Pilz PNOZ ma1p User manual

PNOZ ma1p
Operating Manual 21687-EN-04
}Configurable safety systems PNOZmulti

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
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Section 1 Introduction 4
1.1 Validity of documentation 4
1.2 Using the documentation 4
1.3 Definition of symbols 4
Section 2 Overview 6
2.1 Scope 6
2.2 Unit features 6
2.3 Front view 7
Section 3 Safety 8
3.1 Intended use 8
3.2 System requirements 8
3.3 Safety regulations 9
3.3.1 Safety assessment 9
3.3.2 Use of qualified personnel 9
3.3.3 Warranty and liability 9
3.3.4 Disposal 9
3.3.5 For your safety 10
Section 4 Function Description 11
4.1 Integrated protection mechanisms 11
4.2 Functions 12
4.3 Block diagram 13
Section 5 Installation 14
5.1 General installation guidelines 14
5.2 Dimensions 14
5.3 Connecting the base unit and expansion modules 15
Section 6 Commissioning 16
6.1 Wiring 16
6.2 Download modified project to the PNOZmulti system 16
6.3 Connection 17
Section 7 Operation 18
7.1 LED indicators 18
Section 8 Technical details 19
8.1 Safety characteristic data 22
Section 9 Order reference 23
9.1 Product 23
9.2 Accessories 23

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ ma1p. It is valid until new documentation
is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
1.3 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

Introduction
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
2.1 Scope
}Expansion module PNOZ ma1p
}Jumper
2.2 Unit features
Using the product PNOZ ma1p:
Expansion module for connection to a base unit from the configurable control system
PNOZmulti
The product has the following features:
}2 safe analogue inputs for current or voltage measurement
}Each input can be configured separately
}Voltage range: -10,24 ... +10.2375 V
}Current range: 0 ... 25.59 mA
}Resolution
– Voltage measurement: 13 Bit (signed 12 Bit)
– Current measurement: 12 Bit
}Range monitoring to monitor for wiring errors or errors in the sensor (4 range limits can
be configured)
}Threshold value monitoring to monitor process variables (8 threshold values can be
configured)
}Max. 4 PNOZ ma1p units can be connected to the base unit
}Exact analogue value can be passed to a fieldbus for diagnostic purposes
}LEDs for
– Operating state
– State of the input signals (Ch0, Ch1)
– Error
}Coated version:
Increased environmental requirements (see Technical details [ 19])
}Plug-in connection terminals:
either spring-loaded terminal or screw terminal available as an accessory (see order
reference)
}Please refer to the document "PNOZmulti System Expansion" for the PNOZmulti base
units that can be connected.

Overview
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2.3 Front view
1
1 1 1
Key:
}0 V, 24 V:
Supply connections
}I0+, I0-:
Inputs for current measurement
}U0+, U0-
Inputs for voltage measurement

Safety
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3 Safety
3.1 Intended use
The expansion module is an analogue input module. It provides 2 safe analogue inputs for
current or voltage measurement. For current measurement, both inputs can be used inde-
pendently. For voltage measurement, both inputs must always be wired. The analogue in-
puts are suitable for connecting transducers or input devices with standardised 10 V
voltage signals or 20 mA current signals. The analogue inputs are designed as differential
inputs. Each analogue input has a signal range of –10 VDC to +10 VDC or 0 mA to 25 mA.
The expansion module may only be connected to a base unit from the PNOZmulti system
(please refer to the document "PNOZmulti System Expansion" for details of the base units
that can be connected).
The configurable small control systems PNOZmulti are used for the safety-related interrup-
tion of safety circuits and are designed for use in:
}E-STOP equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
The following is deemed improper use in particular:
}Any component, technical or electrical modification to the product
}Use of the product outside the areas described in this manual
}Use of the product outside the technical details (see Technical details [ 19]).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
The coated version of the product PNOZ ma1p is suitable for use where there are in-
creased environmental requirements (see Technical details [ 19]).
3.2 System requirements
Please refer to the "Product Modifications PNOZmulti" document in the "Version overview"
section for details of which versions of the base unit and PNOZmulti Configurator can be
used for this product.

