Table of Contents
Advertisement
Quick Links
PSSu Key-in-Pocket Extended
Product
Type:
FS_KeyInPocket_SignInOut, FS_KeyInPocket_Manager, FS_KeyInPocket_BlindSpotCheck
Name:
PSS 4000, PITreader, PITgatebox, PSENmlock
Manufacturer:
Pilz GmbH & Co. KG, Safe Automation
Document
Release Number: 01
Release Date:
16 May 2023
Application Note – 1006505-EN-01
Advertisement
Chapters
Table of Contents
Related Manuals for Pilz PSS 4000
Summary of Contents for Pilz PSS 4000
- Page 1 PSSu Key-in-Pocket Extended Product Type: FS_KeyInPocket_SignInOut, FS_KeyInPocket_Manager, FS_KeyInPocket_BlindSpotCheck Name: PSS 4000, PITreader, PITgatebox, PSENmlock Manufacturer: Pilz GmbH & Co. KG, Safe Automation Document Release Number: 01 Release Date: 16 May 2023 Application Note – 1006505-EN-01...
- Page 2 We are grateful for any feedback on the contents. May 2023 All rights to this publication are reserved by Pilz GmbH & Co. KG. We reserve the right to amend specifications without prior notice. Copies may be made for the user’s internal purposes.
- Page 3 Abbreviations Abbreviations Abbreviation / term Description Source Application Note www.pilz.com > AN content (1002400) PNOZ Pilz E-STOP positive-guided www.pilz.com > PNOZ (DE: Pilz NOT-AUS-Zwangsgeführt) Programmable control system www.pilz.com > PSS (DE: Programmierbares Steuerungssystem) PSS u2 PSSuniversal, 2 generation www.pilz.com > PSS u2...
-
Page 4: Table Of Contents
Contents Contents Preface............................. 6 Useful documentation ......................7 Documentation from Pilz GmbH & Co. KG ........................7 Documentation from other sources of information ....................7 Used hardware and software ....................8 Pilz products ....................................8 Structure of the application (schematic) .......................... 9 Application description ....................... - Page 5 Contents 8.1.6 Wiring diagram 6/8 ................................39 8.1.7 Wiring diagram 7/8 ................................40 8.1.8 Wiring diagram 8/8 ................................41 Table of figures ........................42 Application Note PSSu Key-in-Pocket Extended │ 5/43 1006505-EN-01...
-
Page 6: Preface
Pilz guarantees that a plant cannot (re-)start until the last person has left the danger zone. A PSSu PLC from the automation system PSS 4000 is used as the safety controller. The general procedure for a successful basic configuration is shown. -
Page 7: Useful Documentation
Reading the documentation listed below is necessary for understanding this Application Note. The availability of the software used and its safe handling are also presupposed for the user. Documentation from Pilz GmbH & Co. KG No. Description Item No. /Download Pilz international homepage, download section www.pilz.com... -
Page 8: Used Hardware And Software
Software platform PAS4000 V 1.25 The Pilz product portfolio also includes servo amplifiers and drives. However, they are not described in detail here, as they are not central to this Application Note. Application Note PSSu Key-in-Pocket Extended │... -
Page 9: Structure Of The Application (Schematic)
Used hardware and software Structure of the application (schematic) Figure 1: Application – Structure of the hardware (schematic) Failsafe controller PSSu PLC Transponder key PITgatebox – pushbutton unit with PITreader (Safety gate 1 outside) Door handle module for PSENmlock (Safety gate 1 outside) Safety gate system PSENmlock (Safety gate 1 outside) PITreader and pushbutton (Safety gate 1 inside) PITgatebox –... -
Page 10: Application Description
Transponders from the authentication system PITreader from Pilz are used to sign in and out. The example shows the application of the key-in-pocket system on a machine that executes hazardous movements within a protective enclosure (protective grille and safety gate). -
Page 11: Figure 3: Access To The Danger Zone
Application description Figure 3: Access to the danger zone It is only possible to enter the danger zone if: ‒ A person has used their personal transponder to sign in to the key-in-pocket system’s sign in list via the PITreader integrated within the PITgatebox ‒... -
Page 12: Key-In-Pocket
Application description Activation (lock) and deactivation (unlock) of guard locking are assigned to the upper pushbutton. The status of guard locking (activated/deactivated) is displayed via the integrated indicator lamp. The lower pushbutton is used to sign a transponder in to the sign in list and to sign a transponder out of the sign in list. -
Page 13: Monitoring Of Safety Gate And Guard Locking
Application description Pressing the upper pushbutton (lock/unlock) activates guard locking. The activated status is displayed via the indicator lamp staying continuously lit. The operator presses the lower pushbutton (sign in/sign out) and then releases it (0.5 … 5 seconds). The indicator lamp goes out, so indicating that the transponder has been signed out of the sign in list. -
