Elan PROTECT-PSC Series User manual

Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
Standard Field Bus Gateway
for Safety Compact Controller
ELAN Schaltelemente GmbH & Co. KG
Instruction Manual

Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
This Instruction Manual is protected by copyright.
All rights reserved, also to the translation, reprint and reproduction of the document or parts thereof. No part
of this Instruction Manual may be reproduced or processed, copied or disseminated using electronic systems
in any form (photocopy, microfilm or a different procedure), also not for purposes of teaching, without the
written consent of ELAN Schaltelemente GmbH & Co. KG.

Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
Preface
Thank you for deciding in favour of our programmable safety controller.
This Instruction Manual contains a description of PROTECT-PSC Universal-
Gateway with the currently available standard field bus connections.
Descriptions, technical correlations, details on external control units, installation
and operating information or similar have been provided to the best of our knowl-
edge. However, this does not mean that warranted characteristics or other proper-
ties under liability law may be assumed which extend beyond the “General Terms
of Delivery for Products and Services of the Electrical Industry”. We trust you will
understand that the user must therefore check our information and recommenda-
tions before using the equipment.
In order to guarantee the safe operation of the products these and all associated
instruction manuals must be read thoroughly and understood. They must be
stored in a safe place after reading and be accessible at the workplace at any time.
Please ensure that this Instruction Manual is made accessible to the end users of
the equipment.
We reserve the right to modify specifications and similar for the purpose of techni-
cal extension/improvement.
We would like to point out that, under the provisions of the law on foreign currency
and commercial transactions, an export approval is to be obtained from the Japa-
nese Government for the export of products and services for strategic use.
In the event of a defect occurring within the warranty period for which the manufac-
turer is responsible, the repair or replacement of the defective part shall be per-
formed at our discretion and at our expense. We trust you will understand that the
manufacturer is not liable for damage of a direct or indirect nature for which others
are responsible.
The reproduction of names, trade names, trademarks etc. in this Instruction Man-
ual, even if not especially marked as such, shall not entitle the user to assume that
such names are viewed as free within the meaning of trademark and brand protec-
tion law and may therefore be used by anyone.
Subject to technical amendments and error. The data used in this document are
carefully checked for typical standard values.

Table of Contents
Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
Table of Contents
1Overview 1–1
1.1 Preliminary Remarks 1–2
1.2 Definition of Terms 1–2
1.3 Structure of the Document 1–3
1.4 Product Description 1–4
1.5 Mode of Operation 1–5
1.6 Safety Function 1–5
2Important Information 2–1
2.1 Safety Warnings 2–2
2.2 Correct Use 2–5
3System Description 3–1
3.1 Overview 3–2
3.2 Power Supply 3–4
3.3 Connection of a Standard Field Bus Adapter (Bus Coupler) 3–5
3.4 Connection of Power Supply 3–14
3.5 Connection SN-I/F (PROTECT-PSC) 3–14
3.6 Displays / Display Area 3–15
3.7 Operating Elements / Operating Area 3–16
4Installation / Project Planning 4–1
4.1 Assembly 4–2
4.2 Wiring 4–6
5Programming / Parameter Assignment 5-1
5.1 Overview 5-2
5.2 Memory Mapping in the PROTECT-PSC 5-2
5.3 Memory Mapping in External Systems 5-2
5.4 Configuration of the PROTECT-PSC Universal-Gateway in the Target System5-4
6Annex 6-1
6.1 Technical Data 6-2
6.2 Considered Standards 6-3
6.3 Literature References 6-3

