OPERATING INSTRUCTIONS

Flexi Classic

Modular Safety Controller

en
 Operating instructions
Flexi Classic

This document is protected by the law of copyright, whereby all rights established therein remain with the
company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits
of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without
the explicit written approval of the company SICK AG.

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Operating instructions Contents
Flexi Classic

Contents
1 About this document.........................................................................................................6
1.1 Function of this document....................................................................................6
1.2 Target group ..........................................................................................................6
1.3 Information depth .................................................................................................6
1.4 Scope .....................................................................................................................7
1.5 Abbreviations.........................................................................................................7
1.6 Symbols used ........................................................................................................7

2 On safety...........................................................................................................................11
2.1 Qualified safety personnel..................................................................................11
2.2 Applications of the device...................................................................................11
2.3 Correct use ..........................................................................................................12
2.4 General safety notes and protective measures ................................................12
2.5 Environmental protection ...................................................................................13
2.5.1 Disposal .............................................................................................13
2.5.2 Separation of materials ....................................................................13

3 Product description.........................................................................................................14
3.1 Special features ..................................................................................................14
3.2 Structure..............................................................................................................15
3.2.1 UE410-MU main module ..................................................................15
3.2.2 UE410-GU main module ...................................................................16
3.2.3 UE410-8DI input extension module.................................................17
3.2.4 UE410-XU input/output extension ...................................................17
3.2.5 UE410-2RO/UE410-4RO output modules.......................................17
3.2.6 Gateways ...........................................................................................17
3.2.7 Module overview, adjustments and facilities for connecting
sensors ..............................................................................................18
3.3 UE410-MU main module ....................................................................................21
3.3.1 Controls and status indicators .........................................................23
3.3.2 Terminal assignment ........................................................................24
3.3.3 Outputs ..............................................................................................25
3.4 UE410-GU main module .....................................................................................26
3.4.1 Controls and status indicators .........................................................27
3.4.2 Terminal assignment ........................................................................28
3.4.3 Global emergency stop with the UE410-GU ....................................28
3.4.4 Local emergency stop on the UE410-GU.........................................30
3.4.5 Inputs .................................................................................................31
3.4.6 Outputs ..............................................................................................31
3.4.7 Connection of a UE410-8DI..............................................................32
3.4.8 Power-up delay and response time of the UE410-GU.....................32
3.4.9 Diagnostics and troubleshooting for the UE410-GU .......................32
3.5 UE410-XU module...............................................................................................34
3.5.1 Controls and status indicators .........................................................34
3.6 UE410-MU/UE410-XU programs .......................................................................35
3.6.1 Program 1..........................................................................................36
3.6.2 Program 2..........................................................................................37
3.6.3 Programs 3.1 and 3.2.......................................................................38
3.6.4 Program 4..........................................................................................39
3.6.5 Programs 5.1 and 5.2.......................................................................40
3.6.6 Program 6..........................................................................................41

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3.6.7 Program 7 ......................................................................................... 42

3.6.8 Program 8 ......................................................................................... 43
3.6.9 Program 9 ......................................................................................... 44
3.6.10 Connection of sensors to the UE410-MU/UE410-XU ..................... 45
3.7 UE410-GU programs .......................................................................................... 48
3.8 UE410-8DI input extension module .................................................................. 50
3.8.1 AND link............................................................................................. 51
3.8.2 OR link ............................................................................................... 52
3.8.3 Bypass ............................................................................................... 52
3.8.4 Reciprocal assignment — Mirror mode............................................ 53
3.8.5 Connection of sensors to the UE410-8DI........................................ 53
3.8.6 Controls and status indicators......................................................... 55
3.8.7 Inputs and outputs ........................................................................... 56
3.9 UE410-2RO/UE410-4RO output modules ........................................................ 56
3.9.1 Output module UE410-2RO ............................................................. 56
3.9.2 Output module UE410-4RO ............................................................. 57
3.9.3 Controls and status indicators......................................................... 58
3.9.4 UE410-2RO inputs and outputs....................................................... 58
3.9.5 UE410-4RO inputs and outputs....................................................... 58

4 Special applications and functions............................................................................... 59

4.1 RE300 magnetic safety switch .......................................................................... 60
4.2 IN4000 inductive safety switch ......................................................................... 61
4.3 Testable single-beam photoelectric safety switches ........................................ 62
4.4 Two-hand operation/jog mode........................................................................... 65
4.5 OR function ......................................................................................................... 66
4.6 Muting function................................................................................................... 67
4.6.1 Muting with two sensors .................................................................. 68
4.6.2 Muting cycle ...................................................................................... 68
4.6.3 Muting sensors ................................................................................. 68
4.7 Placement of muting sensors ............................................................................ 69
4.7.1 Muting with two sensors (a sensor pair), crossed placement ....... 70
4.7.2 4-sensor muting, sequential layout ................................................. 71
4.7.3 Muting with UE410-MU/UE410-XU ................................................. 71
4.8 SICK muting sensors .......................................................................................... 72
4.9 Bypass ................................................................................................................. 73
4.10 Connecting S1, S2, S3 ....................................................................................... 74
4.10.1 Operation with restart interlock ....................................................... 74
4.10.2 Operation without restart interlock.................................................. 74
4.10.3 Operation with external device monitoring (EDM) .......................... 74
4.11 Retriggering of the delayed OSSDs.................................................................... 75
4.12 Grouping of subsystems..................................................................................... 77
4.13 ENABLE input ...................................................................................................... 78
5 Mounting/dismantling ................................................................................................... 79
5.1 Steps for mounting the modules ....................................................................... 79
5.2 Steps for dismantling the modules.................................................................... 80
5.3 Removing the anti-manipulation cover ............................................................. 81
6 Electrical installation ..................................................................................................... 82

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7 Application examples and connection diagrams ........................................................84

7.1 L21 on the UE410-MU/XU..................................................................................84
7.2 Emergency stop on the UE410-MU/XU..............................................................84
7.3 RE300 on the UE410-MU/XU.............................................................................85
7.4 Two-hand IIIC on the UE410-MU/XU ..................................................................85
7.5 C2000 and emergency stop on the UE410-MU/XU, two hazardous
areas ....................................................................................................................86
7.6 i11 on the UE410-MU/XU, two independent hazardous areas........................86
7.7 IN4000 on the UE410-MU/XU ...........................................................................87
7.8 C4000 on the UE410-MU/XU, 2-sensor muting................................................87
7.9 Global emergency stop with two UE410-GU......................................................88

8 Commissioning ................................................................................................................89
8.1 Validation of the application...............................................................................89
8.2 Test notes ............................................................................................................90
8.2.1 Tests before the first commissioning...............................................90
8.2.2 Regular testing ..................................................................................90
8.2.3 Regular inspection of the protective device by qualified
safety personnel................................................................................90
9 Configuration ...................................................................................................................91
9.1 Accepting the system configuration...................................................................91

10 Diagnostics ......................................................................................................................92
10.1 In the event of faults or errors............................................................................92
10.2 Replacement of a module ..................................................................................92
10.3 SICK support........................................................................................................93
10.4 Error indications of the ERR error LED...............................................................93
10.5 Anti-manipulation measures ..............................................................................94

11 Technical specifications.................................................................................................95
11.1 Data sheet ...........................................................................................................95
11.1.1 UE410-MU/UE410-XU modules .......................................................95
11.1.2 UE410-GU module ......................................................................... 100
11.1.3 UE410-8DI input extension module.............................................. 104
11.1.4 UE410-2RO/UE410-4RO output modules.................................... 106
11.2 Dimensional drawings ..................................................................................... 110
11.2.1 UE410-MU and UE410-GU main modules.................................... 110
11.2.2 UE410-XU, UE410-8DI, UE410-2RO, UE410-4RO, UE410-
PRO, UE410-DEV, UE410-CAN modules....................................... 110

12 Ordering information.................................................................................................... 111

12.1 Available modules ............................................................................................ 111
12.2 Accessories/spare parts.................................................................................. 114
12.2.1 Single-beam photoelectric safety switches .................................. 114
12.2.2 Non-contact safety switches.......................................................... 115
12.2.3 Safety light curtains and multiple light beam safety devices ...... 116
12.2.4 Safety laser scanners and safety camera system ....................... 116
12.2.5 Muting lamps and cables .............................................................. 116
12.2.6 Anti-manipulation cover................................................................. 116

13 Annex ............................................................................................................................. 117

13.1 Compliance with EU directives ........................................................................ 117
13.2 Manufacturer’s checklist ................................................................................. 117
13.3 List of tables ..................................................................................................... 118
13.4 List of illustrations............................................................................................ 119

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Chapter 1 About this document Operating instructions
Flexi Classic

1 About this document

Please read this chapter carefully before working with this documentation and the Flexi
Classic modular safety controller.

1.1 Function of this document

These operating instructions are designed to address the technical personnel of the ma-
chine manufacturer or the machine operator in regards to safe mounting, configuration,
electrical installation, commissioning, operation and maintenance of the Flexi Classic
modular safety controller.
These operating instructions do not provide instructions for operating machines on which
the safety controller is, or will be, integrated. Information on this is to be found in the ap-
propriate operating instructions for the machine.

1.2 Target group

These operating instructions are addressed to planning engineers, machine designers and
operators of plants and systems which are to be protected by a Flexi Classic modular safe-
ty controller. They are also addressed to people who integrate the Flexi Classic modular
safety controller into a machine, initialise its use, or who are in charge of servicing and
maintaining the device.

1.3 Information depth

These operating instructions contain the following information on the Flexi Classic modular
safety controller:
mounting fault, error diagnosis and
electrical installation troubleshooting
commissioning and configuration part numbers
care and maintenance conformity and approval
Planning and using SICK protective devices also require specific technical skills which are
not detailed in this documentation.
When operating the Flexi Classic modular safety controller, the national, local and statu-
tory rules and regulations must be observed.
General information on accident prevention using opto-electronic protective devices can
be found in the competence brochure “Guidelines Safe Machinery”.
Note We also refer you to the homepage on the Internet at www.sens-control.com.
Here you will find information on:
product and application animations
configuration aid
these operating instructions in different languages for viewing and printing

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Operating instructions About this document Chapter 1
Flexi Classic

1.4 Scope
These operating instructions are original operating instructions.
These operating instructions apply to all Flexi Classic safety controller modules with the
following entry in the field Operating Instructions on the type label: “EK01” or higher. Take
into account the respectively applicable operating instructions (refer to the type label entry
on the modules).

1.5 Abbreviations
EDM External device monitoring
ESPE Electro-sensitive protective equipment (e.g. C4000)
OSSD Output signal switching device
PLC Programmable logic controller
SIL Safety Integrity Level
SILCL SIL claim limit

1.6 Symbols used

Note Refer to notes for special features of the device.
, , LED symbols describe the state of a diagnostics LED. Examples:
The LED is illuminated constantly.
The LED is flashing.
The LED is off.
Take action … Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.

Warning!
A warning notice indicates an actual or potential risk or health hazard. They are designed
WARNING to help you to prevent accidents.
Read carefully and follow the warning notices!

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Chapter 1 About this document Operating instructions
Flexi Classic
Tab. 1: Sensor symbols Symbol Sensors
Electro-mechanical safety switches

Emergency stop button

Electro-sensitive protective equipment (ESPE)

Sensors that can be tested (e.g. photoelectric switches)

Inductive safety sensors (e.g. IN4000)

Two-hand operating panel (IIIA)

Two-hand operating panel (IIIC)

Jog mode via two-hand operating panel (IIIA) (time limit 5 s)

Muting lamp and Reset required lamp (not monitored)

Lamp permanently ON: Muting active
Lamp flashing 1 Hz: Reset required
Pressure sensitive mats (4-wire system)

Reset button

Flexi Loop

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Flexi Classic
Tab. 2: Module function Symbol Module functions
symbols
Bypass function with electro-mechanical dual-channel equivalent switch
(e.g. enabling switch),
Bypass function limited to 60 s

Muting station with two inputs for muting sensors

Retriggering
N

Monitored semiconductor output

Q1

Off delay

ENABLE (EN)
EN

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Tab. 3: Input assignment Symbol Input assignment
symbols
Single-channel N/C contact

Single-channel N/C contact, cross-circuit detecting

Single-channel N/C contact at two inputs

Dual-channel N/C contact, equivalent, cross-circuit detecting, with

monitoring of synchronisation (1500 ms)

Dual-channel N/C contact, equivalent, cross-circuit detecting

Dual-channel N/C contact, equivalent

Dual-channel N/C / N/O contact, complementary, cross-circuit detecting

Dual-channel N/C / N/O contact, complementary, cross-circuit detecting,

with monitoring of synchronisation (1500 ms), (e.g. magnetically coded
switch RE300)
Dual-channel semiconductor input, monitored (ESPE)

Single-channel N/C contact/semiconductor input (e.g. sensors that can be

tested)

Switching mats, pressure-sensitive (4-wire system)

Tab. 4: Logic symbols Symbol Logic

OR link

& AND link

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Operating instructions On safety Chapter 2
Flexi Classic

2 On safety
This chapter deals with your own safety and the safety of the equipment operators.
Please read this chapter carefully before working with the Flexi Classic modular safety
controller or with the machine protected by the Flexi Classic modular safety controller.

2.1 Qualified safety personnel

The Flexi Classic modular safety controller must be mounted, commissioned and serviced
only by qualified safety personnel.
Qualified safety personnel are defined as persons who …
have undergone the appropriate technical training
and
who have been instructed by the responsible machine operator in the operation of the
machine and the current valid safety guidelines
and
have access to the operating instructions of the Flexi Classic and those of the particular
modules and have read and familiarised themselves with them
and
have access to the operating instructions for the protective devices (e.g. C4000)
connected to the safety controller and have read and familiarised themselves with
them.

2.2 Applications of the device

The Flexi Classic modular safety controller is a configurable control system for safety
applications.
The category in accordance with EN ISO 13 849K1 or the SIL in accordance with IEC 61 508
and the SILCL in accordance with EN 62 061 depend on the external circuit, the realisation
of the wiring, the choice of the sensors and their location at the machine.
The device corresponds to up to category 4 in accordance with EN ISO 13 849K1; appli-
cations can reach up to SIL3 in accordance with IEC 61 508, up to SILCL3 in accordance
with EN 62 061 or PL e in accordance with EN ISO 13 849K1. The emergency stop function
in the device corresponds to stop category 0 or 1 in accordance with EN 60 204K1.
In order to reach the SIL3 safety level (see chapter 11 “Technical specifications” on
page 95) in accordance with IEC 61 508, the following test must be made at least every
365 days:
The Flexi Classic system must be powered down.
The Flexi Classic system must be powered up.
All safety functions of the connected safety sensors must be verified.
The type of safety sensors as well as the method of wiring must be chosen according to
the category which is to be achieved.
Opto-electronic and tactile safety sensors (e.g. light curtains, laser scanners, safety switch-
es, sensors, emergency stop pushbuttons) are connected to the modular safety controller
and are linked logically. The corresponding actuators of the machines or systems can be
switched off safely via the switching outputs of the safety controller.
The Flexi Classic safety controller has been tested in accordance with UL 508.

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Chapter 2 On safety Operating instructions
Flexi Classic

2.3 Correct use

The Flexi Classic modular safety controller may only be used as intended in section 2.2
“Applications of the device”. It may only be used by specialist personnel and only at the
machine at which it was mounted and initially commissioned by qualified safety personnel
in accordance with these operating instructions.
If the device is used for any other purposes or modified in any way — also during mounting
and installation — any warranty claim against SICK AG shall become void.

2.4 General safety notes and protective measures

Observe the safety notes and protective measures!

Please observe the following items in order to ensure correct use of the Flexi Classic
WARNING modular safety controller.

When mounting, installing and using the Flexi Classic, observe the standards and
directives applicable in your country.
The national/international rules and regulations apply to the installation, use and
periodic technical inspection of the Flexi Classic modular safety controller, in particular:
– Machinery Directive
– EMC Directive
– Provision and Use of Work Equipment Directive
– Low Voltage Directive
– The work safety regulations/safety rules
Manufacturers and owners of the machine on which a Flexi Classic is used are
responsible for obtaining and observing all applicable safety regulations and rules.
The notes, in particular the test notes (see chapter 8 “Commissioning” on page 89) of
these operating instructions (e.g. on use, mounting, installation or integration into the
existing machine controller) must be observed.
The tests must be carried out by qualified safety personnel or specially qualified and
authorised personnel and must be recorded and documented to ensure that the tests
can be reconstructed and retraced at any time by third parties.
These operating instructions must be made available to the operator of the machine
where the Flexi Classic is used. The machine operator is to be instructed in the use of
the device by qualified safety personnel and must be instructed to read the operating
instructions.
To meet the requirements of the relevant product standards (e.g. IEC 61 496K1), the
external voltage supply for the devices (SELV) must, among other aspects, be able to
bridge a power failure lasting 20 ms. Suitable power supplies are available as acces-
sories from SICK.
The modules of the Flexi Classic family conform to Class A, Group 1, in accordance with
EN 55 011. Group 1 encompasses all ISM devices in which intentionally generated
and/or used conductor-bound RF energy that is required for the inner function of the
device itself occurs.

The Flexi Classic system complies, as per the “radiated emissions” generic standard,
with the requirements of class A (industrial applications).
WARNING The Flexi Classic system is therefore only suitable for use in an industrial environment.

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Operating instructions On safety Chapter 2
Flexi Classic

Loss of the safety function through an incorrect configuration!

Plan and carry out configuration carefully!
WARNING The configuration of safety applications must be carried out with the greatest accuracy and
must match the status and the condition of the machine or system to be monitored.
Check whether the configured safety application monitors the machine or system as
planned and whether the safety of a configured application is ensured at all times. This
must be ensured in each operating mode and partial application. Document the result
of this check!
In each case, observe the instructions for commissioning and daily checking in the
operating instructions of the protective devices integrated into the safety application!
Note the warnings and function descriptions of protective devices connected to the
safety controller! Contact the respective manufacturer of the protective device if in
doubt!

2.5 Environmental protection

The Flexi Classic modular safety controller has been designed to minimise environmental
impact. It uses only a minimum of power and natural resources.
At work, always act in an environmentally responsible manner.

2.5.1 Disposal
Disposal of unusable or irreparable devices should always occur in accordance with the
applicable country-specific waste-disposal regulations (e.g. European Waste Code
16 02 14).
Note We would be pleased to be of assistance to you on the disposal of these devices.
Contact us.

2.5.2 Separation of materials

Material separation may only be performed by qualified safety personnel!

Caution is required when dismantling devices. There is a risk of injuries.
WARNING
Before you send the devices for appropriate recycling, it is necessary to separate the
different materials in the Flexi Classic.
Separate the housing from the rest of the parts (in particular the circuit board).
Send the separated components for recycling as appropriate (see Tab. 5).
Tab. 5: Overview on disposal Components Disposal
by components
Product
Housing, circuit boards, cables, Electronic recycling
connectors and electrical connecting
pieces
Packaging
Cardboard, paper Paper/cardboard recycling

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Chapter 3 Product description Operating instructions
Flexi Classic

3 Product description
This chapter provides information on the special features and properties of the Flexi
Classic modular safety controller. It describes the construction and the operating principle
of the device.
Please read this chapter before mounting, installing and commissioning the device.

3.1 Special features

Fig. 1: Flexi Classic modular
safety controller

The Flexi Classic series is a safety controller concept comprising different modules that
can be interconnected individually. This allows the system to be extended to up to 104
inputs or outputs.
Each of these modules has a compact width of 22.5 mm. The units are of plug-in style with
communication between the individual units over an internal bus.
The required logic and function is specified by means of rotary switches on the modules.
An exception thereof are the relay modules and the fieldbus modules that are used for
integration in a higher level controller without a safety function. These modules are output
units and have no effect on the logic set or the function of the upstream units.

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Flexi Classic

The Flexi Classic series consists of the following modules:

main module UE410-MU
main module UE410-GU
input/output extension module UE410-XU
input extension module UE410-8DI
output modules UE410-2RO and UE410-4RO
gateways, e.g.
– UE410-PRO (PROFIBUSKDP)
– UE410-CAN (CANopen)
– UE410-DEV (DeviceNet)
– UE410-EN1 (EtherNet/IP)
– UE410-EN3 (Modbus TCP)
– UE410-EN4 (PROFINET IO)

3.2 Structure
A Flexi Classic system always consists of a single main module (UE410-MU or UE410-GU)
and, if necessary, additional input and output extensions as well as a corresponding bus
module.
Fig. 2: Safety controller Main module Input/output extension module Input extension module Output module Gateway
structure Flexi Classic 4 inputs/4 outputs 4 inputs/4 outputs 8 inputs 2/4 outputs
(example with UE410-MU)

Fieldbus
UE4100MU UE4100XU UE41008DI UE41002RO/ E.g. UE4100PRO, UE410-DEV,
UE41004RO UE410-CAN (see operating
instructions Flexi Classic
Gateways)

3.2.1 UE410-MU main module

The UE410-MU is the main module in which the system configuration of the entire Flexi
Classic system is stored.
The UE410-MU has 4 safety inputs, 4 semiconductor outputs and 2 test outputs. The
9 programs that are available can be set by means of rotary switches that ensure the
connection of a large number of safety components. Functions such as EDM, resetting,
etc. are selected by means of the wiring of S1, S2 and S3. The UE410-MU can control two
applications acting independently as well as two applications that are dependent on each
other.

