thorough checks must therefore always be performed.

8.3.1 Thorough checks before the initial commissioning

b Check the effectiveness of the protective device mounted to the machine, usingall selectable operating modes as specified in the checklist in the annex (see"Checklist for the manufacturer", Page 117).

COMMISSIONING 8



8.3.2 Regular thorough check of the protective device by qualified safety personnel

b Check the system, following the inspection intervals specified in the national rulesand regulations. This procedure ensures that any changes on the machine or ma‐nipulations of the protective device after the initial commissioning are detected.

b If any modifications have been made to the machine or the protective device, or ifFlexi Loop has been re-configured, changed or repaired, the system must bechecked again as specified in the checklist in the annex.

8.3.3 Daily functional checks of the protective device

The effectiveness of the protective device must be checked daily by a specialist or byauthorized personnel.

8 COMMISSIONING


9 Troubleshooting9.1 In the event of faults or errors

DANGERIn the event of unclear faults, cease operation! Stop the machine if you cannot clearlyidentify or allocate the error and if you cannot safely rectify the malfunction.

9.2 SICK support

If you cannot rectify an error with the help of the information provided in this chapter,please contact your local SICK subsidiary.

9.3 Indications of the LEDs

9.3.1 MS LED

Figure 93: MS LED

The Flexi Loop nodes and the Flexi Loop accessories have an LED that indicates thecommunication status and the Flexi Loop node status. The designation MS = ModuleStatus is based on the Flexi Soft safety controller.

The indications on the LED have the following meaning:

MS Meaning

Green The safe sensor cascade is in operation on this and all downstream nodesand on all Flexi Loop accessories. No error occurred.On the FLN-EMSS0000105, FLN-EMSS1100108, FLN-OSSD1000105and FLN-OSSD1100108 Flexi Loop nodes:If both EMSS LEDs or both OSSD LEDs are not constantly illuminatedgreen on this node, then the safe sensor cascade has been shut down bythis node.

No operating voltage, or voltage too low

Green (1 Hz) A downstream Flexi Loop node has shut down or a discrepancy or se‐quence error has occurred on a downstream Flexi Loop node.

Green (0.5 Hz) Connection to the Flexi Loop communication driver (e.g. Flexi Soft) exists,but safe sensor cascade communication is interrupted.

Green (2 Hz) Initialization phase, establishing communication.

Green (1 Hz) Communication interrupted, no connection to the Flexi Loop communica‐tion driver (e.g. Flexi Soft)

Red/green(1 Hz)

Configuration error, this node is not configured at this point (incorrect typeor incorrect number).

Table 21: Displays of the MS LEDs

TROUBLESHOOTING 9



MS Meaning

Red/green(2 Hz)

Configuration error, too many nodes connected to the safe sensor cas‐cade

Red (1 Hz) An error occurred on this Flexi Loop node. The type of error is given by thecombination with the EMSS LEDs or the OSSD LEDs (see "LEDs of theEMSS Flexi Loop nodes", Page 87 or see "LEDs of the OSSD Flexi Loopnodes", Page 88).

Red (2 Hz) A critical error has occurred on a downstream node.

Red A critical error occurred on this node. The error can under certain circum‐stances be cleared by switching off and on again.

Table 21: Displays of the MS LEDs

Large distances can be covered using the safe sensor cascade. For this reason theflashing of the MS LEDs indicates the direction in which it is necessary to go from thecontroller to reach the Flexi Loop node on which the shutdown or the error occurred.

Recommendation

From the control cabinet go in the direction of the terminator until you reach the FlexiLoop node on which the MS LED is no longer flashing green at 1 Hz.

Figure 94: Direction indication on the MS LEDs

1 I LED on the Flexi Soft2 MS LEDs of the Flexi Loop nodes3 Direction of propagation to the shutdown4 Flexi Loop node with shutdown

The shutdown of the safe sensor cascade is indicated on the safety controller by theLED for the input; this LED is off. The shutdown or the error occurred on the first FlexiLoop node in the direction of propagation on which the MS LED is no longer flashinggreen at 1 Hz.

9 TROUBLESHOOTING


9.3.2 LEDs of the EMSS Flexi Loop nodes

Figure 95: LEDs of the EMSS Flexi Loop nodes

EMSS1/2 MS Meaning

Green – Switch contact 1 or 2 on the safety switch closed, noerror

– Switch contact 1 or 2 on the safety switch open, noerror

Green Red Discrepancy or sequence error, related switch con‐tact is closed.

Green Red Discrepancy or sequence error, related switch con‐tact is open.

Table 22: EMSS LEDs and MS LED of the EMSS Flexi Loop nodes

• If an error is only indicated on one of the LEDs EMSS1 or EMSS2 (the other is ei‐ther illuminated green or is off), then there is a discrepancy error.

• If an error is indicated on both LEDs EMSS1 and EMSS2, there is a sequence er‐ror.

AUX_IN (8-pin var‐iant only)

Meaning

Green Non-safe input is active.

Non-safe input is inactive.

Table 23: AUX_IN LED of the EMSS Flexi Loop nodes

AUX_OUT (8-pinvariant only)

Meaning

Green Non-safe output is active.

Non-safe output is inactive.

Table 24: AUX_OUT LED of the EMSS Flexi Loop nodes

TROUBLESHOOTING 9



9.3.3 LEDs of the OSSD Flexi Loop nodes

Figure 96: LEDs of the OSSD Flexi Loop nodes

OSSD1/2 MS Meaning

Green – Connected OSSD in the ON state, no error

– Connected OSSD in the OFF state, no error

Green Red Discrepancy or sequence error, related connection ishigh.

