Technical Catalogue PNOZmulti Product Range · 2015-06-05 · Technical Catalogue PNOZmulti Product Range March 2004 edition System configuration manual PNOZmulti modular safety system

Technical CataloguePNOZmulti Product Range

March 2004 edition

System configuration manualPNOZmulti modular safety system

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Safe Automation from Pilz

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Pilz, the company

Pilz offers more than automationtechnology – Pilz offers safe automationand for years has been a competent, reliablepartner for its customers in the most variedof industries. Today, as technology leader,and system/solution supplier, Pilz is one ofthe key brands within automationtechnology worldwide.

Customer orientation

At Pilz, real proximity to customers isevident at all levels, in all areas, and isexperienced through individualconsultation, total flexibility and reliableservice.

Services

Individual solutions are a product of Pilz’scomprehensive, innovative range of services.Specifically on the issue of safety we canoffer:

Safety adviceRisk analysisSafety conceptsSafety checkProject managementDelivery of complete systems

In conjunction with product training andseminars on current safety issues, you willreceive every support with your safetyrequirements.

March 2004

All rights to this publication are reserved byPilz GmbH & Co. We reserve the right toamend specifications without prior notice.Copies may be made for the user’s internalpurposes. The names of products, goods andtechnologies used in this manual aretrademarks of the respective companies.

Innovations

As leaders in innovation, we continuallymonitor, expand and improve our completerange of products and services, inconsultation with our customers.

Overall solutions

We tailor our range of products and servicesto meet our customers’ requirements. Aswell as individual components, Pilz can alsosupply overall, individual and open systems,concepts and solutions.

Products for your safety

Pilz is one of the key manufacturers in theareas of control and monitoring technology,controlling and signalling, sensortechnology, safe control technology,operating and monitoring and operatorterminals. Thanks to our comprehensiveproduct range we can supply both singleproducts and individual overall solutions –always made to measure for your particularapplication requirement.

You can find more details about Pilz and ourproducts and services on the Internet:

www.pilz.com

Introduction

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Exclusion of liability

Our technical catalogue for the PNOZmultihas been compiled with great care. Itcontains information about our companyand our PNOZmulti products. All statementsare made in accordance with the currentstatus of technology and to the best of ourknowledge and belief. However, we cannotexcept liability for the accuracy and entiretyof the information provided, except in thecase of gross negligence. In particular itshould be noted that statements do nothave the legal quality of assurances orassured properties. We are grateful for anyfeedback on the contents of this manual.

Contents

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Safe Automation from PilzIntroduction

1

2

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

2.11

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PNOZmulti Product RangeIntroduction

Overview

Safety

Description

Installation

Commissioning

Configuration and Wiring

Operation and Fault Diagnostics

Technical Details

Unit-specific Descriptions

Applications

ServicePre-sales/after sales

Order ReferencePNOZmulti product range

Safe Automation

Pilz GmbH & Co. KG, Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected] Status 07/031-1

1Contents Page

IntroductionMachinery directive 1-2Risk analysis 1-3Risk assessment and graph 1-6Categories 1-7

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Extract from:Machine safety – On the basis of theEuropean safety standards/Winfried Gräf

1. Machinery directive

This chapter is intended to shed light on thetechnical regulations included in themachinery directive and the correspondingEuropean (EN) standards, designed to turnthe European single market into a reality.According to the German safety equipment act(GSG), the introduction of the single Europeaninternal market on 1.1.93 meant thatnational standards and regulations of EUmember states had to be harmonised. Onaccount of the 9th ordinance of the GSGV,BGB1 Part I 5/93, all member states of theEuropean Economic Area (EEA) are to acceptthe machinery directive as an internal marketdirective and adopt it, unamended, into theirdomestic law, so that plant and machineryregulations within the EEA can be unified.This means that a German DIN, an EnglishBS or a French NF standard etc. isharmonised and converted into an ENstandard, to be valid throughout Europe bylaw. As this can be a very prolonged process,draft copies of the standards are madeavailable as prEN standards before they areratified. Where no EN or prEN standard is available,previous requirements for the design ofmachinery can be used for a transitionalperiod.The European standards for the machinerydirective are subdivided into a hierarchy ofA, B and C standards.

A standards:Basic standards containing essentialinformation on the design, strategy andoperation of the European machinerydirective standardisation.

B standards:Group standards, subdivided into B1 and B2standards. B1 standards detail theoverriding safety aspects while B2 standardscover the actual safety devices.

C standards:Product standards containing detailedrequirements for specific machinery, withreference to the B standards.

Two institutions are responsible for draftingthese standards, namely CEN for non-electrical standards and CENELEC forelectrical standards.

Type A– EN 292 Parts 1 and 2

General principles for design– EN 414

Rules for the drafting and presentationof safety standards

– EN 1050Safety of machinery,Risk assessment

Type B1– EN 294

Safety distances to preventdanger zones being reached

– EN 349Minimum gaps to avoid crushingof parts of the body

– EN 954-1Safety-related parts ofcontrol systemsGeneral principles for design

– prEN 954-2Test, error lists

– EN 1037Prevention of unexpected start-up

Type B2– EN 574

Two-hand control devices– EN 418

E-STOP equipment (e.g. mushroom-headed stop buttons)

– EN 953Design of fixed and movableguards

– EN 1088Interlocking devices

– EN 60204Electrical equipment of machines

– EN 61496Electrosensitive protective equipment

Safe Automation

Pilz GmbH & Co. KG, Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected] Status 07/03

IntroductionMachinery directive

1-2

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Type C– EN 201

Injection moulding machines– EN 422

Blow moulding machines– EN 415

Packaging machines– EN 692

Mechanical presses– EN 693

Hydraulic presses– EN 775

Industrial robots

1.1 CE marking of machinery

According to EU directive 89/392/EEC,since 01.01.1995 it has been necessary toapply a CE mark not only on “completemachines” but also on “machines operatingnon-independently” and “interchangeableequipment”. Since 01.01.1997, “individualsafety components” have also required CEmarking. This EU directive is binding for thewhole internal market, i.e. includingmachinery that does not cross anyinternational border. Even machinery madefor a company’s own use must carry the CEmark.

1.1.1 Recommended procedure

The following procedure is recommendedfor the approval of machinery within theEEA:

1. Check that the machine falls within thescope of the machinery directive

2. Check whether any additional directivesthat provide for CE marking need tobe considered for this product; in thiscase you will need to check conformityto all the directives used

3. Classify the products under the termsof the machinery directive (machine,components, ...)

4. Check whether it is a “dangerousmachine” as detailed in Annex IV; inthis case you will need to contact anaccredited body

5. Check which standards can be used toachieve the safety objectives

6. Carry out a hazard analysis7. Generate the “Technical Documentation”8. Design and build the machine in

accordance with the hazard analysisand the “Technical Documentation”

9. Generate the declaration of conformity(Annex II A)

10. Affix the CE mark

1.1.2 Responsibility

The machinery directive is geared towardsthe machine manufacturer. Everyoneinvolved in the design of the machine istherefore responsible for its safety. Forsafety, the hazard analysis represents animportant link between the technologies andit should be carried out at or before themachine’s design stage, in accordance withthe directive.The directive states: “The manufacturer isobliged to carry out a hazard analysis inorder to determine all the hazards associatedwith the machine; the machine must then bedesigned and built in accordance with thatanalysis.”It is advisable and economical, therefore, forall designers to be informed about therequirements of the machinery directive.

2. Risk analysis

Designers should carry out a risk analysis inorder to judge the regulations that need tobe taken into account, and to what extent.Standard EN 292: “Safety of machinery.General principles for design”, EN 1050:“Principles for risk assessment” and EN954-1: “Safety-related parts of controlsystems” should be used for this purpose.

2.1 Risk limit

EN 1050, 11/96The standard starts from the assumptionthat every machine constitutes a risk, that isto say, its risk without measurement andcontrol safety measures. This risk isdetermined by assessing the machine beforeany safety components are employed. If thelevel of the risk is above the justifiable risklimit, measures must be taken to reduce therisk. These are the “measurement andcontrol safety measures”; these should beused to reduce the actual residual risk tobelow the level of the justifiable risk limit.

Risk limitThis is the highest justifiable riskassociated with a specific technicalprocess or condition. In general, therisk limit cannot be quantified. It isnormally defined indirectly on the basisof established technical principles.HazardThis is the condition in which the risk isgreater than the risk limit.SafetyThis is the condition in which the risk isless than the risk limitResidual riskThis is the risk that remains after all therisk reduction measures have been takenRisk without safety measuresThis is the risk involved when no riskreduction measures are taken on amachine.

Safe Automation


IntroductionRisk analysis

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2.1.1 Risk assessment

Extracts from EN 1050, 11/96The risk assessment of plant or machinerymust include:

The hazard, hazardous situation andevents that could cause harmThe foreseeable probability and severityof harmThe complexity of the machine withregard to safety and

The complexity of the interactionbetween man and machine during alloperations, including foreseeablemisuse.

2.1.2 Basic concept

EN 1050, 11/96 Section 4.1Risk assessment is a series of logical stepsto enable the hazards associated withmachinery to be examined in a systematicway. Depending on the result, the risk

assessment is followed by risk reduction inaccordance with EN 292. Repeating thisassessment results in an interactive processwhich is used to eliminate the hazard as faras possible and to implement safetymeasures.

The risk assessment includes:A risk analysis containing:a) determination of the machine’s design

(effective) limits (see EN 1050);b) hazard identification;c) risk estimation;Risk evaluation.

2.1.3 Information on risk assessment

EN 1050, 11/96 Section 4.2The information for risk assessment and anyqualitative and quantitative analysis shallinclude the following:

The machine’s design (effective) limitsSafety requirements for the individual lifephases of the machineryDesign drawings and other means ofestablishing the nature of the machineryType of energy supplyAny accident and incident history(if available)Information about potential damage tohealth which can be attributed tooperation of the machinery

Safe Automation



1-4

This information shall be updated as thedesign develops and when modifications arerequired.

The absence of an accident history, a smallnumber of accidents or low severity ofaccidents shall not be taken as anautomatic presumption of a low risk.

Point 2.1.4 not shown.

2.1.5 Combination of elements of risk

EN 1050, 11/96 Section 7.2.1The risk associated with a particularsituation or technical process is derivedfrom a combination of the followingelements:

Severity of harmProbability of occurrence of that harm,which is a function of:– the frequency and duration of the

exposure of persons to the hazard– the probability of occurrence of a

hazardous event and the technical andhuman possibilities to avoid or limitthe harm

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1

2.1.6 Elements of risk

Riskrelated to the considered

hazard

is a function of

Severityof the possible harm forthe considered hazard

and

Probability ofoccurrence of that harm in

consideration of the

frequency and duration ofexposure to the hazard

Possibility to avoid or limit the harm

Probability of occurrence of ahazardous event

Several methods have been developed forthe systematic analysis of these elements ofrisk.See EN 1050, 11/96 Annex B.

2.2 Harm

2.2.1 Severity

EN 1050, 11/96 Section 7.2.2The degree of possible harm can beestimated by taking into account thefollowing criteria:

The nature of what is to be protected:a) personsb) propertyc) environmentThe severity of injuries or damage tohealth:a) slight, normally reversibleb) serious, normally irreversiblec) deathThe extent of harm, for each machine:a) one person affectedb) several persons affected

2.2.2 Probability of occurrenceof harm

EN 1050, 11/96 Section 7.2.3The probability of harm occurring is the keyfactor. Experience shows that everyconceivable unpleasant event can occur inreality. This rather general statement couldbe viewed as an exaggeration when referringto the design of a plant or machine. This iswhy the standard allows the frequency andduration of exposure to the hazard and thepossibility of avoiding it to be included inthe assessment. In certain circumstancesthis can result in optimum protection forpersonnel together with a reduction in costs.

2.2.3 Frequency and durationof exposure

EN 1050, 11/96 Section 7.2.3.1Depending on the need to access the dangerzone:

The nature of access,The time spent in the danger zone andThe number of people requiring access

must be assessed because they couldincrease the probability of an accident.

2.2.4 Probability of occurrenceof a hazardous event

EN 1050, 11/96 Section 7.2.3.2According to the standard, the probability ofoccurrence of a hazardous event can bederived from:

The reliability of the technology usedOther statistical dataAccident history (if available)History of damage to health from similarplant or machineryRisk comparison (see EN 1050, 11/96)

Note: The occurrence of a hazardous eventcan be of technical or human origin.

2.3 Harm to people

2.3.1 Persons exposed

EN 1050, 11/96 Section 7.3.1Risk estimation shall take into account allpersons exposed to the hazards (seeEN 292-1 Section 3.21).

2.3.2 Type, frequency and duration ofexposure

EN 1050, 11/96 Section 7.3.2The estimation of the exposure to the hazardrequires analysis of and shall account for allmodes of operation of the machinery. Inparticular this affects the need for accessduring setting, teaching, processchangeover or correction, cleaning, faultfinding and maintenance (see EN 292-1,section 3.11).

Safe Automation



1-5

1

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Safe Automation


IntroductionRisk assessment and graph

1-6

3. Risk assessment

EN 954 -1, prEN 954 -2The European standards EN 954 -1,prEN 954 -2 define categories andrequirements and describe characteristics ofsafety functions and design principles forsafety-related parts of control systems.This includes programmable systems for alltypes of machinery and related protectivedevices. They apply to all safety-related partsof control systems, regardless of the type ofenergy used, (e.g. electrical, hydraulic,pneumatic, mechanical). However, they donot specify which safety functions andwhich categories shall be used in a particularcase.EN 954-1 and prEN 954-2 contain details ofsafety requirements and orientation aids forthe design, construction, programming,operation, maintenance and repair of safety-related parts of control systems formachinery.They also apply to all machinery applicationsfor professional and non-professional use.Where appropriate, they can also apply tothe safety-related parts of control systemsused in other technical applications withsimilar hazards.The categories used in the standards aredesigned to allow for component faults andto accept fault exclusion. (Fault exclusionmeans that a fault can be excluded if thechances of it arising or occurring areimprobable.) In order to have objective andverifiable criteria, EN 954 publishes lists ofpotential component faults which need to be

taken into account when evaluating safety-related parts of control systems. These listsof faults do not claim to be exhaustive and,if necessary, additional faults should also beconsidered.

