Pilz PSS u2 EF 8DI User manual

PSS u2 EF 8DI
Operating Manual-1003619-EN-03
}Control system PSS u2
}Remote I/O system PSS u2

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
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1 Introduction ............................................................................................................................ 5
1.1 Validity of documentation.......................................................................................................... 5
1.2 Using the documentation .......................................................................................................... 5
1.3 Definition of symbols................................................................................................................. 5
2 Overview ................................................................................................................................. 7
2.1 Module features ........................................................................................................................ 7
3 Safety ...................................................................................................................................... 8
3.1 Intended use ............................................................................................................................. 8
3.2 System requirements................................................................................................................ 8
3.3 Safety regulations ..................................................................................................................... 8
3.3.1 Safety assessment ................................................................................................................... 8
3.3.2 Use of qualified personnel ........................................................................................................ 9
3.3.3 Warranty and liability ................................................................................................................ 9
3.3.4 Disposal .................................................................................................................................... 9
4 Function description ............................................................................................................. 10
4.1 Block diagram ........................................................................................................................... 10
4.2 Supply....................................................................................................................................... 10
4.3 Inputs ........................................................................................................................................ 10
4.4 Test pulse outputs .................................................................................................................... 18
4.5 Integrated protection mechanisms............................................................................................ 19
4.6 Reaction times .......................................................................................................................... 19
4.7 Energy-saving functions ........................................................................................................... 19
5 Address assignment ............................................................................................................. 20
6 Installation .............................................................................................................................. 21
6.1 General installation guidelines.................................................................................................. 21
6.1.1 Dimensions ............................................................................................................................... 21
6.2 Inserting and removing an electronic module ........................................................................... 22
6.2.1 Inserting an electronic module.................................................................................................. 22
6.2.2 Removing an electronic module ............................................................................................... 24
6.2.3 Changing an electronic module during operation ..................................................................... 24
7 Wiring ...................................................................................................................................... 26
7.1 General wiring guidelines ......................................................................................................... 26
7.1.1 Connection mechanism for terminal blocks .............................................................................. 26
7.2 Terminal configuration .............................................................................................................. 27
8 Operation ................................................................................................................................ 28
8.1 Display elements and messages .............................................................................................. 28
9 Technical details .................................................................................................................... 30
9.1 Safety characteristic data ......................................................................................................... 31

Contents
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10 Order reference ...................................................................................................................... 33
10.1 Product ..................................................................................................................................... 33
10.2 Accessories .............................................................................................................................. 33

Introduction
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1 Introduction
1.1 Validity of documentation
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
This documentation is valid for the product PSS u2 EF 8DI. It is valid until new documenta-
tion is published.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
Please refer to the PSS u2 Installation Manual.
1.3 Definition of symbols
Information that is particularly important is 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 could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

Introduction
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
Module structure:
A module consists of
}An electronic module
}A terminal block with cage clamp terminals and
}A backplane
The electronic modules are plugged into the backplane and determine the function. The
backplane is used for communication between the head module and the electronic modules
and forms the carrier unit for the electronic modules. The terminal block is plugged into the
electronic modules and is used to connect the field wiring.
Details of the terminal blocks that can be used are available under "Intended Use".
2.1 Module features
Application of the product PSS u2 EF 8DI:
Electronic module with digital inputs for failsafe applications
The product has the following features:
}8 type 1/3 digital inputs in accordance with IEC 61131-2
– Configurable input filter time: 0 … 10.0 ms
– Configurable pulse stretching: 0 … 255 ms
– Configurable discrepancy monitoring 10 … 30000 ms
}4 test pulse outputs
– Configurable max. test pulse duration: 0.3…10.0ms
– Short circuit-proof
– Can be configured either as:
Test pulse outputs
Voltage outputs (periphery supply)
Switched-off outputs
}Energy-saving functions
}LEDs for:
– Status of inputs
– Status of test pulses
– Module error
– Operating status

