Pilz PSS 4000 Automation System

Core positioning and overall value

System positioning

Security+standard automation integrated distributed control system, supporting single machine to whole plant networking, in line with Industry 4.0 requirements.

core advantage

Physical integration of security and automation, logical isolation, no cross interference

Multi master real-time Ethernet SafetyNET p communication, long-distance, high reliability

Modular and scalable, hardware and program decoupled, engineering efficiency increased by about 30%

Unified software platform, one-stop configuration/programming/diagnosis/visualization

Open protocol, compatible with third-party controllers and fieldbus

Applicable scenarios

Automobiles, rail transit, packaging, presses, logistics, elevators, wind power, stage equipment, cable cars, etc.

Hardware System: Controller and I/O

1. Core controller

PSSuniversal PLC

A versatile controller that supports IEC 61131-3 full language programming and can be used as a central PLC or distributed node to meet complex safety and automation tasks.

PSSuniversal multi

Small and lightweight controller, suitable for standalone/small networked devices, using PASmulti graphical programming, simple and efficient.

PSS 4000 I/O

Distributed I/O scheme:

PSSuniversal I/O: Installed inside the cabinet, capable of mounting up to 64 I/O modules

PSS67 I/O: IP67 protection, direct on-site installation without control cabinet

2. Hardware structure and characteristics

Modular combination: Head module+Base+I/O/Power/Function module, freely expandable

Built in power supply, integrated switch, SD card storage project and configuration

Safety level: EN/IEC 61508 SIL3, EN ISO 13849 PL e

Supports linear topology, long-distance transmission, and resistance to electromagnetic interference

3. Module type

Digital/analog I/O, power module

Encoder module (incremental/absolute)

Fast Control Unit (400 μ s level response)

Communication module (RS232/RS485), link module

Special features: safety electronic cam, safety motion monitoring

Communication System: SafetyNET p Real time Ethernet

core position

PSS 4000 system communication backbone, secure and standard data transmission via cable.

Key Features

100Mbps Ethernet, compliant with IEEE 802.3

The security mechanism follows the black channel principle and meets PL e/SIL3 requirements

Transmission distance: 100m for electrical port, 5km for multimode fiber, 32.5km for single-mode, 10km for DSLs, supporting WLAN wireless

Support routing, ring network redundancy (MRP), and parallel coexistence of multiple protocols

compatibility protocol

EtherCAT, EtherNet/IP, Modbus TCP, PROFIBUS, Powerlink, Sercos, etc. can be connected to third-party systems through gateways.

Software Platform: PAS4000

positioning

Unified engineering software covering the entire process of configuration, programming, debugging, diagnosis, and operation and maintenance.

Programming method

IEC 61131-3: Instruction List IL, Structured Text ST, Ladder Diagram LD

Graphics: PASmulti, drag and drop connections, suitable for rapid development

Software Block Library

Security authentication block: emergency stop, safety door, light barrier, dual hand control, muting

Hardware driver blocks: encoder, analog quantity

Application Blocks: Cam Control, Burner Management

Standard logic block: AND/OR/flip-flop/timer

core functionality

Project tree management, hardware configuration, resource allocation, I/O mapping

Unified process diagnosis, variable binding alarm information

Support hardware independent programming and flexible allocation in the later stage

Multi language interface, online help

Visualization and Diagnosis

1. PASvisa (Web Visualization)

Web based, cross platform, client free, local/remote access

Directly linked with PAS4000 project, variables automatically synchronized

Prefabricated safety block diagnostic panel, alarm list, historical records

Supports multiple languages, user permissions Unicode

2. PMVisu (Visual Terminal)

7-inch/12 inch capacitive touch screen

Pre installed PASvisa, plug and play

Built in user management, SD card storage, and multiple interfaces

Core functions and distinctive technologies

Safety Movement Monitoring

Single encoder: maximum PL d, speed/static monitoring

Dual encoder: safe speed+safe position, maximum PL e

Quick response, local fast switching not affected by PLC cycles

Fast Control Unit

Local security logic 400 μ s level output

Capable of processing narrow pulses of 650 μ s

Inductive load back pressure protection

Safety electronic cam

Replace mechanical cam, adapt to press control, comply with EN 692, dynamic safety stop, tamper proof.

distributed control

Centralized program editing, distributed operation, execution of any program segment at any node, unified diagnosis.

Certification and Industry Applications

1. Security certification

Universal: PL e, SIL 3

Rail transit: SIL 2/3/4, EN 5012x series

Elevator/Escalator: EN 81-1/2, EN 115-1

Combustion safety: NFPA 85/86

Global certifications: CE, BG, T Ü V, cULus, EAC, KOSHA

2. Typical industry applications

Automobile: body welding and painting line

Rail transit: speed monitoring, emergency braking, subway signal replacement and renovation

Packaging: Whole line safety monitoring, replacing traditional safety relays

Press: Mechanical cam transformed into electronic safety cam

Logistics: AGV, elevator, cross traffic collision prevention

Other: Stage equipment, cable cars, wind power, bridge safety monitoring

Infrastructure and Selection

web component

Non managed switch: plug and play, LED diagnostic

Management switch: Web management, ring network redundancy, dual power supply

Gateway: Modbus TCP to CANopen/EtherCAT

Industrial connectors, cables, and stripping tools

software license

PASunits point authorization (500/1000/5000/10000), PASkey encrypted USB storage.

service system

Risk assessment, safety plan, design implementation, verification, CE certification LOTO、CMSE ®  Certification training.