Pilz PSS Series User manual

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The spirit of safety.
Programmable Safety Systems
PSS-Range
PSS DI2O Z, PSS1 DI2O Z
Operating Manual
Item No. 20 335-03

All rights to this manual are reserved by Pilz GmbH & Co. KG. Copies may be made for
internal purposes.
While every effort has been made to ensure that the information in this manual is accurate,
no responsibility can be accepted for errors or omissions contained within it.
We reserve the right to amend specifications without notice. We are grateful for any
feedback on the contents of this manual.
The names of products, goods and technologies used in this manual are trademarks of the
respective companies.

1Operating Manual: PSS(1) DI2O Z
Introduction 1-1
Validity of documentation 1-1
Overview of documentation 1-2
Definition of symbols 1-3
Overview 2-1
Front view 2-2
Safety 3-1
Intended use 3-1
System requirements 3-1
CPU versions 3-1
System software versions 3-2
Categories in accordance with EN 954-1 3-2
Digital inputs (DI2) 3-2
Dual-pole outputs (DOZ) 3-3
Function Description 4-1
Digital inputs DI2 4-1
Digital outputs DOZ 4-1
Contents

Contents
2Operating Manual: PSS(1) DI2O Z
Wiring 5-1
Configuration 5-1
Notes on wiring 5-2
Example: Single-channel, failsafe input device,
without test pulse 5-4
Example: Dual-channel input devices, without test pulses 5-6
Example: Single-channel, failsafe input device,
with test pulse 5-8
Example: Dual-channel, failsafe input device,
with test pulse 5-10
Example: Dual-pole outputs 5-12
Operation and Maintenance 6-1
Commissioning 6-1
Faults 6-1
Technical Details 7-1
Power dissipation 7-3
Appendix 8-1
Changes in the documentation 8-1
Changes in Version 20 335-03 8-1

1-1Operating Manual: PSS(1) DI2O Z
This operating manual explains the function and operation of the
centralised input/output module PSS(1) DI2O Z.
Please also refer to the following documentation:
During installation:
• Installation Manual: PSS 3000/PSS 3100 Series
During configuration:
• PSS-Range Safety Manual
• Installation Manual: PSS 3000/PSS 3100 Series
• PSS-Range: FS System Description
This documentation is intended for instruction and should be retained for
future reference.
Validity of documentation
This documentation is valid for the PSS(1) DI2O Z from Version 3.1.
It is valid until new documentation is published. The latest documentation is
always enclosed with the unit.
Introduction

Introduction
1-2 Operating Manual: PSS(1) DI2O Z
Overview of documentation
1 Introduction
The introduction is designed to familiarise you with the contents,
structure and specific order of this manual.
2 Overview
This chapter provides information on the module’s most important
features.
3 Safety
This chapter must be read as it contains important information on
safety regulations and intended use.
4 Function Description
This chapter describes the module’s functions.
5 Wiring
This chapter describes the module’s safety-related wiring.
6 Operation and Maintenance
This chapter explains how to commission the module and advises on
what to do if a fault occurs.
7 Technical Details
8 Appendix

1-3Operating Manual: PSS(1) DI2O Z
Definition of symbols
Information in this manual that is of particular importance can be 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 unit(s) could be damaged and also
provides information on preventive measures 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.

Introduction
1-4 Operating Manual: PSS(1) DI2O Z
Notes

2-1Operating Manual: PSS(1) DI2O Z
Overview
The module PSS(1) DI2O Z has 16 digital inputs and 8 dual-pole 2 A
outputs.
The inputs can be used to monitor emergency stop circuits, for example.
They are generally suitable for connecting:
• Single-channel safety-related input devices
- with test pulses
- without test pulses
• Multi-channel safety-related input devices
- with test pulses
- without test pulses.
The test pulses may come from a PSS(1) DI2O T module, for example.
The outputs are suitable for connecting
• Resistive loads of max. 2 A
• Inductive loads of max. 2 A

Overview
2-2 Operating Manual: PSS(1) DI2O Z
Front view
Fig. 2-1: Front view of the PSS(1) DI2O Z

3-1Operating Manual: PSS(1) DI2O Z
Safety
Intended use
The input/output module PSS(1) DI2O Z is designed for use in safety-
related applications. It is used in the failsafe section of the PSS.
The PSS DI2O Z module is designed for use on a module rack from the
PSS 3000 series.
The PSS1 DI2O Z module is designed for use on a module rack from the
PSS 3100 series.
The following is deemed improper use:
• Any component, technical or electrical modification to the module
• Use of the module outside the areas described in this manual
• Use of the module outside the documented technical details (see chapter
entitled “Technical Details”).
Intended use includes making the installation EMC-compliant. Please refer
to the guidelines given in the “PSS 3000/PSS 3100 Series Installation
Manual” and the “PSS-Range Safety Manual”. The safety manual also
includes check lists designed to help you with the safety-related planning,
construction and operation of a plant.
System requirements
CPU versions
If you wish to use the PSS(1) DI2O Z module, it is essential that the
operating system can support it. On the CPUs listed below, the module is
only supported from the stated version number onwards:
• PSS CPU from Version 1.7
• PSS1 CPU from Version 1.1
All other CPUs support the module without restrictions.