Table of Contents
Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
List of Figures:
Figure 1-1 Page layout of the document..........................................................................................................................................1–3
Figure 3-1 Basic module structure...................................................................................................................................................3–3
Figure 3-2 Front view bus coupler PROFIBUS DP V1 ....................................................................................................................3–5
Figure 3-3 Front view bus coupler DeviceNet..................................................................................................................................3–6
Figure 3-4 Front view bus coupler CANopen...................................................................................................................................3–7
Figure 3-5 Front view bus coupler Modbus RTU.............................................................................................................................3–8
Figure 3-6 Front view bus coupler Modbus TCP.............................................................................................................................3–9
Figure 3-7 Front view bus coupler PROFINET IO.........................................................................................................................3–10
Figure 3-8 Front view bus coupler EtherNet / IP............................................................................................................................3–11
Figure 3-9 Front view bus coupler EtherCAT ................................................................................................................................3–12
Figure 3-10 Front view bus coupler CC-Link...................................................................................................................................3–13
Figure 3-11 Front view plug power supply.......................................................................................................................................3–14
Figure 3-12 Front view plug SN-I/F (PROTECT-PSC) ....................................................................................................................3–14
Figure 3-13 Displays of the gateway ...............................................................................................................................................3–15
FFigure 3-14 DIP switches.................................................................................................................................................................3–16
Figure 4-1 Installed position and position of the PROTECT-PSC Universal-Gateway....................................................................4–2
Figure 4-2 Assembly of a module (1/3)............................................................................................................................................4–4
Figure 4-3 Assembly of a module (2/3)............................................................................................................................................4–4
Figure 4-4 Assembly of a module (3/3)............................................................................................................................................4–5
Figure 4-5 Dismantling of a module.................................................................................................................................................4–5
Figure 4-6 SN-I/F communication cable..........................................................................................................................................4–7
Figure 4-7 Connection of the Universal-Gateway to the power module..........................................................................................4–8
List of Tables:
Table 3-1 Product range..................................................................................................................................................................3–2
Table 3-2 Technical data of the gateway module............................................................................................................................3–4
Table 3-3 States of the status LEDs..............................................................................................................................................3–15
Table 3-4 DIP switch (8)................................................................................................................................................................3–16
Table 3-5 DIP switches (1-7) – setting of the bus address............................................................................................................3–16
Table 3-6 DIP switches (1-2) – number of I/Os to be transferred..................................................................................................3–17
Table 3-7 Status bits of the PROTECT-PSC.................................................................................................................................3–17
Table 3-8 DIP switches (3-7) – transmission parameters..............................................................................................................3–18
Table 4-1 Admissible ambient conditions........................................................................................................................................4–2
Table 4-2 Connector strips used for the modules............................................................................................................................4–6
Table 5-1 Assignment of the “EL” memory area...............................................................................................................................5-2
Table 6-1 General technical data for all modules.............................................................................................................................6-2
Table 6-2 Electromagnetic compatibility...........................................................................................................................................6-2
Table 6-3 Considered standards......................................................................................................................................................6-3

Overview 1
Instruction Manual PROTECT-PSC Universal-GateWay
V 1.0R00 / 07.09
1–1
1 Overview
This chapter describes the structure of the Instruction Manual, and describes in
brief the basic mode of operation and the structure of the PROTECT-PSC Univer-
sal-Gateway.
1.1 Preliminary Remarks 1–2
1.2 Definition of Terms 1–2
1.3 Structure of the Document 1–3
1.3.1 Page Layout 1–3
1.3.2 Explanation of Symbols 1–4
1.4 Product Description 1–4
1.5 Mode of Operation 1–5
1.5.1 Hardware 1–5
1.5.2 Software 1–5
1.6 Safety Function 1–5

Overview 1
Instruction Manual PROTECT-PSC Universal-GateWay
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1.1 Preliminary Remarks
We have prepared this document with due care to the best of our knowledge and
belief. Despite careful checking, the possibility of it containing one or two errors
cannot be ruled out, however.
Before reading this Instruction Manual thoroughly, please read through Chapter 2
carefully. Understanding the information and procedures described in this chapter
is essential for the correct use of the PROTECT-PSC Universal-Gateway described
in the following. Please always remember that faulty installation or programming
can lead to serious injuries/damage to man and machine.
The terms and abbreviations used in this document are standard terms used in
electrical engineering insofar as not described in more detail.
The basic operating functions of a computer with Microsoft Windows operating sys-
tem (as from Windows 2000) are assumed as generally known.
1.2 Definition of Terms
The definition of the terms and abbreviations used most frequently in this docu-
ment are described below.
Module In this document a module is described as an individual
physical unit which is part of the PROTECT-PSC safety
compact controller.
Active module A module which is actively involved in the change of state
of the PROTECT-PSC (corresponding to active compo-
nents in electronics).
Assembly An assembly consists of several individual modules.
Standard field bus- Network interface for communication with standard field
Adapter / Bus coupler bus
Channel A physical input or output of a module
A contact Name of an NO contact
B contact Name of an NC contact
User program The control program of the PROTECT-PSC created by
the programmer
PS program The user program for the safety-oriented applications in
the CPU module for processing of the safe I/O modules
PN program The user program for non safety-oriented (operational)
applications in the CPU module for the processing of op-
erational I/O modules
PSV The PSV (Program Specific Value) is the hash total of the
user program.
Firmware FB Secure function block in the PROTECT-PSC
FB library Library of function blocks
Authorised person Person from the group of persons described more closely
in Chapter 2.1.4
Cat Abbreviation for category (B, 1 to 4 in accordance with
DIN EN 954-1)
PL Performance Level, see DIN EN ISO 13849-1
SIL Safety Integrity Level, see DIN EN 61508

