Pilz PSS Series User manual

The spirit of safety.
Programmable Safety Systems
PSS-Range
PSS(1) ControlNet Adapter
Hardware Manual
Item No. 19 905

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purposes.
While every effort has been made to ensure that the information in this manual is
accurate, no responsibility can be accepted for errors or omissions contained within it.
We reserve the right to amend any specifications without prior notice. We are grateful for
any feedback on the contents of this manual.
The names of products, goods and technologies used in this manual are the trademarks of
the respective companies.
II, 02/02

PSS(1) ControlNet Adapter - Hardware Manual 1
Introduction 1-1
Overview of manual 1-2
Terminology 1-3
Definition of symbols 1-4
Overview 2-1
Module versions 2-1
Software package 2-2
Range 2-2
Safety 3-1
Intended use 3-1
EMC 3-1
ESD 3-1
Warranty and liability 3-2
Disposal 3-2
Safety guidelines 3-3
Use of qualified personnel 3-3
Unit-specific safety regulations 3-3
Installing the module 3-4
Cable material and cable layout 3-4
Measures to protect against interference 3-4
Assembling and connecting the module 3-4
Function 4-1
Module’s operating elements 4-1
Net Address 4-1
Status indicators 4-1
Module interfaces 4-2
ControlNet interfaces 4-2
Network Access Port (NAP) 4-2
Module's mode of operation 4-2
Contents

Contents
2PSS(1) ControlNet Adapter - Hardware Manual
Module 5-1
Front view 5-1
Cables and interfaces 5-2
ControlNet connections 5-2
ControlNet connection cable 5-2
Cable runs 5-2
Network Access Port 5-3
Conenction cable for the Network Access Port 5-3
Net Address 5-4
LEDs for operating and error status 5-5
LED "module status" 5-5
LED "
A
" and LED "
B
" (network status) 5-6
Installation and Configuration 6-1
Installing the module in the module rack 6-1
Configuration 6-1
Setting the Net Address 6-1
Bus termination 6-2
Commissioning and Operation 7-1
Initial commissioning 7-1
Testing the components 7-1
Initialising the PSS 7-1
Quick start 7-1
Error diagnostics 7-2
Operation 7-2
Technical Details 8-1

PSS(1) ControlNet Adapter - Hardware Manual 3
Appendix 9-1
Changes to the operating manual 9-1

PSS(1) ControlNet Adapter - Hardware Manual 1-1
This manual describes the hardware of the communications modules
• PSS ControlNet Adapter and
• PSS1 ControlNet Adapter.
To fully understand this manual you will need to be conversant with the
information found in the general documentation for the PSS-range (Safety
Manual, System Description, Installation Manual, Programming Device
and Programming Manual).
The software is described in a separate manual “ST SB ControlNet”.
To fully understand the bus-specific requirements and any associated
requirements, you will need to be familiar with the “ControlNet Internatio-
nal Specification” Version 2.0 from 31. March 1995.
This manual is intended for instruction and should be retained for future
reference.
Introduction

Introduction
1-2 PSS(1) ControlNet Adapter - Hardware Manual
Overview of documentation
1 Introduction
The introduction is designed to familiarise the user with the contents
and structure of this manual and the definition of the symbols used
within the manual.
2 Overview
Provides information on the most important features of the module
and gives a brief outline of the application area.
3 Safety
This chapter must be read as it contains information on the safety
requirements to be met and the intended use.
4 Function Description
Contains detailed information on the functionality of the module.
5 Module
This chapter explains the operator elements of the modules.
6 Installation and Configuration
This chapter shows you how to install and configure the module.
7 Commissioning and Operation
This chapter is designed to provide support during commissioning and
how the module is put into operation.
8 Technical Details
Tables containing technical details.
9 Appendix
Includes a description of changes to the manual.

PSS(1) ControlNet Adapter - Hardware Manual 1-3
Terminology
• Throughout this manual the designation “module” or “PSS(1) ControlNet
Adapter” is valid for all module versions. If the description relates to a
specific module, then the product name for the module will be used (e.g.
PSS ControlNet Adapter).
• The designation "PSS" is always used where the description is valid for
all PSS programmable safety systems. If the description is only valid for
one particular unit, then the specific product name will be used (e.g.
PSS 3000, PSS 3100).
• In this manual, data transfer is regarded as viewed from the PSS.
Input data or receive data is sent from another ControlNet subscriber to
the PSS via the scanner. Output data or send data is sent from the PSS
to another ControlNet-subscriber via the scanner.
• "Scanner" is a term used in ControlNet documentation. The purpose and
function of a scanner on ControlNet corresponds to a large extent to the
purpose and function of a master on other bus systems.
• "Adapter" is a term used in ControlNet documentation. The purpose and
fucntion of an adapter on ControlNet corresponds to a large extent to the
purpose and function of a slave on other bus systems.
• "Net Address" is a term used in ControlNet documentation.
On ControlNet, the Net Address is used to describe the station address
or node-ID of a bus subscriber.

