Pilz PSS u2 User manual

PSS u2 EF 2DO TP 2A
Operating Manual-1003624-EN-02
}Control system PSS u2
}Remote I/O system PSS u2

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.
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 Third-party manufacturer licence information ........................................................................... 5
1.4 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 Safety assessment ................................................................................................................... 9
3.3.2 Use of qualified personnel ........................................................................................................ 9
3.3.3 Warranty and liability ................................................................................................................ 9
3.3.4 Disposal .................................................................................................................................... 9
4 Function description ............................................................................................................. 10
4.1 Block diagram ........................................................................................................................... 10
4.2 Supply....................................................................................................................................... 10
4.3 Outputs ..................................................................................................................................... 10
4.4 Output capacitance C ............................................................................................................... 14
4.5 Integrated protection mechanisms............................................................................................ 15
4.6 Energy-saving functions ........................................................................................................... 15
4.7 Reaction times .......................................................................................................................... 15
5 Address assignment ............................................................................................................. 16
6 Installation ..............................................................................................................................17
6.1 General installation guidelines.................................................................................................. 17
6.1.1 Dimensions ............................................................................................................................... 17
6.2 Inserting and removing an electronic module ........................................................................... 18
6.2.1 Inserting an electronic module.................................................................................................. 18
6.2.2 Removing an electronic module ............................................................................................... 20
6.2.3 Changing an electronic module during operation ..................................................................... 21
7 Wiring ......................................................................................................................................22
7.1 General wiring guidelines ......................................................................................................... 22
7.1.1 Connection mechanism for terminal blocks .............................................................................. 22
7.2 Terminal configuration .............................................................................................................. 23
7.3 Function test during commissioning ......................................................................................... 24
8 Operation ................................................................................................................................25
8.1 Display elements and messages .............................................................................................. 25
9 Technical Details ...................................................................................................................27
9.1 Safety characteristic data ......................................................................................................... 29

Contents
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10 Order reference ......................................................................................................................30
10.1 Product ..................................................................................................................................... 30
10.2 Accessories .............................................................................................................................. 30

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 EF 2DO TP 2A 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 Third-party manufacturer licence information
The head modules include Open Source software with various licences. Further information
is available in the document "Licence information PSS u2" (document number 1004293) at
www.pilz.com.
1.4 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.

Introduction
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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
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 EF 2DO TP 2A:
Electronic module with digital dual-pole outputs for failsafe applications
The product has the following features:
}2 dual-pole digital outputs
– Semiconductor technology
– Switches to 24 V (O0+) and 0 V (O0-)
– Current load capacity: 2 A
– Short circuit-proof
– Overload-proof
– Free from feedback
– Configurable open circuit detection
– Configurable switch-off delay
– Configurable maximum test duration
– Configurable repetition time of the expanded on tests
}Energy-saving functions
}LEDs for:
– Switch status of each output
– Module error

Safety
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3 Safety
3.1 Intended use
The module provides failsafe outputs and may be used for failsafe applications in the PSS
u2 system.
The module meets the requirements of ENIEC61508 up to and ENISO13849-1 up to
PLe.
The outputs may be used to switch:
}Resistive loads
}Inductive loads
}Capacitive loads
The programmable safety system should be installed in a protected environment that meets
at least the requirements of pollution degree 2. Example: Protected inside space or control
cabinet with protection class IP54.
Make sure that only authorised personnel have access to the programmable safety 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 EF 2DO TP 2A may be used in conjunction with the following terminal
block:
}8-pin terminal block
3.2 System requirements
INFORMATION
The module is supported by
}PASconfig from version 1.0.0
– 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 Safety assessment
Before using a device it is necessary to perform a safety assessment in accordance with
the Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
3.3.2 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.
3.3.3 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.).
3.3.4 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 Block diagram
1
O0+
n.c
9
3
O0-
5
O1+
7
O1-
Module
Supply
Data
(FS)
Periphery
Supply
+24 V DC
Module Bus
n.c
11
n.c
13
n.c
15
Fig.: Block diagram PSS u2 EF 2DO TP 2A
4.2 Supply
}The module is supplied with voltage via the head module.
}The periphery supply provides the outputs with voltage.
}The module routes the periphery supply from the module bus to the terminals on the ter-
minal blocks.
4.3 Outputs
Signals at the output
}“0” signal (0 V) at the output (O0+/O0-):
– Output is high impedance
– No current to the load
}“1” signal (+24 V) at the output (O0+/O0-):
– Output is low impedance
– Current is supplied to the load
Output
}The head module sets the output status via the module bus.
}The max. capacity at an output depends on the load (see characteristic). Connecting a
higher capacity may lead to an error.
}Operation with electronic contactors has not been tested and may lead to errors. Please
contact our Customer Support team if you are using electronic contactors.
}Open circuit detection

Function description
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}Cannot be used as a single-pole output
Output tests (not configurable)
}Asymmetric test in error-free operation
– In this test, one output transistor is switched on and the other switched off for the test
duration t1 as a maximum. The load is not switched on because of the test. If errors
are detected during this test, than an advanced on test is run.
– The maximum test duration t1 can be configured.
– The repetition time of the asymmetric test t2 is determined by the head module.
}Advanced on test in the event of an error
– The test is run for the test duration t1 as a maximum
– The maximum test duration t1 can be configured.
– The test enables precise error diagnostics
– The first test ([1] in the diagram) in the advanced on test is always run directly after an
asymmetric test, in which an error has occurred. It is used to determine the cause of
the error.
– Further tests ([2] to [n] in the diagram) are run after a repetition time t3. The repetition
time t3 can be configured. These tests are used to check whether an error is still
present.
– The load must not switch on because of the test.
– The following errors are detected:
Shorts across contacts (external error)
Short circuits and interruptions on the transistors
Short circuits and open circuit on the connected load
Function diagrams for the output test
Ox t1 t1 t1t2 t2 t
[1] [2] [n]
Fig.: Asymmetric test (only run in error-free operation). The switching capability of O+ and O- is
checked in separate tests.
Legend
t1Configurable maximum test duration (default value: 3 ms)
t2Repetition time between asymmetric tests in error-free operation. The
time is not configurable and is determined by the head module.
[1] [2] [n] Asymmetry tests