Overview 1
Instruction Manual PROTECT-PSC Universal-GateWay
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1.3 Structure of the Document
This Manual is subdivided into 7 chapters. There is an additional Table of Con-
tents preceding every chapter in which the individual sections are shown sepa-
rately.
1.3.1 Page Layout
All pages have the same layout in principle.
F
Fi ig gu ur re e 1 1- -1 1 P Pa ag ge e l la ay yo ou ut t o of f t th he e d do oc cu um me en nt t
1Headline
The number and the name of the respective chapter are located top-right and top-
left respectively.
2Baseline
The document name, version number and creation date are located bottom left.
The page number within the chapter is shown bottom right.
3Margin
This area contains important information, cross-references to other parts of the text
and bibliographic references and the information content of text passages.
4Text / Pictures / Tables
Texts, pictures and tables are named within a chapter with the chapter number and
an additional index and, if necessary, a brief accompanying text.
1
34
2

Overview 1
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1.3.2 Explanation of symbols
Safety warnings
Text passages with a STOP symbol contain important warnings which must be
heeded under all circumstances. Failure to heed these warnings may place the
controller in a state which no longer provides adequate protection for man and/or
machine. Please read through such text sections with particular care.
Warnings
A CAUTION sign gives you important information and warnings which guarantee
the trouble-free operation of the PROTECT-PSC Universal-Gateway. Failure to
heed these warnings does not restrict the safe operation of the PROTECT-PSC.
Information
This symbol indicates useful information intended to facilitate the commission-
ing/servicing of the PROTECT-PSC Universal-Gateway or to provide a deeper in-
sight into the mode of operation of the gateway.
Cross-references
This symbol refers to other text passages within the document which contain addi-
tional information. The first digit describes the chapter and the second the page
within the chapter.
Additional information
This symbol refers to external literature that contains additional information on a
specific topic. You will find the exact title of the additional information in the Annex
(Chapter 6.3) using the number next to the symbol.
1.4 Product Description
The PROTECT-PSC Universal-Gateway is an additional module to the PROTECT-
PSC safety compact controller to facilitate the non safety-oriented data exchange
via a standard field bus with other control and operating units. Using this module
an adjustable number of I/O data can be transferred in both directions.
x.x.x / x-xx
x.x.x / xx

Overview 1
Instruction Manual PROTECT-PSC Universal-GateWay
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1.5 Mode of Operation
1.5.1 Hardware
The PROTECT-PSC Universal-Gateway has two interfaces. The first creates the
connection to the safety compact controller PROTECT-PSC and the second is the
standard field bus adapter (see further below).
Adjustments are made using DIP switches which are accessible on the front side.
There are also 2 bicolour LEDs which signalise operating status and errors.
1.5.2 Software
The programmer describes or reads EL flags in his PROTECT-PSC user program,
the values/status of which are transferred via the PROTECT-PSC Universal-
Gateway via the standard field bus to other bus participants and vice versa.
The gateway appears as so-called slave at the standard field bus. The participant
address and a few bus settings may be set using the DIP switches on the front side
depending on bus type.
1.6 Safety Function
No safety functions may be realised using the PROTECT-PSC Universal-Gateway
because a transmission of safety-oriented data by a standard field bus does not
satisfy the requirements placed on a safety field bus.

Important Information 2
Instruction Manual PROTECT-PSC Universal-GateWay
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2 Important Information
This chapter contains important warnings and information for the safe and correct
use of the PROTECT-PSC Universal-Gateway.
2.1 Safety Warnings 2–2
2.1.1 Definitions 2–2
2.1.2 Danger through Misuse 2–2
2.1.3 Dangers from Modification and Retrofitting 2–2
2.1.4 Authorised Persons 2–2
2.1.5 Electrical Connections 2–3
2.1.6 Shock-Hazard Protection 2–4
2.1.7 Maintenance 2–4
2.1.8 Disposal 2–4
2.1.9 Liability 2–4
2.2 Correct Use 2–5
2.2.1 Application 2–5
2.2.2 Categories, Prototype Tests etc. 2–5

