Pilz PSEN ml ba 1.1 User manual

PSEN ml ba 1.1/2.1/2.2
PSEN ml DHM
Operating Manual-1005456-EN-02
}PSEN sensor technology

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
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1 Introduction ............................................................................................................................6
1.1 Validity of documentation.......................................................................................................... 6
1.2 Using the documentation .......................................................................................................... 6
1.3 Definition of symbols................................................................................................................. 6
2 Safety ...................................................................................................................................... 8
2.1 Intended use ............................................................................................................................. 8
2.2 Safety regulations ..................................................................................................................... 9
2.2.1 Safety assessment ................................................................................................................... 9
2.2.2 Additional documents that apply............................................................................................... 9
2.2.3 Use of qualified personnel ........................................................................................................ 10
2.2.4 Warranty and liability ................................................................................................................ 10
2.2.5 Disposal .................................................................................................................................... 10
2.3 For your safety.......................................................................................................................... 11
3 Overview .................................................................................................................................12
3.1 Approved combinations ............................................................................................................ 12
3.2 Device features......................................................................................................................... 13
4 Function description ............................................................................................................. 14
4.1 Structure ................................................................................................................................... 14
4.2 Activation of safety inputs S31 and S41 (solenoid operation) .................................................. 15
4.2.1 Activation with specification of direction ................................................................................... 15
4.2.2 Activation without specification of direction .............................................................................. 15
4.3 Safety Device Diagnostics ........................................................................................................ 16
4.4 Operating modes ...................................................................................................................... 16
4.5 Block diagram ........................................................................................................................... 19
4.6 Auxiliary release ....................................................................................................................... 20
4.6.1 Recommissioning ..................................................................................................................... 21
4.7 Prevent restart .......................................................................................................................... 21
4.8 Escape release ......................................................................................................................... 22
4.8.1 Recommissioning ..................................................................................................................... 22
4.9 Accessories escape release ..................................................................................................... 22
4.9.1 Recommissioning ..................................................................................................................... 24
5 Wiring ......................................................................................................................................25
5.1 Important information................................................................................................................ 25
5.2 Pin assignment, connector and cable....................................................................................... 25
5.3 EMC requirements.................................................................................................................... 26
6 Connection to control systems and evaluation devices .................................................... 27
6.1 Important information................................................................................................................ 27
6.2 Minimum requirements for activation of guard locking ............................................................. 28
6.3 Single connection ..................................................................................................................... 30
6.4 Connection to Pilz evaluation devices ...................................................................................... 31

Contents
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7 Teaching in the actuator ....................................................................................................... 32
8 Installation ..............................................................................................................................33
8.1 Important information................................................................................................................ 33
8.2 Installation safety switch ........................................................................................................... 34
8.2.1 Installation without mounting plate............................................................................................ 35
8.2.2 Installation with mounting plate................................................................................................. 35
8.2.3 Install fixing screws in parallel to actuator ................................................................................ 36
8.2.4 Install fixing screws side-on to actuator .................................................................................... 37
8.3 Actuator installation ................................................................................................................. 37
8.3.1 Important information................................................................................................................ 37
8.3.2 Install actuator on swing gate ................................................................................................... 39
8.3.3 Install actuator on sliding gate .................................................................................................. 41
8.4 Escape release accessory........................................................................................................ 42
8.4.1 Important information................................................................................................................ 42
8.4.2 Installation positions for escape release................................................................................... 43
8.4.3 Installation stationary escape release....................................................................................... 44
9 Adjustment ............................................................................................................................. 46
9.1 Attach safety switch and actuator ............................................................................................. 46
10 Operation ................................................................................................................................47
10.1 Normal operation mlock............................................................................................................ 47
10.2 Error display.............................................................................................................................. 50
11 Checks and maintenance ...................................................................................................... 51
12 Dimensions ............................................................................................................................53
13 Technical details for safety switch ...................................................................................... 57
14 Technical details for actuator, order no. 6O000001-6O000004 ......................................... 61
15 Technical details for actuator, order no. 6O000005-6O000008 ......................................... 63
16 Technical details for escape release 570460 ...................................................................... 65
17 Classification according to ZVEI, CB24I .............................................................................. 66
18 Safety characteristic data ..................................................................................................... 67
19 Supplementary data ..............................................................................................................68
19.1 Radio approval.......................................................................................................................... 68
20 Order reference ......................................................................................................................69
20.1 System...................................................................................................................................... 69
20.2 Installation accessories............................................................................................................. 70
20.3 Cable accessories .................................................................................................................... 70

Contents
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21 Appendix ................................................................................................................................72
22 EC declaration of conformity ................................................................................................ 73

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN ml ba 1.1/2.1/2.2 from Version 2.0 to-
gether with the actuators PSEN ml DHM.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
1.3 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.

