Pilz PSSu K F FAU B User manual

PSSu K F FAU B
PSSu K F FAU P
Operating Manual-1003434-EN-05
}Decentralised system PSSuniversal I/O

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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1 Introduction ............................................................................................................................5
1.1 Validity of documentation.......................................................................................................... 5
1.1.1 Retaining the documentation .................................................................................................... 5
1.1.2 Terminology: System environment A and B ............................................................................. 5
1.2 Definition of symbols................................................................................................................. 6
2 Overview .................................................................................................................................7
2.1 Module structure ....................................................................................................................... 8
2.1.1 Module features ........................................................................................................................ 8
2.2 Front view ................................................................................................................................. 9
3 Safety ...................................................................................................................................... 11
3.1 Intended use ............................................................................................................................. 11
3.2 Safety regulations ..................................................................................................................... 12
3.2.1 Use of qualified personnel ........................................................................................................ 12
3.2.2 Warranty and liability ................................................................................................................ 12
3.2.3 Disposal .................................................................................................................................... 13
4 Function description ............................................................................................................. 14
4.1 Overview................................................................................................................................... 14
4.2 Module and periphery supply.................................................................................................... 14
4.3 Inputs ........................................................................................................................................ 14
4.4 Outputs ..................................................................................................................................... 15
4.4.1 Single-pole outputs ................................................................................................................... 15
4.4.2 Dual-pole outputs...................................................................................................................... 17
4.4.3 Notes ........................................................................................................................................ 19
4.5 Fast shutdown .......................................................................................................................... 19
4.6 Reaction times with fast shutdown ........................................................................................... 20
4.6.1 Reaction time after protected field is interrupted ...................................................................... 20
4.6.2 Reaction time after signal changes at one of the input pairs .................................................... 20
4.7 Reaction time without fast shutdown ........................................................................................ 20
4.8 Integrated protection mechanisms............................................................................................ 21
4.9 Configuration ............................................................................................................................ 21
4.9.1 Access to I/O data types........................................................................................................... 23
4.10 Communication with the safety system .................................................................................... 26
4.10.1 Communication of tool classes ................................................................................................. 26
4.10.2 Communication regarding configuration of the muting end point ............................................. 29
4.10.3 Communication for configuration of braking ramp monitoring .................................................. 31
4.11 Operating states ....................................................................................................................... 34
5 Interfaces ................................................................................................................................47
5.1 Receiver interface..................................................................................................................... 47
5.2 Transmitter interface................................................................................................................. 47
5.3 Ethernet interface ..................................................................................................................... 48
6 Installation ..............................................................................................................................49
6.1 General installation guidelines.................................................................................................. 49
6.1.1 Dimensions ............................................................................................................................... 49

Contents
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6.2 Install compact module ............................................................................................................. 50
6.3 Install/uninstall connector ......................................................................................................... 51
7 Wiring ......................................................................................................................................53
7.1 General wiring guidelines ......................................................................................................... 53
7.2 Connectors' mechanical connection ......................................................................................... 53
7.3 Connect/disconnect the cables................................................................................................. 53
7.4 Terminal configuration .............................................................................................................. 54
7.5 Connecting the module............................................................................................................. 56
7.6 Function test during commissioning ......................................................................................... 58
8 Operation ................................................................................................................................59
8.1 Messages ................................................................................................................................. 59
8.2 Display elements ...................................................................................................................... 60
8.2.1 Display elements for module diagnostics ................................................................................. 60
8.2.2 Display elements for input and output status............................................................................ 63
9 Technical details ....................................................................................................................64
9.1 Safety characteristic data ......................................................................................................... 68
10 Order reference ......................................................................................................................70
10.1 Product ..................................................................................................................................... 70
10.2 Accessories .............................................................................................................................. 70

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSSu K F FAU. It is valid until new documenta-
tion 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.
1.1.2 Terminology: System environment A and B
The PSSu system can be used in two different system environments. The module's applic-
ation area is described in the chapter "Intended Use" of the manual.
The distinction is made between
}PSSu in system environment A
}PSSu in system environment B
The distinction is based on the application area of the PSSu system.
PSSu in system environment A may be used in the
}Decentralised system PSSu I/O
}Not in the automation system PSS 4000
PSSu in system environment B may be used in the
}Automation system PSS 4000, e.g. with
– Decentralised system PSSu I/O with SafetyNET p
– Control system PSSu PLC
– Control system PSSu multi
The module PSSu K F FAU is exclusively for use in system environment B (automation
system PSS 4000).

