Pilz PSSu E S 2AO I User manual

PSSu E S 2AO I(-T)
Operating Manual-21435-EN-04
}Decentralised system PSSuniversal I/O

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
1.1.1 Retaining the documentation .................................................................................................... 5
1.1.2 Terminology: System environment A and B ............................................................................. 5
1.2 Definition of symbols................................................................................................................. 6
2 Overview ................................................................................................................................. 7
2.1 Module structure ....................................................................................................................... 7
2.2 Module features ........................................................................................................................ 7
2.3 Front view ................................................................................................................................. 8
3 Safety ...................................................................................................................................... 10
3.1 Intended use ............................................................................................................................. 10
3.2 Safety regulations ..................................................................................................................... 11
3.2.1 Use of qualified personnel ........................................................................................................ 11
3.2.2 Warranty and liability ................................................................................................................ 11
3.2.3 Disposal .................................................................................................................................... 11
4 Function description ............................................................................................................. 12
4.1 Block diagram ........................................................................................................................... 12
4.2 Module features ........................................................................................................................ 12
4.2.1 Functions .................................................................................................................................. 12
4.2.2 Integrated protection mechanisms............................................................................................ 13
4.3 Configuration ............................................................................................................................ 13
4.3.1 Current range............................................................................................................................ 13
4.3.2 Data formats ............................................................................................................................. 14
4.3.3 Scaling ...................................................................................................................................... 15
4.3.3.1 DAC raw value.......................................................................................................................... 16
4.3.3.2 Hardware calibration................................................................................................................. 16
4.3.3.3 Manufacturer scaling ................................................................................................................ 17
4.3.3.4 User scaling .............................................................................................................................. 18
4.3.3.5 Example calculation.................................................................................................................. 18
4.3.4 Switch-on value ........................................................................................................................ 19
4.3.5 Summary and overview ............................................................................................................ 20
4.3.6 PSSu assignment in system environment A............................................................................. 20
4.3.6.1 Addresses in the process image............................................................................................... 20
4.3.7 PSSu assignment in system environment B............................................................................. 21
5 Installation .............................................................................................................................. 22
5.1 General installation guidelines.................................................................................................. 22
5.1.1 Dimensions ............................................................................................................................... 22
5.2 Installing the base module ........................................................................................................ 24
5.3 Inserting and removing an electronic module ........................................................................... 25
5.3.1 Inserting an electronic module.................................................................................................. 26
5.3.2 Removing an electronic module ............................................................................................... 27
5.3.3 Changing an electronic module during operation ..................................................................... 27

Contents
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6 Wiring ...................................................................................................................................... 28
6.1 General wiring guidelines ......................................................................................................... 28
6.1.1 Mechanical connection of the base modules............................................................................ 28
6.2 Terminal configuration .............................................................................................................. 30
6.3 Connecting the module............................................................................................................. 32
7 Operation ................................................................................................................................ 33
7.1 Messages ................................................................................................................................. 33
7.2 Display elements ...................................................................................................................... 34
7.2.1 Display elements for module diagnostics ................................................................................. 34
7.2.2 Display elements for output status............................................................................................ 34
8 Technical details .................................................................................................................... 35
9 Order reference ...................................................................................................................... 38
9.1 Product ..................................................................................................................................... 38
9.2 Accessories .............................................................................................................................. 38

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the products PSSu E S 2AO I and PSSu E S 2AO I-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.
Electronic module with analogue outputs for standard applications
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

Introduction
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1.2 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
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:
}2 analogue current outputs
}Configurable current ranges:
– 0 ... 20mA single-pole, referenced to earth (single-ended)
– 4 ... 20mA single-pole, referenced to earth (single-ended)
}Resolution: 12 Bit
}LEDs for:
– Operating status per output
– Module error
}For standard applications in system environment A and B
}T-type:
PSSu E S 2AO I-T: for increased environmental requirements