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The devices listed in the following can be connected to the UE410-MU and the modules
connected to it:
emergency stop pushbuttons
pressure sensitive mats
two-hand controllers
safety switches
non-contact safety switches (e.g. RE300, T4000 Compact, IN4000)
single-beam photoelectric safety switches (e.g. L21, L41)
safety light curtains and multiple light beam safety devices (e.g. MSL, miniTwin,
C/M2000, C/M4000)
safety laser scanners and safety camera systems (e.g. S300, V300, S3000)
Typical applications such as muting and OR links can be implemented simply, depending
on the setting of the program switch. If additional inputs or outputs are required, the
UE410-MU can be supplemented with a UE410-XU input/output extension module and/or
one or several UE410-8DI input extension modules.
If relay outputs are required, these can be implemented with the UE410-2RO/UE410-4RO
output modules.

3.2.2 UE410-GU main module

The UE410-GU is a main module that can be used as an alternative to the UE410-MU. As
in the UE410-MU, the system configuration for the entire Flexi Classic system is saved in
the UE410-GU. The UE410-GU makes possible a global emergency stop function for sev-
eral stations connected together that must each be equipped with a UE410-GU. A local
emergency stop is also possible on each UE410-GU.
The UE410-GU has 4 safety inputs (I1-I4), 1 semiconductor output (Q1), 1 output for a
lamp for “Global emergency stop status” and “Reset required” (Q2), 2 test outputs (X1, X2)
and 2 inputs and 2 outputs for the global emergency stop function (IP, IN, OP and ON). The
safe control inputs I5 and I6 are used to connect external device monitoring and a reset
button. The 9 available programs can be set using a rotary switch and make it possible to
connect a variety of safety components.
The following devices can be connected to the UE410-GU:
emergency stop pushbutton
safety switch
non-contact safety switches (e.g. RE300, T4000 Compact)
single-beam photoelectric safety switches (e.g. L21, L41)
safety light curtains and multiple light beam safety devices (e.g. MSL, miniTwin,
C/M2000, C/M4000)
safety laser scanners and safety camera systems (e.g. S300, V300, S3000)
If additional inputs are required, the UE410-GU can be expanded with one or more input
extension modules UE410-8DI.
The UE410-GU can also be expanded with a UE410-XU. This module does not act on the
global emergency stop.
If relay outputs are required, these can be implemented with the UE410-2RO/UE410-4RO
output modules.
Note The UE410-GU does not support all data sets from all gateways.

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3.2.3 UE410-8DI input extension module

The UE410-8DI module is an input extension with 8 inputs that can be linked using the OR,
AND or Bypass logic function to the respectively upstream UE410-MU, UE410-GU or
UE410-XU module. The 9 switch positions of the UE410-8DI rotary switch determine which
safety components can be connected to the UE410-MU/GU/XU and which type of logic is
used. The input extension module UE410-8DI acts exclusively on the next UE410-MU,
UE410-GU or UE410-XU module positioned to the left in the module structure, thus form-
ing a function group. It is allowed to connect a maximum of 8 UE410-8DI modules to a
UE410-MU, UE410-GU or UE410-XU.
For more informationen on this topic see section 4.12 “Grouping of subsystems” on
page 77.

3.2.4 UE410-XU input/output extension

The UE410-XU module is an input/output extension with 4 safety inputs, 4 semiconductor
outputs and 2 test outputs. It has the same switch positions, logic functions and facilities
for connecting sensors as the UE410-MU. In contrast to the UE410-MU and UE410-GU, the
UE410-XU cannot store the system configuration.
Notes A UE410-XU can only be operated in combination with a UE410-MU or UE410-GU main
module.
A main module and a UE410-XU can be linked logically with each other, thus forming a
subsystem (for further information please refer to section 4.12 “Grouping of subsys-
tems” on page 77).

3.2.5 UE410-2RO/UE410-4RO output modules

The UE410-2RO/UE410-4RO output extensions make one or two dual-channel, contact-
based outputs available. They do not have any influence on the specified logic instructions
of a system structure and are controlled by the UE410-MU, UE410-GU or UE410-XU out-
puts.

3.2.6 Gateways
Gateways (fieldbus modules) can be added to the Flexi Classic modular system for diag-
nostic purposes. They output the system configuration and the input/output states as well
as the error and status information of all the modules.
Several gateways are available, e.g.:
UE410-PRO for PROFIBUSKDP
UE410-DEV for DeviceNet
UE410-EN1 for EtherNet/IP
Note The UE410-GU does not support all data sets from all gateways.
You will find a complete list of all gateways and the data sets supported in the operating
instructions “Flexi Classic Gateways” or in the Internet on our homepage www.sens-
control.com.
All gateways have 4 non-safe application diagnostic outputs. The outputs are short-circuit
protected (see also the Flexi Classic Gateways operating instructions).

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3.2.7 Module overview, adjustments and facilities for connecting sensors

Tab. 6: Module overview Module Description
UE410-MU Main unit of the Flexi Classic modular safety
controller
4 safe inputs and 4 safe outputs
Storage of the system configuration
UE410-GU Central function block of the Flexi Classic
modular safety controller
Global emergency stop can be realized
4 safe inputs
1 safe output
Storage of the system configuration
UE410-XU Input/output extension/subsystem
4 safe inputs and 4 safe outputs
Identical functionality as UE410-MU
UE410-8DI Input extension
8 safe inputs
Information coupling to the upstream UE410-
MU, UE410-GU or UE410-XU module
UE410-2RO 2 contacts (N/O), 1 signal contact (N/C)
UE410-4RO 4 contacts (N/O), 2 signal contacts (N/C)
Flexi Classic gateways Status and diagnostics (information that is not
e.g. UE410-PRO, UE410-DEV, safety relevant) of a Flexi Classic on a fieldbus
UE410-CAN (see Flexi Classic Gateways operating instructions)

Tab. 7: Overview of setting Setting possibility Can be set at the module Comment
possibilities
ENTER button UE410-MU/UE410-GU Saving of all Flexi Classic system
programs, settings and wiring
Program 1-9 UE410-MU/UE410- Selection of the safety sensors
GU/UE410-XU and of the logic elements to be
connected
Off delay UE410-MU/UE410-XU Delays 1 or 2 outputs on the
0-5 s, 0-50 s or module
0-300 s 3 different variants available
(Not on UE410-xxxT0)
Switch position 0-9 UE410-8DI Selection of the logic elements
and of the safety sensors to be
connected

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Tab. 8: Connection of sen- Program
sors to the UE410-MU,
UE410-XU and UE410-8DI Sensor UE410-MU/UE410-XU UE410-8DI
A (I1/I2) B (I3/I4) A (I1-I4) B (I5-I8)
7, 8 1, 2, 7, 8, 9 1, 6, 7 1, 6, 7

7, 8 1, 2, 7, 8, 9 6, 7 6, 7

1, 5, 6, 9 5, 6 2, 3, 8 2, 3, 8

– – 4 4

2 – 5 5

1 – 2 2

3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7

3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7

3, 7, 8 1, 2, 7, 8, 9 6, 7 6, 7

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Program
Sensor UE410-MU/UE410-XU UE410-8DI
A (I1/I2) B (I3/I4) A (I1-I4) B (I5-I8)
4 4 – –

– 5.2 – –

– 5.1 – –

2 – 5 5

3 – – –

1, 5, 6, 7, 8 1, 2, 6, 7, 8, 2, 3, 6, 7, 8 2, 3, 6, 7, 8
9

3 – 1 1

3 3 – –

1, 5, 6, 9 5, 6 2, 3, 8 2, 3, 8

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3.3 UE410-MU main module

The UE410-MU main module is the main module of the Flexi Classic modular safety con-
troller. Only one UE410-MU can be integrated for each Flexi Classic system. A UE410-MU
can control up to two applications acting independently or two applications that are depen-
dent on each other.
In order to increase the number of inputs, one or more UE410-8DI extension modules can
be used additionally.
An additional UE410-XU module can be used in order to increase the number of outputs
(for further information refer to section 4.12 “Grouping of subsystems” on page 77).
The system configuration is stored in the UE410-MU main module (ENTER button to accept
the program settings and system configuration) (for further information refer to section 9.1
“Accepting the system configuration” on page 91).
9 programs that can be set with a screwdriver at the program switch are available.
Fig. 3: Scheme programs 1-3
A B

Q1 Q2 Q3 Q4

Fig. 4: Scheme program 4

AB

Q1 Q2 Q3 Q4

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Fig. 5: Scheme
programs 507, 9
A B

&

Q1 Q2 Q3 Q4

Fig. 6: Scheme program 8

A B

Q1 Q2 Q3 Q4

The following functions can be set by selecting the program and connecting the terminals
S1, S2, and S3 at the module:
type of the logic and of the safety sensors to be connected
restart interlock
external device monitoring (EDM)
Q1 and Q2 always switch off within the response time.
1)
Q3 and Q4 can be deactivated with off delay by using the lower rotary switch (depending
on the device variant 0-5 s/0-50 s/0-300 s/not on UE410-xxxT0).
Note The outputs are tested periodically in order to detect errors in the safety outputs Q1-Q4.
When using XU modules see section 4.12 “Grouping of subsystems” on page 77.
For further information see section 3.6 “UE410-MU/UE410-XU programs” on page 35.

Subsequent changes to the program or to the wiring (S1-S3) without saving will result in a
safety-related shutdown.
WARNING

1)
Q3 has various functions; see section 3.6 “UE410-MU/UE410-XU programs” on page 35.

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3.3.1 Controls and status indicators

Fig. 7: UE410-MU controls
and status indicators

Program switch

Button for accepting the

system configuration

Switch for off delay

(not on UE410-xxxT0),
see Tab. 10

Tab. 9: UE410-MU LED indicators Meaning

indications
PWR (green) Supply voltage present
Q1/Q2, Q3/Q4 (green) Switching state of the safety outputs (high level)
Q3/Q4 (green flashing) Q3/Q4 to high level during the course of the delay time
ERR (red flashing) Indication for erroneous operational status on this
module, see chapter 10 “Diagnostics” on page 92
ERR (red) Indication for erroneous operational status on the whole
system (the error is on another module), see chapter 10
“Diagnostics” on page 92
EN, S1-S3 (green) Voltage is present.
I1-I4 (green) Signal is present.
I1/I2 flash in phase Cross-circuit between I1/I2
I3/I4 flash in phase Cross-circuit between I3/I4
I1/I2 flash out of phase Process error at I1/I2
I3/I4 flash out of phase Process error at I3/I4
I1 to I4 flashes Synchronization time/concurrence error, expected signal
is not present at the respective input.
S1-S3 flashes Expected signal is not present (e.g. EDM or Reset).
Other indicators Device error, see chapter 10 “Diagnostics” on page 92

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Tab. 10: UE410-MU Switch/button Function
operating elements
FUNCTION 10-step rotary switch (position 0 forbidden) for setting an input
circuit function (see section 3.6 “UE410-MU/UE410-XU programs”
on page 35)
X1s, X10s, 10-step rotary switch for setting the off delay time (see section 3.6
2)
X1min “UE410-MU/UE410-XU programs” on page 35)
ENTER Button for accepting the system configuration (Teach-in).
See section 9.1 “Accepting the system configuration” on page 91.

3.3.2 Terminal assignment

Tab. 11: UE410-MU terminal Assignment Description
assignment
I1/I2 Input for logic path A

I3/I4 Input for logic path B

EN ENABLE input, activates the logic path(s)

S1 Input for reset buttons (RESET), restart interlock (EDM), retriggering,
S2 etc.

S3
A1 (+UB) Voltage supply
A2 (GND)
X1 Test outputs: cross-circuit detecting and short-circuit detecting control
3)
X2 signals for controlling safety sensors
3)
Q1-Q4 Monitored semiconductor outputs (OSSD)
Q3 Is used in Program 3 as the output for the muting lamp and Reset
required.

2)
The maximum adjustable duration of the switch off delay is 5, 50 or 300 s depending on the device variant,
see section 12.1 “Available modules” on page 111.
3)
When using multiple modules see section 4.12 “Grouping of subsystems” on page 77.

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3.3.3 Outputs
You have two possibilities to reach SIL3 or Category 4 for your application:
dual-channel wiring of the outputs, e.g. Q1/Q2 to K1/K2
or
single-channel wiring only with routing within protected areas such as in a control
cabinet, e.g. Q1 to K1/K2.

Safety-oriented devices must be suitable for safety related signals!

A function interruption of safety outputs results in a loss of the safety functions so that the
WARNING risk of serious injury exists.
Do not connect any loads that exceed the rated values of the safety outputs.
Wire the Flexi Classic system so that 24 V DC signals cannot contact the safety outputs.
Connect the GND wires of the power supply to earth so that the devices do not switch
on when the safety output line is applied to frame potential.
Use suitable components or devices that fulfil all the applicable regulations and
standards.
Actuators at the outputs can be wired single-channeled. In order to maintain the respective
Safety Integrity Level the lines have to be routed in such a manner that cross circuits to
other live signals can be excluded, for example by routing them within protected areas
such as in a control cabinet or in separate plastic-sheathed cables.

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3.4 UE410-GU main module

The UE410-GU is a main module that can be used as an alternative to the UE410-MU. The
system configuration is stored in the main module (for further information please refer to
section 9.1 “Accepting the system configuration” on page 91).
Only one UE410-GU can be used per Flexi Classic system.
In order to increase the number of inputs, one or more UE410-8DI extension modules can
be used additionally.
To increase the number of outputs, an additional UE410-XU can be used (see section 4.12
“Grouping of subsystems” on page 77). A total of up to 12 Flexi Classic modules and one
gateway can be connected to the UE410-GU.
The UE410-GU makes possible a global emergency stop function for several stations con-
nected together that must each be equipped with a UE410-GU. If the global emergency
stop on a module is operated, the safety outputs on all modules switch off. To reset a glo-
bal emergency stop, the reset button must be operated on the same module on which the
global emergency stop was triggered.
Note A global emergency stop must always be reset manually.
Along with the global emergency stop function, on each module it is also possible to select
a local emergency stop function with or without restart interlock. The local emergency stop
only acts on the safety output on the related module. A local emergency stop can be reset
either automatically or manually.
The safety output Q1 always switches within the response time. A switch off delay as on
the UE410-MU is not possible with the UE410-GU.
Different programs for the local inputs can be selected with the aid of a rotary switch.
9 programs are available using which the following functions can be set:
type of the safety sensors to be connected
global emergency stop or global and local emergency stop
automatic or manual reset of a local emergency stop
For further information see section 3.7 “UE410-GU programs” on page 48.

Subsequent changes to the program will result in a safety-related shutdown without

saving.
WARNING

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3.4.1 Controls and status indicators

Fig. 8: UE410-GU controls
and status indicators

Program switch

Button for accepting the

system configuration

Tab. 12: UE410-GU LED indicators Meaning

indications
PWR (green) Supply voltage is present.
Q1 (green) Safety output Q1 is high.
ERR (red flashing) Indication for erroneous operational status on this module, see
chapter 10 “Diagnostics” on page 92
ERR (red) Indication for erroneous operational status on the whole system
(the error is on another module), see chapter 10 “Diagnostics”
on page 92
I1/I2 (green) Global cut-off path closed
I3/I4 (green) Cut-off path closed
I1/I2 (green flashing Cross-circuit between I1/I2
in phase)
I3/I4 (green flashing Cross-circuit between I3/I4
in phase)
I1/I2 (green flashing Process error at I1/I2
out of phase)
I3/I4 (green flashing Process error at I3/I4
out of phase)
I5 (green) External device monitoring contact is closed.
I6 (green) Reset button is closed.
IP (green) Input IP is high.
IN (green) Input IN is high.
Other indicators Device error, see chapter 10 “Diagnostics” on page 92

Tab. 13: UE410-GU Switch/button Function

operating elements
X 10-step rotary switch (position 0 forbidden) for setting an input
circuit function, see section 3.7 “UE410-GU programs” on
page 48
ENTER Button for accepting the system configuration (Teach-in), see
section 9.1 “Accepting the system configuration” on page 91

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3.4.2 Terminal assignment

Tab. 14: UE410-GU terminal Assignment Description
assignment
I1/I2 Global emergency stop (equivalent switch with test pulses)
I3/I4 Local emergency stop (local input, depending on the program
set)
A1 (+UB) Voltage supply
A2 (GND)
X1 Test outputs: cross-circuit detecting and short-circuit detecting
4)
X2 control signals for controlling safety sensors
4)
Q1 Single-channel safety output (OSSD)
Q2 Connection for the lamp for “Global emergency stop status” and
“Reset required”
I5 Connection for the external device monitoring (EDM)
I6 Connection for the reset button
IP Input signal from the previous module (PRE_IN)
IN Input signal from the next module (NEXT_IN)
OP Output signal to the previous module (PRE_OUT)
ON Output signal to the next module (NEXT_OUT)

3.4.3 Global emergency stop with the UE410-GU

The global emergency stop makes possible the simultaneous shut down of the safety out-
puts on several Flexi Classic stations connected together that are each equipped with a
UE410-GU as the main module.
Notes In theory as many UE410-GU modules as required can be connected together to form a
global emergency stop system. However, it is recommended not to exceed 32 modules,
because each module increases the response time of the overall system (see the infor-
mation on the global response time in section 11.1.2 “UE410-GU module” of the tech-
nical data on page 100).
The different UE410-GU modules that together form a global emergency stop circuit do
not need to be in the same protected area. Faults in the area OX and IX, e.g. a short-
circuit or cross circuit, are detected and will result in shutdown.
All UE410-GU modules that are on a common global emergency stop cut-off path must
be connected to the same GND connection.
Principle of operation
As long as the system is enabled, each UE410-GU sends a signal to the previous UE410-
GU (PRE) and to the next UE410-GU (NEXT). If the global emergency stop is activated on a
module (falling edge on I1/I2), then this module sets its safety output Q1 as well as the
signals to its neighboring modules (outputs OP and ON) to low. The neighboring modules
now also set their safety output Q1 as well as their outputs OP and ON to low.
The status of the global emergency stop is also output via the output Q2. If the global
emergency stop is activated on this UE410-GU, this status is indicated with a signal
flashing at 2 Hz on output Q2. If the global emergency stop has been activated on another
UE410-GU, then this status is indicated with a continuous high on output Q2.

4)
When using multiple modules see section 4.12 “Grouping of subsystems” on page 77.

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Once the cause of the global emergency stop has been rectified (inputs I1 and I2 are high
again, e.g. protective field clear), then the UE410-GU on which the global emergency stop
was originally triggered signals on output Q2 the status Reset required with a signal
flashing at 1 Hz.
Reset
A global emergency stop can only be reset manually. The reset must be undertaken on the
same module on which the global emergency stop was triggered.
Once the global cut-off path for this module is closed again (inputs I1 and I2 are high
again, e.g. protective field clear) and the reset button on this module is then operated, the
safety output Q1 on this module as well as the outputs OP and ON switch to high again.
The following conditions are to be noted for the reset:
Only the falling edge is evaluated.
The minimum actuation time for the reset button is S 50 ms.
The maximum actuation time for the reset button is T 5 s.
If one of these criteria is not met, the emergency stop is not reset.
Wiring of the modules
To connect several UE410-GU modules together, the input IN on the previous UE410-GU
must be connected to the output OP on the next UE410-GU and the output ON on the pre-
vious UE410-GU must be connected to the input IP on the next UE410-GU.
For the specification of the connection cable please refer to the data sheet in sec-
tion 11.1.2 “UE410-GU module” on page 100.
The first and last UE410-GU in an emergency stop system act as end modules. An end
module is a UE410-GU that has only one neighboring station. These modules are defined
by the wiring of the outputs X1 and X2.
The end module without PRE is defined by wiring X1 to IP.
The end module without NEXT is defined by wiring X2 to IN.
This wiring is saved with the configuration and checked each time on switching on.
Fig. 9: Connecting several
UE410-GU modules

First module Module(s) in the middle Last module

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Test the entire emergency stop function after any change to the wiring!
If a UE410-GU is subsequently removed from an emergency stop system and the system is
WARNING then correctly wired, this change will not be detected. For this reason the entire emergency
stop function must always be tested after any change to the wiring.

Stand-alone mode of a UE410-GU

It is also possible to operate a UE410-GU as a standalone device. For this purpose X1
must be wired to IP and X2 must be wired to IN on this device.

