Pilz PSS u2 ES 4AI I User manual

PSS u2 ES 4AI I
Operating Manual-1005112-EN-03
}Control system PSS u2
}Remote I/O system PSS u2

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
2 Overview ................................................................................................................................. 7
2.1 Module features ........................................................................................................................ 7
3 Safety ...................................................................................................................................... 8
3.1 Intended use ............................................................................................................................. 8
3.2 System requirements................................................................................................................ 8
3.3 Safety regulations ..................................................................................................................... 9
3.3.1 Use of qualified personnel ........................................................................................................ 9
3.3.2 Warranty and liability ................................................................................................................ 9
3.3.3 Disposal .................................................................................................................................... 9
4 Function description ............................................................................................................. 10
4.1 Block diagram ........................................................................................................................... 10
4.2 Supply....................................................................................................................................... 10
4.3 Signal processing ..................................................................................................................... 11
4.4 Measuring range....................................................................................................................... 12
4.5 Monitoring in accordance with NAMUR NE43 .......................................................................... 13
4.6 Moving average ........................................................................................................................ 14
4.7 Scaling ...................................................................................................................................... 15
4.8 Range monitoring ..................................................................................................................... 17
4.9 Threshold value monitoring ...................................................................................................... 18
4.10 Data format ............................................................................................................................... 19
4.11 Summary of configuration options ............................................................................................ 21
4.12 Reaction times .......................................................................................................................... 21
4.13 Energy-saving functions ........................................................................................................... 22
5 Structure of the process image ............................................................................................ 23
6 Installation .............................................................................................................................. 26
6.1 General installation guidelines.................................................................................................. 26
6.1.1 Dimensions ............................................................................................................................... 26
6.2 Inserting and removing an electronic module ........................................................................... 27
6.2.1 Inserting an electronic module.................................................................................................. 27
6.2.2 Removing an electronic module ............................................................................................... 29
6.2.3 Changing an electronic module during operation ..................................................................... 30
7 Wiring ...................................................................................................................................... 31
7.1 General wiring guidelines ......................................................................................................... 31
7.2 Terminal configuration .............................................................................................................. 31
7.2.1 Connection examples ............................................................................................................... 32
8 Operation ................................................................................................................................ 34
8.1 Display elements and messages .............................................................................................. 34

Contents
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9 Technical details .................................................................................................................... 36
10 Order reference ...................................................................................................................... 39
10.1 Product ..................................................................................................................................... 39
10.2 Accessories .............................................................................................................................. 39

Introduction
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1 Introduction
1.1 Validity of documentation
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
This documentation is valid for the product PSS u2 ES 4AI I hardware version 01 or higher.
It is valid until new documentation is published.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
Please refer to the PSS u2 Installation Manual.
1.3 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

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

Overview
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2 Overview
Module structure:
A module consists of
}an electronic module,
}a terminal block with cage clamp terminals and
}a module carrier
The electronic modules are plugged into the backplane and determine the function. The
backplane is used for communication between the head module and the electronic modules
and forms the carrier unit for the electronic modules. The terminal block is plugged into the
electronic modules and is used to connect the field wiring.
Details of the terminal blocks that can be used are available under "Intended Use".
2.1 Module features
Application of the product PSS u2 ES 4AI I:
Electronic module with analogue inputs for standard applications
}4 analogue inputs for current measurement
}Each input can be configured separately
}Resolution: 15 bit
}Current limitation per input
}Measuring range [ 12] 0 … 25.6mA
}Data format [ 19]
– 16 bit two's complement
– 15 bit sign and magnitude representation + sign bit (MSB)
}Scaling [ 15]
}Moving average [ 14]
}Monitoring in accordance with NAMUR NE43 [ 13]
}Range monitoring [ 17]
}Threshold value monitoring [ 18]
}LED displays [ 34] for:
– Operating status per input
– Module error
INFORMATION
HART communication
Due to the high limit frequency of the module of 700 Hz the HART protocol
cannot be completely filtered by the input filter.

Safety
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3 Safety
3.1 Intended use
The module provides analogue inputs and may be used for standard applications in the
PSS u2 system.
Intended use includes making the electrical installation EMC-compliant. The module is de-
signed for use in an industrial environment. Interference may occur if used in other areas.
The following is deemed improper use in particular
}Any component, technical or electrical modification to the module,
}Use of the module outside the areas described in this manual,
}Any use of the module that is not in accordance with the technical details.
The module PSS u2 ES 4AI I may be used in conjunction with the following terminal block:
}16-pin terminal block
3.2 System requirements
INFORMATION
The module is supported by
}PASconfig from version 3.0
– We recommend that you always use the latest version (download
from www.pilz.com).

