Pilz PSS 3032 User manual

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Programmable control systems PSS®
PSS 3032
Installation Manual – Item No. 19 891

All rights to this manual are reserved by the publishers. Copies may be made for internal
purposes.
In the interests of continual technical advancement we reserve the right to amend
specifications without prior notice. No responsibility accepted for errors or omissions.
The names of products, goods and technologies used in this manual are trademarks of
the companies concerned.
Version VI, 03/2001

1Installation Manual: PSS 3032
Introduction 1-1
Definition of symbols 1-1
Safety Regulations 2-1
Supplying power to the PSS 2-1
Installation 2-3
Connections 2-4
Electromagnetic Compatibility (EMC) 3-1
Overview 3-1
Making the installation EMC-compatible 3-2
Connecting the earth cables 3-2
Cabling 3-3
Equipotential bonding 3-4
Screened cables 3-5
Suppression of inductive loads 3-5
Miscellaneous 3-5
Installing within an enclosure or wall-mounting 3-6
Testing the EMC-compatibility of an installation 3-7
Installation 4-1
Installing the PSS 3032 4-1
Installing the PSS 3032 in a control cabinet 4-2
Contents

Contents
2Installation Manual: PSS 3032
Connecting the Inputs and Outputs 5-1
Configuration of the screw terminals and connector
description 5-1
Notes on wiring 5-2
Digital inputs 5-4
Configuration 5-5
Example: Single-channel, failsafe input device, unchecked 5-6
Example: Dual-channel input devices, unchecked 5-8
Example: Single-channel, failsafe input device, with test pulse 5-10
Example: Dual-channel, failsafe input device, with test pulse 5-12
Single-pole 0.5 A outputs/test pulses 5-14
Configuration 5-15
Dual-pole 2 A outputs 5-16
Configuration 5-17
Interfaces 6-1
PG programming interface 6-1
RS 232 user interface 6-1
Appendix 7-1
Changes to the Installation Manual 7-1

Installation Manual: PSS 3032 1-1
This installation manual contains all the information you need to install a
PSS 3032 programmable safety system. It gives safety guidelines which
should be followed during installation and also describes the installation
procedure and measures which can be taken to ensure EMC compliance.
Examples are also given to show how the on-board inputs and outputs
should be connected.
Definition of symbols
Information in this manual which is of particular importance can be
identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation which
poses an immediate threat of serious injury and death, and indicates
preventive measures which can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation which
could lead to serious injury and death, and indicates preventive
measures which can be taken.
CAUTION!
This refers to a hazard which can lead to a less serious or minor injury
plus material damage, and also provides information on preventive
measures which can be taken.
NOTICE
This describes a situation in which the unit(s) could be damaged and also
provides information on preventive measures which can be taken.
INFORMATION
This gives advice on applications and provides information on special
features, as well as highlighting areas within the text which are of
particular importance.
Introduction

Introduction
1-2 Installation Manual: PSS 3032
Notes

Installation Manual: PSS 3032 2-1
To ensure that the PSS 3032 programmable safety system functions
correctly, please follow the safety guidelines given below:
•Electrical connections should be made by a qualified electrical engineer
who is familiar with the information in this manual as well as the relevant
regulations concerning health and safety at work.
• Ensure VDE and local regulations are met, especially those relating to
safety. The relevant safety regulations for the respective application
must also be met.
• CAUTION!
Electrostatic discharge can damage components on the PSS 3032.
Ensure against discharge before touching the terminal strips, e.g. by
touching an earthed, conductive surface or by wearing an earthed
armband.
•Ensure all the requirements of the relevant trade associations or TÜV are
met.
•Ensure the wiring instructions in Chapter 5 are followed.
•If the system is altered in any way, such as exchanging a component or
carrying out soldering work, the guarantee, and any approval, will be
rendered invalid.
•The date of manufacture can be found on the test label.
Supplying power to the PSS
•The safety system requires a 24 VDC supply.
Check that the voltage supplied from the external power supply
corresponds.
•The tolerance on the supply voltage for the system's power supply is
+10 % or -15 % maximum. Safe operation cannot be guaranteed outside
this range.
•Overvoltage and spikes of interference can damage the PSS power
supply. If this occurs the unit will switch to a safe condition. Please refer
to the relevant EMC-measures described in Chapter 3.
•To achieve the lowest possible residual ripple (< ± 1.2 V), we
recommend that you install a three-phase bridge rectifier or regulated
supply.
Safety Regulations