Green Red Discrepancy or sequence error, related connection islow.

Table 25: OSSD LEDs and MS LED of the OSSD Flexi Loop nodes

AUX_IN Meaning

Green Non-safe input is active.

Non-safe input is inactive.

Table 26: AUX_IN LED of the OSSD Flexi Loop nodes

AUX_OUT (8-pinvariant only)

Meaning

Green Non-safe output is active.

Non-safe output is inactive.

Table 27: AUX_OUT LED of the OSSD Flexi Loop nodes

9.3.4 LEDs of the PWRI power supply accessory

Figure 97: LEDs of the PWRI power supply accessory

9 TROUBLESHOOTING


PWR Right Meaning

Green Input voltage on the right side (on the male connector PWRI) is in thestipulated range

No or excessively low input voltage on the right side (on the male con‐nector PWRI)

Table 28: PWR Right LED of the PWRI power supply accessory

PWR Left Meaning

Green Operating voltage in the left section in the stipulated range

No or excessively low operating voltage in the left section

Table 29: PWR Left LED of the PWRI power supply accessory

Overload Meaning

Output current in the normal range

Red (1 Hz) Output load critical, however it has not been shut down yet. If this loadremains present, the load is shut down (see "PWRI power supply acces‐sory", Page 101).

Red Overload, all sections to the right of the power supply accessory areshut down. If the load drops below the re-enable value, the power sup‐ply accessory switches back on.

Red (2 Hz) Emergency shutdown, this error can only be cleared by switching offand on again.

Table 30: Overload LED of the PWRI power supply accessory

9.3.5 LEDs of the MSTR1 Flexi Loop accessory

Figure 98: LEDs of the MSTR1 Flexi Loop accessory

1 Node LEDs 1 to 322 Operating mode LED

Node LEDs 1 to 32 MS LED Meaning

– Node not found (not connected, not in opera‐tion)

Green – OSSD or EMSS in the ON state

Green – OSSD or EMSS in the OFF state

Red – Sequence error occurred on the node

Red – Discrepancy error occurred on the node

Green (2 Hz) Red/green (2 Hz) Node found, corresponds to the expected con‐figuration

Table 31: Node LEDs of the MSTR1 and MSTR2 Flexi Loop accessory

TROUBLESHOOTING 9




Red/green (2 Hz) Red/green (2 Hz) Node found, but does not correspond to theconfigured type or the number of nodes config‐ured has been exceeded.

Red (2 Hz) Red/green (2 Hz) Configured node not found

Red/green (1 Hz) Green (0.5 Hz) Node found, but safe sensor cascade offline.If several LEDs are flashing: The connectionhas probably been interrupted after the FlexiLoop node on which the last node LED is flash‐ing.

Red (node 1) Green (0.5 Hz) Number of Flexi Loop nodes allowed notreached

Red (node 32) Green (0.5 Hz) Number of Flexi Loop nodes allowed exceeded


Operating mode LED Meaning


Green Compatible safety controller detected, safe sensor cascade in op‐eration

Orange Safety controller found, compatibility test in progress

Red No safety controller found

Red Configuration required

Red/green Configuration process in progress, please wait

Green Configuration saved successfully, reboot required

Table 32: Operating mode LED of the MSTR1 and MSTR2 Flexi Loop accessories

9.3.6 LEDs of the MSTR2 Flexi Loop accessory

Figure 99: LEDs of the MSTR2 Flexi Loop accessory

1 Node LEDs 1 to 322 Operating mode LED3 IO-Link LED







9 TROUBLESHOOTING




Green (2 Hz) Red/green (2 Hz) Node found, corresponds to the expected con‐figuration

Red/green (2 Hz) Red/green (2 Hz) Node found, but does not correspond to theconfigured type or the number of nodes config‐ured has been exceeded.

Red (2 Hz) Red/green (2 Hz) Configured node not found







Green Compatible safety controller detected, safe sensor cascade in op‐eration

Orange Safety controller found, compatibility test in progress

Red No safety controller found

Red Configuration required

Red/green Configuration process in progress, please wait

Green Configuration saved successfully, reboot required

Table 34: Operating mode LED of the MSTR1 and MSTR2 Flexi Loop accessories

IO-Link LED Meaning

Standard IO mode

Green IO-Link mode, connection established to the IO-Link master

Orange IO-Link in Pre-operate modus

Red Error occurred in the IO-Link communicationor:IO-Link output stage overloaded

Table 35: IO-Link LED of the MSTR2 Flexi Loop accessory

TROUBLESHOOTING 9



9.3.7 LEDs of the DIAG Flexi Loop accessory

Figure 100: LEDs of the DIAG Flexi Loop accessory

1 Node LEDs 1 to 322 Operating mode LED3 Loop integrity LED










Table 36: Node LEDs of the DIAG Flexi Loop accessory



Green Safety controller found and synchronized

Orange Safe sensor cascade in commissioning mode

Red No valid input signal detected

Table 37: Operating mode LED of the DIAG Flexi Loop accessory

Loop integrity LED Meaning


Green Flexi Loop communication is running

Red Flexi Loop communication interrupted. The connection is probablyinterrupted after the Flexi Loop node on which the node LED isflashing.

Table 38: Loop integrity LED on the DIAG Flexi Loop accessory

9 TROUBLESHOOTING


9.4 Extended diagnostics

Usage on Flexi Soft

The Flexi Soft Designer software contains extensive diagnostic facilities. This allows youto narrow down the problem if the error is non-specific or if you experience usage down‐time problems. For details please see the Flexi Soft Designer operating instructions.

Usage on the MSTR2 Flexi Loop accessory

With the aid of the service data the PLC reads parameter values or statuses from theFlexi Loop nodes.