Safety
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3.3 Safety regulations
3.3.1 Safety assessment
Before using a unit it is necessary to perform a safety assessment in accordance with the
Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
3.3.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}Have read and understood the information provided in this description under "Safety"
}And have a good knowledge of the generic and specialist standards applicable to the
specific application.
3.3.3 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended
}Damage can be attributed to not having followed the guidelines in the manual
}Operating personnel are not suitably qualified
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.3.4 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Safety
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3.3.5 For your safety
The unit meets all the necessary conditions for safe operation. However, you should always
ensure that the following safety requirements are met:
}This operating manual only describes the basic functions of the unit. The expanded
functions are described in the PNOZmulti Configurator's online help. Only use these
functions once you have read and understood the documentations.
}Do not open the housing or make any unauthorised modifications.
}Please make sure you shut down the supply voltage when performing maintenance
work (e.g. exchanging contactors).

Function Description
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4 Function Description
4.1 Integrated protection mechanisms
The relay conforms to the following safety criteria:
}The circuit is redundant with built-in self-monitoring.
}The safety function remains effective in the case of a component failure.
The analogue input module can be used for applications up to SIL3.
For applications in accordance with SIL2 or SIL3, input devices must be attached that are
certified for SIL2 in accordance with IEC 61508. The output signal of the input device must
be monitored, i.e. actual and set value must be compared with one another. In the event of
a deviation, a reaction must occur that the PNOZmulti recognises and to which it reacts.
}SIL2 applications:
SIL2 applications are only possible for current measurement. If the analogue input
module is to be used for current measurement on SIL2 applications, both inputs can be
used independently for current measurement.
}SIL3 applications:
If the analogue input module is to be used for SIL3 applications, both inputs must be
configured. They will then be combined to form a SIL3 input. To do this, connect a suit-
able encoder to each input. The analogue input module will then check the feasibility of
the input signals, i.e. the values measured from both input signals are compared.
NOTICE
For SIL3 applications, set a maximum permitted deviation between the
measured values of both input signals (tolerance) in the PNOZmulti Config-
urator. A tolerance is only entered to balance out the imprecision of the sig-
nal recording, the encoder and the analogue input module. To maintain
safety, the tolerance should be set as low as possible. Please note that the
maximum safety-related measurement error for the overall system is
composed of the following measurement errors:
Error during signal recording
+ Sensor measurement error
+ Max. measurement error in the event of a potential module error
To ensure that your application switches off safely in the event of a critical
process variable, the configuration of the range limits/threshold values must
be increased/decreased to take into account the maximum measurement
error.

Function Description
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NOTICE
When using the analogue input module for voltage measurement, please
note the following:
If the input signal is open circuit or there is a short circuit, this will not be de-
tected with an input voltage of 0 V. Please use your risk assessment/hazard
analysis to check whether your application fulfills the safety-related require-
ments or whether additional measures must be taken. We recommend that
you configure a permitted value range between 2 - 10 V PNOZmulti Config-
urator.
4.2 Functions
The analogue input module monitors analogue input signals. It can measure both current
and voltage.
The input signals are collected and read in at each input through two channels and are con-
verted into digital signals. The resolution is 13 Bit for voltage measurement, 12 Bit for cur-
rent measurement.
In the PNOZmulti Configurator you can define limit values, which are to be monitored:
}Range monitoring
With range monitoring you can define the permitted value range. You can define up to 4
range limits (e.g. <3 mA monitored for open circuit; I > 21 mA monitored for encoder er-
ror). Depending on the selected condition ("greater than" or "less than"), the ENBL out-
put bit and output bits 1 - 8 for threshold value monitoring are set to "0" if the recorded
value exceeds or drops below a range limit. An entry is added to the error stack.
Exception: If "automatic start" type has been selected, no entry will be added to the er-
ror stack.
}Threshold value monitoring
You can define up to 8 switching thresholds, which can be used to monitor certain pro-
cess variables (e.g. different temperature values). The thresholds can be configured
with or without scaling. 2 threshold values are configured per threshold. One threshold
value defines when the relevant output bit (1 ... 8) is set to "1". The second threshold
value defines when the output bit is reset to "0". No entry is added to the error stack.
The exact analogue values are made available to the base unit to forward to a fieldbus.
This value is transmitted through a single channel and is not safety-related. It can be used
for diagnostic purposes.
INFORMATION
The online help on the PNOZmulti Configurator contains descriptions of the
operating modes and all the functions of the control system PNOZmulti.

