Pilz PSSu E F INC User manual

PSSu E F INC(-T)
Operating Manual-1001454-EN-09
}Decentralised system PSSuniversal I/O

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation 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 INC(-T)
1001454-EN-09 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 Integrated protection mechanisms 13
4.3 Function description 13
4.3.1 Functional inputs (G, L, S) 14
4.3.2 Overflow 14
4.4 Incremental encoder operating mode 15
4.5 Counter operating mode 16
4.6 Functions 17
4.6.1 Measure period length 17
4.6.2 Transfer counter status via latch pulse 18
4.6.3 Transfer counter status via zero pulse 19
4.6.4 Set counter status 20
4.7 Configuration 21
4.7.1 Operating modes and parameters 21
4.7.2 Input/output data 21
4.7.2.1 PSSu assignment in system environment B 21
Section 5 Installation 23
5.1 General installation guidelines 23
5.1.1 Dimensions 23
5.2 Installing the base module 23
5.3 Inserting and removing an electronic module 24
5.3.1 Inserting an electronic module 25
5.3.2 Removing an electronic module 26
5.3.3 Changing an electronic module during operation 26
Section 6 Wiring 27
6.1 General wiring guidelines 27

Contents
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1001454-EN-09 4
6.1.1 Mechanical connection of the base modules 27
6.2 Terminal configuration 30
6.3 Connecting the module 32
Section 7 Operation 35
7.1 Messages 35
7.2 Display elements 35
7.2.1 Display elements for module diagnostics 35
7.2.2 Display elements for counter status 36
7.2.3 Display elements for status of the functional inputs 36
7.3 Status information 36
Section 8 Technical Details 37
8.1 Safety characteristic data 40
Section 9 Order reference 41
9.1 Product 41
9.2 Accessories 41

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the products PSSu E F INC and PSSu E F INC-T. 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 INC and PSSu E F INC(-T) are exclusively for use in system envir-
onment B (automation system PSS4000).

Introduction
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1001454-EN-09 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
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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:
}Inputs for
– Counter pulses (inputs A, B)
– Zero pulse (inputC)
– Stopping the counter (inputG, Gate)
– Memory function (Input L, Latch)
– Rotary encoder status (Input S, Status)
}Resolution of the counter and latch memory: 32 Bit
}Operating modes:
– Incremental encoder
– Counter
}Inputs A, B, C are operated as differential inputs with inverted signals (A-, B-, C-).
}LEDs for:
– Data transfer per input A, B, C
– Status per functional input (Gate, Latch, Status)
– Module error
}For failsafe applications in system environment B (automation system PSS 4000)
}T-type:
PSSu E F INC-T: for increased environmental requirements

Overview
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2.3 Front view
2111
2212
2414
4131
4232
4434
2313 4333
10
1
3
4
9
8
5
6
7
11
2
12
A
B
Legend:
}A: Electronic module
}B: Base module
}1: LEDs for
– Module diagnostics
– Status of the input channels A, B, C
}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: LEDs for
– Status of function inputs G, L, S
}5: Name of electronic module

Overview
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}6: Connection level 1 (terminals 11, 21, 31, 41)
}7: Connection level 2 (terminals 12, 22, 32, 42)
}8: Connection level 3 (terminals 13, 23, 33, 43)
}9: Connection level 4 (terminals 14, 24, 34, 44)
}10: 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
}11: Round connection holes (connection levels 1, 2, 3 and 4) for connecting the signal
lines
}12: Mounting slot for colour marker to label the connection level (connection levels 1, 2,
3 and 4)

