Pilz PDP67 F 8DI ION User manual

PDP67 F 8DI ION
Operating Manual-1001643-EN-10
}Decentralised periphery

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
1.1.1 Retaining the documentation ....................................................................................................5
1.2 Definition of symbols .................................................................................................................5
2 Overview .................................................................................................................................7
2.1 Unit structure.............................................................................................................................7
2.1.1 Unit features..............................................................................................................................7
2.2 Front view..................................................................................................................................8
2.3 Scope of supply.........................................................................................................................8
3 Safety ......................................................................................................................................9
3.1 Intended use .............................................................................................................................9
3.2 Safety regulations .....................................................................................................................9
3.2.1 Use of qualified personnel.........................................................................................................9
3.2.2 Warranty and liability.................................................................................................................10
3.2.3 Disposal ....................................................................................................................................10
4 Function description ..............................................................................................................11
4.1 Operation ..................................................................................................................................11
4.1.1 Inputs ........................................................................................................................................11
4.1.2 Outputs......................................................................................................................................11
4.2 Data download ..........................................................................................................................11
4.3 Diagnostics................................................................................................................................11
5 Installation ..............................................................................................................................12
5.1 General installation guidelines ..................................................................................................12
5.2 Dimensions ...............................................................................................................................12
6 Wiring ......................................................................................................................................13
6.1 General wiring guidelines..........................................................................................................13
6.2 Connector pin assignment ........................................................................................................14
6.3 Wiring examples........................................................................................................................15
6.3.1 Example: Single-channel, failsafe input device, without test pulse...........................................15
6.3.2 Example: Dual-channel input devices, without test pulses .......................................................16
6.3.3 Example: Single-channel, failsafe input device, with test pulse................................................17
6.3.4 Example: Dual-channel, failsafe input device, with test pulse...................................................19
7 Operation ................................................................................................................................20
7.1 Messages..................................................................................................................................20
8 Technical details ....................................................................................................................21
8.1 Safety characteristic data..........................................................................................................23
9 Order reference ......................................................................................................................25
9.1 Order reference for module.......................................................................................................25
9.2 Order reference for accessories................................................................................................25
9.2.1 Plug ...........................................................................................................................................25

Contents
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9.2.2 Cable (by the metre) .................................................................................................................25
9.2.3 Cable, M12 to M8......................................................................................................................25
9.2.4 Cable, M12 to M12....................................................................................................................26
9.2.5 Adapter......................................................................................................................................27
10 EC declaration of conformity ................................................................................................28
11 UKCA-Declaration of Conformity .........................................................................................29

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the products PDP67 F 8DI ION, PDP67 F 8DI IONVA. It is
valid until new documentation 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 structure
2.1.1 Unit features
Application of the products PDP67 F 8DI ION, PDP67 F 8DI IONVA:
Decentralised input module for connection to a Pilz control system, for use in a rugged in-
dustrial environment up to protection type IP67.
The product has the following features:
}Protection type IP67
}8 inputs for connecting 8 single-channel or 4 dual-channel sensors
}8 outputs, which can be configured as
– Standard outputs
– Test pulse outputs
– 24 V outputs
}LED for:
– Operating status
– Connection status
– Fault
– Input status at each input

Overview
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2.2 Front view
Legend:
}X1 ... X4:
Inputs and outputs
}X5:
Interface to the control system or to X6 on the upstream module
}X6:
Interface to X5 on the downstream module
}LEDs:
– Device
– Fault
– Traffic
– IO0 ... IO7
2.3 Scope of supply
}Decentralised input module PDP67 F 8DI ION/PDP67 F 8DI IONVA
}4 blind plugs

Safety
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3 Safety
3.1 Intended use
The products PDP67 F 8DI ION, PDP67 F 8DI IONVA are decentralised input modules de-
signed for use in a rugged industrial environment up to protection type IP67.
The module can be connected to a link module PNOZ ml2p or PNOZ mml2p from the con-
figurable control system PNOZmulti.
Improper use
The following is deemed improper use in particular
}Any component, technical or electrical modification to the product,
}Use of the product outside the areas described in this operating manual,
}Use of the product outside the technical details (see Technical details).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
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.