Safety
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3 Safety
3.1 Intended use
The module provides failsafe type 1/3 inputs in accordance with IEC61131-2 and may be
used for failsafe applications in the PSS u2 system.
The module meets the requirements of ENIEC61508 up to SIL 3 and ENISO13849-1 up
to PLe.
The programmable safety system should be installed in a protected environment that meets
at least the requirements of pollution degree 2. Example: Protected inside space or control
cabinet with protection class IP54.
Make sure that only authorised personnel have access to the programmable safety system.
Intended use includes making the electrical installation EMC-compliant. The module is de-
signed for use in an industrial environment. Interference may occur if used in other areas.
The following is deemed improper use in particular
}Any component, technical or electrical modification to the module,
}Use of the module outside the areas described in this manual,
}Any use of the module that is not in accordance with the technical details.
The module PSS u2 EF 8DI may be used in conjunction with the following terminal block:
}16-pin terminal block
3.2 System requirements
INFORMATION
The module is supported by
}PASconfig from version 1.0.0
– We recommend that you always use the latest version (download
from www.pilz.com).
3.3 Safety regulations
3.3.1 Safety assessment
Before using a device it is necessary to perform a safety assessment in accordance with
the Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.

Safety
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3.3.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, 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 information provided in this description under "Safety",
}And have a good knowledge of the generic and specialist standards applicable to the
specific application.
3.3.3 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended,
}Damage can be attributed to not having followed the guidelines in the manual,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.3.4 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Function description
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4 Function description
4.1 Block diagram
24 8 6
Module
Supply
Data
(FS)
Periphery
Supply
+24 V DC
Module Bus
10 12 16
14
T0 T1 T2 T3
Input Input InputInput
I0
1
I2
5
I4
9
I6
13
I1
3
I3
7
I5
11
I7
15
Fig.: Block diagram PSS u2 EF 8DI
4.2 Supply
}The module supply provides the module with voltage.
}The periphery supply is used to supply the sensors and test pulses.
}The module switches the periphery supply from the module bus to the terminal block.
When the supply voltage for the periphery supply is interrupted, the periphery supply is buf-
fered for 20ms. The buffering is designed for the input currents.
4.3 Inputs
}The status of the inputs is signalled to the head module via the module bus.
}The inputs are fitted with a configurable software filter.
}Pulse stretching can be configured for the inputs.
}The maximum test pulse duration can be configured for the inputs.
}Discrepancy monitoring can be configured for the inputs.

Function description
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Safety-related guaranteed times
}Safety-related guaranteed maximum processing time tProcIM
The safety-related guaranteed maximum processing time tProcIM is the maximum time a
module requires to process the signal. The maximum processing time tProcIM applies for
the signal change from "1" to "0". It depends on the configured max. test pulse duration
and the configured software filter time. It applies for 2-channel operation:
– Software filter time ≤ 1ms
Max. processing time tProcIM = 1.0 ms + tmax test pulse + tSW filter
– Software filter time ≤ 2ms
Max. processing time tProcIM = 1.3 ms + tmax test pulse + tSW filter
– Software filter time ≤ 3ms
Max. processing time tProcIM = 1.6 ms + tmax test pulse + tSW filter
– Software filter time > 3ms
Max. processing time tProcIM = 1.9 ms + tmax test pulse + tSW filter
tmax test pulse: Configured maximum test pulse duration (if test pulses are not configured
then tmax test pulse = 0)
tSW filter: Configured software filter time (see Technical details [ 30])
}Safety-related guaranteed minimum signal time "0" signal tsignal_min_0
The minimum signal time tsignal_min_0 is the time that a "0" signal must be present in order to
be detected safely. The minimum signal time tsignal_min_0 depends on the configured max.
test pulse duration and the configured software filter time:
– Software filter time ≤ 1ms
Min. signal time "0" signal tsignal_min_0 = 0.9 ms + tmax test pulse + tSW filter
– Software filter time ≤ 2ms
Min. signal time "0" signal tsignal_min_0 = 1.2 ms + tmax test pulse + tSW filter
– Software filter time ≤ 3ms
Min. signal time "0" signal tsignal_min_0 = 1.5 ms + tmax test pulse + tSW filter
– Software filter time > 3ms
Min. signal time "0" signal tsignal_min_0 = 1.8 ms + tmax test pulse + tSW filter
tmax test pulse: Configured maximum test pulse duration (if test pulses are not configured
then tmax test pulse = 0)
tSW filter: Configured software filter time (see Technical details [ 30])
Non-safety-related guaranteed times
}Non-safety-related guaranteed minimum processing time
The non-safety-related guaranteed minimum processing time is the minimum time a mod-
ule requires to process the signal. The minimum processing time applies for the signal
change from "1" to "0" and from "0" to "1".
– Min. processing time = 0 ms
}Non-safety-related guaranteed maximum processing time

