Programmable Safety Systems PSS - Range: Installation Manual - Item No. 19 768-06

Programmable
Safety Systems PSS®-Range
SafetyBUS p
Installation Manual – Item No. 19 768-06

All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes.
Suggestions and comments for improving this documentation will be gratefully received.
The names of products, goods and technologies used in this documentation are registered
trademarks of the respective companies. Automation Workbench®, Pilz®, PIT®, PMI®,
PNOZ®, Primo®, PSS®, SafetyBUS p® are registered trademarks of Pilz GmbH & Co. KG.
Contents
Introduction 1-1
About the SafetyBUS p installation manual 1-1
Applicable documentation 1-1
Overview of installation manual 1-2
Definition of symbols 1-3
Safety 2-1
Safety guidelines 2-1
Use of qualified personnel 2-1
Intended use 2-2
Warranty and liability 2-2
Fault prevention 2-3
Requirements for commissioning and
recommissioning 2-4
Basics 3-1
Topology 3-1
Main branch 3-1
Sub-branches 3-2
Stub lines 3-3
Effective electrical length 3-4
Main line 3-5
Defining the main line on a purely linear structure 3-5
Defining the main line on a linear structure with stub lines 3-6
Defining the main line on sub-branches 3-7
Bus structure with fibre-optic cables 3-9
Bus cable 3-10
Copper cables (CU) 3-10
Bus cable for pure data transfer 3-10
Bus cable for data transfer and supply voltage 3-11
Fibre-optic cables (FO) 3-12
IP protection type 3-13
SafetyBUS p Installation Manual 1

Contents
SafetyBUS p interface 3-14

Design of the SafetyBUS p interface 3-14
Interface assignment on SafetyBUS p subscribers 3-14
Male 9-pin D-Sub connector 3-14
5-pin M12 round connector 3-15
Connecting SafetyBUS p subscribers 3-15
Terminating resistors 3-16
Galvanic isolation of the SafetyBUS p interface 3-17
Number of bus subscribers 3-18
Screening 3-18
Earthing 3-18
Designing a SafetyBUS p Network 4-1

Limiting mechanisms on
SafetyBUS p networks 4-1
Signal attenuation due to resistive losses 4-1
Signal run times 4-1
Voltage drop in the voltage supply lines 4-1
Design regulations when using stub lines 4-2
Defining the length of the bus cable and
transmission rate 4-4
Measures to increase the range 4-15
Reducing the transmission rate 4-15
Using Routers 4-15
Using Bridges 4-17
Using programmable safety systems with
two SafetyBUS p interfaces 4-18
Using FO cable 4-19
Reducing the total cable runs by using active junctions 4-20
Extending the max. number of bus subscribers by using a Bridge 4-21
Extending the max. number of bus subscribers by using
programmable safety systems with two SafetyBUS p interfaces 4-22
2 SafetyBUS p Installation Manual

Connecting SafetyBUS p Subscribers 5-1
Connectors for copper cable 5-1
IP20 connectors 5-1
Plug configuration 5-3
Terminator configuration 5-4
IP67 connectors 5-5
Connectors for FO cable 5-6
Connector pin assignment 5-7
PSS SB SUB-D3 connector 5-7
PSS SB SUB-D4 and PSS SB SUB-D4-DIAG connectors 5-8
Making the bus connections 5-9
Bus connection using copper cable 5-9
Standard application 5-9
Forming stub lines 5-9
Connection for mobile diagnostic units 5-10
Bus connection using FO cable 5-11
Installation and Assembly 6-1

Overview 6-1
Making the installation EMC-compliant 6-3
Earthing the housing 6-3
Equipotential bonding 6-3
Cabling 6-4
Earthing the cable screening (screened cables) 6-5
Earthing concept on SafetyBUS p 6-7
Insulation voltage test 6-8
Power supplies for the supply voltage 6-8
Lighting inside the cabinet 6-8
Testing the EMC-compliance of an installation 6-9
SafetyBUS p Installation Manual 3

Contents
Commissioning 7-1
Initial commissioning 7-1
Recommissioning when exchanging devices 7-2
Bus Diagnostics 8-1

Troubleshooting during commissioning 8-1
Bus diagnostics using the PSS SB TESTER
diagnostic unit 8-2
Check list for bus diagnostics 8-3
Checking the bus topology 8-3
Main branch 8-3
Sub-branches when using Routers 8-4
Selection of bus cable 8-5
Installation, bus cable and connector 8-5
Measuring typical bus characteristics 8-8
Index 9-1
Appendix 10-1
Changes in the documentation 10-1
Changes in Version 19 768-04 10-1
4 SafetyBUS p Installation Manual

Introduction
About the SafetyBUS p installation manual
The SafetyBUS p Manual is a collection of various documents. It is

intended to be used selectively.
Each document within the manual deals with a particular subject area and
is intended for a specific target group of users. The SafetyBUS p Manual
contains a complete overview of all the documents it contains.
This SafetyBUS p Installation Manual is part of the SafetyBUS p Manual

and contains all the details and regulations you need to physically design
the bus correctly and to install a network using SafetyBUS p.
Applicable documentation
The procedure for installing a specific SafetyBUS p subscriber (e.g.

decentralised module) or a specific SafetyBUS p component (e.g.
connector) is described in the relevant manual. Such manuals may
describe separate procedures from those given in this SafetyBUS p
Installation Manual, including certain restrictions.
The relevant publications (guidelines) of the SafetyBUS p Club

International e.V. also apply.
SafetyBUS p Installation Manual 1-1

Introduction
Overview of installation manual
This manual is divided into the following chapters:

1 Introduction
The introduction is designed to familiarise you with the contents,
structure and specific order of this manual.
2 Safety
This chapter must be read as it contains important information on
safety regulations and intended use.
3 Basics
This chapter contains basic information on designing a network with
SafetyBUS p.
4 Designing a SafetyBUS p Network
This chapter contains detailed information about the rules for
designing a SafetyBUS p network.
5 Connecting SafetyBUS p Subscribers
This chapter contains all the key information for selecting and using
the connectors.
6 Installation and Assembly
This chapter provides information on the installation and assembly
regulations for SafetyBUS p.
7 Commissioning
This chapter describes the procedure for initial commissioning and for
recommissioning after modifications have been made.
8 Bus Diagnostics
This chapter provides information on the possibilities and procedures
for fault diagnostics.
9 Index
10 Appendix
The Appendix contains a list showing changes in the documentation.
1-2 SafetyBUS p Installation Manual

Definition of symbols
Information in this manual that is of particular importance can be identified

as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that
poses an immediate threat of serious injury and death and indicates
preventive measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that
could lead to serious injury and death and indicates preventive
measures that can be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices in its immediate
environment could be damaged. It also provides information on preventive
measures that can be taken.
INFORMATION
This gives advice on applications and provides information on special
features, as well as highlighting areas within the text that are of particular
importance.

Introduction
Notes

Safety
Safety guidelines
These safety guidelines are an important part of the SafetyBUS p

Installation Manual. Failure to keep to these guidelines will render all
warranty and liability claims invalid:
• All health and safety / accident prevention regulations for the particular
area of application must be observed.
• Before using the bus system it is necessary to perform a safety
assessment in accordance with the Machinery Directive.
• Please refer to the information given in the manuals for the individual
SafetyBUS p subscribers.
• Please refer to the relevant publications (guidelines) of the SafetyBUS p
Club International e.V.
SafetyBUS p is a bus system for the transfer of safety-related data. The

improper or incorrect physical installation of the bus system could lead to
errors which would reduce the availability of an otherwise safe system.
Use of qualified personnel
SafetyBUS p and its components may only be assembled, installed,

commissioned, operated, maintained and decommissioned by qualified
personnel who, because they are:
• Qualified electrical engineers or
• Have received training from qualified electrical engineers
are suitably experienced to operate devices, systems, plant and machinery
in accordance with the general standards and guidelines for safety
technology.
It is the company’s responsibility only to employ personnel who:

• Are familiar with the basic regulations concerning health and safety /
accident prevention
• Have read and understood the safety guidelines given in the manual.

Safety
Intended use
SafetyBUS p is a bus system for the serial transfer of safety-related data.

The bus system is designed for plants whose safe condition is
characterised by a power-free state.
SafetyBUS p is an open bus system. Products from different

manufacturers may be operated on SafetyBUS p, provided they have
undergone a conformity test via the SafetyBUS p Club International e. V.
WARNING!
Please note that SafetyBUS p is not suitable for use in hazardous areas
(e.g. potentially explosive areas).
Warranty and liability
All claims to warranty and liability will be rendered invalid if

• SafetyBUS p and its components are used contrary to the purpose for
which they are intended
• Damage can be attributed to not having followed the guidelines in the
relevant description or operating manual
• Operating personnel are not suitably trained or sufficiently qualified
• Changes have been made to the bus components, such as:
- opening the housing
- changing the PCB boards (e.g. by exchanging components or soldering
work)
• Bus components are used which have not undergone a conformity test
via the SafetyBUS p Club International e. V.

Fault prevention
Although the bus system and subscribers guarantee a high degree of

safety, they form only one part of the plant’s safety.
During all phases of the operation (e.g. configuration, installation and
programming), it is important to ensure that this high level of safety is not
compromised by errors and lack of attention.
Please note that
• Careful, comprehensive analysis of safety
• Careful project planning
• Careful programming
• Correct wiring and cabling
• Conformity with EMC regulations
• Meeting regulations relating to screening and earthing
all contribute to safety just as much as the use of safe components.

