Pilz PNOZ m ES EtherCAT User manual

PNOZ m ES EtherCAT
Operating Manual-1003057-EN-04
}Configurable control systems PNOZmulti 2

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
Operating Manual PNOZ m ES EtherCAT
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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 of supply 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 Use of qualified personnel 9
3.3.2 Warranty and liability 9
3.3.3 Disposal 9
3.3.4 For your safety 9
Section 4 Function description 10
4.1 Operation 10
4.2 Data access 10
4.3 Block diagram 11
Section 5 Installation 12
5.1 General installation guidelines 12
5.2 Dimensions in mm 12
5.3 Connect the base unit and expansion modules 13
Section 6 Commissioning 14
6.1 General wiring guidelines 14
6.2 Connecting the supply voltage 14
6.3 Interface assignment 15
6.4 Download modified project to the PNOZmulti safety system 15
6.5 Preparing for operation 15
6.6 Connection example 16
Section 7 Operation 17
7.1 Messages 18
Section 8 Technical details 19
Section 9 Order reference 22
9.1 Product 22
9.2 Accessories 22

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ m ES EtherCAT. It is valid until new doc-
umentation 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 of supply
}Expansion module PNOZ m ES EtherCAT
}Jumper
2.2 Unit features
Using the product PNOZ m ES EtherCAT:
Expansion module for connection to a base unit from the configurable control system
PNOZmulti 2 .
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Network protocols: EtherCAT
}Supports CANopen over EtherCAT (DS301 V4.02 compliant)
}Status indicators for communication with EtherCAT and for errors
}128 virtual inputs and outputs on the control system PNOZmulti can be defined in the
PNOZmulti Configurator for communication with the fieldbus EtherCAT.
}Max. 1 PNOZ m ES EtherCAT can be connected to the base unit
}Plug-in connection terminals:
either spring-loaded terminal or screw terminal available as an accessory (see order
reference)
}For details of the PNOZmulti 2 base units that can be connected, please refer to the
document "PNOZmulti System Expansion".

Overview
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2.3 Front view
Legend:
}X1: EtherCAT IN
}X2: EtherCAT OUT
}X4: 0 V, 24 V:
Supply connections
Functional earth
}LEDs:
– Power
– Run
– Error
– L/A 1
– L/A 2
is registered trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany

Safety
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3 Safety
3.1 Intended use
The expansion module PNOZ m ES EtherCAT is used for communication between the con-
figurable control system PNOZmulti with EtherCAT.
EtherCAT is designed for fast data exchange at field level. The expansion module PNOZ m
ES EtherCAT is a passive EtherCAT subscriber (Slave). The basic communication func-
tions with EtherCAT conform to the system description published by the EtherCAT User
Group. The central controller (master) reads input information from the slaves and writes
output information to the slaves as part of each cycle.
The expansion module may only be connected to a base unit from the configurable control
system PNOZmulti (please refer to the document "PNOZmulti System Expansion" for de-
tails of the base units that can be connected)
The configurable control system PNOZmulti is used for the safety-related interruption of
safety circuits and is designed for use in:
}E-STOP equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
The expansion module may not be used for safety-related functions.
Intended use includes making the electrical installation EMC-compliant. The product is de-
signed for use in an industrial environment. It is not suitable for use in a domestic environ-
ment, as this can lead to interference.
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 chapter entitled “Technical De-
tails”)
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 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.
3.3.2 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.).
3.3.3 Disposal
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3.4 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 Operation
The virtual inputs and outputs that are to be transferred via EtherCAT are selected and con-
figured in the PNOZmulti Configurator. The base unit and the expansion module PNOZ m
ES EtherCAT are connected via a jumper. After the supply voltage is switched on or the
PNOZmulti control system is reset, the expansion module PNOZ m ES EtherCAT is con-
figured and started automatically.
The connection to EtherCAT is made via the two RJ45 sockets.
LEDs indicate the status of the expansion module on EtherCAT.
The configuration is described in detail in the PNOZmulti Configurator's online help.
4.2 Data access
The data is structured as follows:
}Virtual data
– Input area PNOZ m ES EtherCAT
The values for the inputs are set in the Master as an output and transferred to the
PNOZmulti 2.
– Output range PNOZ m ES EtherCAT
The outputs are configured in the PNOZmulti Configurator and transferred to the
Master.
}Status of LEDs:
LED status 1 Output Byte
The LED status of the base unit can be requested directly as follows
– Bit 0 = 1: LED OFAULT is lit or flashes
– Bit 1 = 1: LED IFAULT is lit or flashes
– Bit 2 = 1: LED FAULT is lit or flashes
– Bit 3 = 1: LED DIAG is lit or flashes
– Bit 4 = 1: LED RUN FS is lit
– Bit 5: Reserved
– Bit 6 = 1: LED RUN ST is lit (not for PNOZ m B0)
– Bit 7: Reserved
}Data exchange is displayed in Bit 5.
}Polling the payload data: 2 Bytes with the table number and segment number are sent
by the Master for access to the payload data table (15 Bytes are returned to the Mas-
ter).
The document "Communication Interfaces" contains detailed information
}on data exchange (tables, segments) in the section entitled "Fieldbus modules",
}on the virtual data in chapter "Service Data Objects (SDOs)" for PNOZ m ES EtherCAT.

