Pilz PSS u2 ES 4IOL User manual

PSS u2 ES 4IOL
Operating Manual-1004880-EN-01
}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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Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Module features 7
Section 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
Section 4 Function description 10
4.1 Process data 10
4.2 Block diagram 12
4.3 Supply 13
4.4 PROFINET 13
4.5 EtherNet/IP 13
4.6 Reaction time 14
4.7 Configuration options 14
Section 5 Exchanging an IO-Link device 16
Section 6 Exchanging a master 17
Section 7 Installation 18
7.1 General installation guidelines 18
7.1.1 Dimensions 18
7.2 Inserting and removing an electronic module 19
7.2.1 Inserting an electronic module 19
7.2.2 Removing an electronic module 21
7.2.3 Changing an electronic module during operation 21
Section 8 Wiring 22
8.1 General wiring guidelines 22
8.1.1 Connection mechanism for terminal blocks 22
8.2 Terminal configuration 22
8.2.1 Connection examples 23
Section 9 Operation 26
9.1 Display elements and messages 26

Contents
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Section 10 Technical details 29
Section 11 Order reference 31
11.1 Product 31
11.2 Accessories 31

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 4IOL. It is valid until new document-
ation 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
The product has the following features:
}IO-Link master in accordance with IO-Link specification v1.1
}4 IO-Link ports for connecting 4 IO-Link devices or 4 sensors / 4 actuators respectively
}Voltage outputs L+/L- for sensor and actuator supply
}Supported transmission rates:
– COM1 (4.8 kBd)
– COM2 (38.4 kBd)
– COM3 (230.4 kBd)
}Up to 32 bytes of process data per port
}Up to 128 bytes of process data, including header, per module
}Device configuration saved in the master
}Energy-saving functions
}LEDs for:
– IO-Link mode
– Module error
– Operating status

Safety
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3 Safety
3.1 Intended use
The module (IO-Link master) provides standard IO-Link ports and may be used to connect
IO-Link devices or sensors/actuators for standard applications.
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 ES 4IOL 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 3.0.0
– 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 competent persons.
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 preven-
tion,
}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 spe-
cific 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 Process data
}The size of the IO-Link master's process image is variable. It depends on the size of the
process image of the devices that are used.
}The IO-Link master's process image of inputs (PII) consists of the PII of the devices and
a 3 Byte header.
}The IO-Link master's process image of outputs (PIO) consists of the PIO of the devices
and a 3 Byte header.
}The header always precedes the devices' process data.
}The maximum size of the process image of inputs (PII), including the header, is 128
Bytes per module and 32 Bytes per port.
}The maximum size of the process image of outputs (PIO), including the header, is 128
Bytes per module and 32 Bytes per port.
Example of the module's process image
The example below shows the structure of the process image for the IO-Link master mod-
ule. A process image size of 8 Bytes was used for the example. The example uses two IO-
Link sensors, each with a process image size of 2 Bytes and an IO-Link actuator with a pro-
cess image size of 1 Byte. Unused bytes are filled with zeros.
Port 2
Byte 6
Byte 4 Byte 5
EmptyHeader
Byte 3
EmptyEmptyEmpty
Byte 0...2
Port 0
Byte 6
Byte 4 Byte 5
EmptyHeader
Byte 3
Byte 0...2
PII
PIO
Port 0 Port 1 Port 1
Byte 7
Byte 7
Fig.: Example of the module's process image
Legend
PII Process image of inputs
Header For details of structure see sections entitled "Header in the process image
of inputs" and "Header in the process image of outputs".
Port 0 IO-Link device with 2 Bytes of input data
Port 1 IO-Link device with 2 Bytes of input data
PIO Process image of outputs
Port 2 IO-Link device with 1 Byte of output data
Empty Unused bytes, which are filled with zeros

Function description
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Header in the process image of inputs
}The header in the PII contains:
– Status of the process image
– Process data from the "CQ" terminal, which is configured as a digital input in DI
mode.
Port 1Port 0 Port 2 Port 3Header
Not used
Byte 2
CQ input
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Byte 1
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Byte 0
Diagnostics
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Fig.: Header in the process image of inputs
Legend
Diagnostics "0": The port's process data is invalid.
"1": There is an IO-Link connection to the device.
CQ input "0": There is a "0" signal at the configurable CQ input (terminal 2,6,10,14).
"1": There is a "1" signal at the configurable CQ input (terminal 2,6,10,14).

Function description
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Header in the process image of outputs
}The header in the PIO contains process data from the "CQ" terminal, which is con-
figured as a digital output in DO mode.
Port 1Port 0 Port 2 Port 3Header
Not used
Byte 2
CQ output
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Byte 1
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Byte 0
Not used
Port 0 Port 1 Port 2 Port 3
Bit 0 Bit 1 Bit 2 Bit 3 Bit 7
. . .
Fig.: Header in the process image of outputs
Legend
CQ output "0": A "0" signal is output at the configurable CQ output (terminal
2,6,10,14).
"1": A "1" signal is output at the configurable CQ output (terminal
2,6,10,14).
4.2 Block diagram
L+0
1
n.c.
3
CQ0
2
L-
4
L+3
13
n.c.
15
CQ3
14
L-
16
IO-Link Port 0 IO-Link Port 3
Module
Supply
Data
(ST)
Periphery
Supply
+24 V DC
Fig.: Block diagram PSS u2 ES 4IOL