Safety
Requirements for commissioning and recommissioning
You must comply with the following information when commissioning and
recommissioning:
• Setting the device addresses
Setting the device address of a module (e.g. PSS SB DI8O8, PSS SB
DI16, PSS SB DI8OZ4) is a safety-related activity.
WARNING!
Any errors made when setting the device address will result in the loss
of the safety function. If the device addresses of two modules are
transposed, the controlling PSS may unknowingly address the wrong
input/outputs. This may lead to hazardous situations. The safe
operation of the plant is no longer guaranteed.
To avoid this, the greatest possible care must be taken when setting the
device addresses.
• Module connection terminals

Hazardous situations may arise if the connection terminals on a module
(e.g. PSS SB DI8O8, PSS SB DI16, PSS SB DI8OZ4) are transposed.
- Only use the original Pilz terminals. These terminals have the same
inscription as the device.
- Before you commission the device (initial commissioning or
recommissioning), make sure you check the connections.
- Put measures in place to ensure that the connection terminals cannot
be transposed during operation, whether intentionally or unintentionally.
CAUTION!
A function test must be carried out when the system is initially
commissioned and after each modification when recommissioning. Please
also read the information in Chapter 8.

Basics
Topology
Physically, SafetyBUS p is based on CAN. The physical properties of the

bus plus CAN’s transmission type mean that a linear structure is
recommended in terms of the bus architecture (bus topology). A purely
linear structure has neither stub lines nor sub-branches.
Main branch
The SafetyBUS p branch that contains the MD is called the main branch.
On a purely linear structure, all bus subscribers will be on the main branch
(see Fig. 3-1).
The data lines on the main branch must be fitted with terminating resistors
at the start and end of the branch (see Fig. 3-1).
MD
- Main branch
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
I/OD with LD I/OD with

terminating resistor I/OD terminating resistor
(start of branch) (end of branch)
Fig. 3-1: Main branch of SafetyBUS p (example of a purely linear structure)

Basics
Sub-branches
By using active junctions which have been specially designed for

SafetyBUS p (e.g. Active Junction, Router), it is permissible to build a star
or tree structure instead of the specified linear structure, within defined
limits (see Fig. 3-2).
For example, the PSS SB ACTIVE JUNCTION BASIS (with expansion
module if necessary) and PSS SB Router1 may be used as active
SafetyBUS p junctions.
As a rule, the active junctions galvanically isolate the sub-branch from the
main branch. The data lines on sub-branches must be fitted with
terminating resistors at the start and end of the branch (see Fig. 3-2).
MD, LD, I/OD with I/OD with

terminating resistor terminating resistor
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
- Main branch
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Active junction with

terminating resistor
(start of branch)
Sub-branch
I/OD with
(end of branch)
Fig. 3-2: Sub-branch on SafetyBUS p (example)

Stub lines
To a very limited extent, passive junctions (e.g. T-connectors) may be used

to form passive branches (stub lines) off a branch (main branch/sub-
branches). (See Fig. 3-3.)
The data lines on stub lines may not be fitted with terminating resistors.

O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
T-connector
Stub line
- Main branch
I/OD
Fig. 3-3: Stub line on SafetyBUS p (example)
INFORMATION
• Stub lines have undesirable effects on a network. If possible, stub lines
should be avoided.
• If stub lines have to be used, they should be kept as short as possible.

Basics
Effective electrical length
The term “effective electrical length” is used to describe the connection

path between the two bus subscribers that are furthest apart electrically
within a SafetyBUS p network. The effective electrical length Lel is
composed of the sum of the following cable runs:
• The length of the actual cable runs laid between the two bus subscribers
in question,
• (If present) the virtual cable runs of active components between the two
bus subscribers in question,
• (If present) the stub lines between the two bus subscribers in question.
INFORMATION
The effective electrical length Lel can be determined as follows:
Runtime of a pulse between 2 bus subscribers [ns]

Lel =
Signal runtime of bus cable [ns/m]
The effective electrical length Lel is the decisive factor for the max.
permitted transmission rate on a SafetyBUS p network. It can be measured
using the PSS SB TESTER diagnostic unit (see “PSS SB TESTER”
operating manual, section entitled “Length measurement”).

Main line
The course of the bus cable that is used to define the effective electrical
length Lel is described as the “main line”.
Defining the main line on a purely linear structure
Where SafetyBUS p has a purely linear structure, the main line

corresponds to the main branch.
I/OD with MD I/OD with

terminating resistor LD terminating resistor
(start of branch) I/OD (end of branch)
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Length of main line
- Main branch = Main line
Fig. 3-4: Course of the main line on a purely linear structure

Basics
Defining the main line on a linear structure with stub lines
On a linear structure with stub lines, the main line also corresponds to the
main branch. However, to define its course it is necessary to examine all
the combinations between the first and last subscriber across all the
branches.
I/OD with MD I/OD I/OD

terminating resistor LD
(start of branch) I/OD
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
150 m
180 m
210 m
I/OD with
(end of branch)
Fig. 3-5: Course of the main line on a linear structure with stub lines (example)
INFORMATION
• Stub lines have undesirable effects on a network. If possible, stub lines
should be avoided.
• If stub lines have to be used, they should be kept as short as possible.

Defining the main line on sub-branches
On sub-branches, the active junction that is used is the key factor in

defining the main line.
Example: Router as active junction

• Using the Router PSS SB Router1 as the active junction has no effect on
the course of the main line. The main line corresponds to the main
branch and runs in the same way as the linear structure (with/without
stub lines).
• The max. permitted cable runs and transmission rate are defined
separately for each branch.
INFORMATION
Please read the information in the Router manuals.

O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER
RUN ST
RUN FS
F-Stack
ST AUTO PG
SPS
PG
FS RUN
Length of main line
STOP

PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
PSS SB Router1 with

(start of branch)
sub-branch
Length of
I/OD with
(end of branch)
Fig. 3-6: Course of the main line when branches are formed using the PSS SB Router1
(example)

Basics
Example: Active Junction as active junction

• Using the Active Junction PSS SB ACTIVE JUNCTION BASIS (if
necessary with an expansion module) can affect the course of the main
line.
• To define the main line, every connection combination between the first
and last bus subscriber must be examined across every branch.
• The virtual cable runs on the Active Junction must be taken into account.
INFORMATION
Please read the information in the Active Junction manuals.
25 m 5m 170 m

O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
terminating resistor Main line terminating resistor

POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
Lel = L4 = 240 m
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Main line
PSS SB ACTIVE PSS SB ACTIVE

JUNCTION BASIS with JUNCTION BASIS with
50 m
50 m

(start of branch) (start of branch)
5m
Sub-branch Sub-branch
L1
200 m
L2
15 m
90 m
I/OD with L3
I/OD terminating resistor 85 m
L4
(end of branch) 240 m
L5
225 m
L6
125 m
Lvirtual
I/OD with (virtual cable runs
terminating resistor of Active Junction)
(end of branch)
Fig. 3-7: Course of the main line when sub-branches are formed using the PSS SB ACTIVE JUNCTION
BASIS (example)

Bus structure with fibre-optic cables
For particular requirements, e.g. open air or electromagnetically

“contaminated” environments), it is possible to use fibre-optic cables with
SafetyBUS p. A special FO coupler for the SafetyBUS p interface (e.g. PSS
SB SUB-D-FO1) can be used to convert the electrical signals (copper
cables, CU) into optical signals (fibre-optic cables, FO).
INFORMATION
• The FO coupler should only be used to build a purely linear structure.
Star structures are not permitted.
• The FO coupler should only be used with SafetyBUS p subscribers which
provide the supply voltage for the FO coupler via the SafetyBUS p
interface.
• When defining the effective electrical length of the main line, remember
to take into account the virtual length of the FO couplers, at 35 m per FO
path.
• Please read the information in the manual for the FO coupler.

3500m at 20 kBit/s
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN

RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
CU path 1 FO path CU path 2

LCU 1 LLWL LCU 2
L LWLmax = 3500 m - (L CU 1 + L CU 2 + 35 m) at 20 kBit/s
Fig. 3-8: Maximum length of an FO path on the main line (example for 20 kBit/s)

Basics
Bus cable
Copper cables (CU)
INFORMATION
• Only use bus cables that are certified by the SafetyBUS p Club
International e. V.
• Important information on bus cable and bus cable requirements can be
found in the following guidelines from the SafetyBUS p Club International
e. V. :
- SafetyBUS p Technical Guidelines - Data lines (CU)
- SafetyBUS p - IP67 Physical Layer Concept
Bus cable for pure data transfer
The bus cable for pure data transfer is 3-core cable. A distinction is made
between cable for fixed installation, e.g. in cable ducts, and cable for
flexible installation, e.g. for drag lines.
Colour of the core insulation

The colours of the core insulation correspond to DIN 47100 (green, brown,
white). The colour allocation for the 3-core cable is defined by the
SafetyBUS Club International e.V. as follows:
Function Colour of the core insulation

CAN_H green
CAN_L brown
CAN_GND white
INFORMATION
• Make sure that the allocation of cable core colour to signal connection is
the same across the whole plant (on all SafetyBUS p subscribers). The
allocation applies to both IN and OUT bus cables.
• Remember that the min. bending radius will be different for cables from
different manufacturers. If in doubt, contact your supplier or cable
manufacturer for details of the min. bending radius.

