Programmable Safety Systems PSS-Range: PSS 3000/PSS 3100 Series Installation Manual Item No. 18 557

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Item No. 18 557
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18 557-04/01 Printed in Germany
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Telephone +49 (7 11) 34 09-0, Telefax +49 (7 11) 34 09-1 33 The spirit of safety.
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Version XII, April 2001

Contents
Introduction 1-1
Definition of symbols 1-2
Safety Regulations 2-1

Supplying power to the PSS 2-1
PSS(1) PS 24 V 2-2
PSS PS 2-3
PSS1 BMPS 3/1 2-3
Supplying the input/output modules 2-4
Installation 2-6
Connections 2-7
Electromagnetic Compatibility (EMC) 3-1

Overview 3-1
Making the installation EMC-compliant 3-2
Connecting the earth cables 3-2
Cabling 3-3
Equipotential bonding 3-4
Screened cables 3-5
Insulation voltage test 3-5
Suppression of inductive loads 3-5
Miscellaneous 3-6
Installing within an enclosure or wall-mounting 3-6
Testing the EMC-compliance of an installation 3-7
Installation 4-1
Installing the PSS 3000 series 4-1
Installing the base module rack 4-1
Installing the modules for the PSS 3000 series 4-2
Expansion devices for the PSS 3000 series 4-3
Installing the module rack in a control cabinet 4-6
Installation Manual: PSS 3000/PSS 3100 Series 1

Contents
Installing the PSS 3100 series 4-7

Installing the base module rack PSS1 BMPS 5/2 4-7
Installing the base module rack PSS1 BMPS 3/1 4-8
Installing the modules for the PSS 3100 series 4-9
Changing a module 4-10
Installing the PSS1 BMPS 5/2 module rack in a control cabinet 4-11
Installing the PSS1 BMPS 3/1 module rack in a control cabinet 4-12
Connection Diagrams: Failsafe Section 5-1

Configuration of the screw terminals and connector
description 5-1
Notes on wiring 5-2
PSS(1) DI 2 5-4
Configuration 5-5
Example: Single-channel, failsafe input device, without test pulses 5-7
Example: Dual-channel input devices, without test pulses 5-8
Example: Single-channel, failsafe input device, with test pulses 5-10
Example: Dual-channel, failsafe input device, with test pulses 5-12
PSS(1) DI2O T 5-14
Configuration 5-15
PSS(1) DI2O Z 5-16
Configuration 5-17
PSS(1) DIF 5-18
Configuration 5-19
Example: Process interrupt test 5-20
PSS(1) DIF 2 5-22
Configuration 5-23
PSS(1) DOR 5-24
Configuration 5-25
PSS(1) DOS 5-26
Configuration 5-27
2 Installation Manual: PSS 3000/PSS 3100 Series

Connection Diagrams: Standard Section 6-1
P9/P10 DO/DIO 6-2
P9/P10 DI 6-3
P9/P10 AIO/PMI 6-4
P9/P10 DOR 6-5
P9/P10 PMAO 6-6
P9/P10 PMIA 6-7
P9/P10 MMC3/MMC6 6-8
Interfaces 7-1
Optimising the Power Supplies 8-1

Power consumption: failsafe modules 8-2
Power consumption: standard modules 8-3
Appendix 9-1
Changes to the Installation Manual 9-1
Installation Manual: PSS 3000/PSS 3100 Series 3

Contents
4 Installation Manual: PSS 3000/PSS 3100 Series

Introduction
This installation manual contains all the information you need to install a
PSS system from the PSS 3000 or PSS 3100 series.
PSS 3000 series:

• PSS 3000
• PSS SF 3000
• PSS SB 3000
PSS 3100 series:
• PSS 3100
• PSS SF 3100
• PSS SB 3100
If you are using the PSS SB 3000 or PSS SB 3100 you should also refer
to the “SafetyBUS p Installation Manual”.
The installation manual is divided into 9 chapters:

Chapter 1 provides an overview of the contents of the installation manual.
Chapter 2 contains important safety information which must be read.
Chapter 3 describes how to make your installation EMC-compliant.
Chapter 4 explains how to install the safety system.
Chapter 5 details the configuration of individual failsafe modules on the
safety system and provides connection examples.
Chapter 6 provides connection examples for the standard modules.
Chapter 7 describes the interfaces on the safety system.
Chapter 8 contains a table to help you with the specification of the power
supply.
Chapter 9 describes the changes made in the different versions of the
installation manual.
Throughout this manual, the term “safety system” or simply “PSS” will be
used to refer to the programmable safety systems in the PSS 3000 and
PSS 3100 series.
Installation Manual: PSS 3000/PSS 3100 Series 1-1

Introduction
Definition of symbols
Information in this manual which is of particular importance can be

identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation which
poses an immediate threat of serious injury and death, and indicates
preventive measures which can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation which
could lead to serious injury and death, and indicates preventive
measures which can be taken.
CAUTION!
This refers to a hazard which can lead to a less serious or minor injury
plus material damage, and also provides information on preventive
measures which can be taken.
NOTICE
This describes a situation in which the unit(s) could be damaged and also
provides information on preventive measures which can be taken.
INFORMATION
This gives advice on applications and provides information on special
features, as well as highlighting areas within the text which are of
particular importance.
1-2 Installation Manual: PSS 3000/PSS 3100 Series

Safety Regulations
To ensure that the safety system functions correctly, please follow the
safety guidelines given below:
• Electrical connections should be made by a qualified electrical engineer

who is familiar with the information in this manual as well as the relevant
regulations concerning health and safety at work.
• Ensure VDE and local regulations are met, especially those relating to
safety. The relevant safety regulations for the respective application
must also be met.
• CAUTION!
Electrostatic discharge can damage components on the PSS. Ensure
against discharge before touching the terminal strips, e.g. by touching an
earthed, conductive surface or by wearing an earthed armband.
• Ensure all the requirements of the relevant trade associations are met.
• Ensure the wiring instructions in Chapter 5 are followed.
• The internal power supply on the safety system must not be connected
to any other devices.
• If a module is altered in any way, such as exchanging a component or
carrying out soldering work, the guarantee, and any approval, will be
rendered invalid.
• The date of manufacture can be found on the test label.
Supplying power to the PSS
• CAUTION!
The tolerance on the supply voltage for the PSS PS power supply is
+10 % or -15 % maximum. On the PSS(1) PS 24 V, the maximum
tolerance is +20 % or -15 %.
Safe operation cannot be guaranteed outside this range.
• Overvoltage and spikes of interference can damage the PSS power
supply. If this occurs the unit will switch to a safe condition. Please refer
to the relevant EMC-measures described in Chapter 3.

Safety Regulations
PSS(1) PS 24 V
• The “PSS PS 24 V” and “PSS1 PS 24 V” power supplies require a
24 VDC supply. Check that the voltage supplied from the external power
supply corresponds.
• To achieve the lowest possible residual ripple (< ± 1.2 V), we
recommend that you install a three-phase bridge rectifier or regulated
supply.
• The external 24 V power supply must be capable of supplying a
minimum of 8 A for approximately 1 s.
• The fuse between the external and the PSS power supply protects the
cabling. The size of the fuse will depend on the cable cross section and
on local regulations.
• WARNING!
Safe electrical isolation must be ensured for the external 24 V supply.
Failure to do so could result in electric shock. Power supplies must
conform to DIN VDE 0551 / EN 60 742 and DIN VDE 0160.
• The external 24 V supply should be connected to the PSS power supply
as shown in the diagram below. The external supply should be earthed
in accordance with local regulations.
If the external supply is also being used to supply the input/output
modules, the 0 V output should be earthed as shown in the section
entitled “Supplying the input/output modules”.
External power supply PSS 3000/3100 series
+24 V PSS(1) PS 24 V
L1
~
24 V Functional
N = 0V
0V earth
module rack
Optional: Connect in star to the central

Connect to the earth bar
0 V mains and
earth at a single
point
Fig. 2-1: Connecting the PSS(1) PS 24 V power supply

PSS PS
• The “PSS PS” power supply requires a supply voltage of 115 or 230 VAC.
Check that the voltage supplied from the external power supply
corresponds.
• Connect your supply to the PSS power supply as shown in the diagram
below.
PSS 3000 series
PSS PS
L1 (115/230 V) L1
N N Functional
Only link
at 115 V earth
PE module rack
Connect in star to the central

earth bar
Fig. 2-2: Connecting the PSS PS power supply
PSS1 BMPS 3/1

• The power supply on the “PSS1 BMPS 3/1” requires a supply voltage of
24 VDC. Check that the voltage supplied from the external power supply
corresponds.
• To achieve the lowest possible residual ripple (< ± 1.2 V), we recommend
that you install a three-phase bridge rectifier or regulated supply.
• The power supply generating the 24 VDC for the PSS must be capable of
supplying a minimum of 6 A for approx. 200 ms.
• The fuse between the external and the PSS power supply protects the
wiring. The size of the fuse will depend on the cable cross section and on
local regulations.
• WARNING!