Function description
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4.3 Block diagram
Interface
to next module
Data
(ST)
EtherCAT
Interface
to previous
module
24 V
0 V
Module
Supply

Installation
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5 Installation
5.1 General installation guidelines
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Fit the safety system to a horizontal mounting rail. The venting slots must face upward
and downward. Other mounting positions could damage the safety system.
}Use the locking elements on the rear of the unit to attach it to a mounting rail.
}In environments exposed to heavy vibration, the unit should be secured using a fixing
element (e.g. retaining bracket or end angle).
}Open the locking slide before lifting the unit from the mounting rail.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
}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.
NOTICE
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 in mm
101,4 (4,11“)
115,0 (4,53“)
22,5
(0,88“)

Installation
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5.3 Connect the base unit and expansion modules
Connect the base unit and the expansion module as described in the operating instructions
for the base units.
}Connect the black/yellow terminator to the expansion module.
}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 General wiring guidelines
The wiring is defined in the circuit diagram of the PNOZmulti Configurator.
It is possible to define which inputs and outputs on the safety system will communicate with
EtherCAT.
Note:
}Information given in the "Technical details" must be followed.
}Use copper wire that can withstand 75 °C.
}External measures must be used to connect the terminal to the functional earth,
when the mounting rail is not connected to the functional earth.
Please note the following when connecting to EtherCAT:
}The following minimum requirements of the connection cable and connector must be
met:
– Only use standard industrial Ethernet cable and connectors.
– Only use double-shielded twisted pair cable and shielded RJ45 connectors (indus-
trial connectors).
– 100BaseTX cable in accordance with the Ethernet standard (min. Category 5)
}Measures to protect against interference:
Ensure the requirements for the industrial use of EtherCAT are met, as stated in the In-
stallation Manual published by the User Group.
CAUTION!
Only connect and disconnect the expansion module when the supply
voltage is switched off.
6.2 Connecting the supply voltage
Connect the supply voltage to the fieldbus module:
}24 V terminal: + 24 VDC
}0 V terminal: 0 V
}Protect the supply voltage as follows:
– Circuit breaker, characteristic C - 6 A
or
– Blow-out fuse, slow, 6A

Commissioning
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6.3 Interface assignment
RJ45 socket
8-pin PIN Standard
8 1
1 TD+ (Transmit+)
2 TD- (Transmit-)
3 RD+ (Receive+)
4 n.c.
5 n.c.
6 RD- (Receive-)
7 n.c.
8 n.c.
n.c.: Not connected
6.4 Download modified project to the PNOZmulti safety 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.
6.5 Preparing for operation
}Install Device Description File
Install the Device Description File in your configuration software. You can only then use
the PNOZ m ES EtherCAT.
}Connect the supply voltage to the base unit:
Terminals 24 V and A1 (+): + 24VDC
Terminals 0 V and A2 (-) : 0 V

Commissioning
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6.6 Connection example
EtherCAT
Master
EtherCAT
Slave 1
EtherCAT
Slave 3
EtherCAT
Slave 2

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 expansion module PNOZ m ES EtherCAT is configured and started automatically. The
LEDs "L/A 1" and "L/A 2", "Run " and "Error" indicate the status of thePNOZ m ES Ether-
CAT on EtherCAT.