Safety
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3.3 Safety regulations
3.3.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by 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.
3.3.2 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended,
}Damage can be attributed to not having followed the guidelines in the manual,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.3.3 Disposal
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Function description
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4 Function description
4.1 Block diagram
I0+
1
I0-
3
0V(a)
2
I3+
13
I3-
15
0V(a)
14
P0
4
P0
16
P0
8
P0
12
Module
Supply
Data
(ST)
Periphery
Supply
+24 V DC
Fig.: Block diagram PSS u2 ES 4AI I
4.2 Supply
}The module is supplied with voltage via the head module.

Function description
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4.3 Signal processing
A
NAMUR NE43 ST module
bus
IN
[2]
[1] [3] [4] [5] [7]
Data format
[6]
D
[8]
Fig.: Schematic representation of signal processing
}[1] Input filter
The analogue signal is pre-filtered.
}[2] A/D converter
The analogue value is read in and converted into digital signals with a 15bit resolution
(32 767 steps).
}[3] Monitoring in accordance with NAMUR NE43
Workspace monitoring can be activated for the digitalised measured value in order to de-
tect wiring faults.
}[4] Moving averaging
A digital filter can be activated for the digitalised measured value.
}[5] Scaling
The digitalised measured value can be scaled to a 16 bit value.
}[6] Area and threshold value monitoring
The scaled digital value can be monitored to check if ranges and threshold values have
been exceeded.
}[7] Data format
The data format enables the scaled digital value to be represented as a two's comple-
ment or as sign and magnitude.
}[8] ST module bus
The scaled digital value is transmitted to the head module via the ST module bus. As an
option the input module can send status information for each input. All the configuration
data is stored in the head module and is assigned to the input module on restart. This
way the configuration data is retained even if you change the input module.

Function description
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4.4 Measuring range
The module has a measuring range of 0 … 25.6mA. The module is suitable for connecting
sensors with a current output that lies inside the measuring range.
If the value moves outside the measuring range, the valid bit of the corresponding input in
the user program is set to 0 and an error message is issued. The measured positive or neg-
ative maximum value will continue to be registered in the user program as the scaled digital
value.
Negative measured values up to -0.1 mA (-128D) are tolerated so that an error message is
not issued for unwired terminals.
Sensor's measuring range
Module's measuring range
[1] [1]
Fig.: Relationship between the module's measuring range and the sensor's measuring range
Legend
[1] Module's measuring range exceeded
Valid bit = 0

Function description
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4.5 Monitoring in accordance with NAMUR NE43
If you monitor the input value in accordance with NAMUR NE43 you can define a work-
space that is used to detect sensor faults or faults in the wiring, such as open circuit or
short circuit. Monitoring works with the digitalised value before it is scaled. An error mes-
sage is issued if the value moves outside the limit values. The fact that the values move
outside the limit values will also be registered in the user program.
Lower limit Upper limit
1
0
1
0
[1]
[2]
mbar
t
Fig.: Example of values moving outside the lower limit value
Legend
[1] Configurable time for which values outside the limit values will be tolerated
[2] The fact that the values moved outside the limit values in accordance with NAMUR
NE43 is registered in the user program.
Measuring range 25.6 mA
21 mA
3.6 mA
Fig.: Limit values in accordance with NAMUR NE43
The limit values and the duration can be configured. If the NAMUR NE43 recommendation
is active, the following default values apply:
}Lower limit value: 4608D (3.6 mA)
(e.g. open circuit)
}Upper limit value: 26880D (21 mA)
(e.g. short circuit or transducer error)
}Period for which an overshoot or undershoot will be tolerated: 1ms
The NAMUR recommendation NE 43 to standardise the signal level for failure Information
can be activated. We recommend compliance with NAMUR recommendation NE 43.

Function description
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4.6 Moving average
A digital filter can suppress interference frequencies in the input signals. The filter is imple-
mented by forming the moving average. When forming the moving average, the sum of the
latest sampled results is used to calculate an average. The module has a cycle time of 0.1
ms. With a cycle time of 0.1 ms, the input signal is sampled with a frequency of 10 kHz. The
number of sampled results and the period over which the average is calculated is configur-
able in the following steps:
}0.1 ms (no filtering)
}0.2ms
}0.5ms
}Default setting 1 ms
}2ms
}5ms
}10ms
}17 ms, for 60 Hz interference attenuation
}20 ms, for 50 Hz interference attenuation
Special features and examples:
}0.1ms
There is no filtering. The result corresponds to the sampled value.
}0.2ms
The moving average is calculated over 2 cycle times.
}0.5ms
The moving average is calculated over 5 cycle times.
}1ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The prefil-
ter supplies an average as the result of averaging over 10 cycle times. No additional mov-
ing average is formed (division by 1).
}2ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The mov-
ing average for the filter is calculated from 2 averages from the prefilter.
}5ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The mov-
ing average for the filter is calculated from 5 averages from the prefilter.
}10ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The mov-
ing average for the filter is calculated from 10 averages from the prefilter.
}17ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The mov-
ing average for the filter is calculated from 17 averages from the prefilter.
This setting includes interference frequency suppression of 60 Hz.