Overview
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2.3 Front view
2111
2212
2313
2414
11
O0
21
O1
12
0V
22
0V
13
(C)
23
(C)
14 24
Err
PSSu E S
2AO I
O 0 O1
PSSu E S
2AO I
312470
000000
001
1
3
4
8
7
4
5
6
9
10
2
11
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
}6: Connection level 2

Overview
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}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 termin-
als
}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
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3 Safety
3.1 Intended use
The module may be used for standard applications in system environment A and B.
The module provides analogue outputs. It may be used as an output module for standard
functions.
The module PSSu E S 2AO I-T is suitable for use where there are increased environmental
requirements (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
}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
}PAS4000 from Version 1.0.0
– We recommend that you always use the latest version (download
from www.pilz.com).
The PSSu E S 2AO I 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

Safety
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The module PSSu E S 2AO I-T may be used in conjunction with the following base mod-
ules:
}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
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 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.
3.2.2 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-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
Module Bus
Periphery
Supply
+ 24 V DC
Module
Supply
+ 5 V DC
Data
(ST)
11 12 21 22
DAC
13 23
C-Rail
4.2 Module features
4.2.1 Functions
Module supply
}The module supply provides the module with voltage.
Periphery supply
}The supply for the outputs is generated from the periphery supply.
}The periphery supply and the outputs are galvanically isolated.
The output signals for each output are transmitted to the output module via the ST module
bus. The resolution is 12bits (4095 steps). Additional signal processing can be defined us-
ing the system software (see schematic representation of signal processing). The individual
steps are described in the "Configuration" section.
All the configuration data is stored in the head module and is assigned to the output module
on restart. This way the configuration data is retained even if you change the output mod-
ule.
Schematic representation of signal processing:
OUTDAC
Data
format
ST
module
bus
User
scaling
Manufact.
scaling

Function description
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4.2.2 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 Configuration
The following options exist for configuring the module in system environment A:
}Via a fieldbus without the modular device description file
Without the modular device description file it is only possible to configure the input or out-
put range. All other configuration details have default values.
}Via a fieldbus with the modular device description file
With a modular device description file it is possible to configure all the values.
}Via the USB port of the head module, using the PSSuniversal Configurator
All the values can be configured using the PSSuniversal Assistant. Any configuration via
the USB port will overwrite the configuration made via the fieldbus.
If a module has been configured via the head module's USB port, it is locked and cannot be
overwritten by the fieldbus. This lock can be deactivated again in the PSSuniversal Config-
urator.
The following options exist for configuring the module in system environment B:
}Via the head module's USB port with PAS4000.
4.3.1 Current range
You can configure the following current ranges per module:
}0 ... 20mA single-pole, referenced to earth (single-ended)
}4 ... 20mA single-pole, referenced to earth (single-ended)

Function description
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4.3.2 Data formats
The way in which the analogue value is displayed depends on the voltage range, on scaling
and on the data format. The following examples show the relationship between the values
with default scaling.
You can configure the following data formats:
}Two's complement (default)
The 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
The digital values are transferred with 15bits plus a sign bit (MSB). The MSB is "1" with
negative values and "0" with positive values. With negative values there is a distinction
between sign and magnitude representation and two's complement representation.
}Formation of magnitude option
Negative digital values are converted into positive values of equal magnitude.
As the module's resolution is 12bits plus sign bit, the three least significant bits have no
significance for the analogue value.
Analogue value and typical digital value with a current range of 0 ... 20 mA, two's
complement or sign and magnitude representation:
Analogue value of cur-
rent
Decimal digital value Binary digital value Hexadecimal digital
value
0 mA 0 0000 0000 0000 0000 0000H
10 mA 16 384 0100 0000 0000 0000 4000H
20 mA 32 767 0111 1111 1111 1111 7FFFH
Analogue value and typical digital value with a current range of 4 ... 20 mA, two's
complement or sign and magnitude representation:
Analogue value of cur-
rent
Decimal digital value Binary digital value Hexadecimal digital
value
4 mA 0 0000 0000 0000 0000 0000H
12 mA 16 384 0100 0000 0000 0000 4000H
20 mA 32 767 0111 1111 1111 1111 7FFFH