Page 14: Safety Assessments
Application description Safety assessments 4.5.1 Key-in-pocket system The system provides protection against an unintended and unauthorised restart. The restart interlock is set (“Enable” = FALSE on the block “FS_KeyInPocket_Manager”), as soon as one person uses their transponder to sign in to the sign in list, and reset (“Enable” = TRUE), when a person has signed out the list’s last remaining transponder from the list. -
Page 15: Drive System
Application description After the drive has stopped or when the safety gate is opened, the energy supply to the motor is forcibly removed (activation of STO). As a result, the drive can no longer generate a rotational torque and therefore no braking torque either. Additional hazards may therefore arise, which must be taken into consideration. -
Page 16: Safety-Related Characteristic Data In Accordance With En 62061
Application description Requirements: Description Identification Common cause failure (CCF) Requirements are considered to be met (must be checked when implemented) Mission time 20 years Operation interval (electromechanical Sensor 4 operations per hour components) (according to application-related assumption from this example) Characteristic data of servo amplifier - STO Actuator = 5E-09... -
Page 17: Hardware Configuration
PSSu PLC 5.2.1 Overview Figure 5: PSS 4000 hardware configuration The PSSu PLC is assigned the IP address 192.168.0.11. With the E-modules PSSu E F 4DO 0.5, the off tests must be activated (default setting). The on tests for the outputs that activate guard locking and the servo amplifier must also be activated. -
Page 18: Ip Connections
Hardware configuration 5.2.2 IP connections Figure 6: Modbus/TCP client connections The 6 PITreader units supply data to the PSSu PLC via the IP connections configured above. Application Note PSSu Key-in-Pocket Extended │ 18/43 1006505-EN-01... -
Page 19: Software Configuration
Software configuration Software configuration The software development is shown in the alternative programming types “Multi programming” and “IEC 61131 programming”. Multi programming The program can be divided into 3 functional areas: Key-in-pocket system Activation and monitoring of the safety gate with guard locking ... -
Page 20: Figure 8: Parameter Settings "Fs_Keyinpocket_Signinout" For Signing In And Out Of The Sign In List
Software configuration “KiPSignInOut_Door1_Outside” and “KiPSignInOut_Door2_Outside” process the data from the PITreader and the commands from the pushbuttons “SignInOut1” and “SignInOut2” from the gateboxes installed outside beside the gates. The parameter settings are used to activate sign in/sign out and to specify a minimum permission for the transponders: Figure 8: Parameter settings “FS_KeyInPocket_SignInOut”... -
Page 21: Figure 11: Parameter Settings "Fs_Keyinpocket_Blindspotcheck
Software configuration The status of a positioned transponder (signed in/signed out) is displayed via the outputs “SignInStat1” … “SignInStat4”. The enable output “Enable_KiP” from the key-in-pocket system is subsequently incorporated into the machine’s start and stop conditions (see chapter 6.1.3 Activating the machine [���� 24]). -
Page 22: Activation And Monitoring Of The Safety Gate With Guard Locking
Software configuration Figure 12: Selection settings “FS_KeyInPocket_Manager” 6.1.2 Activation and monitoring of the safety gate with guard locking Figure 13: Multi program part “Activating and monitoring the safety gate with guard locking” Application Note PSSu Key-in-Pocket Extended │ 22/43 1006505-EN-01... -
Page 23: Figure 14: Parameter Settings "Psenmlock
Software configuration The following description refers to the upper section (gate 1), but also applies for the lower section (gate 2). With a rising edge at the pushbutton ”ml1_LockUnlock_Outside” or “ml1_LockUnlock_Inside”, guard locking on the PSENmlock1 is activated or deactivated with a pulse at the outputs “ml1_Sol1” and “ml1_Sol2”. -
Page 24: Activating The Machine
Software configuration 6.1.3 Activating the machine Figure 15: Multi program part “Activating the machine” With a rising edge at the “Start” button, the machine can be started under the following conditions (block “StartConditions”): The sign in list is empty, the key-in-pocket system gives the enable: “EnableKiP” = TRUE ... - Page 25 Software configuration PSENml1_LockUnlockEdge_Outside : R_TRIG; PSENml1_LockUnlockEdge_Inside : R_TRIG; PSENml2_LockUnlockEdge_Outside : R_TRIG; PSENml2_LockUnlockEdge_Inside : R_TRIG; StartEdge : R_TRIG; OnOff : RS; DelaySTO : TOF; DelayStandstill : TON; // PI variables for pushbuttons, display elements and actuator SignInOut1 WITH VALID %I* : SAFEBOOL; SignInOut1_Valid EXTENSION VALID OF SignInOut1...