Introduction
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Safety
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2 Safety
2.1 Intended use
The safety gate system is used for interlocking and guard locking swing gates and sliding
gates.
The safety gate system can be operated in two ways:
}Unlocking with condition
The safety gate system prevents the safety gate from being unlocked while there is any
hazard within the danger zone.
}Unlocking without condition
The operator can unlock the safety gate system at any time. After starting the unlocking,
the guard locking creates a stop command. The time required to unlock the interlocking
guard has to be longer than the time required to stop the hazardous machine function.
The hazardous machine function may only be executed under the following conditions:
}There is a high signal at safety outputs 12 and 22 and
}There is a low signal at safety outputs S31 (Lock/Unlock Request 1) and S41 (Lock/Un-
lock Request 2).
Safety inputs S31 and S41 (solenoid operation) may only be operated under the following
condition:
}Plant is in a safe condition
Make sure that this is the case with an AND operation in the safety system immediately
before the output is operated.
The safety switch meets the requirements in accordance with:
}EN 60947-5-3: PDDB
}EN 62061: SIL CL 3
– EN ISO 13849-1: PL e (Cat. 4 )
}ENISO14119
– Coding level with actuator PSEN ml ba 1.1: low, type 4
– Coding level with actuator PSEN ml ba 2.1/2.2: high, type 4
The safety switch may only be used with one of the approved actuators (see Approved
combinations [ 12]).
The safety level PL e (Cat. 4 )/SIL CL 3 is only achieved if
}the safety outputs use 2-channel processing
}The solenoid has 2-channel operation via safe, tested outputs, suitable for PL e (Cat. 4)/
SIL CL 3 applications.

Safety
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With 1-channel operation of the safety inputs S31 (Lock/Unlock Request 1) and S41 (Lock/
Unlock Request 2) it is only possible to achieve safety level PLd(Cat.2)/SILCL2.
NOTICE
Shock stress exceeded: if the safety switch is used together with one of the
actuators PSEN ml DHM (as described in this document), the max. acceler-
ation is reduced to 10g.
Foreseeable misuse
}Use of the product as an emergency release with the escape release accessory. For an
emergency release use a PSEN ml b 1.1/2.1/2.2.
}Safety switches and actuators of the safety gate system must not be used as mechanical
limit stops
}Use of the under corrosive environmental conditions (cooling emulsions, surface treat-
ment, gases, …)
}Use in environments with high dust pollution
2.2 Safety regulations
2.2.1 Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 62061. However, this does not guarantee the functional
safety of the overall plant/machine. To achieve the relevant safety level of the overall plant/
machine’s required safety functions, each safety function needs to be considered separ-
ately.
2.2.2 Additional documents that apply
Please read and take note of the following documents.
Only for use of the Safety Device Diagnostics (SDD)
}Operating manual for the fieldbus module, for example SDD ES ETH or SDD ES
PROFIBUS
}System description "Safety Device Diagnostics"
For the use of passive junctions
}Operating manual for a passive junction
You will need to be conversant with the information in these documents in order to fully un-
derstand this operating manual.

Safety
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2.2.3 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.
2.2.4 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.).
2.2.5 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).

Safety
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2.3 For your safety
}Do not remove the connector's protective cap until you are just about to connect the unit.
This will prevent potential contamination.
WARNING!
Risk of injury due to loss of the safety function.
Substituting an actuator for an inappropriate actuator of the interlock and
guard locking system may lead to serious injury and death.
– You should prevent the interlocking and guard locking system from
being manipulated with an inappropriate actuator.
– Keep the substitute actuator in a safe place and protect it from unau-
thorised access.
– Install substitute actuators as described in Installation [ 33].
– Destroy any used actuators before disposal.

Overview
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3 Overview
3.1 Approved combinations
An approved combination (unit) consists of a safety switch and the corresponding actuator.
For information such as product type, features and order number, see Order
reference [ 69].
PSEN ml ba 1.1
Safety switch Actuator
PSEN ml ba 1.1 switch PSEN ml DHM up l 1.1
PSEN ml DHM up r 1.1
PSEN ml DHM down l 1.1
PSEN ml DHM down r 1.1
PSEN ml ba 2.X
Safety switch Actuator
PSEN ml ba 2.1 switch PSEN ml DHM up l 2.1
PSEN ml DHM up r 2.1
PSEN ml DHM down l 2.1
PSEN ml DHM down r 2.1
PSEN ml ba 2.2 switch PSEN ml DHM up l 2.1
PSEN ml DHM up r 2.1
PSEN ml DHM down l 2.1
PSEN ml DHM down r 2.1
The available actuators are combined in this document as follows.
Product type Designation in this document
PSEN ml DHM up l 1.1 PSEN ml DHM
PSEN ml DHM up l 2.1
PSEN ml DHM up r 1.1
PSEN ml DHM up r 2.1
PSEN ml DHM down l 1.1
PSEN ml DHM down l 2.1
PSEN ml DHM down r 1.1
PSEN ml DHM down r 2.1