Safety Regulations
• Connect the external 24 V supply to the PSS power supply as shown in the
diagram below. The external supply should be earthed in accordance with
local regulations. If the external supply is also being used to supply the
input/output modules, earth the 0 V mains as described in the section
entitled “Supplying the input/output modules”.
External power supply PSS1 BMPS 3/1
+24 V
L1
~
= 0V 24 V
N 0V Earth
module rack
Optional: Connect in star to the central

Connect to the earth bar
0 V mains and
earth at a single
point
Fig. 2-3: Connecting the supply to the input/output modules
Supplying the input/output modules
• The digital inputs and outputs require a 24 V supply (see connection

diagrams in Chapters 5 and 6). Check that the voltage supplied from the
external power supply corresponds
• We recommend that the PSS(1) PS 24 V / PSS1 BMPS 3/1 and the input/
output modules are fed through two separate power supplies. This will
mean that any breaks in the supply to the input/output modules can be kept
away from the CPU.
• CAUTION!
The tolerance on the external supply voltage to the input/output modules
is +20 % or -15 % maximum. Safe operation cannot be guaranteed
outside this range.
• To achieve the lowest possible residual ripple (< ± 1.2 V), we
recommend that you install a three-phase bridge rectifier or regulated
supply.

• The fuse between the external power supply and the module protects the
cabling. The size of the fuse will depend on the cable cross section and on
local regulations.
• Modules should neither be installed nor removed while voltage is applied.
• WARNING!
• The external power supply should be connected to the safety system's
input/output modules as shown in the diagram below.
There must be no direct connection between “N” and the 0 V output on
the external power supply.
Connect together the 0 V connections on all the 24 V power supplies and
earth the 0 V mains at a single point. The connection of the 0 V supply
to the central earth bar or earth fault monitor must be in accordance with
the relevant national regulations (such as EN 60 204, VDE 0113, NFPA
79-1991:17-7, NEC: Article 250, for example).
External power supply PSS 3000/3100 series
+24 V Module
L1
~
24 V Functional
N = 0V
0V earth
module rack
Connect to the 0 V mains Connect in star to the central

and earth at a single point earth bar
Fig. 2-4: Connecting the supply to the input/output modules

Safety Regulations
Installation
• The unit should be installed in an enclosure (e.g. control cabinet) which

conforms to the protection class required.
• When installing the unit in an enclosure such as a control cabinet, the
technical specifications below must be taken into account:
Protection type (EN 60 529, 10/91) IP 20

Mounting position Vertical
Ambient temperature (DIN IEC 68-2-14, 06/87) 0 ... 60 °C
Storage temperature (EN 60 068-2-1/-2, 03/93) -25 ... +70 °C
Relative humidity
(DIN IEC 68-2-30, 09/86) Max. 95 % r.h.
Condensation Not permitted
Vibration (EN 60 068-2-6, 04/95) Frequency range:
10 ... 100 Hz
Amplitude:
0.1 mm, max. 5g
Shock (DIN IEC 68-2-29) 30g, 11 ms/10g, 16 ms
EMC EN 50 082-2, 03/95
EN 55 011 A, 08/96
• Ensure there is sufficient ventilation to prevent heat building up within the

control cabinet.
• In extreme ambient conditions, additional measures may be required in
order to keep within the prescribed value range (e.g. air-conditioning within
the control cabinet).
• CAUTION!
If the unit is operated at an ambient temperature of more than 45 0C,
surface temperatures on the housing may exceed 80 0C at full load. Do
not touch the metal parts on the housing: risk of burns!
• The safety system must be installed in such a way that buttons and
switches cannot be operated unintentionally.

Connections
• Cable layout must meet the EMC-guidelines stated in Chapter 3.

• Each module should have its own power supply cable as shown in the
connection diagrams (do not make through-connections).
• All modules must be supplied with the voltages they require, otherwise it
will not be possible to carry out the module test (error message will be
generated).
• The current at each slot connection contact (block of 8 outputs) should be
a max. 10A.
• Analogue I/Os and incremental signals should be installed with screened
cables.
• Screened cables are not required for digital I/Os.
• It may be necessary to use screened cables for process interrupts,
depending on ambient conditions and signal frequency
• Minimum ranges for cable cross sections on field connection terminals
in mm2, in accordance with EN 61 131-2, 08/94:
- Digital inputs: 0.5 (AWG20) ... 1.5 (AWG16)
- Digital outputs: 0.5 (AWG20) ... 2.0 (AWG14)
- Analogue input/outputs: 0.18 (AWG24) ... 1.5 (AWG16)
- Power supply: 1.5 (AWG16) ... 2.5 (AWG12)
- Earth: 1.5 (AWG16) ... 2.5 (AWG12)
• Use copper wiring.
• The torque setting on the connection terminals should be 0.5 ... 0.6 Nm.

Safety Regulations
Notes

Electromagnetic Compatibility (EMC)
Overview
The safety system is designed to be installed within an electromagnetic

industrial environment. To ensure electromagnetic compatibility the
correct procedures must be carried out when installing the system.
A device is electromagnetically compatible if:

• It functions without error in a given electromagnetic environment.
• It does not adversely affect its own environment.
Electromagnetic interference reaches the system through:

• Radiated fields
• Power supply
• Earth cabling
• Bus
• Interfaces
• Input and output cables
The interference can be transferred from the source to the receiver

(interference sink) via the coupling routes.
Source of Interference
interference Coupling sink
Fig. 3-1: Electromagnetic interference
Interference reaches the interference sink (e.g. the PSS 3000) in various
ways:
• DC coupling
This occurs if the source and sink of interference have common cable
connections. The common cable presents complex resistances, inducing
potential differences. Possible sources of interference are switches/
relays, running motors or varying potentials for other systems on the
same power supply.

• Capacitive (electrical) coupling

A different potential between the source and interference sink (e.g. two
cables) creates an electrical field. Cross-coupling is proportional to the
rate of voltage change.
Possible sources of interference are contactors, static discharge, parallel
signal cables.
• Inductive (magnetic) coupling
A live cable produces a magnetic field which surrounds both the live and
neighbouring cables. Interference voltage is induced. Cross-coupling is
proportional to the rate of current change.
Possible sources of interference are mains cables running in parallel, live
cables, high frequency cables, inductors, transformers, motors.
• Electromagnetic coupling
A cable can emit a signal as a radio wave. This wave is then picked up
by another cable.
Possible sources of interference are transmitters such as radios, sparks
from spark plugs, welding equipment etc.
NOTICE
Stronger HF transmitters should only be operated at a distance of more
than 0.6 m.
• Static discharge
Static discharge occurs where there are very high differences in potential
between two points. If the two points are brought closer together or if the
potential difference is increased, discharges can occur in the air gaps.
Possible sources of interference are people who are statically charged
from a synthetic carpet, for example.
Making the installation EMC-compliant
Connecting the earth cables
The prescribed earth points are designed for your safety and to guarantee
compliance with noise resistance requirements.

• The power supply (PSS PS) and module rack should be connected to the
earth conductor “PE”. A cable cross section of 1.5 mm2 should be used to
connect the power supply, and a cable cross section of at least 2.5 mm2
should be used to connect the module rack. Connections should be kept
as short as possible.
• Always connect the earth conductor “PE” to the central earth point in star
form.
• Connect together the 0 V connections on all the 24 V power supplies and
earth the 0 V mains at a single point. The connection of the 0 V supply
to the central earth bar or earth fault monitor must be in accordance with
the relevant national regulations (such as EN 60 204, VDE 0113, NFPA
79-1991:17-7, NEC: Article 250, for example).
• Connections should be protected from corrosion.
• Flexible earthing straps should be used on moving earth parts (e.g.
machine parts, gates). Ensure these earthing straps are as short and
wide as possible.
Cabling
It is possible to differentiate between cables according to their function.

The following groups exist:
• Group 1: Data and supply lines for DC voltages below 60 V and AC
voltages below 25 V
• Group 2: Data and supply lines for DC voltages from 60 V to 400 V and
AC voltages from 25 V to 400 V
• Group 3: Supply lines above 400 V
Cabling inside buildings:

• The cable groups listed above should be laid separately.
• Cables of the same group can be laid within the same cable duct.
• Lines from group 1 and group 2 should be laid in separate groups or in
cable ducts which are at least 10 cm apart.

• Lines from group 1 and group 3 should be laid in separate groups or in

cable ducts which are at least 50 cm apart.
• Data and signal lines should be laid as close as possible to an earthed
surface.
Cabling to open air systems:
• As far as possible use metal conduits. These should be electrically
connected and earthed.
• Ensure there is sufficient protection against lightning by:
- Using metal conduits earthed at both ends, or concrete cable ducts
with reinforcements connected across the joints.
Equipotential bonding
Potential differences can occur through potential connected couplings

between the safety system and peripheral devices or cable shields, which
are connected at either end and have different earth connections. In order
to avoid interference, equipotential bonding cables must be installed. In
doing so, you must ensure the following:
• Select a low impedance equipotential bonding cable.
• If the safety system and peripheral devices are connected with screened
signal cables which are earthed at either end, the impedance is
calculated as follows:
Impedance equipotential bonding cable = 10% of screen impedance.
• Select the following as standard values for the cross section of the
equipotential bonding cable:
16 mm2 for equipotential bonding cables up to 200 m in length.
25 mm2 for equipotential bonding cables over 200 m in length.
• Use copper or galvanised steel equipotential bonding cable.
• Connect equipotential bonding cables to the earth conductor over as
wide a surface area as possible.
• As short a distance as possible should be kept between the equipotential
bonding cable and signal cable.