Safety Regulations
2-2 Installation Manual: PSS 3032
•The external power supply must be capable of supplying a current which
is calculated as follows:
Sum of all the inputs multiplied by 10 mA
+Total current from the maximum number of outputs that can be driven
simultaneously
+0.5 A quiescent current
This must amount to 10 A maximum.
•The fuse between the external and the PSS power supply protects the
external power supply. The size of the fuse will depend on the cable
cross section and on local regulations.
•WARNING!
Safe electrical isolation must be ensured for the external 24 V supply.
Failure to do so could result in electric shock. Power supplies must
conform to DIN VDE 0551 / EN 60 742 and DIN VDE 0160.
• Connect the external 24 V supply to the PSS power supply and the 0 V
terminal to the inputs, as shown in the diagram below. (It is only
necessary to connect one of the two 0 V terminals to the inputs.) The
external supply should be earthed in accordance with local regulations.
There must be no direct connection between “N” and the 0 V output on
the external power supply.
The 0 V connections on all the 24 V power supplies should be connected
and the 0 V mains earthed at a single point. The connection of the 0 V
supply to the central earth bar or earth fault monitor must be in
accordance with the relevant national regulations (such as EN 60 204,
VDE 0113, NFPA 79-1991:17-7, NEC: Article 250, for example).

Installation Manual: PSS 3032 2-3
~
=
PSS 3032
L1
N
+24 V
0 V
External power supply
24 V
0 V
Functional
earth
Connect in star to the central
earth point
0 V
Connect to the 0 V mains
and earth at a single point
Supply terminal
on the inputs
Supply terminals on the
power supply
Installation
• The system should be installed in an enclosure (e.g. control cabinet)
which conforms to the protection class required.
• When installing the unit in an enclosure such as a control cabinet, the
technical specifications below must be taken into account:
Protection type (EN 60 529, 10/91) IP 20
Protection class (DIN VDE 0106,
Part 1/A1, 04/90) 1
Mounting position Vertical
Ambient temperature (DIN IEC 68-2-14, 06/87) 0 ... 60 °C
Storage temperature (EN 60 068-2-1/-2, 03/93) -25 ... +70 °C
Relative humidity
(DIN IEC 68-2-30, 09/86) Max. 95 % r.h.
Condensation Not permitted
Vibration (EN 60 068-2-6, 04/95) Frequency range:
10 ... 100 Hz
Amplitude:
0.1 mm, max. 5g
Shock (DIN IEC 68-2-29) 30g, 11 ms/10g, 16 ms
EMC EN 50 082-2, 03/95
EN 55 011 A, 08/96
Fig. 2-1: Supplying the system