9.4.1 Diagnostics using Flexi Soft

Once you have completed your project and have established a connection to your FlexiSoft system, you can undertake diagnostics on your system in the Flexi Soft Designer.In the top half of the window for the DIAGNOSTICS view you can see a list of all messages,information, warnings and error messages for your system including the Flexi Loopnode.

If you click one of the entries in the list, details on the selected message are displayedin the bottom half of the window.

Figure 101: Diagnostics in the Flexi Soft Designer

Refer to the “Flexi Soft Designer Software” operating instructions for detailed informa‐tion concerning the use of diagnostics.

9.4.2 Diagnostics using the MSTR2 Flexi Loop accessory

If you have connected the MSTR2 Flexi Loop accessory to a PLC via IO-Link, then youcan retrieve diagnostics information on the safe sensor cascade.

TROUBLESHOOTING 9



b Login to the configuration software for the standard controller as OBSERVER.b Change to PARAMETER on the IO-Link port used.b Open there the OBSERVATION MENU branch.✓ The test options contained in the IODD are displayed.

Figure 102: Observation Menu

1 Parameter2 Observation Menu3 MSTR status4 Diagnostic Data5 View Config. Data

Flexi Loop string

b Open the MSTR STATUS branch.✓ The FLEXI LOOP COMMUNICATION STATUS branch indicates the status of the communica‐

tion in the safe sensor cascade.

° The value is 0 if the safe sensor cascade communication is interrupted.

° The value is 1 or 2 if the safe sensor cascade communication is initialized.

° The value is 3 or 4 if the communication in the safe sensor cascade is run‐ning.

° The value is 6 if the safe sensor cascade is not terminated (missing termina‐tor, open safe sensor cascade).

° The value is 7 if there is a configuration error (e.g. incorrect number of no‐des) in the safe sensor cascade.

✓ The TOTAL NODE COUNT branch indicates the number of Flexi Loop nodes.✓ The SAFETY CONTROLLER STATUS branch indicates whether the signal from the safety

controller is detected.

° The value is 0 if there is no supply voltage on FC_IN.

° The value is 1 if a safety controller has not been found on FC_IN.

° The value is 2 if a safety controller has been found on FC_IN and the compat‐ibility test is in progress.

° The value is 3 if a compatible safety controller has been found on FC_IN andthe safe sensor cascade is operational.

✓ The MSTR VOLTAGE branch indicates the voltage on FC_IN.

Diagnostics information

b Open the DIAGNOSTIC DATA branch.

9 TROUBLESHOOTING


✓ The branch indicates the currently valid status of the diagnostics data:

° state of the cut-off path

° dynamic errors

° static errors

° number of Flexi Loop nodes

MSTR2 Flexi Loop accessory and Flexi Loop node

b Open the VIEW CONFIG DATA branch.✓ The VIEW MSTR SETTINGS branch indicates the expected configuration for the MSTR2

Flexi Loop accessory.✓ The VIEW CONFIGURATION DATA [N] branches indicate the expected configuration for all

Flexi Loop node positions. They also indicate information on the Flexi Loop nodeactually found at this position.

° type code of the Flexi Loop node configured

° all parameters configured

° type code of the Flexi Loop node detected

° manufacturer

° software version

° serial number

° node voltage, if this has been read using a command (see "Standard com‐mands", Page 81)

9.4.3 Test tools for the configuration

With the aid of the PLC you can read information from the MSTR2 Flexi Loop accessory.

b Login to the configuration software for the standard controller as OBSERVER.b Change to PARAMETER on the IO-Link port used.b Change to OBSERVATION MENU in the command tree.b Open the CONFIG. CHECK branch.✓ Test operations for the configuration are displayed.

Figure 103: Test operations for the configuration

1 Parameter2 Observation Menu3 Config. Check

TROUBLESHOOTING 9



Config Error

Open an overview of incorrectly configured Flexi Loop nodes using the NODE CONFIG. MIS‐MATCH command.

The index is 4 bytes long. The 32 bits are each allocated to one of the Flexi Loop nodes.Bit 0 to 31 correspond to the Flexi Loop nodes 32 to 1.

• The bit is 1 if there is a different Flexi Loop node configuration.• The bit is 0 if there is no difference.

Checksum

Using the FLEXI LOOP CRC command you can read the checksum for the currently validconfiguration.

Cable connection

You can open information on possible cable breaks using the CABLE INTEGRITY CHECK com‐mand.

The subindex STATUS contains the status of the cables.

• 0: cable connection in order, safe sensor cascade terminated• 1: communication cable with short-circuit to GND• 2: communication cable with short-circuit to VDC• 3: more nodes than allowed and safe sensor cascade not terminated• 4: more nodes than allowed and safe sensor cascade terminated

The subindex POSITION contains the node position after which an interruption has beendetected.

9 TROUBLESHOOTING


10 Technical data10.1 Data sheet

10.1.1 Overall system

Overall system

Safety-related parameters 1) 2)

Safety Integrity Level SIL3 (IEC 61 508)

SIL claim limit SILCL3 (EN 62 061)

Category Category 4 (EN ISO 13 849-1)

Performance Level PL e (EN ISO 13 849-1)

PFHd (probability of a dangerous fail‐ure per hour) of a Flexi Loop safesensor cascade

0.76 × 10–9

TM (mission time) 20 years

Table 39: Data sheet overall system

1) For detailed information on the safety design of your machine/system, please contact your local SICKsubsidiary.

2) This information relates to an ambient temperature of +40 °C, which is normally used for the statisticalcalculation of the values.