Introduction
1-4 PSS(1) ControlNet Adapter - Hardware Manual
Definition of symbols
Information in this manual that is of particular importance can be identified
as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that
poses an immediate threat of serious injury and death, and indicates
preventive measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that
could lead to serious injury and death, and indicates preventive
measures that can be taken
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices in its immediate
environment could be damaged. It also provides information on preventive
measures that can be taken.
INFORMATION
This gives advice on applications and provides information on special
features, as well as highlighting areas within the text that are of particular
importance.

PSS(1) ControlNet Adapter - Hardware Manual 2-1
The communications module PSS(1) ControlNet Adapter is used to
connect a PSS modular safety system to the ControlNet bus system in
accordance with the requirements of ControlNet International Version 2.0,
03/1998. The PSS operates in conjunction with the module and the
relevant software package as the ControlNet Adapter.
Pilz programmable safety systems (PSS) have been designed for use in
plant and machinery safety circuits. They consist of a failsafe (FS) setion
and a standard (ST ) section.
Overview
The module may only be used on the standard section of a PSS modular
safety system.
Module versions
There are individual modules to use with the PSS 3000 and PSS 3100.
• PSS ControlNet Adapter module may only be used on the module rack
of the PSS 3000.
• PSS1 ControlNet Adapter module may only be used on the module rack
of the PSS 3100.
There is no difference in the functionality of both modules
Fig. 2-1: Structure of the PSS
Steuerung von
sicherheitsgerichteten
Aufgaben
z. B.: NOT-AUS usw.
Steuerung und
Regelung von
nicht sicherheitsgerichteten
Aufgaben
z. B.: Diagnose usw.
Fail-safe-
Teil
Standard-
Teil
PSS
Failsafe
section
Standard
section
Control of
safety-related
tasks
e.g.: E-STOP circutis etc
Control and monitoring of
non-safety-related
tasks
e. g.: diagnostics etc.

Overview
2-2 PSS(1) ControlNet Adapter - Hardware Manual
Software package
There is a separate software package available for data exchange
between the PSS and the ControlNet Scanner. The standard function
block within the software must be incorporated within the user program in
the standard section of the PSS. It carries out all of the tasks for data
exchange between the PSS and the ControlNet Scanner.
Range
The hardware package consists of:
• One module
- PSS ControlNet Adapter or
- PSS1 ControlNet Adapter
• One operating Manual
PSS(1) ControlNet Adapter - Hardware Manual

PSS(1) ControlNet Adapter - Hardware Manual 3-1
Intended use
The module is intended for use as a ContolNet Adapter in accordance with
the requirements of ControlNet International Version 2.0, 03/1998. The
module may only be used in the standard bus of the corresponding PSS
programmable safety system.
PSS ControlNet Adapter may only be used in the standard bus of the
PSS 3000 .
PSS1 ControlNet Adapter may only be used in the standard bus of the
PSS 3100 .
The module may only be used in conjunction with the software package
"ST SB ControlNet" from Pilz.
Details of the module can be found in the chapter “Technical Details”.
Use of the standard function block outside the specifications will be
deemed as improper application.
Any changes made by exchanging components or soldering work etc will
be deemed as improper application.
Use of the module outside the application areas described in the operating
manual will be deemed as improper application.
Following the guidelines given in the manual contributes to the intended
use.
EMC
The module is intended for use in industrial environments only. Use in a
domestic environment could lead to interference.
ESD
Electrostatic discharge can damage components on the module. Ensure
against discharge before touching the terminal strips, e.g. by touching an
earthed, conductive surface or by wearing an earthed armband.
Safety

Safety
PSS(1) ControlNet Adapter - Hardware Manual3-2
Warranty and liability
All claims to warranty and liability will be rendered invalid if
• The module was used contrary to the purpose for which it is intended
• Damage can be attributed to not having followed the guidelines in the
operating manual
• Operating personnel are not suitably trained or sufficiently qualified
• The housing was opened
• Changes have been made (e.g. by exchanging components or soldering
work etc.).
Disposal
The unit must be disposed of properly when it reaches the end of its
service life

PSS(1) ControlNet Adapter - Hardware Manual 3-3
Safety guidelines
This chapter is an important part of this manual. Failure to keep to the
following guidelines and safety requirements will render all warranty,
guarantee and liability claims invalid.
All rules and regulations for accident prevention relating to the specific
area of application must be met. In particular, VDE and all local
regulations regarding health and safety must be observed.
Use of qualified personnel
The module may only be assembled, installed, programmed,
commissioned, operated, maintained and decommissioned by qualified
personnel who, because they are:
• Qualified electrical engineers
• Have received training from qualified electrical engineers,
are suitably experienced to operate devices, systems, plant and
machinery in accordance with the general standards and guidelines for
safety technology.
It is the company's responsibility only to employ personnel who:
• Are familiar with the basic regulations concerning health and safety /
accident prevention
• Have read and understood the safety guidelines given in the manual
Unit-specifc safety regulations
Before installing and commissioning the module, you should refer to any
guidelines laid down by the pant manufacturer or operator.