Important Information 2
Instruction Manual PROTECT-PSC Universal-GateWay
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2.1 Safety Warnings
Graded safety warnings
Safety warnings are marked in this Instruction Manual by a symbol and the key-
word CAUTION or WARNING in the margin of the page. The safety warnings are
printed in bold type and in a box.
2.1.1 Definitions
Safety warnings
Text passages with a STOP symbol contain important warnings which must be
heeded under all circumstances. Failure to heed these warnings may place the
controller in a state which no longer provides adequate protection for man and/or
machine. Please read through such text sections with particular care.
Warnings
A CAUTION sign gives you important information and warnings which guarantee
the trouble-free operation of the PROTECT-PSC Universal-Gateway. Failure to
heed these warnings does not restrict the safe operation of the PROTECT-PSC.
2.1.2 Danger through Misuse
The consequences of incorrect use (see Chapter 2.1.9 and 2.2) may be personal
injury to the user or third parties as well as damage to the controller, the product or
environmental damage. Only use the PROTECT-PSC Universal-Gateway for its
intended purpose!
2.1.3 Dangers from Modification and Retrofitting
The PROTECT-PSC Universal-Gateway has been designed and constructed by us
to operate safely.
It is not therefore permitted to make modifications or to retrofit the equipment.
This may affect the correct operation of the PROTECT-PSC Universal-Gateway
with the consequence of personal injury, property or environmental damage and
loss of any liability.
2.1.4 Authorised Persons
Only sufficiently qualified and instructed persons may operate the PROTECT-PSC
Universal-Gateway!
The user software may only be handled and modified by authorised and instructed
persons (programmers)!
An electrical technician must perform commissioning!

Important Information 2
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Only qualified personnel may perform service, maintenance, troubleshooting and
error correction work!
Operator
An operator is a duly instructed person.
The operator switches the system on and off.
The operator is the actual beneficiary of the safety function.
Programmer
The programmer is a specially authorised and instructed person.
The programmer
•creates or
•modifies
the user programs
Commissioner
The commissioner is an electrical technician.
The commissioner
•performs commissioning under increased safety measures,
•sets the device parameters and
•performs the requisite tests.
Maintenance technician
The maintenance technician is a qualified skilled worker. He
•services the electrical and mechanical components of the controller,
•performs maintenance work, and
•looks for errors and eliminates them.
2.1.5 Electrical Connections
The PROTECT-PSC Universal-Gateway must be connected to an electrical power
supply.
CAUTION: electrical voltage
An electrician must connect the system to the mains.
The power supply (24 VDC) of the PROTECT-PSC Universal-Gateway and all
components electrically connected to the gateway must satisfy DIN EN 61000-6-2
and one of the following requirements:
•Safety mains transformer to DIN EN 61558/VDE 0570 Part 2-6: “Special Re-
quirements Placed on Safety Transformers for General Applications (IEC
61558-2-6:1997)”

Important Information 2
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•Switching mains pack according to DIN EN 60950-1: “Equipment of Informa-
tion Technology Safety” and in accordance with DIN EN 50178: “Equipment
of Heavy Current Equipment with Electronic Resources”. Furthermore the
power pack must be suitable to supply SELV power circuits in accordance
with DIN EN 60950-1.
The mains must be appropriately fused!
The information in Chapters 3 to 5 must be taken into consideration in particular for
the operation of the PROTECT-PSC Universal-Gateway.
6.1.2 / 6-2
The PROTECT-PSC Universal-Gateway satisfies the pertinent provisions of the
EMC Directive.
2.1.6 Shock-Hazard Protection
The PROTECT-PSC Universal-Gateway is intended for use in control circuits to
DIN EN 60204 for a rated voltage of 24 VDC. The appropriate requirements
placed on shock hazard protection must be satisfied for the applications.
For reasons of shock hazard protection, all connections must be assigned to the
appropriate mating connectors.
2.1.7 Maintenance
Maintenance work
Incorrect maintenance could lead to death, injury, damage or environmental dam-
age. Only qualified persons may perform maintenance, troubleshooting and error
elimination work! Switch off the power supply to the PROTECT-PSC Universal-
Gateway! Directly after completing maintenance work replace all protective clad-
ding and safety equipment and check that they function correctly!
Spare parts
The use of unsuitable spare parts could lead to death, injury, damage or environ-
mental damage. Spare parts must comply with the technical requirements of the
manufacturer. Only use original ELAN spare parts!
2.1.8 Disposal
Electrical waste (components, screens etc.) can damage the environment. Dis-
pose of electrical resources correctly or commission a specialised company to do
so!
2.1.9 Liability
The contents of the following Instruction Manual are subject to technical modifica-
tion which may arise particularly due to constant development of the products from
ELAN. ELAN assumes no liability for any printing errors or any other inaccuracies
which may be contained in this Instruction Manual unless these are serious faults
which ELAN demonstrably already knew about. The applicable national and inter-
national standards and provisions must be observed under all circumstances in
addition to the instructions contained in the Instruction Manual.