Safety
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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
4.1 Operation
The functions of the inputs and outputs are configured in the system software.
4.1.1 Inputs
Single and dual-channel sensors can be connected to the inputs, with or without test
pulses.
Input signals must show a “High” (“1” signal) of 15 VDC (+15 ... +30 VDC) and a “Low” (“0”
signal) of 0 VDC (-3 ... +5 VDC).
The input status is signalled to the control system via the bus.
Green LEDs indicate the status of the inputs.
Test pulses can be used to check the inputs for shorts across contacts and correct function-
ality.
4.1.2 Outputs
The outputs can be used as standard outputs, as test pulse outputs or as 24 VDC outputs.
The test pulse outputs are suitable for testing the sensor wiring. All safety-related inputs
must operate in accordance with the failsafe principle (on switching off).
Two test pulses are available on each plug-in connector; these test pulses are permanently
assigned to the inputs. The assignment of the test pulses to the inputs cannot be changed
in the system software's configurator.
If the test pulse outputs are not being used, they can be configured as standard outputs or
24 VDC outputs in the system software's configurator.
4.2 Data download
Communication with the control system is via a safe data link. Data is exchanged cyclically.
4.3 Diagnostics
The status and error messages shown by the LEDs are saved in an error stack. The sys-
tem software can read this error stack.

Installation
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5 Installation
5.1 General installation guidelines
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.
Unused connectors should be sealed using blind plugs.
To install the system, proceed as follows:
}Fit 2 x M4 internal threads on the mounting surface.
}Use two fixing screws to attach the product to the mounting plate.
}With shielded cables, connect the functional earth to the upper fixing screw X0.
5.2 Dimensions
60
4,5
123
133
4,5
29,6
5,6
22,1

Wiring
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6 Wiring
6.1 General wiring guidelines
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.
}Please refer to the link module's operating manual for details of the maximum cable
length.
}Pilz pre-assembled cable can be used to connect the inputs and outputs (see order refer-
ence).
}We recommend you use pre-assembled Pilz connectors to connect the inputs and test
pulse outputs (see order reference).
CAUTION!
The power supply must meet the regulations for extra low voltages with pro-
tective electrical separation (SELV, PELV).
CAUTION!
In order to guarantee protection type IP67, unused plug-in connectors
should be sealed using the blind plugs 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/outputs
X1 to X4
Assignment
5-pin M12 female
connector
A-coded
1: Test pulse x / 24 VDC / ST output.
2: Input X
3: 0 V
4: Input X + 1
5: Test pulse X + 1 / 24 VDC / ST output
23
4
1
5
Interface to the link
module: X5
Assignment
5 pin M12 male con-
nector
A-coded
1: VCC
2: CAN-
3: GND
4: CAN+
5: Shield
2
3
41
5
Interface to the
next decentralised
module: X6
Assignment
5-pin M12 female
connector
A-coded
1: VCC
2: CAN-
3: GND
4: CAN+
5: Shield
23
4
1
5

Wiring
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6.3 Wiring examples
6.3.1 Example: Single-channel, failsafe input device, without test pulse
Features:
}Depending on the application area and its respective regulations, this connection diagram
is suitable for input devices with frequent and infrequent operation in accordance
with ENISO13849-1 up to PL d and ENIEC62061 up to SIL CL 2.
}The input device must be approved for failsafe applications.
}Please read the instructions provided with the input device.
WARNING!
Short circuits between the cable to the input device and the 24 V line or
between cables to various input devices will not be detected. Depending on
the application, serious injury or death may result.
Avoid short circuits by
– Appropriate wiring
– Wiring in accordance with the requirements of IEC 61076-2-101 and
IEC 60204-1, clause 14.1.1 and 14.1.2
24 V
Single-channel, fail-
safe input device
Please ensure safety regulations and EMC guidelines are met!