Function Description
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4.3 Block diagram
24V 24V
=
Power
=
0V 0V
Interface
to previous
module
Interface
to next
module
0V24V
Input
I0+ I0- U0+ U0- I1+ I1- U1+ U1-
=
=
24V 24V
24V 0V 0V 0V
ADC
Input

Installation
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5 Installation
5.1 General installation guidelines
}The control system should be installed in a control cabinet with a protection type of at
least IP54. Fit the control system to a horizontal mounting rail. The venting slots must
face upward and downward. Other mounting positions could destroy the control system.
}Use the notches on the rear of the unit to attach it to a mounting rail. Connect the con-
trol system to the mounting rail in an upright position, so that the earthing springs on the
control system are pressed on to the mounting rail.
}The ambient temperature of the PNOZmulti units in the control cabinet must not exceed
the figure stated in the technical details, otherwise air conditioning will be required.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
CAUTION!
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
5.2 Dimensions
94 (3.70")
45
(1.77")
121 (4.76")

Installation
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5.3 Connecting the base unit and expansion modules
Connect the base unit and the expansion module as described in the operating instructions
for the base units.
}Do not connect a terminator to the last expansion module on the left-hand side.
}Install the expansion module in the position in which it is configured in the PNOZmulti
Configurator.
The position of the expansion modules is defined in the PNOZmulti Configurator. The ex-
pansion modules are connected to the left or right of the base unit, depending on the type.
Please refer to the document "PNOZmulti System Expansion" for details of the number of
modules that can be connected to the base unit and the module types.

Commissioning
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6 Commissioning
6.1 Wiring
The wiring is defined in the circuit diagram of the PNOZmulti Configurator.
Please note:
}Information given in the Technical details [ 19] must be followed.
}Use copper wire that can withstand 75°C.
}The power supply that feeds the expansion module and the input devices must meet
the regulations for extra low voltages with protective separation (SELV, PELV).
}6 connection terminals are available for each of the supply connections 24 V and 0 V.
This means that the supply voltage can be looped through several connections and the
encoder can be supplied.
}Use shielded, twisted pair cable for the connections on the input current circuits.
}Separate the supply voltage cable from the analogue input current lines.
}If the analogue input module is used to measure current, the voltage inputs must be
short-circuited.
}For transducers located outside the control cabinet: Where the cable enters the
control cabinet, the cable shield must be connected to the earth potential over a wide
surface area and with low impedance (connect in star).
NOTICE
If the analogue input module is used to measure voltage, both inputs must
be wired.
6.2 Download modified project to the PNOZmulti system
As soon as an additional expansion module has been connected to the system, the project
must be amended using the PNOZmulti Configurator. Proceed as described in the operat-
ing instructions for the base unit.
NOTICE
For the commissioning and after every program change, you must check
whether the safety devices are functioning correctly.

Commissioning
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6.3 Connection
Example for current measurement
SIL2 application
I0+
PNOZ ma1p
I0-
24 V
0 V
SIL3 application
I0+
PNOZ ma1p
I0-
I1+
I1-
24 V
0 V
24 V
0 V
Connection to transducer (SIL2 or SIL3)
Please note:
}The transducers are SIL2 certified
}The voltage supply to the input device is optional
}With current measurement, the voltage inputs U+ - U- must be short-circuited.
CAUTION!
A constant load of ± 15 V or ± 50 mA per input must not be exceeded under
any circumstances

Operation
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7 Operation
When the supply voltage is switched on, the PNOZmulti safety system copies the configur-
ation from the chip card.
The LEDs “POWER”, “DIAG”, “FAULT”, “IFAULT” and “OFAULT” will light up on the base
unit.
The PNOZmulti safety system is ready for operation when the "POWER" and "RUN" LEDs
on the base unit and the "READY" LED on the PNOZ ma1p are lit continuously.
7.1 LED indicators
Legend
LED on
LED flashes
LED off
LED LED status Meaning
READY Gree
n
The unit is ready for operation
The unit is not ready for operation
FAULT Red External error
Red Internal error
No fault
CH0 Red Value at I0 has fallen below the lower range
limit
Red Upper threshold value at I0 exceeded; with
SIL3 (Ch0 and Ch1 flashing alternately): set
tolerance exceeded
Gree
n
Measuring range at I0 within the defined range
CH1 Red Value at I1 has fallen below the lower range
limit
Red Upper threshold value at I1 exceeded; with
SIL3 (Ch0 and Ch1 flashing alternately): set
tolerance exceeded
Gree
n
Measuring range at I1 within the defined range