Function description
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4.3 Supply
}The module is supplied with voltage via the head module.
}The periphery supply provides the voltage for the actuator/sensor supply at the termin-
als L+/L-.
}The actuator/sensor supply L+/L- provides voltage to the IO-Link devices, sensors and
actuators.
}The actuator/sensor supply L+/L- is protected against short circuit.
4.4 PROFINET
In order to configure the module in a PROFINET-enabled controller you will need to down-
load and install the GSDML file from the PILZ website. The GSDM file contains IO-Link
modules with the following process data lengths for the input and output data:
Input data Output data Input and output data
8 Byte 8 Byte 8 Byte
16 Byte 16 Byte 16 Byte
32 Byte 32 Byte 32 Byte
64 Byte 64 Byte 64 Byte
128 Byte 128 Byte 128 Byte
INFORMATION
The process data stated in the GSDML applies to the whole IO-Link module
and not for a port.
The module has a variable process image (see also Process data [ 10]). Note that the
process data length from the GSDML in the PROFINET-enabled controller must match the
process data length configured in PASconfig. If the process data lengths do not match, an
error message will be issued in the PROFINET-enabled controller.
INFORMATION
If the configured process data length is too short, data may be lost.
4.5 EtherNet/IP
The *.l5x file can be exported from PASconfig for configuration of the IO-Link master with
the Ethernet/IP head module.

Function description
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4.6 Reaction time
The reaction time for IO-Link is composed of the following times:
}Min. cycle time of the IO-Link master (see Technical details [ 29]). This time corres-
ponds to the internal processing time of the IO-Link master.
}Min. cycle time for the connection between the IO-Link master and the IO-Link device.
This time corresponds to the time defined in the IODD. The IO-Link master must not ad-
dress the IO-Link device during this time.
}Min. cycle time of a device. Internal processing time of the IO-Link device (see operat-
ing manual for the IO-Link device)
}Cycle time of the head module and module bus: 2 x ST cycle time = 2 ms
4.7 Configuration options
Operating modes
The following operating modes can be set for each port:
}Port deactivated
A device connected to the port will not be detected. Terminal L+ is switched off.
}DI mode
The port is used as a digital ST input. The CQ terminal can be configured as an ST in-
put for each port. The input current can also be configured for the ST inputs in DI mode.
}DO mode
The port is used as a digital ST output. The CQ terminal can be configured as an ST
output for each port.
}Fixedmode
The port is used in I/O-Link mode. When searching for connected devices, the master
checks whether the configured manufacturer ID and device ID match the actual manu-
facturer ID and device ID on the connected device.
}Scanmode
The port is used in I/O-Link mode. When searching for connected devices, the master
does not check whether the connected device matches the configured device.
Save the device configuration
The configured properties of a device can be saved in the master. The master can then
write these to the new device when a device is exchanged.
}Deactivate/delete
In this mode, all data in the data memory is deleted and the data memory is deactiv-
ated.
}Upload
In this mode, the configuration is loaded from the device into the master. This setting
can be used when devices already contain configured data and this data is to be ap-
plied to the master.

Function description
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}Download
In this mode, the configuration saved in the master is written to the device. This setting
can be used when a device needs to be exchanged.

Exchanging an IO-Link device
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5 Exchanging an IO-Link device
A device's configuration can be saved in the master (see section entitled "Saving the device
configuration" under Configuration options [ 14]). It can then be written to the new
device when a device is exchanged during servicing.
Prerequisites
}The device's configuration has already been saved in the IO-Link master ("Upload" set-
ting).
}The master port containing the device to be exchanged has been configured as follows:
– "Operating mode" -> "Fixedmode"
– "Save the device configuration" -> "Download"
The master configuration is described in the online help.
Procedure
1. Remove the device you wish to exchange
2. Connect the new device to the master module. The configuration saved in the master
module is written to the device.
INFORMATION
Should the device already contain a configuration, this will be overwritten
during any download.

Exchanging a master
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6 Exchanging a master
The configuration of the ports is saved in the PSSu2 head module. The configuration of the
devices can be saved in the master module. The procedure varies, depending on the value
that has been set under "Saving the device configuration" prior to the exchange.
Procedure if "Upload" or "Deactivate/Delete" has been set at all ports under "Save
the device configuration":
1. Remove the terminal block from the master module.
2. Disconnect the master module from the backplane.
3. Insert a new master module on to the backplane.
Procedure if "Download" has been set at one or more ports under "Save the device
configuration":
1. Remove the terminal block from the master module.
2. Disconnect the master module from the backplane.
3. Insert a new master module on to the backplane.
4. In the IO-Link Configurator, select "Upload" under "Saving the device configuration".
5. Download the ST configuration to PASconfig so that the amended value is adopted.
The PSS u2 system will be restarted.
6. Connect the terminal block to the new master module and wait until all devices are
ready for operation.
7. In the IO-Link Configurator, select "Download" under "Save the device configuration".
8. Download the ST configuration to PASconfig so that the amended value is adopted.
The PSS u2 system will be restarted.

Installation
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7 Installation
7.1 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.
7.1.1 Dimensions
The dimensions include the backplane, electronic module and terminal block.
12,5
50,1
54.4
88,37
6
51,1 60
111,1
(95.3)
51,7
Fig.: Dimensions in mm, including backplane, electronic module and terminal block

Installation
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7.2 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
removed 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 re-
moved when the load is switched off. Unforeseeable error reactions may be triggered if
modules are inserted and removed under load.
7.2.1 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.