In general, the following observations onfaults should be borne in mind:

Two independent, random faults shallnot occur simultaneouslyShould a fault cause other componentsto fail, the first fault and all consequentfaults shall be viewed as a single faultSystematic multiple faults shall beviewed as single faults

The following faults should be consideredon electrical/electronic components:

Short circuit or open circuit, e.g. shortcircuit to the protective conductor or toany bare conductive part, open circuit ofany conductorShort circuit or open circuit in singlecomponents, e.g. position switchesNon drop-out or non pick-up ofelectromagnetic components, e.g.contactors, relays, solenoid valvesNon-starting or non-stopping of motorsMechanical blocking of movingelements,e.g. position switchesDrift beyond the tolerance values foranalogue components, e.g. resistors,capacitorsOscillation of unstable output signals inintegrated, non-programmablecomponents

Loss of entire function or partialfunctions in the case of programmablecomponents (worst case behaviour)

Note from the standards committee:

The categories are not intended to be usedin any given order or in any given hierarchyin respect of safety requirements.

The risk assessment will indicate whether thetotal or partial loss of the safety function(s)arising from faults is acceptable. It is clear,therefore, that discussions over whetherproduct XY should be category 2, 3 or 4goes against the intentions of the standardscommittee and is not in the spirit of thestandard. Most machines have a front and aback. The dangerous side is the front,because it is generally from there that themachine is assembled and operated. Theback of the machine is less dangerousbecause it can usually be encased by metalplates and guard rails.

3.1 Risk graph

EN 954 -1, Annex B 12/96This risk evaluation must be carried outseparately for each application.The graphic below may be helpful.

Starting point for risk estimation for thesafety-related part of the control system

S Severity of injuryS1 Slight (normally)

reversible) injuryS2 Serious (normally

irreversible) injury,including death.

F- Frequency and/or exposuretime to the hazardF1 Seldom to quite often and/or

the exposure time is shortF2 Frequent to continuous and/or

the exposure time is long

1

1

� ��

� � � ��

��

��

��

��

��

��

�

�

��

��

� ��

��

��

��

��

�

Safe Automation


IntroductionCategories

1-7

P- Possibility of avoidingthe hazard(generally related to the speed andfrequency with which the hazardous partmoves and to the distance from thehazardous part)P1 Possible under specific conditionsP2 Scarcely possible

B, 1-4 Categories for safety-related partsof control systems

Preferred category for reference pointsPossible categories which can requireadditional measuresMeasures which can be overdimensioned for the relevant risk

The risk is a statement of probability thattakes into account the anticipated frequencyof a hazard occurring and the consequentseverity of injury. Appropriate measuresshould be used to reduce the anticipated riskto the level of safety required for theapplication.

3.2 Overview of categories

The main point of this summary is to classifythe safety requirements of control systemsinto five sensible categories, irrespective of thetechnology. These range from simple tocomplex requirements, such as single faulttolerance, redundancy, diversity and/or self-monitoring.

System behaviour

The occurrence of a fault can lead to theloss of the safety function

As for category B, but with greater safety-related reliability of the safety functions.

The occurrence of a fault can leadto the loss of the safety function betweenthe checks.The loss of the safety function is detectedby the check.

When the single fault occurs, the safetyfunction is always performed. Some but notall faults will be detected.Accumulation of undetected faultscan lead to the loss of the safety function.

When the faults occur the safety function isalways performed.The faults will be detected in timeto prevent the loss of the safety function.

Summary of requirements

Safety-related parts of control systems and/or their protectiveequipment, as well as their components, shall be designed,constructed, selected, assembled and combined in accordance withrelevant standards, so that they can withstand the expectedinfluence.

Requirements of B shall apply.Use of well-tried components and well-tried safety principles.

Requirements of B and the use of well-tried safety principles shallapply.Safety function shall be checked at suitable intervals by the machinecontrol system.

Requirements of B and the use of well-tried safety principles shallapply. Safety-related parts shall be designed so that:– a single fault in any of these parts does not lead to a loss of the

safety function; and– whenever reasonably practicable, the single fault is detected.

Requirements of B and the use of well-tried safety principles shallapply. Safety-related parts shall be designed so that:– a single fault in the control system does not lead to a loss of the

safety function; and– the single fault is detected at or before the next demand upon the

safety function. If this is not possible, then an accumulation of faultsshall not lead to a loss of the safety function.

Principles toachieve safety

Mainlycharacterised byselection ofcomponents.

Mainlycharacterised bystructure.

Mainlycharacterised bystructure.

Cat.

B

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2

3

4

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Pilz GmbH & Co. KG, Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected]

1

1

PNOZmulti Product Range

2-1Pilz 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] Status 03/04

2

2

Contents Page

PNOZmulti product rangeIntroduction 2.1-1

Definition of symbols 2.1-1Overview 2.2-1Safety 2.3-1

Safety assessments 2.3-1General safety requirements 2.3-1Intended use 2.3-1

Description 2.4-1Safety features 2.4-1Hardware 2.4-1

Design of the modular safety system 2.4-1Operation of the units 2.4-1RS 232 interface 2.4-1Safety functions 2.4-1Operating modes 2.4-1

Software 2.4-2Installation 2.5-1Commissioning 2.6-1

Requirements 2.6-1Input devices 2.6-1ESPE 2.6-1Initial commissioning 2.6-1Recommissioning after modifications 2.6-1

Configuration and Wiring 2.7-1Function elements 2.7-1Select switch types 2.7-1Connection assignment 2.7-4Reset modes 2.7-4Automatic reset 2.7-4Manual reset 2.7-4Monitored reset 2.7-4


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Contents Page

PNOZmulti product rangeReset element 2.7-4Test pulses and detection of shorts across contacts 2.7-4Start-up test 2.7-4Output elements 2.7-5Relay 2.7-5Semiconductor 2.7-5Feedback loop 2.7-5Cascading 2.7-6

Series connection 2.7-6Tree structure 2.7-8Installing the networked units 2.7-9Wiring 2.7-9

Operation and Fault Diagnostics 2.8-1Errors 2.8-1

Technical Details 2.9-1Approvals 2.9-3

Unit-specific Descriptions 2.10-1Units from the PNOZmulti modular safety system 2.10-1PNOZmulti coated version 2.10-1Base unit PNOZ m1p 2.10-2

Intended use 2.10-2Description 2.10-2Terminal configuration 2.10-2Wiring 2.10-2Inputs 2.10-2Outputs 2.10-2Dimensions 2.10-3Input circuit 2.10-3Reset circuit 2.10-4Outputs 2.10-4Feedback loop 2.10-5



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2

Contents Page

PNOZmulti product rangePNOZ mo1p expansion module 2.10-6

Intended use 2.10-6Description 2.10-6Terminal configuration 2.10-6Wiring 2.10-6Dimensions 2.10-6Supply voltage for outputs 2.10-7Outputs 2.10-7Feedback loop 2.10-7

PNOZ mo2p expansion module 2.10-8Intended use 2.10-8Description 2.10-8Terminal configuration 2.10-8Wiring 2.10-8Dimensions 2.10-8Outputs 2.10-9Feedback loop 2.10-9

PNOZ mi1p expansion module 2.10-10Intended use 2.10-10Description 2.10-10Terminal configuration 2.10-10Wiring 2.10-10Dimensions 2.10-10Input circuit 2.10-11

PNOZ mc1p expansion module 2.10-12Intended use 2.10-12Description 2.10-12Terminal configuration 2.10-12Wiring 2.10-12Dimensions 2.10-12Supply voltage for auxiliary outputs 2.10-13Auxiliary outputs 2.10-13


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Contents Page

PNOZmulti product rangePNOZ mo4p expansion module 2.10-14

Intended use 2.10-14Description 2.10-14Terminal configuration 2.10-14Wiring 2.10-14Dimensions 2.10-14Outputs 2.10-15Feedback loop 2.10-15

PNOZ ms1p expansion module 2.10-16Intended use 2.10-16Description 2.10-16Terminal configuration 2.10-16Wiring 2.10-17Dimensions 2.10-17Adapter for incremental encoder 2.10-20

PNOZ mc3p expansion module 2.10-23Intended use 2.10-23Description 2.10-23Terminal configuration 2.10-23Wiring 2.10-24Dimensions 2.10-24PNOZ mc3p technical details 2.10-24Setting the station address 2.10-25

PNOZ mc4p expansion module 2.10-26Intended use 2.10-26Description 2.10-26Terminal configuration 2.10-26Wiring 2.10-27Dimensions 2.10-27PNOZ mc4p technical details 2.10-27Setting the station address 2.10-28Setting the transmission rate 2.10-28



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Contents Page

PNOZmulti product rangePNOZ mc5p expansion module 2.10-29

Intended use 2.10-29Description 2.10-29Terminal configuration 2.10-29Wiring 2.10-30Dimensions 2.10-30PNOZ mc5p technical details 2.10-30Setting the transmission rate 2.10-31

PNOZ mc6p expansion module 2.10-32Intended use 2.10-32Description 2.10-32Terminal configuration 2.10-32Wiring 2.10-33Dimensions 2.10-33PNOZ mc6p technical details 2.10-33Setting the station address 2.10-34Setting the transmission rate 2.10-34

Communication with fieldbus systems 2.10-36Table assignment 2.10-40

Applications 2.11-1Safety 2.11-1Base unit configuration 2.11-3Using connection points 2.11-5E-STOP and light guard, Category 4, EN 954-1 2.11-13Two-hand with override, Category 4, EN 954-1 2.11-19Muting, Category 4, EN 954-1 2.11-26Star-delta start-up, Category B, EN 954-1 2.11-35Motor ON/OFF, Category B, EN 954-1 2.11-39


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2

Introduction

PNOZmulti product range

2.1-1Pilz GmbH & Co. KG, Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected] Status 11/03

2 2.1

This system manual describes the PNOZmConfig software and the units:• PNOZ m1p• PNOZ mi1p• PNOZ mo1p• PNOZ mo2p• PNOZ mo4p• PNOZ mc1p• PNOZ ms1p• PNOZ mc3p• PNOZ mc4p• PNOZ mc5p• PNOZ mc6pfrom the PNOZmulti modular safety system.

The first part of the manual containsinformation relating to the whole safetysystem. This is followed by descriptions ofthe specific units. The last chapter containsvarious application examples.

The manual is divided into the followingchapters:1 IntroductionThe introduction is designed to familiariseyou with the contents, structure and specificorder of this manual.2 OverviewThis chapter provides information on themost important features of the safetysystem and provides a brief overview of theapplication range.3 SafetyThis chapter must be read as it containsimportant information on safety regulations.4 DescriptionThe description contains information on the

units’ functionality and the PNOZm Configsoftware.5 Installing the unitsThis chapter describes how to install theunits.6 CommissioningThis chapter contains important guidanceon wiring the units.7 Configuration and WiringThis chapter describes the configurationand wiring options for the inputs andoutputs, the reset modes and wiring withdetection of shorts across contacts.8 Operation and Fault DiagnosticsThis chapter describes how the units reactduring operation and how faults aredisplayed.9 Technical details of the PNOZmultisafety systemThis chapter contains the technical detailsrelevant for all units in the PNOZmulti safetysystem.10 Unit-specific DescriptionsThese descriptions refer exclusively to thespecific features for the unit, such asintended use, description, parametersettings and wiring of individual units.11 ApplicationsThis chapter is a collection of applicationexamples.

Definition of symbols

Information in this manual that is ofparticular importance can be identified asfollows:

DANGER!This warning must be heeded! Itwarns of a hazardous situation thatposes an immediate threat ofserious injury and death, andindicates preventive measures thatcan be taken.

WARNING!This warning must be heeded! Itwarns of a hazardous situation thatcould lead to serious injury anddeath and indicates preventivemeasures that can be taken.

CAUTION!This refers to a hazard that can leadto a less serious or minor injury plusmaterial damage, and also providesinformation on preventive measuresthat can be taken.

NOTICEThis describes a situation in whichthe unit(s) could be damaged andalso provides information onpreventive measures that can betaken.

INFORMATIONThis gives advice on applicationsand provides information on specialfeatures, as well as highlighting areaswithin the text that are of particularimportance.


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2.1

Overview

PNOZmulti modular safety system


2

2.2

The modular safety system consists of abase unit and several expansion modules.The base unit provides several inputs andoutputs and is fully functional even withoutan expansion module. The expansionmodules supplement the base unit withadditional inputs or outputs.

Whereas the function of the PNOZ units isdetermined through the unit itself, thefunction of this safety system is definedthrough the configurator PNOZm Config.PNOZm Config is a graphic tool, which isused to define the functions of the units.Using predefined symbols, a simple circuitdiagram shows how the units’ inputs andoutputs should be connected. This circuitdiagram is then downloaded to the baseunit. From this data, the base unitrecognises the safety functions it is toperform. For example, safety functionssuch as E-STOP, two-hand monitoring andsafety gate monitoring are available. Withthe correct circuitry it is possible to achievecategories 2, 3 and 4 in accordance with EN954-1.

The fact that the system is modular andconfigurable guarantees the highest level offlexibility. The safety system can beexpanded or the safety functions modifiedat any time.

Fig. 2-1: Modular safety system

Units in the PNOZmulti modular safetysystem provide both semiconductor andrelay safety outputs. The auxiliary outputsuse semiconductor technology. The safetyoutputs use semiconductor technology,require no maintenance and are non-wearing; they are therefore suitable forapplications with frequent operations orcyclical functions. They can be used for 24VDC applications.The relay safety outputs are suitable for lessfrequent operations, but they have a higherbreaking capacity and can be used for ACapplications.

Base unit + expansion modules


2 2.2

2.2-2

Safety


3-2.3-1Pilz GmbH & Co. KG, Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected] Status 03/04

2

2.3

Safety assessments

Before using a unit it is necessary toperform a safety assessment in accordancewith the Machinery Directive. The safetysystem guarantees functional safety, but notthe safety of the entire application. Youshould therefore define the safetyrequirements for the plant as a whole, andalso define how these will be implementedfrom a technical and organisationalstandpoint.

General safety requirements

Always ensure the following safetyrequirements are met:• Only install and commission the unit if

you are familiar with the information inthe operating instructions or thistechnical catalogue, as well as therelevant regulations concerning healthand safety at work and accidentprevention.

• Only use the unit for the purpose forwhich it is intended and comply with boththe general and specific technical details.

• Transport, storage and operatingconditions should all conform to EN60068-2-6, 01/00 (see general technicaldetails).

• Adequate protection must be providedfor all inductive loads.

• Do not open the housing or undertakeany unauthorised modifications.

You must observe the warning notes givenin other parts of this manual. These arehighlighted visually through the use ofsymbols.

CAUTION!Failure to keep to these safetyregulations will render the warrantyinvalid.