-
Page 26: Instruction Part
Software configuration 6.2.2 Instruction part Note: For reasons of clarity, the emergency stop function is not represented here. For program description see chapter 6.1 Multi programming [���� 19]. // Key in Pocket - Access safety gate 1 outside (sign in/sign out of sign in list) KiP_SignInOut_Door1_Outside( ActivateSignInOut := TRUE,... - Page 27 Software configuration SignInOutData := KiP_SignInOut_BlindSpotCheck1.SignInOutData, ConfirmCheck := BlindSpot1_ConfirmCheck, ConfirmCheck_Valid := BlindSpot1_ConfirmCheck_Valid, ReadyForCheck => BlindSpot1_ReadyForCheck // Blind spot check 2 // (activated by confirmation of blind spot check 1) KiP_BlindSpotCheck2( ActivateBlindSpotCheck := KiP_BlindSpotCheck1.BlindSpotCheckOK, DeactivateTimeout := FALSE, Timeout := T#60s, RequiredSecurityID := KiP_Manager.SecurityID_BlindSpotCheck, RequiredSerialNumber := KiP_Manager.SerialNumberBlindSpotCheck, SignInOutData...
- Page 28 Software configuration PSENml1_SwitchingPulse( := PSENml1_EnableGuardLocking, := T#400ms PSENml1_Solenoid1 := PSENml1_SwitchingPulse.Q; PSENml1_Solenoid2 := PSENml1_SwitchingPulse.Q; // Safety gate system PSENmlock safety gate 2 - Activate/deactivate guard locking from outside via edge PSENml2_LockUnlockEdge_Outside( PSENml2_LockUnlock_Outside // Safety gate system PSENmlock safety gate 2 - Activate/deactivate guard locking from inside via edge PSENml2_LockUnlockEdge_Inside( PSENml2_LockUnlock_Inside...
-
Page 29: Resource Assignment
Software configuration Resource assignment The program “FS_Program” must be assigned to a task on the FS resource. Figure 16: FS resource assignment Application Note PSSu Key-in-Pocket Extended │ 29/43 1006505-EN-01... -
Page 30: I/O Mapping
Software configuration I/O mapping The PI variables available in the user program can be mapped in the hardware configuration’s I/O Mapping Editor. The following illustrations refer to IEC 61131 programming. The following I/O mappings are to be made with the filter “PI variables <-> Module bus”: Figure 17: I/O mapping PI variables <->... -
Page 31: Figure 18: I/O Mapping Pi Variables <-> Ip Connections
Software configuration The following I/O mappings are to be made with the filter “PI variables <-> IP connections”: Figure 18: I/O mapping PI variables <-> IP connections Application Note PSSu Key-in-Pocket Extended │ 31/43 1006505-EN-01... -
Page 32: Application Conditions
Application conditions Application conditions NOTICE When using the key-in-pocket system, make sure that the following training takes place: ‒ Each person who comes into contact with the plant must be trained to know that they may only access the danger zone if they have previously signed in to the key- in-pocket system's internal sign in list. - Page 33 Application conditions NOTICE When using the key-in-pocket system, make sure that the following requirements are met: ‒ Where there is a movable guard that prevents access to the danger zone, a person may only open it if they have already signed in successfully to the key-in-pocket system's internal sign in list.
-
Page 34: Appendix
312 601 312 601 312 601 312 601 Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz Basic Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page:... -
Page 35: Wiring Diagram 2/8
LockUnlock Outside EStop S1 EStop S2 Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz PIT gb RLLE 1 Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page: Dep. -
Page 36: Wiring Diagram 3/8
LockUnlock Inside OSSD1 OSSD2 Closed Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz PSEN ml b 2.1 Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page:... -
Page 37: Wiring Diagram 4/8
LockUnlock Outside EStop S1 EStop S2 Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz PIT gb RLLE 2 Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page: Dep. -
Page 38: Wiring Diagram 5/8
LockUnlock Inside OSSD1 OSSD2 Closed Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz PSEN ml b 2.1 Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page:... - Page 39 BlindSpot1 Button BlindSpot2 Button BlindSpot1 BlindSpot2 ConfirmCheck ConfirmCheck Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz PITreaderBlindSpot Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page: Dep.
- Page 40 Button Eth.-Switch DeleteList Start Stop ResetEStop n.c. Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz Switches Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page: Dep.
- Page 41 ENABLE STO 1 STO 2 Servo amplifier Mounting place Revision 08.03.2023 Date 27.02.2023 EN ISO 13849-1 PL d PSSu Pilz GmbH & Co. KG AN_1006505_01 Name Pilz Name Pilz Drive Felix-Wankel-Strasse 2 D-73760 Ostfildern EN 62061 SIL 2 Page: Dep.
- Page 42 Figure 3: Access to the danger zone ..........................11 Figure 4: PITgatebox with pushbutton assignment ....................11 Figure 5: PSS 4000 hardware configuration ........................17 Figure 6: Modbus/TCP client connections ........................18 Figure 7: Multi program part “Key-in-Pocket” ......................19 Figure 8: Parameter settings “FS_KeyInPocket_SignInOut”...
- Page 43 Table of figures Application Note PSSu Key-in-Pocket Extended │ 43/43 1006505-EN-01...