3.4.4 Local emergency stop on the UE410-GU

A local emergency stop can be configured on each UE410-GU depending on the program
set (see section 3.7 “UE410-GU programs” on page 48).
Principle of operation
If the local emergency stop is activated on a UE410-GU (falling edge on I3 and/or I4, de-
pending on the program set), this module sets its safety output Q1 to low. The signals OP
and ON remain high, i.e. the local emergency stop only acts on the safety output on the
UE410-GU on which the local emergency stop was triggered.
Once the cause of the local emergency stop has been rectified (inputs I3 and I4 are high
again, e.g. protective field clear), the safety output Q1 on the module switches to high
again after a successful reset.
Reset
A local emergency stop can be reset either manually or automatically depending on the
program set:
Automatic reset: Once the local cut-off path is closed again (e.g. protective field clear),
then the safety output Q1 on the module also switches to high again.
Manual reset: Once the local cut-off path is closed again (e.g. protective field clear),
output Q2 starts to flash at 1 Hz. If the reset button is then operated, the safety output
Q1 on the module switches to high again.
The following conditions are to be noted for the manual reset:
Only the falling edge is evaluated.
The minimum actuation time for the reset button is S 50 ms.
The maximum actuation time for the reset button is T 5 s.
If one of these criteria is not met, the emergency stop is not reset.

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3.4.5 Inputs

Connection of the emergency stop pushbutton for the global emergency stop
(I1 and I2)
A two-pole equivalent safety switch must be connected to the inputs I1 and I2 as the
emergency stop pushbutton for the global emergency stop. The emergency stop push-
button is tested via the connection of X1–I1 and X2–I2.
Connection of the sensors for the local emergency stop (I3 and I4)
The sensors for the local emergency stop are connected to the inputs I3 and I4 (see sec-
tion 3.7 “UE410-GU programs” on page 48). The sensors are tested via the connection of
X1–I3 and X2–I4.
Connection of the external device monitoring (EDM) (I5)
The external device monitoring (EDM) is connected to I5.
Before each enable it is checked whether I5 is high. If this condition is not met, the safety
output Q1 is not set to high.
Connection of the reset button (I6)
The reset button must be connected to input I6.
Notes The reset button acts both as a reset button for the global emergency stop and for the
local emergency stop, if a program with manual reset is set for the local emergency stop
(program 2, 4, 6 or 8) (see section 3.7 “UE410-GU programs” on page 48).
If a program with automatic reset is set for the local emergency stop, then the reset
button only acts on a global emergency stop, i.e. if a global emergency stop has been
triggered on the module and the module has the status Reset required.

3.4.6 Outputs

Lay the single-channel connection in a protected area!

To achieve SIL3 or category 4, you must lay the single-channel connection Q1 to K1/K2
WARNING such that cross-circuits to other electrical signals can be excluded, e.g. by laying in pro-
tected areas such as in a control cabinet or in separate plastic-sheathed cables.

Safety-relevant devices must be suitable for safety-relevant signal requirements!

Serious injury may occur due to breakdown of safety outputs or loss of required safety
WARNING functions.
Do not connect loads that exceed the rated value of the safety outputs.
Wire the Flexi Classic system so that 24 V DC signals cannot contact the safety outputs.
Connect the GND wires of the power supply to earth so that the devices do not switch
on when the safety output line is applied to frame potential.
All UE410-GU modules that are on a common global emergency stop cut-off path must
be connected to the same GND connection.
Use appropriate components or devices in accordance with regulations and standards.

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3.4.7 Connection of a UE410-8DI

A UE410-8DI acts on the cut-off path A/B on a UE410-GU as follows:
Input A (I1-I4) QA acts on the global cut-off path.
Input B (I5-I8) QB acts on the local cut-off path.
Note An OR function or a bypass function that acts on the global cut-off path of the UE410-GU
(switch position 7 or 8, input A on the UE410-8DI) is not permitted and will result in a
configuration error (ERROR).

3.4.8 Power-up delay and response time of the UE410-GU

Power-up delay
The power-up delay of the UE410-GU is calculated as follows:
Power-up delay = local power-up delay + (N–1) × global power-up delay
Where:
Local power-up delay = power-up delay for the module on which the emergency stop was
triggered and reset
Global power-up delay = power-up delay of the other modules in the system
N = number of the UE410-GU modules in the system
You will find the values for the power-up delay on the data sheet in section 11.1.2 “UE410-
GU module” on page 100.
Response times

Extended response time of the overall system on the usage of several UE410-GU
modules!
WARNING In a system consisting of several UE410-GU modules connected together, the power-up
delay and the response time are increased depending on the number of UE410-GU mo-
dules connected together. Take this aspect into account on planning your system. Other-
wise the operator of the system will be in danger.

The response time of the UE410-GU is calculated as follows:

Response time = local response time + (N–1) × global response time
Where:
Local response time = response time of the module on which the emergency stop was
triggered
Global response time = response time of the other modules in the system
N = number of the UE410-GU modules in the system
You will find the values for the response times on the data sheet in section 11.1.2
“UE410-GU module” on page 100.

3.4.9 Diagnostics and troubleshooting for the UE410-GU

If a system with a global emergency stop function comprising several UE410-GU modules
is either entirely or partially at the standstill, then you can determine which module has
triggered the emergency stop as follows:
Based on the LED indicators on any UE410-GU module in the system check whether the
emergency stop has been triggered by this module or the direction of the module that
has triggered the global or local emergency stop, see Tab. 15.

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Fig. 10: Diagnostic displays
on the UE410-GU
LED I1/I2: emergency stop LED I3/I4: sensor with local
pushbutton with global action action

LED Q1: safety output Q1

LED IP: status of all previous LED IN: status of all next
modules modules

Also pay attention to the lamp on output Q2 (“Global emergency stop status”, “Reset
required”) on the related UE410-GU.
Tab. 15: Diagnostics on the Q1 I1/I2 I3/I4 IP IN Lamp Q2 Cause
UE410-GU
The LED or lamp is A local emergency stop has been
illuminated constantly. triggered on this station.
The LED or lamp is
flashing (1 Hz). X X A previous station has triggered a
The LED or lamp is global emergency stop.
flashing (2 Hz).
The LED or lamp is off. X X A next station has triggered a global
X Any emergency stop.
X X X A global emergency stop has been
triggered on this station.
Reset is required on this station.
The safety output on the module is
active and the system enabled.

Note A combination of several causes may occur, e.g. if a local emergency stop and a global
emergency stop have been triggered.
LED I5 and I6 indications
In normal operation with safety output Q1 active the LEDs I5 and I6 are Off.
Tab. 16: Significance of the LED Meaning
diagnostics LEDs I5 and I6 on
the UE410-GU I5 illuminates Green The safety output Q1 is shut down, the external actuators
have dropped out. Otherwise check the wiring.
I5 flashes Green EDM error. Check the wiring. If necessary, replace the
actuator.
I6 illuminates Green The reset button is pressed. Otherwise check the wiring.
I6 flashes Green The reset button has been operated for too long. Check the
wiring if necessary.

Also note the description of the LED indicators on the UE410-GU in section 3.4.1 “Controls
and status indicators” on page 27 as well as chapter 10 “Diagnostics” on page 92.

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3.5 UE410-XU module

The UE410-XU module is an input/output extension or a subsystem with 4 safe inputs and
outputs. It has the identical functionality to the UE410-MU main module, however without
the system save using the ENTER button.
The UE410-XU cannot be used as a stand-alone device and always requires a UE410-MU
main module.

3.5.1 Controls and status indicators

Fig. 11: UE410-XU controls
and status indicators

Program switch

Switch for off delay

(not on UE410-xxxT0)

Indicators, controls and terminal assignments are the same as on the UE410-MU main
module (see Tab. 9-Tab. 11).

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3.6 UE410-MU/UE410-XU programs

The modules have 9 settable programs each that can be set via a rotary switch.
Up to two applications acting independently or two applications that are dependent on
each other (A and B) can be controlled. These can act independently or dependent on
each other, depending on the program (see Fig. 3-Fig. 6).
The program selection determines the type of safety sensor equipment to be connected
and the logic instructions.
Tab. 17: UE4100MU/UE410- Program Description
XU programs
0 Module inactive
1-2 Input control circuit A is linked by means of OR logic to input control
circuit B and acts on all the safety outputs Q1-Q4.
3.1-3.2 Input control circuit A acts on the safety outputs Q1, Q2, Q4.
Input control circuit B is muting input and controls the muting lamp
via Q3.
4 Input control circuit AB acts on all the safety outputs AB (two-hand IIIC).
5-7 Input control circuit A acts on both safety outputs Q1/Q2 and Q3/Q4.
Input control circuit B acts only on the safety output Q3/Q4.
8 Input control circuit A acts only on the safety output Q1/Q2.
Input control circuit B acts only on the safety output Q3/Q4.
9 Input control circuit A acts on both safety outputs Q1/Q2 and Q3/Q4.
Input control circuit B acts only on the safety output Q3/Q4.

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3.6.1 Program 1

1 logic path
Inputs/ A B
sensors Dual-channel equivalent N/C Single-channel N/C contact
contact Dual-channel equivalent N/C
Cross-circuit detecting control contact (not cross-circuit
signals detecting)
Synchronous time monitoring ESPE (sensors with
(1500 ms) semiconductor output)
Pressure-sensitive switching
mats (four-wire)
Flexi Loop

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock • with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

Connecting of S2:
S2 may not be connected.

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay Off delay acts on Q3/Q4

(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q3/Q4 with/without EDM Q3/Q4

• retriggering ON • retriggering OFF
Outputs Undelayed OSSDs Q1/Q2
Delayable OSSDs Q3/Q4

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3.6.2 Program 2

1 logic path
Inputs/ A B
sensors Dual-channel complementary Single-channel N/C contact
N/C / N/O contact Dual-channel equivalent N/C
ESPE (e.g. RE300) contact (not cross-circuit
Cross-circuit detecting control detecting)
signals ESPE (sensors with
Synchronous time monitoring semiconductor output)
(1500 ms)

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock
with restart interlock Q1/Q2, without EDM

without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

Connecting of S2:
S2 may not be connected.

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay acts on Q3/Q4

Off delay
(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q3/Q4 with/without EDM Q3/Q4
• retriggering ON • retriggering OFF

Outputs Undelayed OSSDs Q1/Q2

Delayable OSSDs Q3/Q4

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3.6.3 Programs 3.1 and 3.2

Program 3.1 Program 3.2
1 logic path
Inputs/ Single-channel N/C contact X1-I1 IN4000; Bridge X2-I2.
sensors Dual-channel equivalent N/C X2-I2 ESPE (sensors with PNP
contact (not cross-circuit semiconductor output)
detecting) Bridge X1-I1.
ESPE (sensors with Bridge the input circuit not
semiconductor output) used (does not apply to I3-I4).

OR with UE410-8DI — switch position 7

OR

Muting Muting sensors I3-I4 (PNP switching)

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock • with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

Tested Connecting of S2:

S2 is connected to UB.

Connecting of S2:
S2 may not be connected.

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay Off delay acts only on Q4

(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q4 with/without EDM Q4

• retriggering ON • retriggering OFF
Outputs Undelayed OSSDs Q1/Q2
Delayable OSSD Q4
Output for muting lamp and Reset required lamp Q3
Q3 permanently High: Muting active
Q3 1 Hz flashing: Reset required

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3.6.4 Program 4

1 logic path
Inputs/ 2 dual-channel complementary N/C / N/O contacts
sensors Two-hand control (to EN 574 IIIC)
Cross-circuit detecting control signals

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Connecting of S1:
without restart interlock/with two-hand control start-up testing
(to EN 574 IIIC)

• with EDM Q1/Q2

• without EDM Q1/Q2

Connecting of S2:
S2 may not be connected.

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay No off delay — switch DELAY to 0.

An off delay may not be set!

Connecting of S3:
with/without EDM Q3/Q4

Outputs Undelayed OSSDs Q1-Q4

No delayable OSSDs (two-hand standard)

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3.6.5 Programs 5.1 and 5.2

Program 5.1 Program 5.2
2 linked logic paths
Inputs/ A B
sensors Dual-channel equivalent N/C 2 single-channel N/C contacts
contacts Two-hand control
Flexi Loop (to EN 574 IIIA) with or without
jog mode
Cross-circuit detecting control
signals

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock • with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

AND

Jog mode Connecting of S2:

without restart interlock + with start-up testing (two-hand standard)
Acts only on Q3/Q4.

Switch off path B:

Two-hand control unit (to EN 574 IIIA) with jog mode
Jog mode max. 5 s (Q3/Q4 remain switched on for only 5 s)

Two-hand control unit (to EN 574 IIIA) without jog mode

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay No off delay — switch DELAY to 0.

An off delay may not be set!
Connecting of S3:
with/without EDM for Q3/Q4

Outputs Undelayed OSSDs Q1-Q4

No delayable OSSDs (two-hand standard)

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3.6.6 Program 6

2 linked logic paths

Inputs/ A B
sensors Dual-channel equivalent N/C Dual-channel equivalent N/C
contacts contacts
Cross-circuit detecting control Cross-circuit detecting control
signals signals
Flexi Loop Flexi Loop

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock
• with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

AND

Restart Connecting of S2:

interlock
• with restart interlock Q3/Q4, without EDM Q3

• without restart interlock Q3/Q4, without EDM Q3

• with restart interlock Q3/Q4, with EDM Q3

• without restart interlock Q3/Q4, with EDM Q3

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay Off delay acts only on Q4

(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q4

• retriggering ON
• retriggering OFF

Outputs Undelayed OSSDs Q1-Q3

Delayable OSSD Q4

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3.6.7 Program 7

2 linked logic paths

Inputs/ A B
sensors Single-channel N/C contact Single-channel N/C contacts
Dual-channel equivalent N/C Dual-channel equivalent N/C
contact contact
(not cross-circuit detecting) (not cross-circuit detecting)
ESPE and sensors with ESPE and sensors with
semiconductor output semiconductor output

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock • with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

AND

Restart Connecting of S2:

interlock • with restart interlock Q3/Q4, without EDM Q3

• without restart interlock Q3/Q4, without EDM Q3

• with restart interlock Q3/Q4, with EDM Q3

• without restart interlock Q3/Q4, with EDM Q3

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay acts only on Q4

Off delay (not on UE410-xxxT0).

Connecting of S3:
Retriggering
with/without EDM Q4

• retriggering ON
• retriggering OFF

Undelayed OSSDs Q1-Q3

Outputs
Delayable OSSD Q4

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3.6.8 Program 8

2 independent logic paths

Inputs/ A B
sensors Single-channel N/C contact Single-channel N/C contacts
Dual-channel equivalent N/C Dual-channel equivalent N/C
contact contact
(not cross-circuit detecting) (not cross-circuit detecting)
ESPE and sensors with ESPE and sensors with
semiconductor output semiconductor output

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock • with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

AND

Restart Connecting of S2:

interlock • with restart interlock Q3/Q4, without EDM Q3

• without restart interlock Q3/Q4, without EDM Q3

• with restart interlock Q3/Q4, with EDM Q3

• without restart interlock Q3/Q4, with EDM Q3

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay Off delay acts only on Q4

(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q4

• retriggering ON
• retriggering OFF

Outputs Undelayed OSSDs Q1-Q3

Delayable OSSD Q4

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3.6.9 Program 9

2 linked logic paths

Inputs/ A B
sensors Dual-channel equivalent Single-channel N/C contacts
N/C contacts Dual-channel equivalent
Cross-circuit detecting control N/C contact
signals (not cross-circuit detecting)
Flexi Loop ESPE and sensors with
semiconductor output

OR OR with UE410-8DI — switch position 7

AND AND with UE410-8DI — switch position 1-6

Restart Connecting of S1:

interlock
• with restart interlock Q1/Q2, without EDM

• without restart interlock Q1/Q2, without EDM

• with restart interlock Q1/Q2, with EDM

• without restart interlock Q1/Q2, with EDM

AND

Restart Connecting of S2:

interlock
• with restart interlock Q3/Q4, without EDM Q3

• without restart interlock Q3/Q4, without EDM Q3

• with restart interlock Q3/Q4, with EDM Q3

• without restart interlock Q3/Q4, with EDM Q3

Bypass OR limited 60 s with UE410-8DI — switch position 8

ENABLE Always wire ENABLE (expected 24 V DC)!

At ENABLE low Q1-Q4 are always low.

Off delay Off delay acts only on Q4

(not on UE410-xxxT0).

Retriggering Connecting of S3:

with/without EDM Q4

• retriggering ON
• retriggering OFF

Outputs Undelayed OSSDs Q1-Q3

Delayable OSSD Q4

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3.6.10 Connection of sensors to the UE410-MU/UE410-XU

Notes The allocation of the outputs X1 to X2 to the inputs I1 to I4 depends on the selected
input circuit function.
The functions of logic paths A and B can be set independently of each other.

Warning!
Unused inputs must be bridged as per the state shown!
WARNING
Connect the sensors (type depending on the switch position) in accordance with
Tab. 18.

Program Inputs of logic path A Inputs of logic path B

0 Module inactive
1 Dual-channel equivalent X1-I1 Dual-channel non-isolated UB -I3
N/C contact X2-I2 semiconductors UB -I4
cross-circuit detecting
synchronisation time Dual-channel N/C contact, UB -I3
monitoring 1500 ms three-wire UB -I4

Four-wire X1-I1 Single-channel N/C contact UB -I3

cross-circuit detecting X2-I2 UB -I4
(e.g. cross-circuit detecting
switching mats)
2 Dual-channel X1-I1 Dual-channel non-isolated UB -I3
complementary N/C X2-I2 semiconductors UB -I4
contact
cross-circuit detecting Dual-channel N/C contact, UB -I3
synchronisation time three-wire UB -I4
monitoring 1500 ms
Dual-channel X1-I1 Single-channel N/C contact UB -I3
complementary N/C X2-I2 UB -I4
contact
cross-circuit detecting
synchronisation time
monitoring 1500 ms

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Program Inputs of logic path A Inputs of logic path B

3 Single-channel UB -I1 Muting UB -I3
N/C contact UB -I2 2 single-channel N/C contacts UB -I4
or
Dual-channel N/C UB -I1
dual-channel non-isolated
3.1

contact, three-wire UB -I2

semiconductor
Dual-channel non- UB -I1
isolated semi- UB -I2
conductors
Single-channel N/C X2-I2
contacts/ESPE (bridge
3.2

(sensors with semi- X1-I1)

conductor output)
Single-channel N/C X1-I1
contacts/IN4000 (bridge
3.2

(inductive switch with X2-I2)

semiconductor output)
4 Two-hand control (X1-I1 X1-I1 Two-hand control (X1-I3 N/O X2-I3
N/O contact; X1-I2 N/C X1-I2 contact; X2-I4 N/C contact) X2-I4
contact)

5 Dual-channel equivalent X1-I1 2 single-channel N/O contacts, X1-I3

N/C contact X2-I2 cross-circuit detecting X2-I4
cross-circuit detecting

6 Dual-channel equivalent X1-I1 Dual-channel equivalent N/C X1-I3

N/C contact X2-I2 contact X2-I4
cross-circuit detecting cross-circuit detecting
7 Dual-channel non-isolated UB -I1 Dual-channel non-isolated UB -I3
semiconductors UB -I2 semiconductors UB -I4

Dual-channel N/C contact, UB -I1 Dual-channel N/C contact, UB -I3

three-wire UB -I2 three-wire UB -I4

Single-channel N/C UB -I1 Single-channel N/C contact UB -I3

contact UB -I2 UB -I4

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Program Inputs of logic path A Inputs of logic path B

8 Dual-channel non-isolated UB -I1 Dual-channel non-isolated UB -I3
semiconductors UB -I2 semiconductors UB -I4

Dual-channel N/C contact, UB -I1 Dual-channel N/C contact, UB -I3

three-wire UB -I2 three-wire UB -I4

Single-channel N/C UB -I1 Single-channel N/C contact UB -I3

contact UB -I2 UB -I4

9 Dual-channel equivalent X1-I1 Dual-channel non-isolated UB -I3

N/C contact X2-I2 semiconductors UB -I4
cross-circuit detecting
Dual-channel N/C contact, UB -I3
three-wire UB -I4

Single-channel N/C contact UB -I3

UB -I4

Tab. 18: Connection of sensors to the UE410-MU/UE410-XU

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3.7 UE410-GU programs

The UE410-GU has 9 programs that are set using the program switch.
The global emergency stop function with manual reset is active in all programs. Depending
on the program set, a local emergency stop function can also be configured with which it is
possible to choose between manual reset and automatic reset.
The selection of the program defines the type of safety sensor to be connected and the
principle of operation of the local reset. The operator logic is identical for all programs.
Tab. 19: UE410-GU Program Function I1/I2 Function I3/I4 Moni- Function I6
programs
(global emergency (local emergency stop) toring (reset of the local
5)
stop) emergency stop)
1 – – –

2 Equivalent switch, cross- I3–X1 Manual

circuit detecting I4–X2

3 Automatic

4 Dual-channel N/C / N/O I3–X1 Manual

contact, complementary, I4–X2
cross-circuit detecting
5 Automatic

Equivalent switch,
cross-circuit
6)
6 detecting OSSD or untested safety I3–Ux Manual
switch I4–Ux

7 Automatic

7)
8 Single-channel N/C I3–n. u. Manual
contact, cross-circuit I4–X2
detecting, e.g.
9 emergency stop Automatic
pushbutton
safety switch
testable sensors
(e.g. L41)

Note Switch position 0 is not permitted.