Intended use

The PNOZm Config software is designed toconfigure units from the PNOZmulti modularsafety system for use on E-STOP equipmentand safety circuits, in accordance withEN 60204-1 (VDE 0113-1), 11/98 and IEC60204-1, 12/97.

The units’ intended use depends on theindividual unit and is therefore explained inthe chapter entitled “Unit-specificDescriptions”.


2

2.3

Description



2

2.4

Safety features

The relay meets the following safetyrequirements:• The circuit is redundant with built-in self-

monitoring.• The safety function remains effective in

the case of a component failure.• Safety outputs that are switched on are

periodically tested via a disconnectiontest.

Hardware

Design of the modular safety systemThe modular safety system consists of thebase unit and up to 8 expansion modules.The base unit itself has 20 inputs, 2 relayoutputs and 4 semiconductor outputs. Thenumber of inputs and outputs can beincreased at any time using the expansionmodules. The modules are linked via ajumper. The system is configured using thePNOZm Config. For example, specialexpansion modules enable data exchangevia a fieldbus (non-safety-related) or safespeed monitoring (see Chapter 10).

Operation of the unitsThe configurator PNOZm Config generatesa project file which is downloaded to thePNOZ m1p base unit; there it defines:

• Which safety functions the inputs are tocarry out, e.g. E-STOP monitoring, safetygate monitoring

• How the inputs are connected to theoutputs via logic functions

• Which output is configured(semiconductor, relay)

The units react the same, irrespective ofthese functions: If the start-up condition ofthe specific safety function is met, there willbe a high signal at the output “Out1” (seeFig. 4-1). The output signal can be linked via

a logic function and is then present as the“Out2” signal at the output on thePNOZmulti unit.

RS 232 interfaceThe base unit has an RS 232 interface fordownloading the project and reading theerror stack (see operating manual for thePNOZmulti diagnostic interface).

Safety functionsThe PNOZmulti safety system can beconfigured to monitor:• E-STOP buttons• Operating mode selector switches• Enable switches• Two-hand buttons• Safety gates• Light curtains

Various switch types are available for therequired safety-related applications. Withsome switch types it is possible to monitorfor simultaneity (see Chapter 7,“Configuration and Wiring”).

Operating modesThe following operating modes areavailable, depending on the selected safetyfunction:• Single-channel operation: Input wiring

in accordance with EN 60204, no redun-dancy in the input circuit; earth faults inthe input circuit are detected

• Dual-channel operation: Redundantinput circuit; earth faults in the inputcircuit are detected, with or withoutdetection of shorts between the inputcontacts.

• Triple-channel operation: Redundantinput circuit; earth faults in the inputcircuit are detected, with or withoutdetection of shorts between the inputcontacts.

• Automatic reset: Unit is active as soonas the input circuit is closed.

• Manual reset: The unit is not active untilthe reset button has been operated.

• Monitored reset: Unit is not active untilthe reset button has been operated andthen released. This eliminates thepossibility of the reset button beingoverridden, triggering automaticactivation.

• Detection of shorts between contactsin the input circuit: Enabled by pulsingthe input circuits. This operating mode isautomatically detected on start-up.

• Detection of shorts between contactsin the reset circuit:Only on E-STOP, safety gate and lightcurtain

• Start-up test: The unit checks whethersafety gates that are closed are openedand then closed again when supplyvoltage is applied.

• Increase in the number of safetycontacts available by connecting acontact block (e.g. PZE 9P) or externalcontactors.

Fig. 4-1: Operation of the PNOZmulti units

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Description



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2.4

Software

In the configurator PNOZm Config, the firststep is to enter the units that are to be usedin the safety system. Each unit must begiven a resource label. When all the unitsare selected, the interface appears forentering the circuit diagram. The circuitdiagram describes the application for whichthe safety system is to be used. It is herethat you determine which inputs areassigned to which safety functions. Theinputs and/or the results of the safetyfunctions can be linked through logicfunctions. The results of the logic functionsor the results of the safety functions arechannelled to the outputs on the PNOZmultiunits.The circuit diagram is generated on agraphical interface. Symbols are providedfor the safety functions, logic functions andthe various output types. These are simplydragged on to a workspace, configured andinterconnected.

Once the circuit diagram is complete, thedata must be saved and downloaded to thebase unit. The circuit diagram, unitconfiguration and all the data that has beenentered are stored within a project. Whenthe project is saved, various passwords canbe used to protect it from unauthorisedaccess.

Fig. 4-2: PNOZmulti Config interface

Once it is saved, the project has to bedownloaded to the base unit. To do this, theproject data is transferred to a chip card.The data can either be downloaded via theRS 232 interface or via a chip card reader.After downloading it is necessary to checkthat the safety devices function correctly.

Installation



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2.5

Fig. 5-1: Installing the PNOZmulti units

Connecting the base unit and expansionmoduleThe modules are linked via jumpers. A max.of 8 expansion modules may be connectedto one base unit.

CAUTION!Electrostatic discharge can damagecomponents on the safety system.Ensure against discharge beforetouching the device, e.g. by touchingan earthed, conductive surface or bywearing an earthed armband.

There are 2 pin connectors on the back ofthe PNOZ m1p base unit. The right-hand pinconnector contains a terminator.• Remove the terminator from the right-

hand pin connector.• Connect the base unit and the expansion

modules using the jumpers supplied (itemno. 774639).

CAUTION!The terminator must be fitted to thelast expansion module. Only useterminators for the PNOZmultimodular safety system (item no.779110).

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Installing the safety system in a controlcabinet

CAUTION!The safety system should beinstalled in a control cabinet with aprotection type of at least IP54.Fit the safety system to a horizontalDIN rail. Other mounting positionscould damage the safety system.

• Use the notches on the back of the safetysystem to attach it to a DIN rail. Connectthe safety system to the DIN rail in anupright position, so that the earthingsprings on the safety system are pressedon to the DIN rail.

• To comply with EMC requirements, theDIN rail must have a conductiveconnection to the control cabinethousing.


2

2.5

Commissioning



2

2.6

Requirements

Please note the following when preparing tocommission the unit:• The safety system and input circuits must

always be supplied by a single powersupply. The power supply must meet theregulations for extra low voltages withsafe separation (SELV, PELV).

• The plug-in terminals for the inputs andoutputs are not supplied with the system.You can select between a cage clampconnection or a screw connection.

• Use copper wire that will withstandtemperatures of 60/75°C.

• Torque setting on the connectionterminals (M3 slotted-head screws), seetechnical details.

• Test pulse wires should not not not not not be laidtogether with actuator wires withinunprotected multicore cable.

• Test pulse outputs must only be used totest the inputs. It is not permitted not permitted not permitted not permitted not permitted to usethem to drive loads.

• Only safety outputs should be used forsafety-related applications.

• The auxiliary outputs can be used forcommunication with a PLC or textdisplay, for example. Appropriatemeasures should be taken to protect theauxiliary outputs on the PNOZmulti unitswhen driving contactors or relays.

• Only contactors with positive-guidedcontacts should be used on thePNOZmulti’s safety outputs (see“Feedback loop” in Chapter 7).

Input devices

When selecting input devices, you mustcomply with the technical details of theinput circuits on the PNOZmulti units. Tohelp you in your selection, Pilz hasperformed application tests with a numberof input devices. The following input deviceshave passed the application test:• Light barriers:

- SICK FGS- SICK C4000- Honeywell MEYLAN- CEDES Safe 4- OMRON F3SN-A- Fiessler ULVT- STI Minisafe 4600 (from S/N:

AC283791 or BA022933)- STI Optofence OF 4600

• Limit switches:- Schmersal AZ 16-02- Guardmaster ferrocode- Euchner NP1-628AS- Euchner CES-A-C5E-01 (only when

operating without detection of shortsacross contacts)

- Euchner CES-A-C5E-01 (only with testpulse wiring)

- Euchner ENG-071990- Euchner NM11KB

The following may not be used:• Limit switches:

- Euchner CES-A-C5E-01 with pulsesignals

The following is generally valid: Inputdevices with mechanical contacts (relays)can be used in operating modes with orwithout detection of shorts across contacts,provided you comply with the technicaldetails. It is not always possible to use inputdevices with semiconductor outputs whenoperating with detection of shorts acrosscontacts.

Devices with OSSD semiconductoroutputsDevices with OSSD semiconductor outputs(e.g. self-testing light barriers) may only beused if the PNOZmulti is operated withoutdetection of shorts across contacts.

ESPEIf the function of an ESPE (e.g. light barrier)is switched off via an operating modeselector switch, the supply voltage to theESPE must be switched off at the sametime.

Initial commissioning

The units must be wired and the projectdata must be downloaded:• Connect the base unit and the expansion

modules using the jumpers.• Wire the inputs and outputs on the base

unit and expansion modules inaccordance with the circuit diagram.

• Transfer the current project on to the chipcard in the base unit. To do this, either

use the chip card reader or connect thecomputer containing PNOZmConfig tothe base unit via the serial interface (seePNOZm Config online help).

• Connect the supply voltage:- Supply voltage for the units: Connect

+24 VDC to the “A1” terminal and 0 Vto the “A2” terminal on the base unit.

- Supply voltage for the semiconductoroutputs: Connect +24 VDC to the “24V” terminal and 0 V to the “0 V”terminal on the base unit.Two terminals are available for eachsupply connection. This means thatthe supply voltage can be loopedthrough several connections betweenthe units. The current at each terminalmust not exceed 9 A.

CAUTION!After exchanging a chip card ordownloading a project, it isnecessary to check that the safetydevices function correctly.

Recommissioning after modifications

The function of the modular safety systemcan be modified or expanded at any time.For example, you can add an expansionmodule or modify a safety function. Eachtime a change is made, the project datamust be adapted accordingly. New unitsmust be entered in the configurator. The

Commissioning



2

2.6

circuit diagram must be adapted. The newproject data can then be downloaded to thebase unit.

CAUTION!After exchanging a chip card ordownloading a project, it isnecessary to check that the safetydevices function correctly.

Sequence:If the project data is being downloaded viachip card, before commissioning you willneed to make sure that the base unit on themodular safety system does not contain anyproject data. The project data must becleared:• Switch off the supply voltage.• Remove all the connections to the

terminals on the safety outputs andauxiliary outputs.

• Link terminals OA0 and I19.• Connect the supply voltage:

- Supply voltage for the units: Connect+24 VDC to the “A1” terminal and 0 Vto the “A2” terminal on the base unit.

- Supply voltage for the semiconductoroutputs: Connect +24 VDC to the“24 V” terminal and 0 V to the “0 V”terminal on the base unit.

• Wait until the “DIAG” LED flashes.

The memory of the PNOZmulti safetysystem is now clear.

The units must now be wired and the projectdata downloaded:• Switch off the supply voltage.• Remove the chip card from the chip card

slot.• Remove the link between terminals OA0

and I19.• lf you wish to supplement the system

using expansion modules:Connect the units using the jumpers.

• Wire the inputs and outputs on the baseunit and expansion modules inaccordance with the circuit diagram.

• Slide the chip card containing the currentproject into the card slot or insert thechip card and download the project viathe RS 232 interface (see PNOZm Config.online help).

• Connect the supply voltage:- Supply voltage for the units: Connect

+24 VDC to the “A1” terminal and 0 Vto the “A2” terminal on the base unit.

- Supply voltage for the semiconductoroutputs: Connect +24 VDC to the“24 V” terminal and 0 V to the “0 V”terminal on the base unit.




2

2.7

Function elements

The inputs on the PNOZmulti units areconfigured in the PNOZmulti Configurator.You can define the following:• Switch types for various safety functions• Connection assignment• Detection of shorts between contacts in

the input circuit• Reset modes• Start-up test• Detection of shorts between contacts in

the reset circuit with test pulseassignment

Some configuration options can only beselected for particular safety functions (e.g.the start-up test can only be selected for thesafety gate and light curtain safetyfunctions).

Select switch typeThe PNOZmulti Configurator provides theuser with various switch types for safety-related applications. The switch types thatcan be selected will depend on the type ofinput element (e.g. E-STOP, safety gate).The switches drawn below are shown in aninactivated state, e.g. with the safety gateclosed or E-STOP not operated.On switches that are monitored forsimultaneity, the values for maximum on-time and maximum off-time will be thesame. These values can be found in the“Description” and “Timing diagram”columns.

Switch type1

2

2 - Simultaneity

3

3 - Simultaneity

DescriptionSafety contacts:1 normally closed (N/C)without switch on/offtime

Safety contacts:1 normally closed (N/C)1 normally open (N/O)without switch on/offtime

Safety contacts:1 normally closed (N/C),1 normally open (N/O)with switch on/off time3 s

Safety contacts2 normally closed (N/C)without switch on/offtime

Safety contacts2 normally closed (N/C)with switch on/off time3 s

Switch symbol Timing diagramApplicationE-STOPEnable switch

Safety gate

Safety gate

E-STOPSafety gateLight curtainEnable switch

E-STOPSafety gateLight curtainEnable switch

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2.7


Switch type4

4 - Simultaneity

5

5 - Simultaneity

DescriptionSafety contacts:2 normally closed (N/C),1 normally open (N/O)without switch on/offtime

Safety contacts:2 normally closed (N/C),1 normally open (N/O)with switch on/off time3 s

Safety contacts:3 normally closed (N/C)without switch on/offtime

Safety contacts:3 normally closed (N/C)with switch on/off time3 s

Switch symbol Timing diagramApplicationSafety gate

Safety gate

Safety gate

Safety gate

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2.7

Switch type6

7

9

10

11

12

DescriptionSafety contacts:2 changeover contacts(C/O)with simultaneitymonitoring 0.5 s, off-timenot monitored

Safety contacts:2 normally open (N/O)with simultaneitymonitoring 0.5 s, off-timenot monitored

Safety contacts:Switch 1 from 2




Switch symbol Timing diagramApplicationTwo-hand button

Two-hand button➀

Operating mode

Operating mode

Operating mode

Operating mode

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➀ Without test pulses: can only be used up to category 1 in accordance with EN 954-1



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2.7


Connection assignmentInputs on the PNOZmulti units are assignedto particular safety functions (e.g. E-STOP,safety gate) in the PNOZm Config. Thesafety contacts must be connected to theinputs on the PNOZmulti units inaccordance with their configuration.

Reset modesA reset button triggers an enable for a safetydevice when all the corresponding safetyswitches (e.g. E-STOP) are closed. Thisprevents a machine starting upautomatically after the supply has beeninterrupted or after a safety device hasclosed, for example.

When configuring inputs for E-STOPs,safety gates or light guards in the PNOZmConfigurator, it is possible to define thereset mode:• Automatic reset• Manual reset• Monitored reset

Automatic resetWith an automatic reset, the output on thefunction element goes to “1” when thesafety switches on the input circuit areclosed.