Technical details
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8 Technical details
General 773812 773813
Approvals
BG, CCC, CE, EAC (Eurasian),
TÜV, cULus Listed
BG, CCC, CE, EAC (Eurasian),
TÜV, cULus Listed
Electrical data 773812 773813
Supply voltage
for Module supply Module supply
Voltage 24,0 V 24,0 V
Kind DC DC
Voltage tolerance -15 %/+20 % -15 %/+20 %
Output of external power supply
(DC) 2,0 W 2,0 W
Residual ripple DC 5 % 5 %
Status indicator LED LED
Analogue inputs 773812 773813
Number of analogue inputs 2 2
Type of analogue inputs Voltage, current Voltage, current
Input filter 1st order, RC filter 1st order, RC filter
Cutoff frequency 80 Hz 80 Hz
Current measurement
Signal range 0,00 - 25,59 mA 0,00 - 25,59 mA
Value range 0 - 4095 d 0 - 4095 d
Resolution 12 Bit 12 Bit
Value of least significant bit
(LSB) 6,25 µA 6,25 µA
Input resistance 100,000 Ohm 100,000 Ohm
Max. continuous current 50 mA 50 mA
Voltage measurement
Signal range -10,2400 - 10,2375 V -10,2400 - 10,2375 V
Value range -4096 - 4095 d -4096 - 4095 d
Resolution 13 Bit (signed 12 Bit) 13 Bit (signed 12 Bit)
Value of least significant bit
(LSB) 5 mV 5 mV
Input resistance 290 kOhm 290 kOhm
Max. continuous voltage -30 - 30 V -30 - 30 V
Deviations from the measuring
range limit value
Output variable error at 25 ℃0,5 % 0,5 %
Temperature coefficient 0,0025 %/K 0,0025 %/K
Greatest transient deviation dur-
ing el. interference test 1,0 % 1,0 %
Max. measurement error at full
temperature range 0,5 % 0,5 %
Max. measurement error in the
case of a potential module error 1,5 % 1,5 %

Technical details
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Analogue inputs 773812 773813
Max. voltage between inputs I0 and
I1 with current or voltage measure-
ment 30 V 30 V
Filter time constant 2,0 ms 2,0 ms
Potential isolation No No
Times 773812 773813
Switch-on delay 5,00 s 5,00 s
Supply interruption before de-ener-
gisation 20 ms 20 ms
Max. reaction time when the input
signal changes 100 ms 100 ms
Environmental data 773812 773813
Ambient temperature
In accordance with the standard EN 60068-2-14 EN 60068-2-14
Temperature range 0 - 60 °C -25 - 60 °C
Forced convection in control
cabinet off 55 °C 55 °C
Storage temperature
In accordance with the standard EN 60068-2-1/-2 EN 60068-2-1/-2
Temperature range -25 - 70 °C -25 - 70 °C
Climatic suitability
In accordance with the standard EN 60068-2-30, EN 60068-2-78 EN 60068-2-30, EN 60068-2-78
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during operation Not permitted Short-term
EMC EN 61131-2 EN 61131-2
Vibration
In accordance with the standard EN 60068-2-6 EN 60068-2-6
Frequency 10,0 - 150,0 Hz –
Acceleration 1g 1g
Broadband noise
In accordance with the standard – EN 60068-2-64
Frequency – 5 - 500 Hz
Acceleration – 1,9grms
Shock stress
In accordance with the standard EN 60068-2-27 EN 60068-2-27
Acceleration 15g 15g
Duration 11 ms 11 ms
Max. operating height above sea
level 2000 m 2000 m
Airgap creepage
In accordance with the standard EN 61131-2 EN 61131-2
Overvoltage category III III
Pollution degree 2 2
Rated insulation voltage 30 V 30 V