Pilz PSSu E F AI U User manual

PSSu E F AI U(-T)(-R)
Operating Manual-21993-EN-10
}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
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 3
Section 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
Section 2 Overview 7
2.1 Module structure 7
2.2 Module features 7
2.3 Front view 8
Section 3 Safety 10
3.1 Intended use 10
3.2 Safety regulations 12
3.2.1 Use of qualified personnel 12
3.2.2 Warranty and liability 12
3.2.3 Disposal 12
Section 4 Function description 13
4.1 Block diagram 13
4.2 Module features 13
4.3 Measures for achieving process safety 15
4.3.1 Example of 1-channel operation 15
4.3.2 Example of 2-channel operation 16
4.4 Integrated protection mechanisms 17
4.5 Configuration 17
4.5.1 Converter characteristics/default value 17
4.5.2 Input/output data 18
Section 5 Installation 19
5.1 General installation guidelines 19
5.1.1 Dimensions 19
5.2 Installing the base module 20
5.3 Inserting and removing an electronic module 21
5.3.1 Inserting an electronic module 22
5.3.2 Removing an electronic module 23
5.3.3 Changing an electronic module during operation 23
Section 6 Wiring 24
6.1 General wiring guidelines 24
6.1.1 Mechanical connection of the base modules 25
6.2 Terminal configuration 27
6.3 Connecting the module 30
Section 7 Operation 31
7.1 Messages 31
7.2 Display elements 31

Contents
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 4
7.2.1 Display elements for module diagnostics 31
7.2.2 Display elements for input status 32
Section 8 Technical details 33
8.1 Safety characteristic data 36
Section 9 Order reference 37
9.1 Product 37
9.2 Accessories 37

Introduction
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 5
1 Introduction
1.1 Validity of documentation
This documentation is valid for the product types PSSu E F AI U, PSSu E F AI U-T and
PSSu E F AI U-R. 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.
1.1.2 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 modules PSSu E F AI U and PSSu E F AI U(-T)(-R) are exclusively for use in system
environment B (automation system PSS 4000).

Introduction
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 6
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
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 7
2 Overview
2.1 Module structure
A module consists of
}Electronic module and
}Base module with
– Screw terminals or
– Cage clamp terminals
The base modules are the carrier units for the electronic modules and are used to connect
the field wiring. The electronic modules are inserted on to the base modules and determine
the module's function.
Details of the base modules that can be used are available in the chapter entitled “Intended
Use”.
2.2 Module features
The product has the following features:
}1 Analogue voltage input
}Voltage range:
-10.24 V ... +10.2375 V Dual-pole, differential input
}Resolution:
13 Bit (representation of negative values in the two's complement)
}LEDs for:
– Operating status per input
– Module error
}For failsafe applications in system environment B (automation system PSS 4000)
}T-type:
PSSu E F AI U-T: for increased environmental requirements
}R-type:
PSSu E F AI U-R: for railway applications

Overview
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 8
2.3 Front view
2111
2212
2313
2414
1
3
8
7
4
5
6
10
2
11
9
A
B
Legend:
}A: Electronic module
}B: Base module
}1: LEDs for
– Module diagnostics
– Status indicator
}2: Labelling strip with:
– Name of electronic module
– Order number
– Serial number
– Hardware version number
– 2D code
}3: Labelling strip for the terminal configuration on the base module
}4: Name of electronic module
}5: Connection level 1

Overview
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 9
}6: Connection level 2
}7: Connection level 3
}8: Connection level 4
}9: Square mounting holes (connection levels 1, 2, 3 and 4)
– With screw to loosen/tighten the screw terminal on base modules with screw termin-
als
– With mechanism to operate the cage clamp on base modules with cage clamp ter-
minals
}10: Round connection holes (connection levels 1, 2, 3 and 4) for connecting the signal
lines
}11: Mounting slot for colour marker to label the connection level (connection levels 1, 2,
3 and 4)