Introduction
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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.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
PSENvip is a camera-based protection and measuring system (electrosensitive protective
equipment) for press brakes. It consists of a transmitter, receiver and a PSSu module to
evaluate recordings. It monitors the detection zone between the transmitter and receiver
below the moving upper tool. Operation, visualisation and configuration is via a web inter-
face on the CNC or control system driving the press.
[1] [3][2]
Fig.: Components of the PSENvip
Receiver PSENvip R [1]
}Receives the light generated by the transmitter
}Sends image date to the special module PSSu K F FAU
}LED display for the status of the OSSD signal
Transmitter PSENvip E [2]
}Generates parallel beam
}2 inputs for controlling the light source
Special module PSSu K F FAU [3]
}Image evaluation of the data provided by the receiver
}Evaluation of protected field and fast shutdown of the press if the protected field is viol-
ated
}2 outputs to control the transmitter
}Communication via Ethernet interface with the CNC
}Troubleshooting and diagnostics
This operating manual describes
}The module's inputs and outputs
}The module interfaces
}Access to the module's I/O data types
Module types described in the manual:
}PSSu K F FAU-B: monitors a configured protected field for violation.
}PSSu K F FAU-P: reduces the protected field dynamically during the press stroke (dy-
namic muting) and monitors this dynamic protected field for violation.

Overview
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}Unless stated otherwise, the descriptions in this manual apply to both module types. The
common name for both module types is: PSSu K F FAU.
Further information on the PSENvip system can be found in the operating manual PSENvip
R, PSENvip E
2.1 Module structure
The module combines the function unit (inputs or outputs, interfaces) and connection levels
in one housing.
Wiring is via a Mini-IO socket, male connector and RJ45 connector (connection to HMI of
the press controller).
2.1.1 Module features
}For failsafe applications in system environment B (automation system PSS 4000)
}Interface for connecting the PSENvip receiver
}Interface for connecting the PSENvip transmitter
}4 Digital inputs
}Configurable input filter time
}2 Independent test pulse outputs that use different test pulses
}2 Digital outputs
– Semiconductor technology
– Single-pole
– Positive-switching
– Current load capacity per output: 1,75 A
– Short circuit-proof
– Overload-proof
– Free from feedback
}2 Dual-pole digital outputs
– Semiconductor technology
– Switches to 24 V (Ox+) and 0 V (Ox-)
– Current load capacity: 3 A
– Short circuit-proof
– Overload-proof
– High discharge voltage
– Free from feedback
}2 Ethernet Interfaces
}Reset button
}LEDs for:
– Switch status of each input/output
– Module error

Overview
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– Module status
Accessories:
}Connector with spring-loaded terminals (necessary for operation)
2.2 Front view
1
RST
2
3
4
5
6
7
8 9
10
11
RUN
PROT
OSSD
RLNK
HMI
LNK1
LNK2
FLT
HALT
MUTE*
MBUS
M2M
TRF1
TRF2
On Err
O00
O01
I00
I01
I02
I03
O02
O03
X21
NC
I 00
I 01
I 02
I 03
T 00
T 00
T 01
T 01
0 V<
X12
24 V>
O 00+
O 00+
O 00-
O 00-
O 01+
O 01+
O 01-
O 01-
0 V>
X22
24 V<
O 02
O 02
O 03
O 03
0 V<
0 V<
0 V<
0 V<
0 V>
X33
RLNK
5V<
X34
24 V<
ESY
EON
0 V<
X31
ETH1
X32
ETH2
PSSu K F FAU
* PSSU K F FAU P only
Legend:
}1: Name of compact module
}2: Labelling strip with:
– 2D code
– Order number
– Serial number
– Hardware version number
}3: LEDs for status display and module diagnostics
}4: Connector strip X21 for connectors with spring-loaded terminals and labelling strip
}5: Ethernet interface
}6: Ethernet interface

Overview
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}7: Reset button
}8: Connector strip X12 for connectors with spring-loaded terminals and labelling strip
}9: Connector strip X22 for connectors with spring-loaded terminals and labelling strip
}10: Interface to receiver
}11: Interface to transmitter