Safety Regulations
2-4 Installation Manual: PSS 3032
• Ensure there is sufficient ventilation to prevent heat building up within the
control cabinet.
• In extreme ambient conditions, additional measures may be required in
order to keep within the prescribed value range (e.g. air-conditioning
within the control cabinet).
• The PSS 3032 must be installed in such a way that buttons and switches
cannot be operated unintentionally.
Connections
• Cable layout must meet the EMC-guidelines stated in Chapter 3.
• The current at each 24 V supply terminal should be 10 A maximum.
• Screened cables are not required for digital I/Os.
• Minimum ranges for cable cross sections on field connection terminals
in mm2, in accordance with EN 61 131-2, 08/94 and A11, 06/96:
- Digital inputs: 0.5 (AWG20) ... 1.5 (AWG16)
- Digital outputs: 0.5 (AWG20) ... 2.0 (AWG14)
- Power supply: 1.5 (AWG16) ... 2.5 (AWG12)
- Earth: 1.5 (AWG16) ... 2.5 (AWG12)
• If you are using a multi-stranded wire with a cross section of 1.5 mm2to
connect the inputs and outputs, crimp ferrules in accordance with
DIN 46 228 Part 1 and Part 2 0.5 ... 1.5 mm2, type A or C are required,
i.e. bootlace ferrules.
To crimp the bootlace ferrules use a type A or C crimping tool, in
accordance with EN 60 947-1 (e.g. PZ 1.5 or PZ 6.5 from Weidmüller).
• Use copper wiring.
• The torque setting on the connection terminals should be 0.5 ... 0.6 Nm.

Installation Manual: PSS 3032 3-1
Overview
The PSS 3032 is designed to be installed within an electromagnetic
industrial environment. To ensure electromagnetic compatibility the
correct procedures must be carried out when installing the system.
A device is electromagnetically compatible if:
• It functions without error in a given electromagnetic environment.
•It does not adversely affect its own environment.
Electromagnetic interference reaches the system through:
•Radiated fields
•Power supply
•Earth cabling
•Bus
•Interfaces
•Input and output cables
The interference can be transferred from the source to the receiver
(interference sink) via the coupling routes.
Interference reaches the interference sink (e.g. PSS 3032) in various
ways:
•DC coupling
This occurs if the source and sink of interference have common cable
connections. The common cable presents complex resistances, inducing
potential differences. Possible sources of interference are switches/
relays, running motors or varying potentials for other systems on the
same power supply.
Fig. 3-1: Electromagnetic interference
Electromagnetic Compatibility (EMC)
Coupling
Interference
sink
Source of
interference

Electromagnetic Compatibility (EMC)
3-2 Installation Manual: PSS 3032
•Capacitive (electrical) coupling
A different potential between the source and interference sink (e.g. two
cables) creates an electrical field. Cross-coupling is proportional to the
rate of voltage change.
Possible sources of interference are contactors, static discharge, parallel
signal cables.
• Inductive (magnetic) coupling
A live cable produces a magnetic field which surrounds both the live and
neighbouring cables. Interference voltage is induced. Cross-coupling is
proportional to the rate of current change.
Possible sources of interference are mains cables running in parallel, live
cables, high frequency cables, inductors, transformers, motors.
•Electromagnetic coupling
A cable can emit a signal as a radio wave. This wave is then picked up
by another cable.
Possible sources of interference are transmitters such as radios, sparks
from spark plugs, welding equipment etc.
NOTICE
Stronger HF transmitters should only be operated at a distance of more
than 0.6 m.
•Static discharge
Static discharge occurs where there are very high differences in potential
between two points. If the two points are brought closer together or if the
potential difference is increased, discharges can occur in the air gaps.
Possible sources of interference are people who are statically charged
from a synthetic carpet, for example.
Making the installation EMC-compatible
Connecting the earth cables
PSS safety systems all meet protection class 1 (DIN VDE 0106, Part 1/A1,
04/90). The prescribed earth points are designed for your safety and to
guarantee compliance with noise resistance requirements.