Safety
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 10
3 Safety
3.1 Intended use
The module may be used for failsafe applications in system environment B (automation
system PSS 4000).
The modules PSSu E F AI U and PSSu E F AI U-T may be used as a safety components in
accordance with the Lifts Directive 95/16/EC in accordance with the requirements of
EN81-1/2:1998+A3:2009, EN81-20:2015, EN81-50:2015, EN81-22:2014 and
EN115-1:2008+A1:2010.
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 and corresponding air conditioning.
The module provides an analogue input.
To guarantee safety integrity you will need to use 2 analogue input modules (2 PSSu E F AI
U or one PSSu E F AI U + one PSSu E F AI I). PL e (Cat. 4) and SIL CL 3 can be achieved
as a result of redundant input data.
The module guarantees functional safety, but not the safety of the entire process.
Please note the following during configuration and within the user program:
}With 2-channel operation, check the feasibility by using two inputs and two sensors.
Take appropriate measures to avoid common cause errors in the sensor technology, by
using diverse sensors or a separate supply voltage for the sensors, for example.
}We recommend that you monitor a defined measuring range of 2 … 10 V, as an open
circuit or short circuit cannot be detected at 0 V, for example.
The measured value is attenuated through the input filter. At the cutoff frequency, the amp-
litude of the measured value is 70 % of the amplitude of the input signal.
We strongly recommend the use of the following function blocks:
}FS_AnalogueInputSingle (using one input)
}FS_AnalogueInputDual (using two inputs)
The function blocks contain "Feasibility check" (only on FS_AnalogueInputDual) and "Limit
value monitoring" functions, which enable you to detect errors in the sensor as well as the
wiring. For the "Range monitoring" function we recommend that you use a measuring range
of 2 … 10 V.
The module PSSu E F AI U-T is suitable for use where there are increased environmental
requirements (see Technical Details).
The module PSSu E F AI U-R is suitable for use where there are increased environmental
requirements demanded by railway applications (see Technical details).
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

Safety
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 11
}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.
INFORMATION
The module is supported by
}PSSuniversal Configurator and PSSuniversal Assistant from Version
1.4.0 (base type, T-type)
}PAS4000 from Version 1.1.1 (base type, T-type)
}PAS4000 from Version 1.5.0 (R-type)
– We recommend that you always use the latest version (download
from www.pilz.com).
The PSSu E F AI U module may be used in conjunction with the following base modules:
}PSSu BP 1/8 S
}PSSu BP 1/8 C
}PSSu BP 1/12 S
}PSSu BP 1/12 C
}PSSu BP-C 1/8 S
}PSSu BP-C 1/8 C
}PSSu BP-C 1/12 S
}PSSu BP-C 1/12 C
The PSSu E F AI U-T and PSSu E F AI U-R modules may be used in conjunction with the
following base modules:
}PSSu BP 1/8 S-T
}PSSu BP 1/8 C-T
}PSSu BP 1/12 S-T
}PSSu BP 1/12 C-T
}PSSu BP-C 1/8 S-T
}PSSu BP-C 1/8 C-T
}PSSu BP-C 1/12 S-T
}PSSu BP-C 1/12 C-T

Safety
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 12
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 preven-
tion,
}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 spe-
cific 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.).
3.2.3 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 13
4 Function description
4.1 Block diagram
Module Bus
Periphery
Supply
+ 24 V DC
Module
Supply
+ 5 V DC
Data
(FS)
Input
11 14
ADC
13 23
C-Rail
4.2 Module features
Module supply
}The module supply provides the module with voltage.
Input signal processing:
}The analogue input signal is prefiltered, amplified and stored as a digital measured
value.
}To achieve functional safety, a test signal is generated in the microcontroller.
}The test signal is fed back to the amplifier via the D/A converter; there it is added to the
measured value that has been read in.
}The test signal is subtracted again from this total value and the result is compared with
the original measured value that was read in. The tolerance in this comparison process
is 5%. If this tolerance is exceeded, the signal is considered to be faulty. The module's
safety-related accuracy is therefore 5%. This must be considered in the application. It
can also be reduced through certain measures. For further information see Measures
for achieving process safety [ 15].

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 14
Schematic representation of signal processing:
Input Micro-
controller
FS
module
bus
Analogue
Digital
Analogue
Digital
Head
module
Resolution of analogue-digital converter
}The resolution of the analogue-digital converter is 12 bits wide. There is also an addi-
tional 1 sign bit. It therefore has 4096 quantisation levels in both the positive and negat-
ive range.
}Due to the system, the LSB always changes by 2 bits instead of 1. The resolution re-
mains unaffected.