Screened cables
Interference currents arising from electrical, magnetic or electromagnetic

fields of interference must be diverted to cable screens via the earth bars
connected to the enclosure. Please remember the following:
• Connect the screens with low impedence to the earth conductor.
• Use cables with braided screening, with a minimum cover area of 80%.
• For high frequency areas connect the screen at both ends.
• For low frequency areas connect the screen at one end; this is also valid
when laying cables without equipotential bonding or using foil screens.
• Use metal or metallised plugs to connect cables for serial data transfer.
• The screen must have no connection to the connector housing if it is not
located at the end of the cable.
• At the point where the cable enters the cabinet, connect the screen to
the earth bar, without making a break in the cable. Use metal cable
clamps which cover the screen over a wide surface area.
Take the screen as far as the module, but do not lay it on top of the
module
Insulation voltage test
The modules PSS(1) PS 24V, PSS(1) AI and PSS BMPS 3/1are

connected to the functional earth through protective elements on the supply
voltage. Insulation voltage tests can only be carried out with voltages up to
approximately 42 V.
Suppression of inductive loads
Suppression should not be used to protect semiconductor outputs.

Suppression will be necessary if relay outputs (e.g. PSS(1) DOR) are used
to switch inductive loads. In this case you should use flywheel diodes,
varistors or RC modules.

Miscellaneous
Connecting the programming device
The programming device requires a mains connection in each cabinet.

The mains connection must be connected to the same distributor as the
earth conductor for the cabinet.
Lighting inside the cabinet
Use incandescent panel lighting as available from LINESTRA.
NOTICE
Fluorescent lamps should be avoided as they create interference fields.
However, if it is absolutely necessary to use fluorescent lamps, the
guidelines listed below should be followed:
• Place shield screening over the lamp.
• Used screened cable.
• Install a metal-sheathed switch.
• Use a mains filter or screened power supply cable.
Installing within an enclosure or wall-mounting
Care must be taken to avoid interference when installing the unit within an
enclosure or wall-mounting:
• Shielding, earth conductor bars and the base module rack should be
attached to metal parts in order to divert any coupled interference on to
large metal areas. For wall-mounting we recommend that the overall
potential surfaces are made of steel.
• For varnished or anodised metal parts you should use special contact
plates or remove the protective coating.
• Install an earth bar for the cable screens.
• The earth bar can also be used as the ground conductor bar.
• Connect the earth bar to the mounting plate over a wide surface area
and with low impedance.

Testing the EMC-compliance of an installation
Use the following list to check that the safety system has been installed to
conform with EMC-regulations.
Check Action Done

Before installation:
Are there areas with a high Make detailed plans for EMC
probability of interference? protection in these areas.
(e.g. computers running,
process control areas,
distribution cabinets, cable
casing, frequency converters,
hand-held radios etc.)
Are areas where computers If necessary shield the whole
are running and areas such area.
as process control rooms
sufficiently shielded from
electromagnetic coupling?
Have you, or the installer, Some important points: Lay
sufficient knowledge where cables close to earth, keep clear
cable layout is concerned? of other electrical equipment,
keep cables in ducts separate
from other parts of the
installation, keep cables as short
as possible.
Is the supply voltage free Build in a mains filter where
of interference? interference may occur.
EMC characteristics of Test under operating conditions,
individual units / all e.g. while hand-held radios are in
units once installed? use, or HF frequency generators
are close by. Test static discharge
with operating personnel, test
mutual interference between
units under different operating
conditions.

Check Action Done

During installation:
Earthed parts connected Most important are the
correctly? connections to base module
racks, racking bars, earth
conductors and earth bars.
Inactive metal parts should be
connected over a wide surface
area and earthed to a central point.
With insulated metal: Remove
insulation or use special
contact fixings. Protect the
connection from corrosion. Connect
the cabinet doors to the body of
the cabinet using earthing straps.
Are the cables laid Separate cables into groups.
correctly? Supply and signal leads
must be laid separately.
Are the shields connected Use shielded cables for analogue
correctly? and data leads.
Use metallic plugs.
Connect cable shields to earth bar
at point of entry to cabinet.
Connect cable shields over a wide
surface area and with low
impedance.
Equipotential bonding Equipotential bonding cables
carried out? should be laid if the installation
extends over a wide area.
Are inductive loads Inductive loads not switched by
switched? the safety systems must be wired
with suppression elements.
24 VDC power supply? The power supply must conform to
DIN VDE 0551 / EN 60 742 and
DIN VDE 0160.

Installation
Installing the PSS 3000 series
Installing the base module rack

Drill 4 x M6 holes in the mounting plate of the control cabinet, as per the
installation dimensions for the base module rack. Screw the base module
rack on to the mounting plate in your control cabinet.
465 8,8 43,5 262,4 8,8

43,5 (10.33") (0.35")
(1.71") (18.31") (0.35") (1.71")
190,5 277,5
190,5 277,5 (7.5") (10.93")
(7.5") (10.93")
280
482,6 (11.02")
(19")
Dimensions of module rack PSS 3000 BM8 Dimensions of module rack PSS 3000 BM4
Dimensions stated in mm (") Dimensions stated in mm (")
INFORMATION
The modules require at least 65 mm free space for insertion (see diagram
below).
65
(2.56")
Back plate
(Pilz bus)
Insert the module into

250 the base module rack
(9.84")
Dimensions stated in mm (")

Installation
Installing the modules for the PSS 3000 series
WARNING!
Before installing the modules, switch off all the power to the terminals and
power supply. You should also switch off all the power before inserting or
removing a connector. Serious, even fatal injuries could occur due to electric
shock if you touch conductive parts while power is applied.
• Attach the module to the

upper holder at an angle,
as shown.
• Carefully push the module
with a swivel movement
into the bus slot(s).
• Tighten the two securing screws to prevent the module from coming loose
and to make the earth conductor connection.
• The module is secured correctly when the plastic sheath is embedded (see
diagram below).
Failsafe bus
Plastic
Pilz bus sheath
embedded
Securing screw
with plastic
sheath
INFORMATION
The first module slot is reserved for the power supply.
The second module slot is reserved for the CPU on the base module rack,
and for an expansion connection on expansion module racks.

Expansion devices for the PSS 3000 series
A maximum of two expansion racks can be added to the PSS 3000 base
module rack. This provides an extra 16 slots for standard modules. The
expansion module racks can be configured in different ways:
INFORMATION
Failsafe modules cannot be used on the expansion rack!
• Configuration below the base module rack
Expansion connection
for base unit
Failsafe and
standard C 1 3 5 7
modules P
P
S U0 2 4 6
Expansion connection
for expansion rack
Standard
modules only 9 11 13 15
P
S 8 10 12 14
Standard
modules only 17 19 21 23
P
S 16 18 20 22
One power supply may be sufficient for two racks, depending on the
modules' power input requirements (see Chapter 8).
- The rack is addressed consecutively, starting with the base module rack.
- Maximum cable length: between base unit and expansion rack: 1200 mm,
between expansion units 320 mm.
NOTICE
Bus expansion cables must not be laid in the cable duct.

Installation
• Configuration next to the base module rack
Expansion connection Expansion connection

for base unit for expansion rack
C 1 3 5 7 9 11 13 15
P P P
S U0 2 4 6 S 8 10 12 14
Standard
modules only
17 19 21 23
P
S 16 18 20 22
- Maximum cable length: between base unit and expansion rack: 1200 mm,
between expansion units 320 mm.
NOTICE
Bus expansion cables should not be laid in the cable duct.

• Configuration next to and below the base module rack
Expansion connection Expansion connection

for base unit for expansion rack
C 1 3 5 7 17 19 21 23
P P P
S U0 2 4 6 S 16 18 20 22
Standard
modules only
9 11 13 15
P
S 8 10 12 14
Standard
modules only
- Maximum cable length: between base unit and expansion unit: 1200 mm.
NOTICE
Bus expansion cables should not be laid in the cable duct.