Function description
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The non-safety-related guaranteed maximum processing time is the maximum time a
module requires to process the signal. The maximum processing time applies for the sig-
nal change from "1" to "0" and from "0" to "1". It depends on the configured max. test
pulse duration and the configured software filter time.
– SW filter time ≤ 1ms:
Max. processing time = 0.8 ms + tmax test pulse + tSW filter
– SW filter time ≤ 2ms:
Max. processing time = 1.1 ms + tmax test pulse + tSW filter
– SW filter time ≤ 3ms:
Max. processing time = 1.4 ms + tmax test pulse + tSW filter
– SW filter time > 3ms:
Max. processing time = 1.7 ms + tmax test pulse + tSW filter
tmax test pulse: Configured maximum test pulse duration (if test pulses are not configured
then tmax test pulse = 0)
tSW filter: Configured software filter time (see Technical details [ 30])
}The non-safety-related guaranteed signal suppression time tpulse_sup is the maximum time
that a "0" signal or "1" signal may be present in order to be filtered out:
– t“0“-pulse_sup < ( tSW filter - 190 µs)
tSW filter: Configured software filter time (see Technical details [ 30])
}The non-safety-related guaranteed signal time tsignal_min is the time that a signal must be
present in order to be detected. This time applies for the detection of "0" signals and "1"
signals. The signal time tsignal_min depends on the max. test pulse duration and the con-
figured software filter time
– SW filter time ≤ 1ms
Signal time tsignal_min = 0.7 ms + tmax test pulse + tSW filter
– SW filter time ≤ 2ms
Signal time tsignal_min = 1.0 ms + tmax test pulse + tSW filter
– SW filter time ≤ 3ms
Signal time tsignal_min = 1.3 ms + tmax test pulse + tSW filter
– SW filter time > 3ms
Signal time tsignal_min = 1.6 ms + tmax test pulse + tSW filter
tmax test pulse: Configured maximum test pulse duration (if test pulses are not configured
then tmax test pulse = 0)
tSW filter: Configured software filter time
Signal detection in the head module
A signal is always detected and signalled to the head module's PII if it is present for longer
than the sum of the following times:
}Minimum signal time tsignal_min
}FS cycle time of module bus

Function description
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Pulse stretching:
The module stretches a 1-signal or 0-signal at the input terminals to the configured pulse
stretch time tstretch. If the signal is longer than the pulse stretch time, then it is not stretched
any further.
Signal requirements at the terminals:
The 0-signal and the subsequent 1-signal together must be present at the input for longer
than twice the configured pulse stretch time tstretch.
Initialise position
0-signal in the module 1-signal in the module
1-signal stretching
0-signal in the module
0-signal stretching
0-signal in the module
Waiting for 1-signal
1-signal in the module
Waiting for 0-signal
0-signal at the terminal
after pulse stretching has
elapsed
Pulse stretching active
0-signal at the terminal
1-signal at the terminal
1-signal at the terminal starts
pulse stretching
0-signal at the terminal
starts pulse stretching
1-signal at the terminal
after pulse stretching has
elapsed
1-signal at the terminal
after pulse stretching has
elapsed
0-signal at the terminal
after pulse stretching has
elapsed
Fig.: States for pulse stretching

Function description
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stretch
tstretch
t
TRUE
tFALSE
t
Clamp
Pulse
stretching
Stretched
signal
1-signal
t0-signal
t
ttsignal_min tsignal_min_0
Fig.: Timing diagram: pulse stretching ≤ signal duration of 1-signal
Legend
Clamp Signal at the terminal
Pulse stretching Pulse stretching
Stretched signal Stretched signal
t1-signal Duration of 1-signal
tstretch Duration of pulse stretching
tsignal_min_0 Time for which a 0-signal must be present in order to be detec-
ted safely
tsignal_min Time for which a 1-signal must be present in order to be detec-
ted.
tTRUE Stretched 1-signal in the module
tFALSE Stretched 0-signal in the module
stretch
tstretch
t
Clamp
Pulse
stretching
Stretched
signal
1-signal
t
stretch
t
FALSE
t
TRUE
t
0-signal
t
1-signal
t
ttsignal_min ttsignal_min_0
Fig.: Timing diagram: pulse stretching > signal duration of 1-signal