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 15
4.3 Measures for achieving process safety
The module will detect internal module errors. Sensor errors and wiring errors can be de-
tected using the blocks FS_AnalogueInputSingle and FS_AnalogueInputDual. See Chapter
Intended use.
Please note that the overall accuracy must be considered when defining monitored limit val-
ues in the user program. Detailed information on calculating the overall accuracy can be
found in the following examples.
4.3.1 Example of 1-channel operation
The overall accuracy is calculated by adding the following values
}Safety-related accuracy of 5% (see "Technical details").
}Module's measuring accuracy
This value is calculated by adding all deviations from the measuring range limit value
(see "Technical details"). The value "Max. measurement error during EMC test" need
only be considered in environments with strong EMC interference. A measuring accur-
acy of 0.5% is assumed for this example.
}Sensor's measuring accuracy
This value is taken from the sensor's technical details. A value of 0.5% is assumed for
this example (in relation to the overall measuring range of -10.24…10.24 V).
Calculation of monitored limit values:
}In this example the overall accuracy as a % is therefore 5% + 0.5% + 0.5% = 6%.
This calculated overall accuracy refers to the overall measuring range of -
10.24 ...10.2375V.
}In relation to the overall measuring range, the overall accuracy in volts is:
(|-10.24V|+10.2375V) * 6% = 1.23V
}The sensor has a measuring range of 0...100 °C at 2 V...10 V. The resolution of the
sensor is 100°C / (10 V - 2 V) = 12.5°C per volt.
}The overall accuracy in °C is therefore: 1.23 V * 12.5 °C per volt = 15.38°C.
This overall accuracy must be considered when defining monitored limit values in the user
program. For example, if a hazardous situation should arise at a temperature above 80°C,
a safe reaction must occur in the user program at a temperature above 80°C-15.38°C=
64.62°C.

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 16
4.3.2 Example of 2-channel operation
With 2-channel operation, two inputs and two sensors must be used, as well as the "Feas-
ibility test" function of the block "FS_AnalogueInputDual". Instead of the module's safety-re-
lated accuracy, an empirically established tolerance is used with 2-channel operation.
The overall accuracy is calculated by adding the following values:
}Empirically established tolerance
This value must be established empirically. In the properties view of the block "FS_Ana-
logueInputDual", enter a value for feasibility monitoring, at which availability is still main-
tained. The tolerance consists of the current deviation between two current measured
values.
A deviation of 2 % between the two analogue input values has been established for the
example.
For availability reasons we recommend that you use a slightly higher value for the toler-
ance than the empirically established deviation. If the set tolerance is exceeded, the en-
able will be reset. A tolerance of 3% has been set for the feasibility test.
}Module's measuring accuracy
This value is calculated by adding all deviations from the measuring range limit value
(see "Technical details"). The value "Max. measurement error during EMC test" need
only be considered in environments with strong EMC interference. A measuring accur-
acy of 0.5 % is assumed for this example (in relation to the overall measuring range of
-10.24…10.23V). The following calculation of the overall accuracy assumes a meas-
uring range of 0 … 10.23V, so this value must be doubled. In the example below, a
measuring accuracy of 1% is used in the calculation.
}Sensor's measuring accuracy
This value is taken from the sensor's technical details. A value of 0.5 % is assumed for
this example (in relation to a measuring range of 0…10.23V).
Calculation of monitored limit values:
In this example the overall accuracy as a % is therefore 3 % + 1 % + 0.5 % = 4.5 %. The
calculated overall accuracy refers to a measuring range of 0 ...10.23V. It applies in both
the positive and negative range.
}In relation to a measuring range 0 ...10.23 V, the overall accuracy in V is:
(0V+10.2375V) * 4.5% = 0.46V
}The sensor has a measuring range of 0...500 mbar at 2V ...10V. The resolution of
the sensor is 500mbar / (10V - 2 V) = 62.5mbar per volt.
}The overall accuracy in mbar is therefore: 0.46 V * 62.5mbar per volt = 28.79mbar.
This overall accuracy must be considered when defining monitored limit values in the user
program. For example, if a hazardous situation should arise at a pressure above 300mbar,
a safe reaction must occur in the user program at a pressure above 300mbar–
28.79mbar= 271.21mbar.

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 17
WARNING!
Limit values selected in the user program too low or too high!
Risk of serious injury and death!
– Consider the max. overall accuracy when defining the limit values in
the user program.
4.4 Integrated protection mechanisms
When the PSSuEFPS1(-T) or PSSu E F PS2(-T)(-R) is used to supply the system, the
module supply is buffered for 20ms if the supply voltage is interrupted.
The module detects the following errors:
}Start-up error
}Configuration error
}FS communication error
}Bus termination error
4.5 Configuration
4.5.1 Converter characteristics/default value
The table below shows the converted data formats of the analogue input voltages. When
the digital values are converted into I/O data elements, the three highest binary digits are
filled with "0" for positive values and "1" for negative values.
Analogue
value
Digital value (13 Bit) I/O data element "Data" (16 Bit)
Binary
Hexa-
decima
l
Decim
al
Binary
Hexa-
decimal Decimal
10.2375 V 0 1111 1111 1111 0FFF 4095 0000 1111 1111 1111 0FFF 4095
10.00 V 0 1111 1010 0000 0FA0 4000 0000 1111 1010 0000 0FA0 4000
9.00 V 0 1110 0001 0000 0E10 3600 0000 1110 0001 0000 0E10 3600
8.00 V 0 1100 1000 0000 0C80 3200 0000 1100 1000 0000 0C80 3200
7.00 V 0 1010 1111 0000 0AF0 2800 0000 1010 1111 0000 0AF0 2800
6.00 V 0 1001 0110 0000 0960 2400 0000 1001 0110 0000 0960 2400
5.00 V 0 0111 1101 0000 07D0 2000 0000 0111 1101 0000 07D0 2000
4.00 V 0 0110 0100 0000 0640 1600 0000 0110 0100 0000 0640 1600
3.00 V 0 0100 1011 0000 04B0 1200 0000 0100 1011 0000 04B0 1200
2.50 V 0 0011 1110 1000 03E8 1000 0000 0011 1110 1000 03E8 1000
2.00 V 0 0011 0010 0000 0320 800 0000 0011 0010 0000 0320 800
1.00 V 0 0001 1001 0000 0190 400 0000 0001 1001 0000 0190 400
2.5 mV 0 0000 0000 0001 0001 1 0000 0000 0000 0001 0001 1