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).
The modules PSSu E F INC and PSSu E F INC-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.
With the counter module you can implement the following safety functions:
Monitoring of:
}Position
}Speed
}Standstill
To guarantee safety integrity you will need to use
}2 sensors and
}2 counter modules: a PSSu E F INC and a PSSu E F ABS SSI and
}the function blocks FS_IncrementalEncoder, FS_AbsoluteEncoder and FS_Counter-
Dual
This means that with redundant and diverse input values, PL e and SIL CL 3 can be
achieved.
To apply the module you will need to have read and understood the description of the func-
tion blocks (s. Online help).
Requirements of the PSSu system:
}The counter modules must be part of a control system PSSu PLC or PSSu multi (not
decentralised I/O system).
}The function blocks have to be assigned to the FS resource of the PSSu system where
the counter modules are inserted. Control via SafetyNet is not permitted.
Demands on the sensors:
}Incremental encoders with RS422 interfaces may be used as sensors.
}Connect the sensors mechanically independently to the axis. If this is not possible, the
connection should be positive-locking without wearing parts as e.g. chains or drive
belts. If it is not possible to avoid this, the mechanical connection of the sensors must
be monitored.
Alternatively, it is possible to use a sensor that internally has 2 independent measured
value recording systems.
Please note during configuration and within the user program:
}The input values must be diverse. This can be achieved through different
– Scaling

Safety
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1001454-EN-09 11
– Direction of rotation/count direction
– Offset
}If more than two counters are used, each individual counter module of a PSSu system
must supply diverse input values to the other counter modules of the PSSu system.
}Safe standstill monitoring must be carried out by feasibility with a safe travel command
in the function block.
}Test the safety functions when commissioning or recommissioning.
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.
INFORMATION
The module is supported by PAS4000 from Version 1.1.1. We recommend
that you always use the latest version (download from www.pilz.de).
The PSSu E F INC module may be used in conjunction with the following base modules:
}PSSu BP 2/16 S
}PSSu BP 2/16 C
}PSSu BP-C 2/16 S
}PSSu BP-C 2/16 C
The module PSSu E F INC-T may be used in conjunction with the following base modules:
}PSSu BP 2/16 S-T
}PSSu BP 2/16 C-T
}PSSu BP-C 2/16 S-T
}PSSu BP-C 2/16 C-T

Safety
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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 this description under "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
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4 Function description
4.1 Block diagram
Module Bus
Periphery
Supply
+ 24 V DC
Module
Supply
+ 5 V DC
Data
(ST)
Input A
11 14
Input B
21 24
Input C
31 34 41 42 44
Inputs
G, S, L
4.2 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
}ST communication error
}Bus termination error
4.3 Function description
Module supply
}The module supply provides the module with voltage.
Inputs
}3 dual-pole, differential inputs A, B, C for connecting an incremental encoder or an en-
coder that provides rising edges as counter pulses.
}3 single-pole inputs referenced to earth: G, L, S, for special functions
Operating modes
}Incremental encoder
}Counter
Functions
}Period length measurement
or
}Storing the counter status in latch memory after a latch pulse or zero pulse

Function description
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1001454-EN-09 14
}Setting the counter status
The module transfers the data and status information to the head module via the module
bus. The choice of function and the function's configuration are defined via the system soft-
ware.
4.3.1 Functional inputs (G, L, S)
The single-pole inputs (G, L, S) are used for special functions. Inputs G and L may be con-
nected to external signal sources, e.g. to a higher order control system. If the gate signals
are generated by a non-safety-related device or if the gate inputs are connected, common
cause failures may arise. A failure mode and effects analysis must be carried out when wir-
ing the gate inputs.
}Input G (gate input)
The counter is stopped with a 1 signal. The module ignores the counter pulses at the in-
puts until a 0 signal returns.
}Input L (input for latch pulse)
At a rising edge, the module stores the current counter value in the latch memory. The
counter continues counting; it is not stopped by the latch pulse. The module transmits
the stored value to the head module. The period length measurement may be con-
figured as an alternative to the latch function.
}Input S (status input)
The encoder's fault signal output can be connected to the status input. The module
transmits the input state to the head module with the status information.
4.3.2 Overflow
In both operating modes the counter can accept values from 00000000H to FFFFFFFFH.
}With an underflow the value drops below 00000000H and the counter continues from
FFFFFFFFH.
}With an overflow the value FFFFFFFFH is exceeded and the counter continues from
00000000H.
The overflow or underflow is signalled to the head module as status information.
The status information overflow is reset:
}if the value again falls below 00000000H (underflow).
}if 55550000H is exceeded (the lower third of the value range).
The status information underflow is reset:
}if FFFFFFFFH is exceeded again (overflow).
}if AAAAFFFFH is exceeded (the upper third of the value range).