5)
A reset button for the global emergency stop must always be connected to I6. This button also acts as the
reset button for manually resetting the local emergency stop if necessary.
6)
Ux = independent 24 V supply that must be connected to the same GND connection as the power supply for
the UE410-GU.
7)
Not connected, i.e. I3 must not be connected.

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2 linked logic paths

Inputs/ A B
sensors Global emergency stop Local cut-off path
e.g. program 6 for programs see Tab. 19
Dual-channel equivalent N/C e.g. program 6
contacts Single-channel N/C contacts
Cross-circuit detecting control Dual-channel equivalent N/C
signals contact (not cross-circuit
Flexi Loop detecting)
ESPE and sensors with
semiconductor output

OR OR with UE410-8DI — switch position 7 input B

Switch position 7 input A is not permitted, UE410-GU switches to
ERROR (configuration error).

AND AND with UE410-8DI — switch position 1-6

Restart Global reset — connecting of I6:

interlock
• with restart interlock Q1

Restart Local reset — connecting of I6:

interlock
• with restart interlock Q1

• only in the programs 2, 4, 6, 8

OR limited 60 s with UE410-8DI — switch position 8 input B

Switch position 8 input A is not permitted, UE410-GU switches to
ERROR (configuration error).

Output

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3.8 UE410-8DI input extension module

The UE410-8DI module is an input extension with 8 safe inputs.
A UE410-8DI is used to add additional inputs either to a UE410-MU, UE410-GU or UE410-
XU. The simultaneous use of up to UE410-8DI per UE410-MU, UE410-GU or UE410-XU is
possible.
A UE410-8DI input extension module acts exclusively on the next UE410-MU, UE410-GU or
UE410-XU module on the left in the module structure. It has two separate input groups
each with 4 inputs for connecting safe signal detectors and sensors. The UE410-8DI has a
separate switch for each input group (input A and B). The 9 positions on the rotary switch
determine the type of safety component which can be connected and with which logic (OR,
AND or Bypass) it will act on the UE410-MU, UE410-GU or UE410-XU.
The input group A of a UE410-8DI acts on the logic path A of a connected UE410KMU,
UE410-GU or UE410-XU.
The input group B of a UE410-8DI acts on the logic path B of a connected UE410KMU,
UE410-GU or UE410-XU.
Each input group consists of two input pairs. At input A, for example, this is I1/I2 and
I3/I4. Two inputs are AND-linked and form an input pair. This does not apply for switch
position 1.
Tab. 20: UE410-8DI switch Switch Description
positions
position
0 Selected input (A/B) is inactive — input signals are ignored.
The connected single-channel sensor equipment is AND-linked to the
respective logic path of the UE410-MU/UE410-GU/UE410-XU modules.
1
Unused inputs have to be jumpered in accordance with the state logical “1”
(e.g. X4-I4, UB -I4).
The connected dual-channel sensor equipment is AND-linked to the
respective logic path of the UE410-MU/UE410-GU/UE410-XU modules.
2-6
Unused inputs have to be jumpered in accordance with the state logical “1”
(e.g. X4-I4, UB -I4).
The connected dual-channel sensor equipment is OR-linked to the
7 8)
respective logic path of the UE410-MU/UE410-GU/UE410-XU modules.
The connected dual-channel sensor equipment is Bypass-linked to the
8 respective safety outputs of the UE410-MU/UE410-GU/UE410-XU modules
9)
(time-limited OR function).
Reciprocal assignment of input A/input B in order to link all 8 inputs on a
9
logic path.

For more informationen on this topic see section 4.12 “Grouping of subsystems” on
page 77.

8)
An OR function that acts on the global cut-off path on the UE410-GU (switch position 7, input A on the
UE410K8DI) is not permitted and will result in a configuration error (ERROR).
9)
A bypass function that acts on the global cut-off path on the UE410-GU (switch position 8, input A on the
UE410-8DI) is not permitted and will result in a configuration error (ERROR).

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3.8.1 AND link

The switch settings 1 to 6 of the UE410-8DI add inputs to the UE410-MU/UE410-GU/
UE410-XU modules and link them with AND logic.
If the input conditions I1-I4 and I5-I8 are logical “1”, the AND function is active and the
LED QA or QB is illuminated.
Tab. 21: UE410-8DI switch Switch Application Electrical configuration
positions
position
0 For unused inputs –
1 Emergency stop button Single-channel N/C contact
Safety switch
Testable sensors
2 Emergency stop button Dual-channel N/C contact,
Safety switch equivalent, cross-circuit
detecting
Switching mat (pressure-
sensitive)
Flexi Loop
3 Emergency stop button Dual-channel N/C contact,
Safety switch equivalent, cross-circuit
detecting, synchronous time
Flexi Loop
monitoring 1500 ms
4 Safety switch Dual-channel N/C / N/O
contact, complementary, cross-
circuit detecting

5 Safety switch Dual-channel N/C / N/O

RE300 contact, complementary, cross-
circuit detecting, synchronous
time monitoring. 1500 ms
6 Emergency stop button
Safety switch Single-channel N/C contact
ESPE (e.g. C4000)

Dual-channel N/C contact,

equivalent

Dual-channel semiconductor
output

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3.8.2 OR link
The switch position 7 of the UE410-8DI adds inputs to the UE410-MU/UE410-XU modules
and links these with OR logic.
All input pairs are AND-linked internally. For example, only if I1 and I2 are high is the OR
signal from this pair active. If the input conditions I1/I2 or I3/I4 are logical “1”, the OR
function is active and the LED QA or QB is illuminated.
OR function on the UE410-GU via UE410-8DI
On the UE410-GU the OR function is only available via the UE410-8DI input extension
module (switch position 7) and only on the local cut-off path, i.e. via input B.
Note An OR function that acts on the global cut-off path on the UE410-GU (switch position 7,
input A on the UE410-8DI) is not permitted and will result in a configuration error (ERROR).
Tab. 22: OR link UE410-8DI Switch Application Electrical configuration
position
7 Safety switch
ESPE (e.g. C4000) SingleKchannel N/C contact

DualKchannel N/C contact,

equivalent

DualKchannel semiconductor
output

3.8.3 Bypass
The switch position 8 of the UE410-8DI jumpers the outputs of the UE410-MU/UE410-XU
modules for the maximum duration of 60 s. The bypass is only active if I1 and I2 or I5 and
I6 are logical “1”. input pairs I3/I4 and I7/I8 do not have to be wired, they have no
function.
Bypass function on the UE410-GU via UE410-8DI
On the UE410-GU the bypass function is only available via the UE410-8DI input extension
module (switch position 8) and only on the local cut-off path, i.e. via input B.
Note A bypass function that acts on the global cut-off path on the UE410-GU (switch position 8,
input A on the UE410-8DI) is not permitted and will result in a configuration error (ERROR).
Tab. 23: Bypass UE410-8DI Switch Application Electrical configuration
position
8 Teach-in key-operated Dual-channel N/C contact,
switch equivalent, cross-circuit
Enabling switch detection

Bypass bypasses the safety device!

It should only be possible to generate the bypass signal by means of a dual-channel N/O
WARNING key switch. The bypass should only be activated through a conscious act of the operator
and with a view of the hazardous area.

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3.8.4 Reciprocal assignment — Mirror mode

Switch position 9:
The functionality and logical link of input B is assigned to the logic of input A. Input group A
then has 8 inputs.
Or:
The functionality and logical link of input A is assigned to the logic of input B. Input group B
then has 8 inputs.
Note Function 9 may only be selected for one of the two input groups respectively. Otherwise a
device error ERROR is generated and the ERR LED flashes.

3.8.5 Connection of sensors to the UE410-8DI

A UE410-8DI has two test pulse generators. This means that short-circuits between odd
(X1) and evenly (X2) numbered outputs will be detected. Short-circuits between two odd
(i.e. X1 and X3) or two evenly (i.e. X2 and X4) numbered outputs will not be detected.
WARNING Please heed this when wiring the safety sensors.

Notes The assignment of outputs X1 to X8 to inputs I1 to I8 depends on the selected rotary

switch position.
The functions of logic paths A and B can be set independently of each other.

When AND logic is used, unused inputs have to be jumpered in accordance with the state
logical “1” (e.g. X4-I4, UB -I4)!
WARNING
Connect the sensors (type depending on the switch position) in accordance with
Tab. 24.
Switch Input A Input B
position
0 All the inputs of Group A or B N.c. Terminals not connected Terminals not connected
are not used
1 AND X1-I1 X2-I2 X3-I3 X4-I4 X5-I5 X6-I6 X7-I7 X8-I8
4 × single-channel with testing

AND X1-I1 X2-I2 X3-I3 X4-I4 X5-I5 X6-I6 X7-I7 X8-I8

4 × single-channel with
sensors that can be tested
(ESPE)
2 AND X1-I1 X3-I3 X5-I5 X7-I7
2 × dual-channel, cross-circuit X2-I2 X4-I4 X6-I6 X8-I8
detection
AND X1-I1 X3-I3 X5-I5 X7-I7
2 × dual-channel, cross-circuit X2-I2 X4-I4 X6-I6 X8-I8
detection

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Switch Input A Input B

position
3 AND X1-I1 X3-I3 X5-I5 X7-I7
2 × dual-channel, cross-circuit X2-I2 X4-I4 X6-I6 X8-I8
detection, synchronous time
monitoring 1500 ms
4 AND X1-I1 X3-I3 X5-I5 X7-I7
2 × dual-channel, cross-circuit X2-I2 X4-I4 X6-I6 X8-I8
detection
5 AND X1-I1 X3-I3 X5-I5 X7-I7
2 × dual-channel, cross-circuit X2-I2 X4-I4 X6-I6 X8-I8
detection, synchronous time
monitoring 1500 ms
6 AND OSSD1Sensor-I1 OSSD1Sensor-I3 OSSD1Sensor-I5 OSSD1Sensor-I7
2 × dual-channel, OSSD2Sensor-I2 OSSD2Sensor-I4 OSSD2Sensor-I6 OSSD2Sensor-I8
semiconductor
AND +UB -I1 +UB -I3 +UB -I5 +UB -I7
2 × dual-channel, three-wire +UB -I2 +UB -I4 +UB -I6 +UB -I8

AND +UB -I1 +UB -I3 +UB -I5 +UB -I7

2 × single-channel +UB -I2 +UB -I4 +UB -I6 +UB -I8

7 OR OSSD1Sensor-I1 OSSD1Sensor-I3 OSSD1Sensor-I5 OSSD1Sensor-I7

2 × dual-channel, OSSD2Sensor-I2 OSSD2Sensor-I4 OSSD2Sensor-I6 OSSD2Sensor-I8
semiconductor
OR +UB -I1 +UB -I3 +UB -I5 +UB -I7
2 × dual-channel, +UB -I2 +UB -I4 +UB -I6 +UB -I8
three-wire
OR +UB -I1 +UB -I3 +UB -I5 +UB -I7
2 × single-channel +UB -I2 +UB -I4 +UB -I6 +UB -I8

8 Bypass X1-I1 I3 n.c. X5-I5 I7 n.c.

1 × dual-channel, cross-circuit X2-I2 I4 n.c. X6-I6 I8 n.c.
detection
9 Input supplement – Function as for input B Function as for input A

With AND logic, unused inputs must be bridged to logical “1” (e.g. X4-I4, UB -I4)!

Tab. 24: Connection of sensors to the UE410-8DI

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3.8.6 Controls and status indicators

Fig. 12: UE410-8DI controls
and status indicators

Program switch input A

Program switch input B

Tab. 25: UE410-8DI LED LED indicators Meaning

indications
PWR (green) Supply voltage via safety bus is present.
I1-I8 (green) Logical “1” is applied at the corresponding input.
I1, I2 flash in phase Cross-circuit between I1, I2
I3, I4 flash in phase Cross-circuit between I3, I4
I5, I6 flash in phase Cross-circuit between I5, I6 or modules with different revision
code (see section 10.2 “Replacement of a module” on
page 92)
I7, I8 flash in phase Cross-circuit between I7, I8 or modules with different revision
code (see section 10.2 “Replacement of a module” on
page 92)
I1, I2 flash out of phase Process error at I1, I2
I3, I4 flash out of phase Process error at I3, I4
I5, I6 flash out of phase Process error at I5, I6
I7, I8 flash out of phase Process error at I7, I8
I1 or I2 flashing Synchronous time (1500 ms) exceeded
I3 or I4 flashing Synchronous time (1500 ms) exceeded
I5 or I6 flashing Synchronous time (1500 ms) exceeded
I7 or I8 flashing Synchronous time (1500 ms) exceeded
QA (green) Input conditions input A of inputs I1 to I4 are fulfilled.
QB (green) Input conditions input B of inputs I5 to I8 are fulfilled.
ERR (red flashing) Erroneous operational status on this module, see chapter 10
“Diagnostics” on page 92
ERR (red) Erroneous operational status on the whole system (the error
is on another module), see chapter 10 “Diagnostics” on
page 92

Tab. 26: UE410-8DI Switch/button Function

operating elements
INPUT A 10-step rotary switches for setting an input circuit function
INPUT B (input group A or B)

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3.8.7 Inputs and outputs

Tab. 27: Terminals Assignment Description
UE41008DI
I1-I4 Inputs for the connection of signal detectors or sensors (input A)
Test outputs: cross-circuit detecting control signals for controlling
X1-X4
sensors of the module (input A)
I5-I8 Inputs for the connection of signal detectors or sensors (input B)
Test outputs: cross-circuit detecting control signals for controlling
X5-X8
sensors of the module (input B)

For more informationen on this topic see section 4.12 “Grouping of subsystems” on
page 77.

3.9 UE410-2RO/UE410-4RO output modules

The UE410-2RO/UE410-4RO output modules make dual-channel contact-based outputs
with positively guided relay contacts available.
The output modules may only be operated in a system combination with a UE410-MU/XU.
A maximum of four UE410-4RO or eight UE410-2RO can be connected to a Flexi Classic
system.
The slot of an output module in the Flexi Classic system is on the end of the safety
assembly.

3.9.1 Output module UE410-2RO

The UE410-2RO has one control input (B1). This input controls two internal relays and
forms a redundant shutdown path comprising:
two “safe enable current paths” (13/14, 23/24), dual-channel and floating,
one “safe enable current path” (Y14), dual-channel and not floating,
one “external device monitoring feedback circuit” (Y1/Y2), dual-channel and floating.
Fig. 13: Internal structure
UE410-2RO

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3.9.2 Output module UE410-4RO

The UE410-4RO has two control inputs (B1, B2). These inputs control two-by-two internal
relays that form two independent redundant shutdown paths.
Control input (B1) operates two internal relays and forms one redundant shutdown path
comprising:
two “safe enable current paths” (13/14, 23/24), dual-channel and floating,
one “safe enable current path” (Y14), dual-channel and not floating,
one “external device monitoring feedback circuit” (Y1/Y2), dual-channel and floating.
Control input (B2) operates two internal relays and forms one redundant shutdown path
comprising:
two “safe enable current paths” (33/34, 43/44), dual-channel and floating,
one “safe enable current path” (Y24), dual-channel and not floating,
one “external device monitoring feedback circuit” (Y3/Y4), dual-channel and floating.
The UE410-4RO therefore has twice the functionality of an UE410-2RO.
Fig. 14: Internal structure
UE410-4RO

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3.9.3 Controls and status indicators

Fig. 15:
UE41002RO/UE41004RO
controls and status indicators

Tab. 28: LED indicators Meaning

UE41002RO/UE41004RO
indicators PWR (green) Supply voltage via safety bus is present
K1/2 (green) Relay K1/K2 — safety contacts closed
K3/4 (green) Relay K3/K4 — safety contacts closed

3.9.4 UE410-2RO inputs and outputs

Tab. 29: Terminals Assignment Description
UE41002RO
B1 Connecting relay K1/K2
13/14 and 23/24 Safety contacts for switch-off circuit K1/K2
Y1/Y2 Feedback circuit external device monitoring (EDM), N/C contact
N/O safety contact K1/K2, current-limited,
Y14
see chapter 11 “Technical specifications” on page 95

3.9.5 UE410-4RO inputs and outputs

Tab. 30: Terminals Assignment Description
UE41004RO
B1 Connecting relay K1/K2
B2 Connecting relay K3/K4
13/14 and 23/24 Safety contacts for switch-off circuit outputs K1/K2
33/34 and 43/44 Safety contacts for switch-off circuit outputs K3/K4
Y1/Y2 Feedback EDM K1/K2, N/C contact
Y3/Y4 Feedback EDM K3/K4, N/C contact
N/O safety contact K1/K2, current-limited,
Y14
see chapter 11 “Technical specifications” on page 95
N/O safety contact K3/K4, current-limited,
Y24
see chapter 11 “Technical specifications” on page 95

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4 Special applications and functions

This chapter describes the special applications and functions that can be implemented
with a Flexi Classic system.
These are the connection and configuration of the safety sensors and the settings at the
Flexi Classic system:
RE300 magnetic safety switch
IN4000 inductive safety switch
connection of testable single-beam photoelectric safety switches
two-hand operation/jog mode
OR function
muting function
bypass function
connecting of S1, S2, S3
– restart interlock
– external device monitoring (EDM)
retriggering
grouping of subsystems
ENABLE input

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4.1 RE300 magnetic safety switch

RE300 magnetic safety sensors can be connected directly to the inputs of the
UE410KMU/UE410KGU/UE410-XU as well as UE410-8DI units. Up to eight RE300 can be
connected in series.
The necessary test signals for the RE300 switch are only generated in program 2 on the
UE410-MU/UE410-XU and in switch position 5 on the UE410-8DI. They comply with the
requirements for an application up to PL e according to EN ISO 13 849K1.
An RE300 can only be connected to the local cut-off path on I3 and I4 on the UE410-GU in
program 4 or 5. The necessary test signals (X1/X2) for the magnetic safety switch RE300
meet the requirements for applications up to PL e as per EN ISO 13 849-1.

Pay attention to the safety notes for the RE300 switch.

WARNING

Fig. 16: Connection of a

RE300 to the UE410-MU/XU

Notes If RE300 sensors are cascaded, these have to be tested/activated regularly (for
example opening and closing of the protective doors connected to the sensors).
Cascading of several RE300 sensors is limited by the line resistance (refer to the
operating instructions of the RE300 for further information).
If RE300 sensors (N/C / N/O contacts) are connected, the unused input pairs have to
be connected to simulate a logical “1” input correspondingly at the UE410-8DI. The odd-
numbered inputs/test outputs have to be jumpered respectively (for example I1-X1), the
even-numbered inputs/test outputs are not interconnected (for example I2-X2).

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4.2 IN4000 inductive safety switch

IN4000 inductive safety sensors can be connected directly to the inputs of the
UE410KMU/UE410-XU units. The required test signals for the sensors are generated in the
program 3.2 of the UE410KMU/UE410-XU.
Up to nine safety sensors can be cascaded per input.
Note Inductive safety switches IN4000 cannot be connected to a UE410-GU.
Connection:
A safety sensor/cascade is connected to the input I1 and test output X1.
Further information is available in the IN4000 operating instructions.
Fig. 17: Connection of an
IN4000

Fig. 18: Connection of two

IN4000

Note Input I2 and test output X2 have to be jumpered. Terminal S2 may not be interconnected.
A selection of the IN4000 safety sensors is available in section 12.2 “Accessories/spare
parts” on page 114.

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4.3 Testable single-beam photoelectric safety switches

Testable single-beam photoelectric safety switches can be connected directly to the inputs
of the UE410-MU/UE410-GU/UE410-XU as well as UE410-8DI units.
Notes For category 2 testable photoelectric safety switches (e.g. L21) the response time of the
respective program applies.
For category 4 testable photoelectric safety switches (e.g. L41), the response time is
calculated from the response time of the program plus the test period of the program.
You can find the response times of the programs in chapter 11 “Technical specifica-
tions” on page 95.
The required test signals at X2 for the sensors are generated in program 3.2 of the
UE410KMU/UE410-XU.
The required test signals are generated on X2 in programs 8 and 9 on the UE410-GU.
In switch position 1 of the UE410-8DI the required test signals are generated at outputs
X1 to X8.
Up to 4 testable single-beam photoelectric switches can be cascaded per input. This
means, at the modules UE410-MU/UE410-GU/UE410-XU with one input (I2) each
respectively, at the UE410-8DI with inputs I1 to I8.
A selection of the testable single-beam photoelectric safety switches is available in
section 12.2 “Accessories/spare parts” on page 114.