Bus cable for data transfer and supply voltage
The bus cable for data transfer and supply voltage is 4-core cable. In
addition to the data lines, the cable also carries the lines for the voltage
supply to the field devices, plus screening. The cable is mainly designed
for use with M12 round connectors for an IP67 environment.
The SafetyBUS p Club International e. V. defines cables with different cable
cross sections (e.g. low current cable, high current cable).
Colour of the core insulation

The colour allocation for the 4-core cable is defined by the SafetyBUS Club
International e.V. as follows:
Function Colour of the core insulation

Screening —-
VCC red
VCC_GND and white
CAN_GND
CAN_H green
CAN_L brown
INFORMATION
• Make sure that the allocation of cable core colour to signal connection is
the same across the whole plant (on all SafetyBUS p subscribers). The
allocation applies to both IN and OUT bus cables.
• Remember that the min. bending radius will be different for cables from
different manufacturers. If in doubt, contact your supplier or cable
manufacturer for details of the min. bending radius. The following bus
cables are currently defined:

Basics
Fibre-optic cables (FO)
The following FO cables are suitable for the FO coupler PSS SB SUB-D-
FO1:
• 50/125µm graded index glass fibre,
attenuation 2.7 dB/km
or
62.5/125µm graded index glass fibre,
attenuation 3.2 dB/km
• Wavelength 850 nm
• Bending radius (see manufacturer’s details)
INFORMATION
Please read the information in the FO coupler manual and the details
provided by the cable manufacturer.

IP protection type
Generally, SafetyBUS p is designed for IP20 environments. Standard

components such as bus cables and connectors meet the requirements of
IP20 as a minimum.
INFORMATION
The IP protection type of the SafetyBUS p cable should not be confused
with the IP protection type of a bus subscriber!
An appropriate active junction (e.g. PSS SB ACTIVE JUNCTION BASIS)

can be used to connect field devices in an IP67 environment to the main
branch (IP20) of SafetyBUS p. In this case, make sure appropriate bus
cable and connection material is used for the IP67 environment.
INFORMATION
Important information on this subject can be found in the guidelines
entitled “SafetyBUS p - IP67 Physical Layer Concept”, issued by the
SafetyBUS p Club International e.V.

Basics
SafetyBUS p interface
Design of the SafetyBUS p interface
Each SafetyBUS p subscriber has a SafetyBUS p interface. The key factor

in the design of the interface is the SafetyBUS p IP protection type for
which the bus subscriber was designed.
Bus subscribers designed for use with SafetyBUS p in an IP20

environment have a male 9-pin D-SUB connector. Bus subscribers
designed for use in an IP67 environment have a 5-pin M12 round
connector (male connector).
Interface assignment on SafetyBUS p subscribers
Male 9-pin D-Sub connector
Male 9-pin D-Sub connector

1: n.c.
1 2: CAN_L (brown)
6
3: CAN_GND (white)
4: n.c.
9 5 5: CAN_SHLD
6: n.c.
7: CAN_H (green)
8: Supply voltage for fibre-optic
couplers from Pilz
9: n.c.
n.c. = not connected
Fig. 3-9: Assignment for male D-Sub connector

5-pin M12 round connector
5-pin M12 round connector (male)

4 3
5 1: Screening
1 2 2: VCC (red)
3: GND (white)
4: CAN_H (green)
5: CAN_L (brown)
Fig. 3-10: Assignment for M12 round connector
INFORMATION
Important information on this subject can be found in the guidelines
entitled “SafetyBUS p - IP67 Physical Layer Concept”, issued by the
SafetyBUS p Club International e.V.
Connecting SafetyBUS p subscribers
SafetyBUS p subscribers are connected to SafetyBUS p via the

SafetyBUS p interface. Various connectors are available to meet the
different connection requirements (see Chapter 5).

Basics
Terminating resistors
To avoid reflection on the bus line, data lines must be fitted with a
terminating resistor in accordance with the defined stipulations. With
SafetyBUS p for IP20, the connectors should be fitted with the prescribed
terminating resistors. With SafetyBUS p for IP67, special connectors with
an integral terminating resistor are required.
The data lines on the first and last bus subscribers on a branch (main
branch and sub-branches) must be fitted with terminating resistors.
Specification: 120 Ohm, 5%, 1/4 Watt
First Second Penultimate Last

bus subscriber bus subscriber bus subscriber bus subscriber
120 Ohm 120 Ohm
SafetyBUS p main branch
Fig. 3-11: Bus termination (example for main branch)
INFORMATION
If you are using active junctions (e.g. Active Junction, Router), please read
the information in the relevant manual.

Galvanic isolation of the SafetyBUS p interface
The physical SafetyBUS p interfaces on each bus subscriber are

galvanically isolated from the device electronics. On each bus subscriber,
voltage is supplied to the bus interfaces through a galvanically isolated DC/
DC converter (see Fig. 3-12).
SafetyBUS p Subscriber
CAN
Interface
CAN L
CAN H
CAN GND
Shield
DC +
GND
DC
Fig. 3-12: Galvanic isolation of the SafetyBUS p interface

Basics
Number of bus subscribers
A maximum of 64 bus subscribers may be operated on a SafetyBUS p

network.
INFORMATION
Please note how bus subscribers affect the bus load (attenuation). (See
Chapter 4.)
Screening
To guarantee noise immunity, the cable screening within a branch must be

uninterrupted. It is connected when the connector configuration is
assembled.
INFORMATION
Please read the information in Chapter 6.
Earthing
Specific earthing regulations apply to a SafetyBUS p network in order to

guarantee noise immunity. It is essential that these regulations are adhered
to (see Chapter 6).

Designing a SafetyBUS p Network
Limiting mechanisms on SafetyBUS p networks
Where copper cables are used, the extension of a SafetyBUS p network is

limited by the three mechanisms described in the following sections.
Signal attenuation due to resistive losses
The cable resistance of the data line cores on a SafetyBUS p cable causes
a voltage drop in conjunction with the current flowing through it. The longer
the cable is and the greater number of bus subscribers there are, the more
this voltage drop attenuates the signals. A larger cable cross section on the
data line cores reduces this effect.
Signal run times
Due to the special bus allocation mode on CAN, a signal only has a limited
time in which to cover the path between any two bus subscribers. This time
depends on the selected transmission rate.
Voltage drop in the voltage supply lines
If the SafetyBUS p cable also carries the supply voltage, an additional

limiting effect is felt. The supply current from the bus subscribers causes a
voltage drop in the supply voltage cables. At the specified supply current
and cable cross section of the supply voltage cable, therefore, the bus
cable runs are restricted, because otherwise the bus suscribers' supply
voltage would drop below the specified minimum values.

Design regulations when using stub lines
When designing a SafetyBUS p network, try to use a linear structure.

Under certain conditions, however, it is possible to deviate from the branch
(main branch/sub-branches) in the form of stub lines. If this is the case,
follow the rules below:
• On every branch containing stub lines (main branch/sub-branches),
define the course of the branch.
The course of the branch depends on how long the deviation is, i.e. the
length of the deviation is the key factor in determining which part belongs
to the branch and which part is defined as a stub line.

L4 = 2 m
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
L5 = 1 m
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
L1 = 210 m L2 = 4 m
L3 = 3 m
I/OD with
(end of branch)
Fig. 4-1: SafetyBUS p network with stub lines (example)
- In the example in Fig. 4-1, L3 belongs to the main branch and L5 is

viewed as a stub line, as L3 > L5.
So the following applies for the course of the main line in Fig. 4-1:
Lbranch = L1 + L2 + L3
INFORMATION
If it were the other way round (L5 > L3), L5 would be part of the main
branch and L3 a stub line.

- In the example in Fig. 4-1, stub line L4 must be shorter than L2 + L3,
otherwise the main branch would consist of L1 + L4 and the two stub
lines would consist of L2 + L3 and L2 + L5.
• Define the effective electrical length Lel branch of a branch.
Consider the longest stub line on the branch in question (main branch/
sub-branches) and multiply its length by 6.
Calculating the effective electrical length of a branch with stub

lines:
Lel branch = Lbranch + (6 x Ldrop line max.)
INFORMATION
The effective electrical length should be determined in this way for each
branch containing stub lines.
• Terminating resistors
Stub lines should never be fitted with terminating resistors.

Defining the length of the bus cable and transmission rate
NOTICE
In the information that follows, please note:
• None of the steps may be omitted!
• None of the values in Tables 4-1 to 4-5 of this chapter may be exceeded!
1. Define the course of the main line

The effective electrical length of the main line is the decisive factor for
the max. permitted transmission rate on the SafetyBUS p network.
Important information on this subject can be found in Chapter 3.
When defining the main line, differentiate between the following cases:
1.1
The SafetyBUS p network consists of a purely linear structure, without
FO paths, i.e.:
• There are no stub lines
• There are no active junctions
• There are no FO converters
The main line runs between the two bus subscribers that are furthest
apart electrically. The effective electrical length Lel corresponds to the
length Lcable of the bus cable laid between the two bus subscribers.
Lel = Lcable
I/OD with MD I/OD with

terminating resistor LD terminating resistor
(start of branch) I/OD (end of branch)
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Main line
Lel = LCable
Fig. 4-2: Effective electrical length of a branch without stub lines

(example for main branch without stub lines)

1.2
The SafetyBUS p network consists of a linear structure without FO
paths, but with stub lines, i.e.:
• There are stub lines
• There are no active junctions
apart electrically.
• Define the length Lcable of the bus cable laid between these two bus
subscribers.
• Then define the longest stub line in the main branch.
• When calculating the effective electrical length Lel, consider the
longest stub line Ldrop line max and multiply its length by 6.
Lel = Lcable + ( 6 x Ldrop line max)
INFORMATION
Please refer also to the design regulations stated in the section entitled
“Design regulations when using stub lines”.