Installation
Installing the module rack in a control cabinet (PSS 3000 series)

The expansion rack is installed in the same way as the base module rack.
It is essential that you keep to the minimum distance between racks (see
diagram below).
Distance from top

min. 130 mm (5.12")
482.6 (19")
Earth
connector
cross- FS Bus
section:
>2.5 mm2 277.4
(AWG#12) (10.92")
ST Bus
10 PS CPU DI DI DO
(0.39") pilz pilz pilz pilz pilz
min.65
W x H cable duct (2.56")
max. 100 mm (3.94") x 50 mm (1.97") max. 120
(4.72")
10
(0.39")
ST Bus
min. 50
PS DI DI DO
(1.97")
pilz pilz pilz pilz pilz
Distance from
control cabinet
min. 100 mm (3.94") min. 60 (2.36")
Power section
Modular depth: 244 mm

Installing the PSS 3100 series
Installing the base module rack PSS1 BMP 5/2
10 320,6 10
(0.39") (12.62") (0.39")
37,7
(1.48") M6
190,5
(7.5") 265,9
(10.47")
340,6
(13.41")
Dimensions of module rack PSS BMP 5/2


Installation
Installing the base module rack PSS1 BMPS 3/1

9,7 240 9,7

(0.38") (9.448") (0.38")
37,7
(1.48") M6
190,5
(7.5") 265,9
(10.47")
259,4
(10.21")
Dimensions of module rack PSS BMPS 3/1

Installing the modules for the PSS 3100 series
WARNING!
power supply.
• Insert the module along the guide rail.
• Push the module firmly into the socket on the bus plate.
• Tighten the screws at the front to prevent the module coming loose and
to make the earth conductor connection.

Installation
WARNING!
Unused slots should always be covered with a blanking plate (order
reference: 303 200). If not, an electric shock could endanger life, or
foreign bodies could cause a short circuit and damage the unit.
The first module slot is reserved for the power supply and the second
module slot is reserved for the CPU (not on the PSS1 BMPS 3/1).
Changing a PSS 3100 module
WARNING !
power supply.
• Remove the two screws securing the module to the module rack (1).
• Use a screwdriver on the groove of the upper securing rail to lever the
module out (2).

Installing the PSS1 BMP 5/2 module rack in a control cabinet
It is essential that you keep to the minimum distance between the wall of
the control cabinet and the power section.
Distance from top

min. 130 mm (5.12")
304.6
(12")
265.9
M4 earth (10.47")
connector
cross section
>2.5 mm2
(AWG#12)
Distance from Distance from
control cabinet control cabinet
min. 50 mm min. 60 mm min. 50 mm
(1.97") (2.36") (1.97")
Power section

Installation
Installing the PSS1 BMP 3/1 module rack in a control cabinet
It is essential that you keep to the minimum distance between the wall of
the control cabinet and the power section.
Distance from top

min. 130 mm (5.12")
223.4
(8.76")
265.9
M4 earth (10.47")
connector
cross section
>2.5 mm2
(AWG#12)
Distance from Distance from
control cabinet control cabinet
min. 50 mm min. 60 mm min. 50 mm
(1.97") (2.36") (1.97")
Power section

Connection Diagrams: Failsafe Section
Configuration of the screw terminals and connector description
Terminal configuration Terminal configuration

General Example: PSS DI
__X__.1 Connector __X__.1

1 description: I 00 1
2 I 01 2
3 I 02 3
4 I 03 4
5 X1 I 04 5
6 I 05 6
7 I 06 7
8 I 07 8
9 0V 9
10 0V 10
__X__.2 __X__.2
1 I 08 1
2 I 09 2
3 I 10 3
4 I 11 4
5 I 12 5
6 X2 6
Failsafe
I 13
7 I 14 7
8 I 15 8
9 0V 9
10 0V 10
__X__.3 __X__.3
1 I 16 1
2 I 17 2
3 I 18 3
4 I 19 4
5 I 20 5
6 X3
I 21 6
7 I 22 7
8 I 23 8
9 0V 9
10 0V 10
__X__.4 __X__.4
1 I 24
2 1
I 25 2
3 I 26 3
4 I 27 4
5 I 28
6
X4 5
I 29 6
7 I 30 7
8 I 31 8
9 9
10 0V
0V 10
PSS DI

Notes on wiring
Where safety-relevant applications are concerned, it is essential that

short circuits and line breaks are unable to cause a hazardous condition
within a plant.
The way in which this is done will depend on the degree of hazard within
the plant itself, the switching frequency of the input devices and the level
of safety of the input devices and actuators. These points must be
assessed in conjunction with the relevant standards or approvals body
(e.g. BG or TÜV).
The following terms are important:

• Test pulses
These are signals which change status on several occasions within a
period of time.
• Single-channel safe input devices
These are positively-driven normally-closed contacts which open on
actuation (failsafe principle).
• Elimination of short circuits between signals
This is possible within electrically-enclosed areas and also outside
electrically-enclosed areas for signals conducted in different multicore
cables. However, all components must meet the relevant regulations in
accordance with EN, DIN and VDE.
• In principle, the possibility of earth faults and line breaks occurring
cannot be eliminated.
If a dual-pole switching output on the PSS(1) DIO Z is used to drive the

actuators, a test for short circuits and line breaks will automatically be
carried out during each cycle. For this purpose the actuator will be
switched off for approximately 100 µs. Where the PSS(1) DO or PSS(1)
DIO T is installed, a switch-off test will only be carried out if designed into
the self-check. If the unit powers-up unintentionally, this will be detected
immediately.
With multi-channel pulsed input devices, short circuits and line breaks can
be detected via feasibility checks in the control program.

The input test on the programmable safety system uses test pulses to
enable the system's operating program to carry out a test to detect short
circuits and line breaks. The following pages contain details of connection
examples which may be of use when wiring the unit.
NOTICE
Please read the description for each application!
Failsafe

PSS(1) DI 2
Features:
• Input module with 32 inputs
• Response time: I00 ... I15: 1 ms, I16 ... I31: 3 ms
• Module code: 8003 8003
• Depending on the application area and its respective regulations, this
module 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, the module must always use test pulses.
• Only one 0 V output terminal needs to be connected
• Only input signals which operate in accordance with the zero signal
principle (on switching off) are permitted for safety-related applications
• Signals may be connected using unscreened cables.
CAUTION!
The connection shown overleaf is only approved for non-safety
applications. The connection of safe input devices for safety-relevant
applications is described later in the chapter.

PSS(1) DI 2 configuration
__X__.1
I 00 Input X.0 (X: slot)
I 01
I 02
I 03 Input device is not failsafe
I 04
I 05
I 06
I 07
0V
0V
__X__.2
I 08 Input X.8
I 09
I 10
I 11
I 12
I 13
I 14
I 15
0V
0V
Failsafe
__X__.3
I 16 Input X.16
I 17
I 18
I 19
I 20
I 21
I 22
I 23
0V
0V
__X__.4
I 24 Input X.24
I 25
I 26
I 27
I 28
I 29
I 30
I 31
0V
0V
PSS DI 2
L+
24 V DC
L-
Please ensure safety regulations and EMC guidelines are observed!

PSS(1) DI 2
Example: Single-channel, failsafe input device, without test pulses
Features:
connection diagram is suitable for pulsed and continuous input
devices up to category 2 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.
• The input device must be approved for failsafe applications.
• Please read the instructions provided with the input device.
• If you are using the PSS(1) DI module, the connection shown overleaf is
only approved for non-safety applications.
CAUTION!
It will not be possible to detect short circuits in the cable between the input
device and input with the L+ line or between adjacent inputs. Nor will a
short circuit between several input devices be detected. Depending on the
type of input device connected, this could create a risk to both personnel
and machinery (e.g. emergency stop). You should always ensure that the
unit is suitably wired to eliminate the risk of short circuits.

PSS(1) DI 2
Example: Single-channel, failsafe input device, without test pulses
__X__.1
I 00
I 01
I 02
I 03
I 04
I 05
I 06
I 07 Single-channel, failsafe input
0V device
0V
__X__.2
I 08
I 09
I 10
I 11
I 12
I 13
I 14
I 15
0V
Failsafe
0V
__X__.3
I 16
I 17
I 18
I 19
I 20
I 21
I 22
I 23
0V
0V
__X__.4
I 24
I 25
I 26
I 27
I 28
I 29
I 30
I 31
0V
0V
PSS DI 2
L+
24 V DC
L-

PSS(1) DI 2
Example: Dual-channel input devices, without test pulses
Features:
• PSS(1) DI and PSS(1) DI 2: Depending on the application area and its
respective regulations, this connection diagram is suitable for pulsed
input devices up to category 4 in accordance with EN 954-1, provided
the functionality of both input device channels is monitored in the user
program via a feasibility check (see example in the Programming
Manual).
• PSS(1) DI2: Depending on the application area and its respective
regulations, this connection diagram is suitable for continuous input
devices up to category 3 in accordance with EN 954-1, provided the
functionality of both sensor channels is monitored in the user program
via a feasibility check (see example in the Programming Manual).
• The possibility of short circuits occurring between adjacent connector
terminals cannot be eliminated. For this reason, the two identical
(homogenous) channels on an input device must not be connected to
adjacent inputs.
• If you are using input devices with different (diverse) channels, adjacent
inputs may be used. Short circuits will be detected in the application
program via the feasibility check (see example in the Programming
Manual).
CAUTION!
It will not be possible to detect short circuits in the cable between the input
device and input with the L+ line, nor short circuits between several input
devices. Depending on the type of input device connected, this could
create a risk to both personnel and machinery (e.g. emergency stop). You
should always ensure that the unit is suitably wired to eliminate the risk of
short circuits.