Ensure protected laying of the connection cables!

If cascades are used, protected separate laying of the connection cables must be ensured.
WARNING
Connection to UE410-MU/UE410-XU
A testable single-beam photoelectric safety switch/cascade uses the input I2 and test
output X2.
Connection to UE410-GU
A testable single-beam photoelectric safety switch/cascade uses the input I4 and test
output X2.
Connection to UE410-8DI
A testable single-beam photoelectric safety switch/cascade uses the inputs and test
outputs that belong together (for example I1/X1 to I8/X8).
Note UE410-MU/UE410-XU:
Input I1 and test output X1 have to be jumpered. Terminal S2 may not be
interconnected.
UE410-8DI:
The unused inputs have to be jumpered to the corresponding test outputs (for example
the free inputs I2/X2 to I8/X8).

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Ensuring the protective function when a Flexi Classic system with single-beam
photoelectric safety switches is used
Single-beam photoelectric safety switches may only be used as access protection in
accordance with EN ISO 13 855. Usage as finger and hand protection is not permissible.
Interference beams (for example, direct/indirect sun irradiation, remote controls) are to
be prevented since they can reduce the availability of single-beam photoelectric safety
switches.
The number of beams of the sender and receiver as well as the distance between the
beams must agree.
Mutual influence of single-beam photoelectric safety switches
If several pairs of single-beam photoelectric safety switches are used, it is imperative
that the aperture angle of the sensors is observed to avoid the possibility of mutual
interference.
If the senders are only mounted on one side, the light beams may not overlap on the
receiver side, i.e. the light beam of one sender may not reach two receivers.
If the senders and receivers are mounted alternately, ensure that the light beam of
sender S1 cannot be received by receiver R3 and that the light beam of sender S3
cannot be received by receiver R1.
Fig. 19: Mounting to avoid
mutual optical influence

S1 R1

R2 S2

S3 R3

Mutual optical influence between cascades must be excluded.

Reflective surfaces that exist within the sending and receiving cones, placed or mounted
there can cause incorrect reflection and therefore non-detection of an object or a person.
All reflective surfaces and objects (for example material bins) must therefore be located at
a minimum distance (a) rotational-symmetrically around the optical axis between the
sender and receiver.

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Fig. 20: Minimum distance

(a) to reflective surfaces,
correct mounting and
alignment

S = Sender R = Receiver
D = Distance sender-receiver a = Minimum distance from reflective surfaces
1 = Limit of the hazardous area 3 = Direction of access to the hazardous area
2 = Reflective surface 4 = Optical axis
Fig. 21: Minimum distance
(a) as a factor of the distance
D for testable single-beam
photoelectric safety switches

The minimum distance (a) to reflective surfaces for single-beam photoelectric safety
switches with a field of view of 10° is calculated as follows:
If the distance D = 3 m, the minimum distance a = 260 mm.
If the distance D > 3 m, the minimum distance (a) is calculated using the following
equation:
a (mm) = 88.2 × D × 10³ (m)
Example:
Distance D between the sender and receiver amounts to 28 m.
With the corresponding value entered:
a (mm) = 88.2 × 28 m × 10³ = 2469.6 mm
The minimum distance (a) to the reflective surface has to amount to 2469.6 mm in this
example.

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4.4 Two-hand operation/jog mode

The two-hand operation function in accordance with type IIIC can be set in program 4 of
the UE410-MU/UE410-XU:
Two pairs of complementary inputs (N/O / N/C contact pairs of both two-hand buttons)
are monitored.
A valid input signal is only generated if the ON state (H/L level) exists at both inputs
within a period of 0.5 s (synchronous change, both two-hand buttons pressed) and if
both were in the OFF state (L/H level) beforehand.
In Program 5 at the main module UE410-MU the logic path B can monitor normal two-hand
operation (synchronous pressing of two pushbuttons within 0.5 s program 5.1), or two-
hand operation in jog mode (program 5.2), for example for traversing movements. Two-
hand operation in jog mode allows feeding or setting-up procedures.
The two-hand operation function in accordance with type IIIA can be set in program 5.1 of
the UE410-MU/UE410-XU:
Two equivalent inputs (N/O contacts of both two-hand buttons) are monitored.
A valid input signal is only generated if the ON state (H level) exists at both inputs within
a period of 0.5 s (synchronous change, both two-hand buttons pressed) and if both
were in the OFF state (L level) beforehand.
The jog operation function can be set in program 5.2 of the UE410-MU/XU:
The evaluation in jog mode corresponds to two-hand operation IIIA with the difference
that the ON signal is limited to a duration of 5 s.
In the case of two-hand operation in jog mode an output signal is only generated as long
as both actuating parts are pressed. In jog mode, the duration for which the safety outputs
Q3/Q4 are on is limited to 5 s.
When the two actuating parts are released, the time is reset. Renewed activation of the
two actuation parts is possible.
In order to activate jog mode, terminal S2 remains unused. For two-hand applications,
S2 is jumpered with the supply voltage +UB.
Note It is not impossible to implement two-hand applications using a UE410-GU.

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4.5 OR function
Note The OR function can be implemented at the UE410-MU/UE410-XU modules (switch
positions 1 and 2) or by an input extension module UE410-8DI (switch position 7).

Switch the machine to a safe state when using the OR function!

As long as the OR function is active, the outputs of the main module do not switch off. You
WARNING must ensure that while the OR function is being used, for example for the set-up mode,
other protective measures, e.g. the safe set-up mode of the machine, are activated so that
there is no danger to persons or parts of the machine while the OR function is being used.

A logic path A/B can be muted by using an OR signal. Thus, for example, a safety function
can be muted in set-up mode by means of an enabling switch. An OR link of two safety
functions is also possible.
The OR function does not have a time limit.
OR function with input extension module
All the programs of the main module offer the possibility of linking signals of the OR func-
tion at the UE410-8DI input extension modules to the input signals of the UE410KMU/
UE410KXU by means of a logical OR (also refer to section 3.8.2 “OR link” on page 52).
OR function on the UE410-MU/UE410-XU
The OR function can be implemented in the programs 1 and 2. I1/I2 is linked to I3/I4 OR.
OR function on the UE410-GU via UE410-8DI
On the UE410-GU the OR function is only available via the UE410-8DI input expansion mo-
dule (switch position 7) and only on the local cut-off path, i.e. via input B.
Note An OR function that acts on the global cut-off path on the UE410-GU (switch position 7,
input A on the UE410-8DI) is not permitted and will result in a configuration error (ERROR).

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4.6 Muting function

Muting overrides the protective effect of a safety device temporarily. This means that
material can be transported to or from a machine or system without the working process
having to be interrupted.
In the case of muting additional sensor signals are used to differentiate between humans
and material. To this purpose an evaluation unit (for example the Flexi Classic modular
safety controller) evaluates the signals from external sensors logically and, if the muting
condition is valid, mutes the protective device so that the material to be transported can
pass the protective device. As soon as anything except the material enters the hazardous
area, the working process is interrupted.
Note It is not possible to implement muting applications using the UE410-GU.

Pay attention to the following safety notes!

Muting is only allowed to be activated during the period when the material to be trans-
WARNING ported (e.g. on a pallet) blocks the access to the hazardous area.
Muting must be triggered by at least two independently wired signals (e.g. from muting
sensors) and must not depend entirely on software signals (for instance from a PLC).
Muting must be removed immediately as soon as the material to be transported no
longer blocks the access to the dangerous movement so that the protective device is
once more effective.
The material to be transported must be detected over its entire length, i.e. there must
be no interruption in the output signals.
Always position the sensors so that the minimum distance to the protective device is
observed!
Prevent the unintentional triggering of muting by a person by mounting the sensors
appropriately!
Fig. 22: Safety on mounting
the muting sensors

Ensure that muting cannot be unintentionally triggered

by a person!

Note Always mount the muting lamp where it can be clearly seen!
The muting lamp must be clearly visible from all sides of the hazardous area and for the
system operator.

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4.6.1 Muting with two sensors

Fig. 23: Schematic layout Means of transport Hazardous area
ESPE

A1
Material

A2

In the example, the material moves from left to right on a conveyor belt . As soon as the
muting sensors A1 and A2 are activated , the protection provided by the ESPE protective
device is muted and the material can move into the hazardous area. As soon as the
muting sensors are clear again , the protection provided by the protective device is re-
activated.

4.6.2 Muting cycle

The muting cycle is the defined sequence of all processes that take place during muting.
The cycle starts when the first muting sensor is activated. The cycle ends when the last
muting sensor returns to its initial state (e.g. clear light path for optical sensors). Only then
is it possible to activate muting again.
Material can be transported several times during a muting cycle, if the muting condition is
maintained continuously, i.e. at least one pair of sensors remains activated continuously.

4.6.3 Muting sensors

Muting sensors detect material and supply the necessary signals as required by an eva-
luation unit (e.g. the Flexi Classic modular safety controller.) If the muting conditions are
met, the evaluation unit can mute the protective device based on the sensor signals.
Sensor signals can be generated by the following external sensors:
optical sensors
inductive sensors
mechanical switches
controller signals

SICK muting sensors

An overview of the SICK muting sensors is available in the section 4.8 “SICK muting
sensors” on page 72.

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4.7 Placement of muting sensors

Pay attention to the following notes on the placement of the muting sensors!
Always position the muting sensors such that only the material is detected and not the
WARNING means of transport (pallet or vehicle).
Always position the muting sensors such that material can pass unhindered, but people
are reliably detected.
Fig. 24: Detection of material
during muting Means of transport Material

Muting sensor
Transport level

Always position the muting sensors such that, on the detection of the material ,a
minimum distance to the light beams on the ESPE is maintained.
Note The minimum distance provides the processing time necessary until muting is activated.
Fig. 25: Minimum distance, ESPE Hazardous area
material detection to the
ESPE on muting

S
v

How to calculate the minimum distance:

S v × 61 ms
Where …
S = minimum distance (mm)
v = velocity of the material (e.g. of the conveyor) (m/s)
Use optical sensors with background suppression. These detect material only up to a
specific distance. Objects that are further away than the material to be detected are not
detected.
Fig. 26: Principle of operation
of sensors with background Detection zone Background
suppression

Sensor

Material is Material is not

detected detected

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4.7.1 Muting with two sensors (a sensor pair), crossed placement

Fig. 27: Muting with two Hazardous area
S2
sensors, crossed placement

S1
A1

A2
S3
ESPE

In the example, the material moves from left to right or, alternatively, from right to left. As
soon as the muting sensors A1 and A2 are activated, the protection provided by the pro-
tective device (ESPE) is muted.
The following requirements must be met:
Tab. 31: Conditions for Condition Description
muting with two sensors,
crossed placement A1 & A2 Muting applies as long as this condition is met.

How to calculate the distance:

S1 v × 61 ms
Where …
S1 = minimum distance between the light beams of the ESPE and the detection by the
muting sensors (mm)
v = velocity of the material (e.g. of the conveyor) (m/s)
Notes The material can flow in both directions.
In order for materials to be conveyed in both directions, place the intersection of the
muting sensors exactly on the course of the light beams of the ESPE. In order for
material to be conveyed in one direction only, place the intersection behind the light
beams of the ESPE seen from the conveyor direction.
This placement is suitable for through-beam photoelectric switches and photoelectric
reflex switches.

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4.7.2 4-sensor muting, sequential layout

Fig. 28: Simulated 4-sensor
muting ESPE Hazardous area
S3

A1 A2 B1 B2

S1

S2

In the example, the material moves from left to right. As soon as the muting sensors A1 &
A2 are activated, the protection provided by the protective device (ESPE) is muted. The
protection remains muted until one of the sensors in the muting sensor pair B1 & B2 is
clear again.

4.7.3 Muting with UE410-MU/UE410-XU

A simple muting function can be implemented at the UE410-MU/UE410-XU modules
(programs 3.1 and 3.2) by using inputs I3 and I4 for the muting sensors. Inputs I3 and I4
are AND-linked to each other and mute the safety sensor equipment connected to I1/I2.
A muting lamp can be connected to output Q3.
Features of the muting function for UE410-MU/UE410-XU:
The outputs on the muting sensors must be “0” on powering up the Flexi Classic, other-
wise a process error will be generated and the system will generate ERROR.
Muting duration indefinite
Switching behaviour of the muting sensors is not limited in time.
Direction independent muting
Inputs I3/I4 for muting sensors can be “1” simultaneously.
The muting lamp is not current monitored and has two functions:
– Muting lamp ON continuously, then muting is active,
– Muting lamp flashes at 1 Hz, then the Reset required is active.
Muting with 4 sensors:

With this 4-sensor muting two muting sensors each are connected to one input of the
UE410-MU/UE410-XU. Take into account that the muting sensors A1/B2 and A2/B1
WARNING are combined respectively.
Only “high-side”-switching sensors may be used for 4-sensor muting. Thereby it has to
be ensured that a “high” always overwrites a “low”. This type of muting may only be
used after thorough risk analysis/error analysis.

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4.8 SICK muting sensors

Tab. 32: Selection of the Sensor Type Switching output Q type
optical SICK muting sensors
Photoelectric proximity WT24-2 Light switching
switch WT27K3
WT260
Photoelectric reflex switch WL23-2 Dark switching
WL27-3
WL260
WL12-3
WL14-2
WL18K3
Through-beam photoelectric WS/WE24-2 Dark switching
switch WS/WE27-3
WS260/WE260

Notes For the selection and settings for the SICK optical muting sensors in muting applications,
the following applies:
The outputs must be PNP switching.
Other type series are possible.

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4.9 Bypass
The bypass function bypasses the logic paths A/B in the UE410-MU/UE410-XU or the logic
path B in the UE410-GU and forces their safety outputs to logical “1” for 60 s. The bypass
function overrides the logic paths A/B in the UE410-MU/UE410-XU and forces the corres-
ponding safety outputs to logical “1” for 60 s. The bypass function can be implemented via
a UE410-8DI input extension module (switch position 8).
The bypass signal is limited to a duration of 60 s. After the period has expired, bypass ope-
ration can be activated again after deactivation.
Notes On the UE410-GU the bypass function can only be implemented on the local cut-off path
via input B.
A bypass function on the UE410-GU that acts on the global cut-off path (input A) is not
permitted and will result in a configuration error (ERROR).

Ensure that there is no danger during bypass operation!

As long as the bypass function is active, the safety outputs of the UE410-MU/UE410-GU/
WARNING UE410-XU modules are activated. You have to ensure that there is no danger to persons or
parts of the machine or system during bypass operation.

The bypass function may only be activated by a key-operated switch with an automatic
reset and two levels or by two input signals that are independent of each other, e.g. two
position switches.

Check the connected key-operated pushbutton for bypass regularly!

Using organisational measures, ensure that the key-operated pushbutton for bypass is
WARNING actuated once after a certain interval. This is necessary so that the Flexi Classic can
identify an error condition of the key-operated pushbutton for bypass or an error condi-
tion in its connection cable that occurs up until then. The interval is to be defined to suit
the specific case dependant on the application.
Constantly check in the operating mode in which you have configured the bypass active
whether the bypass function can be activated and deactivated.

Notes It must be possible to view the entire hazardous point when pressing the key-operated
pushbutton for bypass.
It may not be possible to actuate the key-operated pushbutton for bypass in the hazard-
ous area.
The safety controller ends the bypass automatically when an error occurs.

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4.10 Connecting S1, S2, S3

Three control inputs S1, S2, and S3 are available for the configuration of the control circuit
functions (restart interlock, retriggering, EDM) at the UE410-MU/UE410-XU modules.
Note No control inputs are available on the UE410-GU.

4.10.1 Operation with restart interlock

In the case of operation with a restart interlock the reset button is connected to the re-
spective input (S1/S2). The required starting condition for cancelling the restart interlock
is only fulfilled, when the reset button is pressed and released again and the feedback
circuit is closed.

4.10.2 Operation without restart interlock

The outputs are activated as soon as the input conditions of the safety sensors have the
value of logical “1”. A reset button is not required.

4.10.3 Operation with external device monitoring (EDM)

The static EDM monitors whether the controlled contactors have dropped out during re-
setting. The EDM is included in the feedback circuits S1, S2 and S3 in accordance with the
set program.
Tab. 33: EDM by means Connecting S1
of S1
Without EDM With EDM
Manual reset (with restart
interlock)

UB S1 UB S1

Automatic reset (without

restart interlock)
X1 S1
X1 S1

Tab. 34: EDM by means Connecting S2

of S2
Without EDM With EDM
Manual reset (with restart
interlock)

UB S2 UB S2

Automatic reset (without

restart interlock)
X2 S2
X2 S2

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4.11 Retriggering of the delayed OSSDs

The behaviour of the off delay (not on UE410-xxxT0) can be influenced by means of retrig-
gering. Retriggering is specified by connecting Terminal S3 to the voltage supply +UB or the
module-specific cycle output X2.
Note Retriggering is not possible on the UE410-GU.
Example: Retriggering ON
During automatic operation a protective door is opened and the off delay is started for the
corresponding releases. If the door is closed again before the delay time has expired, the
releases do not switch off and the machine continues to run without interruption.
Example: Retriggering OFF
During manual operation the emergency stop pushbutton is activated and the off delay is
started for the corresponding releases. If the emergency stop pushbutton is reset again
before the delay time has expired and the reset button is pressed, the releases are never-
theless de-activated. Renewed releasing via the reset button is not possible until the delay
time has expired.
Tab. 35: Retriggering time Retriggering Course
response
ON If the safe input state (all input conditions are valid) of the input circuits is
attained again before the time has expired, the delayed output circuits do
not change and the delay time is reset
OFF The delayed output circuits open after the delay time has expired irres-
pective of the state of the input circuits.
In the case of an automatic start and a safe input state before the delay
time has expired, the delayed OSSDs are de-activated for 400 ms, and
are then re-activated

Fig. 29: Retriggering ON,

with/without restart interlock Inputs
Output QX

Can be set up to x seconds

Fig. 30: Retriggering OFF,

with restart interlock Inputs
Start button
Output QX

Can be set up to x seconds

Fig. 31: Retriggering OFF,

without restart interlock Inputs
Output QX

Can be set up to x seconds

Fig. 32: Retriggering OFF,

without restart interlock Inputs
Output QX

Can be set up to x seconds 400 ms

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Tab. 36: EDM by means Connecting S3
of S3
Without EDM With EDM
Without retriggering

UB S3
UB S3

With retriggering

X2 S3
X2 S3

Notes S1 and S3 must always be connected.

S2 must be connected depending on the program.

All later changes at the connection of S1, S2 and S3 cause a lock-out (ERR).

WARNING During the configuration phase (when the voltage is activated) of the manual reset with
the reset button, the corresponding S-input must be open or be connected to a high-
resistance output, for example of a PLC (high or low potential causes an incorrect
configuration).
In order to monitor external contactors that may be connected to the safe outputs Q1 to
Q4, the N/C contacts of the respective contactors or output extensions have to be con-
nected in series with the corresponding control inputs.

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4.12 Grouping of subsystems

Note In case of single-channel wiring of a safety capable output (Q1-Q4) to a signal input (EN), it
is possible to achieve category 4 in accordance with EN ISO 13 849K1 or SILCL3 in accord-
ance with EN 62 061.
Fig. 33: Cascading of safety
circuits

Exclude cross-circuits by means of appropriate cabling!

If several modules are used (> 1), cross-circuits on test pulse outputs (X1-Xn) can not
WARNING always be detected.
If two modules are used (UE410-MU or UE410-GU and a UE410- XU), cross-circuits on
safety outputs (Q1-Q4) can not always be detected.
If several modules are used, the possibility of cross-circuits has to be excluded by
means of appropriate cabling measures (protected installation, plastic-sheathed cable
etc.).

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4.13 ENABLE input

For all UE410-MU- and UE410-XU-devices with a type label entry from E1: In case of single-
channel wiring of a safety capable output (Q1-Q4) to a signal input (EN), it is possible to
achieve category 4 in accordance with EN ISO 13 849K1 or SIL3 in accordance with
IEC 61 508.
Note The ENABLE input is not available on the UE410-GU.
Fig. 34: ENABLE input
ENABLE function
ENABLE-Funktion
QStart
(switch on and switch off
signal for the start function)

EN & QEN
(output of the ENABLE function)

Start-up interlock

The ENABLE input makes it possible to cascade safety circuits or to form sub-systems. The
ENABLE input has a higher priority than all other input signals (sensors, muting, bypass,
OR function).
Note Unused ENABLE inputs must be connected to the supply voltage +UB.
When the ENABLE input goes low (0 V DC), the OSSDs (Q1-Q4) always go low and at the
same time no signal such as a reset or muting is detected until ENABLE is high again.
Switching OFF and switching ON ENABLE does not require a renewed reset on the related
modules, the OSSDs (Q1-Q4) go high.
If a time delay has been set on Q3/Q4, the delay starts after the ENABLE input goes low.