Ldrop line 1 = 2 m

Ldrop line 2 = 1 m
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
POWER F-Stack
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
L1 = 210 m
L2 = 3 m
Main line
Lel = L1 + L2 + (6 x Ldrop line 1) = 225 m
I/OD with
(end of branch)
Fig. 4-3: Effective electrical length of a branch with stub lines

(example for main branch with stub lines)

1.3
Sub-branches lead off from the main branch via active junctions. There
are no FO paths and no stub lines, i.e.:
• There are no stub lines
• There are active junctions
apart electrically. The effective electrical length Lel is made up of the
length of the bus cable laid between the two bus subscribers that are
furthest apart electrically, Lcable, plus the virtual cable runs of the active
junctions that are traversed, Lvirtual.
Lel = Lcable + (Lvirtual 1 + ... + Lvirtual n)
25 m 5m 170 m
MD I/OD
Lel = L4 = 240 m
O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
F-Stack
LD
I/OD
POWER
Main line
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Active Junction Active Junction Main branch

50 m
50 m
5m
L1
200 m
L2
90 m
15 m
L3
I/OD 85 m
I/OD L4
240 m
L5
225 m
L6
125 m
Lvirtual
(Virtual cable runs
I/OD of Active Junction)
Fig. 4-4: Effective electrical length on sub-branches with active junctions and without stub lines (example
with PSS SB ACTIVE JUNCTION BASIS)

1.4
Sub-branches lead off from the main branch via active junctions. There
are also stub lines within the branches (main branch/sub-branches);
however, there are no FO paths, i.e.:
• There are stub lines
• There are active junctions
apart electrically.
The effective electrical length Lel is made up of the length of the bus
cable laid between the two bus subscribers that are furthest apart
electrically, Lcable, plus the virtual cable runs of the active junctions that
are traversed, Lvirtual, plus 6 times the length of the longest stub lines
from the sub-branches that are traversed, Ldrop line max 1, plus 6 times the
length of the longest stub lines from the section of the main branch that
is traversed, Ldrop line max 2.
• Consider the stub lines in all the branches separately (see example
in Fig. 4-5).
• In each branch, only consider stub lines which lead out from the
section that is actually traversed.
• In each main branch section, sub-branch and sub-branch section that
is traversed, consider the longest stub line and multiply its cable runs
by 6.
Lel = Lcable + (Lvirtual 1 + ... + Lvirtual n) + (6 x (Ldrop line max 1 + ... + Ldrop line max n)

25 m 5m 150 m 20 m
MD Lel = L4 + 6 x (Ldrop line 1 + Ldrop line 2) = 270 m I/OD

O23+
O22+
O21+
O20+
O19+
O18+
O17+
O16+
O23-
O22-
O21-
O20-
O19-
O18-
O17-
O16-
24 V
24 V
24 V
24 V
O15
O14
O13
O12
O10
O11
0V
0V
0V
0V
O9
O8
O7
O6
O5
O4
O3
O2
O1
O0
F-Stack
LD
I/OD
POWER
Main path
ST AUTO PG
RUN ST SPS
PG
FS RUN
RUN FS STOP
PG RS 232
24 V
0V
0V
0V
0V
0V
I10
I12
I13
I14
I15
I16
I17
I18
I19
I20
I21
I22
I23
I24
I25
I26
I27
I28
I29
I30
I31
I11
I0
I1
I2
I3
I4
I5
I6
I7
I8
I9
Active Junction Active Junction Main branch

50 m
50 m
Stub line
3m
(Ldrop line 2)
2m
1m
5m
2m
Stub line
3m
L1
(Ldrop line 3) 200 m
I/OD L2
Stub line 90 m
(Ldrop line 1) L3
85 m
10 m
L4
I/OD 240 m
L5
225 m
L6
125 m
Lvirtual
(Virtual cable runs
I/OD of Active Junction)
Fig. 4-5: Effective electrical length on sub-branches with active junctions and stub lines (example with
PSS SB ACTIVE JUNCTION BASIS)
1.5
There is a fibre-optic path on the main line
INFORMATION
• When defining the effective electrical length of the main line, take into
account the virtual length of the FO couplers, at 35 m per FO path.
• Please read the information in the manual for the FO coupler (see
instructions enclosed with the FO coupler PSS SB SUB-D-FO1).

2. Define the max. permitted transmission rate
Once the effective electrical length Lel of the main line has been defined,
you can determine the transmission rate in accordance with Table 4-1.
Lel ≤ 3 500 m 1 450 m 550 m 240 m 95 m

20 kBit/s 50 kBit/s 125 kBit/s 250 kBit/s 500 kBit/s
Table 4-1
INFORMATION
The transmission rate defined in accordance with Table 4-1 is the
maximum achievable transmission rate in theory. Under certain
circumstances, limiting mechanisms on copper cables may reduce the
defined transmission rate (see step 3).

3. Examine each branch with regard to the limitation arising from the
cable cross section of the data lines and the number of bus
subscribers.
At 20, 50, 125 and to some extent at 250 kBit/s, the cable cross section
of the data line cores has a limiting effect on the max. permitted cable
runs of the main branch and sub-branches.
Check whether the main branch and sub-branches on your SafetyBUS p
network fall within the permitted limits (see Tables 4-2 to 4-5). Proceed
as follows:
• The main branch, each sub-branch and branch sections divided by
fibre-optic paths should be regarded separately.
• Define the number of bus subscribers for each branch or branch
section.
• If you are using active junctions:
- Active junctions in both the main branch and each of its sub-
branches should be considered bus subscribers.
- If there are several Active Junctions within a branch, account for that
number of bus subscribers.
• If you are using Routers:
- The check should be carried out on each of the Router’s bus
segments.
- A Router should be considered a bus subscriber in each of its bus
segments
• If you are using Bridges
- A Bridge should be considered a bus subscriber in each of its
networks.
- If there are several Bridges within a branch, account for that number
of bus subscribers.
NOTICE
With regard to the information in Tables 4-2 to 4-5, please note:
• The information refers exclusively to the bus cable (CU). Neither the
virtual cable runs from active junctions and fibre-optic couplers, nor the
lengths of the fibre-optic paths are taken into account.
• The information can be used on each branch. If branches are divided
into branch sections through fibre-optic paths, each branch section
should be regarded separately.

• If you assess the individual branches using Tables 4-2 to 4-5,
according to the table, longer cable runs may be permitted. If this is the
case, never lengthen the cable runs of the relevant branch without
considering these issues again (starting at step 1).
• For transmission rates that are not listed, the information in Table 4-1 will
apply.
3.1.
Cable cross section of 0.75 mm2 data lines
Table 4-2 contains details of the maximum permitted cable runs per
branch depending on the transmission rate and the number of bus
subscribers, where the cable cross section of the data lines is 0.75 mm2
(e.g. SafetyBUS p standard cable).
Number LBranch max LBranch max LBranch max

of at at at
bus subscribers 20 kBit/s 50 kBit/s 125 kBit/s
2 965 m 965 m 490 m
5 945 m 945 m 490 m
10 920 m 920 m 485 m
20 870 m 870 m 480 m
30 825 m 825 m 475 m
40 785 m 785 m 470 m
50 750 m 750 m 460 m
60 715 m 715 m 455 m
64 705 m 705 m 450 m
Table 4-2

3.2
(e.g. SafetyBUS p high current cable).
Number of LBranch max LBranch max LBranch max LBranch max

bus subscribers at at at at
20 kBit/s 50 kBit/s 125 kBit/s 250 kBit/s
2 795 m 795 m 465 m 235 m
5 780 m 780 m 465 m 235 m
10 760 m 760 m 460 m 235 m
20 720 m 720 m 450 m 235 m
30 680 m 680 m 445 m 230 m
40 650 m 650 m 440 m 230 m
50 620 m 620 m 430 m 230 m
60 590 m 590 m 425 m 225 m
64 580 m 580 m 425 m 225 m
Table 4-3

3.3
(e.g. SafetyBUS p low current cable).
Number of bus LBranch max LBranch max LBranch max LBranch max
subscribers at at at at
20 kBit/s 50 kBit/s 125 kBit/s 250 kBit/s
2 310 m 310 m 310 m 200 m
5 300 m 300 m 300 m 195 m
10 295 m 295 m 295 m 195 m
20 280 m 280 m 280 m 190 m
30 265 m 265 m 265 m 190 m
40 250 m 250 m 250 m 185 m
50 240 m 240 m 240 m 185 m
60 230 m 230 m 230 m 180 m
64 225 m 225 m 225 m 180 m
Table 4-4

4. Examine each branch with regard to the limitation arising from the
cable cross section of the supply voltage lines
If the SafetyBUS p cable carries the supply voltage, additional limits will
need to be considered, as shown in Table 4-5, depending on the type of
cable that is used.
INFORMATION
Please note: the information in Table 4-5 is valid for a minimum supply to
the field devices of 20.4 V.
Max. cable runs per branch depending on current consumption:

Load current Low current cable High current cable
(in A) LBranch max (in m) LBranch max (in m)
0.4 69 189
0.8 35 95
1.0 28 76
1.5 18 51
2.0 14 38
3.0 9 25
Table 4-5
INFORMATION
The supply voltage to a sub-branch can take a max. 3 A load.

