Pilz PSS67 PLC1 16FDI User manual

PSS67 PLC1 16FDI
Operating Manual-1004541-EN-03
}Control system PSSuniversal PLC

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
1.4 Third-party manufacturer licence information ........................................................................... 6
2 Overview .................................................................................................................................7
2.1 Unit features ............................................................................................................................. 7
2.2 Front view ................................................................................................................................. 8
2.3 Scope of supply ........................................................................................................................ 9
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 .................................................................................................................................... 10
4 Function description ............................................................................................................. 11
4.1 Supply voltages ........................................................................................................................ 11
4.2 Head module ............................................................................................................................ 12
4.2.1 Connection to SafetyNET p ...................................................................................................... 12
4.2.2 External communication ........................................................................................................... 13
4.2.3 Integrated protection mechanisms............................................................................................ 13
4.2.4 microSD card ............................................................................................................................ 13
4.2.5 Reset button ............................................................................................................................. 14
4.3 Input modules ........................................................................................................................... 15
4.3.1 Integrated protection mechanisms............................................................................................ 15
4.3.2 PSSu assignment in system environment B............................................................................. 16
4.3.3 Reaction times .......................................................................................................................... 16
4.4 Derating diagram ...................................................................................................................... 17
5 Installation ..............................................................................................................................18
5.1 General installation guidelines.................................................................................................. 18
5.1.1 Dimensions ............................................................................................................................... 19
6 Wiring ......................................................................................................................................20
6.1 General wiring guidelines ......................................................................................................... 20
6.2 Connector pin assignment ........................................................................................................ 21
6.3 Connecting the supply voltage.................................................................................................. 22
6.4 Wiring examples ....................................................................................................................... 24
6.4.1 Dual-channel homogeneous safety switch with separate test pulse ........................................ 24
6.4.2 Dual-channel homogeneous safety switch with common test pulse......................................... 25
6.4.3 Electronic safety switch with OSSD outputs ............................................................................. 26
7 Operation ................................................................................................................................27
7.1 Messages ................................................................................................................................. 27
7.2 Display elements ...................................................................................................................... 27

Contents
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7.2.1 I0 ... I3 (X01 ... X08).................................................................................................................. 27
7.2.2 FS RUN .................................................................................................................................... 28
7.2.3 ST RUN .................................................................................................................................... 29
7.2.4 DIAG ......................................................................................................................................... 30
7.2.5 FS FORCE................................................................................................................................ 31
7.2.6 ST FORCE................................................................................................................................ 32
7.2.7 FS SNp ..................................................................................................................................... 33
7.2.8 ST SNp ..................................................................................................................................... 34
7.2.9 SD CARD.................................................................................................................................. 35
7.2.10 LNK, TRF (X21, X22)................................................................................................................ 36
7.2.11 MS ............................................................................................................................................ 36
7.2.12 NS/BF ....................................................................................................................................... 37
7.2.13 5V, 24V (X31, X32)................................................................................................................... 38
8 Technical details ....................................................................................................................39
8.1 Safety characteristic data ......................................................................................................... 43
9 Order reference ......................................................................................................................44
9.1 Product ..................................................................................................................................... 44
9.2 Accessories .............................................................................................................................. 44
10 EC declaration of conformity ................................................................................................ 46
11 UKCA-Declaration of Conformity ......................................................................................... 47

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSS67 PLC1 16FDI from Version 02.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
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.
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.
1.4 Third-party manufacturer licence information
This product includes Open Source software with various licences.
Further information is available in the document „Third-party manufacturer licence informa-
tion PSS 4000-exclusive devices“ (document number 1003883) at www.pilz.com.
The relevant source codes can be requested via [email protected].
Your request should include the following: (a) the firmware name, (b) the firmware version,
(c) your name, (d) your company name (if applicable), (e) your reply address and (f) your E-
mail address (if possible).
Pilz can charge a fee for the data medium and for sending.
The request for the source code must be received 3 years at the latest after the receipt of
the relevant GPL or LPGL. Irrespective of this period we will send you a complete, ma-
chine-readable copy of the source code as long as Pilz offers spares or technical support
for this device.