Function description
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}20ms
The prefilter is active (see section entitled "Operating principle of the prefilter"). The mov-
ing average for the filter is calculated from 20 averages from the prefilter.
This setting includes interference frequency suppression of 50 Hz.
Operating principle of the prefilter
}The prefilter is activated from a filter setting ≥ 1ms. The prefilter cycle time is 1 ms. The
prefilter records 10 measured values in the space of one module cycle time of 0.1 ms. Of
these 10 measured values, the largest and the smallest recorded measured values are
rejected and an average is calculated from the remaining 8 values. The prefilter supplies
a new value every 1 ms.
INFORMATION
A filter always results in attenuation and a delay of the (input) signal.
4.7 Scaling
The scaling function can be used to convert the digitalised measured value into a scaled di-
gital value. The scaled measured value is represented with a 16 bit resolution (-32768D…
32767D) and is registered in the user program. The default values are selected to give a
scaling with gradient m of 256 and an offset (y axis intercept) of 0. If the scaled digital value
is outside the range of values that can be represented, the input's valid bit is set to 0 and an
error message is issued.
Scaling can only be used with linear input variables.
}The digitalised measured value signal is scaled over a two-point characteristic.
}Any two points on a straight line can be selected.
}The two points are configured as follows:
– Lower limit value of the measuring range (MeasuringLow): Point 1 on the X-axis
– Upper limit value of the measuring range (MeasuringHigh): Point 2 on the X-axis
– Lower limit value of the scaled range (ScaledLow): Point 1 on the Y-axis
– Upper limit value of the scaled range (ScaledHigh): Point 2 on the Y-axis
Calculating the scaled digital value from the digitalises measured value:
}Calculating the gradient m:
m = ((ScaledHigh – ScaledLow)*256)/(MeasuringHigh - MeasuringLow)
}Calculating the offset b:
b = ((ScaledHigh*256) – (m*MeasuringHigh))/256
}Calculating the scaled value y:
y = ((m*x)/256) +b
}The value y is available as a scaled digital value in the user program.
}The default values are selected to give a scaling with gradient m of 256 and an offset of
0.

Function description
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Example:
In this example, a pressure of 0 to 10,000 mbar is monitored.
MeasuringLow Lower limit value of the measuring
range
4608D
MeasuringHigh Upper limit value of the measuring
range
26880D
ScaledLow Lower limit value of the scaled range 0 bar
ScaledHigh Upper limit value of the scaled range 10 000 mbar
}Gradient m = ((ScaledHigh – ScaledLow)*256)/(MeasuringHigh - MeasuringLow)=
= ((10000D–0D) *256/(26880D-4608D)=114
}Offset b = ((ScaledHigh * 256) – (m*MeasuringHigh))/256=((10000D*256)–
(114*26880D))/256=-1970D
Scaled digital value y = ((m*x)/256)+b = (114 * x)/256 – 1970D
4608
4 mA
26880
20 mA
0 Measuring range
Scaling range
10 000 mbar
0 mbar
y = (114 *x) / 256 - 1970
Fig.: Scaling
Legend
Scaling range Scaled values
Measuring range Measured current value
INFORMATION
Scaling may influence the accuracy of the digitalised measured value.

Function description
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4.8 Range monitoring
Range monitoring works with the scaled digital value. Up to 4 individually configurable
ranges can be monitored per input. Range monitoring compares the upper and lower limit
value for each configured range with the digital value after scaling and registers the result
of the comparison in the user program. If a value moves outside a range, the measured
scaled digital value will continue to be registered in the process image.
The result is "1" when the following condition is met:
}Configured lower limit value <= Scaled digital value <= Configured upper limit value
If the scaled digital value is outside a range's lower or upper limit value, then the result for
this range will be "0".
Lower limit Upper limit
1
0
[1]
mbar
t
0
Fig.: Range monitoring
Legend
[1] Evaluation of range monitoring in the user program
Example:
In this example, the scaled values from 0 to 10,000 mbar from the Scaling [ 15] chapter
are to be used. If the pressure falls below 2,000mbar or exceeds 8,000 mbar, the fact that
the range has been exceeded is to be registered in the user program.
Configuration:
Lower limit value: 2,000 mbar
Upper limit value: 8,000 mbar