Measures to increase the range
Reducing the transmission rate
Reducing the transmission rate enables you to increase the max. permitted
length of the bus cable within the stated limits (see Tables 4-1 to 4-5).
Using Routers
A PSS SB Router1 can be used to divide a SafetyBUS p network into 2

bus segments (logical division!). The two bus segments can be operated at
different transmission rates. Within the bus segments, the procedure in
accordance with steps 1 to 4 above still applies.
Example 1: Routers used with physically remote bus subscribers
MD
Short distance Long distance

High transmission rate Low transmission rate
PSS SB Router1
I/OD I/OD I/OD I/OD
Fig. 4-6: Routers used with physically remote bus subscribers (e.g. E-STOP buttons)
INFORMATION
Please refer to the information in the operating manual for the PSS SB
Router 1.

Example 2: Increasing the range by connecting Routers in series
MD
20 kBit/s 20 kBit/s 20 kBit/s

Lmax Branch 1 = 945 m Lmax Branch 2 = 965 m Lmax Branch 3 = 965 m
Bus segment 1 Bus segment 2 Bus segment 3
PSS SB Router1 PSS SB Router1
I/OD I/OD I/OD
Fig. 4-7: Connecting Routers in series (example)
Defining the maximum cable runs per bus segment

• Bus segment 1:
- Number of bus subscribers: 4
- Cable cross section: 0.75 mm2
- Transmission rate: 20 KBit/s
Maximum cable runs Lmax Branch 1 = 945 m
• Bus segment 2 and bus segment 3:
- Number of bus subscribers: 2 each
Maximum cable runs Lmax Branch 2 = Lmax Branch 3 = 965 m
INFORMATION
• Consider the appropriate Router correction factor when measuring the
cycle timeout and event timeout.
• Please note:
The max. number of Routers that can be connected in series is limited by
the cycle timeout (max. 300 ms) and event timeout (max. 300 ms).
• Please note that the overall reaction time is increased.
• Please refer to the information in the operating manual for the PSS SB
Router1.

Using Bridges
Using a Bridge divides the system into two independent SafetyBUS p

networks. The rules regarding the interdependence of transmission rate
and bus cable runs apply within the individual networks. It is possible to
use several Bridges.
INFORMATION
BRIDGE.
MD
(Segment 1)
20 kBit/s
Lmax Branch 1 = 945 m
PSS SB BRIDGE PSS SB BRIDGE

MD MD
(Network 2) (Network 3)
20 kBit/s 20 kBit/s
Lmax Branch 2 = 945 m Lmax Branch 3 = 945 m
I/OD I/OD
I/OD I/OD
Fig. 4-8: Using Bridges to increase the overall length of SafetyBUS p (example)
Defining the maximum cable runs per network

• Network 1:
Maximum cable runs Lmax Branch 1 = 945 m
• Network 2 and network 3:
- Number of bus subscribers: 4 each
Maximum cable runs Lmax Branch 2 = Lmax Branch 3 = 945 m
Using programmable safety systems with two SafetyBUS p interfaces
Some Pilz PSS-range programmable safety systems have two

SafetyBUS p interfaces. These programmable safety systems are able to
undertake bus management functions for two independent SafetyBUS p
networks. The rules regarding the interdependence of transmission rate
and bus cable runs apply within the individual networks.
MD 1 MD 0
(SafetyBUS p 1) (SafetyBUS p 0)
Lmax SafetyBUS p 1 = 945 m
Lmax SafetyBUS p 0 = 945 m
PSS PSS
(LD,I/OD) (LD,I/OD)
Network 2
Network 1
20 kBit/s
20 kBit/s
I/OD I/OD
I/OD I/OD
Fig. 4-9: Using a PSS with two SafetyBUS p interfaces to increase the overall length of SafetyBUS p
(example)
Determining the maximum cable runs per network:

• Network 1 (SafetyBUS p 0):
Maximum cable runs Lmax SafetyBUS p 0 = 945 m
• Network 2 (SafetyBUS p 1):
Maximum cable runs Lmax SafetyBUS p 1 = 945 m

Using FO cable
As a signal refresh occurs within the FO couplers, the values from Table
4-1 may be used to calculate the length.
INFORMATION
• The values from Table 4-1 must not be exceeded.
• The max. cable runs are reduced by 35 m per FO path.
MD
Lmax = 3500 m at 20 kBit/s
100 m 3 185 m 180 m

LCU1 LFO=Lmax-(LCU1+LCU2+35 m) LCU2
PSS SB SUB-D-FO1 PSS SB SUB-D-FO1
I/OD I/OD I/OD I/OD
Fig. 4-10: Increasing the range using fibre-optic cables (example)
MD
Lmax1 = 3500 m at 20 kBit/s Lmax2 = 3500 m at kBit/s
Bus segment A Bus segment B
LCU1 LFO1=Lmax1-(LCU1+35 m) LLWL2=Lmax2-(LCU2+35 m) LCU2

PS
PS
PS
PS
PS
SS
SS
SS
SS
SS
BS
BS
BR
BS
BS
UB
UB
UB
UB
ou
I/OD I/OD I/OD I/OD

ter
-D
-D
-D
-D
1
-FO
-FO
-FO
-FO
1
Fig. 4-11: Increasing the range by connecting FO paths in series via a Router (example)

Reducing the total cable runs by using active junctions
Active junctions (e.g. Active Junction) can be used to build a star topology
(star structure). No return lines are required in the sub-branches. This can
reduces the total cable runs and, under certain circumstances, increase
the transmission rate.
MD MD
Active Junction e.g.

PSS SB ACTIVE JUNCTION BASIS
PSS SB ACTIVE JUNCTION EXPANSION
I/OD I/OD I/OD I/OD I/OD I/OD I/OD I/OD
Fig. 4-12: Active junction used to reduce the total cable runs (example uses Active Junction)

Extending the max. number of bus subscribers by using a Bridge
A SafetyBUS p network is limited to a maximum of 64 bus subscribers.

The use of Bridges means that a system can be divided into independent
SafetyBUS p networks, each of which may have a maximum of 64
subscribers.
INFORMATION
BRIDGE.
MD MD
(Network 1) (Network 2)
PSS SB BRIDGE
I/OD 1 I/OD 64 I/OD 1 I/OD 64
Fig. 4-13:Interconnecting 2 SafetyBUS p networks to increase the number of bus

subscribers (example)

Extending the max. number of bus subscribers by using programmable safety

systems with two SafetyBUS p interfaces
A SafetyBUS p network is limited to a maximum of 64 bus subscribers. By

using programmable safety systems with two SafetyBUS p interfaces, a
system can be divided into independent SafetyBUS p networks, each of
which may have a maximum of 64 subscribers.
MD 1 MD 0
(SafetyBUS p 1) (SafetyBUS p 0)
max. 64 bus subscribers
max. 64 bus subscribers
PSS PSS
(LD,I/OD) (LD,I/OD)
Network 2
Network 1
I/OD I/OD
I/OD I/OD
Fig. 4-14:Interconnecting 2 SafetyBUS p networks to increase the number of bus

subscribers (example)

Connecting SafetyBUS p Subscribers
Connectors for copper cable
When configuring a connector, you need to distinguish between the bus

cable IN and OUT:
• Bus cable IN
The incoming bus cable comes from the MD.
• Bus cable OUT
The outgoing bus cable leads away from the MD.
Details of how to use a connector can be found in the relevant manual,

which is supplied with the connector.
IP20 connectors
Pilz supplies various connectors to link a bus subscriber to SafetyBUS p

(IP20 environment). The following connectors are currently available for
copper cable (CU bus cable):
• PSS SB SUB-D3
- Suitable for bus cable that exclusively carries data lines (3-core)
- Cable feed perpendicular to mating direction
- Single strands connected via screw terminals
- Multiple configuration or reconfiguration as often as necessary
- Terminating resistor can be selected/de-selected externally
- When using the connector, it is possible to lock the front cover flap on
SafetyBUS p compatible CPUs from the PSS 3000 and PSS 3100
series.

• PSS SB SUB-D4
- Suitable for bus cable that exclusively carries data lines (3-core)
- Cable feed perpendicular to mating direction
- Single strands connected via IDC terminals
- Using IDC terminals to connect the single strands means there’s no
need to strip the cable
- Multiple configuration or reconfiguration possible to a limited extent
(max. 10 contact cycles)
- Terminating resistor can be selected/de-selected externally
- When using the connector, it is possible to lock the front cover flap on
SafetyBUS p compatible CPUs from the PSS 3000 and PSS 3100
series.
• PSS SB SUB-D4-DIAG
- Diagnostic connector
- As PSS SB SUB-D4, but with an additional connector for diagnostics
- When using the connector, it is not possible to lock the front cover flap
on SafetyBUS p compatible CPUs from the PSS 3000 and PSS 3100
series.

Plug configuration
Connectors without a terminating resistor or with the terminating resistor

deactivated are referred to as plugs. They are used on bus subscribers on
which the bus cable is through-connected (bus nodes).
On PSS SB SUB-D3, PSS SB SUB-D4 and PSS SB SUB-D4-DIAG

connectors, the terminating resistor can be selected/de-selected externally
(switch setting “OFF”: bus cables IN and OUT are through-connected).
1: Changeover switch for

2: IDC terminals
1
(2 x 3-pin)
5 3: Metal contact surface for the
screened cable connection
2 4: Bus cable OUT
6 5: Female D-SUB connector (9-pin)
3 (not visible)
6: Cover flap with integral strain
relief and
4 7: Bus cable IN
7
Fig. 5-1: Plug (example: PSS SB SUB-D4)

Terminator configuration
Connectors with a terminating resistor are referred to as terminators.