Important Information 2
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NB
Incorrect use/liability exclusion
ELAN shall not be liable for damage caused through incorrect use or application of
the products.
The exact knowledge of the contents of this Instruction Manual is similarly viewed
to be correct use. In particular, the information and safety warnings contained in
this Instruction Manual must be heeded.
If products are used in connection with other components such as safety modules,
controllers or sensors, the respective user information must be heeded.
2.2 Correct Use
2.2.1 Application
The PROTECT-PSC Universal-Gateway is an additional module in order to trans-
port exclusively non safety-oriented information of the PROTECT-PSC safety com-
pact controller from and to a standard field bus.
Design, implementation and operating errors may affect the correct operation of
the PROTECT-PSC Universal-Gateway, resulting in injury, damage or environ-
mental damage. This is why only sufficiently qualified persons may operate the
PROTECT-PSC Universal-Gateway!
The PROTECT-PSC Universal-Gateway is exclusively intended for use in ma-
chines within the scope of DIN EN 60204-1 (Electrical Equipment of Machinery).
Additional requirements arising from other provisions and regulations are not nec-
essarily satisfied by the PROTECT-PSC Universal-Gateway.
The PROTECT-PSC Universal-Gateway may not be used in potentially explosive
areas.
2.2.2 Categories, Prototype Tests etc.
- Not applicable –

System Description 3
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3 System Description
This chapter describes the individual components of the PROTECT-PSC Univer-
sal-Gateway.
3.1 Overview 3–2
3.1.1 Product Range 3–2
3.1.2 Module Structure 3–3
3.2 Power Supply 3–4
3.2.1 General Description 3–4
3.2.2 Technical Data 3–4
3.2.3 External Power Supply Units 3–4
3.3 Connection of a Standard Field Bus Adapter (Bus Coupler) 3–5
3.3.1 PROFIBUS DP V1 3–5
3.3.2 DeviceNet 3–6
3.3.3 CANopen 3–7
3.3.4 Modbus RTU 3–8
3.3.5 Modbus TCP 3–9
3.3.6 PROFINET IO 3–10
3.3.7 EtherNet / IP 3–11
3.3.8 EtherCAT 3–12
3.3.9 CC-Link 3–13
3.4 Connection of Power Supply 3–14
3.5 Connection SN-I/F (PROTECT-PSC) 3–14
3.6 Displays / Display Area 3–15
3.7 Operating Elements / Operating Area 3–16
3.7.1 DIP Switches 3–16
3.7.2 Operation 3–16

System Description 3
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3.1 Overview
3.1.1 Product Range
Component Name Description
Gateway
- PROTECT-PSC-UNI-GATEWAY
PROFIBUS DP V1
- PROTECT-PSC-UNI-GATEWAY
DEVICENET
- PROTECT-PSC-UNI-GATEWAY
CANOPEN
- PROTECT-PSC-UNI-GATEWAY
MODBUS RTU
- PROTECT-PSC-UNI-GATEWAY
MODBUS TCP
- PROTECT-PSC-UNI-GATEWAY
PROFINET IO
- PROTECT-PSC-UNI-GATEWAY
ETHERNET IP
- PROTECT-PSC-UNI-GATEWAY
ETHERCAT
- PROTECT-PSC-UNI-GATEWAY
CC-LINK
Article No.: 1209346
Article No.: 1209347
Article No.: 1209350
Article No.: 1209349
Article No.: on request
Article No.: 1209352
Article No.: 1209353
Article No.: 1209351
Article No.: 1209348
Power connection Phoenix FRONT-MSTB 2,5/ 3-ST-
5,08
Communication
connection Phoenix FRONT-MSTB 2,5/ 4-ST- 5,08
SN-I/F commu-
nication cable Part of scope of delivery
Communication cable between PRO-
TECT-PSC safety compact controller
and PROTECT-PSC Universal-
Gateway
T
Ta ab bl le e 3 3- -1 1 P Pr ro od du uc ct t R Ra an ng ge e
Information on the individual modules can be found in the following chapters.