Function description
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Legend
Clamp Signal at the terminal
Pulse stretching Pulse stretching
Stretched signal Stretched signal
t1-signal Duration of 1-signal
tstretch Duration of pulse stretching
tsignal_min_0 Time for which a 0-signal must be present in order to be detec-
ted safely
tsignal_min Time for which a 1-signal must be present in order to be detec-
ted.
tTRUE Stretched 1-signal in the module
tFALSE Stretched 0-signal in the module
0-signal
t
stretch
tstretch
t
TRUE
t
Clamp
Pulse
stretching
Stretched
signal
1-signal
t
FALSE
t
tsignal_min tsignal_min_0
Fig.: Timing diagram: pulse stretching with variable signal duration
Legend
Clamp Signal at the terminal
Pulse stretching Pulse stretching
Stretched signal Stretched signal
t1-signal Duration of 1-signal
tstretch Duration of pulse stretching
tsignal_min_0 Time for which a 0-signal must be present in order to be detec-
ted safely
tsignal_min Time for which a 1-signal must be present in order to be detec-
ted.
tTRUE Stretched 1-signal in the module
tFALSE Stretched 0-signal in the module

Function description
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Discrepancy monitoring
}Discrepancy monitoring monitors signals at the inputs of a terminal pair. A terminal pair
consists of two consecutive inputs, e.g. I0 and I1.
}2-channel equivalent or non-equivalent sensors can be connected to a terminal pair.
}The process image during the discrepancy time can be configured. The configured value
is in the PII, provided:
– the discrepancy exists
– the maximum duration of discrepancy monitoring has not elapsed.
Configuration options:
– Set the value for the terminal pair in the PII to "0"
– Retain the last valid value in the PII. The last valid value for the lower order input of a
terminal pair (in this example input I0) before the discrepancy arose is evaluated.
I0
I1
tconf_discr
PII I0=0/I1=0
1
0
1
0
t
t
tdiscr
PII dependent on
configuration I0=1/I1=1
Fig.: Example for discrepancy monitoring of equivalent signals
Legend
I0 Input I0
I1 Input I1
PII Process image of inputs
tdiscr Discrepancy of both input signals
Discrepancy monitoring is retriggered as soon as both signals are as
expected.
The PII during this time depends on the configuration:
}Keep last valid value: I0=0 (I1 is not evaluated)
}Set value to "0": I0=0/I1=0
tconf_discr Configurable maximum duration of discrepancy monitoring
If the configured duration has elapsed and the expected signals are
not present, a discrepancy error is signalled and the PII is set to "0/0".

Function description
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Behaviour in the event of a discrepancy error
An error message is issued for each input of a terminal pair. Both errors take into account
the last valid state of both inputs before the discrepancy time elapsed.
Reintegration after a discrepancy error
After an error, discrepancy monitoring will either start automatically as soon as there is no
longer a discrepancy or it will start with a restart interlock, depending on the configuration.
}Without restart interlock (no acknowledgement required)
As soon as there is no longer a discrepancy, monitoring begins again
}With restart interlock (acknowledgement required)
Equivalent sensor:
A "0" signal must be present at both inputs in a discrepancy group in order to start a new
monitoring task.
Antivalent sensor:
Within a discrepancy group, a "0" signal must be present at the input with the lower ter-
minal number and a "1" signal must be present at the input with the higher terminal num-
ber.
Example:
Terminal pair 01:
"0" signal at terminal 0 and "1" signal at terminal 1
Terminal pair 23
"0" signal at terminal 2 and "1" signal at terminal 3
Example 1: Sensor type is configured as "non-equivalent".
I0
I1
tconf_discr
PII I0=0/I1=1 PII dependent on configuration Error reaction
1
0
1
0
t
t
Legend
tconf_discr Maximum duration of discrepancy monitoring
The PII during this time depends on the configuration:
}Keep last valid value: I0=0 (I1 is not evaluated)
}Set value to "0": I0=0/I1=0