Installation Manual: PSS 3032 3-3
•The housing should be connected to the earth conductor. A cable cross
section of at least 2.5 mm2should be used. Connections should be kept
as short as possible.
•Always connect the earth conductor to the central earth point in star
form.
•The 0 V connections on all the 24 V power supplies should be connected
and the 0 V mains earthed at a single point. The connection of the 0 V
supply to the central earth bar or earth fault monitor must be in
accordance with the relevant national regulations (such as EN 60 204,
VDE 0113, NFPA 79-1991:17-7, NEC: Article 250, for example).
•Connections should be protected from corrosion.
•Flexible earthing straps should be used on moving earth parts (e.g.
machine parts, gates). Ensure these earthing straps are as short and
wide as possible.
Cabling
It is possible to differentiate between cables according to their function.
The following groups exist:
•Group 1: Data and supply lines for DC voltages below 60 V and AC
voltages below 25 V
•Group 2: Data and supply lines for DC voltages from 60 V to 400 V and
AC voltages from 25 V to 400 V
•Group 3: Supply lines above 400 V
Cabling inside buildings:
•The cable groups listed above should be laid separately.
•Cables of the same group can be laid within the same cable duct.
• Lines from group 1 and group 2 should be laid in separate groups or in
cable ducts which are at least 10 cm apart.
•Lines from group 1 and group 3 should be laid in separate groups or in
cable ducts which are at least 50 cm apart.

Electromagnetic Compatibility (EMC)
3-4 Installation Manual: PSS 3032
•Data and signal lines should be laid as close as possible to an earthed
surface.
Cabling to open air systems:
•As far as possible use metal conduits. These should be electrically
connected and earthed.
•Ensure there is sufficient protection against lightning by:
- Using metal conduits earthed at both ends, or concrete cable ducts
with reinforcements connected across the joints.
Equipotential bonding
Potential differences can occur through potential connected couplings
between the PSS and peripheral devices or cable shields, which are
connected at either end and have different earth connections. In order to
avoid interference, equipotential bonding cables must be installed. In
doing so, you must ensure the following:
•Select a low impedance equipotential bonding cable.
•If the PSS and peripheral devices are connected with screened signal
cables which are earthed at either end, the impedance is calculated as
follows:
Impedance equipotential bonding cable = 10% of screen impedance.
•Select the following as standard values for the cross section of the
equipotential bonding cable:
16 mm2for equipotential bonding cables up to 200 m in length.
25 mm2for equipotential bonding cables over 200 m in length.
•Use copper or galvanised steel equipotential bonding cable.
•Connect equipotential bonding cables to the earth conductor over as
wide a surface area as possible.
• As short a distance as possible should be kept between the equipotential
bonding cable and signal cable.

Installation Manual: PSS 3032 3-5
Screened cables
Interference currents arising from electrical, magnetic or electromagnetic
fields of interference must be diverted to cable screens via the earth bars
connected to the enclosure. Please remember the following:
• Connect the screens with low impedence to the earth conductor.
•Use cables with braided screening, with a minimum cover area of 80%.
• For high frequency areas connect the screen at both ends.
•For low frequency areas connect the screen at one end; this is also valid
when laying cables without equipotential bonding or using foil screens.
•Use metal or metallised plugs to connect cables for serial data transfer.
•The screen must have no connection to the connector housing if it is not
located at the end of the cable.
•At the point where the cable enters the cabinet, connect the screen to
the earth bar, without making a break in the cable. Use metal cable
clamps which cover the screen over a wide surface area.
Take the screen as far as the module, but do not lay it on top of the
module
Suppression of inductive loads
Suppression should not be used to protect the semiconductor outputs.
Miscellaneous
Connecting the programming device
The programming device requires a mains connection in each cabinet.
The mains connection must be connected to the same distributor as the
earth conductor for the cabinet.

Electromagnetic Compatibility (EMC)
3-6 Installation Manual: PSS 3032
Lighting inside the cabinet
Use incandescent panel lighting as available from LINESTRA.
NOTICE
Fluorescent lamps should be avoided as they create interference fields.
However, if it is absolutely necessary to use fluorescent lamps, the
guidelines listed below should be followed:
•Place shield screening over the lamp.
•Used screened cable.
•Install a metal-sheathed switch.
•Use a mains filter or screened power supply cable.
Installing within an enclosure or wall-mounting
Care must be taken to avoid interference when installing the unit within an
enclosure or wall-mounting:
•Shielding, earth conductor bars and the base module rack should be
attached to metal parts in order to divert any coupled interference on to
large metal areas. For wall-mounting we recommend that the overall
potential surfaces are made of steel.
• For varnished or anodised metal parts you should use special contact
plates or remove the protective coating.
•Install an earth bar for the cable screens.
•The earth bar can also be used as the ground conductor bar.
• Connect the earth bar to the mounting plate over a wide surface area
and with low impedance.