PSS(1) DI 2
Example: Dual-channel input devices, without test pulses
__X__.1
I 00
I 01 Input for other
I 02 other input devices
I 03
I 04
I 05
I 06
I 07 Dual-channel input
0V
0V device with identical
__X__.2 (homogenous)
I 08 channels
I 09
I 10
I 11
I 12
I 13
I 14 Dual-channel input
I 15 device with different
0V (diverse) channels
0V
Failsafe
__X__.3
I 16
I 17
I 18
I 19
I 20
I 21
I 22
I 23
0V
0V
__X__.4
I 24
I 25
I 26
I 27
I 28
I 29
I 30
I 31
0V
0V
PSS DI (2)
L+
24 V DC
L-

PSS(1) DI 2
Example: Single-channel, failsafe input device, with test pulses
Features:
connection diagram is suitable for applications up to category 2 in
accordance with EN 954-1.
• The input device must be approved for failsafe applications.
• Please read the instructions provided with the input device.
• The test pulse must be allocated to the input via the configurator on the
programming device (see Programming Manual).
• Testing will detect short circuits between lines L+ and L-, and also
between the pulsed outputs.
• Only input devices with N/C contacts can be approved.
• Cable runs: 1 ms inputs: 200 m;
With 1 kOhm resistance parallel to input:
Max. 800 m
3 ms inputs: 800 m
CAUTION!
Short circuits between the cable from the signal to the input device and the
cable from the input device to the input will not be detected.

PSS(1) DI and PSS(1) DI 2
Example: Single-channel, failsafe input device, with test pulses
__X__.1 __X__.1
I 00 I 00
I 01 I 01
I 02 I 02
I 03 I 03
I 04 I 04
I 05 I 05
I 06 I 06
I 07 I 07
0V 0V Single-
0V 0V channel,
__X__.2 __X__.2 failsafe
I 08 I 08
I 09 I 09 input
I 10 I 10 device
I 11 I 11
I 12 I 12
I 13 I 13
I 14 I 14
I 15 I 15
0V 0V
0V 0V
Failsafe
__X__.3 Test pulse 0 __X__.3
O 16 I 16
O 17 I 17
O 18 I 18
O 19 I 19
O 20 I 20
O 21 I 21
O 22 I 22
O 23 I 23
24 V 0V
0V 0V
__X__.4 __X__.4
O 24 I 24
O 25 I 25
O 26 I 26
O 27 I 27
O 28 I 28
O 29 I 29
O 30 I 30
O 31 I 31
24 V 0V Additional
0V 0V input
PSS DIO T PSS DI (2)
devices
L+
24 V DC
L-

PSS(1) DI 2
Example: Dual-channel, failsafe input device, with test pulses
Features:
connection diagram is suitable for applications up to category 4 in
• This type of connection is mainly used for continuous signals.
• The operating system will detect all shorts between contacts and short
circuits to L+ and L-.
• Short circuits across the contact can be detected via the feasibility check
in the application program.
• The test pulse must be allocated to the input via the configurator on the
• Only input devices with N/C contacts can be approved (in the case of
diverse channels, only the N/C contact).
• On input devices with identical channels, each channel should be given
a separate signal, where possible. This will ensure that all short circuits
are detected, with the exception of short circuits which short out the
input device (cable from the signal to the input device and cable from the
input device to the input).
• If the input device has only one signal, a short circuit between the
cables from the input device to the inputs will not be detected. You
should always ensure that the unit is suitably wired to avoid the risk of
this type of short circuit.
• Cable runs: 1 ms inputs: 200 m;
With 1 kOhm resistance parallel to input:
Max. 800 m
3 ms inputs: 800 m

PSS(1) DI 2
Example: Dual-channel, failsafe input device, with test pulses
Input for other input
__X__.1 __X__.1 devices
I 00 I 00
I 01 I 01
I 02 I 02
I 03 I 03
I 04 I 04
I 05 I 05 Dual-channel
I 06 I 06 input device with
I 07 I 07 identical
0V 0V channels
0V 0V
__X__.2 __X__.2
I 08 I 08
I 09 I 09
I 10 I 10
I 11 I 11
I 12 I 12
I 13 I 13 Dual-
I 14 I 14 channel input
I 15 I 15 device with
0V 0V identical
Failsafe
0V 0V channels
__X__.3 Test pulse 0 __X__.3
O 16 I 16
O 17 I 17
O 18 Test I 18 Dual-
O 19 pulse I 19 channel
O 20 1 I 20 input
O 21 I 21
O 22 I 22 device
O 23 I 23 with
24 V 0V diverse
0V 0V chan-
__X__.4 __X__.4 nels
O 24 I 24
O 25 I 25
O 26 I 26
O 27 I 27
O 28 I 28
O 29 I 29
O 30 I 30
O 31 I 31
24 V 0V More
0V 0V input
PSS DIO T PSS DI (2) devices
L+
24 V DC
L-

PSS(1) DI2O T
Features:
• Test pulse output module with 16 inputs.
• The inputs correspond to the 1 ms inputs on the PSS(1) DI2.
• The outputs are push-pull outputs. Do not use the push-pull level to drive
a load to L+, otherwise the switch-off test will detect a connection to L+
and will register an error.
• In the configurator on the programming device, outputs can be
configured as test pulses or as single-pole 2 A outputs in groups of 8
(see Programming Manual). Configuration is carried out automatically,
depending on the number of test pulses used:
Number < 8: X.16 ... X.23 are test pulse outputs
X.24 ... X.31 are single-pole 2 A outputs
Number > 8: X.16 ... X.31 are test pulse outputs
Number = 0: X.16 ... X.31 are single-pole 2 A outputs
• If the number of pulses is less than 8, test pulse outputs up to and
including X.23 must remain unwired.
• DIF2 and DI2 inputs must not be connected to the same pulsed output.
• Adjacent inputs should not be operated with the same pulse.
NOTICE
When using single-pole outputs, always ensure that line or cable breaks
and short circuits between lines can always be detected, or ensure they
cannot occur by using appropriate wiring.
• Outputs configured as 2 A outputs have monitoring inputs available
under the same address. These can be used for feasibility checks.
• If cable runs are greater than 200 m with a cable cross section of
1.5 mm2, or cable runs are greater than 300 m with a cable cross section
of 2.5 mm2, the operating system will not detect a short circuit to earth.
• If cable runs are greater than 800 m, interference from switching
operations in 24 VDC signals may affect the pulsed outputs.
• Each output is protected against short circuit, overload and
overtemperature. Outputs are designed for resistive and inductive loads.
• For details of press applications please refer to the relevant application
description.

PSS(1) DI2O T configuration
__X__.1
I 00
I 01
I 02
I 03
I 04
I 05
I 06
I 07
0V
0V
Inputs __X__.2
I 08
I 09
I 10
I 11
I 12
I 13
I 14
I 15
0V
0V
__X__.3
Failsafe
O 16
O 17 Test pulses for
O 18 input devices
O 19
O 20
O 21
O 22
O 23
24 V
Test pulse 0V
outputs or single- __X__.4
pole 2 A outputs O 24
O 25
O 26
O 27
O 28
O 29
O 30
O 31
24 V
0V
PSS DI2O T
L+
24 V DC
L-

PSS(1) DI2O Z
Features:
• Dual-pole switching output module with 16 inputs
• The inputs correspond to the 1 ms inputs on the PSS(1) DI.
• The outputs are dual-pole switching 2 A outputs.
• The operating system of the programmable safety system tests the
outputs during each cycle. Any short circuits or open circuits to the load
will be detected.
• To avoid overloading the contacts, the current at the connection
terminals should be 10 A maximum.
• The maximum continuous current over all the outputs is 10 A.
• During testing, the load is isolated from the supply for 100 ... 200 µs
in each cycle (depending on the load and the line length).
The load must not switch off during this time.
Outputs that are switched off are switched on for approximately 100 µs,
in order to test the monitoring inputs. The load must not switch on 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 too high an inductance on the contactors. In this case it
helps to have a 1 kOhm resistor connected in parallel to the contactor
coil.
• Each output is protected against short circuit, overload and
overtemperature. Outputs are designed for resistive and inductive loads.

PSS(1) DI2O Z configuration
__X__.1
I 00
I 01
I 02
I 03
I 04
I 05
I 06
I 07
0V
0V
__X__.2
I 08
I 09
I 10
I 11
I 12
I 13
I 14
I 15
0V
0V
__X__.3
O 16+ Output X.16 (X: slot)
Failsafe
O 16-
O 17+
O 17-
O 18+
O 18-
O 19+
O 19- Output X.19
24 V
24 V
__X__.4
O 20+ Output X.20
O 20-
O 21+
O 21-
O 22+
O 22-
O 23+
O 23-
Output X.23
0V
0V
PSS DI2O Z
L+
24 V DC
L-

PSS(1) DIF
Features:
• Input module with facility for process interrupts: maximum 16
• This module will trigger a CPU interrupt if the pulse edge at an input
changes.
• The inputs that trigger a process interrupt and the pulse edge that
causes the interrupt to be triggered are defined via the configurator in the
• Only one 0 V output terminal needs to be connected.
• The 0 V terminals between the inputs prevent short circuits occurring
between the inputs.
• Only those process interrupts triggered by a pulse edge change from “1”
to “0” are safety-relevant.
• The input signals may require screened cables, depending on the signal
frequency and the ambient conditions. If screened cables are used, the
0 V terminal between the inputs may be used for the screen.
• Process interrupts which are safety-relevant must be tested to ensure
they function correctly. The inputs may be tested using test pulses or via
the feasibility check (see example “Process interrupt test”).
• If a cable run exceeds 50 m, a resistance of 1 kOhm must be connected
in parallel with the input. The maximum cable run will then be 400 m.
NOTICE
Do not replace a DIF 2 module with a DIF module!
If a DIF module is inserted instead of a DIF 2 module, alarms could be lost
because the two modules have a different filter time.

