Pilz PSS67 IO1 16FDI User manual

PSS67 IO1 16FDI
Operating Manual-1004417-EN-03
}Decentralised periphery

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
1.1.1 Retaining the documentation 5
1.2 Definition of symbols 5
Section 2 Overview 7
2.1 Unit features 7
2.2 Front view 8
2.3 Scope of supply 9
Section 3 Safety 10
3.1 Intended use 10
3.2 Safety regulations 10
3.2.1 Use of qualified personnel 10
3.2.2 Warranty and liability 10
3.2.3 Disposal 11
Section 4 Function description 12
4.1 Supply voltages 12
4.2 Head module 13
4.2.1 Connection to SafetyNET p 13
4.2.2 Integrated protection mechanisms 13
4.2.3 microSD card 14
4.2.4 Reset button 14
4.3 Input modules 14
4.3.1 Integrated protection mechanisms 15
4.3.2 PSSu assignment in system environment B 15
4.3.3 Reaction times 16
4.4 Derating diagram 16
Section 5 Installation 17
5.1 General installation guidelines 17
5.1.1 Dimensions 18
Section 6 Wiring 19
6.1 General wiring guidelines 19
6.2 Connector pin assignment 20
6.3 Connecting the supply voltage 21
6.4 Wiring examples 22
6.4.1 Dual-channel homogeneous safety switch with separate test pulse 22
6.4.2 Dual-channel homogeneous safety switch with common test pulse 23
6.4.3 Electronic safety switch with OSSD outputs 24
Section 7 Operation 25
7.1 Messages 25
7.2 Display elements 25
7.2.1 I0 ... I3 (X01 ... X08) 25

Contents
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7.2.2 DIAG 26
7.2.3 FS SNp 27
7.2.4 SD CARD 28
7.2.5 LNK, TRF (X21, X22) 29
7.2.6 5V, 24V (X31, X32) 29
Section 8 Technical details 30
8.1 Safety characteristic data 33
Section 9 Order reference 34
9.1 Product 34
9.2 Accessories 34

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSS67 IO1 16FDI. It is valid until new docu-
mentation is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
1.1.1 Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.
1.2 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
2.1 Unit features
Application of the product PSS67 IO1 16FDI:
PSS67 device of the performance class "PSS 4000 I/O" for use in a rugged industrial envir-
onment up to protection type IP67, for connection to a control system with SafetyNETp.
The product has the following features:
}2 free switch ports for connection to SafetyNETp
}16 digital inputs distributed over 4 slots
}16 test pulse outputs distributed over 4 slots. Test pulse outputs with the same name
are connected on a slot. The test pulse outputs can be configured as:
– Independent test pulse outputs that use different test pulses (device supply)
– Outputs with constant voltage (device supply)
}SD card used to store the device project and the naming data
}Reset pushbutton
– For warm reset
– To transfer the naming data and/or device project from the SD card to the device
memory
}Supply voltage
– Device supply is buffered for 20ms if the supply voltage is interrupted
}LEDs for:
– Switch status of each input
– Status display of the device

Overview
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2.2 Front view
Germany
1
2
3
4
5
6
7
8
9
10
11
12
Fig.: Front view
Legend
1 Input module on slot 0 with plug-in connectors X01 and X02
2 Input module on slot 1 with plug-in connectors X03 and X04
3 Input module on slot 2 with plug-in connectors X05 and X06
4 Input module on slot 3 with plug-in connectors X07 and X08
5 Diag LED
6 End cap for the microSD card and reset button
7 Status LEDs
8 Field for 2D code, field for firmware and hardware version, field for MAC ad-
dress

Overview
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9 SafetyNETp interface with plug-in connectors X21 and X22
10 Interface to power supply for the supply voltage for device supply and load
supply
11 Functional earth X0
12 Type designation/abbreviation for the performance class PSS 4000 I/O
2.3 Scope of supply
}PSS67 device PSS67 IO1 16FDI with:
– End cap for the microSD card and reset button
– 13 label strips
– 2 x M4 locking washers for the functional earth
– 1 x M4 screw for the functional earth
– 1 x microSD card
– 2 x set with 4 protective caps

Safety
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3 Safety
3.1 Intended use
The PSS67 device PSS67 IO1 16FDI is suitable for use in a rugged industrial environment
up to protection type IP67. It may not be used in a potentially explosive area.
The PSS67 device PSS67 IO1 16FDI is suitable for use in safety-related applications with
SafetyNETp.
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 within a do-
mestic environment.
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 Safety regulations
3.2.1 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.
3.2.2 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 or
}Operating personnel are not suitably trained.