Overview
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3.2 Device features
}Safe guard locking for swing gates and sliding gates
}Safe interlocking (position monitoring)
}Transponder technology
}2 safety outputs
}Safety Device Diagnostics (SDD)
– Safety Device Diagnostics can be used to poll sensor information, to perform actions
and to read configuration parameters
– Manipulation protection in accordance with ISO 14119 is possible by verifying the
short name of the actuator through the controller via SDD communication
}Diagnostic input for Y1 for Safety Device Diagnostics (SDD)
}Signal output/diagnostic output Y32 for Safety Device Diagnostics
}Monitoring of shorts between the safety outputs
}Guard locking element keeps the safety gate from being opened unintentionally
}Auxiliary release for opening the safety gate
}1 signal output
}Suitable for left and right hinged safety gates
}Pilz coding type
– PSEN ml ba 1.1: coded
– PSEN ml ba 2.1: fully coded
– PSEN ml ba 2.2: uniquely coded
}M12, 8-pin male connector
}LEDs:
– Supply voltage/fault
– Status of actuator
– Status of guard locking
– Input lights up yellow (without function)
}Escape release in accordance with EN ISO 14119
The escape release enables manual release of guard locking from inside the danger
zone without aids and corresponds to escape unlocking.
}Actuator with door handles and integrated escape release

Function description
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4 Function description
4.1 Structure
The interlocking and guard locking system prevents the safety gates to the danger zone
from being opened while there is any hazard within the danger zone (machine movement,
voltage, ...).
The safety outputs may have a high or low signal, depending on the position of the actuator
and the signal path of safety inputs S31 and S41 (solenoid operation).
Gate open Gate closed
Safety outputs 12 and 22
Under these conditions there is a high signal at safety outputs 12 and 22:
}Actuator is detected and
}Guard locking pin has successfully been activated (guard locking pin is in the locked posi-
tion)
If one of these conditions is not met, the signal at the safety outputs will be low.
}Diagnostic input Y1
If a fieldbus module of the SDD is used, the diagnostic input Y1 is automatically activated
and data is read.
If no fieldbus module of the SDD is used, the diagnostic input Y1 must not be used.
}Signal output/diagnostic output Y32
The status of the actuator is output. If a fieldbus module of the SDD is used, the signal
output/diagnostic output for the writing of data is activated.

Function description
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4.2 Activation of safety inputs S31 and S41 (solenoid operation)
}If there is a low signal at safety inputs S31 and S41, the guard locking pin does not
change its position.
}Guard locking may only be deactivated once the hazardous movement has been com-
pleted.
Active use of Safety Device Diagnostics
}The safety inputs S31 and S41 have a high signal within max. 500 ms after the receipt of
the guard locking activation.
Guard locking is activated through a high signal (duration 350 - 400 ms) at inputs S31 and
S41 (solenoid operation). After activation, the inputs must be low. Another pulse (duratiion
350 - 400 ms) at these inputs deactivates guard locking.
4.2.1 Activation with specification of direction
}The guard locking is activated when the time between the rising edges from S31 to S41 is
between 40ms and 500ms (S31 before S41).
}The guard locking is deactivated when the time between the rising edges from S31 to
S41 is between 40ms and 500ms (S41 before S31).
S31
S41
tmax
Guard locking
S31
S41
tmax
Guard locking
Activation
Deactivation
Legend
tmax Maximum time between the rising edges from S31 and S42
4.2.2 Activation without specification of direction
}The guard locking changes its state when the time between the rising edges from S31
and S41<20ms.