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Operating instructions Mounting/dismantling Chapter 5
Flexi Classic

5 Mounting/dismantling
This chapter describes the mounting of the modules and the anti-manipulation cover for
the Flexi Classic modular safety controller.
The following steps are necessary after mounting and installation:
completing the electrical connections (chapter 6)
configuration (chapter 9)
checking the installation (section 8.2)

5.1 Steps for mounting the modules

The Flexi Classic system is only for use in a control cabinet rated to at least IP 54.

WARNING
In a Flexi Classic system the main module UE410-MU is positioned at the extreme left
and one of the optional gateways, e.g. UE410-PRO, at the extreme right.
The connection between the modules is effected by means of the plug connection
integrated in the housing.
Mounting according to EN 50 274
The modules are located in a 22.5 mm wide housing for 35 mm DIN mounting rails as
per EN 60 715.
Fig. 35: Hanging the module
into the DIN mounting rail

2 1

Hang the device onto the DIN mounting rail ( ).

Ensure that the earthing spring contact is positioned correctly ( ). The earthing spring
contact of the module must contact the DIN mounting rail making good electrical
contact.
Latch the module onto the DIN mounting rail by pressing it lightly in the direction of the
arrow ( ).

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Fig. 36: Installing the end
clips

If there are several modules, slide the modules together individually in the direction of
the arrow until the side plug connection latches in.
Install end clips on the right and left.

5.2 Steps for dismantling the modules

Fig. 37: Removing the plug-in
terminals

Remove the plug-in terminals with wiring and the end clips.
Fig. 38: Disconnecting the
plug connection

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Flexi Classic

If there are several modules, slide the modules away from each other individually in the
direction of the arrow until the side plug connection is separated.
Fig. 39: Removing the
module from the DIN
mounting rail

Press the module downwards ( ) and remove it from the DIN mounting rail in the
direction of the arrow while keeping it pressed down ( ).

5.3 Removing the anti-manipulation cover

To prevent tampering on the Flexi Classic, SICK provides an optional anti-manipulation
cover (see section 12.2.6 “Anti-manipulation cover” on page 116).
Fig. 40: Anti-manipulation
cover

Insert a screwdriver in the opening ( ).

The cover fastening is released by upward movements. The cover can be removed ( ).
The cover is closed by engaging it.

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Chapter 6 Electrical installation Operating instructions
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6 Electrical installation
Switch the entire machine/system off line!
The machine/system could inadvertently start up while you are connecting the devices.
WARNING

Notes The Flexi Classic modular safety controller fulfils the EMC requirements in accordance
with the basic specification EN 61 000K6K2 for industrial use and EN 61 131K2 for con-
trol systems.
The control cabinet or mounting housing of the Flexi Classic must at least comply with
enclosure rating IP 54.
The modules of the Flexi Classic family conform to Class A, Group 1, in accordance with
EN 55 011. Group 1 encompasses all ISM devices in which intentionally generated
and/or used conductor-bound RF energy that is required for the inner function of the
device itself occurs.
Mounting according to EN 50 274
In order to ensure EMC safety, the DIN mounting rail must be connected to FE.
You must connect the Flexi Classic to the same voltage supply as the connected protec-
tive devices.
To meet the requirements of the relevant product standards (e.g. IEC 61 496K1), the
external voltage supply for the devices (SELV) must, among other aspects, be able to
bridge a power failure lasting 20 ms. Suitable power supplies are available as acces-
sories from SICK.
When several power supplies are used, all mass connections (GND) must be connected
to each other.
All UE410-GU modules that are on a common global emergency stop cut-off path must
be connected to the same GND connection.
The power supply as well as all signals connected have to fulfil the regulations for extra-
low voltages with safe separation (SELV, PELV) in accordance with EN 60664 and
EN 50178 (equipment of electrical power installation with electronic devices) or NEC
Class 2 according to UL 1310.
For installation in environments with overvoltage category III, external protection
elements must be used. The required level of protection as per EN 62 305K1 can be
achieved using an external snubber circuit. The protection elements (SPD – surge
protective devices) must comply with the requirements as per EN 61 643K11.
The cables of a connected reset button must be laid in separate plastic-sheathed
cables.
All connected sensors and downstream controllers and wiring/installation must corres-
pond to the required category according to EN ISO 13 849K1 and to the SILCL according
to EN 62 061 (e.g. protected installation, single plastic-sheathed cable with shielding
etc.).
In order to protect the safety outputs and to increase the life of the module, the external
load must be equipped with e.g. varistors and RC circuits. Please also note that the
selection of the arc suppression can increase the total response time of the safety
function.

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The wiring of single-channel safety outputs as well as the external device monitoring
(EDM) and ENABLE (EN) must be performed inside the control cabinet.
External faults (e.g. cross-circuits) between two modules within a Flexi Classic system
are to be avoided through use of appropriate countermeasures (separating effected
wires, single plastic-sheathed cable etc.). For more informationen on this topic see
section 4.12 “Grouping of subsystems” on page 77.

Special features to note during wiring:

A UE410-8DI has two test pulse generators. This means that short-circuits between odd
WARNING (X1) and evenly (X2) numbered outputs will be detected. Short-circuits between two odd
(i.e. X1, X3, X5, X7) or two evenly (i.e. X2, X4, X6, X8) numbered outputs will not be de-
tected (see also section 4.12 “Grouping of subsystems” on page 77).

Mount the reset device so that it cannot be actuated by a person located in the ha-
zardous area. When operating the reset device, the operator must have full visual
command of the hazardous area.

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Chapter 7 connection diagrams Operating instructions
Flexi Classic

7 Application examples and connection diagrams

Note By taking into account all the necessary boundary conditions and their evaluation in a
Failure Mode and Effects Analysis (FMEA), applications up to a maximum of SIL3
(IEC 61 508) can be achieved.

7.1 L21 on the UE410-MU/XU

Program 3.2 with restart interlock and EDM
Fig. 41: Connection of three
L21 to the UE410-MU/XU

7.2 Emergency stop on the UE410-MU/XU

Program 1 with restart interlock and EDM
Fig. 42: Connection of an
emergency stop to the +24V
UE410-MU/XU S1

k1

k2

I1 I2 A1 X1 X2 S1 S2 S3
4 5
3 6
2 7
1 1 8 FE
UE410-MU/XU 0 9
Function

I3 I4 A2 Q1 Q2 Q3 Q4 EN

K1

K2

0V
PE LV

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7.3 RE300 on the UE410-MU/XU

Program 2 with restart interlock and EDM
Fig. 43: Connection of an
RE300 to the UE410-MU/XU +24V
S1

BL

RE300- KA
YE k1
RE300-DA GR
RD

k2

I1 I2 A1 X1 X2 S1 S2 S3
4 5
3 6
2 7
1 2 8 FE
UE410-MU/XU 0 9
Function

I3 I4 A2 Q1 Q2 Q3 Q4 EN

K1

K2

0V
PE LV

7.4 Two-hand IIIC on the UE410-MU/XU

Program 4 without restart interlock and with EDM
Fig. 44: Connection of a two-
hand switch IIIC to the +24V
UE410-MU/XU

k1

k2

I1 I2 A1 X1 X2 S1 S2 S3
4 5
3 6
2 7
1 4 8 FE
UE410-MU/XU 0 9
Function
S2 S1
I3 I4 A2 Q1 Q2 Q3 Q4 EN

K1

K2

0V
PE LV

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7.5 C2000 and emergency stop on the UE410-MU/XU,

two hazardous areas
Program 7 with restart interlock and EDM
Fig. 45: Connection of a
C2000 and emergency stop +24V
to the UE410-MU/XU S1

k1 k3

k2 k4
WH 1 1 WH
Sel1 Sel1
BN 2 2 BN
+24V +24V
GN 3 3 GN
Sel2 Sel2 I1 I2 A1 X1 X2 S1 S2 S3
4 4 YE 4 5
n.c. n.c. 2
3 6
7
GY 5 5 GY 1 7 8 FE
Test OSSD1 UE410-MU/XU 0 9

6 6 Function
PK
n.c. OSSD2
BU 7 7 BU I3 I4 A2 Q1 Q2 Q3 Q4 EN
GND GND
8 8
Shield Shield
K1 K3
C2000S C2000R

K2 K4

0V
PE LV

7.6 i11 on the UE410-MU/XU, two independent hazardous

areas
Program 8 with restart interlock and EDM
Fig. 46: Connection of two
i11 to the UE410-MU/XU, two +24V
hazardous areas
S1 S2

k1 k3

31 21 13

32 22 14 k2 k4

I1 I2 A1 X1 X2 S1 S2 S3
4 5
3 6
2 7
1 8 8 FE
UE410-MU/XU 0 9
Function

I3 I4 A2 Q1 Q2 Q3 Q4 EN

31 21 13 K1 K3

32 22 14

K2 K4

0V
PE LV

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Flexi Classic

7.7 IN4000 on the UE410-MU/XU

Program 3.2 with restart interlock and EDM
Fig. 47: Connection of two
IN4000 to the UE410-MU/XU +24V
S1
1 BN

2 WH

IN40-D 3 BU
k1
4 BK

k2

1 BN

2 WH I1 I2 A1 X1 X2 S1 S2 S3

IN40-D 3 BU 3
4 5
6
2 7

BK 1 3 8 FE
4 UE410-MU/XU 0 9
Function

I3 I4 A2 Q1 Q2 Q3 Q4 EN

K1

K2

0V
PE LV

7.8 C4000 on the UE410-MU/XU, 2-sensor muting

Program 3.1 with restart interlock and EDM
Fig. 48: Connection of a
C4000 to the UE410-MU/XU, +24V
2-sensor muting S1

+24V +24V
1 1
Test RES
3 5
n.c. EDM k1
4 6
n.c. OSSD1
5 3
n.c. OSSD2
6 4 k2
GND GND
2 2
FE FE
FE FE

I1 I2 A1 X1 X2 S1 S2 S3

C4000S C4000R 2
3
4 5
6
7
1 3 8 FE
UE410-MU/XU 0 9
Function
+24V +24V
I3 I4 A2 Q1 Q2 Q3 Q4 EN
0V 0V

TE WS 27-2 WE 27-2 Q
K1
MUT

+24V +24V

0V 0V K2
TE WS 27-2 WE 27-2 Q

0V
PE LV C4000 - FE muss angeschlossen werden.
C4000 - FE must be connected

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 Application examples and
Chapter 7 connection diagrams Operating instructions
Flexi Classic

7.9 Global emergency stop with two UE410-GU

Program 1 (global emergency stop only)
Fig. 49: Global emergency
stop with two UE410-GU

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Operating instructions Commissioning Chapter 8
Flexi Classic

8 Commissioning
Do not commission without a check by qualified safety personnel!
Before the initial commissioning of the system in which you are using a Flexi Classic modu-
WARNING lar safety controller, it must be checked and released documented by qualified safety
personnel.

Check the hazardous area!

You must ensure that no one is located in the hazardous area before commissioning.
WARNING Check the hazardous area and secure it against being entered by people (e.g. set up
warning signs, attach blocking ropes or similar). Observe the relevant laws and local
regulations.

8.1 Validation of the application

You may only commission the system if validation was successful. Validation may only be
performed by professionals trained accordingly.
The general acceptance comprises the following test points:
Check whether the connection of the components to the connections corresponds to
the required Performance Level in accordance with EN ISO 13 849K1 or to the SIL in
accordance with IEC 61 508 or the SILCL in accordance with EN 62 061.
Check the devices connected to the safety controller in accordance with the test notes
from the accompanying operating instructions.
Note You will find the “Tests before the first commissioning” chapter for this in the operating
instructions of the ESPE from SICK AG.
Clearly mark all connection cables and plugs at the safety controller.
Perform a complete verification of the safety functions of the system in each operating
mode and an error simulation. Observe the response times of the individual applica-
tions in particular.
Completely document the configuration of the system, the individual devices and the result
of the safety check.
Note The software for the configuration documentation is available
on the Internet under http://www.sick.com/senscontrol
on the Flexi Classic Mini CD (part no. 2040332)

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Flexi Classic

8.2 Test notes

8.2.1 Tests before the first commissioning

Check the protective device as described below and in accordance with the applicable
standards and regulations.
Check the effectiveness of the protective device mounted to the machine, using all
selectable operating modes and functions.
Ensure that the operating personnel of the machine fitted with the safety controller are
instructed by the qualified safety personnel of the machine owner before beginning
work. Instructing the operating personnel is the responsibility of the machine owner.

8.2.2 Regular testing

The Flexi Classic system must be tested regularly.

In order to reach SILCL3 in accordance with EN 62 061 (see chapter 11 “Technical

specifications” on page 95), the following test must be made at least every 365 days:
WARNING The Flexi Classic system must be powered down.
The Flexi Classic system must be powered up.
All safety functions of the connected safety sensors must be verified.

8.2.3 Regular inspection of the protective device by qualified safety personnel

Check the system following the inspection intervals specified in the national rules and
regulations. This procedure ensures that any changes on the machine or manipulations
of the protective device after the first commissioning are detected.
Each safety application must be checked at an interval specified by you. The effective-
ness of the protective devices must be tested by qualified personnel.
If any modifications have been made to the machine or the protective device, or if the
safety controller has been changed or repaired, the system must be checked again as
specified in the checklist in the annex.

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Operating instructions Configuration Chapter 9
Flexi Classic

9 Configuration
Check the configuration for the protective device after every change!
If you change the configuration, you must check the effectiveness of the protective device.
WARNING Please observe the test notes in the operating instructions of the connected protective
device.

To configure the Flexi Classic you will need:

a screwdriver

9.1 Accepting the system configuration

Switch off the voltage supply (terminals A1, A2) at all the main modules.
Use a screwdriver to set the desired switch positions (programs and functions) at the
rotary switches of all the modules of the system.
Set the control functions at all the modules of the system by external connecting of the
terminals S1, S2 and S3.
Switch on the voltage supply of all the modules while keeping the ENTER button of the
main module UE410-MU or UE410-GU pressed.

Do not actuate any of the RESET buttons connected when in this state!

WARNING When the ERR indicator begins to flash, release the ENTER button within 3 seconds.
The selected operating mode is stored in non-volatile memory and is active.
Note If the ENTER button is pressed for more than 3 seconds, the entire system switches to the
error state. The ERR indicator flashes.
Please refer to the description in section 10.4 “Error indications of the ERR error LED” on
page 93.

All later changes at the connection of S1, S2 and S3 will cause a lock-out (ERR).

WARNING

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Chapter 10 Diagnostics Operating instructions
Flexi Classic

10 Diagnostics
10.1 In the event of faults or errors

Cease operation if the cause of the malfunction has not been clearly identified!
Stop the machine if you cannot clearly identify or allocate the error and if you cannot safely
WARNING rectify the malfunction.
Complete function test after rectification of fault!
Carry out a full functional test after a malfunction has been remedied.

The ERROR operational status

With certain malfunctions or a faulty configuration, the Flexi Classic enters the safe status.
The ERR LEDs of the safety controller modules show the corresponding errors. To place
the device back in operation:
Rectify the cause of the malfunction in accordance with the indication of the ERR LED.
Switch the voltage supply of the Flexi Classic off and back on again.

10.2 Replacement of a module

If in an existing Flexi Classic system a module is replaced, the following has to be
observed:
UE410-MU and UE410-GU
Each time a device is replaced, it is necessary to accept the system configuration again
(see section 9.1 “Accepting the system configuration” on page 91).
UE410-XU
If in an existing Flexi Classic system a device is replaced by another device with a differing
revision code (e.g. C-XX to E-XX), then it is necessary to accept the system configuration
again (see section 9.1 “Accepting the system configuration” on page 91). This is not
necessary if the revision code remains the same.
UE410-8DI
If in an existing Flexi Classic system a device is replaced by another device with a differing
revision code (e.g. C-XX to E-XX), then the system configuration must be accepted again
(see section 9.1 “Accepting the system configuration” on page 91). This is not necessary if
the revision code remains the same.
Additionally from revision code D-XX or higher you must pay attention to the wiring: If the
devices were wired as described in these operating instructions (see section 3.8.5
“Connection of sensors to the UE410-8DI” on page 53), no change is necessary. If the
devices were wired e.g. via external distributor modules (X1 and X2 led back to I1 to I8),
then a module exchange from revision code C-XX to S D-XX requires that connection I5 is
exchanged with I6 and I7 is exchanged with I8.

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Operating instructions Diagnostics Chapter 10
Flexi Classic

10.3 SICK support

If you cannot rectify an error with the help of the information provided in this chapter,
please contact your local SICK representative.
Note If you send in a device for repair, you will receive it back in the delivery state. Therefore
write down the configuration(s) of your devices.

10.4 Error indications of the ERR error LED

This section explains what the LED error indications mean and how you can respond.
Tab. 37: Error indications of LED indicators Possible cause Rectification of the error
the ERR LED
Sequential error on modules that Eliminate the error at the
did not detect the error initially respective module.
2× Error at the module configuration Repeat the configuration.
3× Rotary switch manipulated Turn the rotary switch back to
the original position.
Carry out a power-up or repeat
teaching-in.
4× Change to the configuration in the Reset configuration to original
electrically unpowered state state or
on the rotary switch or Re-connect module to original
to S1-S3 (UE410-MU/XU only) position or
or Carry out a power-up and accept
the configuration again.
Slot list comparison found diffe-
rence or differing module revisions
5× Supply voltage defective Check the voltage supply.
6× Self-diagnostics, internal error, etc. Cycle power. Check wiring and
rotary switch setting.

Note S3 and ENABLE must always be wired on the UE410-MU/XU. Otherwise the outputs Q1-Q4
cannot be enabled.

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10.5 Anti-manipulation measures

Tab. 38: Anti-manipulation Reaction of the system Cause Rectification of the error
measures
Immediate de-activa- Changeover of a Return the switch back to the old
tion of all outputs rotary switch position (setting aid if voltage
System changes to remains activated: flashing PWR
“System error” status. LED changes to steady green).
Red ERR LED of the Restart the system by switching
respective module the voltage off and on again.
flashes.
Green PWR LED
flashes.
All other ERR LEDs to
steady red
Message via diagnos-
tics module
De-activation of the UE410-MU/XU only: Reset the old configuration at
outputs of the system/ Change in the control S1, S2, S3.
subsystem during the circuit configuration Restart the system by switching
next cycle (inputs S1, S2, S3) the voltage off and on again.
Red ERR LED of the
respective module
flashes.
Message via diagnos-
tics module
The last configurations Intentional use of an You can read out the last (correct)
are saved internally in incorrect configuration using one of the Flexi
non-volatile memory and configuration Classic Gateways.
can be read by the Check the configuration visually
manufacturer if required. at regular intervals.
Outputs of the system Changeover of a Return the switch back to the old
cannot be activated. rotary switch position (setting aid if voltage
Red ERR LED of the remains activated: flashing PWR
master module LED changes to steady green).
(UE410KMU) flashes. Restart the system by switching
All other ERR LEDs to the voltage off and on again.
steady red
Outputs of the UE410-MU/XU only: Reset the old configuration at
system/subsystem Change in the control S1, S2, S3.
cannot be activated. circuit configuration Restart the system by switching
Red ERR LED of the (inputs S1, S2, S3) the voltage off and on again.
master module
(UE410KMU) flashes.
All other ERR LEDs to
steady red

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Operating instructions Technical specifications Chapter 11
Flexi Classic

11 Technical specifications

11.1 Data sheet

11.1.1 UE410-MU/UE410-XU modules

Tab. 39: Data sheet Minimum Typical Maximum
UE4100MU/UE410-XU

Supply circuit (A1, A2)

Supply voltage UB 19.2 V DC 24 V DC 30 V DC
Type of supply voltage PELV or SELV
The current of the power supply unit for the main
module has to be limited to a maximum of 6 A —
either by the power supply unit itself or by a fuse.
Residual ripple Uss – – 3V
Power consumption – – 3W
Maximum switch-on time – – 60 s
Short-circuit protection 4 A gG with tripping characteristic B or C

Input circuit (I1-I4, EN, S1-S3)

Number of inputs – – 8
Input voltage (high) 13 V DC – 30 V DC
Input voltage (low) –5 V DC – 5 V DC
Input current (high) 2.4 mA 3 mA 3.8 mA
Input current (low) –2.5 mA – 2.1 mA
Input capacitance 9 nF 10 nF 11 nF
10)
Minimum switch-off time (I1/I2) 7 ms – –
program 3.1, 7, 8
10)
Minimum switch-off time (I1/I2) 20 ms – –
program 1, 2, 4, 5, 6, 9
10)
Minimum switch-off time (I1/I2) 20 ms – –
pressure sensitive mat
10)
Minimum switch-off time (I3/I4) 7 ms – –
program 1, 2, 7, 8, 9
10)
Minimum switch-off time (I3/I4) 20 ms – –
program 4, 5, 6
10)
Minimum switch-off time 70 ms/20 ms – –
(X1KI1/X2-I2) program 3.2
Minimum switch-off time (EN) 7 ms – –
Maximum break time of the input – – 1 ms
signal without switching of the
outputs (Q1-Q4)

10)
Time without sensor, the data for the sensors connected apply in addition.