Function description
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4.9 Threshold value monitoring
8 thresholds per input can be defined; these can be used to monitor the scaled signal. As a
result, various warning and fault levels can be set up when monitoring physical values, for
example.
Each threshold consists of a lower and an upper threshold value. The result of monitoring is
registered in the user program. For each threshold it is possible to configure whether to re-
gister in the user program that the value has exceeded the upper threshold value or fallen
below the lower threshold value.
Lower threshold Upper threshold
1
0
1
0
[1]
[2]
mbar
t
Hysteresis
mbar
t
Hysteresis
Lower threshold Upper threshold
Fig.: Threshold value monitoring
Legend
[1] Configuration-dependent evaluation of the threshold value in the user program:
}Threshold value is set when the value has exceeded the upper threshold value.
}Threshold value is reset when the value falls below the lower threshold value.
[2] Configuration-dependent evaluation of the threshold value in the user program:
}Threshold value is set when the value falls below the lower threshold value.
}Threshold value is reset when the value exceeds the upper threshold value.
Example:
In this example, the scaled values from 0 to 10,000 mbar from the Scaling [ 15] chapter
are to be used. If the pressure of 8,000 mbar is exceeded, the fact that the threshold value
has been exceeded is to be registered in the user program.
Configuration:
Lower threshold value: 2,000 mbar
Upper threshold value: 8,000 mbar

Function description
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4.10 Data format
The data format enables the scaled digital value to be represented as:
}Two's complement
The scaled digital values are transferred with 16bits.
}Sign and magnitude
The scaled digital values are transferred with 15bits plus a sign bit (MSB). The MSB is
"1" with negative values and "0" with positive values.
Sign and magnitude representation and two's complement representation differ only on
negative values.
Analogue value in a two’s complement with default values for scaling:
Analogue value
0mA … 25.6mA
Binary Hexadecimal Decimal
25.59921875 mA
(25.6 mA – 1 LSB)
0111 1111 1111 1111 7FFFH32767
20.0 mA 0110 0100 0000 0000 6400v 25600
17.5 mA 0101 0111 1000 0000 5780H22400
15.0 mA 0100 1011 0000 0000 4B00H19200
12.5 mA 0011 1110 1000 0000 3E80H16000
10.0 mA 0011 0010 0000 0000 3200H12800
7.5 mA 0010 0101 1000 0000 2580H9600
5.0 mA 0001 1001 0000 0000 1900H6400
2.5 mA 0000 1100 1000 0000 0C80H3200
1.0 mA 0000 0101 0000 0000 0500H1280
0.1 mA 0000 0000 1000 0000 0080H128
50 μA 0000 0000 0100 0000 0040H64
25 μA 0000 0000 0010 0000 0020H32
12.5 μA 0000 0000 0001 0000 0010H16
6.25 μA 0000 0000 0000 1000 0008H8
3.125 µA 0000 0000 0000 0100 0004H4
1.5625 µA 0000 0000 0000 0010 0002H2
0.78125 µA 0000 0000 0000 0001 0001H1
0 A 0000 0000 0000 0000 0000H0
-0.1 mA 1111 1111 1000 0000 FF80H-128

Function description
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Analogue value in a sign and magnitude with default values for scaling:
Analogue value
0mA … 25.6mA
Binary Hexadecimal Decimal
25.59921875 mA
(25.6 mA – 1 LSB)
0111 1111 1111 1111 7FFFH32767
20.0 mA 0110 0100 0000 0000 6400H25600
17.5 mA 0101 0111 1000 0000 5780H22400
15.0 mA 0100 1011 0000 0000 4B00H19200
12.5 mA 0011 1110 1000 0000 3E80H16000
10.0 mA 0011 0010 0000 0000 3200H12800
7.5 mA 0010 0101 1000 0000 2580H9600
5.0 mA 0001 1001 0000 0000 1900H6400
2.5 mA 0000 1100 1000 0000 0C80H3200
1.0 mA 0000 0101 0000 0000 0500H1280
0.1 mA 0000 0000 1000 0000 0080H128
50 μA 0000 0000 0100 0000 0040H64
25 μA 0000 0000 0010 0000 0020H32
12.5 μA 0000 0000 0001 0000 0010H16
6.25 μA 0000 0000 0000 1000 0008H8
3.125 µA 0000 0000 0000 0100 0004H4
1.5625 µA 0000 0000 0000 0010 0002H2
0.78125 µA 0000 0000 0000 0001 0001H1
0 A 0000 0000 0000 0000 0000H0
-0.1 mA 1000 0101 0000 0000 8500H-128