Function description
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 18
0.00 V 0 0000 0000 0000 0000 0 0000 0000 0000 0000 0000 0
-2.5 mV 1 1111 1111 1111 1FFF -1 1111 1111 1111 1111 FFFF -1
-1.00 V 1 1110 0111 0000 1E70 -400 1111 1110 0111 0000 FE70 -400
-2.00 V 1 1100 1110 0000 1CE0 -800 1111 1100 1110 0000 FCE0 -800
-3.00 V 1 1011 0101 0000 1B50 -1200 1111 1011 0101 0000 FB50 -1200
-4.00 V 1 1001 1100 0000 19C0 -1600 1111 1001 1100 0000 F9C0 -1600
-5.00 V 1 1000 0011 0000 1830 -2000 1111 1000 0011 0000 F830 -2000
-6.00 V 1 0110 1010 0000 16A0 -2400 1111 0110 1010 0000 F6A0 -2400
-7.00 V 1 0101 0001 0000 1510 -2800 1111 0101 0001 0000 F510 -2800
-8.00 V 1 0011 1000 0000 1380 -3200 1111 0011 1000 0000 F380 -3200
-9.00 V 1 0001 1111 0000 11F0 -3600 1111 0001 1111 0000 F1F0 -3600
-10.00 V 1 0000 0110 0000 1060 -4000 1111 0000 0110 0000 F060 -4000
-10.24 V 1 0000 0000 0000 1000 -4096 1111 0000 0000 0000 F000 -4096
If the measured range is exceeded, the default value 0x0000 (0000 hexadecimal) is output
and the valid bit is set to "0".
4.5.2 Input/output data
Data access is via pre-defined I/O data types.
I/O data name I/O data type I/O data element Meaning
I0(11) FS_I_AI Data: SAFEWORD Input data

Installation
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 19
5 Installation
5.1 General installation guidelines
Please also refer to the PSSuniversal Installation Manual.
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.
5.1.1 Dimensions
Base modules with four connection levels:
12,6 mm
76 mm
52,1 mm8,1 mm
67,7 mm
12,6 mm
56,1 mm 71,8 mm 0,8 mm
128,9 mm
72,6 mm
(2.051")(0.319")
(0.496") (2.858")
(0.496")
(2.99")
(2.209") (2.827") (0.031")
(5.075")
(2.665")

Installation
Operating Manual PSSu E F AI U(-T)(-R)
21993-EN-10 20
Base modules with six connection levels:
12,6 mm
76 mm
52,1 mm8,1 mm
67,7 mm
82,0 mm 71,8 mm 0,8 mm
72,6 mm
(2.051")(0.319")
(2.858")
(0.496")
(2.99")
(3.228") (2.827") (0.031")
(2.665")
12,6 mm
(0.496")
154,6 mm (6.087")
5.2 Installing the base module
Prerequisite:
}The head module must be installed.
}If the head module does not have an integrated power supply, a supply voltage module
must be installed to the right of the head module.
Please note:
}For mechanical reasons it is not possible to mix base modules with screw terminals and
base modules with cage clamp terminals.
}All contacts should be protected from contamination.
}The mechanics of the base modules are designed for 50 plug in/out cycles.
Procedure:
}We recommend that you wire up the base modules before inserting the electronic mod-
ules.
}Slot the groove on the base module on to the mounting rail from below [1].
}Push the base module back [2] until you hear it lock into position.
}On the mounting rail, slide the base module to the left until you hear the two lateral
mounting hooks on the adjacent module lock into position [3].