PSS(1) DIF configuration
__X__.1
I 00
0V
I 01
0V
I 02
0V
I 03
0V
0V
0V
__X__.2
I 04
0V
I 05
0V
I 06
0V
I 07
0V
0V
0V
Failsafe
__X__.3
I 08
0V
I 09
0V
I 10
0V
I 11
0V
0V
0V
__X__.4
I 12
0V
I 13
0V
I 14
0V
I 15
0V
0V
0V
PSS DIF
L+
24 V DC
L-

PSS(1) DIF
Example: Process interrupt test
Features:
• The test pulse must be allocated to an input via the configurator in the
• PSS(1) DIF inputs have a shorter filter time than PSS(1) DI inputs. The
test period automatically adjusts to the DIF.
• DIF and DI inputs must not be connected to the same pulsed output.

PSS(1) DIF
Example: Process interrupt test
__X__.1 __X__.1
I 00 I 00
I 01 0V
I 02 I 01
I 03 0V
I 04 I 02
I 05 0V
I 06 I 03
I 07 0V
0V 0V
0V 0V
__X__.2 __X__.2
I 08 I 04
I 09 0V
I 10 I 05
I 11 0V
I 12 I 06
I 13 0V
I 14 I 07
I 15 0V
0V 0V
0V 0V
Failsafe
__X__.3 __X__.3
O 16 I 08
O 17 Test pulse 2 0V
O 18 I 09
O 19 0V
O 20 I 10
O 21 0V
O 22 I 11
O 23 0V
24 V 0V
0V 0V
__X__.4 __X__.4
O 24 I 12
O 25 0V
O 26 I 13
O 27 0V
O 28 I 14
O 29 0V
O 30 I 15
O 31 0V Additional
24 V 0V sensors with
0V 0V
PSS DIO T
process
PSS DIF
interrupt
L+
24 V DC
L-

PSS(1) DIF 2
Features:
• Input module with facility for process interrupts: maximum 16
• This module will trigger a CPU interrupt if the pulse edge at an input
changes.
• The inputs that trigger a process interrupt and the pulse edge that
causes the interrupt to be triggered are defined via the configurator in the
• Only one 0 V output terminal needs to be connected.
• The 0 V terminals between the inputs prevent short circuits occurring
between the inputs.
• Only those process interrupts triggered by a pulse edge change from “1”
to “0” are safety-relevant.
• The input signals may require screened cables, depending on the signal
frequency and the ambient conditions. If screened cables are used, the
0 V terminal between the inputs may be used for the screen.
• If a cable run exceeds 50 m, a resistance of 1 kOhm must be connected
in parallel with the input. The maximum cable run will then be 400 m.
CAUTION!
The DIF 2 module cannot be tested via the test signal on the DIO T
module because of the greater response time of the input filters. The DIF 2
should only be used with pulsed input signals which can be monitored via
a feasibility check.
NOTICE
Do not replace a DIF 2 module with a DIF module!
If a DIF module is inserted instead of a DIF 2 module, alarms could be lost
because the two modules have a different filter time.

PSS(1) DIF 2 configuration
__X__.1
I 00
0V
I 01
0V
I 02
0V
I 03
0V
0V
0V
__X__.2
I 04
0V
I 05
0V
I 06
0V
I 07
0V
0V
0V
Failsafe
__X__.3
I 08
0V
I 09
0V
I 10
0V
I 11
0V
0V
0V
__X__.4
I 12
0V
I 13
0V
I 14
0V
I 15
0V
0V
0V
PSS DIF 2
L+
24 V DC
L-

PSS(1) DOR
Features:
• All relay outputs are volt-free.
• The module meets the guidelines for the safe separation of relays
separated by a free connection (e.g. O 01 and O 02).
• Maximum switching voltage: 250 VAC/250 VDC, switching current: AC:
0.1 - 4 A, DC: maximum 4 A at 24 V, maximum 0.1 A at 250 V.
• Switching capability in accordance with EN 60 947-5-1:
- AC15/C300: 120 V/1.5 A; 240 V/0.75 A
- DC13/Q300: 125 V/0.55 A; 250 V/0.27 A
• Switching frequency at maximum load: 15/minute
• Each relay has a monitoring input available via positive-guided contacts.
Relay outputs and monitoring outputs have the same address.
• The application program must carry out function tests, if necessary.
• The supply voltage must be at least 21.6 V. Select a suitable power
supply and connect it to the module using individual supply cables. If the
supply falls below 21.6 V an error may be registered, with error message
“F06 n60” (n = channel A, B or C).
• Suppression will be required if inductive loads are being switched. Use
flywheel diodes, varistors or RC modules.
CAUTION!
Voltage must only be applied to the terminals on the PSS1 DOR module
when the module is inserted in the PSS 3100 module rack. Serious, even
fatal injuries could occur due to electric shock if you touch conductive parts
while power is applied.
CAUTION!
Switch off all the power before inserting or removing a connector. Serious,
even fatal injuries could occur due to electric shock if you touch conductive
parts while power is applied.

PSS(1) DOR configuration
__X__.1
O 00 13 L1
O 00 14 N
O 01 13
O 01 14
*
O 02 13 L1
O 02 14 M N
* __X__.2 1~
O 03 13 L1 Standard
connection
O 03 14
O 04 13
for safe
N actuators
O 04 14
*
N
O 05 13
O 05 14
*
Failsafe
__X__.3
O 06 13
O 06 14
O 07 13
O 07 14
O 08 13
O 08 14
*
24 V
* __X__.4
O 09 13
O 09 14
O 10 13
O 10 14
O 11 13 Fuse max. 10 A
O 11 14
*
0V
PSS DOR
L+
24 V DC
L- * Safe separation

PSS(1) DOS
Features:
• Output module with 32 single-pole 1.5 A outputs
• Shorts between contacts are detected via test pulses when switching on
and off. These are generated by the operating system.
• If a short circuit occurs between the lead from the output to the load and
the 24 VDC supply lead, it will no longer be possible to switch off the
load. The following remedies are possible:
- Eliminate the possibility of an error by using separate multicore cable
for the 24 VDC
- Use dual actuators for safety
- Use an additional shutdown device such as a main contactor.
• The module has a second shutdown route and can therefore be used for
single-channel operation in applications conforming to EN 954-1 (11/94)
up to safety category 3 (depending on the application area and its
respective regulations). Please note that the second shutdown route is
only tested when the system switches from “STOP” to “RUN”.
To achieve category 4, dual actuators must be connected to adjacent
blocks of 8 outputs.
• A separate fuse should be connected in series with each block of 8
outputs.

PSS(1) DOS configuration
__X__.1
O 00
O 01
O 02
O 03
O 04
O 05
O 06
O 07
24 V
0V
__X__.2
O 08
O 09
O 10
O 11
O 12
O 13
O 14
O 15
24 V
0V
__X__.3
O 16
Failsafe
O 17
O 18
O 19
O 20
O 21
O 22
O 23
24 V
0V
__X__.4
O 24
O 25
O 26
O 27
O 28
O 29
O 30
O 31
24 V
0V F1 F2 F3 F4
PSS DOS
24 V DC
0V

Notes

Connection Diagrams: Standard Section
The following connection diagrams show the wiring for standard modules.
The PSS 3000 uses modules from the P10-range as standard modules,
while the PSS 3100 uses modules from the P9-range.
NOTICE
Standard modules are not approved for safety applications.
Module code:
P9/P10 DO: 4120
P9/P10 DIO: 2120
P9/P10 DI: 0020
P9/P10 AIO: A023
P9/P10 DOR: 4420
P9/P10 PMAO: E0A6
P9/P10 PMIA: E1A6
P9/P10 MMC3: E2A7
P9/P10 MMC6: E3A7