Safety
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3 Safety
3.1 Intended use
The module may be used for failsafe applications in system environment B (automation
system PSS 4000).
It provides interfaces for connecting the PSENvip.
It provides type 1 failsafe inputs in accordance with IEC 61131-2.
It provides type 1 single and dual-pole failsafe outputs in accordance with IEC 61131-2.
The outputs may be used to switch:
}Resistive loads
}Inductive loads
}Capacitive loads (refer to the characteristics "Capacitance C on single-pole outputs de-
pendent on load current I" and "Capacitance C on dual-pole outputs dependent on load
current I")
Intended use includes making the electrical installation EMC-compliant. Please refer to the
guidelines stated in the "PSSuniversal Installation Manual". The module is designed for use
in an industrial environment. It is not suitable for use in a domestic environment, as this can
lead to interference.
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.
NOTICE
Overvoltages can damage the module.
Test and evaluate the potential implications of overvoltage on the module.
In doing so, consider the duration and level of the overvoltage.
INFORMATION
The module is supported by PAS4000 from version 1.10.0. We recommend
that you always use the latest version (download from www.pilz.com).
INFORMATION
Only use PSENvip transmitters and receivers from Version 1.0 with a spe-
cial module PSSu K F FAU B/PSSu K F FAU P from hardware version 01
and software version 01 (1.0.0).

Safety
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INFORMATION
Configuration of the muting end point is supported by the PSSu K F FAU P
from hardware version 2 and software version 1.1.
INFORMATION
Configuration of braking ramp monitoring is supported by the PSSu K F
FAU P from hardware version 3 and software version 2.0.
INFORMATION
Measurement mode is supported by the PSSu K F FAU B/P from hardware
version 3 and software version 2.2.
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 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,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).

Safety
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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 Overview
The module monitors and evaluates the detection zone between the PSENvip transmitter
and PSENvip receiver. If a detection zone is violated, the module switches off its outputs.
4.2 Module and periphery supply
Module supply
}The module supply provides the module and the receiver with voltage.
Periphery supply
}The periphery supply is used to supply the transmitter.
}The periphery supply is used to supply the test pulse outputs.
}The periphery supply that supplies the outputs must be fed externally. The single and
dual-pole outputs must have a common supply voltage.
4.3 Inputs
}The inputs I00 ... I03 form two input pairs (I00 and I01, I02 and I03). Only by using these
input pairs is it possible to achieve PL e (Cat. 4) and SIL CL 3.
}Test pulses can be used to check the inputs for shorts across contacts and correct func-
tionality.
}The inputs can be used to connect foot switches, for example.
}Configurable settings see Configuration [ 21].
NOTICE
Possible loss of safety functions by using test pulses!
The duration of the test pulse can be longer than the configured input filter
time, whereby input signals are not detected. That way, an output may not
safely shut down and, depending on the application, may cause serious in-
jury and death.
Make sure that you always use an input pair for an input signal and that you
assign test pulse T0 to one input in the input pair and test pulse T1 to the
other input in the input pair.
Test pulse outputs
}2 test pulse outputs that use different test pulses (test pulse T00, test pulse T01)
}Short circuit-proof
}Overload-proof
}Free from feedback
}Current-limiting

Function description
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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T00, test pulse T01).
}Only the module's test pulses may be used to detect shorts.
}The module's test pulses may not be used to detect shorts between inputs on other mod-
ules.
}Shorts between inputs of the same module with the same test pulses will not be detected.
}Test pulses can be switched on or off.
}Test pulses are switched on in the default setting.
}When test pulses are switched off, the periphery supply is constantly available at the test
pulse outputs.
4.4 Outputs
4.4.1 Single-pole outputs
}2 single-pole digital outputs
Output test
}Outputs that are switched on are checked via regular off tests.
– Test pulses for outputs that are switched on: see Technical details [ 64]
– Outputs that are switched on are switched off for the duration of the test pulse.
– The load must not switch off because of the test.
}Outputs that are switched off are checked via regular on tests.
– Test pulses for outputs that are switched off: see Technical details [ 64]
– Outputs that are switched off are switched on for the duration of the test pulse.
– The load must not switch on because of the test.
Testing for shorts
}A test is regularly carried out to check for shorts between the outputs.
Excluding individual outputs from the output test:
}If a plant is particularly sensitive to the test pulses, the output test may be switched off for
individual outputs.
}The test must be replaced by other measures, depending on the safety requirement.
}When test pulses are switched off:
– The correct switch status is always checked.
– The output's ability to switch will not be detected until the next time the output is
switched on/off.