Manual resetA N/O contact on the reset input generatesthe reset signal. The reset button must be

operated after the safety switch has closed.The output on the function element is set to“1” when the reset button is operated (seeFig. 7-1).

Fig. 7.2: Timing diagram: monitored reset

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Monitored resetA N/O contact on the reset input generatesthe reset signal. The reset button must beoperated after the safety switch has closed.The output on the function element is set to“1” when the reset button is released (seeFig. 7-1).

Reset elementThe reset element in the PNOZmConfigurator can be used to configure areset button at logic level.You can select between a monitored and anon-monitored (manual) reset. The timingdiagram in Fig. 7-1 is valid for the manualreset, the timing diagram in Fig. 7-2 for themonitored reset.

Test pulses and detection of shortsacross contacts• Under certain circumstances, signal

inputs with infrequent operation (constantsignals) supply an unchanging signal overa long period of time. During this time,the function of the periphery devices canonly be monitored to a limited extent.Faults that arise may remain undetected.Signal inputs with infrequent operationmust therefore be checked via testpulses from category 2 onwards, inaccordance with EN 954-1.

• Test pulses are assigned to inputs in thePNOZm Configurator. If “Detection ofshorts between contacts in the inputcircuit” has been selected, the base unitprovides 4 test pulses.

• Two-hand button: Switch type 6 containsa N/C / N/O combination per two-handbutton.If switch type 7 is used, the two N/Ocontacts should use different test pulses.During configuration please refer toclause 4 of EN 574.

• Detection of shorts between contacts in

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Fig. 7.1: Timing diagram: manual reset

the reset circuit: Monitored reset modewill detect a short across the contacts.For wiring reasons the reset circuit mayalso use test pulses.

CAUTION!Test pulse outputs must only be usedto test the inputs. It is not permitted not permitted not permitted not permitted not permittedto use them to drive loads.

Start-up testA start-up test is available for the safetygate and light curtain safety functions.When supply voltage is removed and thenre-applied, the safety gate is enabled(output on the safety gate input element =“1”) only after the gate has been openedand then closed. In this way you are forcedto check the correct function of the safetygate and safety gate switch.

INFORMATIONThe PNOZmulti switches to a STOPcondition after an error. The PNOZmultiswitches back to a RUN conditionwhen the supply voltages are switchedon and off. For this reason the start-uptest must be carried out again aftereach STOP.




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2.7

Output elements

The outputs on the PNOZmulti units areconfigured in the PNOZmulti Configurator.You can define the following:• Relay• Semiconductor• Single-channel or redundant• Feedback loop

INFORMATIONWhen establishing the reaction timeof the safety device, the switch-offdelay on the outputs must be takeninto account (see Technical details).The switch-off delay indicates thetime between the safety function onthe input of the PNOZmulti unitbeing triggered and the outputcontacts switching over / thesemiconductor outputs carrying alow signal.

RelaysThe relay contacts meet the requirementsfor safe separation through increasedinsulation compared with all other circuits inthe safety system.Single-channel or redundant relay outputsare available. The redundant outputs aresuitable for applications with a higher levelof safety (for wiring options please see thechapter entitled “Unit-specificDescriptions”).

NOTICELoads should be driven through 2separate channels or, in the case ofredundant relay outputs, shortsacross contacts should beprevented e.g. by installing thesafety system and its loads(contactors) in a control cabinet.In terms of load on the relays, keepto the max. permitted operationsstated in the technical details.

SemiconductorsSingle-channel or redundant semiconductoroutputs are available. The redundantoutputs are suitable for applications with ahigher level of safety (for wiring optionsplease see the chapter entitled “Unit-specific Descriptions”).

Feedback loopThe feedback loop is used to monitor theactuators that are being driven.On a feedback loop, positive-guided N/Ccontacts on the driven contactors(actuators) are connected in series. If24 VDC are present at the input on thefeedback loop, all the connected contactorsare de-energised. If the N/O contact on acontactor has welded, the feedback loop isnot closed. The safety output will not beswitched if the feedback loop is interrupted.



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2.7


Cascading

Base units on the modular safety systemcan be networked. The cascading output onone base unit is connected to the cascadinginput on another base unit. In this way, onebase unit can have direct access to a logicoutput and/or an input on the connectedbase unit.The base units can be connected in seriesor a tree structure can be built.

CAUTION!A ring-shaped connection is notpermitted.

PNOZelog units may also be included in thenetwork.

CAUTION!The cascading outputs may not beused to drive loads. The same alsoapplies to outputs on PNOZelogunits that are connected tocascading inputs on PNOZmultiunits.If necessary, a reset lock must beprovided on each cascaded unit.

System requirements:PNOZmulti Configurator: from Version 3.0.0Please contact Pilz if you have an olderversion.

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Series connectionAs many PNOZ m1p base units asnecessary may be connected in series. Thenumber of units connected in successionwill depend only on the reaction timerequired by the application. As the delaytimes on the individual units are addedtogether, the reaction time increases witheach unit.

Example:Delay between input I0 - cascading outputUnit 1: 40 msDelay between input I0 - cascading outputUnit 2: 40 + 40 msDelay between input I0 - semiconductor o/pUnit 3: 40 + 40 + 40 msDelay between input I0 - relay outputUnit 4: 40 + 40 + 40 + 60 ms

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Delay time on the PNOZmultiBetween input and cascading outputBetween cascading input and a semiconductoroutputBetween cascading input and a relay output

Between cascading input and a cascadingoutput

Switch-off delaymax. 40 ms

max. 40 ms

max. 60 ms

max. 40 ms

Switch-on delaytyp. 100 ms

typ. 100 ms

typ. 120 ms

typ. 120 ms



2.7-7

2

2.7


PNOZelog units may also be included in theseries connection. The delay times on theindividual units are also added together withthis type of cascading. Remember toconsider the switch-on delay and anypotential delay time for the outputs on thePNOZelog units (see operating manual orPNOZelog technical catalogue).

NOTICEWhen connecting PNOZmulti -PNOZelog, the cascading output“CO-” is not connected.

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2.7


Tree structureTree structures may be designed with asmany levels as necessary.Conditions:• On each level, a max. 4 PNOZmulti units

may be connected in parallel.• PNOZelog units may only be connected

to the PNOZmulti units in series. Amaximum of one PNOZelog unit ispermitted on each level.

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2.7-9

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2.7


Supply voltage for the cascaded unitsThe cascaded PNOZmulti units may besupplied via a power supply. The powerconsumption of the individual units shouldbe considered when deciding on the size ofthe power supply.

CAUTION!Cascaded PNOZelog units and allPNOZmulti units connected directlyto PNOZelog units must be suppliedvia a common power supply. Thevoltage tolerance on the powersupply may be a maximum of +20%or -10%.

Installing the networked unitsIf PNOZmulti units alone are beingnetworked, the networked units may behoused in separate control cabinets.If PNOZelog units are integrated into thenetwork, these PNOZelog units and theircascade cables must always be housed inthe same control cabinet as the PNOZmultiunits that are connected directly to thePNOZelog units.

WiringPlease observe the following when wiring:• Cable runs between the connected units:

- PNOZmulti - PNOZmulti: max. 100 m- PNOZelog - PNOZmulti cascaded

directly: max. 10 m• Cable material: see technical details

CAUTION!Outside the control cabinet, the twolines from the cascading input (CI+,CI-) and the lines from the cascadingoutput (CO+, CO-) must be laid inseparate multi-core cables. ��

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2.7


Operation and Fault Diagnostics



22.8

When the supply voltage is switched on, thePNOZmulti safety system copies theconfiguration from the chip card. While thisis happening, the LEDs “POWER”, “DIAG”,“FAULT”, “IFAULT” and “OFAULT” will light.The PNOZmulti safety system is ready foroperation when the LEDs “POWER” and“RUN” are lit continuously.

ErrorThe “DIAG” LED flashes as soon as an erroroccurs. The “RUN” LED goes out if the errorleads to a safe condition.The “RUN” LED stays lit if the error does notlead to a safe condition. The auxiliary outputis shut down.

In the safe condition, the semiconductoroutputs carry a low signal and the relayoutputs are open.

RemedyIf an error occurs on which the “RUN” LEDis lit, the error indicated through the“FAULT”, “IFAULT” or “OFAULT” LED mustbe rectified. If the “RUN” LED goes out,once the error has been rectified, the unitcan only be restarted by switching thesupply voltage off and then on again.

Legend:LED offLED onLED flashes

ErrorThe existing user program has been deleted.External error on the base unit, leading to a safe condition, e.g. terminator notconnectedExternal fault leading to a safe condition; the fault is at the inputs whose LEDs areflashing, e.g. short across the contactsExternal error on the outputs of the base unit, e.g. short across the contacts, leadingto a safe conditionExternal error leading to a safe condition; the error is at the inputs/outputs whoseLEDs are flashing, e.g. short across the contactsExternal error at the outputInternal error on the base unitInternal error on the base unitInternal error on the base unitInternal error on the expansion moduleExternal error on the inputs of the base unit, e.g. partially operated; outputs that aredriven through these inputs will switch to a safe condition, the unit remains in a RUNconditionExternal error on the inputs of the base unit, e.g. feedback input defective; outputsthat are driven through these inputs will switch to a safe condition, the unit remains ina RUN conditionExternal error on the inputs of the base unit, e.g. partically operated, feedback inputdefective; outputs that are driven through these inputs will switch to a safe condition,the unit remains in a RUN conditionThe base unit was set to a STOP condition by the user.The fieldbus module has not been recognised.Error on cascading input; unit remains in a RUN conditionError on cascading output; unit remains in a RUN condition

Base unitRUNInput Ix DIAG FAULT IFAULT OFAULT FAULT In/OutCI CO

Exp. module


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2.8

Technical Details


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2.9


Electrical dataSupply voltage (UB)Voltage toleranceResidual ripple UB

Power consumption at UB without loadTimesSwitch-on delaySimultaneity channel 1/2/3Supply interruption before de-energisationReaction times PNOZ ms1pf>100 Hzf<100 HzInputsNumberVoltage and currentGalvanic isolation

Cascading inputSignal level at “0”Signal level at “1”Input delayStatus displayPulsed outputsNumberVoltage and currentOff time during self testGalvanic isolationShort circuit protectionStatus displaySemiconductor outputsNumber

for EN 954-1, 12/96, Cat. 4for EN 954-1, 12/96, Cat. 3

Switching capabilityExternal supply voltage (UB)Voltage tolerance

24 VDC85 ... 120%+/- 5%Max. 8 W + 2.5 W per expansion module

5 s (after UB is applied)3 s, two-hand control device: 0.5 sMin. 20 ms

10 ms + switch-off delay PNOZ m1p1/f + 10 ms + switch-off delay PNOZ m1p

See unit-specific data24 VDC/8 mANo500 VAC-3 ... +5 VDC15 ... 30 VDC0.6 ... 4 msLED

See unit-specific data24 VDC/0.5 A< 5 msNoYesLED

See unit-specific dataSee unit-specific data24 VDC/max. 2 A/max. 48 W24 VDC85 ... 120 %

Off time during self testGalvanic isolationShort circuit protectionSwitch-off delayResidual current at “0”Signal level at “1”Status displayMax. capacitive loadRelay outputsNumber

for EN 954-1, 12/96, Cat. 4for EN 954-1, 12/96, Cat. 2

Switching capabilityin accordance with EN 60947-4-1, 02/01

in accordance with EN 60947-5-1, 11/97

Contact fuse protection to EN 60947-5-1, 08/00Blow-out fuseCircuit breaker 24 VDCSwitch-off delayStatus displayAuxiliary outputsNumberVoltage and currentExternal supply voltage (UB)Voltage toleranceGalvanic isolationShort circuit protectionResidual current at “0”Signal level at “1”Status display

< 300 µsYesYes< 30 ms< 0.5 mAUB -0.5 VDC at 2 ALED2 µF

See unit-specific dataSee unit-specific data

AC1: 240 V/6 A/1440 VADC1: 24 V/6 A/144 WAC15: 230 V/3 A/690 VADC13: 24 V/3 A/72 W

6 A quick or 6 A slow6 A (characteristic C)50 msLED

See unit-specific data24 VDC, max. 0.5 A24 VDC85 ... 120 %YesYes< 0.5 mAUB -0.5 VDC at 0.5 ALED

Technical Details



22.9

Environmental dataAirgap creepage betweenRelay contactsRelay contacts and othercircuitsClimatic suitabilityEMC

Vibration to FrequencyAmplitude

Ambient temperature

Storage temperatureMechanical dataProtection type

Mounting (e.g. control cabinet)HousingTerminals

Maximum cable runsPer inputSum of individual cable runs atthe test pulse outputCross section of external conductorsRigid single-core, flexible multi-core or multi-corewith crimp connectors

Power supply (X7), inputs (X5, X6), semiconductoroutputs (X2), test pulse outputs (X1),auxiliary output (X2), cascading outputRelay outputs (X3)

Flexible multi-core with crimp connectorsRelay outputs (X3)

DIN VDE 0110-1, 04/973 mm

5.5 mmDIN IEC 60068-2-3, 12/86EN 60947-5-1, 01/00PNOZ mc3p: EN 61000-6-2, 10/01EN 60068-2-6, 04/9510 ... 55 Hz0.35 mm0 ... + 55 °CCoated version: 0 ... + 50 °C-25 ... + 70 °C

IP54IP20IP20

1 km

40 km

0.5 ... 1.5 mm2

0.5 ... 2.5 mm2

0.5 ... 1.5 mm2

Torque setting for connection terminals(screws)

Power supply (X7), inputs (X5, X6), semi-conductor outputs (X2), test pulse outputs (X1),auxiliary output (X2), cascading outputRelay outputs (X3)

Housing materialFrontHousing

Dimensions H x W x DWeight with connector

0.2 ... 0.25 Nm0.4 ... 0.5 Nm

ABS UL 94 V0PPO UL 94 V0See unit-specific dataSee unit-specific data

Technical Details


2

2.9


Approvals

Type

PNOZ m1p ● ● ● ●

PNOZ mi1p ● ● ● ●

PNOZ mo1p ● ● ● ●



PNOZ ms1p ● ● ● -PNOZ mc1p ● ● ● ●

PNOZ mc3p - ● ● -

*PNOZmulti coated version: units do not have TÜV approval!

