Pilz PSSuniversal User guide

System Description — No. 21256-EN-04
Programmable control systems PSS®
PSSuniversal
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This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Co ies may be made
for internal ur oses.
Suggestions and comments for im roving this documentation will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS ®, SafetyEYE®,
SafetyNET ®, the s irit of safety® are registered and rotected trademarks of
Pilz GmbH & Co. KG in some countries.
SD means Secure Digital.
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Telephone: [phone], Telefax: [phone], E-Mail: [email protected] 1
Contents
Contents
Contents Page
Chapter 1 Introduction
1.1 Validity of the documentation 1-1
1.2 Overview of the documentation 1-2
1.3 Definition of symbols 1-3
Chapter 2 Overview
2.1 General 2-1
2.2 Objective of the PSSu system 2-2
2.3 Features of the PSSu system 2-3
2.4 System software for PSSu systems 2-4
Chapter 3 Safety
3.1 General guidelines 3-1
3.2 Intended use 3-2
3.3 Use of qualified personnel 3-3
3.4 Failsafe inputs/outputs 3-4
Chapter 4 Basics
4.1 Structure of a PSSu system 4-1
4.2 Module layout 4-3
4.3 Module descriptions 4-5
4.4 Module bus 4-7
4.5 Connections on the base modules 4-9
4.5.1 Connection levels on input/output mod-
ules
4-9
4.5.2 Colour marking on the connection levels 4-10
4.6 Connections on the compact modules 4-11
4.7 Maximum system expansion 4-12
4.7.1 SafetyBUS p and standard bus systems 4-13
4.7.2 Number of modules and number of inputs/
outputs on a PSSu system
4-14
4.7.3 Maximum current load 4-15
4.7.3.1 Maximum current load capacity on the
supply voltage modules
4-15
4.7.3.2 Maximum current load capacity based on
temperature
4-16
4.8 Device description files 4-17
4.9 Local enable principle 4-19
4.10 Slots on a PSSu system 4-21
4.11 Addressing the modules 4-22
4.11.1 Addressing principle 4-22
4.11.2 Addresses and bit requirement of a PSSu
system
4-23
4.11.3 Status bytes 4-24

Contents
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4.11.4 Configurations that impact the address
and bit requirement
4-25
4.11.5 Overview of the modules' bit requirement 4-26
4.11.6 Example: Bit requirement and addressing 4-29
4.11.7 Optimisation of module layout 4-32
4.12 Supply voltage and insulation 4-39
4.13 Supply groups 4-42
4.14 Reaction times of the PSSuniversal 4-44
4.14.1 Scan time of a PSSu system 4-45
4.14.2 Input/output processing time 4-45
4.14.3 Input reaction time 4-46
4.14.4 Output reaction time 4-47
Chapter 5 PSSuniversal on SafetyBUS p
5.1 Configure PSSu for SafetyBUS p 5-1
5.2 Circuit examples 5-3
5.2.1 1-channel actuator with feedback loop and
local enable
5-3
5.2.2 2-channel actuator with feedback loop and
local enable
5-6
Chapter 6 Commissioning
6.1 Procedure 6-1
6.1.1 Assembly of the PSSu systems in the
PSSuniversal Assistant
6-2
6.1.2 Programming in the SafetyBUS p
Configurator
6-3
Chapter 7 Diagnostics
7.1 Diagnostic data of electronic modules 7-1
7.2 Head module's error stack 7-4
Chapter 8 Appendix
8.1 Glossary 8-1
8.2 Modules' hexadecimal code 8-5

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1.1 Validity of the documentation
1 Introduction
11000IntroductionIntroduction1-1.1Validity of the documentation1100Validity of the documentation1-][Einführun g PSSu Gül tigkeit Sys A
This documentation is valid for PSSu systems in system environment A.
A PSSu system in system environment A may be used in the
Decentralised system PSSu I/O with SafetyBUS p
Decentralised system PSSu I/O with ST fieldbuses such as CANopen,
DeviceNet
Not in the automation system PSS 4000
It is valid until new documentation is published.
The latest documentation is always enclosed with the product.