Function description
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4.3 Safety Device Diagnostics
Safety Device Diagnostics is an option that can be selected independently of the safety-re-
lated wiring.
When using the Safety Device Diagnostics, up to 16 sensors can be connected as a sub-
scriber to a fieldbus module.
The communication of the sensors with the fieldbus module is automatically built up again
with each new supply of the supply voltage. As a result, a sensor can be exchanged, e.g.
when servicing, without the need for special measures.
An exchange can be detected via the fieldbus module e.g. through the serial number.
}With Safety Device Diagnostics there are the following diagnostic options for the fieldbus
module:
– Poll information of the sensors (examples: what sensor in the series has switched, at
what point could there be an open circuit in the series connection)
– Read configuration parameters of the sensor (examples: Number of teach-in pro-
cesses remaining, serial number of the switch)
– Perform actions (example: poll updated actuator name)
– Selectively activate or deactivate guard locking of individual PSEN ml within a series
connection
The results of the sensor diagnostics can be checked already during the installation phase
via the display in the fieldbus module, without the need to connect the fieldbus module to
the network.
}With Safety Device Diagnostics there are the following diagnostic options for the fieldbus
module for simple wiring:
– Information is passed on via the fieldbus module directly to the network
– Mappings of the signal outputs to the sensor are automated by the SDD.
This prevents wiring errors and an expansion or reduction of the sensors is possible
without the need to change existing wiring.
– Wiring in accordance with IP20: Rapid installation in the control cabined is enabled.
Further information on Safety Device Diagnostics can be found in Additional documents
that apply [ 9].
4.4 Operating modes
The safety switch can be used in various operating modes.
}Operation without safety device diagnostics
– Standard operating mode
After every restart the safety switch is in operation without Safety Device Diagnostics.
– No communication with Safety Device Diagnostics
– Activating/deactivating the guard locking is only via the signals S31 and S41
}Operation with passive use of the Safety Device Diagnostics
– Safety switch supplies diagnostic data to Safety Device Diagnostics
– Activating/deactivating the guard locking is only via the signals S31 and S41

Function description
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}Operation with active use of the Safety Device Diagnostics
– Activate/deactivate the guard locking by a combination of a Safety Device Diagnostics
command and the status of the safety inputs S31 and S41 (S31 and S41 must have a
high signal).
The safety requirements are guaranteed by the signals S31 and S41 (the fieldbus for
Safety Device Diagnostics communication is not safe).
}Operation with specified direction when activating/deactivating guard locking
A specified direction can be used to control switching of the guard locking status.
– Toggle: The safety switch changes the guard locking status (activated <-> deactiv-
ated) each time S31 and S41 are activated simultaneously.
– Force direction: The safety switch is selectively activated or deactivated by offset ac-
tivation of the rising edges at S31 and S41.
Timing diagrams
[7]
S31 + S41
Y32
12 + 22
[1] [4]
[5]
[8]
[t1] [t1]
[t2]
[6]
[t2]
Y1
[2] [3]
SDD command guard locking
Guard locking
Actuator
Fig.: Active use of Safety Device Diagnostics
Legend
[1] Gate is open
[2] Gate is closed
[3] Guard locking is activated by the safety control system
[4] Guard locking is activated
[5] Execution of the hazardous machine function is permitted
[6] Outputs will be deactivated
[7] Guard locking will be deactivated
[8] Gate is open
[t1] Processing time of guard locking signal = 100 ms

Function description
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[t2] Time window for changing guard locking status
S31 + S41
Y32
12 + 22
[1]
[4]
[5] [6] [8][7]
[t1] [t1]
[t2]
[t2]
Y1
[2] [3]
Guard locking
Actuator
Fig.: Passive use of the Safety Device Diagnostics
Legend
[1] Gate is open
[2] Gate is closed
[3] Guard locking is activated
[4] Execution of the hazardous machine function is permitted
[5] Outputs will be deactivated
[6] Guard locking will be deactivated
[7] Gate is open
[t1] Processing time of guard locking signal = 100 ms
[t2] Time window for changing guard locking status

Function description
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4.5 Block diagram
Actuator
A1 A2
12
22
&
S31 S41
UB
Device
Receiver
Safety Gate
Magnet
Lock
Power
Y32
Lock Sensor 1
Lock Sensor 2
&
Y1
&
Signal
Diagnostic
Output

Function description
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4.6 Auxiliary release
The auxiliary release enables guard locking to be opened from the access side to the
danger zone.
The safety switch has auxiliary releases on three sides.
[1]
[2]
Legend
[1] Auxiliary release screw Torx T10
[2] Security screw Torx T10, sealed with varnish when delivered
Mode of operation
1. Remove the security screw [2] using a Torx T10 screwdriver.
2. Rotate the auxiliary release screw [1] half a turn anti-clockwise using a Torx T10 screw-
driver. The guard locking pin is displaced and the bolt is released.
The safety gate to the danger zone can be opened.
INFORMATION
If guard locking is deactivated using the auxiliary release, there is a low sig-
nal at safety outputs 12 and 22. A warning will be output (see chapter
Operation [ 50]). The safety switch does not switch to the fault condi-
tion.
It is possible to open the guard locking using the control system.
The safety switch switches to normal operation when recommissioning without restart.