Type EN 954-1 IEC 61508

PNOZ m1p Cat. 4 SIL 3PNOZ mi1p Cat. 4 SIL 3PNOZ mo1p Cat. 4 SIL 3PNOZ mo2p Cat. 4 SIL 3PNOZ mo4p Cat. 4 SIL 3PNOZ ms1p Cat. 3 -PNOZ mc1p * *PNOZ mc3p * *

*Not a safety component

Suitable for applications up to:

*

2

2.9

2.9-4Pilz GmbH & Co., Safe Automation, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany, Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected] Status 03/04



2 2.10

Units from the PNOZmulti modular safetysystem

The previous chapters have all describedthe common features of the base unit andexpansion modules. This chapter will dealwith the specific features of each unit.Table 10-1 shows the units’ most importantfeatures. The pages that follow provideinformation on intended use, wiring andunit-specific data for each individual unit.

PNOZmulti coated versionOn the “coated version”, the PCB boards inthe PNOZmulti units are varnished andtherefore better protected againstenvironmental influences. The environmentalconditions under which the units may beused must be checked in each individualcase.The “coated version” of the units may bemixed with all the other PNOZmulti unitswithin a safety system. Please note that themax. ambient temperature of the overallsystem will only correspond to that of thePNOZmulti “coated version”.

Tab. 10-1: Number and type of inputs and outputs

Inputs and outputs

InputsTest pulse outputsSafety outputs using semiconductor technology

in accordance with EN 954-1 up to Cat. 3in accordance with EN 954-1 up to Cat. 4

Safety outputs using relay technologyin accordance with EN 954-1 up to Cat. 2in accordance with EN 954-1 up to Cat. 4

Auxiliary outputs

Base unitPNOZm1p204

42

211

Signal modulePNOZ mc1p--

--

--16

Input modulePNOZ mi1p8-

--

---

Output modulePNOZ mo1p--

42

---


--

21-


--

42-

Fieldbus modulePNOZ mc...-Fieldbusinterface

Inputs and outputs

InputsOutputs

Speed monitorPNOZms1p2 axes-


2

2.10


Intended use

The PNOZ m1p base unit from thePNOZmulti modular safety system is usedfor the safety-related interruption of safetycircuits.The unit is designed for use on:• E-STOP equipment• Safety circuits in accordance with VDE

0113 Part 1, 11/98 and EN 60204-1,12/97 (e.g. on movable guards)

INFORMATIONThe unlabelled LEDs and the LEDs atterminals A1 and A2 have nofunction.

Description

The basic functions of the PNOZ m1p aredescribed in Chapter 4. Specific features are:• 20 inputs for connecting:

- E-STOP buttons- Two-hand buttons- Safety gate limit switches- Light barriers- Scanners- Enable switches- PSEN- Operating mode selector switches

• Outputs using semiconductortechnology:- 2 safety outputs in accordance with

EN 954-1, 12/96, Cat. 4 or4 safety outputs in accordance withEN 954-1, 12/96, Cat. 3

- 1 auxiliary output

Base unit PNOZ m1p

• Relay outputs:1 safety contact in accordance withEN 954-1, 12/96, Cat. 4 or2 safety contacts in accordance withEN 954-1, 12/96, Cat. 2

• 4 test pulse outputs• Monitors shorts across contacts at the

inputs• Monitors shorts between the safety

outputs• Weight: 530 g

Terminal configuration

Wiring

The wiring is defined in the circuit diagramin the Configurator. There you can select theinputs that are to perform a particular safetyfunction and the outputs that will switch thissafety function.

InputsInputs I0 ... I19 include the input circuits forconnecting the safety elements and also thereset circuits for connecting the reset

buttons. The Configurator lists theconnections that are available for a safetyelement or reset button. You can select therequired inputs from the list or leave theselection to the Configurator.The number and assignment of the inputsdepends on the type of safety elements thatare used.

OutputsOutputs O4 and O5 are relay outputs,outputs O0 to O3 are semiconductoroutputs, OA0 is an auxiliary output.

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Input circuit Single-channel Dual-channel

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described in the table

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2

2.10


Reset circuit:The unit can be reset automatically,manually or with monitoring. With amonitored or manual reset, detection ofshorts across contacts can also beselected. The assignment of the reset circuitis defined in the PNOZm Config.

• The input circuit should be connected asdescribed in the table

Outputs:The unit has relay and semiconductoroutputs. These may be configured as single-pole or redundant outputs. The outputassignment is defined in the PNOZm Config.

• The output circuit should be connectedas described in the table

Reset circuit

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2 2.10

Output circuit Relay outputs

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NOTICELoads should be driven through 2separate channels or, in the case ofredundant relay outputs, shortsacross contacts should beprevented e.g. by installing thesafety system and its loads(contactors) in the same controlcabinet.


2

2.10


Intended use

The PNOZ mo1p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. The PNOZmulti modular safetysystem is used for the safety-relatedinterruption of safety circuits and isdesigned for use on:• E-STOP equipment• Safety circuits in accordance with VDE


INFORMATIONThe unlabelled LEDs and the LEDs atthe 24 V and 0 V terminals have nofunction.

Description

The basic functions of the PNOZ mo1p aredescribed in Chapter 4. Specific featuresare:• Outputs using semiconductor

technology:- 2 safety outputs in accordance with

EN 954-1, 12/96, Cat. 4 or4 safety outputs in accordance withEN 954-1, 12/96, Cat. 3

• Max. 6 PNOZ mo1p units can beconnected to the PNOZ m1p base unit

• Weight (with connector): 150 g

PNOZ mo1p expansion module


Wiring

The wiring is defined in the circuit diagramin the Configurator.


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2 2.10


Supply voltage for outputs:• Connect the supply voltage:

24 V terminal: +24 VDC0 V terminal: 0V

Outputs:The unit has 4 semiconductor outputs.These may be configured as single-pole orredundant outputs. The output assignmentis defined in the PNOZm Config.


Feedback loop:On a feedback loop, positive-guided N/Ccontacts on the driven contactors(actuators) are connected in series. The N/Ccontacts are connected to an input (e.g. onthe base unit). The assignment is defined inthe PNOZmulti Configurator.

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2.10


Intended use



Description

The basic functions of the PNOZ mo2p aredescribed in Chapter 4. Specific featuresare:• Relay outputs:

- 1 safety output in accordance withEN 954-1, 12/96, Cat. 4 or2 safety outputs in accordance withEN 954-1, 12/96, Cat. 2


• Weight: 170 g



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Outputs:The unit has 2 relay outputs. These may beconfigured as single-pole or redundantoutputs. The output assignment is definedin the PNOZm Config.

• The output circuit should be connectedas described in the table.

NOTICELoads should be driven through 2separate channels or, in the case ofredundant relay outputs, shortsacross contacts should beprevented e.g. by installing thesafety system and its loads(contactors) in a control cabinet.


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2

2.10


Intended use

The PNOZ mi1p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. The PNOZmulti modular safetysystem is used for the safety-relatedinterruption of safety circuits and isdesigned for use on:• E-STOP equipment• Safety circuits in accordance with VDE


Description

The basic functions of the PNOZ mi1p aredescribed in Chapter 4. Specific featuresare:• 8 inputs for connecting:

- E-STOP buttons- Two-hand buttons- Safety gate limit switches- Light barriers- Scanners- Enable switches- PSEN- Operating mode selector switches

• Monitors shorts across contacts at theinputs

• Max. 8 PNOZ mi1p units can beconnected to the PNOZ m1p base unit

• Weight (with connector): 130 g

PNOZ mi1p expansion module


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PNOZ mi1p expansion module

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Input circuit Single-channel Dual-channel

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Input circuit:The N/C contact on the trigger element (e.g.E-STOP) must be connected to the inputcircuit. A short circuit in the input circuit mayor may not be detected, depending on theconfiguration and wiring. The test pulseoutputs on the base unit must be used todetect shorts across contacts. The inputassignment is defined in the PNOZm Config.• The input circuit should be connected as

described in the table. The wiring at I0and I1 is illustrated as an example; inputsI2 ... 17 are wired in a similar way.

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Intended use

The PNOZ mc1p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. The PNOZ mc1p exclusivelyprovides auxiliary outputs.

CAUTION!Auxiliary outputs may notnotnotnotnot be used forsafety-related functions.

INFORMATIONThe LEDs at the 24 V and 0 Vterminals have no function.

Description

The basic functions of the PNOZ mc1p aredescribed in Chapter 4. Specific featuresare:• 16 auxiliary outputs• Max. 8 PNOZ mc1p units can be

connected to the PNOZ m1p base unit• Weight (with connector): 185 g

PNOZ mc1p expansion module

Dimensions in mm (")Terminal configuration

Wiring


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2 2.10


Supply voltage for auxiliary outputs:• Connect the supply voltage:

24 V terminal: +24 VDC0 V terminal: 0V

Auxiliary outputs:The auxiliary outputs can be used forcommunication with a PLC or text display,for example. The output assignment isdefined in the PNOZm Config.


Output circuit

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2 2.10

Intended use



Description

The basic functions of the PNOZ mo4p aredescribed in Chapter 4. Specific featuresare:• Relay outputs:

- 2 safety outputs in accordance withEN 954-1, 12/96, Cat. 4 or4 safety outputs in accordance withEN 954-1, 12/96, Cat. 2


• Weight: 205 g


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Outputs:The unit has 4 relay outputs. These may beconfigured as single-pole or redundantoutputs. The output assignment is definedin the PNOZm Config.

• The output circuit should be connectedas described in the table.

NOTICELoads should be driven through 2separate channels or, in the case ofredundant relay outputs, shortsacross contacts should beprevented e.g. by installing thesafety system and its loads(contactors) in a control cabinet.


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2.10


PNOZ ms1p expansion module

Intended use

The PNOZ ms1pPNOZ ms1pPNOZ ms1pPNOZ ms1pPNOZ ms1p speed monitor may onlybe connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. It monitors standstill, speed anddirection of rotation up to category 3 inaccordance with EN 954-1.The PNOZmulti modular safety system isused for the safety-related interruption ofsafety circuits and is designed for use on:• Emergency stop equipment• Safety circuits in accordance with VDE0113 Part 1, 11/98 and EN 60204-1, 12/97(e.g. on movable guards)

WARNING!Users must take appropriatemeasures to detect or exclude errors(e.g. slippage or broken shearpin)which mean that the frequency of theinput device signal is no longerproportional to the monitored speed.

System requirements• PNOZmulti Configurator: from Version

3.0.0• PNOZ m1p: from Version 3.0Please contact Pilz if you have an olderversion.

Description

The PNOZ ms1p speed monitor can monitortwo axes independently for standstill, speedand direction of rotation. The PNOZ ms1p

signals the status of the monitored values tothe base unit. Depending on the safetycircuit that is loaded, it may be possible totransmit the values from the base unit to arelay output on the safety system, forexample.Incremental encoders and/or proximitydetectors can be used to record the values.

INFORMATIONMonitoring the direction of rotation:If an internal error occurs or there isan error due to a defectiveincremental encoder (LED “FAULT” islit), an incorrect direction of rotationmay be registered for ca. 500 ms.

Module features:• Monitors 2 independent axes• Connection of

- 2 incremental encodersor- 4 proximity switches (2 proximity

switches per axis)or- 1 incremental encoder on axis 1 and 2

proximity switches on axis 2or- 1 incremental encoder on axis 2 and 2

proximity switches on axis 1• Measured variables:

- standstill- speed (8 values can be set)- direction of rotation

• Axis types, input device types and resetmode can be selected in the PNOZmConfig

• Status indicators for- supply voltage- incremental encoder- proximity switch- axis status, standstill and excess

speed- error on the system

• Connection technology on proximityswitch: plug-in terminals, either with cageclamp connection or screw connection

• Connection technology on incrementalencoder: RJ-45 female connector

• Galvanic isolation of female connectorand terminals

• Max. of 4 speed monitors can beconnected to the PNOZ m1p base unit

• Weight (with jumpers): 250 g



2.10-17

2 2.10




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The wiring is defined in the circuit diagramin the Configurator. Details of the input type,axis type and reset mode, plus the valuesfor standstill, speed monitoring anddirection of rotation are also defined in thePNOZm Config.

Proximity switches• Only “pnp” type proximity switches may

be used (N/O contact, positive-switching)• The proximity switches must be

positioned in such a way that at least oneis energised (carries a high signal).

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• The proximity switches must be offset insuch a way that the recorded signalsoverlap.

CAUTION!Appropriate installation measuresshould be taken to prevent a foreignbody coming between the signalinput device and the proximityswitch. The foreign body could causeone of the proximity switches to beconstantly energised (constant highsignal).

The outputs of both the proximity switchesfor axis 1 are connected to terminals I10and I11; both the outputs of the proximityswitches for axis 2 are connected toterminals I20 und I21. If only one axis is tobe monitored, either terminals I10 and I11 orterminals I20 and I21 will remain free. Theproximity switch must always be connectedto a 0 V terminal on the PNOZ ms1p. The0 V terminals are linked internally.

Fig. 10-1: Example of the signal behaviour ofthe proximity switches

The proximity switches require a 24 VDCsupply. To reduce the amount of wiringinvolved, this supply voltage can beconnected to one of the “24 V” terminals onthe PNOZ ms1p. As all 3 “24 V” terminalsare linked internally, 24 V will be present atall 3 terminals. The proximity switches cantherefore be connected directly to the 24 Vterminals on the PNOZ ms1p, rather thanthe power supply.

Requirements of the proximity switches

Signal level at the outputs High signalLow signal

Input resistance at I10 ... I21Frequency rangeConnection technologyCross section of external conductorsRigid single-core, flexible multi-core or multi-corewith crimp connectorsFlexible multi-core with crimp connectors

11 V 30 V-3 V ... +5 V3 kOhm0 ... 3 kHzCage clamp terminals or screw terminals

0.5 ... 2.5 mm2

0.5 ... 1.5 mm2


2

2.10



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2.10-19

2 2.10



Incremental encoders• Only incremental encoders with a

differential output of the following typeare permitted:- Sin/Cos- TTL (RS 422)

• Please note the values stated in thetechnical details.