1.2 Overview of the documentation
1 Introduction
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1-2
1.2Overview of the documentation1200Overview of the documentation1-][Einfhrung Sys bersicht
1 Introduction
The introduction is designed to familiarise you with the contents, struc-
ture and specific order of this system description.
2 Overview
This chapter contains a brief description of what constitutes a PSSu sys-
tem.
3 Safety
This chapter must be read as it contains important information on safety
regulations.
4 Basics
This chapter describes the PSSu system as a whole and provides con-
figuration guidelines.
5 PSSu systems on SafetyBUS p
This chapter shows how the PSSu systems are connected to
SafetyBUS p.
6 Commissioning
This chapter describes the commissioning process step-by-step and
explains the aids that are available.
7 Diagnostics
This chapter contains a description of the available diagnostic proce-
dures.
8 Appendix
The appendix contains information in table format.

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1.3 Definition of symbols
1 Introduction
1.3Defi nition of symb ols1300Defi nition of symb ols1-Einfhrung Zeichen
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 preven-
tive 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 damaged and also provides information on preventive meas-
ures that can be taken.
INFORMATION
This gives advice on applications and provides information on
special features, as well as highlighting areas within the text that
are of particular importance.

1 Introduction
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2.1 General
2Overview
22000OverviewOverview2-2.1General2100General2-][Uebersicht PSSu-System Sys A
A PSSu system is assembed from a variety of modules, to suit the func-
tions required. The modular structure makes it easier to react to modifi-
cations and adjustments.
The scope of a PSSu system can also be adapted retrospectively, e.g.
by
Extending the number of I/Os
Modifying the I/O technology
(e.g. by using relay outputs instead of semiconductor outputs)
Adding I/O functions
(e.g. by retrospectively adding analogue evaluation, counter func-
tions, temperature evaluation)
PSSu systems can be assembled for
Safety-related tasks
Module selection must be based on failsafe modules (FS modules).
Non-safety-related tasks
Standard modules (ST modules) may be selected.
Safety-related and non-safety-related tasks
The PSSu system can be assembled using a mixture of FS and ST
modules.
SafetyBUS p is the preferred system to use for safety-related networked
tasks.
Data transfer via SafetyBUS p is based on CAN technology. The safety
of the data transfer is achieved through the protocol. The protocol in-
cludes the following security mechanisms:
Formation of CRC sums
Echo mode
Connection tests
Addressing tests
Time monitoring functions

2.2 Objective of the PSSu system
2Overview
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2.2Objective of the PSSu system2200Objective of the PSSu system2-][Uebersicht Zie lsetzu ng Sys A
The objective in using PSSu systems is to achieve the following:
Standard and safety in one product
Multifunctionality
Function and performance range tailored exactly to the application
Flexibility and expandability
Less work involved in installation, commissioning and maintenance
Greater availability
Uncomplicated control of safety-related systems
Standardised functionality for safety-related components

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2.3 Features of the PSSu system
2Overview
2.3Features of the PSSu system2300Features of the PSSu system2-][U ebe rsicht Merkmale S ys A
PSSu systems are characterised by the following features:
The head module determines the application range of a PSSu system,
for example:
– Application as a decentralised I/O system
– Connection to various fieldbus systems
– Safety-related communication via SafetyBUS p
– Safety-related communication via PROFINET with PROFIsafe Profil
The input/output modules determine the functions of a PSSu system,
for example:
– Digital input/output
– Analogue input/output
– Counter for incremental encoder and absolute encoder
Using the local enable principle, an ST control system can switch the
FS outputs on a PSSu system via an ST bus system.
Only the base modules are hard-wired, so electronic modules can be
exchanged without having to rewire.
Wireless links can be established for data transfer using InduraNET p
from Pilz.