P9/P10 DO __X__.1 __X__.1

O 00
P9/P10 DIO O 00
O 01 O 01
O 02 O 02
O 03 O 03
O 04 O 04
O 05 O 05
O 06 O 06
O 07 O 07
24 V 24 V
0V 0V
__X__.2 __X__.2
O 08 O 08
O 09 O 09
O 10 O 10
O 11 O 11
O 12 O 12
O 13 O 13
O 14 O 14
O 15 O 15
24 V 24 V
0V 0V
__X__.3 __X__.3
O 16 I 00
O 17 I 01
O 18 I 02
O 19 I 03
O 20 I 04
O 21 I 05
O 22 I 06
O 23 I 07
24 V 24 V
0V 0V
__X__.4 __X__.4
O 24 I 08
O 25 I 09
O 26 I 10
O 27 I 11
O 28 I 12
O 29 I 13
O 30 I 14
O 31 I 15
24 V 24 V
0V 0V
DO DIO
24 V, range 20 ... 30 V
incl. 5 % residual ripple
3~
0V
Connection to earth bar (EN 60 204 Part 1)

or earth fault monitoring

P9/P10 DI
__X__.1
I 00 CAUTION!
I 01
I 02 On PSS systems, the “24 V”
I 03 terminals on the P9/P10 DI
I 04
I 05 module must remain
I 06 unwired. These terminals
I 07
24 V should only be connected on
0V
__X__.2 P9/P10 systems.
I 08 Incorrect wiring could cause
I 09
I 10 a malfunction leading to a
I 11 dangerous condition, as the
I 12
I 13 inputs will not always be
I 14
I 15 read in correctly.
24 V
0V
__X__.3
I 16
I 17
I 18
I 19
I 20
I 21
I 22
I 23
24 V
0V
__X__.4
I 24
I 25
I 26
I 27
I 28
I 29
I 30
I 31
24 V
0V
DI
24 V, range 20 ... 30 V
3~
0V


P9/P10 AIO _X_ .1 _X__.1

P9/P10 PMI Range mA 1) C
T1
C
Input 1
10 V T2
H COM H K
20 mA 0
0
T1 Incremental
C CAUTION!
Range mA 1) T2 sensor with
C H
Input 2
10 V K Screened
1 push-pull
H COM
cables should
20 mA output
1
be used on
_X _.2 _X__.2 analogue inputs
Range mA 1) T1 and outputs.
C C T2
Input 3
10 V
H COM H K
e.g.
20 mA 2
2 Counter
Range mA 1) C T1 1) Bridge when
C 10 V H T2 installed as
Input 4
K
H COM 3 current input.
20 mA
3
_X_ .3 _X__.3
Range mA 1) T1
2) On analogue
C C T2 outputs, the
Input 5
10 V
H COM H K voltage and
20 mA 4
4 current output
Range mA 1) C T1 can be used
C 10 V H T2 simultaneously.
Input 6
K
H COM 5
5 20 mA
_X_.4 _X__.4
Output 1 Output 2
C 10 V
H COM
6 20 mA
2) 10 V 3) Integration
C
H 20 mA time for all
7 COM analogue
+15 V 3) inputs with
0V bridge is:
24 V
-15 V
0V 16.6 ms
AIO PMI (mains: 60 Hz)
+15-V-
voltage
supply
24 V, range 20 ... 30 V 3~
incl. 5 % residual ripple 0V

P9/P10 DOR ___X__.1 All relay contacts are
O 00 13 L0 volt-free and are
O 00 14 N0
O 01 13 L1
protected with a varistor
O 01 14 N1 (430 V).
O 02 13 L2
O 02 14 N2
O 03 13 L3
O 03 14 N3
O
+24 V Switching voltage:
O
___X__.2
AC: max. 240 V
O 04 13 L4 L1 DC: max. 100 V
O 04 14 N4 N
O 05 13 L5
O 05 14 N5
O 06 13 L6 Switching current:
O 06 14 N6 AC: max. 2 A
O 07 13 L7 L1
O 07 M DC: max. 0.5 A
14 N7 N
1~
O
O
___X__.3
O 08 13 L8
O 08 14 N8
O 09 13 L9
O 09 14 N9
O 10 13 L10
O 10 14 N10
O 11 13 L11
O 11 14 N11
O
O
___X__.4
O 12 13 L12
O 12 14 N12
O 13 13 L13
O 13 14 N13
O 14 13 L14
O 14 14 N14
O 15 13 L15
O 15 14 N15
O
0V
O
DOR
24 V, range 20 ... 30 V
3~
0V


P9/P10 PMAO _X_ .1

T1
Input 1
T2
K
Voltage
24 V
supply for
0V
input device
T1
Input 2
T2
K
24 V Voltage
0V supply for
_X _.2 input device
T1
Input 3
T2
K
Voltage
24 V
supply for
0V
input device
T1
Input 4
T2
K
24 V Voltage
0V supply for
_X_ .3 input device
Output 3 Output 2 Output 1
10 V
COM
20 mA
10 V
COM
20 mA
10 V
COM
20 mA
_X__.4
Output 4
10 V
COM
20 mA
Supply
24 V
0V
PMAO
24 V, range 20 ... 30 V
3~
0V
Connection to earth bar (EN 60 204

Part 1) or earth fault monitoring

P9/P10 PMIA
INPUT
A B
K1 1
9
-K1 2
10
3 K2 5 V signals at channel
11
K0 4 -K2 A, B, C, D
12
-K0 5
13
24 V 6
14 RS 422 bridge
or 7
5V 15
0V 8 Screen
Screen
INPUT
C D
1
9
2 T1
10
T2 3
11
4 24 V signals at channel
12
5 T0 A, B, C, D
13
24 V 6
14
7
15 Screen
0V 8
Screen
OUTPUT
1/2 3/4
10 V 1
9 10 V
COM 2
10 COM Voltage and current
20 mA 3
11 20 mA ouputs at channel 1/2
4
12 and 3/4
5
13
6
14
7
15
8 Screen
Screen
Supply Error
5V
supply to
i/p device
Power
+5 V
+24 V
0V 24 V, range 20 ... 30 V
3 ~ incl. 5 % residual ripple
PMIA


P9/P10 MMC3
READY
P9/P10 MMC6 INPUT
D A
Inputs:
MMC3: Input A .... C
MMC6: Input A ... F
1 1: K1 9: Free
9 2: -K1 10: K2
2
E 10 3: Free 11: -K2
B 3
11 4: K0 12: Cam
4 5: -K0 13: Start
12
5 6: 24 V 14: Stop
13
6 7: 5 V 15: Registration
14
7 8: 0 V
15
8
K and -K: 5 V differential signal
F C
Screen
Outputs:
3 outputs per connector
MMC3: Output 1, outputs A ... C
1 MMC6: Output 1 and 2, outputs A ... F
9
2 1: Root (base) A (D) 9: Analogue o/p A (D)
OUTPUT 10
3 2: N/C contact A (D) 10: GND
2 1 11 3: N/O contact A (D) 11: Root (base) B (E)
4
12 4: Analogue o/p B (E) 12: N/C contact B (E)
5
13 5: GND 13: N/O contact B (E)
6
14 6: Root (base) C (F) 14: N/O contact C (F)
7
15 7: N/C contact C (F) 15: GND
8
8: N/O contact C (F)
Screen
5V
supply to
+5 V
Power
i/p device
+24 V
0V 24 V, range 20 ... 30 V
3~


Interfaces
PSS(1) CPU, PSS(1) SF CPU, PSS(1) SB CPU
PG programming interface
The programming interface is an RS 485 interface, enabling communication

between the programming device and the PSS safety system.
1 N. C.
N. C. 6
2 N. C
A 7
3 B
N. C. 8
4 N. C.
N. C. 9
5 N. C. N.C. = no connection
Fig. 7-1: Configuration of the programming interface
RS 232 user interface
The user interface operates to the RS 232C standard and can be

individually configured. A detailed description of the interface can be found
in the “FS System Description” and “ST System Description” which form
part of the “PSS-Range System Manual”.
1 N. C.
DSR 6
2 RXD
RTS 7
3 TXD
CTS 8
4 DTR
N. C. 9
5 GND N.C. = no connection
Fig. 7-2: Configuration of the user interface
PSS(1) SB CPU: SafetyBUS p interface
Connection to SafetyBUS p is via a male 9-pin D-Sub connector. Detailed

information on SafetyBUS p can be found in the SafetyBUS p manual.

Interfaces
1 N. C.
N. C. 6
2 CAN_L brown
green CAN_H 7
3 CAN_GND white
N. C. 8
4 N. C.
N. C. 9
5 CAN_SHLD N.C. = no connection
Fig. 7-3: Configuration of the SafetyBUS p interface
PSS(1) CPU 2
PG programming interface
The programming interface is a combined RS 232/RS 485 interface. Both

interfaces are available on a male 9-pin D-Sub connector and enable
communication between the programming device and the PSS safety
system.
1 RXD
TXD 6
2 N.C.
A 7
3 B
N. C. 8
4 N. C.
N. C. 9
N.C. = no connection
5 GND
Fig. 7-4: Configuration of the programming interface PSS CPU2 and PSS1 CPU2
RS 232/485 user interface
The user interface is a combined RS 232/RS 485 interface. Both interfaces

are available on a male 9-pin D-Sub connector. A detailed description of the
interfaces can be found in the “FS System Description” and “ST System
Description” which form part of the “PSS-Range System Manual”.
1 A
DSR 6
2 RXD
RTS 7
3 TXD
CTS 8
4 DTR
B 9
5 GND
Fig. 7-5: Configuration of the user interface PSS CPU2 and PSS1 CPU2

Optimising the Power Supplies
When an expansion rack is used on the PSS 3000, the number of power
supplies required will depend on the total power required by the modules:
• Total power < 10 A

