Pilz PSEN ml sa 1.1 User manual

PSEN ml sa 1.1/2.1/2.2
Operating Manual-1005296-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.
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 ........................................................................................................ 9
2.2.4 Warranty and liability ................................................................................................................ 10
2.2.5 Disposal .................................................................................................................................... 10
2.3 For your safety.......................................................................................................................... 10
3 Overview .................................................................................................................................11
3.1 Approved combinations ............................................................................................................ 11
3.2 Device features......................................................................................................................... 11
4 Function description ............................................................................................................. 13
4.1 Structure ................................................................................................................................... 13
4.2 Activation of safety inputs S31 and S41 (solenoid operation) .................................................. 14
4.2.1 Activation with specification of direction ................................................................................... 16
4.2.2 Activation without specification of direction .............................................................................. 16
4.3 Safety Device Diagnostics ........................................................................................................ 17
4.4 Operating modes ...................................................................................................................... 18
4.5 Block diagram ........................................................................................................................... 21
4.6 Auxiliary release ....................................................................................................................... 22
4.6.1 Recommissioning ..................................................................................................................... 23
4.7 Prevent restart .......................................................................................................................... 23
4.8 Escape release accessory........................................................................................................ 24
4.8.1 Recommissioning ..................................................................................................................... 25
5 Wiring ......................................................................................................................................26
5.1 Important information................................................................................................................ 26
5.2 Pin assignment, connector and cable....................................................................................... 26
5.3 EMC requirements.................................................................................................................... 27
6 Connection to control systems and evaluation devices .................................................... 28
6.1 Important information................................................................................................................ 28
6.2 Minimum requirements for activation of guard locking ............................................................. 29
6.3 Single connection ..................................................................................................................... 31
6.4 Series connection ..................................................................................................................... 32
6.5 Connection to Pilz evaluation devices ...................................................................................... 35

Contents
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7 Teaching in the actuator ....................................................................................................... 37
8 Installation ..............................................................................................................................38
8.1 Important information................................................................................................................ 38
8.2 Installation types ....................................................................................................................... 39
8.2.1 Installation on sliding gate ........................................................................................................ 39
8.2.2 Installation on swing gate ......................................................................................................... 40
8.3 Installation safety switch ........................................................................................................... 42
8.3.1 Installation without mounting plate............................................................................................ 43
8.3.2 Installation with mounting plate................................................................................................. 43
8.3.3 Installation using L-brackets ..................................................................................................... 44
8.4 Actuator installation ................................................................................................................. 45
8.4.1 Installation without mounting bracket........................................................................................ 45
8.4.2 Installation with mounting bracket............................................................................................. 45
8.4.3 Install fixing screws side-on to actuator .................................................................................... 46
8.4.4 Install fixing screws in parallel to actuator ................................................................................ 46
8.4.5 Centre the bolt in the actuator housing..................................................................................... 47
8.4.6 Rotate the bolt in the actuator housing 90°............................................................................... 48
8.5 Escape release ......................................................................................................................... 49
8.5.1 Important information................................................................................................................ 49
8.5.2 Installation positions for escape release................................................................................... 50
8.5.3 Installation stationary escape release....................................................................................... 52
8.5.4 Installation external escape release ......................................................................................... 54
8.5.5 Dismantling of escape release (order no. 570466 - 570 475)................................................... 57
8.6 Auxiliary release ....................................................................................................................... 58
9 Adjustment ............................................................................................................................. 59
9.1 Attach safety switch and actuator ............................................................................................. 59
10 Operation ................................................................................................................................60
10.1 Normal operation mlock............................................................................................................ 60
10.2 Error display.............................................................................................................................. 63
11 Checks and maintenance ...................................................................................................... 64
12 Dimensions ............................................................................................................................66
13 Technical details ....................................................................................................................74
14 Classification according to ZVEI, CB24I .............................................................................. 79
15 Safety characteristic data ..................................................................................................... 80
16 Supplementary data ..............................................................................................................81
16.1 Radio approval.......................................................................................................................... 81
16.2 Technical details for mounting bracket without handle unit ...................................................... 81
16.3 Technical details for mounting bracket with handle unit ........................................................... 81
16.4 Technical details for escape release 570460 - 570462, 570470 .............................................. 82

Contents
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16.5 Technical details for escape release 570463 ........................................................................... 82
16.6 Technical details escape release 570466-570469 ................................................................... 82
16.7 Technical details escape release 570471-570473 ................................................................... 83
16.8 Technical details escape release 570474-570475 ................................................................... 83
16.9 Technical details for auxiliary release 570461.......................................................................... 83
17 Order reference ......................................................................................................................84
17.1 System...................................................................................................................................... 84
17.2 Accessories .............................................................................................................................. 84
18 Appendix ................................................................................................................................89
19 EC declaration of conformity ................................................................................................ 90

Introduction
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1 Introduction
1.1 Validity of documentation
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
This documentation is valid for the product PSEN ml sa 1.1/2.1/2.2 from Version 2.0.
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 sa 1.1: low, type 4
– Coding level with actuator PSEN ml sa 2.1/2.2: high, type 4
The safety switch may only be used with one of the approved actuators (see Approved
combinations [ 11]).
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.
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.

Safety
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Foreseeable misuse
}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
}Use of the product as an emergency release with the escape release accessory. For an
emergency release use a PSEN ml s 1.1/2.1/2.2.
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.
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.