Function description
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4.4 Incremental encoder operating mode
The counter outputs and the output for the incremental encoder's zero pulse are connected
to the dual-pole inputs (A, B, C).
}Inputs A, B
The first channel of the encoder is connected to input A, the second to input B. The
second channel is 90° out of phase. If channel A is leading, the module counts for-
wards. If channel A is lagging, the module counts backwards (see timing diagram).
}InputC
The output for the incremental encoder's zero pulse is connected to input C. An incre-
mental encoder typically supplies one zero pulse per rotation. If the zero pulse function
is activated, the module copies the last value prior to the zero pulse into the latch
memory and passes it to the process image of inputs (see chapter entitled "Transfer
counter status via latch pulse").
C+
G
L
C-
a b c d e
B+
B-
A+
A-
Legend:
}a: The counter counts backwards because the signal at channel A is lagging.
}b: The module has received a zero pulse. Provided the function is activated, the
counter value is copied into the latch memory with a rising edge at input C+.
}c: The counter counts forwards because the signal at channel A is leading.
}d: The module has received a latch pulse. Provided the function is activated, the
counter value is copied into the latch memory with a rising edge at input L.
}e: The counter is disabled because there is a 1 signal at input G.

Function description
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4.5 Counter operating mode
"Counter" operating mode is not recommended for safety functions because pulses can be
generated if there are any track errors. Compare errors can arise as a result, which can
lead to a shutdown or to common cause errors.
In "Counter" operating mode, the module's dual-pole, differential inputsA, B, C have the fol-
lowing functions:
}InputA (Count)
Input A is the input for the encoder's counter pulses. The module counts each rising
edge.
}InputB (Up/down)
At a 0 signal the module counts forwards. At a 1 signal the module counts backwards.
}InputC (Gate/Latch)
The counter is stopped with a 1 signal. The module ignores the counter pulses at the in-
put until a 0 signal returns.
C+
G
L
a b c d e
B+
A+
Legend:
}a: The counter counts forwards because there is 0 signal at channel B.
}b: At the next rising edge at channel A, the counter counts backwards because there is
a 1 signal at channel B.
}c: The counter is disabled because there is a 1 signal at input C.
}d: The module has received a latch pulse. Provided the function is activated, the
counter value is copied into the latch memory with a rising edge at input L.
}e: The counter is disabled because there is a 1 signal at input G.

Function description
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4.6 Functions
4.6.1 Measure period length
The module can record the period length of the counter pulses on channelA. The period
length is the time between two rising edges at channelA. It is transferred to the process im-
age of inputs as multiple of 200 ns.
Prerequisite: This function is configured in PAS4000.
PIO
PII
Legend:
}PIO: Process image of outputs, I/O datum: OutputData.LatchOrMeasure
}PII: Process image of inputs, I/O datum: InputData.LatchOrMeasureDone
Key to timing diagram:
Section Function
Procedure for PSSu in system environ-
ment B
a Start measurement In the user program, set OutputData.Lat-
chOrMeasure
b Output measured value
Set status bit
Measured value is written in InputData.Lat-
chOrPeriod
The module sets InputData.LatchOrMeas-
ureDone
c Finish measurement In the user program, reset OutputData.Lat-
chOrMeasure
d Ready for new measure-
ment
The module resets InputData.LatchOrMeas-
ureDone
The result of the last period length measurement remains in the process image of inputs
until the module signals a new measurement result by setting the status information. Before
the initial measurement the process image of inputs contains 00000000H or FFFFFFFF H.
The module issues the result of period length measurement in multiples of 200ns.
Example:
}The process image of inputs contains 32H/50D
}The period length is 200 ns x 50 = 10μs

