Pilz PSS u2 ES 4DO R 8A User manual

PSS u2 ES 4DO R 8A
Operating Manual-1004548-EN-03
}Control system PSS u2
}Remote I/O system PSS u2

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
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.
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 Use of qualified personnel ........................................................................................................ 8
3.3.2 Warranty and liability ................................................................................................................ 9
3.3.3 Disposal .................................................................................................................................... 9
4 Function description ............................................................................................................. 10
4.1 Block diagram ........................................................................................................................... 10
4.2 Supply....................................................................................................................................... 10
4.3 Integrated protection mechanisms............................................................................................ 10
4.4 Outputs ..................................................................................................................................... 11
4.5 Reaction times .......................................................................................................................... 11
4.6 Energy-saving functions ........................................................................................................... 11
5 Address assignment ............................................................................................................. 12
6 Installation .............................................................................................................................. 13
6.1 General installation guidelines.................................................................................................. 13
6.1.1 Dimensions ............................................................................................................................... 13
6.2 Protective coding on terminal block .......................................................................................... 14
6.3 Inserting and removing an electronic module ........................................................................... 15
6.3.1 Inserting an electronic module.................................................................................................. 15
6.3.2 Removing an electronic module ............................................................................................... 17
6.3.3 Changing an electronic module during operation ..................................................................... 18
7 Wiring ...................................................................................................................................... 19
7.1 General wiring guidelines ......................................................................................................... 19
7.1.1 Connection mechanism for terminal blocks .............................................................................. 19
7.2 Terminal configuration .............................................................................................................. 20
8 Operation ................................................................................................................................ 21
8.1 Display elements and messages .............................................................................................. 21
9 Technical Details ................................................................................................................... 23
9.1 Service life graphs .................................................................................................................... 25
10 Order reference ...................................................................................................................... 26
10.1 Product ..................................................................................................................................... 26

Contents
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10.2 Accessories .............................................................................................................................. 26

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 ES 4DO R 8A hardware version 02 or
higher. It is valid until new documentation 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 module carrier
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 ES 4DO R 8A:
Electronic module with relay outputs for standard applications
The product has the following features:
}4 relay contacts
– N/O contact
– Volt-free
– Current load capacity per output: See chapter Service life graphs [ 25]
}Energy-saving functions
}LEDs for:
– Switch status of each output
– Module error

Safety
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3 Safety
3.1 Intended use
The module provides relay outputs. It may be used to switch:
}Resistive loads
}Inductive loads
The module PSS u2 ES 4DO R 8A may be used in conjunction with the following terminal
block:
}8-pin terminal block
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.
3.2 System requirements
INFORMATION
The module is supported by
}PASconfig from version 2.0.0
– We recommend that you always use the latest version (download
from www.pilz.com).
3.3 Safety regulations
3.3.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
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 the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the specific
application.

Safety
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3.3.2 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.).
3.3.3 Disposal
}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
1
O0.13
K0
5
O0.14
15
O3.44
K3
Module
Supply
Data
(FS)
Periphery
Supply
+24 V DC
Module Bus
13
O3.44
. . .
. . .
Fig.: Block diagram PSS u2 ES 4DO R 8A
4.2 Supply
}The module is supplied with voltage via the head module.
4.3 Integrated protection mechanisms
The module has the following protection mechanisms:
}Protective separation between both relay contacts (see Technical details [ 23])
}Protective separation between both relay contacts and the periphery supply as well as
the module supply, in accordance with DINVDE0110 overvoltage category 2 in a protec-
ted industrial network
}Temperature monitoring
The module provides the following diagnostic data:
}Start-up error
}Configuration error
}ST communication error
}Temperature warning: too warm
}Temperature error: too hot

Function description
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4.4 Outputs
Outputs
}The head module sets the output status via the module bus.
If the module does not receive a process image of outputs from the head module, then sub-
stitute values are used for the process data. The value that is to be used as the substitute
value can be configured.
Substitute values may be:
}Output switched off (default value)
}Output switched on
}Last valid value
4.5 Reaction times
Detailed information on the reaction times is available in the operating manual of the head
modules.
4.6 Energy-saving functions
The energy-saving levels are controlled by the head module and are not configurable. The
module supports the following energy-saving levels:
}Switching off the LEDs
The LEDs have two energy-saving levels:
– Switching off the LEDs that display the terminal status
– Switching off the LEDs that display the module and terminal status
}Switching off the relay coils
}Standby mode
– All module functions are inactive.
– The LEDs for displaying the module and terminal status are switched off.