10.1.2 All Flexi Loop nodes and Flexi Loop accessories

Flexi Loop node and Flexi Loop accessories

General data

Protection class III (EN 61 140)

Enclosure rating IP 65 and IP 67 (EN 60 529)UL Type 1

Ambient temperature in operation –25 … +55 °C

Storage temperature –25 … +70 °C

Shock resistance

Continuous shock 10 g, 16 ms (EN 60 068-2-64)

Single shock 30 g, 11 ms (EN 60 068-2-27)

Electromagnetic compatibility Class A (EN 61 000-6-2, EN 55 011)

Dimensions 1) (W × H × D) 68.15 × 45 × 18 mm

Weight 1) 28 g (±5 %)

Housing material Polycarbonate (PC)Acrylonitrile butadiene styrene (ABS)Polyester

Torque for the plug connector M12 Max. 0.2 Nm

Response time with Flexi Soft For the response time of the Flexi Soft safety controller(see section “Calculation of the response times” in theFlexi Soft Hardware operating instructions) it is necessa‐ry to add to the sum E1 (case b = testable sensors type4) the following value:10 ms

Table 40: Data sheet Flexi Loop node and Flexi Loop accessories

TECHNICAL DATA 10




Response time with Flexi Classic For the response time of the Flexi Classic safety control‐ler (see section "Technical specifications" in the FlexiClassic operating instructions) it is necessary to add tothe value "Response time on connection of Flexi Loop"the following value:10 ms

Minimum shutdown time

FLN-OSSD 7)

FLN-EMSS 8)

10 ms40 ms

Minimum time before switching backon 2)

120 ms

Max. power-up delay after switchingon the operating voltageFLN-OSSD, FLN-EMSS and FLA-DIAGFLA-PWRIFLA-MSTR

5 s10 s30 s

Propagation times of the diagnostic bits and the bits for the non-safe inputs and outputs

AUX_IN 3)

with 1 … 8 Flexi loop nodeswith 9 … 16 Flexi loop nodeswith 17 … 24 Flexi loop nodeswith 25 … 32 Flexi loop nodes

404 ms540 ms668 ms796 ms

AUX_OUT 3)


305 ms441 ms569 ms697 ms

DIAG_IN 3) 4)


712 ms1400 ms2288 ms3376 ms

DIAG_OUT 3) 4)


708 ms1396 ms2284 ms3372 ms

Electrical data

Supply voltage (VS) 16.8 … 30 V DC

Supply voltage for UL/CSA applica‐tions

24 V DC

Type of supply voltage SELV or PELV

Overvoltage shutdown At 34.5 V DC ±2 V DC

Undervoltage shutdown At 15.5 V DC ±1 V DC

Maximum current at 40 °C 4 A 5)

Maximum current at 55 °C 3.19 A

Current on Flexi Loop communicationinputs

3 … 6.2 mA


10 TECHNICAL DATA



Maximum short-circuit currents(Flexi Loop communication andTest outputs)

13.5 mA

Current consumption

FLN-OSSD 45 mA

FLN-EMSS 55 mA

FLA-PWRI 30 mA (PWR Left)/55 mA (PWR Right)

FLT-TERM 30 mA

FLA-DIAG 55 mA

FLA-MSTR 60 mA

System connection M12 male/female connector 6)


1) Not terminator.2) Time following shutdown after which the device can be switched on again at the earliest.3) Applies for an execution time within the logic of 4 ms.4) Applies on the occurrence of one event.5) The current from the power supply that supplies the Flexi Loop must be limited externally to max. 4 A —

either by the power supply itself or by a fuse.6) Terminator, only male connector.7) Time without sensor, in addition the data for the sensors connected apply.8) Is taken into account automatically on the calculation of the joint response time of the safety controller

and the safe sensor cascade.

10.1.3 EMSS Flexi Loop node (FLN-EMSS0000105 and FLN-EMSS1100108)

FLN-EMSS0000105FLN-EMSS1100108

EMSS inputs/outputs

Test pulse duration (test spacing) 12 ms

Test period 40 ms

Current due to the test signal via theswitch contacts

3 … 6.2 mA AC 1) at VS –3 V

Discrepancy time monitoring 3 s

Table 41: Data sheet EMSS Flexi Loop node

1) Pulsing alternating current with test spacing.

Additional data on the 8-pin variant FLN-EMSS1100108

FLN-EMSS1100108

Non-safe input (AUX_IN)

Logic level switching points

HIGH >13 V/3.5 mA

LOW <5 V/2.5 mA

Maximum input current 6.2 mA

Debouncing 100 ms

Non-safe output (AUX_OUT)

Type of output Highside driver, short-circuit protected

Output current Max. 500 mA

Table 42: Additional data on the FLN-EMSS1100108 variant

TECHNICAL DATA 10



FLN-EMSS1100108

Permissible capacitive load Max. 1 µF

Internal discharging resistance Typical 200 kOhm

Table 42: Additional data on the FLN-EMSS1100108 variant

10.1.4 OSSD Flexi Loop node (FLN-OSSD1000105 and FLN-OSSD1100108)

FLN-OSSD1000105FLN-OSSD1100108

OSSD inputs

Input voltage HIGH 13 … 30 V DC

Input voltage LOW –5 … +5 V DC

Input current HIGH 3.5 … 6.2 mA

Input current LOW –2.5 … +2.5 mA

Test pulse duration (test spacing) 1) <1 ms

Discrepancy time monitoring 3 s

Voltage supply for OSSD devices

Supply voltage 16.8 … 30 V DC

Maximum current

FLN-OSSD1000105 at 40 °C 3.9 A

FLN-OSSD1100108 at 40 °C 2 A

FLN-OSSD1000105 at 55 °C 3.1 A

FLN-OSSD1100108 at 55 °C 1.5 A



HIGH >13 V/3.5 mA

LOW <5 V/2.5 mA


Debouncing 100 ms

Table 43: Data sheet OSSD Flexi Loop node

1) Is defined by the OSSD device.