They are used on bus subscribers on which SafetyBUS p must be
terminated using terminating resistors (see Chapter 3, section entitled
“Bus termination”).
On PSS SB SUB-D3, PSS SB SUB-D4 and PSS SB SUB-D4-DIAG

connectors, the terminating resistor can be selected/de-selected externally
(switch setting “ON”: terminating resistor is activated).
1: Changeover switch for

1 2: IDC terminals
5 (2 x 3-pin)
3: Metal contact surface for the
screened cable connection
2 4: Cover flap with integral strain
relief
6 5: Female D-SUB connector (9-pin)
3
(not visible)
6: Bus cable IN
4
Fig. 5-2: Terminator (example: PSS SB SUB-D4)

INFORMATION
Please note the following when wiring terminators:
• On terminators, only connect the bus IN cable.
• On connectors on which the terminating resistor can be selected
externally, the terminal for the bus cable IN and OUT is permanently
specified. Arrows are used to identify the terminal within the connector.
The terminal for the bus IN cable must be used on terminators.
IP67 connectors
Connectors for connecting the device:

Connectors are available for the direct connection of a SafetyBUS p
subscriber in an IP67 environment. They have the following properties, as
a minimum:
• 5-pin M12 round plug-in connector (female connector)
• Suitable for carrying the supply voltage for field devices
• Cable screening via PIN 5 (no link to connector housing)
T-connector for connection to SafetyBUS p:

In an IP67 environment, SafetyBUS p subscribers are connected to the
bus cable via special T-connectors (no IN/OUT bus cable within the
connector!).
Terminator with integral terminating resistor:

Bus termination in an IP67 environment occurs through special terminators
(no bus termination via the connector!). The terminators are connected to
the T-connectors.

Connectors for FO cable
The FO coupler PSS SB SUB-D-FO1 is integrated within the connector for

the FO cable.
1: Female D-Sub connector (9-pin)

for connecting the CU copper
1 3 cable connector
2: ST connection: transmitter (black)
3: Male D-Sub connector (9-pin)
for connection to the
SafetyBUS p interface of a bus
subscriber
4: ST connection: receiver (blue)
2 4
Fig. 5-3: FO coupler PSS SB SUB-D-FO1
INFORMATION
• When installing, please note that the lines are crossed. Connect the
transmitter (T) to the receiver (R).
• Please read the information in the manual for the FO coupler, which is
supplied with the FO coupler.

Connector pin assignment
PSS SB SUB-D3 connector
Female 9-pin D-Sub connector

1: n.c.
1 6 2: CAN_L (brown)
3: CAN_GND (white)
9 4: n.c.
5 5: CAN_SHLD
6: n.c.
7: CAN_H (green)
8: n.c.
9: n.c.
Fig. 5-4: Pin assignment on the PSS SB SUB-D3 connector
2 x 3-pin screw terminal

Bus cable IN:
CANL-IN (brown)
CANGND (white)
CANH-OUT
CANL-OUT
CANH-IN (green)
CANGND
CANGND
CANH-IN
CANL-IN
Bus cable OUT:

CANL-OUT (brown)
CANGND (white)
CANH-OUT (green)
Fig. 5-5: Pin assignment of the screw terminal on the PSS SB SUB-D3 connector

PSS SB SUB-D4 and PSS SB SUB-D4-DIAG connectors
Female 9-pin D-SUB connector
1 1: n.c.
6 2: CAN_L (brown)
3: CAN_GND (white)
9 4: n.c.
5 5: CAN_SHLD
6: n.c.
7: CAN_H (green)
8: n.c.
9: n.c.
Fig. 5-6: Pin assignment on the PSS SB SUB-D4 and PSS SB SUB-D4-DIAG
connectors
2 x 3-pin IDC terminal

CAN-HIGH
CAN-LOW
CAN-GND
CAN-HIGH
CAN-LOW
CAN-GND
1: Bus cable OUT:

CAN-HIGH (green)
CAN-GND (white)
CAN-LOW (brown)
2: Bus cable IN
1 2
CAN-HIGH (green)
CAN-GND (white)
CAN-LOW (brown)
Fig. 5-7: Pin assignment on the IDC terminal in the PSS SB SUB-D4 and PSS SB
SUB-D4-DIAG connectors

Making the bus connections
Bus connection using copper cable
Standard application
All the connectors for CU copper cable may be used.
Bus subscriber Bus subscriber Bus subscriber Bus subscriber
Fig. 5-8: Standard version of bus connection
Forming stub lines
The PSS SB SUB-D4-DIAG connector is required in order to form stub

lines.
Bus subscriber Bus subscriber Bus subscriber
Stub line
PSS SB SUB-D4-DIAG
Bus subscriber
Fig. 5-9: Forming stub lines with the PSS SB SUB-D4-DIAG

Connection for mobile diagnostic units
To connect a mobile diagnostic unit such as the PSS SB TESTER it is

necessary to separate the bus subscriber from SafetyBUS p. The
corresponding I/O-Group will switch to a STOP condition. This can be
avoided by using the PSS SB SUB-D4-DIAG connector.
PSS SB SUB-D4-DIAG
F3
F2 L
VA
F1 P
HL
C
ES
ON FF
O
PSS SB TESTER
Fig. 5-10: Connecting mobile diagnostic units

Bus connection using FO cable
PSS SB SUB-D-FO1
Copper cable FO cable
Fig. 5-11: Bus connection using FO cable

Notes

Installation and Assembly
Overview
SafetyBUS p is designed for use in an industrial environment. To ensure

electromagnetic compatibility the correct procedures must be carried out
during installation and assembly.
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:

• Electrical fields
• Power supply
• Earth cabling
• Interfaces
on the bus.
The interference can be transferred from the source to the receiver

(interference sink) via the coupling routes.
Source of Coupling Intererence

intererence sink
Fig. 6-1: Electromagnetic interference
Interference reaches the interference sink (SafetyBUS p data lines) 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, 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 change in the electrical field.
Possible sources of interference are contactors, static discharge, parallel
data lines, for example.
• Inductive (magnetic) coupling
A live cable produces a magnetic field which surrounds both the live and
adjacent cables. Interference voltage is induced. Cross-coupling is
proportional to the rate of change in the magnetic field.
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
Powerful 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 source of interference: people who are statically charged from
a synthetic carpet, for example.

Making the installation EMC-compliant
Earthing the housing
The prescribed earth points (functional earth) are designed to guarantee

compliance with noise immunity requirements.
• Please note the protection class of the individual bus subscribers (DIN
VDE 0160, Part 1/A1, 04/90). Further information can be found in the
Installation Manual of the corresponding bus subscriber.
• A cable cross section of at least 2.5 mm2 should be used for earthing the
bus subscribers.
• On each bus subscriber, connect the specified earth connection
(functional earth) to the central earth point in star form.
• 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.
Equipotential bonding
Potential differences can occur if the bus subscribers are connected to

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.
• 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 bar over as wide a
surface area as possible.
• As short a distance as possible should be kept between the equipotential
bonding cable and data lines.

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.
• Cables from group 1 and group 2 should be laid in separate groups or in
cable ducts which are at least 10 cm apart.
• Cables from group 1 and group 3 should be laid in separate groups or in
cable ducts which are at least 50 cm apart.
• Data lines should be laid as close as possible to an earthed surface.
Cabling to open air systems:

• The use of FO cable is preferable.
• If it is not possible to use FO cable, then it is preferable to use copper
cable that is suitable for burial underground. Be aware generally of the
temperature range of the cable you are using.
• With copper cable, 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.

Earthing the cable screening (screened cables)
• In each connector, connect the braided screening on the bus cable with low
impedance to the clamp provided (metal strain relief).
INFORMATION
The screening on the SafetyBUS p cable is connected to PIN 5 on the
SafetyBUS p interface. It is connected to the functional earth connection
inside the bus subscriber via an HF filter. This connection serves to filter
out high frequency interference.
SafetyBUS p
subscribers
Connector
2 CAN L 2
7 CAN H 7
3 CAN GND 3
Shield 5 Shield 5
Shield
1
4
5
2
1: HF filter (inside the device)
2: Functional earth connection
3: Terminal
4: Metal strain relief to connect the
braided screening, with connection
to Pin 5 (Shield)
5: Braided screening on the bus
cable
(with stripped cable insulation)
Fig. 6-2: Connecting the cable screening 6: Bus cable IN/OUT

NOTICE
Ensure that the cable screening is connected throughout in each branch
(main branch, sub-branches). Ensure the connection for the IN/OUT bus
cable is made correctly in each connector (see Fig 6-2).
• The cable screening should be earthed once per branch (main branch,
sub-branches). For this reason, connect the screened cable with low
impedance to the screen bar or earth bar, once per branch.
To keep transient currents low, it is an advantage for earthing to occur
right in the middle of the branch. However, earthing normally occurs at
the start or end of the branch, i.e. where the bus cable enters/leaves the
control cabinet.
INFORMATION
An appropriate connection material (e.g. screened terminals) should be
used to connect the cable screening to the earth bar or bus bar.
1: Bus cable
1 2: Braided screening on the bus
cable
3: Screened terminal
2
4: Earth or screening bar
3
4
Fig. 6-3: Earthing the screened cable

Earthing concept on SafetyBUS p
Bus Bus Bus Bus

subscriber subscriber subscriber subscriber
Power supply
24 V
0V
Earth bar
Central earth point
(plant, machine, control cabinet ...)
Key:
Functional earth
Cable screening
Fig. 6-4: Earthing on SafetyBUS p (e.g. main branch)
INFORMATION
• In each connector, connect the braided screening on the bus cable (bus
cable IN and OUT) with low impedance to the clamp provided (see Fig.
6-2, Fig. 6-4). Make sure the connection is continuous!
• Connect the cable screening with low impedance to the screen bar/earth
bar, once per branch (main branch, sub-branches). (See Fig. 6-4.)
Please refer to the information in the operating manual for active
junctions.
• Each bus subscriber should be connected in star to the functional earth.
Please refer to the earthing regulations in the documentation for the
relevant bus subscriber.