Function description
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Error messages:
Input I0: Discrepancy error. Signal at input I0 is "1"
Input I1: Discrepancy error. Signal at input I1 is "1"
Example 2: Sensor type is configured as "equivalent".
I0
I1
tconf_discr
PII I0=1/I1=1 PII dependent on configuration Error reaction
1
0
1
0
t
t
Legend
tconf_discr : Maximum duration of discrepancy monitoring
The PII during this time depends on the configuration:
}Keep last valid value: I0=1 (I1 is not evaluated)
}Set value to "0": I0=0/I1=0
Error messages:
Input I0: Discrepancy error. Signal at input I0 is "0"
Input I1: Discrepancy error. Signal at input I1 is "1"
4.4 Test pulse outputs
}Test pulses are used to detect shorts between inputs and to detect short circuits to 24V.
Shorts between inputs and short circuits to 24V are detected when
– the test pulses are different (test pulse 0, test pulse 1) or when
– the test pulses originate from other modules on the PSS u2 system.
}Shorts between inputs of the same module with the same test pulses will not be detected.
}The test pulses are assigned to the following inputs in the default setting:
– T0: I0 and I4
– T1: I1 and I5
– T2: I2 and I6
– T3: I3 and I7
}Inputs may only be wired to test pulses of the same module.

Function description
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}If inputs have the option "No test pulse assigned" selected in PASconfig, they should not
be connected to a test pulse that has already been assigned to another input on the mod-
ule as test pulse. Otherwise, the test pulses can be detected in the process image, de-
pending on the configured input filter time and test pulse duration.
}Example of an unfavourable test pulse assignment in PASconfig:
– the option "Test pulse 0 (T0)" is selected for I0
– the option "No test pulse assigned" is selected for I1
– the option "Test pulse 0 (T0)" is selected for I2
– the option "Test pulse 1 (T1)" is selected for I3
If a test pulse is assigned to an input, a test pulse is generated at the test pulse output.
As I3 is assigned to T1, a test pulse is generated at test pulse T1. If I1 is wired to T1, then
the test pulse T1 can be detected in the process image, depending on the configured in-
put filter time and test pulse duration.
}The periphery supply will constantly be available at the test pulse outputs if they have not
been assigned to an input (24 V option in the PASconfig).
}The test pulses can be switched off if they are not assigned to an input. The test pulse
outputs are then high impedance to the periphery supply (High impedance HiZ option in
the PASconfig).
}The maximum test pulse duration can be configured: 0.3…10.0ms
Default setting: 3 ms.
4.5 Integrated protection mechanisms
Test pulse signals are buffered for a minimum of 20ms. The buffering is designed for the
input currents.
The module provides the following diagnostic data:
}Start-up error
}Configuration error
}FS communication error
}Temperature error: too warm, too hot
}Test pulse error
}Errors that are detected through test pulses
4.6 Reaction times
You can find information about the reaction times in the operating manual for the head
module PSSu2P0 F/S PN.
4.7 Energy-saving functions
The energy levels are supported by the head module and are not configurable. The module
supports the following energy levels:
– Switching off the LEDs that display the module and terminal status
– Switching off the LEDs that display the terminal status

Address assignment
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5 Address assignment
The module occupies 2 Bytes in the process image.
PII Meaning State
Byte 0 Bit 0 Input data I0 0: "0" signal (0 V) at the input or error at the in-
put, when the valid bit of the input is 0
1: "1"-signal (+ 24 V) at the input
Bit 1 Input data I1
Bit 2 Input data I2
Bit 3 Input data I3
Bit 4 Input data I4
Bit 5 Input data I5
Bit 6 Input data I6
Bit 7 Input data I7
Byte 1 Bit 0 Valid bit of input I0 0: Error at the input, the input is forced at zero.
1: No error at the input
Bit 1 Valid bit of input I1
Bit 2 Valid bit of input I2
Bit 3 Valid bit of input I3
Bit 4 Valid bit of input I4
Bit 5 Valid bit of input I5
Bit 6 Valid bit of input I6
Bit 7 Valid bit of input I7