Additional data on the 8-pin variant FLN-OSSD1100108

FLN-OSSD1100108

Non-safe output (AUX_OUT)

Type of output Highside driver, short-circuit protected


Permissible capacitive load Max. 1 µF

Internal discharging resistance Typical 200 kOhm

Table 44: Additional data on the FLN-OSSD1100108 variant

10 TECHNICAL DATA


10.1.5 Terminator

FLT-TERM00001

Dimensions terminator(W × H × D)

54 × 13.6 × 13.6 mm

Weight terminator 8 g (±5 %)

Current consumption 30 mA

Table 45: Data sheet FLT-TERM00001 terminator

10.1.6 PWRI power supply accessory

FLA-PWRI00001

Electrical data

Internal resistance Approx. 50 mΩ

Output current monitoring

Permissible capacitive load Max. 4.7 mF

Permissible inductive load Max. L = 0.74 J/I²e.g.: 0.18 H @ 2.0 A2.90 H @ 0.5 A

Table 46: Data sheet PWRI power supply accessory

Characteristic curve

Figure 104: Characteristic curve for PWRI power supply accessory

1 Current characteristic at 40 °C2 Tolerance3 Permissible continuous current4 Emergency shutdown

TECHNICAL DATA 10



10.1.7 MSTR Flexi Loop accessory

FLA-MSTR00001FLA-MSTR00002

Test inputs for the Flexi Classic connection layout (FC_A1 and FC_B1)

Input voltage HIGH 13 … 30 V DC

Input voltage LOW –5 … +5 V DC

Input current HIGH 3.5 … 6.2 mA

Input current LOW –2.5 … +2.5 mA

Test outputs for the Flexi Classic connection layout (FC_A2 and FC_B2)

Maximum short-circuit currents 13.5 mA

Table 47: Data sheet MSTR Flexi Loop accessory

Additional data on the variant FLA-MSTR00002 with IO-Link interface

FLA-MSTR00002

General electrical data

Supply voltage (VS) on usage of IO-Link

18 … 30 V DC

Non-safe output (C/Q or AUX_OUT)

Type of output Highside driver, short-circuit protected, or IO-Link


Permissible capacitive load Max. 100 nF

Debouncing 100 ms



HIGH >13 V/3.5 mA

LOW <5 V/2.5 mA


Debouncing 100 ms

Table 48: Additional data on the FLA-MSTR00002 variant

10 TECHNICAL DATA


10.2 Dimensional drawings

10.2.1 Dimensional drawing Flexi Loop node

Figure 105: Dimensional drawing Flexi Loop node (mm)

10.2.2 Dimensional drawing PWRI power supply accessory

Figure 106: Dimensional drawing PWRI power supply accessory (mm)

TECHNICAL DATA 10



10.2.3 Dimensional drawing terminator

Figure 107: Dimensional drawing Flexi Loop termination element (mm)

10.2.4 Dimensional drawing C-Fix bracket

Figure 108: Dimensional drawing C-Fix bracket (mm)

10 TECHNICAL DATA


10.2.5 Dimensional drawing MSTR Flexi Loop accessory

Figure 109: Dimensional drawing FLA-MSTR00001 Flexi Loop accessory (mm)

Figure 110: Dimensional drawing FLA-MSTR00002 Flexi Loop accessory (mm)

TECHNICAL DATA 10



10.2.6 Dimensional drawing DIAG Flexi Loop accessory

Figure 111: Dimensional drawing DIAG Flexi Loop accessory (mm)

10.2.7 Dimensional drawing YCON Flexi Loop accessory

Figure 112: Dimensional drawing FLA-YCON (EMSS/OSSD) Flexi Loop accessory

10 TECHNICAL DATA


11 Ordering information11.1 Scope of delivery

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

• Flexi Loop node or Flexi Loop accessory depending on order• general safety notes

11.2 Flexi Loop node

Part Description Part number

FLN-OSSD1000105 Flexi Loop nodefor a safety sensor with monitored semiconductoroutput (OSSD)with one non-safe input

1061709

FLN-OSSD1100108 Flexi Loop nodefor a safety sensor with monitored semiconductoroutput (OSSD)with one non-safe inputwith one non-safe output

1061710

FLN-EMSS0000105 Flexi Loop nodefor a dual-channel, equivalent switching, electro-mechanical safety switch

1061711

FLN-EMSS1100108 Flexi Loop nodefor a dual-channel, equivalent switching, electro-mechanical safety switchwith one non-safe inputwith one non-safe output

1061712

Table 49: Part numbers Flexi Loop nodes

11.3 Flexi Loop accessories


FLA-PWRI00001 Flexi Loop accessoriesfor supply of powerfor electrical isolationfor overcurrent shutdown

1061715

FLT-TERM00001 Flexi Loop termination element 1061716

FLA-MSTR00001 Flexi Loop accessoriesfor connection to Flexi Classic or to safe relayfor system monitoring during commissioning/inoperation

1061713

FLA-MSTR00002 Flexi Loop accessoriesfor connection to Flexi Classic or to safe relayfor system monitoring during commissioning/inoperationIO-Link interface for diagnostics and standardIO controller

1067650

FLA-DIAG00001 Flexi Loop accessoriesfor system monitoring during commissioning/inoperation