2.4 System software for PSSu systems
2Overview
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2.4System software for PSSu systems2400System software for PSSu systems2-][Systemsoftwar e Sys A neu
System software is available to provide support when designing and as-
sembling a PSSu system, configuring modules and during the wiring
test. It consists of the following parts:
PSSuniversal Assistant
The PSSuniversal Assistant is a software package that provides support
for designing and assembling PSSu systems. The software is available
licence-free and can be used independently from the system software
PSS WIN-PRO.
The PSSuniversal Assistant has the following function range, for exam-
ple:
Create project with PSSu systems and assemble PSSu systems
Configuration of module parameters
Generate project parts list
Update modules' firmware
Print/documentation
PSSuniversal Configurator
The PSSuniversal Configurator is a software package used to configure
a PSSu system for SafetyBUS p or PROFINET/PROFINET with
PROFIsafe profile. The software can only be used in conjunction with the
SafetyBUS p Configurator of the PSS WIN-PRO system software or the
Siemens software SIMATIC STEP 7 - HW Config.
The PSSuniversal Configurator has the following function range, for ex-
ample:
Assemble PSSu system
Configure PSSu system for SafetyBUS p
Configure PSSu system for local enable principle
Configuration of module parameters
Configure PSSu system for PROFINET or PROFINET with PROFIsafe
profile
A licence for PSSuniversal Startup is required to download the FS
configuration to a PSSu system via the Siemens software SIMATIC
STEP 7 – HW Config.
Print/documentation

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2.4 System software for PSSu systems
2Overview
PSSuniversal Startup
PSSuniversal Startup is a software package used to test the wiring of a
PSSu system connected online. A separate licence is required for the
software. The software has the following function range, for example:
Upload the system data of a PSSu system
Test the wiring of the inputs on a PSSu system
Test the wiring of the outputs on a PSSu system (forcing)
Display system properties and system information
Read error stack
Print/documentation
PSSu systems can be assembled using both the PSSuniversal Assistant
and PSSuniversal Configurator. However, it is easier and clearer to as-
semble a system while designing a configuration with the PSSuniversal
Assistant. Already assembled PSSu systems can be imported in both
system software sections.
Once installed, all the above system software sections are available.
PSSuniversal Assistant and PSSuniversal Startup can be launched via
the "Programs" directory" or a desktop icon, while PSSuniversal Config-
urator can only be launched via the SafetyBUS p Configurator of the
PSS WIN-PRO system software or the Siemens software SIMATIC
STEP 7 - HW Config.

2Overview
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3.1 General guidelines
3 Safety
33000SafetySafety3-3.1General guidelines3100General guidelines3-][Sicherheit Allgemeine Hinweise Sys A
Please refer to the safety guidelines in the operating manual for the
products you are using, and in the “Safety Manual PSS 3000”. The safe-
ty manual also includes check lists designed to help you with the safety-
related planning, construction and operation of a plant.
You should also refer to the information provided
In the PSSuniversal Installation Manual
In the system software's online help
The standards current at the time of going to print shall apply.

3.2 Intended use
3 Safety
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3.2Intended use3200Intended use3-][Sicherheit PSSu Bestimmung Sys A
A PSSu system is designed for use in an industrial environment as fol-
lows.
Safety-related applications in the FS section, including connection to
safe bus systems
Non-safety-related applications in the standard section, including
connection to standard bus systems.
Before using a PSSu system in safety-related applications it is neces-
sary to perform a safety assessment in accordance with the Machinery
Directive.
In principle, PSSu systems can be used in any situation where the result
of the risk assessment indicates they may be used. However, they are
primarily suitable for use in machine safety circuits in which a safe con-
dition is brought about by the removal of power.
Examples:
Presses
Transfer lines
Tank storage facilities
E-STOP functions
Burner control systems
Cable cars/traction operations
Stage technology
Process engineering
The following is deemed improper use in particular:
Any component, technical or electrical modification to a product
Use of a product outside the areas described in the product docu-
mentation
Use outside the documented technical details.