Safety
3-2 Operating Manual: PSS(1) DI2O Z
System software versions
The following system software is required in order to configure the module:
• PSS SW PG from Version 4.0
• PSS WIN-PRO from Version 1.0
Please contact Pilz if you have an older version of the system software.
Categories in accordance with EN 954-1
WARNING!
Please note: To achieve the corresponding category or requirement class,
the whole system including all safety-related components (parts, devices,
user program etc.) must be included in the assessment. For this reason,
Pilz cannot accept liability for the correct classification into a category or
requirement class.
Digital inputs (DI2)
Depending on the application area and its respective regulations, the
inputs may be used without test pulses for applications up to Category 3 in
accordance with EN 954-1. The possibility of a short circuit occurring in the
external wiring between different inputs or against L+ must be eliminated
through appropriate wiring.
For Category 4 applications, shorts between the input contacts must be
detected. This can be achieved through the use of test pulses on the PSS
or, depending on the type of input device, through a feasibility test or
through detection of shorts across the contacts on the input device (e.g.
light barrier) (for connection examples please see Chapter 5, “Wiring”).

3-3Operating Manual: PSS(1) DI2O Z
Dual-pole outputs (DOZ)
The dual-pole outputs can be used for applications up to Category 4 in
accordance with EN 954-1 (11/94).

Safety
3-4 Operating Manual: PSS(1) DI2O Z
Notes

Operating Manual: PSS(1) DI2O Z 4-1
Function Description
Digital inputs DI2
The module PSS(1) DI2O Z has 16 DI2 type inputs (I0 ... I15).
Input signals must show a “High” of 24 VDC (+15 ... +30 VDC) or a “Low”
of 0 VDC (-3 ... +5 VDC). The inputs have a filter and are galvanically
isolated from the control electronics through optocouplers and converters.
Input status is transmitted to the CPU as a “0” signal (“Low”) or “1” signal
(“High”). LEDs indicate the status of the inputs. An LED lights up as soon
as a “1” signal is present at the input.
Diagnostic circuitry checks the function of the inputs, including the input
filter and optocoupler. If an error occurs, the PSS will switch to a STOP
condition, switch off the outputs and trigger a message on the CPU-
display.
Digital outputs DOZ
The module PSS(1) DI2O Z has 8 dual-pole 2 A DOZ type outputs
(O16 ... O23).
The outputs are protected against short-circuit, overload and excess
temperature. They can switch both resistive and inductive loads. The
outputs are galvanically isolated from the control electronics through
optocouplers.
If the CPU sends a “1” signal to an output, the PSS(1) DI2O Z will apply a
voltage of 24 VDC to the corresponding output. LEDs indicate the status of
the outputs. An LED lights up as soon as a “1” signal is present at the
output.

Function Description
4-2 Operating Manual: PSS(1) DI2O Z
Diagnostic circuitry checks the function of the outputs. On outputs that are
switched on, the CPU will alternately switch off the “+” and “-” terminals as
part of each cycle. This is to check that the corresponding output
transistors can be switched off and that there is no interruption to the load.
In addition, outputs that are connected but switched off will be switched on
for approx. 200 µs during each self test. Where inductive loads are
switched, this time is increased. If an error occurs, the PSS will switch to a
STOP condition, switch off the outputs and trigger a message on the CPU-
display.

Operating Manual: PSS(1) DI2O Z 5-1
Fig. 5-1: Configuration of the PSS(1) DI2O Z
Wiring
Configuration
_X_.1
I 00
I 01
I 02
I 03
I 04
I 05
I 06
I 07
0 V
0 V
_X_.2
I 08
I 09
I 10
I 11
I 12
I 13
I 14
I 15
0 V
0 V
_X_.3
O 16+
O 16-
O 17+
O 17-
O 18+
O 18-
O 19+
O 19-
24 V
24 V
_X_.4
O 20+
O 20-
O 21+
O 21-
O 22+
O 22-
O 23+
O 23-
0 V
0 V
PSS DI2O Z
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
Connector
description:
X1 Digital inputs
DI2
I0 ... I7
X2 Digital inputs
DI2
I8 ... I15
X3 Dual-pole outputs
DOZ
O16 ... O19
X4 Dual-pole outputs
DOZ
O20 ... O23

Wiring
5-2 Operating Manual: PSS(1) DI2O Z
Notes on wiring
In addition to the “Notes on wiring” in the “PSS 3000/PSS 3100 Series
Installation Manual”, please note the following:
• Safety-related input signals must operate in accordance with the failsafe
principle (on switching off).
• In the user program, make sure that a “0” signal from the module always
causes the relevant outputs to shut down.
• Do not assign the same test pulse to adjacent inputs.
• Do not connect DIF and DI2 inputs to the same test pulse.
• The max. continuous current over all the outputs must not exceed 10 A.
• When testing the outputs, the load is isolated from the supply for max.
200 µs in each cycle (depending on the load and cable runs). The load
must not drop off during this time.
• Error messages can occur when testing outputs on which the contactors
are smaller than the recommended load. The error messages are
triggered by the high inductance on the contactors. In this case it helps to
have a 1 kOhm resistor connected in parallel to the contactor coil.
• Contactors with a pull-in power of up to 200 W can be driven via
the 2 A outputs.
• Only one 0 V terminal needs to be connected to terminals X1 und X2.
• One of the two 24 V terminals and 0 V terminals must be connected to
terminals X3 and X4.
• Use copper as the conductive material.
• The torque setting on the connection terminals should be 0.5 … 0.6 Nm.
NOTICE
Please refer to the following application examples!

Operating Manual: PSS(1) DI2O Z 5-3
Notes