1061714

Table 50: Part numbers Flexi Loop accessories

ORDERING INFORMATION 11




FLA-YCON00001 Flexi Loop connection adapter (EMSS)

• FLN: male connector, M12, 8-pin

• AUX: female connector, M12, 5-pin

• EMSS: female connector, M12, 5-pin

2074672

FLA-YCON00002 Flexi Loop connection adapter (OSSD)

• FLN: male connector, M12, 8-pin

• AUX: female connector, M12, 5-pin

• OSSD: female connector, M12, 5-pin

2074674

Table 50: Part numbers Flexi Loop accessories

11.4 Accessories

11.4.1 Plug connectors


STE – 12 05 – G Male connector, M12, IP 67, 5-pin, Imax 4 A 6022083

STE – 12 08 – G Male connector, M12, IP 67, 8-pin, Imax 2 A 6033269

DOS – 12 05 – G Female connector, M12, IP 67, 5-pin, Imax 4 A 6009719

DOS – 12 08 – G Female connector, M12, IP 67, 8-pin, Imax 2 A 6028422

Table 51: Part numbers plug connectors

11.4.2 Pre-assembled cables


STL – 12 05 – G 01M C Cable male connector/stranded conductor,M12, 5-pin, 5 × 0.34 mm², 1 m

6037741


6051951


6051952


6051953


6051954


6051955


6051956


6051957

DSL – 12 05 – G 0M6 C Cable male/female connector, M12, 5-pin, 5 ×0.34 mm², 0.6 m

6025930

DSL – 12 05 – G 01M C Cable male/female connector, M12, 5-pin, 5 ×0.34 mm², 1 m

6029280


6029281

Table 52: Part numbers pre-assembled cables

11 ORDERING INFORMATION




6025931


6029282


6038954


6044991


6051940


6051941


6051942


6051943


6051944


6038956


6038957


6051945

DOL – 12 05 – G 05M C Cable stranded conductor/female connector,M12, 5-pin, 5 × 0.34 mm², 5 m

6025907


6025908


6051946


6050247


6050248

DSL – 12 04 – G 0M2 C Adapter cable male/female connector, M12,4-pin male connector to 4-pin female connec‐tor, 4 × 0.34 mm², 0.2 m

6051998

Table 52: Part numbers pre-assembled cables

11.4.3 Mounting accessories

Part Part number

C-Fix bracket 2068830

Table 53: Part numbers mounting accessories

ORDERING INFORMATION 11



12 List of figuresFig. 1. Flexi Loop safe sensor cascade........................................................................12Fig. 2. Error masking.....................................................................................................14Fig. 3. Subdivision of the safe sensor cascade.......................................................... 15Fig. 4. Supply of power................................................................................................. 16Fig. 5. The Flexi Loop safe input bit in the Flexi Soft Designer logic editor.............. 17Fig. 6. Diagnostics information in the Flexi Soft Designer logic editor......................17Fig. 7. Diagnostics information on the individual Flexi Loop nodes in the Flexi Soft

Designer logic editor..........................................................................................18Fig. 8. MSTR1 Flexi Loop accessor on the Flexi Classic safety controller.................19Fig. 9. IO functions of the MSTR2 Flexi Loop accessory............................................ 20Fig. 10. IO-Link functions of the MSTR2 Flexi Loop accessory.................................... 21Fig. 11. FLN-EMSS0000105 Flexi Loop node — 5-pin................................................. 22Fig. 12. FLN-EMSS1100108 Flexi Loop node — 8-pin................................................. 23Fig. 13. FLN-OSSD1000105 Flexi Loop node — 5-pin..................................................23Fig. 14. FLN-OSSD1100108 Flexi Loop node — 8-pin..................................................23Fig. 15. FLA-PWRI00001 power supply accessory....................................................... 24Fig. 16. FLT-TERM00001 terminator.............................................................................24Fig. 17. FLA-MSTR00001 Flexi Loop accessory............................................................24Fig. 18. FLA-MSTR00002 Flexi Loop accessory............................................................25Fig. 19. FLA-DIAG00001 Flexi Loop accessory............................................................. 25Fig. 20. MS LED...............................................................................................................26Fig. 21. LEDs of the EMSS Flexi Loop nodes................................................................ 26Fig. 22. LEDs of the OSSD Flexi Loop nodes.................................................................26Fig. 23. LEDs of the PWRI power supply accessory......................................................27Fig. 24. Node LEDs 1 to 32............................................................................................ 27Fig. 25. Application example.......................................................................................... 27Fig. 26. Direct connection to the power source for the Flexi Soft safety controller... 29Fig. 27. Connection via PWRI power supply accessory................................................ 30Fig. 28. Direct connection to the power source for the Flexi Classic safety controller

............................................................................................................................ 30Fig. 29. Connection via PWRI power supply accessory................................................ 31Fig. 30. Division into sections........................................................................................ 32Fig. 31. Configuring Flexi Loop modules....................................................................... 35Fig. 32. Switching to design........................................................................................... 36Fig. 33. Calculating voltage drop and power consumption..........................................36Fig. 34. Calculated energy balance............................................................................... 37Fig. 35. Implementation of reset and restart as well as the flashing mode in the

logic editor..........................................................................................................38Fig. 36. Reset with the Flexi Classic safety controller.................................................. 39Fig. 37. Connection of a safety locking device to the EMSS node.............................. 40Fig. 38. Elements on the EMSS node............................................................................ 41Fig. 39. Locking device in the logic editor..................................................................... 41Fig. 40. Locking device with the Flexi Classic safety controller................................... 42Fig. 41. Mounting in a cable channel............................................................................ 44Fig. 42. Mounting with cable tie.....................................................................................44Fig. 43. C-Fix bracket...................................................................................................... 45Fig. 44. Mounting the Flexi Loop node with C-Fix bracket............................................45Fig. 45. Terminals on the Flexi Soft expansion modules..............................................46Fig. 46. Connection to Flexi Soft.................................................................................... 47Fig. 47. Terminals on the Flexi Classic main module................................................... 47Fig. 48. Connection to Flexi Classic............................................................................... 48Fig. 49. Connections of the Flexi Loop nodes............................................................... 48Fig. 50. Connection FL_OUT to FL_IN............................................................................ 49Fig. 51. Connections of the EMSS Flexi Loop node...................................................... 49Fig. 52. Connection sketch dual-channel equivalent switch........................................50

