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SICK FLX3-CPUC100 User Manual

SICK FLX3-CPUC100
156 pages
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O P E R A T I N G I N S T R U C T I O N S
Flexi Compact
Safety controller
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SICK FLX3-CPUC100 Specifications

General IconGeneral
BrandSICK
ModelFLX3-CPUC100
CategoryController
LanguageEnglish

Summary

1 About this document

1.1 Purpose of this document

Explains the goal of the operating instructions for the safety controller.

1.2 Scope

Defines the applicability of the operating instructions to the Flexi Compact safety controller.

1.3 Target groups and structure of these operating instructions

Identifies intended users and organizes content by device lifecycle phases.

1.4 Further information

Provides links to additional resources and information available via the internet.

1.5 Symbols and document conventions

Explains symbols and conventions used throughout the document for clarity.

2 Safety information

2.1 General safety notes

Covers essential safety information applicable to the safety controller.

2.2 Intended use

Describes the Flexi Compact safety controller's purpose for safety applications.

2.3 Improper use

Lists applications for which the safety controller is not suitable.

2.4 Requirements for the qualification of personnel

Outlines the necessary qualifications for personnel involved in safety controller tasks.

3 Product description

3.1 Configuration of the safety controller

Details the components and configuration of the Flexi Compact safety controller system.

3.2 Overview of the module

Provides a visual overview and identification of key components for the safety controller modules.

3.3 Configuration and function

Explains the module's interfaces, configuration options, and overall function.

3.4 Status indicators

Describes the LEDs and their meanings for indicating the status of the device.

3.5 Interfaces

Details the available interfaces for the safety controller, including SmartPlug and network connections.

4 Project planning

4.1 Manufacturer of the machine

Addresses obligations and hazards related to the machine manufacturer's role.

4.2 Operating entity of the machine

Covers obligations and hazards for the operating entity of the machine.

4.3 Design

Outlines design considerations including mounting, IP ratings, and air circulation.

4.4 Muting application

Details safety notes and general descriptions for implementing muting functions.

4.5 Electrical integration

Covers internal circuitry, fault detection using test outputs, and safety outputs.

4.6 Integration into the controller network

Explains network topologies and integration via fieldbus interfaces.

4.7 Testing plan

Defines requirements for thorough checks during commissioning and regular maintenance.

5 Mounting

5.1 Safety

Provides critical safety warnings regarding electrical voltage and unintended machine start.

5.2 Mounting procedure

Details prerequisites and steps for mounting the main and expansion modules.

5.3 Mounting the SmartPlug in the main module

Describes the procedure for installing the SmartPlug into the main module.

5.4 Disassembly

Explains the steps required to disassemble the safety controller modules.

5.5 Module exchange

Outlines the procedure for replacing a defective module with a new one.

6 Electrical installation

6.1 Safety

Provides critical safety warnings before commencing electrical installation.

6.2 Device connection

Details prerequisites for electrical connection and network cable requirements.

6.3 Coding

Explains the overview and options for coding front connectors and modules to prevent mix-ups.

7 Configuration

7.1 Safety Designer configuration software

Introduces the Safety Designer software for configuring the safety controller.

7.2 Offline, online and security configuration

Describes different configuration types: offline, online, and security settings.

7.3 Overview main navigation menu

Mentions that the Overview menu contains configuration information.

7.4 Configuration main navigation menu

Guides through combining modules and elements, using the catalog, and navigation pane.

7.5 Configuring the network interfaces

Details how to configure Modbus and SLMP connections for network communication.

7.6 Logic editor main navigation

Introduces the graphic logic editor for programming function logic.

7.6.1 Inputs

Lists available input elements for creating logic programs in the Safety Designer.

7.6.2 Function blocks

Explains that logic is programmed using function blocks, which contain inputs, outputs, and logic.

7.6.2.4 Function blocks for input evaluation

Describes function blocks for evaluating inputs, including two-hand control and dual-channel monitors.

7.6.2.4.3 Dual channel monitor V1

Details the Dual Channel Monitor V1 function block for evaluating dual-channel switches.

7.6.2.4.4 Edge detection V1

Explains the Edge Detection V1 function block for detecting rising and falling signal edges.

7.6.2.5 Function blocks for output control

Covers function blocks used for controlling outputs, such as external device monitoring.

7.6.2.5.1 External device monitoring V1

Describes monitoring a switching amplifier with a feedback channel.

7.6.2.5.2 Fast shut off V1

Explains the Fast Shut Off V1 function block for minimizing switch-off time.

7.6.2.6 Function blocks for applications

Introduces function blocks designed for specific application logic, like reset and restart.

7.6.2.6.1 Reset V1

Details the Reset V1 function block for acknowledging safety stops and restarting applications.

7.6.2.6.2 Restart V1 (Restart)

Explains the Restart V1 function block for implementing restart functionality.

7.6.2.6.3 Multi operator V1

Describes the Multi Operator V1 function block for operating multiple two-hand controls.

7.6.2.6.4 Operating mode switch V1

Explains the Operating Mode Switch V1 function block for selecting outputs based on input values.

7.6.2.6.5 Multi enable V1

Details the Multi Enable V1 function block for enabling outputs based on input and release signals.

7.6.2.6.6 Multi latch V1

Explains the Multi Latch V1 function block for saving input statuses to outputs.

7.6.2.7 Function blocks for muting

Introduces function blocks specifically for implementing muting sequences.

7.6.2.7.1 Parallel muting V1

Describes the Parallel Muting V1 function block for muting with sensor pairs in parallel.

7.6.2.7.2 Sequential muting V1

Details the Sequential Muting V1 function block for muting with sensor pairs in sequence.