The incremental encoders are connected viaan adapter (e.g. PNOZ msi4p) or areconnected directly to the PNOZ ms1p. Theadapter is connected between theincremental encoder and the drive. Theoutput on the adapter is connected to theRJ-45 female connector on the PNOZ ms1p.The incremental encoder on connector X12monitors axis 1; the incremental encoder onconnector X22 monitors axis 2.Pin assignment on connectors X12 and X22:

Pin Assignment1 +5 VDC2 0 V3 Not assigned4 A5 /A6 Not assigned7 B8 /BScreening S

Requirements of the incremental encoders

Signal level at the inputsDifferential signalSupply voltageInput resistance at X12, X22Frequency rangeConnection technology

0 ... +5 V, overload-proof up to -30 V .... +30 V+/-0.2 V ... +/-5 V+5 V +/-10 %10 kOhm0 ... 500 kHzRJ-45 female connector

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Adapter for incremental encoders

The adapter records the data between theincremental encoder and the drive andmakes it available via the RJ-45 femaleconnector on the PNOZms1p. Users canmake this adapter themselves or useexisting adapters. Pilz supplies completeadapters as well as ready-made cable withRJ-45 female connectors, which can beused when making an individual adapter.The range of products in this area isconstantly being expanded. Please contactus about the range of adapters that iscurrently available.

PNOZ msi11p/msi10p cableThe cable connects the output on theincremental encoder to the RJ-45 connectoron the PNOZ ms1p. The cable cores arestrands with crimp connectors. The cablecores are labelled. An RJ-45 connector isused for connection to the PNOZ ms1p.

Pin assignment of the RJ-45 connector:Pin Assignment1 UB2 0 V3 Not assigned4 A5 /A6 Not assigned7 B8 /BScreening S

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Cable runsPNOZ msi11pPNOZ msi10p

CableTemperature resistance of insulation materialAdapter connectionPNOZ ms1p connection

1.5 m2.5 mCAT5 cable, flexible, silicone-freeMax. 60 °CStrands with crimp connectorsRJ-45 connector, 8-pin



2.10-21

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PNOZ msi1p ... PNOZ msi4p adapter forSiemens or Haidenhain

These adapters are designed for the drivesfrom Siemens or Haidenhain (for furtherinformation please refer to the drives’documentation). One is connected via afemale D-Sub connector, one via a maleD-Sub connector. Various versions areavailable:• PNOZ msi1p

25-pin D-Sub connector and cable runsof 2.5 m

• PNOZ msi2p25-pin D-Sub connector and cable runsof 1.5 m



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Climatic suitability in accordance with EN 60068-2-78CondensationAmbient temperatureStorage temperatureProtection typeHousing materialDimensions H x W x DLength LWeight

40 °C, 93 % r.h.Not permitted0 ... +60° C-25 ... 70 ° CIP20PBTSee drawing1.5 m or 2.5 mPNOZ msi1p: 190 gPNOZ msi2p: 135 gPNOZ msi3p: 175 gPNOZ msi4p: 120 g



2.10-23

2 2.10



Intended use

The PNOZ mc3pPNOZ mc3pPNOZ mc3pPNOZ mc3pPNOZ mc3p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. It is used for communicationbetween the modular safety system andPROFIBUS-DP.

CAUTION!The PNOZ mc3p expansion modulemay not be used for safety-relatedfunctions.



Description

PROFIBUS-DP is designed for fast dataexchange at field level. The PNOZ mc3pexpansion module is a passive PROFIBUS-DP subscriber (Slave). The basic functionsof communication with PROFIBUS-DPconform to EN 50170. The central controller(Master) reads input information from theslaves and writes output information to theslaves as part of each cycle. As well as thecyclical transfer of usable data, PROFIBUS-DP can also be used for diagnostics andcommissioning functions. Data traffic ismonitored on the Master/Slave side.

Module features:• Can be configured using the PNOZmulti

Configurator• Station addresses from 0 ... 99, selected

via rotary switch• Status indicators for communication with

PROFIBUS-DP and for errors• Max. 1 PNOZ mc3p can be connected to

the PNOZ m1p base unit• Weight (with jumper): 140 g

A maximum of 24 outputs on the PNOZmultisafety system can be defined in the PNOZmConfig for communication with PROFIBUS-DP. These outputs can be connected to theoutputs on• Logic elements• Time elements• Event counters• Connection pointsand to inputs on the safety system.

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CAUTION!The PNOZ mc3p expansion modulemust always be installed to the left ofthe base unit.A distance of at least 20 mm must bemaintained between the PNOZmc3p and any external heat sources.


PNOZ mc3p technical detailsNon-safety-related applicationsSlaveLED0 ... 999.6 kBit/s ... 12 MBit/s9-pin D-Sub connector (female)

1: Not assigned2: Not assigned3: B (RxD/TxD-P)4: CNTR-P5: DGND6: VP7: Not assigned8: A (RxD/TxD-N)9: Not assigned

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The wiring is defined in the circuit diagramin the Configurator. It is possible to definewhich outputs on the safety system willcommunicate with PROFIBUS-DP. Theconnection to PROFIBUS-DP is made via afemale 9-pin D-Sub connector.


2.10-25

2 2.10


Please note the following when connectingto PROFIBUS:• Only use metal plugs or metallised plastic

plugs.• Twisted pair, screened cable must be

used to connect the interfaces.

Setting the station addressTwo rotary switches are used to set thestation address (decimal) on thePNOZ mc3p.• On the upper rotary switch, use a small

screwdriver to set the tens digit for theaddress.

• On the lower rotary switch, set the onesdigit for the address (“6” in the example).

Station address 36 is set in the diagramsas an example.


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Intended use

The PNOZ mc4p PNOZ mc4p PNOZ mc4p PNOZ mc4p PNOZ mc4p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. It is used for communicationbetween the modular safety system andDeviceNet.




Description

DeviceNet is designed for fast dataexchange at field level. The PNOZ mc4pexpansion module is a passive DeviceNetsubscriber (Slave). The basiccommunication functions meet therequirements of the DeviceNet specification,Release 2.0. The central controller (master)reads input information from the slaves andwrites output information to the slaves aspart of each cycle. As well as the cyclicaltransfer of usable data, the PNOZ mc4p canalso be used for diagnostics andcommissioning functions.



via DIP switch• Status indicators for communication with

DeviceNet and for errors• Max. 1 PNOZ mc4p can be connected to


A maximum of 24 outputs on the PNOZmultisafety system can be defined in the PNOZmConfig for communication with DeviceNet.These outputs can be connected to theoutputs on• Logic elements• Time elements• Event counters• Connection pointsand to inputs on the safety system.

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PNOZ mc4p technical details

Non-safety-related applicationsSlaveLED0 ... 63125, 250, 500 kBit/s5-pin screw connector

1: V-2: CL (CAN_L)3: SD (screen)4: CH (CAN_H)5: V+

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Wiring

The wiring is defined in the circuit diagramin the Configurator. It is possible to definewhich outputs on the safety system willcommunicate with DeviceNet. Theconnection to DeviceNet is made via a 5-pinscrew connector.


2

2.10


Setting the station addressThe station address of the PNOZ mc4p isset via switches 1 ... 32 on the DIP switch:

Switch setting Station address

0

1

2

3

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62

63


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Set transmission rateThe transmission rate is set via switches S1and S2 on the DIP switch:

Switch setting Transmission rate

125 KBit/s

250 KBit/s

500 KBit/s

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2.10-29

2 2.10



Intended use

The PNOZ mc5p PNOZ mc5p PNOZ mc5p PNOZ mc5p PNOZ mc5p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. It is used for communicationbetween the modular safety system andINTERBUS.




Description

INTERBUS is designed for fast dataexchange at field level. The PNOZ mc5pexpansion module is a passive INTERBUSsubscriber (Slave). The basiccommunication functions conform to EN50254. The central controller (Master) readsinput information from the slaves and writesoutput information to the slaves as part ofeach cycle. As well as the cyclical transferof usable data, the PNOZ mc5p can also beused for diagnostics and commissioningfunctions.


Configurator• Status indicators for communication with

INTERBUS and for errors• Max. 1 PNOZ mc5p can be connected to


A maximum of 24 outputs on the PNOZmultisafety system can be defined in the PNOZmConfig for communication with INTERBUS.These outputs can be connected to theoutputs on• Logic elements• Time elements• Event counters• Connection pointsand to inputs on the safety system.



2

2.10


Application rangeDevice typeStatus displayTransmission rateConnections


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PNOZ mc5p technical details

Non-safety-related applicationsSlaveLED500 kBit/s, 2 MBit/s9-pin female D-Sub connector plus maleconnector

Wiring

The wiring is defined in the circuit diagramin the Configurator. It is possible to definewhich outputs on the safety system willcommunicate with INTERBUS. Theconnection to INTERBUS is made via two 9-pin screw connectors.

IBS IN

1: DO12: DI13: GND4: Not assigned5: Not assigned6: /DO17: /DI18: Not assigned9: Not assigned

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2.10-31

2 2.10



Set transmission rateThe transmission rate is set with a jumper:

Jumper position Transmission rate

500 KBit/s

2 MBit/s

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2

2.10



Intended use

The PNOZ mc6p PNOZ mc6p PNOZ mc6p PNOZ mc6p PNOZ mc6p expansion module mayonly be connected to a base unit (e.g. PNOZm1p) from the PNOZmulti modular safetysystem. It is used for communicationbetween the modular safety system andCANopen.




Description

CANopen is designed for fast dataexchange at field level. The PNOZ mc6pexpansion module is a passive CANopensubscriber (Slave). The basiccommunication functions conform to CiADS-301 V3.0. The central controller (Master)reads input information from the slaves andwrites output information to the slaves aspart of each cycle. As well as the cyclicaltransfer of usable data, the PNOZ mc6p canalso be used for diagnostics andcommissioning functions.



via rotary switch• Status indicators for communication with

CANopen and for errors• Max. 1 PNOZ mc6p can be connected to


A maximum of 24 outputs on the PNOZmultisafety system can be defined in the PNOZmConfig for communication with CANopen.These outputs can be connected to theoutputs on• Logic elements• Time elements• Event counters• Connection pointsand to inputs on the safety system.

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CAUTION!The PNOZ mc6p expansion modulemust always be installed to the left ofthe base unit.


PNOZ mc6p technical detailsNon-safety-related applicationsSlaveLED1 ... 9910, 20, 50, 125, 250, 500, 800 kBit/s, 1 MBit/sMale 9-pin D-Sub connector

1: Not assigned2: CAN_L3: Not assigned4: Not assigned5: CAN_SHLD6: Not assigned7: CAN_H8: Not assigned9: Not assigned

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The wiring is defined in the circuit diagramin the Configurator. It is possible to definewhich outputs on the safety system willcommunicate with CANopen. Theconnection to CANopen is made via afemale 9-pin D-Sub connector.


2

2.10



Setting the station addressTwo rotary switches are used to set thestation address on the PNOZ mc6p.• On the middle rotary switch, use a small

screwdriver to set the tens digit for theaddress (“3” in the example).

• On the lower rotary switch, set the onesdigit for the address (“6” in the example).

Station address 36 is set in the diagramsas an example.

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Set transmission rate:On the upper rotary switch DR, use a smallscrewdriver to set the transmission rate (inthe example, “4” corresponds to 125 kBit/s)

Switch setting Transmission rate0 -1 10 KBit/s2 20 kBit/s3 50 kBit/s4 125 kBit/s5 250 kBit/s6 500 kBit/s7 800 kBit/s8 1 MBit/s9 -

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2

2.10


Communication with fieldbus systems

An area of 20 Bytes is reserved forcommunication via the fieldbus systems;this is updated approx. every 15 ms. TheMaster can process the information inbytes, words or in double words.

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Note on the PNOZ mc6p (CANopen):The output data on the PNOZmulti is storedas follows:

The input data on the PNOZmulti is stored asfollows:


2.10-37

2 2.10


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The current status of the outputs configuredfor the fieldbus plus the current LED statusare always stored in Byte 0 ... Byte 3. Allother information is stored in various tables.

Assignment of Byte 0 ... Byte 3The outputs are defined in the PNOZmultiConfig. Each output that is used is given anumber there, e.g. o0, o5... . The status ofoutput o0 is stored in Bit 0 of Byte 0; thestatus of output o5 is stored in Bit 5 of Byte0 etc.

The status of the LEDs is stored in Byte 3:Bit 0 = 1: OFAULT LED is litBit 1 = 1: IFAULT LED is litBit 2 = 1: FAULT LED is litBit 3 = 1: DIAG LED is litBit 4 = 1: RUN LED is litBit 5 = 1: If communication between the

PNOZmulti and thefieldbus is working

Bit 6: ReservedBit 7: Reserved

Assignment of Byte 4 ... Byte 18Each table consists of one or moresegments. Each segment is made up of amax. 13 Bytes. There are 6 tables, whoseassignment is fixed.

The Master must request the table numberand segment number required. The Slave(e.g. PNOZ mc3p) repeats the two numbersand sends the requested data. If a numberis requested that is not available, the Slavesends the error message “FF” instead of thesegment number.The segments may be requested in anysequence.


2

2.10


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Example 1:The Master requests segment 5 from table2. The fieldbus module repeats both thesedetails and sends segment 5. Then the datafrom segment 8 in table 2 is transmitted.


2.10-39

2 2.10


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Example 2:The Master requests segment 8 from table2. The fieldbus module repeats both ofthese details and sends segment 8. Thenthe Master requests segment 25 from table5. As this table does not contain a segment25, the Slave registers an error and sendsback “FF”.


2

2.10


Byte01234567891011120123456789101112

Segment

0

1

Contents

Product number (hex)

Unit version (hex)

Serial number (hex)

FreeProject check sum (hex)

Chip card check sum (hex)

Project creation date (hex)

FreeFreeFreeFreeFree

Example/Comment

Product number 773 100: 000BCBEC hexByte 0: 00, Byte 1: 0B, Byte 2: CB, Byte 3: EC

Unit version 20: 14 hexByte 4: 00, Byte 5: 00, Byte 6: 00, Byte 7: 14

Serial number 123 456: 0001E240 hex.Byte 8: 00, Byte 9: 01, Byte 10: E2, Byte 11: 40

Check sum A1B2 hex:Byte 0: A1, Byte 1: B2Check sum 3C5A hex:Byte 2: 3C, Byte 3: 5A

Creation date : 28.11.2003Byte 4: 1C, Byte 5: 0B, Byte 6: 07, Byte 7: D3

FreeFreeFreeFreeFree


Table assignment

There are a total of 6 tables, with thefollowing contents:Table 1: ConfigurationTable 2: ReservedTable 3: Input statusTable 4: Output statusTable 5: LED statusTable 6: Reserved

Table 1Table 1 consists of 6 segments, each ofwhich has 13 Bytes. It contains device datafrom the base unit and the project datadefined in the PNOZm Config.