Function description
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4.3.3 Scaling
Scaling is a multi-stage process to adapt the values to the DA converter. The straight path
in the diagram indicates the default configuration.
Raw value
output?
Manuf.
scaling
active?
Hardware
calibration
Manufacturer
scaling
User
scaling
active?
User
scaling
Input
formats
N
Y
Y
YN
N
DAC
raw value

Function description
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Analogue value and typical digital value with a current range of 0 ... 20 mA and de-
fault values:
Analogue value of current Decimal digital value
0 mA 0
10 mA 16 384
20 mA 32 767
10 mA 12 mA 14 mA 16 mA 18 mA8 mA6 mA4 mA2 mA0 mA 20 mA
32 76729 49026 21422 93719 66016 38413 1079 8306 5533 2770
Analogue value and typical digital value with a current range of 4 ... 20 mA and de-
fault values:
Analogue value of current Decimal digital value
4 mA 0
12 mA 16 384
20 mA 32 767
12 mA4 mA 20 mA
32 76716 3840
6 mA
4096
8 mA
8192
10 mA
12 288
14 mA
20 479
16 mA
24 575
18 mA
28 671
4.3.3.1 DAC raw value
You can configure each channel so that the raw value is transferred directly to the DA con-
verter, without calibration or scaling.
4.3.3.2 Hardware calibration
Each channel is calibrated ex-works in order to correct component dispersion and other in-
fluences.
The range is divided so that zero is assigned the value 0 and the end point is assigned the
value 4095D (0FFFH).

Function description
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4.3.3.3 Manufacturer scaling
The manufacturer scaling is used to define the offset (zero point compensation) and gain
(amplification) of the digital signal.
Manufacturer scaling active (default setting)
}Default values for manufacturer scaling:
– Offset (b1): 0
– Gain (a1): 32D (20H)
INFORMATION
The default setting for gain (a1) means an amplification factor of 0.125 (1/8).
The digital value after manufacturer scaling is calculated using the following for-
mula:
}y = (a1 / 256D * x) + b1 or
}y = (a1 / 100H * x) + b1
Key:
}y: Digital value after manufacturer scaling
}x: Digital value before manufacturer scaling
}a1: Gain
}b1: Offset
}a1 / 256D: Amplification factor
INFORMATION
With the given amplification factor, gain (a1) is calculated as follows:
Gain (a1) = Amplification factor * 256D
Amplification by 5% is therefore:
1.05 * 256D = 269 D

Function description
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Arithmetic examples using decimal values:
Digital value
before manu-
facturer scaling
(x)
Gain (a1) Offset (b1) Amplification
factor (a1 /
256D)
Value after
manufacturer
scaling (y)
1 000 256 0 1 1 000
1 000 512 0 2 2 000
1 000 32 0 0,125 125
1 000 269 500 1,05 1 550
1 000 128 -50 0,5 450
The module always uses two's complement representation for internal processing, irre-
spective of the configured data format. The values from 0000H to FFFFH form a number
circle in the two's complement representation. 8000H follows 7FFFH (=32767D) and is inter-
preted as the lowest negative number (=-32768D). 32767D is never exceeded; the value
never falls below -32,768D.
INFORMATION
If 7FFFH is exceeded as a result of scaling, unintended values may be set
on the output.
4.3.3.4 User scaling
User scaling is an additional scaling level prior to manufacturer scaling. You can use this
scaling to correct local influences. The function is the same as that of manufacturer scaling:
y = (a2 / 256D * x) + b2 or
y = (a2 / 100H * x) + b2
a2 = Amplification factor * 256D
User scaling is deactivated in the default setting. The default value for offset is 0. The de-
fault value for gain is 256D (100H). That corresponds to amplification factor1.
4.3.3.5 Example calculation
Task:
If the PIO shows a decimal value of 20 000, there should be 20mA at the output. User scal-
ing should be used in this case (Gain a2). Manufacturer scaling should not be changed. All
numbers are decimals.
Solution:
User scaling
y = (a2 / 256 * x) + b2
and manufacturer scaling
y = (a1 / 256 * x) + b1