Wiring
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6.3.2 Example: Dual-channel input devices, without test pulses
Features:
}This type of connection is mainly used for signal inputs with frequent operation.
}Depending on the application area and its respective regulations, this connection diagram
is suitable for input devices with frequent operation and diverse channels in accord-
ance with EN ISO 13849-1 up to PL e and ENIEC62061 up to SIL CL 3, provided the
functionality of both input device channels is monitored in the user program via a feasibil-
ity check.
}The input device must be approved for failsafe applications.
}If you are using input devices with different (diverse) channels, adjacent inputs may be
used. The user program will detect short circuits via the feasibility check.
WARNING!
Short circuits between the cable to the input device and the 24 V line or
between cables to various input devices will not be detected. Depending on
the application, serious injury or death may result.
Avoid short circuits by
– Appropriate wiring
– Wiring in accordance with the requirements of IEC 61076-2-101 and
IEC 60204-1, clause 14.1.1 and 14.1.2

Wiring
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Dual-channel input device
with different
(diverse) channels
24 V
24 V
Please ensure safety regulations and EMC guidelines are met!
6.3.3 Example: Single-channel, failsafe input device, with test pulse
Features:
}Depending on the application area and its respective regulations, this connection diagram
is suitable in accordance with ENISO13849-1 up to PL d and ENIEC62061 up to SIL
CL 2.
}The input device must be approved for failsafe applications.
}Test pulses can be used to check the inputs for short circuit to 24 V and correct function-
ality. Short circuits that short out the input device (cable from the test pulse to the input
device and cable from the input device to the input) will not be detected.
}Please read the instructions provided with the input device.
}Only input devices with N/C contacts can be tested.

Wiring
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CAUTION!
Short circuits between the cable to the input device and the 24 V line or
between cables to various input devices will not be detected.
Avoid short circuits by
– Appropriate wiring
– Wiring in accordance with the requirements of IEC 61076-2-101 and
IEC 60204-1, clause 14.1.1 and 14.1.2
Test pulse T0
Single-channel, fail-
safe input device
Please ensure safety regulations and EMC guidelines are met!

Wiring
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6.3.4 Example: Dual-channel, failsafe input device, with test pulse
Features:
}Depending on the application area and its respective regulations, this connection diagram
is suitable in accordance with ENISO13849-1 up to PL e and ENIEC62061 up to SIL
CL 3.
}The input device must be approved for failsafe applications.
}This type of connection is mainly used for signal inputs with infrequent operation.
}As the test pulses are permanently assigned to the inputs, all short circuits will be detec-
ted, with the exception of short circuits that short out the input device (cable from the test
pulse to the input device and cable from the input device to the input).
Dual-channel input device
with diverse channels
Test pulse T1
Test pulse T0
Test pulse T1
Test pulse T0
Dual-channel input device
with identical channels
Please ensure safety regulations and EMC guidelines are met!

Operation
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7 Operation
7.1 Messages
The module is ready for operation when the "Ready" LED on the link module is lit continu-
ously.
Legend
LED on
LED flashes
LED off
LED LED status Meaning
Device Green The unit is ready for operation
Green The supply voltage is/was too low.
Once the fault has been rectified, the LED will not stop
flashing until the system has been switched off and then
on again.
The unit is not ready for operation
FAULT Red Internal error
No error
Traffic Yellow Connection to control system established
Yellow Error in the connection to the control system. Flashing
stops a max. of 1 min. after the fault has been rectified.
No connection to control system established
Input LEDs Green 1 signal is present
Green Link module has detected a pulse error.
Once the fault has been rectified, the decentralised input
module will continue to work normally after a waiting period
of just a few seconds.
0 signal is present