Installation Manual: PSS 3032 3-7
Testing the EMC-compatibility of an installation
Use the following list to check that the PSS 3032 has been installed to
conform with EMC-regulations.
Check Action Done
Before installation:
Are there areas with a high Make detailed plans for EMC
probability of interference? protection in these areas.
(e.g. computers running,
process control areas,
distribution cabinets, cable
casing, frequency converters,
hand-held radios etc.)
Are areas where computers If necessary shield the whole
are running and areas such area.
as process control rooms
sufficiently shielded from
electromagnetic coupling?
Have you, or the installer, Some important points: Lay
sufficient knowledge where cables close to earth, keep clear
cable layout is concerned? of other electrical equipment,
keep cables in ducts separate
from other parts of the
installation, keep cables as short
as possible.
Is the supply voltage free Build in a mains filter where
of interference? interference may occur.
EMC characteristics of Test under operating conditions,
individual units / all e.g. while hand-held radios are in
units once installed? use, or HF frequency generators
are close by. Test static discharge
with operating personnel, test
mutual interference between
units under different operating
conditions.

Electromagnetic Compatibility (EMC)
3-8 Installation Manual: PSS 3032
Check Action Done
During installation:
Earthed parts connected Most important are the
correctly? connections to base module
racks, racking bars, earth
conductors and earth bars.
Inactive metal parts should be
connected over a wide surface
area and earthed to a central point.
With insulated metal: Remove
insulation or use special
contact fixings. Protect the
connection from corrosion. Connect
the cabinet doors to the body of
the cabinet using earthing straps.
Are the cables laid Separate cables into groups.
correctly? Supply and signal leads
must be laid separately.
Are the shields connected Use shielded cables for analogue
correctly? and data leads.
Use metallic plugs.
Connect cable shields to earth bar
at point of entry to cabinet.
Connect cable shields over a wide
surface area and with low
impedance.
Equipotential bonding Equipotential bonding cables
carried out? should be laid if the installation
extends over a wide area.
Are inductive loads Inductive loads not switched by
switched? the PSS 3032 must be wired
with suppression elements.
24 VDC power supply? The power supply must conform to
DIN VDE 0551 / EN 60 742 and
DIN VDE 0160.

Installation
Installation Manual: PSS 3032 4-1
Installing the PSS 3032
There are two ways to install the PSS 3032. Both are shown in Fig. 3-1.
Drill 4 x M5 or M6 holes in the mounting plate of the control cabinet as
shown in Fig. 3-1 (tolerance: +/-0.3 mm/0.012"). Screw the PSS 3032 to
the mounting plate using washers.
Dimensions in mm ("):
H x W x D: 246.4 x 74 x 161 (9.70" x 2.91" x 6.34")
Fig. 4-1: Installing the PSS 3032, dimensions stated in mm (")
RUN FS
PG
RUN ST
POWER
RUN
STOP
AUTO PG
SPS
O -1.16
O +1.16
O 1.8
O 1.9
O 1.10
O 1.11
O 1.12
O 1.13
O 1.14
O -1.17
O +1.17
O 1.15
O/T 1.0
O/T 1.1
I 0.0
I 0.1
I 0.2
I 0.3
0V
I 0.4
I 0.5
I 0.6
I 0.7
I 0.8
I 0.9
I 0.10
I 0.11
0V
I 0.12
I 0.13
I 0.14
I 0.15
I 0.16
I 0.17
I 0.18
I 0.19
ST
FS
24 V
0 V
F-Stack
PG
RS 232
120 (4.72") 40 (1.58")
236.4
(9.31")
236.4
(9.31")