Operation
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7.1 Messages
LED LED status Meaning
PWR Supply voltage is present
Supply voltage is not present
Run green The device is in "OPERATIONAL" status
1
green The device is in "SAFE-OPERATIONAL" status
green The device is in "PRE-OPERATIONAL" status
The device is in "INIT" status
L/A 1 green Bus connection available at X1
Green Data traffic present at X1
Bus connection is not available at X1
L/A 2 green Bus connection available at X2
Green Data traffic present at X2
Bus connection not available at X2
Error red Application Watchdog Timeout
2
red Sync Manager Watchdog Timeout.
1
red The Slave device application has changed the Ether-
CAT status independently: The "Change" parameter in
the AL status register is set to 01 (change/error).
red Configuration error
EtherCAT communication is in operation
Legend
LED off
1
LED flashes once
2
LED flashes twice
LED flashes briefly
LED flashes
LED on

Technical details
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8 Technical details
General
Approvals CE, EAC (Eurasian), cULus Listed
Electrical data
Supply voltage
for Module supply
Voltage 24 V
Kind DC
Voltage tolerance -20 %/+25 %
Max. continuous current that the external power
supply must provide 35 mA
Output of external power supply (DC) 0,9 W
Potential isolation yes
Supply voltage
for Module supply
internal Via base unit
Voltage 3,3 V
Kind DC
Current consumption 60 mA
Power consumption 0,2 W
Max. power dissipation of module 1,5 W
Status indicator LED
Fieldbus interface
Fieldbus interface EtherCAT
Device type Slave
Log CANopen over EtherCAT
Transmission rates 100 MBit/s
Connection RJ45
Galvanic isolation yes
Environmental data
Ambient temperature
In accordance with the standard EN 60068-2-14
Temperature range 0 - 60 °C
Forced convection in control cabinet off 55 °C
Storage temperature
In accordance with the standard EN 60068-2-1/-2
Temperature range -25 - 70 °C
Climatic suitability
In accordance with the standard EN 60068-2-30, EN 60068-2-78
Condensation during operation Not permitted
Max. operating height above sea level 2000 m
EMC EN 61131-2

Technical details
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Environmental data
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10 - 150 Hz
Acceleration 1g
Shock stress
In accordance with the standard EN 60068-2-27
Acceleration 15g
Duration 11 ms
Airgap creepage
In accordance with the standard EN 61131-2
Overvoltage category II
Pollution degree 2
Rated insulation voltage 30 V
Protection type
In accordance with the standard EN 60529
Housing IP20
Terminals IP20
Mounting area (e.g. control cabinet) IP54
Potential isolation
Potential isolation between Fieldbus and module voltage
Type of potential isolation Functional insulation
Rated surge voltage 500 V
Mechanical data
Mounting position Horizontal on top hat rail
DIN rail
Top hat rail 35 x 7,5 EN 50022
Recess width 27 mm
Material
Bottom PC
Front PC
Top PC
Connection type Spring-loaded terminal, screw terminal
Conductor cross section with screw terminals
1 core flexible 0,25 - 2,5 mm², 24 - 12 AWG
2 core with the same cross section, flexible without
crimp connectors or with TWIN crimp connectors 0,2 - 1,5 mm², 24 - 16 AWG
Torque setting with screw terminals 0,5 Nm
Conductor cross section with spring-loaded terminals:
Flexible with/without crimp connector 0,2 - 2,5 mm², 24 - 12 AWG
Spring-loaded terminals: Terminal points per connec-
tion 2
Stripping length with spring-loaded terminals 9 mm