Insulation voltage test
Pilz SafetyBUS p subscribers are connected to the functional earth

via protection elements on the supply voltage. Insulation voltage tests are
only possible with voltages up to ca. 42 V.
Power supplies for the supply voltage
Safe electrical isolation must be ensured for the external 24 V supplies.

Failure to do so could result in electric shock. Power supplies must
conform to EN 60950, 03/97, section 2.3, EN 60742, 9/95 or EN 50178,
10/97.
Lighting inside the cabinet
Use low interference panel lighting for inside the control cabinet.

Testing the EMC-compliance of an installation
Use the following list to check that the installation of the safety system is
EMC-compliant.
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 units e.g. while hand-held radios are in
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 con-
correctly? nections to base module racks,
racking bars, earth conductors and
earth bars.
• Inactive metal parts should be
connected over a wide surface
area and
• earthed at 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 data lines 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 PSS must be wired with
suppression elements.
24 VDC power The power supply must conform to
supply? EN 60950, 03/97, section 2.3, EN
60742, 9/95 or EN 50178, 10/97.

Commissioning
Initial commissioning
When commissioning a SafetyBUS p system for the first time, follow the
instructions below:
1. Device address
Check the device address on all the SafetyBUS p subscribers. Set
the correct device address where necessary. Please proceed with the
utmost care!
2. Voltage supply
Please note:
SafetyBUS p must not be active at this point!
Connect all the necessary voltages to each SafetyBUS p subscriber.
Consider the display elements on the bus subscribers:
- The relevant supply voltage LED must indicate the presence of
each required voltage.
- Status LEDs must not indicate any errors.
Please refer to the operating manual of the relevant bus subscriber for
an analysis of the LEDs.
3. Connectors
Check the connectors of each SafetyBUS p subscriber with regard to
- The bus cable IN and OUT: check it is inserted the right way round
- Terminating resistors
Check the switch setting on the changeover switch for the termi-
nating resistor. The terminator must be in the “ON” position (termi-
nating resistor is activated), the plugs must be in the “OFF” position
(bus cables IN and OUT are through-connected).
Further information on bus diagnostics and troubleshooting is avail-
able in Chapter 8.
4. Prepare PSS
Load the linked user program with the complete bus configuration on
to all the programmable safety systems (MD-PSS, LD-PSS).
Please note:
No FS output may be set through the user program at this point!
SafetyBUS p Installation ManualCC 7-1

Commissioning
5. Assignment of I/O-Groups
Check the assignment of the I/O-Groups.
6. I/O test
Activate all the sensors and actuators in order to test the wiring of the
inputs and outputs plus the test pulse assignment.
7. Function test
Carry out a complete function test. Test the safety functions first,
followed by the procedures.
8. Work processes
Finally check all the work processes.
Recommissioning when exchanging devices
A controlled procedure is absolutely essential when exchanging a

SafetyBUS p subscriber.
WARNING!
Hazardous situations may arise on the plant if devices become mixed up.
Only ever change one device after the other in order to avoid confusion.
Proceed as follows:
1. Set the device address
Set the device address on the exchange device to the same address
as that of the device you are replacing.
WARNING!
Any errors made when setting the device address will result in the
loss of the safety function. If the device addresses of two modules are
transposed, the controlling PSS may unknowingly address the wrong
input/outputs. This may lead to hazardous situations. The safe opera-
tion of the plant is no longer guaranteed.
To avoid this, the greatest possible care must be taken when setting
the device addresses.
2. Change the equipment identifier

Remove any equipment identifiers from the old device and attach
them to the exchange device.
3. Change the labelling strips
Remove any labelling strips from the old device and attach them to
the exchange device.

4. Set up the connections
Set up all the plug-in connections on the exchange device.
WARNING
Hazardous situations may arise if the connection terminals on a
module (e.g. PSS SB DI8O8, PSS SB DI16, PSS SB DI8OZ4) are
transposed. Test the inputs and outputs by activating all the sensors
and actuators in order to check the wiring and the test pulse assign-
ment.
Consider the display elements on the bus subscribers:

- The relevant supply voltage LED must indicate the presence of
each required voltage.
- Status LEDs must not indicate any errors.
Please refer to the operating manual of the relevant bus subscriber for
an analysis of the LEDs.
5. Carry out a function test

Carry out a function test. Test the safety functions first, followed by the
procedures.
Repeat steps 1 ... 5 for each exchange device.

Commissioning
Notes

Bus Diagnostics
Troubleshooting during commissioning
Troubleshooting during commissioning can be made easier if bus

subscribers are switched on or off in stages. This is relatively easy to
achieve if you use connectors on which the terminating resistor can be
selected/de-selected externally (see Chapter 5).
INFORMATION
When configuring, ensure the bus cables IN and OUT are inserted the
right way round. An arrow within the connector indicates the direction for
insertion.
Bus subscriber Bus subscriber Bus subscriber Bus subscriber Bus subscriber
R R
Disconnected bus subscribers
Fig. 8-1: Switching bus subscribers on/off in stages

Bus Diagnostics
Bus diagnostics using the PSS SB TESTER diagnostic unit
The mobile diagnostic unit PSS SB TESTER can be used to perform

various tests and measurements on SafetyBUS p.
• Connection test
- Checks the terminating resistors
- Checks the bus cable wires for short circuits
• Screening test
- Checks the cable screening for open circuits
• Length measurement
- Measures the length of the bus line
- Determines the location of a short circuit between CAN_H and CAN_L
• Signal test
- Tests the transmission rate
- Tests the electrical signal level on the lines CAN_H and CAN_L
- Tests the signal edges on the lines CAN_H and CAN_L
• Real-time mode
- Measures the bus load
- Measures error rate, failure rate and number of errors

Check list for bus diagnostics
To ensure a SafetyBUS p system functions properly, you will need to

check or define the following points:
INFORMATION
Please note the following when plants are already in operation:
• All SafetyBUS p subscribers must be freely accessible
• The plant must be shut down for some measurements.
Checking the bus topology
Check whether the plant complies with the boundary conditions for
SafetyBUS p. Please refer to the information in Chapter 3 and Chapter 4.
Main branch
Main branch
Set transmission rate Transmission rate: ..........kBit/s
of main branch:
Actual length of main branch Cable runs: ............... m
Number of stub lines on the main Number: ...........................
branch
Length of the longest stub line on Cable runs: ............... m
the main branch
Is the longest stub line < 0.5 x the YES ❐
length of the main branch?
Does the system stay within the YES ❐
max. permitted cable runs for the
set transmission rate
Lmax ≤ (LMain branch + 6 x LStub line max.)?
None of the stub lines have a YES ❐
terminating resistor?

Bus Diagnostics
Sub-branches when using Routers
INFORMATION
The following applies when using Routers: carry out the following test for
each sub-branch/each Segment B.
Sub-branch/Segment B
Set transmission rate of sub- Transmission rate: ..........kBit/s
branch/Segment B:
Actual length of sub-branch/ Cable runs: ............... m
Segment B
Number of stub lines on the sub- Number: ...........................
branch/Segment B
Length of the longest stub line on Cable runs: ............... m
the sub-branch/Segment B
Is the longest stub line < 0.5 x the YES ❐
length of the sub-branch/
Segment B?
Does the system stay within the YES ❐
max. permitted cable runs for the
set transmission rate
Lmax ≤ (LBr./Seg. + 6 x LStub line max.)?
None of the stub lines have a YES ❐
terminating resistor?

Selection of bus cable
INFORMATION
When selecting a bus cable, please note: the bus cable must meet the
specifications of the technical guidelines “SafetyBUS p - Data lines (CU)”.
A copy of the guidelines is available from the SafetyBUS p Club
international e. V.
Installation, bus cable and connector
Terminating resistors
INFORMATION —-
Connector with terminating
resistor, which can be selected/
de-selected externally via a
changeover switch:
The direction for inserting the
bus cable IN and OUT is
indicated. This is mandatory.
In the “OFF” position, the integral

terminating resistor is de-activated.
The bus cable IN and OUT is
connected.
In the “ON” position, the integral
terminating resistor is activated. The
bus OUT cable is disconnected.
On the first bus subscriber in a
branch, is the terminating resistor
configured/connected?
Main branch: YES ❐
Sub-branches: YES ❐
On the last bus subscriber in a
branch, is the terminating resistor
configured/connected?

Bus Diagnostics
INFORMATION
Connector with terminating
resistor, which can be
selected/de-selected externally
via a changeover switch:
In each branch, the
connections marked “CANH-
IN” and “CANL-IN” must be
used on the first and last bus
subscriber (follow the arrows!)
Have the bus cables IN and OUT

been inserted the right way round
in each connector?
Resistance measurement between
CAN_H and CAN_L:
Is the result of the measurement
around 60 Ohm (both terminating
resistors connected in parallel!)?
CAN_H and CAN_GND:
“infinity” (no short circuit!)?
CAN_L and CAN_GND:
“infinity” (no short circuit!)?

Screening
On each connector you should
check:
Is the cable screening connected
over a wide surface area to the
clamp provided within the
connector housing? YES ❐
INFORMATION
Please note that the screening
procedures may be different
when using active junctions
(e.g. Active Junction, Router).
Is the cable screening connected

with low impedance to the screen
bar or earth bar, once per branch?
Segment A and B (Router only): YES ❐
Check that the screening is
continuous:
- Remove the screen earthing.
- Insert a jumper at the end of the
cable between SHLD and
CAN_GND.
- Measure the resistance between
SHLD and CAN_GND at the start
of the cable
around < 100 Ohm (continuity!)?