12 LIST OF FIGURES


Fig. 53. Connections of the OSSD Flexi Loop node...................................................... 50Fig. 54. Connections of the PWRI power supply accessory..........................................52Fig. 55. Connections of the MSTR1 Flexi Loop accessory............................................52Fig. 56. Connections of the MSTR2 Flexi Loop accessory............................................53Fig. 57. Connections of the DIAG Flexi Loop accessory............................................... 54Fig. 58. Selection of the firmware for the main module...............................................55Fig. 59. Selection of firmware for the I/O module........................................................ 56Fig. 60. Flexi Loop strings 1 to 8....................................................................................56Fig. 61. Identification via Flexi Loop number................................................................ 57Fig. 62. Selection of the Flexi Loop string..................................................................... 57Fig. 63. Connection symbols for a Flexi Loop string..................................................... 57Fig. 64. Flexi Loop view...................................................................................................58Fig. 65. Selection of additional interfaces.....................................................................58Fig. 66. Selection of a Flexi Loop node..........................................................................59Fig. 67. Flexi Loop node in the Flexi Loop configuration.............................................. 59Fig. 68. Flexi Loop in the Flexi Soft Designer................................................................ 60Fig. 69. Module properties............................................................................................. 61Fig. 70. Pin assignment.................................................................................................. 62Fig. 71. Flexi Loop error report.......................................................................................63Fig. 72. Disabling tamper protection............................................................................. 64Fig. 73. Changing to the elements.................................................................................64Fig. 74. Selection of the element...................................................................................64Fig. 75. Suitable free inputs or outputs.........................................................................65Fig. 76. Flexi Loop node with element...........................................................................65Fig. 77. Button for exporting and importing the configuration.....................................66Fig. 78. Flexi Loop in the logic editor of the Flexi Soft Designer..................................66Fig. 79. Tooltips in the logic editor.................................................................................67Fig. 80. Non-safe inputs and outputs in the Flexi Soft Designer logic editor..............67Fig. 81. Diagnostics information in the Flexi Soft Designer logic editor......................68Fig. 82. Diagnostics information on the individual Flexi Loop nodes in the Flexi Soft

Designer logic editor..........................................................................................68Fig. 83. Activation of the flashing mode........................................................................69Fig. 84. Deactivate the output monitoring.................................................................... 69Fig. 85. Transfer of a configuration............................................................................... 70Fig. 86. Transfer and start of a configuration............................................................... 70Fig. 87. The safe sensor cascade in operation............................................................. 70Fig. 88. Available bytes of the safe sensor cascade.................................................... 71Fig. 89. Report in the Flexi Soft Designer......................................................................72Fig. 90. MSTR Flexi Loop accessory with operating mode LED................................... 73Fig. 91. Commands and parameters in the IODD.........................................................74Fig. 92. Logical numbering of the Flexi Loop nodes..................................................... 75Fig. 93. MS LED...............................................................................................................26Fig. 94. Direction indication on the MS LEDs................................................................86Fig. 95. LEDs of the EMSS Flexi Loop nodes................................................................ 87Fig. 96. LEDs of the OSSD Flexi Loop nodes.................................................................88Fig. 97. LEDs of the PWRI power supply accessory......................................................88Fig. 98. LEDs of the MSTR1 Flexi Loop accessory........................................................89Fig. 99. LEDs of the MSTR2 Flexi Loop accessory........................................................90Fig. 100. LEDs of the DIAG Flexi Loop accessory............................................................92Fig. 101. Diagnostics in the Flexi Soft Designer..............................................................93Fig. 102. Observation Menu............................................................................................. 94Fig. 103. Test operations for the configuration...............................................................95Fig. 104. Characteristic curve for PWRI power supply accessory................................101Fig. 105. Dimensional drawing Flexi Loop node (mm)................................................. 103Fig. 106. Dimensional drawing PWRI power supply accessory (mm)..........................103Fig. 107. Dimensional drawing Flexi Loop termination element (mm)....................... 104Fig. 108. Dimensional drawing C-Fix bracket (mm)......................................................104

LIST OF FIGURES 12



Fig. 109. Dimensional drawing FLA-MSTR00001 Flexi Loop accessory (mm)........... 105Fig. 110. Dimensional drawing FLA-MSTR00002 Flexi Loop accessory (mm)........... 105Fig. 111. Dimensional drawing DIAG Flexi Loop accessory (mm)................................106Fig. 112. Dimensional drawing FLA-YCON (EMSS/OSSD) Flexi Loop accessory........ 106