2.10-41

2 2.10


Segment

2

3

Byte01234567891011120123456789101112

ContentsConfiguration, expansion leftConfiguration, 1st expansion rightConfiguration, 2nd expansion rightConfiguration, 3rd expansion rightConfiguration, 4th expansion rightConfiguration, 5th expansion rightConfiguration, 6th expansion rightConfiguration, 7th expansion rightConfiguration, 8th expansion rightFreeFreeFreeFree

1st character

2nd character

3rd character

4th character

5th character

6th character7th character (High Byte)

Example/CommentByte 0 ... 8 contains the Hex code of theexpansion modules :PNOZ mi1p: 08PNOZ mo1p: 18PNOZ mo2p: 10PNOZ mo4p: 28PNOZ mc1p: 20PNOZ ms1p: 88Fieldbus module PNOZ mc...: 30No expansion module: 00

Byte 0 ... 12 of the project name defined in thePNOZm Config under “Enter project data”; thisis stored in UNICODE format, 2 Bytes containthe Hex code of the individual UNICODEcharacters

Segment

4

5

Byte01234567891011120123456789101112

Contents7th character (Low Byte)

8th character

9th character

10th character

11th character

12th character

13th character

14th character

15th character

16th characterEnd character FFEnd character FFFreeFreeFreeFreeFree

Example/Comment

Project name Byte 13 ... 25

Project name Byte 26 ... 31

The end of the character string is signalled with“FFFF”.

Table 1, Segment 2 and 3 Table 1, Segment 4 and 5



2

2.10


Table 3This table consists of just one segment. Itcontains the status of the inputs.

Segment

0

Byte0123456789101112

ContentsI0 ... I7 base unitI8 ... I15 base unitI16 ... I19 base unit00I0 ... I7 1st expansion moduleI0 ... I7 2nd expansion moduleI0 ... I7 3rd expansion moduleI0 ... I7 4th expansion moduleI0 ... I7 5th expansion moduleI0 ... I7 6th expansion moduleI0 ... I7 7th expansion moduleI0 ... I7 8th expansion module

Example/CommentThe safety system consists of a base unit and onePNOZ mi1p.Byte 0: PNOZ m1pByte 1: PNOZ m1pByte 2: PNOZ m1pByte 3:Byte 4:Byte 5: PNOZ mi1p

If an input has a high signal, the corresponding Bitwill contain “1”; if the input is open (low signal), theBit will contain “0”.

Table 4This table consists of 2 segments. Itcontains the status of the outputs.

Segment

0

1

Byte01234567891011120123456789101112

Contents000O0 ... O3 of the base unitO4 and O5 of the base unitO0 ... O7 1st expansion moduleO0 ... O7 2nd expansion moduleO0 ... O7 3rd expansion moduleO0 ... O7 4th expansion moduleO0 ... O7 5th expansion moduleO0 ... O7 6th expansion moduleO0 ... O7 7th expansion moduleO0 ... O7 8th expansion module00000O8 ... O15 1st expansion moduleO8 ... O15 2nd expansion moduleO8 ... O15 3rd expansion moduleO8 ... O15 4th expansion moduleO8 ... O15 5th expansion moduleO8 ... O15 6th expansion moduleO8 ... O15 7th expansion moduleO8 ... O15 8th expansion module

Example/CommentAssignment of Bytes depends on the unit:PNOZ m1pSegment 0, Byte 3:

Segment 0, Byte 4:

PNOZ mo1pSegment 0, Byte 5 ... 12:

Segment 1, Byte 5 ... 12:





PNOZ mc1pSegment 0, Byte 5 ... 12:


If an output has a high signal, thecorresponding Bit will contain “1”; if the outputis open (low signal), the Bit will contain “0”.

I7 I6 I5 I4 I3 I2 I1 I0I15 I14 I13 I12 I11 I10 I9 I80 0 0 0 I19 I18 I17 I160 0 0 0 0 0 0 00 0 0 0 0 0 0 0

I7 I6 I5 I4 I3 I2 I1 I0

0 0 1 1 O3 O2 O1 O0

0 0 0 0 0 0 O5 O4

0 0 1 1 O3 O2 O1 O0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 O1 O0

0 0 0 0 0 0 0 0

0 0 0 0 O3 O2 O1 O0

0 0 0 0 0 0 0 0

A7 A6 A5 A4 A3 A2 OA1OA0

A15 A14 A13 A12 A11 A10 A9 A8



2.10-43

2 2.10


Table 5This table consists of 3 segments. Itcontains the LED status.

Seg-ment

0

1

Byte

01234567891011120123456789101112

Contents

RUNDIAGFAULTIFAULTOFAULTFAULT 1st expansion moduleFAULT 2nd expansion moduleFAULT 3rd expansion moduleFAULT 4th expansion moduleFAULT 5th expansion moduleFAULT 6th expansion moduleFAULT 7th expansion moduleFAULT 8th expansion moduleLED I0 ... I7 base unitLED I8 ... I15 base unitLED I16 ... I19 base unit00LED I0 ... I7 1st expansion moduleLED I0 ... I7 2nd expansion moduleLED I0 ... I7 3rd expansion moduleLED I0 ... I7 4th expansion moduleLED I0 ... I7 5th expansion moduleLED I0 ... I7 6th expansion moduleLED I0 ... I7 7th expansion moduleLED I0 ... I7 8th expansion module

Example/Comment

Depending on the LED status, the following Hexcode will be in Byte 0 ... 12:00 hex: LED offFF hex: LED on30 hex: LED flashing

The safety system consists of a base unit and onePNOZ mi1p.Byte 0 PNOZ m1pByte 1 PNOZ m1pByte 2 PNOZ m1pByte 3Byte 4Byte 5 PNOZ mi1p

If the LED on an input is flashing, thecorresponding Bit will contain “1”; if the LED is notflashing, the Bit will contain “0”.

I7 I6 I5 I4 I3 I2 I1 I0I15 I14 I13 I12 I11 I10 I9 I80 0 0 0 I19 I18 I17 I160 0 0 0 0 0 0 00 0 0 0 0 0 0 0

I7 I6 I5 I4 I3 I2 I1 I0


Seg-ment

2

Contents

LED1: Not assignedLED2: Status of fieldbus moduleLED3: Status of fieldbus moduleLED4: Status of fieldbus moduleFreeFreeFreeFreeFreeFreeFreeFreeFree

Example/Comment

Position of LED1 ... LED4:

LED offLED greenLED redThe functions of the LED are described in therelevant operating manual.

Byte

0123456789101112

0 0 0 0 0 0 0 00 0 0 0 0 0 0 10 0 0 0 0 0 1 0

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Applications


2

2.11

Safety assessments

Before using a unit it is necessary toperform a safety assessment in accordancewith the Machinery Directive. The units asindividual components guarantee functionalsafety, but not the safety of the entireapplication. You should therefore define thesafety requirements for the plant as a whole,and also define how these will beimplemented from a technical andorganisational standpoint (e.g. refer to BIA[BG Institute for Occupational Safety]Report 6/97).

Safety


2

2.11

Applications


2

2.11

All the applications use the PNOZ m1p.Details of how the unit is wired are givenjust once, at the start of the chapter.

PNOZ m1pBase unit configuration

2.11-4

2 2.11


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2.11

Features

● 3 E-STOP buttons● 2 light guards● Dual-channel with detection of shorts

across contacts● 3 instantaneous load shutdowns

DescriptionThis example illustrates the use ofconnection points in the PNOZmultiConfigurator. Connection point elementsenable you to create wiring diagrams thatextend over several pages in the PNOZmultiConfigurator.Three E-STOP buttons are AND-linked. Ifnone of the buttons are operated, there willbe a high signal at output A1.o0. The resultof the AND operation is AND-linked to thesignal from light guard 2 via a connectionpoint. The signal at output A1.o2 will only behigh if no E-STOP button has been operatedand the light guard is not interrupted. Lightguard 1 is AND-linked to E-STOP button 1

via a connection point. The signal at outputA1.01 will only be high if E-STOP button 1has not been operated and the light guard isnot interrupted.

Feedback loopThe feedback loop is not used.

ResetThe unit is ready for operation when theconditions at the inputs have been met(automatic reset).

Safety assessment● A short circuit between 24 VDC and

inputs A1.i0 ... A1.i9 will be detected asan error. The safety outputs will carry alow signal.

● A short circuit between 24 VDC and asafety output will be detected and thesafety outputs will carry a low signal.

PNOZ m1pUsing connection points

Pilz units

Number Type Features Order number1 PNOZ m1p 24 VDC 773 100

Drawing file:

Page 14 ... 16 in the project EPLAN4/Pilz/PNOZ1002


2

2.11

Applications


2

2.11


Configuration, page 1

● 3 E-STOPs- Switch type 3 (2 N/C)- Detection of shorts between contacts

(A1.i0, A1.i2, A1.i4 - test pulse 0,A1.i1, A1.i3, A1.i5 - test pulse 1)

- Automatic reset● 2 connection point elements

- Source connection point 1 and sourceconnection point 2

● AND element- 3 inputs

● Output- Safety output, semiconductor type- Single-pole

Continued overleaf

Applications


2 2.11


● 2 light guards- Switch type 3 (2 N/C)- Detection of shorts between contacts

(A1.i6, A1.i8 - test pulse 0,A1.i7, A1.i9 - test pulse 1)

- Automatic reset● 2 connection point elements

- Destination connection point 1 anddestination connection point 2

● 2 AND elements- 2 inputs

● 2 outputs- Safety output, semiconductor type- Single-pole


2.11-9

2

2.11


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Applications


2

2.11

Features

● 1 E-STOP button● 1 light guard● Dual-channel with detection of shorts

across contacts● 1 PLC enabling signal● 1 instantaneous controller enable● 1 delayed load shutdown

DescriptionA light guard is used to protect a hazardousarea. The machine’s motor will only beswitched on if:● The light guard is not interrupted and● The E-STOP button has not been

operated.

If these safety conditions are met, a pulse(not safety-related) at the enable input willstart the motor and the controller will beenabled. If the light guard is interrupted orthe E-STOP button is operated, the signal atoutputs A1.o0, A1.o4 and A1.o5 will switchfrom high to low. The controller enable willbe interrupted and the motor will switch offafter a delay of 0.5 s.

Feedback loopThe N/C contacts KM1.2 and KM2.2 oncontactors KM1.2 and KM2.2 are connectedto the feedback loop input A1.i8.

ResetIf the conditions for starting the motor havebeen met and the feedback loop is closed,the PLC enabling pulse must be sent. Thispulse (monitored reset) enables plantoperation.

Safety assessment● The PNOZ m1p and contactors

KM1.2 and KM2.2 must be installed in asingle location.

● If a switch contact (A1.i0 ... A1.i3) isoverridden, this will be detected as anerror at the next operation. Safetyoutputs A1.o4 and A1.o5 will carry a lowsignal.

● A short circuit between 24 VDC andinputs A1.i0 ... A1.i3 will be detected asan error. All the safety outputs will carry alow signal.

● A short circuit between 24 VDC and asafety output will be detected and all thesafety outputs will carry a low signal.

PNOZ m1pE-STOP and light guard, Category 4, EN 954-1

Pilz units


Drawing file:

Page 7 ... 9 in the project EPLAN4/Pilz/PNOZ1002

Applications


2 2.11

PNOZ m1pE-STOP and light guard, Category 4, EN 954-1

Configuration

● Light guard- Switch type 3 (2 N/C)- Detection of shorts between contacts

(A1.i0 - test pulse 0, A1.i1 - test pulse 1)- Automatic reset- Start-up test

● E-STOP- Switch type 3 (2 N/C)- Detection of shorts between contacts

(A1.i2 - test pulse 2, A1.i3 - test pulse 3)- Automatic reset


● Reset element- Monitored reset

● Delay element- 500 ms

● Motor output- Safety output, relay type- Redundant- Use feedback loop

● Controller enable output- Safety output, semiconductor type- Single-pole

2.11-15

2

2.11


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2.11

Applications


2

2.11

Features

● 1 operating mode selector switch● 1 E-STOP button● 2 two-hand controls● Dual-channel with detection of shorts

across contacts● 1 instantaneous load shutdown

DescriptionA machine can be operated by one or twopeople. The machine is enabled via two-hand buttons.The machine’s motor is switched on if:● The E-STOP button has not been operated

and● The operating mode selector switch is in

position “0” and both two-hand buttonsare operated orthe operating mode selector switch is inposition “1” and two-hand button 2 isoperated.

If one of these conditions is not met, thesignal at output A1.o0 will switch from high

to low and the motor will be switched off.The status of the operating mode selectorswitch is signalled at outputs A1.o1 andA1.o3.

Feedback loopThe N/C contacts KM1.3 and KM2.3 oncontactors KM1.3 and KM2.3 are connectedto the feedback loop input A1.i11.

ResetE-STOP monitoring must be activatedthrough the reset button S6.3 (manualreset). If the conditions for starting themotor have been met and the feedback loopis closed, operation of the plant is enabled.

Safety assessment● If a switch contact (A1.i0 ... A1.i14) is

overridden, this will be detected as anerror at the next operation. Safetyoutputs A1.o0 and A1.o2 will carry a lowsignal.

● A short circuit between 24 VDC andinputs A1.i0, A1.i1, A1.i3 ... A1.i10 will bedetected as an error. The safety outputswill carry a low signal.

PNOZ m1pTwo-hand with override, Category 4, EN 954-1

Pilz units


Drawing file:

Page 10 and 11 in the project EPLAN4/Pilz/PNOZ1002

● A short circuit between 24 VDC and thereset input A1.i12 will be detected.

● A short circuit between 24 VDC and theoverride input A1.i13 or A1.i14 will bedetected.


● It must be possible to protect theoperating mode selector switch fromunauthorised operation.