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Minimum Typical Maximum

Power-up delay 70 ms – –
Synchronous time monitoring – 1500 ms –
program 1, 2
Synchronous time monitoring – 500 ms –
program 4 and 5
11)
Muting ON program 3 – – 61 ms
12)
Muting OFF program 3 – 61 ms 165 ms
Muting gap suppression 95 ms – 100 ms
13)
program 3
Reset time – – 124 ms
Teach-in time of ENTER button – – 3s
UE410-MU (during power-up)
Duration of actuation of the reset 50 ms – 5s
button (only S1, S2)
Control outputs (X1, X2)
Number of outputs – – 2
Type of output PNP semiconductors, short-circuit protected, cross-
14)
circuit detecting
Output voltage 16 V DC – 30 V DC
15)
Output current – – 120 mA
Test period (X1, X2) program 1, 2, – – 40 ms
4, 5, 6, 9
Test period (X1, X2) program 3.2 – – X1 = 384 ms
X2 = 40 ms
Load capacity – – 1,000 nF
Cable resistance – – 100 [

Output circuit (Q1, Q2, Q3, Q4)

Number of outputs – 4 –
Type of output PNP semiconductors, short-circuit protected, cross-
14)
circuit detecting
Switching voltage 18.4 V DC – 30 V DC
Switching current
IQn, TA T 45 °C – – 2,0 A
IQn, TA T 55 °C – – 1,6 A

11)
Time between muting condition valid (I3/I4 high) and muting possible.
12)
Max. switch-off time at muting error.
13)
One muting input (I3 or I4) may be LOW for the specified time.
14)
Cross circuit detecting only within a module.
15)
The total output current for a Flexi Classic system is limited. The current for supplying all sensors that are
connected to the UE410-MU/XU (X1/X2) and UE410-8DI (X1-X8) must be I < 600 mA and the current on a
Flexi Classic gateway must be I < 100 mA. If this total current is insufficient, please contact the SICK hotline.

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Flexi Classic

Minimum Typical Maximum

Total current Isum

]IQn, TA T 45 °C – – 4A
]IQn, TA T 55 °C – – 3.2 A

Load diagram for the Q1 to Q4 outputs of the

UE4100MU/UE410-XU modules

C IQn [A] Total current per temperature

TA [°C]

TA max

Test pulse width 500 ^s 640 ^s 700 ^s

Test pulse frequency 12.5 Hz – 32 Hz
Inductive switch-off energy – – 370 mJ
E = 0.5 × L × I²
Load capacity – – 500 nF
2
Cable length (single, 1.5 mm ) – – 100 m
16)
Response time (I1/I2) program – – 13 ms
3.1, 7, 8
16)
Response time (I1/I2) program – – 29 ms
1, 2, 4, 5, 6, 9
16)
Response time (I1/I2) program – – 38 ms
1 pressure sensitive mat
Response time of all programs – – 56 ms
with tested ESPE Cat. 4 (e.g. L41)
16)
Response time (I3/I4) – – 13 ms
program 1, 2, 7, 8, 9
16)
Response time (I3/I4) – – 29 ms
program 4, 5
16)
Response time (I1-X1, I2-X2) – – 79 ms/29 ms
program 3.2
17)
Response time on connection of 56 ms
Flexi Loop

16)
Time without sensor, the data for the sensors connected apply in addition.
17)
Response time not including Flexi Loop and not including sensor. Also take into account the response times of
Flexi Loop and the sensors connected.

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Minimum Typical Maximum

18)
Response time (EN) – – 13 ms
Time delay (adjustable) 0 / 0.5 / 1 /1.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 s
0 / 5 / 10 / 15 / 20 / 25 / 30 / 35 / 40 / 50 s
0 / 0.5 / 1 / 1.5 / 2 / 2.5 / 3 / 3.5 / 4 / 5 min
General system data
Weight (without packaging) – 0.18 kg –
Electrical safety Class III
Interference resistance EN 61 000-6-2
Radiated emission EN 61 000-6-4

Operating data
Ambient operating temperature –25 °C – 55 °C
(UL/CSA: ambient temperature)
Storage temperature –25 °C – 70 °C
Air humidity 10 % to 95 %, non-condensing
Climatic conditions EN 61 131K2

Mechanical strength
Vibration EN 61 131K2
Vibration resistance 5-500 Hz/5 grms (EN 60 068K2K64)

Terminal and connection data

Single-wire or fine-wire 1 × 0.14 mm² to 2.5 mm² or
2 × 0.14 mm² to 0.75 mm²
Fine-wire with terminal crimps to 1 × 0.25 mm² to 2.5 mm² or
EN 46 228 2 × 0.25 mm² to 0.5 mm²
Insulation stripping length – – 8 mm
Maximum tightening torque – – 0.6 Nm
For UL 508 and CSA applications
UE410-xx3…, UE410-xxx3…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)
– Tightening torque 5-7 lbain
UE410-xx4…, UE410-xxx4…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)

18)
Cascading subsystems.

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Flexi Classic

Minimum Typical Maximum

Safety specific characteristics

All these data are based on an ambient temperature of +40 °C.
19)
Safety Integrity Level SIL3 (IEC 61 508)
19)
SIL claim limit SILCL3 (EN 62 061)
Category Category 4 (EN ISO 13 849K1)
19)
Performance Level PL e (EN ISO 13 849K1)
TM (mission time) 20 years (EN ISO 13 849K1)
-6
PFD 3.9 × 10
-9
PFHd (1/h) 2.5 × 10
SFF 96 %
DC 99 %

Tab. 40: PFD and PFHd Single-channel Single-channel Dual-channel Dual-channel

values for UE410-MU/
UE410-XU input, single- input, dual- input, single- input, dual-
channel output channel output channel output channel output
–5 –6 –5 –6
PFD ( ) 2.2 × 10 5.2 × 10 2.1 × 10 3.9 × 10
% of SIL3 2.2 % 0.5 % 2.1 % 0.4 %
–9 –9 –9 –9
PFHd (1/h) 6.0 × 10 2.5 × 10 6.0 × 10 2.5 × 10
% of SIL3 6.0 % 2.5 % 6.0 % 2.5 %

19)
For detailed information on the safety design of your machine/system, please contact your local SICK
representative.

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Flexi Classic

11.1.2 UE410-GU module

Tab. 41: Data sheet Minimum Typical Maximum
UE4100GU

Supply circuit (A1, A2)

Supply voltage UB 19.2 V DC 24 V DC 30 V DC
Type of supply voltage PELV or SELV
The current from the power supply that supplies the
main module must be limited externally to max. 6 A
— either by the power supply itself or by a fuse.
Residual ripple Uss – – 3V
Power consumption – – 3W
Maximum switch-on time – – 60 s
Short-circuit protection 4 A gG with tripping characteristic B or C

Input circuit (I1-I4, IP, I5, I6, IN)

Number of inputs – – 8
Input voltage (high) 13 V DC – 30 V DC
Input voltage (low) –5 V DC – 5 V DC
Input current (high) 2.4 mA 3 mA 3.8 mA
Input current (low) –2.5 mA – 2.1 mA
Input capacitance 9 nF 10 nF 11 nF
20)
Minimum switch-off time (I1/I2) 20 ms – –
20)
Minimum switch-off time (I3/I4) 7 ms – –
program 6, 7
20)
Minimum switch-off time (I3/I4) 20 ms – –
program 2, 3, 4, 5, 8, 9
Maximum interruption time for the – – 1 ms
input signal without switching the
output (Q1)
Local power-up delay (I1-I4) – – 70 ms
Local reset time – – 124 ms
Teach-in time of ENTER button – – 3s
(during power-up)
Duration of actuation of the reset 50 ms – 5s
button (I6)

20)
Time without sensor, in addition the data for the sensors connected apply.

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Flexi Classic

Minimum Typical Maximum

Control outputs (X1, X2)

Number of outputs – – 2
Type of output PNP semiconductors, short-circuit protected, cross-
21)
circuit detecting
Output voltage 16 V DC – 30 V DC
22)
Output current – – 120 mA
Test period (X1, X2) – – 40 ms
Load capacity – – 1,000 nF
Cable resistance – – 100 [
Output circuit (Q1, Q2)
Number of outputs – 2 –
Type of output PNP semiconductors, short-circuit protected, cross-
21)
circuit monitored
Switching voltage 18.4 V DC – 30 V DC
Switching current
IQn, TU T 45 °C – – 2.0 A
IQn, TU T 55 °C – – 1.6 A
Total current Isum
] IQn, TU T 45 °C – – 4A
] IQn, TU T 55 °C – – 3.2 A

Load diagram for the Q1 and Q2 outputs of the

UE4100GU modules

C IQn [A] Total current per temperature

TU [°C]

TU max

Test pulse width 500 ^s 640 ^s 700 ^s

Test pulse frequency 12.5 Hz – 32 Hz
Inductive switch-off energy – – 370 mJ
E = 0.5 × L × I²

21)
Cross-circuit detecting only within a module.
22)
The total output current for a Flexi Classic system is limited. The current for supplying all sensors that are
connected to the UE410-GU/XU (X1/X2) and UE410-8DI (X1-X8) must be I < 600 mA and the current on a
Flexi Classic gateway must be I < 100 mA. If this total current is insufficient, please contact the SICK hotline.

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Minimum Typical Maximum

Load capacity – – 500 nF

Cable length (single, Ø 1.5 mm²) – – 100 m
Local response time cut-off path – – 29 ms
23)
(I1/I2)
Local response time cut-off path – – 29 ms
23)
(I3/I4) program 2, 3, 4 and 5
Local response time cut-off path – – 13 ms
23)
(I3/I4) program 6, 7
Local response time cut-off path – – 56 ms
23)
(I4) program 8, 9 with tested
electro-sensitive protective device
cat. 4 (e.g. L41)
24)
Local response time on – – 56 ms
connection of Flexi Loop

Global emergency stop circuit (OP-IN, ON-IP)

Cable length OX to IX – – 100 m
Cable length all stations, global – – 1000 m
25)
emergency stop function
Number of stations, global – – 32
emergency stop function
Global response time IX to OX – – 40 ms
Global power-up delay IX – 80 ms 120 ms

General system data

Weight (without packaging) – 0.18 kg –
Electrical safety Class III
Interference resistance EN 61 000-6-2
Radiated emission EN 61 000-6-4
Operating data
Ambient operating temperature –25 °C – 55 °C
(UL/CSA: ambient temperature)
Storage temperature –25 °C – 70 °C
Air humidity 10 % to 95 %, non-dewing
Climatic conditions EN 61 131-2

Mechanical strength
Vibration EN 61 131-2
Vibration resistance 5-500 Hz/5 grms (EN 60 068-2-64)

23)
Time without sensor, in addition the data for the sensors connected apply.
24)
Response time not including Flexi Loop and not including sensor. Also take into account the response times of
Flexi Loop and the sensors connected.
25)
The input voltage levels (I1-I6, IP,IN) must be met.

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Flexi Classic

Minimum Typical Maximum

Terminal and connection data

Single-wire or fine-wire 1 × 0.14 mm² to 2.5 mm² or
2 × 0.14 mm² to 0.75 mm²
Fine-wire with terminal crimps to 1 × 0.25 mm² to 2.5 mm² or
EN 46 228 2 × 0.25 mm² to 0.5 mm²
Insulation stripping length – – 8 mm
Maximum tightening torque – – 0.6 Nm
For UL 508 and CSA applications
UE410-xx3…, UE410-xxx3…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)
– Tightening torque 5-7 lbain
UE410-xx4…, UE410-xxx4…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)
Safety specific characteristics
All these data are based on an ambient temperature of +40 °C.
26)
Safety Integrity Level SIL3 (IEC 61 508)
26)
SIL claim limit SILCL3 (EN 62 061)
Category Category 4 (EN ISO 13 849-1)
26)
Performance Level PL e (EN ISO 13 849-1)
TM (mission time) 20 years (EN ISO 13 849-1)
–5
PFD 2.1 × 10
–9
PFHd (1/h) 6.0 × 10
SFF 96 %
DC 99 %

Tab. 42: PFD and PFHd Single-channel input, Dual-channel input,

values for UE410-GU
single-channel output single-channel output
–5 –5
PFD ( ) 2.2 × 10 2.1 × 10
% of SIL3 2.2 % 2.1 %
–9 –9
PFHd (1/h) 6.0 × 10 6.0 × 10
% of SIL3 6.0 % 6.0 %

26)
For detailed information on the safety design of your machine/system, please contact your local SICK
subsidiary.

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11.1.3 UE410-8DI input extension module

Tab. 43: Data sheet Minimum Typical Maximum
UE41008DI

Supply circuits (via UE410-MU or UE410-GU)

Power consumption – – 3W

Input circuit (I1-I8)

Number of inputs – – 8
Input voltage (high) 13 V DC – 30 V DC
Input voltage (low) –5 V DC – 5 V DC
Input current (high) 2.4 mA 3 mA 3.8 mA
Input current (low) –2.5 mA – 2.1 mA
Input capacitance 9 nF 10 nF 11 nF
Minimum switch-off time See response times
Break time of the input signal – – 1 ms
without switching of the outputs
Monitoring of synchronisation, – 1500 ms –
switch position 3, 5
Power-up delay 70 ms – –
Reset time – – 120 ms

Output circuit (X1-X8)

Number of outputs – – 8
Type of output PNP semiconductors, short-circuit protected, cross-
27)
circuit detecting
Output voltage 16 V DC – 30 V DC
28)
Output current – – 30 mA
Test period – – 40 ms
Load capacity – – 1,000 nF
Cable resistance – – 100 [

Response time UE410-8DI on safety outputs UE410-MU/UE410-XU (Q1-Q4)

Response time – – 17 ms
29)
switch setting 6, 7
Response time – – 34 ms
29)
switch setting 1, 2, 3, 4, 5, 8
Response time switch setting 2 – – 42 ms
29)
pressure sensitive mat
Response time of all programs – – 60 ms
with tested ESPE Cat. 4 (e.g. L41)
30)
Response time on connection of 60 ms
Flexi Loop

27)
Cross circuit detecting only within a module.
28)
The total output current for a Flexi Classic system is limited. The current for supplying all sensors that are
connected to the UE410-MU/XU (X1/X2) and UE410-8DI (X1-X8) must be I < 600 mA and the current on a
Flexi Classic gateway must be I<100 mA. If this total current is insufficient, please contact the SICK hotline.
29)
Time without sensor, the data for the sensors connected apply in addition.

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Minimum Typical Maximum

General system data

Weight (without packaging) – 0.15 kg –
Electrical safety Class III
Interference resistance EN 61 000-6-2
Radiated emission EN 61 000-6-4

Operating data
Ambient operating temperature –25 °C – 55 °C
(UL/CSA: ambient temperature)
Storage temperature –25 °C – 70 °C
Air humidity 10 % to 95 %, non-dewing
Climatic conditions EN 61 131K2

Mechanical strength
Vibration EN 61 131K2
Vibration resistance 5-500 Hz/5 grms (EN 60 068K2K64)

Terminal and connection data

Single-wire or fine-wire 1 × 0.14 mm² to 2.5 mm² or
2 × 0.14 mm² to 0.75 mm²
Fine-wire with terminal crimps to 1 × 0.25 mm² to 2.5 mm² or
EN 46 228 2 × 0.25 mm² to 0.5 mm²
Insulation stripping length – – 8 mm
Maximum tightening torque – – 0.6 Nm
For UL 508 and CSA applications
UE410-xx3…, UE410-xxx3…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)
– Tightening torque 5-7 lbain
UE410-xx4…, UE410-xxx4…
– Connection cross-section AWG 30-12
(only use 60/75 °C copper flexible wire)

30)
Response time not including Flexi Loop and not including sensor. Also take into account the response times of
Flexi Loop and the sensors connected.

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Minimum Typical Maximum

Safety specific characteristics

All these data are based on an ambient temperature of +40 °C.
31)
Safety integrity level SIL3 (IEC 61 508)
31)
SIL claim limit SILCL3 (EN 62 061)
Category Category 4 (EN ISO 13 849K1)
31)
Performance Level PL e (EN ISO 13 849K1)
TM (mission time) 20 years (EN ISO 13 849K1)
–6
PFD 5.8 × 10
–9
PFHd (1/h) 3.8 × 10
SFF 96 %
DC 99 %

Tab. 44: PFD and PFHd Single-channel Single-channel Dual-channel Dual-channel

values for UE410-8DI
input, single- input, dual- input, single- input, dual-
channel output channel output channel output channel output
–5 –6 –5 –6
PFD ( ) 2.4 × 10 7.0 × 10 2.3 × 10 5.8 × 10
% of SIL3 2.4 % 0.7 % 2.3 % 0.6 %
–9 –9 –9 –9
PFHd (1/h) 7.3 × 10 3.8 × 10 7.3 × 10 3.8 × 10
% of SIL3 7.3 % 3.8 % 7.3 % 3.8 %

11.1.4 UE410-2RO/UE410-4RO output modules

Tab. 45: Data sheet Minimum Typical Maximum
UE41002RO/UE410-4R0

Supply circuit (via UE410-MU)

Power consumption
UE410-4RO – – 3.2 W
UE410-2RO – – 1.6 W

Input circuit B1, B2

Input voltage 18 V DC – 30 V DC

Output circuit (13/14, 23/24, 33/34, 43/44)

Number of N/O contacts
UE410-2RO – 2 –
UE410-4RO – 4 –
Number of N/C contacts
UE410-2RO – 1 –
UE410-4RO – 2 –

31)
For detailed information on the safety design of your machine/system, please contact your local SICK
representative.

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Minimum Typical Maximum

Switching voltage AC 5 V AC 230 V AC 253 V AC

Electrical endurance output modules UE410-2RO/

UE410-4RO

250 V AC resistive load

on 1 N/O contact

Operations
Switching current [A]

Switching voltage DC 5 V DC 230 V DC 253 V DC

Maximum DC current
UE410-2RO/UE410-4RO

Resistive load
DC voltage [V DC]

DC current [A]

Switching current 10 mA – 6A
Minimum contact load 50 mW – –
with Un = 24 V DC
Total current – – 8A
32)
Response time – – 30 ms
Type of output Floating N/O contacts, positively guided
Contact material AgSnO2
Output circuit fusing 6 A (gG), per current path
Usage category AC-15: Ue 250 V, Ie 3 A
DC-13: Ue 24 V, Ie 3 A

32)
Time from LOW on B1/B2 to relay drop-out.

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Minimum Typical Maximum

Output circuit (Y14, Y24)

Type of output Non-isolated N/O contact, positively guided,
current-limited
Number of N/O contacts Y14/24
UE410-2RO – 1 –
UE410-4RO – 2 –
Output voltage 16 V DC 24 V DC 30 V DC
33)
Output current – – 75 mA
Load capacity – – 200 nF

General data
Electrical isolation
Supply circuit-input circuit No
Supply circuit-output circuit Yes
Input circuit-output circuit Yes
Weight (without packaging)
UE410-2RO 0.16 kg
UE410-4RO 0.19 kg

Operating data
Ambient operating temperature –25 °C – 55 °C
(UL/CSA: ambient temperature)
Storage temperature –25 °C – 70 °C
Air humidity 10 % to 95 %, non-condensing
Climatic conditions EN 61 131K2

Mechanical strength
Vibration resistance 5-150 Hz/1 G (EN 60 068-2-6)
10-500 Hz/3 Grms (EN 60 068-2-64)
Shock resistance
Continuous shock 10 g, 16 ms (EN 60 068-2-27)
Single shock 30 g, 11 ms (EN 60 068-2-27)

33)
The total output current is limited. Maximum total current for all relay modules on Y14 and Y24 is I < 400 mA.

