Pilz PDP67 F4 code troubleshooting

Output O1 (12) safety signal to X5

4 outputs O2 (22) safety signal output to X5 (redundant channel)

Diagnostic output Diag (Y32) sensor status signal (non safety)

6 inputs I1 (S11) safety sensor channel A

7 0 V (A2) sensor power supply negative pole

Lock (S31) is an electromagnetic lock control command used for PSENslock

Engineering Tip: For PSENcode encoded sensors, only use pins 1/3/4/6; For PSENslock, pins 8 and 5 (Diag optional) need to be connected.

2. X5 connection evaluation device security input

Pin signal description

1. Connect I2 to the safety input channel of the evaluation device. 2

2 24 V DC (UB) module power supply positive pole (from evaluation equipment or external power source)

6 inputs I1 connected to evaluation device security input channel 1

7 0 V (UB) power supply negative pole

The remaining pins (3, 4, 5, 8) are idle (n.c.).

3. X6 connects standard I/O and lock control

Purpose of Pin Signal

Diagnostic status of X1 sensor corresponding to Diag 1

2 Diag 2 corresponds to X2

3 Diag 3 corresponds to X3

4 Diag 4 corresponds to X4

5 Lock 1 controls the magnetic locking of X1 sensor

6 Lock 2 Control X2

7 Lock 3 Control X3

8 Lock 4 Control X4

Important: The Diag signal is a non safety output and is only used for status indication or PLC monitoring. It should not be used for safety functions.

Independent circuit and series connection operation

1. Independent circuit (for single module use)

Connect 1-4 sensors to X1 → X4 in sequence, and the evaluation device must be connected to the last available mother socket (for example, if X1/X2 sensors are connected, X3 or X4 must be occupied by the evaluation device); If only X1 is used, the evaluation device can be connected to any of X2~X5, but it must be ensured that it is the interface that was not connected to the sensor at the end.

Typical error: If the evaluation device is connected to X2 and X3 also has a sensor, the sensor signal of X3 will not be recognized by the evaluation device, resulting in complete failure of the safety function. The manual clearly emphasizes this risk in the form of a warning.

2. Module series connection (extended to 8 or more sensors)

Multiple PDP67 F4 code modules can be connected in series through the adapter PDP67 Connector cs:

The last available female socket (such as X5) of the first module is connected to X1 of the second module.

The maximum number of series connections is limited by the supply voltage drop and total current (up to 2A per module).

It is necessary to ensure that the power supply voltage of the end module is not lower than the minimum allowable value of the sensor and module (usually 24V -10%=21.6V).

3. Voltage drop calculation method

When wiring long-distance on site, voltage drop may cause sensor undervoltage reset or misoperation. Calculation formula:

ΔU=Itotal×Rcable×L

ΔU=I total×R cable×L

among which

Itotal total=total current of all modules and sensors (A)

Rcable=resistance per unit length of cable (Ω/m)

L=cable length (m)

Reference data (provided by Pilz):

0.25 mm ² sensor cable: 0.15 V drop per 10 m and per 100 mA current

0.34 mm ² cable: 0.11 V/(10m · 100mA)

0.5 mm ² cable: 0.07 V/(10m · 100mA)

Example: Using 0.25 mm ² cable, length 50 m, total current 1.2 A.

Every 10 meters of voltage drop=0.15 V × (1200 mA/100 mA)=1.8 V.

50 m total voltage drop=1.8 V × 5=9 V.

If the starting voltage is 24 V and the end voltage is only 15 V, it is much lower than the minimum operating voltage.

Countermeasure: Increase the wire diameter, reduce the length, or increase the starting voltage (but not exceeding 26.4 V).

Debugging and Status Diagnosis

1. Meaning of LED indicator lights

Meaning of LED status

The power supply of the Power module is normally on

Extinguish without power supply or internal insurance (if any) damaged

The Diag constant light corresponds to the actuator of the sensor being within the response range (such as the encoder sensing in place)

The extinguishing actuator is not within the response range, or the sensor is not connected

Lock constantly on. Received magnetic lock control command (high level)

Extinguish unlock command or lock release

Note: Diag and Lock LEDs correspond to the currently activated sensors, but the manual does not specify which LED corresponds to which channel. In practice, the mapping relationship needs to be determined by triggering a single sensor to observe LED changes.

2. Power on self-test process

Connect the 24V power supply, the Power LED must be constantly on.

Trigger each safety sensor one by one (such as opening the safety door, moving the encoder execution block), observe and evaluate whether the corresponding input of the device flips.

Check and evaluate whether the safety output of the equipment follows logical actions (such as contactor disconnection).

For PSENslock, send a separate Lock unlock command and confirm the Lock LED and electromagnet sound.

3. Common fault phenomena and troubleshooting

Possible causes and solutions for the fault phenomenon

The power LED does not light up. If the power supply is disconnected, short circuited, or the module is damaged internally, the voltage at pins 2-7 of X5 should be 24V. Check the power capacity