Overview
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2 Overview
2.1 Unit features
Application of the product PSS67 PLC1 16FDI:
PSS67 device of the performance class "PSS 4000 PLC" for use in a rugged industrial en-
vironment up to protection type IP67, for connection to a control system with SafetyNETp
or for non-safety-related applications for external communication.
The product has the following features:
}2 free switch ports for connection to SafetyNETp
}External connections:
– Modbus/TCP
– Raw UDP
– Raw TCP
– EtherNet/IP
– PROFINET
}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)
}One FS resource and one ST resource
}SD card used to store the device project and the naming data
}Reset button
– 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
1
2
3
4
5
6
7
8
9
10
11
14
15 16 17
12 13
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 Status LEDs
6 End cap for the microSD card and reset button
7 Status LEDs
8 SafetyNETp interface with plug-in connectors X21 and X22

Overview
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9 Interface to power supply for the supply voltage for device supply and load
supply
10 Functional earth X0
11 Type designation/abbreviation for the performance class PSS 4000 PLC
12 Serial number
13 MAC address
14 2D code 6x6 mm
15 Hardware version
16 Year of manufacture
17 2D code 11x2.5 mm
2.3 Scope of supply
}PSS67 device PSS67 PLC1 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 PLC1 16FDI is suitable for use in a rugged industrial environ-
ment up to protection type IP67. It may not be used in a potentially explosive area.
The PSS67 device PSS67 PLC1 16FDI is suitable for use in safety-related applications with
SafetyNETp and in non-safety-related applications for external communication.
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 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.
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.
3.2.3 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
The PSS67 device PSS67 PLC1 16FDI consists of a head module of the performance
class PSS4000 PLC with a SafetyNETp interface and four input modules. The head mod-
ule and input modules are connected via an internal module bus. The inputs of each mod-
ule are implemented 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 for-
warded 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 safety-related and non-safety-related data transfer
between the PSSu system and other network subscribers.
}The head module receives signals from other network subscribers; it processes these sig-
nals in the user program and passes them on to the connected input/output modules.
}The head module receives signals from the connected input/output modules; it processes
these signals in the user program and passes them on to the other network subscribers.
}If a fault occurs, the module switches the connected failsafe outputs to a safe condition.
MAC address
}The MAC address is a factory-set default. It can found on the labelling strip on the front of
the module.
INFORMATION
Further information on SafetyNETp can be found in the "PSS4000 System
Description".

Function description
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4.2.2 External communication
For non-safety-related applications the following IP connections are supported:
}Modbus/TCP
}Raw UDP
}Raw TCP
For non-safety-related applications the following fieldbuses are supported:
}PROFINET
}EtherNet/IP
Detailed information is available in the "System description PSS 4000".
4.2.3 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
}Infeed for device supply
– Polarity protection
– Voltage monitoring
– Transient voltage limitation
– 20 ms voltage buffer if the supply voltage is interrupted
4.2.4 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 miss-
ing or has been swapped, the next time the PSS67 device is booted it will be unable to
achieve the operating status "PSSu System/PSS67 device in RUN condition without er-
ror".
NOTICE
Damage to files on the SD card
Files may be damaged if the card is removed from the device or the power
to the device is switched off as the SD card is being written.
Remove the SD card only in recovery mode or in switched-off state.

Function description
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4.2.5 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 ac-
tion to transfer the naming data and/or device project from the SD card to the device
memory).
}Perform recovery mode.
INFORMATION
The warm reset and the recovery mode and transfer of the naming data
and/or device project are described in the "PSS4000 System Description".
This is also where the general effects on the device are described in detail.

Function description
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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 func-
tionality.
}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.
}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 de-
tected 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 detected.
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

Function description
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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
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".

Function description
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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
80
100
0
60
1 2 3 4 5 6 7 8 9 10 I[A]
T [°C]
11 12 13 14 15 16
70
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 fixing
screw (X0).
We recommend that you connect the functional earth to the lower fixing screw (X0). Min-
imum 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 fre-
quency 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 [ 39].
}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 of an external device must be protective extra low
voltages with safe electrical separation (PELV or SELV). Protective separa-
tion must be ensured for the external power supplies that generate the sup-
ply voltages. Failure to do so could result in electric shock. The external
power supplies must comply with the current applicable 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.
Guidelines for UL certification
}Only use cables rated with a minimum temperature of 90°C.