Segment A and B (Router only): YES ❐

Bus Diagnostics
Measuring typical bus characteristics
Typ. bus characteristics

Load on the bus system Bus load: .......................... %
(bus load in %)
Aid:
- PSS SW PG/PSS WIN PRO
- PSS SB TESTER
Number of Error Frames (Rate/s) Error Frames: ............... 1/s
Aid:
- PSS SW PG/PSS WIN PRO
Measurement of signal level
Aid:
- Oscilloscope
- PSS SB TESTER
Measure at both the start and end

of a branch (main branch and sub-
branches)!
Signal level checked: YES ❐

Index
A PSS SB SUB-D1 5-1, 5-8

PSS SB SUB-D1-DIAG 5-2, 5-8
Applicable documentation 1-1 PSS SB SUB-D2 5-2, 5-10
Active Junction 3-8, 4-19 PSS SB SUB-D3 5-2, 5-11
Active junctions 3-2 Copper cables (CU) 3-10
Active Junction 3-8, 4-19
Router 3-7, 4-15, 4-16 D
B Data lines
Cable cross section 4-11, 4-12, 4-13
Bridge 4-17, 4-20 Definition of symbols 1-3
Bus cable 3-10 Diagnostic units 5-13, 7-2
Copper cables (CU) 3-10 Connection 5-13
Defining the length 4-4 PSS SB TESTER 5-13, 7-2
Fibre-optic cables (FO) 3-12
For data transfer and supply voltage 3-11 E
For pure data transfer 3-10
Earthing 3-18
Bus connections
Cable screening 6-5
Copper cable CU 5-12
Earthing concept 6-7
FO cable 5-14
Housing 6-3
Making ... 5-12
Earthing concept 6-7
Stub lines 5-12
Effective electrical length 3-4
Bus diagnostics 7-1
With active subscribers 4-6, 4-8
Bus cable 7-5
With stub lines 4-5
Check list 7-3
Without stub lines 4-4
Checking the bus topology 7-3
EMC 6-3
Connector 7-5
EMC-compliance 6-9
Diagnostic unit PSS SB TESTER 7-2
Installation 6-3
Installation 7-5
Equipotential bonding 6-3
Measurements 7-8
Troubleshooting 7-1 F
Bus subscribers
Limitation arising from ... 4-10 Fault prevention 2-3
Number 3-18, 4-11, 4-12, 4-13, 4-20 Fibre-optic cables (FO) 3-9, 4-18
Signal attenuation ... 4-1 FO coupler 3-9
Bus topology. See Topology H
C High current cable 3-11
Cable cross section I
Data lines 4-11, 4-12, 4-13
Limitation arising from ... 4-10, 4-14 Insulation voltage test 6-8
Cabling 6-4 Intended use 2-2
Commissioning 2-4, 7-1 IP protection type 3-13
Conformity test 2-2 Bus subscribers 3-13
Connector 5-1 Connector 5-1, 5-5
Configuration 5-7 SafetyBUS p 3-13
D-Sub connector 3-14 SafetyBUS p Club International e.V. 3-13
For copper cable CU 5-1
For FO cable 5-6
M12 round connector 3-15
PSS SB SUB-D0 5-1, 5-7

Index
L Screened cables 6-5

Screening 3-18
Limiting mechanisms 4-1 Signal attenuation 4-1
Signal attenuation 4-1 Signal run times 4-1
Signal run times 4-1 Star structure 3-2, 4-19
Voltage drop in the supply lines 4-1 Stub lines 3-3, 5-12
Linear structure 3-2 Design regulations 4-2
Low current cable 3-11 Sub-branch 3-2
T
M
Terminating resistor 3-16, 5-3, 5-4
Main branch 3-1 Main branch 3-1
Main line 3-5 Stub line 3-3
Defining the ... 3-5, 3-6, 3-7, 4-4 Sub-branch 3-2
Linear structure with stub lines 3-6 Terminator 5-4
Pure linear structure 3-5 Topology 3-1
Sub-branches 3-7 Total cable runs
O Reducing the ... 4-19
Transmission rate
Open bus system 2-2 Defining the ... 4-9
Tree structure 3-2
P
Troubleshooting 7-1
Panel lighting 6-8
Passive branch 3-3 U
Passive junction 3-3 Use of qualified personnel 2-1
Plug 5-3
Power-free state 2-2 V
Power supplies 6-8 Voltage supply lines
Q Cable cross section 4-14
Qualified personnel 2-1

R
Range, increasing the.. 4-15
Bridge 4-17
Fibre-optic cables 4-18
Measures to... 4-15
Router 4-15, 4-16
Transmission rate 4-15
Recommissioning 2-4, 7-2
Router 3-7, 4-15, 4-16
S
Safe condition 2-2
SafetyBUS p Club International e.V. 1-1, 2-1,
2-2, 3-13
SafetyBUS p interface 3-14
Configuration 3-14
Design 3-14
Galvanic isolation 3-17

Appendix
Changes in the documentation
Changes in Version 19 768-04
Old New Changes

page page
—- —- Completely revised
Old New Changes

page page
--- 4-18 New section:
“Using programmable safety systems with two
SafetyBUS p interfaces”
”Extending the max. number of bus subscribers by using
programmable safety systems with two SafetyBUS p
interfaces”
5-1 --- Sections removed:
and ”PSS SB SUB-D0", “PSS SB SUB-D1”, “PSS SB SUB-
5-2 D1-DIAG” and “PSS SB SUB-D2”
--- 5-2 New sections:
”PSS SB SUB-D4" and “PSS SB SUB-D4 DIAG”
5-4 --- Connection diagram for PSS SB SUB-D0 terminator
removed
5-5 --- Connection diagram for PSS SB SUB-D0 plug removed
5-7 --- Sections removed:

to ”PSS SB SUB-D0 connector”,
5-10 ”PSS SB SUB-D1 and “PSS SB SUB-D1-DIAG”
connectors and “PSS SB SUB-D2 connector”

“PSS SB SUB-D4 and PSS SB SUB-D4-DIAG
connectors”

Appendix
Old New Changes

page page
1-2 1-2 New Chapter 7:
"Commissioning"
"Requirements for commissioning and recommissioning"
7-1 7-1 New Chapter 7:

and and "Commissioning"
beyond beyond

... www
In many countries we are www.pilz.com
represented by our subsidiaries
and sales partners.
Technical support
Please refer to our Homepage +49 711 3409-444
for further details or contact our
headquarters.
19 768-06, 2006-08 Printed in Germany
Pilz GmbH & Co. KG

Sichere Automation
Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Telephone: +49 711 3409-0
Telefax: +49 711 3409-133
E-Mail: [email protected]

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Programmable

Safety Systems PSS®-Range

Installation Manual – Item No. 19 768-06

SafetyBUS p Installation Manual 1

SafetyBUS p interface 3-14

Designing a SafetyBUS p Network 4-1

2 SafetyBUS p Installation Manual

Installation and Assembly 6-1

SafetyBUS p Installation Manual 3

Bus Diagnostics 8-1

4 SafetyBUS p Installation Manual

About the SafetyBUS p installation manual

The SafetyBUS p Manual is a collection of various documents. It is

This SafetyBUS p Installation Manual is part of the SafetyBUS p Manual

The procedure for installing a specific SafetyBUS p subscriber (e.g.

The relevant publications (guidelines) of the SafetyBUS p Club

SafetyBUS p Installation Manual 1-1

Overview of installation manual

This manual is divided into the following chapters:

1-2 SafetyBUS p Installation Manual

Information in this manual that is of particular importance can be identified

SafetyBUS p Installation Manual 1-3

1-4 SafetyBUS p Installation Manual

These safety guidelines are an important part of the SafetyBUS p

SafetyBUS p is a bus system for the transfer of safety-related data. The

Use of qualified personnel

SafetyBUS p and its components may only be assembled, installed,

It is the company’s responsibility only to employ personnel who:

SafetyBUS p Installation Manual 2-1

SafetyBUS p is a bus system for the serial transfer of safety-related data.

SafetyBUS p is an open bus system. Products from different

Warranty and liability

All claims to warranty and liability will be rendered invalid if

2-2 SafetyBUS p Installation Manual

Although the bus system and subscribers guarantee a high degree of

SafetyBUS p Installation Manual 2-3

Requirements for commissioning and recommissioning

• Module connection terminals

2-4 SafetyBUS p Installation Manual

Physically, SafetyBUS p is based on CAN. The physical properties of the

I/OD with LD I/OD with

Fig. 3-1: Main branch of SafetyBUS p (example of a purely linear structure)

SafetyBUS p Installation Manual 3-1

By using active junctions which have been specially designed for

MD, LD, I/OD with I/OD with

Active junction with

Fig. 3-2: Sub-branch on SafetyBUS p (example)

3-2 SafetyBUS p Installation Manual

To a very limited extent, passive junctions (e.g. T-connectors) may be used

MD, LD, I/OD with I/OD with

Fig. 3-3: Stub line on SafetyBUS p (example)

SafetyBUS p Installation Manual 3-3

Effective electrical length

The term “effective electrical length” is used to describe the connection

Runtime of a pulse between 2 bus subscribers [ns]

3-4 SafetyBUS p Installation Manual

Defining the main line on a purely linear structure

Where SafetyBUS p has a purely linear structure, the main line

I/OD with MD I/OD with