If the total power required by the modules on both racks is less than
10 A, only one power supply will be required, installed on rack A. Expan-
sion rack B is connected to the power supply on rack A via a power
supply cable (part no. 374 210).
C 1 3 5 7
P P A
S U 0 2 4 6
Power supply
cable
9 11 13 15
B
8 10 12 14
CAUTION!
The power supply cable must not be laid in the I/O or expansion cable duct!
• Total power > 10 A

If the total power required by the modules on both racks is greater than
10 A, each module rack will require a power supply.
C 1 3 5 7
P P A
S U 0 2 4 6
9 11 13 15
B
P
S 8 10 12 14
The following tables list the power requirements for the individual modules.
This will enable you to calculate the total power requirement for the module
racks.
Power consumption: failsafe modules
Module Order no. Order no. Power Quantity Power consumption

PSS 3100 PSS 3000 consumption in A of the modules
series series in A at +5 V on the base rack
PSS(1) CPU 302 060 301 060 1.5

PSS(1) CPU2 302 063 301 063 1.5
PSS(1) SF CPU 302 061 301 061 1.5
PSS(1) SB CPU 302 070 301 070 1.9
PSS(1) DI 302 100 301 100 0.35
PSS(1) DI 2 302 101 301 101 0.35
PSS(1) DIF 302 105 301 105 0.25
PSS(1) DIF 2 302 106 301 106 0.25
PSS(1) DO 302 110 301 110 0.45
PSS(1) DIO Z 302 108 301 108 0.6
PSS(1) DI2O Z 302 109 301 109 0.48
PSS(1) DIO T 302 107 301 107 0.45
PSS(1) DI2O T 302 112 301 112 0.38
PSS(1) DOS 302 111 301 111 1.0
PSS(1) AI 302 121 301 121 0.75
PSS(1) DOR 302 122 301 122 0.7
PSS(1) AI Ip 302 123 301 123 0.75
Total power requirement of failsafe modules (rack A)

Power consumption: standard modules
Module Order no. Order no. Power Quantity Power consumption
PSS 3100 PSS 3000 consumption in A of the modules
series series in A at +5 V on rack:
A B
P9/P10 DI 303 100 304 100 0.02
P9/P10 DO 303 111 304 110 0.3
P9/P10 DOR 16 303 122 304 122 0.3
P9/P10 DIO 303 108 304 107 0.2
P9/P10 AIO 303 120 304 120 0.4
P9/P10 DIF 303 105 304 105 0.03
P9 AIO PT 303 121 - 0.4
P10 PMI - 304 115 0.45
P9/P10 PMIA 303 118 304 118 0.6
P9/P10 PMIA S 303 119 304 119 0.75
P10 PMIA X - 304 114 0.6
P10 MMC3 - 304 517 0.8
P10 MMC6 - 304 518 1.2
PSS(1) IBS-S 302 150 301 150 0.55
PSS(1) DP-S 302 151 301 151 0.65
PSS(1) DN-S 302 152 301 152 0.34
PSS(1) Control 302 156 301 156 0.8
Net Adapter
P10 EPB - 304 091 0.03 -
P10 EPE - 304 096 1.5 -
Total power requirement of module rack A (FS and ST section)
Total power requirement of module rack B
Total power requirement of module racks A and B

Notes

Appendix
Changes to the Installation Manual
Changes from version VI to version VII
The information on earthing given on page 1-4 of the chapter entitled

“Safety Regulations” was expanded.
Changes from version VII to version VIII
The Installation Manual was completely revised and is now also valid for
the PSS SF 3000, PSS SF 3100, PSS SB 3000 and PSS SB 3100.
The most significant changes are as follows:

• Chapter entitled: “Safety Regulations” was restructured and the contents
corrected
• Page 3-3, section entitled “Cabling” was amended.
• Chapter 5 was completely revised with regard to the categories stated in
• Page 5-18, section inserted, describing the test on the outputs of the
PSS(1) DIO Z module when wired with inductive loads.
• Page 5-31, fuse added to the supply line of the PSS(1) DOR module.
• Page 5-28, description of the PSS(1) DIF 2 module inserted.
• Pulsed outputs, alarm inputs etc. are determined via the configurator in
the programming device and no longer have to be entered in DB 0002.
• Chapter 7 was added to include a description of the interface
configurations.
Changes from version VIII to version IX
• Page 5-21, fuse deleted in the PSS(1) DO module supply line.

• Page 5-31, fuse inserted in the PSS(1) DOR module supply line.

Appendix
Changes from version IX to version X
• Page 2-5, environmental data: condensation is not permitted.

• Page 2-6, the use of wiring which can withstand insulation temperatures of
75° C is no longer specified.
• Page 4-2, before installing the modules, switch off all the power to the
terminals and power supply.
Changes from version X to version XI
• Page 2-3, section inserted on PSS1 BMPS 3/1 module rack.

• Page 4-2, warning note expanded: “You should also switch off all the power
before inserting or removing a connector...”
• Page 4-8, section inserted on installing the PSS1 BMPS 3/1 module rack.
• Page 4-12, section inserted on installing the PSS1 BMPS 3/1 module rack
in a control cabinet.
• Page 5-4 and 5-5 (Version X), “PSS(1) DI” section deleted.
• Page 5-10 to 5-15 (Version X), “PSS(1) DI” section deleted.
• Page 5-14 to 5-15, section renamed “PSS(1) DI2O T”.
• Page 5-16 to 5-17, section renamed “PSS(1) DI2O Z”.
• Page 5-20 to 5-23 (Version X), “PSS(1) DO” section deleted.
• Page 5-24, additional caution notes added: “Voltage must only be applied
to the terminals...”
Changes from version XI to version XII
• Page 2-2 to 2-5 (Fig. 2-1 to 2-4): Functional earth

• Page 2-6: Protection class deleted
• Page 3-2: Section "Connecting the earth cables" deleted: PSS safety
systems all meet protection class 1.
• Page 3-5: "Insulation voltage test": PSS BMPS 3/1 inserted

Notes

Appendix
Notes

Programmable Safety Systems PSS-Range: PSS 3000/PSS 3100 Series Installation Manual Item No. 18 557

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Version XII, April 2001

Safety Regulations 2-1

Electromagnetic Compatibility (EMC) 3-1

Installation Manual: PSS 3000/PSS 3100 Series 1

Installing the PSS 3100 series 4-7

Connection Diagrams: Failsafe Section 5-1

2 Installation Manual: PSS 3000/PSS 3100 Series

Optimising the Power Supplies 8-1

Installation Manual: PSS 3000/PSS 3100 Series 3

4 Installation Manual: PSS 3000/PSS 3100 Series

PSS 3000 series:

The installation manual is divided into 9 chapters:

Installation Manual: PSS 3000/PSS 3100 Series 1-1

Information in this manual which is of particular importance can be

1-2 Installation Manual: PSS 3000/PSS 3100 Series

• Electrical connections should be made by a qualified electrical engineer

Supplying power to the PSS

Installation Manual: PSS 3000/PSS 3100 Series 2-1

External power supply PSS 3000/3100 series

Optional: Connect in star to the central

Fig. 2-1: Connecting the PSS(1) PS 24 V power supply

2-2 Installation Manual: PSS 3000/PSS 3100 Series

PSS 3000 series

Connect in star to the central

PSS1 BMPS 3/1

Installation Manual: PSS 3000/PSS 3100 Series 2-3

External power supply PSS1 BMPS 3/1

Optional: Connect in star to the central

Supplying the input/output modules

• The digital inputs and outputs require a 24 V supply (see connection

2-4 Installation Manual: PSS 3000/PSS 3100 Series

External power supply PSS 3000/3100 series

Connect to the 0 V mains Connect in star to the central

Fig. 2-4: Connecting the supply to the input/output modules

Installation Manual: PSS 3000/PSS 3100 Series 2-5

• The unit should be installed in an enclosure (e.g. control cabinet) which

Protection type (EN 60 529, 10/91) IP 20

• Ensure there is sufficient ventilation to prevent heat building up within the

2-6 Installation Manual: PSS 3000/PSS 3100 Series

• Cable layout must meet the EMC-guidelines stated in Chapter 3.

Installation Manual: PSS 3000/PSS 3100 Series 2-7

2-8 Installation Manual: PSS 3000/PSS 3100 Series

The safety system is designed to be installed within an electromagnetic

A device is electromagnetically compatible if:

Electromagnetic interference reaches the system through:

The interference can be transferred from the source to the receiver

Fig. 3-1: Electromagnetic interference

Installation Manual: PSS 3000/PSS 3100 Series 3-1

• Capacitive (electrical) coupling

Making the installation EMC-compliant

Connecting the earth cables

3-2 Installation Manual: PSS 3000/PSS 3100 Series

It is possible to differentiate between cables according to their function.

Cabling inside buildings:

Installation Manual: PSS 3000/PSS 3100 Series 3-3

• Lines from group 1 and group 3 should be laid in separate groups or in

Potential differences can occur through potential connected couplings

3-4 Installation Manual: PSS 3000/PSS 3100 Series

Interference currents arising from electrical, magnetic or electromagnetic

X.1 Connector X.1