Address assignment
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5 Address assignment
The module occupies 1 Byte in the process image of outputs.
PIO Meaning State
Bit 0 Output data O0
N/O contact O0.13/O0.14
0: N/O contact is open
1: N/O contact closed
Bit 1 Output data O1
N/O contact O1.23/O1.24
Bit 2 Output data O2
N/O contact O2.33/O2.34
Bit 3 Output data O3
N/O contact O3.43/O3.44
Bit 4-7 None Permanently "0"

Installation
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6 Installation
6.1 General installation guidelines
NOTICE
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
6.1.1 Dimensions
88,37
6
51,1 60
111,1
(95.3)
54.4
50.1
51.7
25
Fig.: Dimensions in mm, including backplane, electronic module and terminal block

Installation
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6.2 Protective coding on terminal block
If voltages over 50 VAC or 120 VDC are connected to a module's switch contacts, then pro-
tective coding must be used. Protective coding prevents the terminal block from being
plugged into another module.
1. Insert the protective
coding into the 8-pin ter-
minal block
2. The protective coding
must be visible on the
terminal side
3. Rotate the protective
coding until is embed-
ded within the terminal
block.

Installation
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4. Plug the coded ter-
minal block into the
module.
6.3 Inserting and removing an electronic module
Please note:
}Backplane must be installed first.
}Electronic modules may only be plugged or unplugged if the terminal block has been re-
moved first.
}The mechanics of the electronic modules are designed for 20 plug in/out cycles.
}On electronic modules with outputs, the terminal block may only be inserted and removed
when the load is switched off. Unforeseeable error reactions may be triggered if modules
are inserted and removed under load.
6.3.1 Inserting an electronic module
1. Insert the electronic
module into the suspen-
sion lug on the back-
plane.

Installation
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2. Swivel the electronic
module downwards until
you hear it click into
place.
3. Insert the terminal
block into the suspen-
sion lug on the module.
4. Swivel the terminal
block upwards until you
hear it click into place.

Installation
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6.3.2 Removing an electronic module
1. Press the unlocking
mechanism on the ter-
minal block that is
shown by the arrow and
pull off the terminal
block forward.
2. Press the unlocking
mechanism that is
shown by the arrow and
pull off the electronic
module upwards.

Installation
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6.3.3 Changing an electronic module during operation
An electronic module can be hot swapped.
Effects:
}Module bus communication between the other modules is not interrupted.
}The configuration data is retained.
}The module is detected automatically as soon as the module is re-inserted.
Procedure:
1. Removing an electronic module
2. Inserting an electronic module
A new electronic module can be inserted during operation.
Procedure:
}Inserting an electronic module
Effects:
}Module bus communication between the other modules is not interrupted.
}To detect the new module the following steps can be necessary:
– Creating a new configuration or changing an existing configuration
– Download of the configuration to the head module
– Restart of the head module. After a restart, the system behaves as after a warm reset
using a reset pushbutton (see operating manual of the head module, chapter “Reset
pusbutton", section "Carrying out a warm reset (restart)").
}On electronic modules with outputs, the terminal block may only be inserted and removed
when the load is switched off. Unforeseeable error reactions may be triggered if modules
are inserted and removed under load.

Wiring
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7 Wiring
7.1 General wiring guidelines
Please note:
}The actuators may be connected using unshielded cables.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details).
}With inductive loads, adequate protection must be provided on all output contacts.
}If voltages higher than 50VAC or 120VDC are connected to the relay contacts, please
note the following:
– Specific accident prevention regulations apply.
– These voltages must only be applied at the upper terminals (Ox3), to guarantee pro-
tection against contact when removing the terminal blocks.
}Use copper wiring.
7.1.1 Connection mechanism for terminal blocks
Procedure:
}Use a flat head screwdriver.
}Strip the wire back 9 mm.
}Feed the stripped cable as far as it will go into the opening for the spring-loaded terminal.
}Check that the cable is firmly seated.
Please note:
}The minimum cable cross section for field connection terminals on the terminal blocks is
0.15mm2 (AWG26).
}The maximum cable cross section for field connection terminals on the terminal blocks is
1.5mm2 with ferrules (AWG14)
}Use copper wiring.

Wiring
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7.2 Terminal configuration
Terminal configuration Connection examples
Output O0
Terminal 1 - 3
Contacts: O0.13 - O0.14
Output O1
Terminal 5 - 7
Contacts: O1.23 – O1.24
Output O2
Terminal 9 - 11
Contacts: O2.33 – O2.34
Output O3
Terminal 13 - 15
Contacts: O3.43 – O3.44
1-channel actuator
1
3
5
7
9
1
3
1
5
11