Safety
PSS(1) ControlNet Adapter - Hardware Manual3-4
Installing the module
•Please read the Safety Manual and the Installation Manual for the
relevant PSS before installing and commissioning the module.
• Keep as large a distance as possible between the PSS and any
electromagnetic fields, particularly when frequency converters are
nearby. Where necessary, use suitable screening to separate the PSS
from the source of interference
• Ensure the maximum ambient and operating temperatures are not
exceeded
• Avoid the build up of heat
• Protect the module from direct sunlight and dust.
• Ensure that liquids or objects cannot get into the module
• Do not use chemicals close to the module
• Do not position the module close to flammable materials.
Cable material and cable layout
NOTICE
Only use screened cables and follow any requirements laid down by
ControlNet.
Measures to protect against interference
Follow any requirements laid down by ControlNet.
Assembling and connecting the module
• Only install the module when no voltage is applied
• The information given in “Technical Details” must be followed.

PSS(1) ControlNet Adapter - Hardware Manual 4-1
The PSS, together with the module, operates as a ControlNet Adapter
within the bus system. The module supports redundant data transfer via
the dual-channel transmission of bus data. Both bus cables are connected
to the module via separate connections. This provides a greater
availability of data.
The module supports data exchange for Scheduled and Unscheduled
Data.
Data transfer on ControlNet is carried out using a fixed bit rate of 5 MBit/s.
The software package from Pilz is required for commissioning and
operating the module.
The module occupies part of the range of freely-programmable word
modues (XW-access) on the PSS. The address range for the module
consists of 1024 words.
Module's operating elements
Net address
The module must be assigned an address so that it can be identified on
the bus. Two rotary switches are available to set the address and are
marked as “Net Address” .
Status indicators
Various errors and the operating status are displayed via the LEDs on the
module.
LED "module status" shows the operating status or communication faults
between the module and PSS.
LEDs "
A
" and "
B
" shows the operating status or communication faults
on both redundant transmission channels.
Function Description

Function Description
4-2 PSS(1) ControlNet Adapter - Hardware Manual
Module interfaces
The module has two ControlNet interfaces (channel A and channel B) and
a connection for temporary bus access (NAP).
ControlNet interfaces
There are two channel available to connect the module to ControlNet
redundantly. It is connected via two standard BNC plug connectors. They
are marked as “
A
” and “
B
”.
Network Access Port (NAP)
The Network Access Port is used to access the bus temporarily. It can
therefore be used for diagnostic and configuration changes using a
suitable monitoring tool.
Module's mode of operation
As a ControlNet Adapter the module carries out data exchange of
Scheduled Data (process data) exclusively at the request of the
ControlNet Scanners. Communication via ControlNet is carried out in PSS
using the standard function block SB236 (software package).
SB 236 provides the link for the module and supports all the tasks
required for data exchange of Scheduled Data .
Data exchange of Unscheduled messages is also supported via SB 236.

5-1PSS(1) ControlNet Adapter - Hardware Manual
Module
Front view
Fig. 5-1: Front view
NAP
B
module status
A
net
address
x 10
x 1
ControlNet
5
4
3
2
1
0
9
8
7
6
5
4
3
2
1
0
9
8
7
6
B
A
Operating status and error LEDs:
• Communication: module and PSS
(module status)
• Communication: ControlNet
(channel A and B)
Rotary switches to set the
Net Address
Network Access Port (NAP) for
temporary access
Interfaces to connect to ControlNet
(channel A and B)

5-2
Module
PSS(1) ControlNet Adapter - Hardware Manual
Cables and interfaces
ControlNet connections
Connections for ControlNet channel A and channel B use Standard
BNC-connectors. Requirements for the BNC-connectors are defined in the
ControlNet International Specification (Version 2.0, 03/1998) in the chapter
"Connectors".
ControlNet connection cable
The ControlNet International Specification specifies that the connection
cable used for the Trunkline (remote bus) and Droplines (stub lines) should
be coax cable. The connection cable must conform to the requirements of
ControlNet International Specification (Version 2.0, 03/1998). The
requirements are defined in the chapter “Topology” and “Tabs”.
Cable runs
On ControlNet the correlation between cable runs and the number of bus
subscribers can be illustrated simply using a diagram (see Fig. 5-2).
Fig. 5-2: Correlation between the cable run and number of bus subscribers
2162348
Number of network nodes
Repeaters are
required in this
area.
1000
750
500
250
Coaxial-cable run in m for Trunkline (remote bus)

5-3PSS(1) ControlNet Adapter - Hardware Manual
INFORMATION
More detailed information on the topology conditions can be found in the
ControlNet International Specification (from Version 2.0, 03/1998).
Network Access Port
Connection cable for the Network Access Port
INFORMATION
Only use screened cables for the NAP cable. The connection cable must
meet the requirements of the ControlNet International Specification (from
Version 2.0, 03/1998).
Western plug connector (RJ45)
8-pin
Fig. 5-4: Layout of the western plug connector (View from below)
8
1
Fig. 5-3: Socket for western plug connector (top view)
1: GND REF
2: N.C.
3: Tx_H
4: Tx_L
5: Rx_L
6: Rx_H
7: N.C.
8: GND REF
Socket for western plug connector
(RJ45)
8-pin
81
N.C. = No connection