Until now, users have needed different safety relays for different safety systems such as: two-hand control applications; contact-based safety outputs, such as safety interlock switches; semiconductor-based safety outputs, from light curtains or laser scanners; and emergency stop applications. Combating this unnecessary complexity, the UE410-FLEXI can handle all of these devices and, using the modules, combine them logically, thanks to eight possible settings.

Another benefit the UE410-FLEXI offers is that the number of different relays needed for a particular application is drastically reduced – saving on spares and panel space. Devices that can connect to the UE410-FLEXI include: emergency stop pushbuttons, Type IIIA and IIIC two-hand controls, safety interlock switches, non-contact switches, testable Type 2 sensors, hold to run switches, safety light curtains and safety light grids, safety laser scanners and muting sensors for two-input muting.

50% reduction of cabinet space: The UE410-MU handles the function of two safety relays in a single 22.5mm housing and, by supporting eight inputs, it can replace an additional four safety relays.

Simple commissioning and no software: The safety logic of most machines is generally less complicated than the standard control of the machine. Using program switches on the front of the modules, users can implement AND, OR, Bypass and Muting functionality without the use of software tools.

Wiring savings: The logic blocks are accessed by selecting pre-configured functions using the program switches, therefore the typical wiring used to achieve this logic disappears. For example: the UE410-8 Dual-channel Safety Input Module can take four dual channel inputs and combine them with the inputs on a UE410-FLEXI main control unit using AND, OR, or Bypass logic. All that is required is connection of the monitored devices and setting the program switches. To implement a similar logic scheme using safety relays, ten or more relays would be necessary.

Relay Expansion: Once this logic has been implemented, semiconductor outputs located on the main control unit can be used to switch off the dangerous motion. Easy implementation of relay outputs can be achieve using the one and two dual-channel Safety Relay Output Module

Diagnostics and fieldbus: For diagnostic information, each module has LEDs that provide the state of the associated inputs and outputs as well as fault conditions and reset requirements. Additionally, the DeviceNet and the Profibus modules can be used to deliver a wide range of status and diagnosis information.

A real-world example
An example of the advantages the UE410-FLEXI offers can be seen at Haloila Oy in Finland – a leading manufacturer of thin-film wrapping machines. Haloila`s machines have a reputation for their speed and flexibility in the industry, using two parallel plastic foil rolls to wrap pallets which, in turn, protects and stabilises the palletised goods.

In order to satisfy the requirements of Haloila`s safety application, six safety relays were previously needed, consuming 225mm of DIN rail space in the control panel. Each of the relays was wired to one another in order to achieve the logic needed in the application.

Four relays were used to integrate two M4000 entry exit systems. These relays were then logically 'ANDed' with an emergency stop circuit safety relay (safety relay 5) and another safety relay that monitored a safety door interlock at a gate where the foil was reloaded (safety relay 6).

The logic required for this installation required significant extra wiring – a level not needed using the FLEXI system. With the UE410-FLEXI solution, just two units are used to integrate all six sensors, reducing the total solution size from 225mm to 45mm. If an additional interlock or E-Stop is added, this is done through simply adding an additional FLEXI module.