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Minimum Typical Maximum

Electrical safety EN 61 131-2

Impulse voltage withstand level 4 kV
(Uimp)
Overvoltage category II
Contamination level 2 inside, 3 outside
Rated voltage 300 V AC
Enclosure rating IP 40/IP 20 (EN 60 529)
housing/terminals
Interference resistance EN 61 000-6-2
Radiated emission EN 61 000-6-4

Terminal and connection data

Single-wire or fine-wire 1 × 0.14 mm² to 2.5 mm² or
2 × 0.14 mm² to 0.75 mm²
Fine-wire with terminal crimps to 1 × 0.25 mm² to 2.5 mm² or
EN 46 228 2 × 0.25 mm² to 0.5 mm²
Insulation stripping length – – 8 mm
Maximum tightening torque – – 0.6 Nm
For UL 508 and CSA applications
UE410-xx3…, UE410-xxx3…
– Connection cross-section AWG 30-12 (only use 60/75°C copper flexible wire)
– Tightening torque 5-7 lbain
UE410-xx4…, UE410-xxx4…
– Connection cross-section AWG 30-12 (only use 60/75°C copper flexible wire)

Safety specific characteristics

All these data are based on an ambient temperature of +40 °C.
34)
Safety integrity level SIL3 (IEC 61 508)
34)
SIL claim limit SILCL3 (EN 62 061)
Category Category 4 (EN ISO 13 849K1)
34)
Performance Level PL e (EN ISO 13 849K1)
-7
PFD 1.6 × 10
–9
PFHd at I = 0.75 A, 1.2 × 10 (see also Tab. 46)
–1
switching frequency = h
B10d value, 0.75 A (AC 15)/4,150,000 (see also Tab. 46)
–1
switching frequency = h
SFF 99.6 %
DC 99 %
TM (mission time) Depending on PFHd value, ambient temperature,
load and switching operations (see Tab. 46)

34)
For detailed information on the safety design of your machine/system, please contact your local SICK
representative.

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Tab. 46: PFHd values Load Switching operations
I[A] Switching frequency B10d PFHd
type per annum
-10
0.1 1/h 8760 10,000,000 5.00 x 10
-09
0.75 1/h 8760 4,150,000 1.20 x 10
AC15 -08
3 1/h 8760 400,000 1.20 x 10
-08
5 1/h 8760 70,000 7.20 x 10
-09
1 1/h 8760 2,000,000 2.50 x 10
DC13 -08
3 1/h 8760 450,000 1.10 x 10
-09
2 1/h 8760 1,000,000 5.00 x 10
AC1 -09
4 1/h 8760 600,000 8.40 x 10

11.2 Dimensional drawings

11.2.1 UE410-MU and UE410-GU main modules

Fig. 50: Dimensional drawing 114.4
UE410-MU and E410-GU
(mm)
96.5

93.3

58

78
22.5 93.7

120.8

11.2.2 UE410-XU, UE410-8DI, UE410-2RO, UE410-4RO, UE410-PRO, UE410-DEV,

UE410-CAN modules
Fig. 51: Dimensional drawing 114.4
UE410-XU, UE410-8DI,
UE410-2RO, UE410-4RO,
UE410-PRO, UE410-DEV,
UE410-CAN (mm)
96.5

93.3

58

78

22.5 93.7
29 120.8

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12 Ordering information

12.1 Available modules

Tab. 47: Part numbers of Device type Part Part number
Flexi Classic safety controller
modules UE410-MU3T0 Main module 6035242
4 inputs/4 outputs
No delay
Plug-in screw terminals
UE410-MU3T5 Main module 6026136
4 inputs/4 outputs
Delay possible: 0-5 s
Plug-in screw terminals
UE410-MU3T50 Main module 6026137
4 inputs/4 outputs
Delay possible: 0-50 s
Plug-in screw terminals
UE410-MU3T300 Main module 6026138
4 inputs/4 outputs
Delay possible: 0-300 s
Plug-in screw terminals
UE410-GU Main module 1072177
4 inputs/1 output
Plug-in screw terminals
UE410-8DI3 Input extension module 6026139
4 dual-channel inputs
Plug-in screw terminals
UE410-2RO3 Output module 6026144
2 N/O contacts and 1 24 V DC alarm signal
Plug-in screw terminals
UE410-4RO3 Output module 6026143
4 N/O contacts and 2 24 V DC alarm signals
Plug-in screw terminals
UE410-XU3T0 Input/output extension module 6035244
4 inputs/4 outputs
No delay
Plug-in screw terminals
UE410-XU3T5 Input/output extension module 6032470
4 inputs/4 outputs
Delay possible: 0-5 s
Plug-in screw terminals

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Device type Part Part number

UE410-XU3T50 Input/output extension module 6032471
4 inputs/4 outputs
Delay possible: 0-50 s
Plug-in screw terminals
UE410-XU3T300 Input/output extension module 6032472
4 inputs/4 outputs
Delay possible: 0-300 s
Plug-in screw terminals
UE410-MU4T0 Main module 6035243
4 inputs/4 outputs
No delay
Plug-in spring terminals
UE410-MU4T5 Main module 6032669
4 inputs/4 outputs
Delay possible: 0-5 s
Plug-in spring terminals
UE410-MU4T50 Main module 6032670
4 inputs/4 outputs
Delay possible: 0-50 s
Plug-in spring terminals
UE410-MU4T300 Main module 6032671
4 inputs/4 outputs
Delay possible: 0-300 s
Plug-in spring terminals
UE410-XU4T0 Input/output extension module 6035245
4 inputs/4 outputs
No delay
Plug-in spring terminals
UE410-XU4T5 Input/output extension module 6032672
4 inputs/4 outputs
Delay possible: 0-5 s
Plug-in spring terminals
UE410-XU4T50 Input/output extension module 6032673
4 inputs/4 outputs
Delay possible: 0-50 s
Plug-in spring terminals
UE410-XU4T300 Input/output extension module 6032674
4 inputs/4 outputs
Delay possible: 0-300 s
Plug-in spring terminals

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Device type Part Part number

UE410-8DI4 Input extension module 6032675
4 dual-channel inputs
Plug-in spring terminals
UE410-4RO4 Output module 6032676
4 N/O contacts and 2 24 V DC alarm signals
Plug-in spring terminals
UE410-2RO4 Output module 6032677
2 N/O contacts and 1 24 V DC alarm signal
Plug-in spring terminals
UE410-PRO3 PROFIBUS-DP gateway 6028407
Plug-in screw terminals
UE410-PRO4 PROFIBUS-DP gateway 6032678
Plug-in spring terminals
UE410-CAN3 CANopen gateway 6033111
Plug-in screw terminals
UE410-CAN4 CANopen gateway 6033112
Plug-in spring terminals
UE410-DEV3 DeviceNet gateway 6032469
Plug-in screw terminals
UE410-DEV4 DeviceNet gateway 6032679
Plug-in spring terminals
UE410-EN1 EtherNet/IP gateway 1042964
Plug-in screw terminals
UE410-EN3 Modbus TCP/IP and Ethernet TCP/IP gateway 1042193
Plug-in screw terminals
UE410-EN4 PROFINET IO gateway 1044078
Plug-in screw terminals

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12.2 Accessories/spare parts

12.2.1 Single-beam photoelectric safety switches

Tab. 48: Part numbers of Part Description Part number
single-beam photoelectric
safety switches L21S-33MA2A Single-beam photoelectric safety switch, sender, 6034870
24 V DC, operating range 60 m, PNP, physical size
M30, M12 × 4 plug
L21E-33MA2A Single-beam photoelectric safety switch, receiver, 6034871
24 V DC, operating range 60 m, PNP, physical size
M30, M12 × 4 plug
L21S-21KA1A Single-beam photoelectric safety switch, sender, 6034872
24 V DC, operating range 16 m, PNP, physical size
M18, M12 × 4 plug
L21E-21KA1A Single-beam photoelectric safety switch, receiver, 6034873
24 V DC, operating range 16 m, PNP, physical size
M18, M12 × 4 plug
L21S-11MA1A Single-beam photoelectric safety switch, sender, 6034876
24 V DC, operating range 5 m, radial axis, PNP,
physical size M18, M12 × 4 plug
L21E-11MA1A Single-beam photoelectric safety switch, receiver, 6034877
24 V DC, operating range 5 m, radial axis, PNP,
physical size M18, M12 × 4 plug
L27S-3D2430 Single-beam photoelectric safety switch, sender, 2043906
24 V DC, operating range 25 m, PNP, Q+/Q,
M12 × 4 plug
L27E-3P2430 Single-beam photoelectric safety switch, receiver, 2043904
24 V DC, operating range 25 m, PNP, Q+/Q,
M12 × 4 plug
L28S-3D2431 Single-beam photoelectric safety switch, sender, 2044515
24 V DC, operating range 18 m, PNP, Q+/Q,
M12 × 4 plug
L28E-3P2431 Single-beam photoelectric safety switch, receiver, 2044516
24 V DC, operating range 18 m, PNP, Q+/Q,
M12 × 4 plug
L41S-33MA2A Single-beam photoelectric safety switch, sender, 6034863
24 V DC, operating range 60 m, PNP, physical size
M30, M12 × 4 plug
L41E-33MA2A Single-beam photoelectric safety switch, receiver, 6034862
24 V DC, operating range 60 m, PNP, physical size
M30, M12 × 4 plug

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Part Description Part number

L41S-21KA1A Single-beam photoelectric safety switch, sender, 6034864
24 V DC, operating range 10 m, PNP, physical size
M18, M12 × 4 plug
L41E-21KA1A Single-beam photoelectric safety switch, receiver, 6034865
24 V DC, operating range 10 m, PNP, physical size
M18, M12 × 4 plug
L41S-11MA1A Single-beam photoelectric safety switch, sender, 6034868
24 V DC, operating range 5 m, radial axis, PNP,
physical size M18, M12 × 4 plug
L41E-11MA1A Single-beam photoelectric safety switch, receiver, 6034869
24 V DC, operating range 5 m, radial axis, PNP,
physical size M18, M12 × 4 plug

12.2.2 Non-contact safety switches

Tab. 49: Part numbers of Part Description Part number
non-contact safety switches
RE21-DA05 RE21 sensor and actuator, 5 m cable 6035617
RE27-DA05L RE27 sensor and actuator, 5 m cable 6034343
RE13-DAC RE13 sensor and actuator, M8 plug 6036769
RE31-DAC RE31 sensor and actuator, M8 plug 6036768
T4000-E0101K T4000 Direct sensor 6035041
T4000-1KBQ Actuator for T4000 Direct, cuboid 5311153
IN40-D0101K IN4000 switch Q40, M12 plug 6027389
IN40-D0202K IN4000 switch M30, M12 plug 6027392
IN40-D0303K IN4000 switch M18, M12 plug 6027391
IN40-E0101K IN4000 Direct Q40, M12 plug 6027388
DOL-1204-G10M IN4000 connecting cable 6010543
M12, 4-pin with 10 m cable
DOL-1208- T4000 Direct connecting cable 6022152
G10MA M12, 8-pin with 10 m cable
DOL-0804-G10M RE13/RE31 connecting cable 6010754
M8, 4-pin with 10 m cable

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12.2.3 Safety light curtains and multiple light beam safety devices
Tab. 50: Safety light curtains Part Description Part number
and multiple light beam
safety devices C4000 All variants –
M4000 All variants –
C2000 All variants –
M2000 All variants –
miniTwin All variants –

12.2.4 Safety laser scanners and safety camera system

Tab. 51: Laser scanner Part Description Part number
S3000 All variants –
S300 All variants –
V300 All variants –

12.2.5 Muting lamps and cables

Tab. 52: Part numbers of Part Description Part number
muting lamps and cables
– Muting lamp with mounting kit 2020743
– LED muting lamp with cable 2 m 2019909
– LED muting lamp with cable 10 m 2019910

12.2.6 Anti-manipulation cover

Tab. 53: Part number anti- Part Description Part number
manipulation cover
AM cover 10 anti-manipulation covers 5319789

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13 Annex

13.1 Compliance with EU directives

EU declaration of conformity (excerpt)
The undersigned, representing the following manufacturer herewith declares that the
product is in conformity with the provisions of the following EU directive(s) (including all
applicable amendments), and that the respective standards and/or technical specifica-
tions are taken as the basis.
Complete EU declaration of conformity for download: www.sick.com

13.2 Manufacturer’s checklist

L
Checklist for the manufacturer/installer for installation of the Flexi Classic modular safety controller
The information for the points listed below must at least be available the first time the equipment is commissioned.
They depend on the application the requirements of which must be verified by the manufacturer/installer.
This checklist should be retained and kept with the machine documentation to serve as reference during recurring
tests.
1. Have the safety rules and regulations been observed in compliance with the directives/standards Yes No
applicable to the machine?
2. Are the applied directives and standards listed in the declaration of conformity? Yes No
3. Does the protective device comply with the required PL/SIL claim limit and PFHd in accordance Yes No
with EN ISO 13849-1/EN 62061 and the required type in accordance with IEC 61496-1?
4. Are the required protective measures against electric shock in effect (protection class)? Yes No
5. Has the potective function been checked in compliance with the test notes of this Yes No
documentation? In particular:
• functional check of the input devices, sensors and actuators connected to the safety controller
• test of all switch-off paths
6. Are you sure that the safety controller was tested fully for safety functionality after each Yes No
configuration change?
This checklist does not replace the initial commissioning and regular tests by qualified safety personnel.

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13.3 List of tables

Tab. 1: Sensor symbols ......................................................................................................... 8
Tab. 2: Module function symbols.......................................................................................... 9
Tab. 3: Input assignment symbols...................................................................................... 10
Tab. 4: Logic symbols .......................................................................................................... 10
Tab. 5: Overview on disposal by components.................................................................... 13
Tab. 6: Module overview ..................................................................................................... 18
Tab. 7: Overview of setting possibilities ............................................................................. 18
Tab. 8: Connection of sensors to the UE410-MU, UE410-XU and UE410-8DI ................ 19
Tab. 9: UE410-MU indications ............................................................................................ 23
Tab. 10: UE410-MU operating elements.............................................................................. 24
Tab. 11: UE410-MU terminal assignment............................................................................ 24
Tab. 12: UE410-GU indications............................................................................................. 27
Tab. 13: UE410-GU operating elements .............................................................................. 27
Tab. 14: UE410-GU terminal assignment............................................................................. 28
Tab. 15: Diagnostics on the UE410-GU................................................................................ 33
Tab. 16: Significance of the diagnostics LEDs I5 and I6 on the UE410-GU....................... 33
Tab. 17: UE410KMU/UE410-XU programs ........................................................................... 35
Tab. 18: Connection of sensors to the UE410-MU/UE410-XU ........................................... 47
Tab. 19: UE410-GU programs ............................................................................................... 48
Tab. 20: UE410-8DI switch positions ................................................................................... 50
Tab. 21: UE410-8DI switch positions ................................................................................... 51
Tab. 22: OR link UE410-8DI .................................................................................................. 52
Tab. 23: Bypass UE410-8DI .................................................................................................. 52
Tab. 24: Connection of sensors to the UE410-8DI .............................................................. 54
Tab. 25: UE410-8DI LED indications .................................................................................... 55
Tab. 26: UE410-8DI operating elements ............................................................................. 55
Tab. 27: Terminals UE410K8DI.............................................................................................. 56
Tab. 28: UE410K2RO/UE410K4RO indicators ...................................................................... 58
Tab. 29: Terminals UE410K2RO ............................................................................................ 58
Tab. 30: Terminals UE410K4RO ............................................................................................ 58
Tab. 31: Conditions for muting with two sensors, crossed placement............................... 70
Tab. 32: Selection of the optical SICK muting sensors ....................................................... 72
Tab. 33: EDM by means of S1 .............................................................................................. 74
Tab. 34: EDM by means of S2 .............................................................................................. 74
Tab. 35: Retriggering time response .................................................................................... 75
Tab. 36: EDM by means of S3 .............................................................................................. 76
Tab. 37: Error indications of the ERR LED............................................................................ 93
Tab. 38: Anti-manipulation measures .................................................................................. 94
Tab. 39: Data sheet UE410KMU/UE410-XU ......................................................................... 95
Tab. 40: PFD and PFHd values for UE410-MU/ UE410-XU ................................................. 99
Tab. 41: Data sheet UE410KGU...........................................................................................100

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Tab. 42: PFD and PFHd values for UE410-GU................................................................... 103

Tab. 43: Data sheet UE410K8DI ......................................................................................... 104
Tab. 44: PFD and PFHd values for UE410-8DI.................................................................. 106
Tab. 45: Data sheet UE410K2RO/UE410-4R0 .................................................................. 106
Tab. 46: PFHd values .......................................................................................................... 110
Tab. 47: Part numbers of Flexi Classic safety controller modules ................................... 111
Tab. 48: Part numbers of single-beam photoelectric safety switches ............................. 114
Tab. 49: Part numbers of non-contact safety switches..................................................... 115
Tab. 50: Safety light curtains and multiple light beam safety devices ............................ 116
Tab. 51: Laser scanner ....................................................................................................... 116
Tab. 52: Part numbers of muting lamps and cables......................................................... 116
Tab. 53: Part number anti-manipulation cover.................................................................. 116

13.4 List of illustrations

Fig. 1: Flexi Classic modular safety controller...................................................................14
Fig. 2: Safety controller structure Flexi Classic (example with UE410-MU).....................15
Fig. 3: Scheme programs 1-3.............................................................................................21
Fig. 4: Scheme program 4 ..................................................................................................21
Fig. 5: Scheme programs 5K7, 9 ........................................................................................22
Fig. 6: Scheme program 8 ..................................................................................................22
Fig. 7: UE410-MU controls and status indicators .............................................................23
Fig. 8: UE410-GU controls and status indicators..............................................................27
Fig. 9: Connecting several UE410-GU modules ................................................................29
Fig. 10: Diagnostic displays on the UE410-GU....................................................................33
Fig. 11: UE410-XU controls and status indicators ..............................................................34
Fig. 12: UE410-8DI controls and status indicators.............................................................55
Fig. 13: Internal structure UE410-2RO ................................................................................56
Fig. 14: Internal structure UE410-4RO ................................................................................57
Fig. 15: UE410K2RO/UE410K4RO controls and status indicators......................................58
Fig. 16: Connection of a RE300 to the UE410-MU/XU.......................................................60
Fig. 17: Connection of an IN4000........................................................................................61
Fig. 18: Connection of two IN4000......................................................................................61
Fig. 19: Mounting to avoid mutual optical influence ..........................................................63
Fig. 20: Minimum distance (a) to reflective surfaces, correct mounting and
alignment .................................................................................................................64
Fig. 21: Minimum distance (a) as a factor of the distance D for testable single-
beam photoelectric safety switches .......................................................................64
Fig. 22: Safety on mounting the muting sensors ................................................................67
Fig. 23: Schematic layout .....................................................................................................68
Fig. 24: Detection of material during muting ......................................................................69
Fig. 25: Minimum distance, material detection to the ESPE on muting ............................69
Fig. 26: Principle of operation of sensors with background suppression..........................69
Fig. 27: Muting with two sensors, crossed placement........................................................70

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Fig. 28: Simulated 4-sensor muting .................................................................................... 71

Fig. 29: Retriggering ON, with/without restart interlock..................................................... 75
Fig. 30: Retriggering OFF, with restart interlock ................................................................. 75
Fig. 31: Retriggering OFF, without restart interlock............................................................ 75
Fig. 32: Retriggering OFF, without restart interlock............................................................ 75
Fig. 33: Cascading of safety circuits.................................................................................... 77
Fig. 34: ENABLE input .......................................................................................................... 78
Fig. 35: Hanging the module into the DIN mounting rail.................................................... 79
Fig. 36: Installing the end clips............................................................................................ 80
Fig. 37: Removing the plug-in terminals ............................................................................. 80
Fig. 38: Disconnecting the plug connection........................................................................ 80
Fig. 39: Removing the module from the DIN mounting rail ............................................... 81
Fig. 40: Anti-manipulation cover.......................................................................................... 81
Fig. 41: Connection of three L21 to the UE410-MU/XU..................................................... 84
Fig. 42: Connection of an emergency stop to the UE410-MU/XU ..................................... 84
Fig. 43: Connection of an RE300 to the UE410-MU/XU .................................................... 85
Fig. 44: Connection of a two-hand switch IIIC to the UE410-MU/XU................................. 85
Fig. 45: Connection of a C2000 and emergency stop to the UE410-MU/XU ................... 86
Fig. 46: Connection of two i11 to the UE410-MU/XU, two hazardous areas.................... 86
Fig. 47: Connection of two IN4000 to the UE410-MU/XU ................................................. 87
Fig. 48: Connection of a C4000 to the UE410-MU/XU, 2-sensor muting ......................... 87
Fig. 49: Global emergency stop with two UE410-GU.......................................................... 88
Fig. 50: Dimensional drawing UE410-MU and E410-GU (mm)........................................110
Fig. 51: Dimensional drawing UE410-XU, UE410-8DI, UE410-2RO, UE410-4RO,
UE410-PRO, UE410-DEV, UE410-CAN (mm).......................................................110

120 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YT27/2016-03-15
Subject to change without notice
Operating instructions Annex Chapter 13
Flexi Classic

8011509/YT27/2016-03-15 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 121
Subject to change without notice
Chapter 13 Annex Operating instructions
Flexi Classic

122 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 8011509/YT27/2016-03-15
Subject to change without notice
Operating instructions Annex Chapter 13
Flexi Classic

8011509/YT27/2016-03-15 © SICK AG • Industrial Safety Systems • Germany • All rights reserved 123
Subject to change without notice
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