Safety
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3.2.3 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated 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
The PSS67 device PSS67 IO1 16FDI consists of a head module of the performance class
PSS4000 I/O with a SafetyNETp interface and four input modules. The head module and
input modules are connected via an internal module bus. The inputs of each module are im-
plemented on two plug-in connectors. Plug-in connectors X01 and X02 are used for the
module on slot 0.
Head module
(with supply voltage)
Input modules
0
1
2
3Slots
Fig.: Module structure
4.1 Supply voltages
}Device supply
Supply voltage for the device, sensors and test pulses. The device supply is fed in at
the plug-in connector X31 and is forwarded to the plug-in connector X32. By forwarding
in this way, additional devices can be supplied. The module supply for supplying the
device and the periphery supply for supplying the sensors and test pulses is generated
internally from the device supply.
}Load supply
Supply voltage for the actuators. The supply voltage for load supply is not required for
the operation of this device. The load supply is fed in at the plug-in connector X31 and
is forwarded to the plug-in connector X32.
Device supply and load supply are galvanically isolated within the device.

Function description
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Periphery supply
Device supply (X31) Load supply (X31)
24 V
5 V
Logic Test
pulse
Module supply
24 VDC 0 VDC 24 VDC 0 VDC
Device supply (X32) Load supply (X32)
Fig.: Representation of the internal voltages
4.2 Head module
4.2.1 Connection to SafetyNET p
Functions
}The SafetyNETp interface enables the device to be controlled by means of a higher
level control system (e.g. PSSu PLC).
}The head module in the PSS67 device receives signals from a higher level control sys-
tem and forwards them to the input modules on the PSS67 device.
}The head module in the PSS67 device receives signals from the input modules via the
internal module bus and forwards them to a higher level control system.
MAC address
}The PSS67 device has a MAC address:
– MAC address of PSS67 device. You'll find the address on the front of the PSS67
device.
INFORMATION
Further information on SafetyNETp can be found in the "PSS4000 System
Description".
4.2.2 Integrated protection mechanisms
The PSS67 device has the following protection mechanisms:
}Multi-channel diverse processor section
}Cyclical self tests
}Potentially isolated SafetyNETp interface
}Temperature monitoring

Function description
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}Infeed for device supply
– Polarity protection
– Voltage monitoring
– Transient voltage limitation
– 20 ms voltage buffer if the supply voltage is interrupted
4.2.3 microSD card
The SD card has the following functions:
}The microSD card is used to store the naming data and the device project; see
PSS4000 System Description.
}The microSD card is part of the safety concept on PSS4000. If the microSD card is
missing or has been swapped, the next time the PSS67 device is booted it will be un-
able to achieve the operating status "PSSu System/PSS67 device in RUN condition
without error".
4.2.4 Reset button
The "Reset" button has various functions:
}Perform warm reset.
The reset button can be used to perform a warm reset.
}Transfer the naming data and/or device project from the SD card (deliberate operator
action to transfer the naming data and/or device project from the SD card to the device
memory).
INFORMATION
The warm reset and the transfer of the naming data and/or device project
are described in the "PSS4000 System Description".
4.3 Input modules
Inputs
}The input status is signalled to the head module via the module bus.
}Test pulses can be used to check the inputs for shorts across contacts and correct
functionality.
}The inputs have input filters.
Test pulse outputs
}4 test pulse outputs per slot (2 x test pulse0 and 2 x test pulse1). Test pulse outputs
with the same name are connected on a slot.
}Test pulse outputs T0 and T1 are independent and use different test pulses.
}The test pulse outputs are short circuit-proof.
}Test pule outputs have a current limit.
}Test pulses can be switched on or off.

Function description
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}Test pulses are switched on in the default setting.
}When test pulses are switched off, the device supply (24 V) is constantly available at
the test pulse outputs.
Detection of shorts across contacts
}The test pulses are used to detect shorts between inputs. Shorts between inputs are
detected when the test pulses are different (test pulse0, test pulse 1)
}Shorts between inputs of the same module with the same test pulses will not be detec-
ted.
4.3.1 Integrated protection mechanisms
}Test pulse signals are always buffered for 20ms.
The module provides the following diagnostic data:
}Start-up error
}Configuration error
}FS communication error
}Bus termination error
}Temperature error: Too warm
}Test pulse error
}Input error
4.3.2 PSSu assignment in system environment B
Data access is via pre-defined I/O data types:
I/O data name
Input (Slot:Pin)I/O data type I/O data element Meaning
I0(X01:4)
I1(X01:2)
I2(X02:4)
I3(X02:2)
FS_I_DI Data: SAFEBOOL Input data I0 ... I3 for the module
on slot 0 with plug-in connectors
X01 and X02
I0(X03:4)
I1(X03:2)
I2(X04:4)
I3(X04:2)
FS_I_DI Data: SAFEBOOL Input data I0 ... I3 for the module
on slot 1 with plug-in connectors
X03 and X04
I0(X05:4)
I1(X05:2)
I2(X06:4)
I3(X06:2)
FS_I_DI Data: SAFEBOOL Input data I0 ... I3 for the module
on slot 2 with plug-in connectors
X05 and X06