Function description
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act consecutively, giving:
y = (a1 / 256 * ((a2 / 256 * x) + b2)) + b1 or:
y = (a1 * a2 * x / 65536) + (a1 * b2 / 256) + b1
With default values for a1 = 32, b1 = 0 and the default value b2 = 0:
y = a2 * x / 2048
a2 = y * 2048 / x
Due to the hardware calibration the converter's output range is divided so that the 20 mA
end point is assigned the value x=4095. With the default values y= 4095 and x= 20,000
the result is:
Gain a2 = 419
4.3.4 Switch-on value
When the PSSuniversal is switched on, the output assumes the switch-on value until the
module receives data for the value of the output. You can configure the outputs per channel
with the manufacturer switch-on value (default) or you can use a freely definable user
switch-on value. The manufacturer switch-on value is:
}0mA for the current range 0 … 20mA and
}4mA for the current range 4 … 20mA.
If the module does not receive any data from the module bus for 50 ms, the outputs are re-
set to the switch-on value.
Switch-on values are entered in the system software as decimal vaues. With default scal-
ing, the decimal value (n) is calculated from the analogue value at the output (IStart) as fol-
lows:
}Current range 0 … 20mA:
n = 32 767 * IStart / 20mA
}Current range 4 … 20mA:
n = 32 767 * (IStart – 4mA) / 16mA
example:
}Switch-on values as an analogue value at the output (IStart):
– Switch-on value for channel 1 is to be 8 mA.
– Switch-on value for channel 2 is to be 15 mA.
}Entry in the system software at
Current range 0 … 20mA:
– Switch-on value 1 corresponds to 13 107
– Switch-on value 2 corresponds to 24 576
}Entry in the system software at
Current range 4 … 20mA:
– Switch-on value 1 corresponds to 8 192
– Switch-on value 2 corresponds to 22 528
The relationship between the switch-on value and the actual current at the output is de-
pendent on the scaling. The module sets the current, which corresponds to the switch-on
voltage after scaling. Please refer to the "Scaling" section in this manual.

Function description
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4.3.5 Summary and overview
The module has the following configuration options:
Configurable properties Default
value
Meaning
Output range 0 0 mA ... 20 mA
(1 = 4 mA ... 20 mA)
Manufacturer scaling active 1/TRUE Activated
Manufacturer scaling offset 0 Offset: Magnitude 0
Manufacturer scaling gain 32DAmplification by 1/8, displaced three bit places
User scaling active 0/FALSE Deactivated
User scaling offset 0 Offset: Magnitude 0
User scaling gain 256D1x amplification, signal unchanged
Switch-on value active 0/FALSE Manufacturer switch-on value active
(1/TRUE = User switch-on value active)
Manufacturer switch-on value 0 0 mA / 4 mA on switch-on
User switch-on value 0 0 mA / 4 mA on switch-on
Sign and magnitude representa-
tion active
0/FALSE Deactivated; two's complement is activated
Formation of magnitude active 0/FALSE Deactivated
Output DAC raw value only 0/FALSE Deactivated
4.3.6 PSSu assignment in system environment A
4.3.6.1 Addresses in the process image
Each output channel occupies 16 consecutive bit addresses for the output data.
Configuration Standard bus system
ST-PII ST-PIO
None - - - 32 Bit
Bit sequence in the PIO:
Input PIO Assignment
Output O0 1 LSB
... ...
16 MSB
Output O1 17 LSB
... ...
32 MSB