SICK FX3-XTIO84002 Flexi Soft Safety I/O Module, 8 In / 4 Out

Flexi Soft safety I/O module with 8 inputs and 4 outputs

The SICK FX3-XTIO84002 (part no. 1044125) is a Flexi Soft I/O expansion module with 8 safe inputs, 2 test outputs and 4 safe outputs. It connects to the main module through FLEXBUS+ and is configured in the Flexi Soft Designer software (Safety Designer for the Safe EFI-pro system). The data sheet lists SIL 3 (IEC 61508), category 4 and performance level e (EN ISO 13849).

Pluggable spring terminals simplify wiring, the module is 22.5 mm wide and the enclosure rating is IP20, so it belongs inside a control cabinet.

Technical specifications

Where an XTIO module fits

Flexi Soft is SICK modular safety controller system. A main module (CPU) runs the safety program, and expansion modules add inputs and outputs for emergency stop buttons, light curtains, door switches and contactors. The XTIO84002 offers eight dual-channel-capable inputs, two test pulse generators for short-circuit and cross-circuit detection and four semiconductor outputs rated 2 A each.

Observe the notes in the data sheet: the power supply feeding the module must be current-limited to 4 A, either by the supply or by a fuse, and each test output can supply max. 30 mA in a safe series connection. The module is intended for use with the Flexi Soft system and its safety program must be validated by the machine builder.

Ordering information

Order FX3-XTIO84002 with part no. 1044125. SICK offers other Flexi Soft I/O modules with different input and output counts, and gateways for fieldbus connection; quote the full part number and the main module you intend to use.

Key features of the FX3-XTIO84002

• Eight safe inputs for emergency stop buttons, door interlocks, light curtains, safety mats and other safety sensors.
• Two test outputs that pulse the input circuits, allowing the system to detect short circuits and cross-faults in the field wiring of dry-contact devices.
• Four safe PNP semiconductor outputs, each able to switch up to 2 A, for contactors, safety valves or locking devices.
• Flexi Loop compatibility, so several safety sensors can be cascaded on one loop while keeping individual diagnostics.
• Fast shut-off of 8 ms when inputs and outputs are on the same module, shortening the response time used in safety distance calculations.
• Plug-in spring terminals that let the module be replaced without rewiring.

How the module fits a Flexi Soft system

A Flexi Soft safety controller is built from a main module (CPU) with a system plug that stores the configuration, followed by expansion modules on the FLEXBUS+ backplane. The XTIO is the module that adds both inputs and outputs; where only inputs are needed, an XTDI input module is the usual alternative. Gateway modules can sit in the same station to report diagnostics to a standard PLC over common fieldbus or Ethernet networks.

The safety logic itself is drawn in Flexi Soft Designer using certified function blocks such as emergency stop, two-hand control, muting and restart interlock. Because the logic is software-configured, changing a machine’s safety function usually means editing and re-verifying the project rather than rewiring relays.

Wiring and commissioning notes

• Supply the output section through A1/A2 from a 24 V DC PELV or SELV power supply, within the 16.8 to 30 V window given in the specification.
• Use dual-channel wiring for safety devices where the required performance level demands it; the lower PFHd figure for dual-channel outputs reflects this.
• Connect inductive loads such as contactor coils with suitable suppression, and check the total output current against the module and supply ratings.
• After commissioning, carry out and document a full functional test of every safety function, as required by the machine’s risk assessment and validation plan.
• Keep a copy of the verified configuration file and its checksum with the machine documentation.

Use in Oman and GCC industries

Programmable safety controllers are increasingly specified for packaging lines, palletisers, process skids, cranes and material-handling systems across food and beverage, cement, logistics and oil and gas facilities in the region. A single compact controller replaces several safety relays and makes it easier to extend protection when a machine is modified.

The IP20 rating means the module must be installed in a closed control cabinet. In dusty or hot environments, cabinet sealing and cooling should keep the internal temperature within the operating limit of +55 °C, and terminal connections should be inspected during scheduled maintenance.

What to include in an RFQ

• Type code FX3-XTIO84002 and part number 1044125, with the quantity required.
• The main module and any other Flexi Soft modules in the same station, so compatibility can be checked.
• Whether gateways, system plugs, configuration cables or software are also needed.
• Delivery location and any documentation required, such as declarations of conformity.

Documents and quotation

Download the manufacturer data sheet for FX3-XTIO84002 (part no. 1044125) from this page; it is the source of every specification listed here. To request a price, send the type code and part number to Seven Star LLC, an independent supplier based in Muscat, together with the quantity and the site where the goods are needed. Please confirm before ordering that the version, connector and accessories (a reflector, cordset or protective hood) match your drawings, because published data may change without notice. Related items can be found in PLC and I/O cards and in the SICK nanoScan3 Core I/O safety laser scanner.