Function description
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I/O data name
Input (Slot:Pin)I/O data type I/O data element Meaning
I0(X07:4)
I1(X07:2)
I2(X08:4)
I3(X08:2)
FS_I_DI Data: SAFEBOOL Input data I0 ... I3 for the module
on slot 3 with plug-in connectors
X07 and X08
4.3.3 Reaction times
Information on the reaction times of the inputs can be found in the "PSSuniversal" System
Description and the System Description "Automation system PSS 4000".
4.4 Derating diagram
The relationship between the load current at the load supply and the operating temperature
is illustrated in the following derating diagram. The device supply is limited to a maximum of
8 A.
20
40
60
80
100
0
1 2 3 4 5 6 7 8 9 10 I [A]
T [°C]
11 12 13 14 15 16
55
Fig.: Derating diagram for the load supply

Installation
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5 Installation
5.1 General installation guidelines
To meet the requirements of the protection type IP67, ensure that:
}The cover of the SD card is firmly closed
}The plug-in connectors are fastened tightly
}The protective caps on unused plug-in connectors are fastened tightly
Protect the PSS67 device from:
}Weather conditions (particularly sunlight)
}Chemicals
}Contamination
}Intentional damage
The product must be fastened to a flat mounting surface, so that there is no strain on the
housing when the module is screwed down. The mounting distances will depend on which
plug-in connectors are used and on the bending radius of the cables.
To install the system, proceed as follows:
}Fit 2 x M4 internal threads on the mounting surface.
}Use fixing screws with washers. In environments with vibration we recommend that you
use locking washers.
}When using internal hexagonal fixing screws with a strength class of 8.8, tighten the
mounting screws with a torque of 2.6 Nm to 3.3 Nm.
}Use two fixing screws to attach the product to the mounting plate.
}Attach the functional earth.
The functional earth can be connected to pin 5 of the X31 connector or to the lower fix-
ing screw (X0).
We recommend that you connect the functional earth to the lower fixing screw (X0).
Minimum conductor cross section of the earth cable on the fixing screw (X0) is 2.5mm².
For the fixing screw you can use the supplied ratchet screw for the functional earth con-
nection.
Tighten the fixing screw with a torque of 1.2 Nm.

Installation
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5.1.1 Dimensions
260
61.5
250.5
46
36
11
46
52
36
Fig.: Dimensions in mm

Wiring
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6 Wiring
6.1 General wiring guidelines
Please note:
}Information given in the "Technical details" must be followed.
}Where safety-related applications are concerned, it is essential that short circuits and
open circuits are unable to cause a hazardous condition within a plant. The way in
which this is done will depend on the degree of hazard from the plant section, the
switching frequency of the sensors and the level of safety of the sensors and actuators.
}For details of the cable length for the test pulses see Technical details [ 30].
}Pilz pre-assembled cable can be used to connect the inputs (see order reference).
}We recommend you use pre-assembled Pilz connectors to connect the inputs and test
pulse outputs (see order reference).
CAUTION!
The supply voltages for an external device must be extra low voltages with
safe electrical separation (PELV or SELV) in accordance with VDE0100,
Part 410. Protective separation must be ensured for the external power sup-
plies that generate the supply voltages. Failure to do so could result in elec-
tric shock. The external power supplies must comply with the current applic-
able standard EN 60950-1, EN 61140, EN 50178 or EN 61558-1.
CAUTION!
In order to guarantee protection type IP67, unused plug-in connectors
should be sealed using the protective caps supplied.
CAUTION!
Make sure that the plug-in connectors are connected to the sensors cor-
rectly. Once you have run a function test to check that the plug-in connect-
ors are connected to the sensors correctly, the inputs should be labelled. If
the inputs are connected to the sensors incorrectly, life-threatening situ-
ations may arise on the plant.

Wiring
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6.2 Connector pin assignment
Inputs
X01 to X08 Assignment
5-pin M12 female con-
nector
A-coded
1: Test pulse x / 24 VDC
2: Input X+1
3: GND
4: Input X
5: Test pulse x+1 / 24 VDC
23
4
1
5
SafetyNETp interface
X21 and X22 Assignment
4-pin M12 female con-
nector
D-coded
1: TD+
2: RD+
3: TD-
4: RD-
5: Connection to functional earth on the
connector housing
5
Interface to the 24 V
power supply or to
previous decentralised
module: X31 Assignment
5 pin M12 male con-
nector
L-coded
1: + 24 VDC supply voltage for device
supply
2: 0 V supply voltage for load supply
3: 0 V supply voltage for device supply
4: + 24 VDC supply voltage for load sup-
ply
5: Connection to functional earth
1
2
3
4
5
Interface to the next
decentralised module:
X32 Assignment
5-pin M12 female con-
nector
L-coded
1: + 24 VDC supply voltage for device
supply
2: 0 V supply voltage for load supply
3: 0 V supply voltage for device supply
4: + 24 VDC supply voltage for load sup-
ply
5: Connection to functional earth.
1
2
3
4
5