7.6.2.7.3 Cross muting V1

Explains the Cross Muting V1 function block for muting with sensor pairs arranged crosswise.

7.6.2.7.4 Input Override

Describes the Input Override function for managing transported objects during muting.

7.6.2.7.5 Input Band signal

Details the Input Band signal for controlling muting timers based on conveyor status.

7.6.2.7.6 Output Muting error

Explains the Muting error output and how errors are reset for muting function blocks.

7.6.2.7.7 Parameter Direction detection

Allows tightening muting conditions based on material transport direction.

7.6.2.7.8 Parameter Suppression of sensor signal gaps

Filters out brief faults in muting sensors without interrupting muting.

7.6.2.7.9 Parameter Concurrency monitoring time

Checks if muting sensors are activated simultaneously and if values match.

7.6.2.7.10 Parameter Total muting time

Limits the maximum duration of the muting sequence.

7.6.2.7.11 Parameter Additional muting time after the ESPE is released

Provides extra muting time when the ESPE input switches back to 1.

7.6.2.7.12 Parameter Condition for end of muting

Determines when a valid muting status is over based on sensor or ESPE status.

7.6.2.7.13 Parameter Condition of the other sensor pair for muting start

Defines the start conditions for the next valid muting sequence.

7.6.3 Outputs

Lists the available output elements for logic programs.

7.6.4 Diagnostics

Explains how to use process data status bits as input elements for logic diagnostics.

7.6.5 CPU marker

Describes CPU markers used as input/output elements for creating reverse paths and connecting logic.

7.6.6 Jump addresses

Explains jump addresses for creating reverse paths and connecting logic across pages.

7.6.7 Logic programming in the logic editor

Covers considerations for safety logic, edge detection, and function block execution sequence.

7.6.7.1 Safety

Highlights crucial safety considerations when implementing logic in the editor.

7.6.7.2 Adding an element

Guides on adding elements from the CPU logic catalog to the worksheet.

7.6.7.3 Connecting elements

Explains how to connect inputs and outputs of elements and function blocks.

7.6.7.4 Configuring function blocks

Details the process of configuring parameters for function blocks.

7.6.7.5 Testing the logic program

Describes how to test the logic program using simulation mode.

7.6.8 Logic execution time

Explains the time required to execute one logic cycle and its dependencies.

7.6.9 I/O matrix

Describes the I/O matrix for checking input-output relationships in the logic program.

7.6.10 I/O summary page

Provides an overview of all logic pages, summarizing inputs, blocks, and outputs.

7.6.11 Logic access protection

Covers preventing unauthorized access to logic pages through protection levels.

7.6.11.1 Activating logic access protection

Details how to enable password protection for logic pages and assign access levels.

7.6.11.2 Logging in or out of a logic access level

Explains the procedure for logging into or out of different logic access levels.

7.6.11.3 Setting up logic access protection for a logic page

Describes how to set up access protection for individual logic pages.

7.6.11.4 Removing the logic access protection from a logic page

Explains how to remove existing access protection from logic pages.

7.6.11.5 Applying visibility protection to a logic page

Details how to apply visibility protection to logic pages to control content viewing.

7.6.11.6 Removing visibility protection from a logic page

Explains how to remove visibility protection from logic pages.

7.7 Report main navigation menu

Mentions that the report summarizes controller configuration and can be exported.

7.8 Service main navigation menu

Lists service functions like rebooting, factory reset, and password management.

7.9 Establishing a connection

Guides on connecting the configuration software to the safety controller.

7.10 Transferring the configuration

Explains how to transfer the configuration to the safety controller, with important notes on overwriting.

7.11 Verification

Describes the verification process to confirm configuration accuracy and safety function compliance.

7.11.1 Verifying the configuration content and configuration transfer at the same time

Details the procedure for simultaneously verifying configuration content and transfer.

7.12 Checksums

Explains checksums used for verifying configuration integrity in the project and SmartPlug.

7.13 Testing safety functions

Guides on how to test the safety functions of the application after configuration.

8 Commissioning

8.1 Check during commissioning and modifications

Outlines checks to ensure hazardous area monitoring and prevent unprotected access during commissioning.

9 Operation

9.1 Regular thorough check

Describes regular checks to ensure hazardous area monitoring and prevent access.

10 Maintenance

10.1 Regular thorough check

Details regular checks to verify hazardous area monitoring and prevent access.

11 Troubleshooting

11.1 Status indicators

Explains the PWR and CV indications on the modules for troubleshooting.

11.2 Possible faults

Lists possible faults, their responses, and causes for the controller's inputs and outputs.

11.3 Diagnostics using Safety Designer

Covers using the Diagnostics area in Safety Designer, including error history.

12 Decommissioning

12.1 Disposal

Provides instructions for the proper disposal of unusable devices according to regulations.

13 Technical data

13.1 Data sheet

Presents safety-related characteristic data for inputs, CPU logic, and outputs.

13.2 Maximum response time

Details response times for functions, including calculation methods and examples.

13.3 Data exchange in the network

Explains data exchange protocols like Modbus® TCP and SLMP, including input/output data and checksums.

13.4 Dimensional drawings

Provides visual representations of the controller's physical dimensions.

14 Ordering information

14.1 Scope of delivery

Lists the components included in the standard delivery package of the safety controller.

14.2 Ordering information for main module

Provides part numbers and type codes for ordering main modules.

14.3 Ordering information for expansion module

Lists part numbers and type codes for ordering IO and gateway expansion modules.

14.4 Ordering information for accessories

Details part numbers and type codes for ordering accessories like front connectors and SmartPlugs.

15 Annex

15.1 Compliance with EU directives

Contains an extract of the EU declaration of conformity for the product.

16 List of figures

17 List of tables

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