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3.3 Use of qualified personnel
3 Safety
3.3Use of qualified personnel3300Use of qualified personnel3-Sich Qualif. Personal
The products may only be assembled, installed, programmed, commis-
sioned, operated, maintained and decommissioned by competent per-
sons.
A competent person is someone who, because of their training, experi-
ence and current professional activity, has the specialist knowledge re-
quired to test, assess and operate the work equipment, devices,
systems, plant and machinery in accordance with the general standards
and guidelines for safety technology.
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 safety guidelines given in this descrip-
tion
Have a good knowledge of the generic and specialist standards ap-
plicable to the specific application.

3.4 Failsafe inputs/outputs
3 Safety
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3.4Failsafe inputs/outputs3400Failsafe inputs/outputs3-][Anschlus s FS-Ein/Ausgabe Teil 1
In FS applications, it is essential that short circuits and open circuits are
unable to cause a hazardous condition within a plant.
The way in which this is done will depend on the degree of hazard from
the plant section, the switching frequency of the sensors and the level of
safety of the sensors and actuators. These points must be assessed in
conjunction with the certification body responsible for safety (e.g. BG,
TÜV).
][Anschlus s FS-Ein/Ausgabe Teil 2
Depending on the application area and its respective regulations, the FS
section can be used up to SIL CL 3 of EN 62061 and up to PL e (Cat 4)
of ISO 13849-1.
][Anschlus s FS-Ein/Ausgabe Teil 3
Various tests may be configured on FS input/output modules. These
tests can be used to detect many short circuits and open circuits. Ex-
amples of such tests are:
Off tests for outputs that are switched on
On tests for outputs that are switched off
Tests for shorts between the outputs
Test pulses for detecting shorts between contacts on inputs
Wiring guidelines and connection examples are available in the operat-
ing manuals or data sheets for the input/output modules.

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4.1 Structure of a PSSu system
4Basics
44000BasicsBasics4-4.1Structure of a PSSu system4100Structure of a PSSu system4-][Modularer Aufbau Kpf + Spg Module Sys A
A PSSu system is a modular, programmable system for controlling plant
and machinery. For PSSu systems there is a system software consisting
of PSSuniversal Assistant, Configurator and Start-up. The system soft-
ware provides support as you select, configure and commission com-
ponents. A PSSu system consists of:
One head module
At least one supply voltage module
Input/output modules for standard and failsafe applications
End bracket to secure the system at the start
Terminating plate with integrated bus terminating resistors and end
bracket to secure the system at the end
Head module:
Connects the sensor/actuator level for standard applications with
standard fieldbus systems (e.g. PROFIBUS-DP)
Connects the sensor/actuator level for failsafe applications with Safe-
tyBUS p
Co-ordinates the entire process data traffic
Supply voltage modules:
Consist of an electronic module and a base module
Are available for various functions
][Modularer Aufbau E/A Module Sys A + B
Input/output modules:
Input/output modules are available in different designs:
Electronic module and base module
Compact module
The input/output modules are available for a wide range of input/output
functions.
][Modularer Aufbau Bauformen Sys A + B
Designs:
Electronic modules and base modules:
The electronic modules determine the function of the supply voltage or
input/output module.
Electronic modules
– Are plugged into the base modules
– Communicate with the head module via the module bus

4.1 Structure of a PSSu system
4Basics
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The base modules are the carrier units for the electronic modules.
Base modules
– Are used to connect the field wiring
– Are available with the following connection types:
Cage clamp terminals or screw terminals
Compact modules:
The compact modules combine the function unit (inputs and/or outputs)
and connection levels in one housing. Wiring is via multi-pin connectors
with spring-loaded terminals, which are plugged into the connector
strips on the module.
Compact modules
Do not need base modules
Are used to connect the field wiring
Communicate with the head module via the module bus
][Modula rer Aufbau Ze ichnung S ys A
Electronic module
(grid width 1 x 12,6 mm)
Electronic module
(grid width 2 x 12,6 mm)
End bracket Terminating plate
Base module
(grid width 2 x 12,6 mm)
Base module
(grid width 1 x 12,6 mm)
Head module
Mounting rail
(DIN EN 50022) Supply voltage module (electronic module + b se module)
End bracket
(integr ted into termin ting pl te)
Compact module
(grid width 1 x 30 mm)