Function description
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4.6.2 Transfer counter status via latch pulse
A signal output can be connected to input L on the module for a latch pulse. The latch pulse
may come from a PLC or position switch, for example. Using the latch function it is possible
to record and transmit the counter status at the time of this latch pulse.
Prerequisite: This function is configured in PAS4000.
PIO
PII
Legend:
}PIO: Process image of outputs, I/O datum: OutputData.LatchOrMeasure
}L: Input L for external latch
}PII: Process image of inputs, I/O datum: InputData.LatchOrMeasureDone
Key to timing diagram:
Section Function
Procedure for PSSu in system environ-
ment B
a Activate latch function In the user program, set OutputData.Lat-
chOrMeasure
b Fill latch memory Rising edge at input L: Counter status is
transferred to the latch memory
c Output counter status
Set status bit
Counter status is written in InputData.Lat-
chOrPeriod
The module sets InputData.LatchOrMeas-
ureDone
d Finish latch function In the user program, reset OutputData.Lat-
chOrMeasure
e Ready for new latch func-
tion
The module resets InputData.LatchOrMeas-
ureDone
The contents of the latch memory remains in the process image of inputs until the module
signals a new memory value by setting the status information. Before the initial transfer the
process image of inputs contains 00000000H or FFFFFFFF H.
The module always transmits the counter status when the first latch pulse occurs after the
function has started. All subsequent latch pulses are ignored until the function is completed
and reset.

Function description
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4.6.3 Transfer counter status via zero pulse
The output for the incremental encoder's zero pulse is connected to input C (C+/C-). An in-
cremental encoder typically supplies one zero pulse per rotation. Using the zero pulse func-
tion it is possible to record the last counter status before the zero pulse and transmit it via
the process image of inputs.
INFORMATION
In Counter operating mode, a rising edge at input C stops the counter.
PIO
PII
Legend:
}PIO: Process image of outputs, I/O datum: OutputData.ZeroPulseActive
}C: Input C
}PII: Process image of inputs, I/O datum: InputData.ZeroPulse
Key to timing diagram:
Section Function
Procedure for PSSu in system environ-
ment B
a Activate zero pulse function In the user program, set OutputDa-
ta.ZeroPulseActiv
b Fill latch memory Rising edge at input C: Counter status is
transferred to the latch memory
c Output counter status
Set status bit
Counter status is written in InputData.Lat-
chOrPeriod
The module sets InputData.ZeroPulse
d Finish zero pulse function In the user program, reset Output-
Data.ZeroPulseActiv
e Ready for new latch func-
tion
The module resets InputData.ZeroPulse
The zero pulse function has priority over the latch function and the "Period length measure-
ment" function. If this function is activated, both the other functions are ignored, even if they
have been activated.
The module always transmits the counter status when the first zero pulse occurs after the
function has started. The counter statuses on all subsequent zero pulses are ignored until
the function has been completed and reset.

Function description
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4.6.4 Set counter status
The "Set counter status" function sets the counter to any value. The value is stated in the
user program. The module transfers the value and continues counting from this counter
status.
PIO
PII
Legend:
}PIO: Process image of outputs, I/O datum: OutputData.SetCounter
}PII: Process image of inputs, I/O datum: InputData.SetCounterDone
Key to timing diagram:
Section Function
Procedure for PSSu in system environ-
ment B
a Enter counter status In the user program, assign the default
counter status to OutputData.NewCounter-
Value
b Transfer counter status In the user program, set OutputData.Set-
Counter
c Acknowledge transfer The module sets InputData.SetCounter-
Done; InputData.Underflow and Input-
Data.Overflow are reset
d Finish transfer In the user program, reset OutputData.Set-
Counter
e Ready for new function The module resets InputData.SetCounter-
Done