Function description
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Fig.: On and off test for single-pole outputs
Legend
t1Pulse duration of on/off test (200 μs)
t2Max. waiting time between the on/off test (approx. 4 ms)
t3Repetition time of on and off test in normal circumstances (approx. 2 s)
Characteristic for single-pole outputs: Output capacitance C dependent on load current I
2
4
6
8
10
0
0,4 0,6 0,8 1,2 1,6 2 2,4 2,8 3,2 3,6
C [µF]
I [A]

Function description
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4.4.2 Dual-pole outputs
}2 dual-pole digital outputs (cannot be used as a single-pole output)
Output test
}Outputs that are switched on are checked via regular off tests.
– Test pulses for outputs that are switched on: see Technical details [ 64]
– Outputs that are switched on are switched off for the duration of the test pulse.
– The load must not switch off because of the test.
}Outputs that are switched off are checked via regular on tests.
– Test pulses for outputs that are switched off: see Technical details [ 64]
– Outputs that are switched off are switched on for the duration of the test pulse.
– The load must not switch on because of the test.
Testing for shorts
}A test is regularly carried out to check for shorts between the outputs.
Open circuit detection (only on dual-pole outputs):
}The module will detect an open circuit between outputs O0x+ and O0x-.
}The result from open circuit detection is issued as a warning and the affected output is
deactivated.
}Loads over 0,17 kOhm may mistakenly be detected as an open circuit.
}Unused outputs can be deactivated.
– Make sure that unused outputs are not switched on in the user program, otherwise a
warning will be triggered. The affected output will be shut down and deactivated.
NOTICE
Risk from high discharge voltage!
The discharge voltage when switching off an inductive load is up to -185 V.
The connected load can be damaged by the discharge voltage.
– Limit the discharge voltage if the connected load can be damaged by
this discharge voltage.

Function description
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t1t2t1
t3
t1t2
Fig.: On test for dual-pole outputs
Legend
t1Max. pulse duration of on test (4 ms)
t2Max. waiting time between the on tests (approx. 4 ms)
t3Repetition time of on test in normal circumstances (approx. 2 s)
t3t3
Fig.: Off test for dual-pole outputs
Legend
t1Pulse length of off test (0.2 ms)
t2Max. waiting time between the off tests (approx. 4 ms)
t3Repetition time of off test in normal circumstances (approx. 2 s)
t1 (2 min) t1
[1]
Fig.: Discharge voltage test
Legend
[1] Start of off test for dual-pole outputs
t1 Waiting time between discharge voltage tests (2 min)
t2 Pulse duration of discharge voltage test (approx. 0.3 ms)

Function description
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Characteristic for dual-pole outputs: Output capacitance C dependent on load current
2
4
6
8
10
0
0,4 0,6 0,8 1,2 1,6 2 2,4 2,8 3,2 3,6
C [µF]
I [A]
4.4.3 Notes
WARNING!
When wiring an output with capacitance it is essential to note the pulse dur-
ation, repetition period and scan time of the power-up test, otherwise the
load may switch on unintentionally.
}For applications in accordance with Category 4, PL e and SIL 3, detection of shorts
between contacts must be guaranteed either via the on/off test or through other meas-
ures (e.g. asynchronous switching). A short between contacts must be simulated during
commissioning.
4.5 Fast shutdown
The module switches the outputs off immediately when:
}The signal from the protected field evaluation (OSSD) switches from 1 to 0 (protected
field violated).
}The signal for dynamic muting (MUTE) switches from 1 to 0. (Object interrupts advance
measuring field.)
}The signal switches from 1 to 0 at one of the input pairs I00 and I01, I02 and I03. The
edge used to trigger the fast shutdown can be configured (see Configuration [ 21]).

Function description
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X33
Control Data
OSSD
Mute
1[1]
1[1]
1[1]
1[2]
1[2]
1[2]
1[2]
1[1]
[1] Deactivate fast shutdown for inputs
[2] Deactivate fast shutdown for outputs
4.6 Reaction times with fast shutdown
The overall reaction time with fast shutdown is independent of the PSSu cycle time.
4.6.1 Reaction time after protected field is interrupted
Times that influence the overall reaction time:
}Processing time of the camera system
}Processing time of the outputs
Maximum reaction time for shutdown with falling edge:
tFS-overall reaction time max = 4 ms + 0,25 ms)
4.6.2 Reaction time after signal changes at one of the input pairs
Times that influence the overall reaction time:
}Configured input filter time
}Processing time of the outputs
Maximum reaction time for shutdown with falling edge:
tFS-overall reaction time max = (tconfigured input filter time + 0,25 ms)
4.7 Reaction time without fast shutdown
Information on the reaction times of the inputs can be found in the System Description
"Automation system PSS 4000".
Please note that the configured input filter time has an effect on the reaction time.