12 LIST OF FIGURES


13 List of tablesTab. 1. Available documents........................................................................................... 7Tab. 2. Permissible total current within a section....................................................... 28Tab. 3. Example voltage drop on 10 Flexi Loop nodes................................................33Tab. 4. Example voltage drop on 15 Flexi Loop nodes................................................33Tab. 5. Example voltage drop on 15 Flexi Loop nodes with PWRI..............................33Tab. 6. Example voltage drop on 15 Flexi Loop nodes with wire cross-section 0.75

mm².................................................................................................................... 33Tab. 7. Example voltage drop due to current consumption of connected devices... 34Tab. 8. Example voltage drop on 10 Flexi Loop nodes with PWRI..............................34Tab. 9. Example voltage drop on 10 Flexi Loop nodes with wire cross-section 0.75

mm².................................................................................................................... 34Tab. 10. Pin assignment safety locking device to EMSS node..................................... 40Tab. 11. Pin assignment FL_IN (male connector)..........................................................49Tab. 12. Pin assignment EMSS 5-pin (female connector).............................................50Tab. 13. Pin assignment EMSS 8-pin (female connector).............................................50Tab. 14. Pin assignment OSSD 5-pin (female connector)............................................. 51Tab. 15. Pin assignment OSSD 8-pin (female connector)............................................. 51Tab. 16. Pin assignment PWRI 5-pin (male connector)................................................. 52Tab. 17. Pin assignment FC_IN 8-pin (male connector)................................................ 53Tab. 18. Pin assignment FC_IN 8-pin (male connector)................................................ 53Tab. 19. Pin assignment IO-Link 5-pin (male connector).............................................. 54Tab. 20. Pin assignment FL_IN (male connector)..........................................................49Tab. 21. Displays of the MS LEDs................................................................................... 85Tab. 22. EMSS LEDs and MS LED of the EMSS Flexi Loop nodes................................87Tab. 23. AUX_IN LED of the EMSS Flexi Loop nodes..................................................... 87Tab. 24. AUX_OUT LED of the EMSS Flexi Loop nodes..................................................87Tab. 25. OSSD LEDs and MS LED of the OSSD Flexi Loop nodes................................ 88Tab. 26. AUX_IN LED of the OSSD Flexi Loop nodes..................................................... 88Tab. 27. AUX_OUT LED of the OSSD Flexi Loop nodes.................................................. 88Tab. 28. PWR Right LED of the PWRI power supply accessory..................................... 89Tab. 29. PWR Left LED of the PWRI power supply accessory....................................... 89Tab. 30. Overload LED of the PWRI power supply accessory........................................89Tab. 31. Node LEDs of the MSTR1 and MSTR2 Flexi Loop accessory......................... 89Tab. 32. Operating mode LED of the MSTR1 and MSTR2 Flexi Loop accessories......90Tab. 33. Node LEDs of the MSTR1 and MSTR2 Flexi Loop accessory......................... 89Tab. 34. Operating mode LED of the MSTR1 and MSTR2 Flexi Loop accessories......90Tab. 35. IO-Link LED of the MSTR2 Flexi Loop accessory............................................. 91Tab. 36. Node LEDs of the DIAG Flexi Loop accessory..................................................92Tab. 37. Operating mode LED of the DIAG Flexi Loop accessory..................................92Tab. 38. Loop integrity LED on the DIAG Flexi Loop accessory.....................................92Tab. 39. Data sheet overall system................................................................................ 97Tab. 40. Data sheet Flexi Loop node and Flexi Loop accessories................................97Tab. 41. Data sheet EMSS Flexi Loop node................................................................... 99Tab. 42. Additional data on the FLN-EMSS1100108 variant....................................... 99Tab. 43. Data sheet OSSD Flexi Loop node................................................................. 100Tab. 44. Additional data on the FLN-OSSD1100108 variant..................................... 100Tab. 45. Data sheet FLT-TERM00001 terminator....................................................... 101Tab. 46. Data sheet PWRI power supply accessory.................................................... 101Tab. 47. Data sheet MSTR Flexi Loop accessory.........................................................102Tab. 48. Additional data on the FLA-MSTR00002 variant.......................................... 102Tab. 49. Part numbers Flexi Loop nodes......................................................................107Tab. 50. Part numbers Flexi Loop accessories............................................................ 107Tab. 51. Part numbers plug connectors.......................................................................108Tab. 52. Part numbers pre-assembled cables.............................................................108Tab. 53. Part numbers mounting accessories.............................................................109

LIST OF TABLES 13



Tab. 54. Checklist for the manufacturer...................................................................... 117

13 LIST OF TABLES


14 Appendix14.1 Conformity with EU directives

EU declaration of conformity page 1

APPENDIX 14



EU declaration of conformity page 2

14 APPENDIX


14.2 Checklist for the manufacturer

Checklist for the manufacturer/installer for installation of the Flexi Soft safety controllerThe information for the points listed below must at least be available the first time the equip‐ment is commissioned. They depend on the application the requirements of which must beverified by the manufacturer/installer.This checklist should be retained and kept with the machine documentation to serve as refer‐ence during recurring tests.

Have the safety rules and regulations been observed in compli‐ance with the directives/standards applicable to the machine?

Yes ⃞ No ⃞

Are the applied directives and standards listed in the declarationof conformity?

Yes ⃞ No ⃞

Does the protective device comply with the required category? Yes ⃞ No ⃞Are the required protective measures against electric shock in ef‐fect (protection class)?

Yes ⃞ No ⃞

Has the protective function been checked in compliance with thetest notes of this documentation? In particular:functional check of the input devices, sensors and actuators con‐nected to the safety controllerthorough check of all cut-off paths

Yes ⃞ No ⃞

Are you sure that the safety controller was tested fully for safetyfunctionality after each configuration change?

Yes ⃞ No ⃞

This checklist does not replace the initial commissioning, nor the regular thorough checks byqualified safety personnel.

Table 54: Checklist for the manufacturer

APPENDIX 14



14 APPENDIX


APPENDIX 14



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