2

2.11

Applications


2

2.11



● E-STOP- Switch type 3 (2 N/C)- Detection of shorts between contacts

(A1.i0 - test pulse 0, A1.i1 - test pulse 1)- Manual reset (A1.i12 - test pulse 3)

● Flag element- Flag input 1

Continued overleaf

Applications


2 2.11


● Two-hand buttons- Switch type 6 (N/O - N/C)- Detection of shorts between contacts

(A1.i3, A1.i4 and A1.i7, A1.i8 - testpulse 0A1.i5, A1.i6 and A1.i9, A1.i10 - testpulse 1)

● Operating mode selector switch- Switch type 9- Detection of shorts between contacts

(A1.i13, A1.i14 - test pulse 2)● Flag element

- Flag output 1● OR element

- 2 inputs● AND element

- 3 inputs● Motor output

- Safety output, semiconductor type- Redundant- Use feedback loop

● Two-hand on output- Safety output, semiconductor type- Single-pole

● Two-hand off output- Safety output, semiconductor type- Single-pole


2.11-23

2

2.11


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2

2.11

Features

● 1 light guard● 4 muting sensors for parallel muting● Monitored muting lamp● Button for overriding the muting area● 1 instantaneous load shutdown

DescriptionMuting mode enables the safety function(light guard) to be suspended temporarily, inorder to insert workpieces, for example.In normal mode, the drive is enabled whenthe light guard is clear. The “enable motor”connection point is set and the motor canbe started via input i11. The muting sensorsenable the light guard function to besuspended. The muting sensors (N/O)supply a low signal in an unoperatedcondition. In muting mode, a high signal ispresent at the muting sensor outputs. Thismeans that the motor is enabled, despitethe light barrier being interrupted. The timeelement “max. muting time” is startedsimultaneously (set time: 30 s). Once theset time has elapsed, the enable is reset via

the “enable motor” connection point. Mutingmode can be restarted for another 30 s bypressing the button “continue run_NO” atinput i8.Muting mode is displayed via a monitoredlamp. The lamp is switched on as soon asthe “muting active” connection point is set.The lamp’s outputs are monitored via theinputs i0 and i1. If the lamp is defective, alow signal will be present on at least one ofthe two inputs. The “motor stop” connectionpoint is set and the motor is stopped. The“100 ms” time element bridges the lamp’sswitch-on time.

Feedback loopThe N/C contacts K1.1 and K1.2 oncontactors K1.1 and K1.2 are connected tothe feedback loop input i10. The lamp’s N/Ccontacts are connected to the feedbackloop i0 and i1.

PNOZ m1pMuting, Category 4, EN 954-1

Pilz units


Drawing file:

Page 20-22 in the project EPLAN4/Pilz/PNOZ1002

ResetIf the conditions for starting the motor havebeen met and the feedback loops areclosed, operation of the plant is enabled(automatic reset).

Safety assessment● If a switch contact (A10.i0 ... A10.i10 and

A10.i13, A1.i14) is overridden, this will bedetected as an error at the nextoperation. Safety outputs A10.o1 andA10.o2 will carry a low signal.

● A short circuit between 24 VDC andinputs A10.i6 and A10.i7 will be detectedas an error by the light guard. The safetyoutputs will carry a low signal.

● A short circuit between the inputs A10.i6and A10.i7 will be detected as an error bythe light guard. The safety outputs willcarry a low signal.

● A short between 24 VDC and thefeedback loop input A10.i0 or A10.i1 willbe detected as an error at the nextoperation.


DRAFT!

Applications


2 2.11

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Examples for the muting sensorarrangementThe example can be used for parallel andsequential muting. Muting sensors MS3 andMS4 must be arranged in such a way thatthey energise while MS1 and MS2 are stillactive. Sensors MS1 and MS2 may notbecome inactive until MS3 and MS4 areactive.

Sequential muting with 4 muting sensors:

Parallel muting with 2 muting sensors:


Parallel muting with 4 muting sensors:

DRAFT!

Applications


2

2.11


● Light guard- Switch type 3 (N/C - N/C)- Automatic reset

● Muting sensors- Connect N/O / N/O combination

to switch type 3- Simultaneity: 3 s- Automatic reset

● Flag element- Flag input 2- Flag input 3

● OR elements- 2 inputs

● AND elements- 2 inputs

● Time element- Switch-on delay- 30 s

● Negation elements- 1 input


DRAFT!

Applications


2 2.11


● E-STOP element- Switch type 3 (N/C - N/C) for

monitoring the muting lamp- Simultaneity: 3 s- Automatic reset

● Flag elements- Flag output 3- Flag input 1


● Time element- Switch-on delay- 100 ms

● Negation element- 1 input

● Muting lamp output- Auxiliary output, semiconductor type


DRAFT!

Applications


2

2.11


● Flag elements- Flag output 1- Flag output 2

● OR element- 3 inputs

● RS-Flipflop element- 2 inputs

● Negation elements- 1 input

● Motor output- Safety output, relay type- Redundant- Use feedback loop


DRAFT!

2.11-31

2

2.11


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2.11


Applications


2 2.11

Features

● 1 reset module● 2 logic connections● 3 semiconductor outputs● 1 instantaneous load shutdown● 2 load shutdowns with a 5 s delay

Description

When the motor is switched on, after a 5second delay it is possible to switchbetween a star and a delta connection.A high signal at input A1.i4 selects a starconnection, a high signal at input A1.i5selects a delta connection.


ResetThe PNOZ m1p is ready for operation oncesupply voltage is applied. If there is a highsignal at input A1.i0, the application can beactivated through a signal change from lowto high at input A1.i1.

PNOZ m1pStar-delta start-up, Category B, EN 954-1

Pilz units


Drawing file:

Page 18 and 19 in the project EPLAN4/Pilz/PNOZ1002

Applications


2

2.11

PNOZ m1pStar-delta start-up, Category B, EN 954-1

Configuration

● 1 reset element- Non-monitored reset

● 1 delay element- 5000 ms

● 2 AND elements- 3 inputs

● 2 negation elements- 1 input


2.11-37

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Applications


2 2.11

Features

● 1 E-STOP button● 1 logic connection● 2 instantaneous load shutdowns

DescriptionA motor can be switched on or off if the E-STOP button has not been operated.Pressing the E-STOP button stops themotor immediately.


ResetIf the E-STOP button has not been operatedand there is a high signal at input A1.i2, theapplication can be activated through a pulseedge at input A1.i3.

PNOZ m1pMotor ON/OFF, Category B, EN 954-1

Pilz units


Drawing file:

Page 17 in the project EPLAN4/Pilz/PNOZ1002

Applications


2

2.11

PNOZ m1pMotor ON/OFF, Category B, EN 954-1

Configuration

● E-STOP- Switch type 3 (2 N/C)- Automatic reset


● Reset element- 2 inputs


2.11-41

2 2.11


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Service


Contents Page

ServicePre-sales/after sales – Services, concepts and solutions 3-2

3 3

Worldwide representativesOur worldwide network ofsubsidiaries and sales partnersensures comprehensive support

and assistance with your questions andproblems.

InternetOur homepage at www.pilz.comprovides the latest information,electronic shopping, direct

dialogue and enquiry functions as well asextensive download options.

E-BusinessThe focus of Pilz’s E-Businessactivities is to strengthencustomer orientation through the

use of new media and to increase addedvalue via a supplementary business modelfor Business-to-Business.

Supply and repair serviceFrom a fast, economical repairthrough to a long supplyguarantee to safeguard your

investment - always expect more from Pilz.

Certificates and approvalsPilz is certified to DIN ISO 9001.International approvals andcertification from recognised test

houses confirm our products’ suitability forworldwide use.

Application supportWhen configuring and commis-sioning both hardware andsoftware, our application

engineers can provide support based onexpertise gained from international projects.

Technical supportOur engineers can support you inthe selection, use and applicationof our products. They are in

constant contact with customers from thewidest range of areas and industrial sectorsand are happy to answer your queries at anytime.

E-Mail:[email protected]

Telephone:+49 711 3409-444

HotlineTechnical support is availableround the clock on our centralhotline number

+49 711 3409-444.

Training and educationA wide range of training coursesand seminars helps to pass onknowledge based on theory and

practice.

Safety adviceAs you design your machine oron-site atyour installation, Pilzcan provide professional advice

on safety, based on current standards.

Risk analysisOur application engineers canperform a risk assessment foryou, based on current standards.

Safety conceptsIf the risk assessment shows youneed to reduce the risk, appro-priate protective measures can be

selected and a safety concept drawn up.

Safety checkPilz will assess your application,plant or machinewith regard tothe necessary safety aspects.

System supplierand project managementIf required, Pilz can undertake alltasks from the generation of

documentation and control cabinet designright through to completion - the wholesystem from one source.

3-2

Service


We are happy to advise you, in theconfiguration phase or duringcommissioning.

Pre-sales/after salesServices, concepts and solutions

3

3

Order Reference


Contents Page

Order referenceAlphabetically by type 4-2Numerically by order number 4-3

4 4

4-2

Order Reference


Alphabetically by type

Type Order number PagePNOZ m1p 773 100 2.10-2PNOZ mc1p 773 700 2.10-12PNOZ mc3p 773 721 2.10-23PNOZ mc4p 773 722 2.10-26PNOZ mc5p 773 723 2.10-29PNOZ mc6p 773 724 2.10-32PNOZ mi1p 773 400 2.10-10PNOZ mo1p 773 500 2.10-6PNOZ mo2p 773 520 2.10-8PNOZ mo4p 773 536 2.10-14PNOZ ms1p 774 800 2.10-16

4

4

4-3

Order Reference


Numerically by order number

Order number Type Page773 100 PNOZ m1p 2.10-2773 400 PNOZ mi1p 2.10-10773 500 PNOZ mo1p 2.10-6773 520 PNOZ mo2p 2.10-8773 536 PNOZ mo4p 2.10-14773 700 PNOZ mc1p 2.10-12773 721 PNOZ mc3p 2.10-23773 722 PNOZ mc4p 2.10-26773 723 PNOZ mc5p 2.10-29773 724 PNOZ mc6p 2.10-32774 800 PNOZ ms1p 2.10-16

4 4

Terms and Conditions


The terms of delivery and of payment of therespective Pilz company with whom a salescontract is closed are applied. As a rule thisis the Pilz company that places the order.Please select the legal contract partner fromthe order confirmation.

2

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GB

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NL

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SE

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USA

Pilz Ges.m.b.H.Modecenterstraße 141030 WienAustriaTelephone: 01 7986263-0Telefax: 01 7986264E-Mail: [email protected]

Pilz AustraliaIndustrial Automation LP.9/475 Blackburn RoadMt. Waverley, Melbourne VIC 3149AustraliaTelephone: 03 95446300Telefax: 03 95446311E-Mail: [email protected]

Pilz BelgiumBijenstraat 49051 Gent (Sint-Denijs-Westrem)BelgiumTelephone: 09 3217570Telefax: 09 3217571E-Mail: [email protected]

Pilz do Brasil Sistemas EletrônicosIndustriais Ltda.Rua Ártico, 123 - Jd. do Mar09726-300São Bernardo do Campo - SPBrazilTelephone: 11 4337-1241Telefax: 11 4337-1242E-Mail: [email protected]

Pilz lndustrieelektronik GmbHGewerbepark HintermättliPostfach 65506 MägenwilSwitzerlandTelephone: 062 88979-30Telefax: 062 88979-40E-Mail: [email protected]

Pilz GmbH & Co. KGSichere AutomationFelix-Wankel-Straße 273760 OstfildernGermanyTelephone: 0711 3409-0Telefax: 0711 3409-133E-Mail: [email protected]

Pilz Skandinavien K/SEllegaardvej 25 L6400 SonderborgDenmarkTelephone: 74436332Telefax: 74436342E-Mail: [email protected]

Pilz lndustrieelektronik S.L.Camí Ral, 130Polígono Industrial Palou Nord08400 GranollersSpainTelephone: 938497433Telefax: 938497544E-Mail: [email protected]

Pilz France Electronic1, rue Jacob MayerBP 1267037 Strasbourg CedexFranceTelephone: 03 88104000Telefax: 03 88108000E-Mail: [email protected]

Pilz Skandinavien K/SPakilantie 6100660 HelsinkiFinlandTelephone: 09 27093700Telefax: 09 27093709E-Mail: [email protected]

Pilz Automation TechnologyWillow House, Medlicott CloseOakley Hay Business ParkCorbyNorthants NN18 9NFUnited KingdomTelephone: 01536 460766Telefax: 01536 460866E-Mail: [email protected]

Pilz ltalia SrlVia Meda 2/A22060 Novedrate (CO)ItalyTelephone: 031 789511Telefax: 031 789555E-Mail: [email protected]

Pilz Ireland Industrial AutomationCork Business and Technology ParkModel Farm RoadCorkIrelandTelephone: 021 4346535Telefax: 021 4804994E-Mail: [email protected]

Pilz Japan Co., Ltd.Shin-Yokohama Fujika Building 5F2-5-9 Shin-YokohamaKohoku-kuYokohama 222-0033JapanTelephone: 045 471-2281Telefax: 045 471-2283E-Mail: [email protected]

Pilz de Mexico, S. de R.L. de C.V.Circuito Pintores # 170Cd. SateliteC.P. 53100Naucalpan de Juarez, Edo. de MexicoMexicoTelephone: 55 5572 1300Telefax: 55 5572 4194E-Mail: [email protected]

Pilz NederlandPostbus 1864130 ED VianenNetherlandsTelephone: 0347 320477Telefax: 0347 320485E-Mail: [email protected]

Pilz New Zealand3 Kohanga RoadManagere BridgeAucklandNew ZealandTelephone: 09-6345350Telefax: 09-6345350E-Mail: [email protected]

Pilz Industrieelektronik S.L.R. Eng Duarte Pacheco, 1204 Andar Sala 214470-174 MaiaPortugalTelephone: 229407594Telefax: 229407595E-Mail: [email protected]

Pilz China Representative OfficeRm. 302No. 88 Chang Shu RoadShanghai 200040ChinaTelephone: 021 62493031Telefax: 021 62493036E-Mail: [email protected]

Pilz Korea Office402 Samsung Midas Officetel775-1, Janghang-Dong,Ilsan-Gu, Koyang-SiKyungki-Do 411-837KoreaTelephone: 031 8159541Telefax: 031 8159542E-Mail: [email protected]

In many countries we arerepresented by sales partners.

Please refer to our Homepagefor further details or contact ourheadquarters.

www.pilz.com

Pilz GmbH & Co. KGSichere AutomationFelix-Wankel-Straße 273760 Ostfildern, GermanyTelephone: +49 711 3409-0Telefax: +49 711 3409-133E-Mail: [email protected] A

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Pilz Skandinavien K/SEnergigatan 10 B43437 KungsbackaSwedenTelephone: 0300 13990Telefax: 0300 30740E-Mail: [email protected]

Pilz Elektronik Güvenlik Ürünlerive Hizmetleri Tic. Ltd. †ti.Tan i‡ MerkeziKükürtlü Caddesi No: 67C-Blok Daire: 116080 BursaTurkeyTelephone:0224 2360180Telefax: 0224 2360184E-Mail: [email protected]

Pilz Automation Safety L.P.7150 Commerce BoulevardCantonMichigan 48187USATelephone: 734 354-0272Telefax: 734 354-3355E-Mail: [email protected]

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Documents

Technical Catalogue PNOZmulti Product Range · 2015-06-05 · Technical Catalogue PNOZmulti Product Range March 2004 edition System configuration manual PNOZmulti modular safety system