Function description
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Ox t1 t1 t1t3 t3 t
[1] [2] [n]
Fig.: Advanced on test (only run in the event of an error)
Legend
t1Configurable maximum test duration (default value: 3 ms)
t3Repetition time of advanced on test in the event of an error (default
value: approx. 30 s)
[1] [2] [n] Advanced on tests
INFORMATION
For the maximum test duration t1, set a maximum value at which the load
can neither switch on nor switch off. By setting a maximum permitted test
duration t1 for your application you increase availability and improve fault
detection.
WARNING!
The advanced on tests can cause a capacitive load to switch on uninten-
tionally.
It is essential to note the test duration t1 and the repetition time of the ad-
vanced on test in case of an error.
}The module will detect an open circuit between outputs Ox+ and Ox-.
}The behaviour after an open circuit is detected is configurable:
– Switch off output and send error message.
The outputs are switched off and an error message is sent. The open circuit is re-
gistered in the PII and the open circuit bits [ 16] are set to "0".
– Send error message only.
The module's outputs are not switched off. The open circuit is registered in the PII.
– Ignore open circuit detection
The outputs are not switched off and no error message is sent.
The open circuit is not registered in the PII and the open crcuit bits [ 16] remain
at "1".

Function description
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}Loads over 10kOhm may mistakenly be detected as an open circuit.
Switch-off delay
FS outputs can be switched off with a delay. Even if the process image of outputs switches
from "1" to "0", a "1" signal may remain at the output for the duration of the delay. If there is
another "1" signal during the switch-off delay, the switch-off delay time is reset again and
restarts at the next "0" signal.
In the event of external errors, e.g. if the connection to the controller is lost, the output is
switched off after the set switch-off delay.
However, in the event of internal module errors, the switch-off delay cannot be guaranteed.
Default value: 0 ms (immediate shutdown).
tdelay
t
PAA
Clamp
1
0
0
1
tdelay
Fig.: Switch-off delay
Legend
PIO Process image of outputs
tdelay Configured switch-off delay time
If there is another "1" signal, the time is reset and restarts
at the next "0" signal
Clamp Signal at the terminal

Function description
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4.4 Output capacitance C
0
0
20
40
60
80
100
120
140
500 1000 1500 2000 2500
C [µF]
I [mA]
[1]
[2]
Fig.: Output capacitance C dependent on load current I
Legend
[1] Max. test duration 1 ms
[2] Max. test duration 3 ms

Function description
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4.5 Integrated protection mechanisms
The module has the following protection mechanisms:
}Common second shutdown route, tested regularly
}Cyclical output tests
}Tests for shorts between the outputs
The module provides the following diagnostic data:
}Start-up error
}Configuration error
}FS communication error
}Temperature error: too warm
}Temperature error: too hot
}Open circuit
}Short circuit of load and/or overload
}Interrupted T and/or internal error
}Short circuit of a terminal to the same potential and/or internal error
}Short circuit of a terminal to another potential
4.6 Energy-saving functions
The energy levels are supported by the head module and are not configurable. The module
supports the following energy levels:
– Switching off the LEDs that display the module and terminal status
– Switching off the LEDs that display the terminal status
4.7 Reaction times
Detailed information on the reaction times is available in the operating manual of the head
modules.

Address assignment
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5 Address assignment
The module occupies one bit address in the process image of the outputs.
PIO Meaning State
Bit 0 Output data O0 0: "0" signal (0 V) at the output
1: "1" signal (+ 24 V) at the output
Bit 1 Output data O1
Bit 2-7 None Constant "0"
The module occupies the following Bit address in the process image of inputs:
PII Meaning State
Bit 0 Valid bit of output O0 0: Output error
1: The signal in the PIO corresponds to the
output signal
Bit 1 Valid bit of output O1
Bit 2 Open circuit at output O0 0: Open circuit at output
1: No open circuit at output
Bit 3 Open circuit at output O1
Bit 4-7 None Constant "0"

Installation
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6 Installation
6.1 General installation guidelines
NOTICE
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
6.1.1 Dimensions
12,5
50,1
54.4
88,37
6
51,1 60
111,1
(95.3)
51,7
Fig.: Dimensions in mm, including backplane, electronic module and terminal block

Installation
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6.2 Inserting and removing an electronic module
Please note:
}Backplane must be installed first.
}Electronic modules may only be plugged or unplugged if the terminal block has been re-
moved first.
}The mechanics of the electronic modules are designed for 20 plug in/out cycles.
}On electronic modules with outputs, the terminal block may only be inserted and removed
when the load is switched off. Unforeseeable error reactions may be triggered if modules
are inserted and removed under load.
6.2.1 Inserting an electronic module
1. Insert the electronic
module into the suspen-
sion lug on the back-
plane.

Installation
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2. Swivel the electronic
module downwards until
you hear it click into
place.
3. Insert the terminal
block into the suspen-
sion lug on the module.
4. Swivel the terminal
block upwards until you
hear it click into place.

Installation
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6.2.2 Removing an electronic module
1. Press the unlocking
mechanism on the ter-
minal block that is
shown by the arrow and
pull off the terminal
block forward.
2. Press the unlocking
mechanism that is
shown by the arrow and
pull off the electronic
module upwards.