Safety
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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).
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 [ 38].
– 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 [ 84].
PSEN ml sa 1.1
Safety switch Actuator
PSEN ml sa 1.1 switch PSEN ml 1.1 actuator
PSEN ml 1.1 round actuator
PSEN ml sa 2.X
Safety switch Actuator
PSEN ml sa 2.1 switch PSEN ml 2.1 actuator
PSEN ml 2.1 round actuator
PSEN ml sa 2.2 switch PSEN ml 2.1 actuator
PSEN ml 2.1 round actuator
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 sa 1.1: coded
– PSEN ml sa 2.1: fully coded
– PSEN ml sa 2.2: uniquely coded
}M12, 12-pin male connector

Overview
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}LEDs:
– Supply voltage/fault
– Status of actuator
– Status of guard locking
– Input lights up yellow (without function)
}The bolt in the actuator can be rotated 90° in the actuator housing before the actuator is
installed. As a result, the actuator can be installed vertically or horizontally.
}The safety switch can be expanded with up to three stationary and/or external escape re-
leases (see Order reference: Accessories [ 84]).
The escape release enables the manual release of the guard locking without aids from
inside the danger zone and it corresponds to an escape release in accordance with EN
ISO 14119.
The stationary escape release can be extended by a maximum of 50 mm (twice by
25mm).
The external escape releases are available with push/pull cables with a length of between
0.5 and 4 m (50cm increments).
}On small door radiuses, (see Install the safety switch horizontally at a swing
gate [ 40]) the PSENmlactuatorcenterring can be inserted (see Order reference:
Accessories [ 84]).
}The actuator is available in two types (see Order reference: Accessories [ 84]).
– Standard actuator
– Actuator with rounded tip
Standard actuator Actuator with rounded tip

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).
Safety switch
Actuator
Safety switch
Actuator
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) and
}There is a high signal at the inputs S11 and S21
If one of these conditions is not met, the signal at the safety outputs will be low.
Plausibility monitoring for safety inputs S11 and S21
}If one safety input switches from high to low, while the other safety input remains high, an
unequal status is displayed: Input LED flashes yellow
}If this safety input switches back from low to high, while the other safety input remains
high, a plausibility error is displayed and a partial operation lock is triggered: Input LED
flashes yellow
A switch to a high signal will only lead to normal safety switch operation if both inputs had a
low signal. From this moment on, the switch to high may occur (partial operation lock see
Error display [ 63]).

Function description
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}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 be connected to
24 V. In a series connection the signal output/diagnostic output Y32 must be connected in
series to the diagnostic input Y1 of the next sensor in the series connection.
}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.
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.
Single connection
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.
Series connection
In a series connection with n safety switches the guard locking is activated by a high signal
with a minimum duration of t=n*(350 - 400 ms) at the inputs S31 and S41 (solenoid oper-
ation).
Number of safety switches in
the series connection
Pulse duration Lock/Unlock Request in ms
1 350
2 700
3 1050
4 1400
5 1750
6 2100

Function description
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After activation, the inputs must be low. Another pulse of the specified duration at these in-
puts deactivates guard locking.
3 x PSEN ml s
X1 X2
X3
X1 X2
X3
X1
X2
Safety control system
8-core
12-core
[1] [2]
Legend
[1] PSEN ml Y junction M12
[2] PSEN ml end adapter
}Series connection of diagnostics with Safety Device Diagnostics
Y1 Y32 Y1 Y32
1. PSEN ml 2. PSEN ml
Fieldbus module
}Series connection of the solenoid operation
S31 S41 42 32 S31 S41 32 42
1. PSEN ml 2. PSEN ml

Function description
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}Series connection of the OSSD outputs
S21 S11 12 22 S21 S11 12 22
1. PSEN ml 2. PSEN ml
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.
– Wiring in accordance with IP67: Various passive junctions can be used (see Order
references for accessories [ 84]) to connect several sensors with only one cable
from the field in the control cabinet.
Further information on Safety Device Diagnostics can be found in Additional documents
that apply [ 9].

Function description
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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
}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.

Function description
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Timing diagrams
[7]
66<[1] [4] [5] [8] [9]
[t1] [t1]
[t2]
>@[t2]
<66[2] [3]
32 + 42
[10]
SDD command guard locking
Guard locking
Actuator
Fig.: Active use of Safety Device Diagnostics
Legend
[1] Gate is open
[2] The door connected upstream in the series connection is closed
[3] The door connected upstream in the series connection is locked
[4] Gate is closed
[5] Guard locking is activated by the safety control system
[6] Guard locking is activated
[7] Execution of the hazardous machine function is permitted
[8] Outputs will be deactivated
[9] Guard locking will be deactivated
[10] 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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66<[1] [4] [5] >@[8] [9]
[7]
[t1] [t1]
[t2]
[t2]
<66[2] [3]
32 + 42
[10]
Guard locking
Actuator
Fig.: Passive use of the Safety Device Diagnostics
Legend
[1] Gate is open
[2] The door connected upstream in the series connection is closed
[3] The door connected upstream in the series connection is locked
[4] Gate is closed
[5] Guard locking is activated by the programmable safety system
[6] Guard locking is activated
[7] Execution of the hazardous machine function is permitted
[8] Outputs will be deactivated
[9] Guard locking will be deactivated
[10] Gate is open
[t1] Processing time of guard locking signal = 100 ms
[t2] Time window for changing guard locking status