Pilz PNOZ ml1p User manual

PNOZ ml1p
Operating Manual 21575-EN-06
}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 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Scope 7
2.2 Unit features 7
2.3 Front view 8
Section 3 Safety 9
3.1 Intended use 9
3.2 System requirements 9
3.3 Safety regulations 10
3.3.1 Safety assessment 10
3.3.2 Use of qualified personnel 10
3.3.3 Warranty and liability 10
3.3.4 Disposal 10
3.3.5 For your safety 11
Section 4 Function Description 12
4.1 Integrated protection mechanisms 12
4.2 Functions 12
4.3 System reaction time 14
4.4 Block diagram 14
Section 5 Installation 15
5.1 General installation guidelines 15
5.2 Dimensions in mm 15
5.3 Connecting the base unit and expansion modules 16
Section 6 Commissioning 17
6.1 General wiring guidelines 17
6.2 Download modified project to the PNOZmulti system 18
6.3 Connection 18
6.4 Connection examples 19
6.4.1 Example: Series connection of 3 base units 19
6.4.2 Example: Connection of 5 base units 20
Section 7 Operation 21
7.1 LED indicators 21
7.2 Fault detection 21
Section 8 Technical details 22
8.1 Safety characteristic data 25

Contents
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Section 9 Order reference 26
9.1 Product 26
9.2 Accessories 26

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ ml1p. 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 ml1p
}Jumper
2.2 Unit features
Using the product PNOZ ml1p:
Link module to safely connect two configurable control systems PNOZmulti.
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Point-to-point connection via 4-core shielded and twisted-pair cable
}32 virtual inputs and 32 virtual outputs
}Status indicators
}Plug-in connection terminals (either cage clamp terminal or screw terminal)
}Max. 4 PNOZ ml1p units can be connected to the base unit
}LEDs for
– Operating state
– Error
– Connection status
}Coated version:
Increased environmental requirements (see Technical details [ 22])

Overview
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2.3 Front view
Shield
Key:
}0 V, 24 V:
Supply connections
}CA+, CA-, CB+, CB-:
Connections for 2 expansion modules PNOZ ml1p
}Shield:
Connection for the cable shield

Safety
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3 Safety
3.1 Intended use
The expansion module is used for the point-to-point connection of safe virtual inputs and
outputs between two base units.
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 coated version of the product PNOZ ml1p is suitable for use where there are increased
environmental requirements (see Technical details [ 22]).
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 [ 22]).
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.
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.
4.2 Functions
The PNOZ ml1p link module is used to safely transfer the input information from 32 virtual
inputs and 32 virtual outputs between two PNOZmulti systems. One link module is as-
signed to each base unit. Data is exchanged cyclically.
The function of the inputs and outputs on the control system depends on the safety circuit
created using the PNOZmulti Configurator. A chip card is used to download the safety cir-
cuit to the base unit. The base unit has 2 microcontrollers that monitor each other. They
evaluate the input circuits on the base unit and expansion modules and switch the outputs
on the base unit and expansion modules accordingly.
The LEDs on the base unit and expansion modules indicate the status of the configurable
control system PNOZmulti.
The online help on the PNOZmulti Configurator contains descriptions of the operating
modes and all the functions of the control system, plus connection examples.
Data exchange:
}Data is exchanged cyclically.
}After the end of a PNOZmulti cycle, each base unit sends its output data to its link mod-
ule. This output data is immediately sent to the link module on the other base unit.
}At the same time, the base unit reads the input data from the link module.
Connection of multiple base units:
Any number of base units can be connected via PNOZ ml1p link modules. Two PNOZ mI1p
are required for the connection between two base units. However, only a maximum of 4 link
modules may be connected to any one base unit.
Data transmission time:
The data transmission time tBUS is the time between the virtual output at base unit 1 being
set and the virtual input at base unit 2 becoming available (see Technical details [ 22]).

Function Description
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The maximum reaction time for series connection of n base units
This is the time between the activation of a safety function at the input on one base unit and
the switching of an output on the connected base unit.
}The maximum reaction time tSUM includes the following times:
tON: Input delay = 4 ms
tCOND: Switch-off delay of semiconductor output = 30 ms
tREL: Switch-off delay of relay output = 50 ms
tBUS: Data transmission time between two base units = 35 ms
n: Number of connections between base units
The maximum reaction time tSUM for series connection of n base units
}On semiconductor outputs:
tSUM = tON + (n * tBUS) + tCOND
}On relay outputs:
tSUM = tON + (n * tBUS) + tREL
CAUTION!
For signals that are forwarded or received via the link module, a calculation
must always be made in accordance with the above formulas.
}Input delay and switch-off delay are only included once in the reaction time. The data
transmission time between the link modules is multiplied by the number of connections.
}Please refer to the Connection examples [ 19].
CAUTION!
For signals that are forwarded or received via the link module, the overall
reaction time, e.g. the maximum reaction time of the series connection of n
base units, must always be considered in the risk assessment.
The risk assessment must consider all hazards as regards the reaction time
and the safety distance. The overall reaction time must not delay the arrival
of a safe condition by more than the permitted time.
Virtual inputs and outputs:
Inputs and outputs for both PNOZmulti systems are assigned in the PNOZmulti Configur-
ator. Inputs and outputs with the same number are assigned to each other, e.g. output o5
on one PNOZmulti system to input i5 on the other PNOZmulti system.

Function Description
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Base unit 1
Virtual outputs
o0
...
o31
Virtual inputs
i0
...
i31
Base unit 2
Virtual inputs
i0
...
i31
Virtual outputs
o0
...
o31
4.3 System reaction time
Calculation of the maximum reaction time between an input switching off and a linked out-
put in the system switching off is described in the document "PNOZmulti System Expan-
sion".
4.4 Block diagram
24V 24V
=
Power
=
0V 0V
Interface
to next
module
Interface
to previous
module
CA+ CA- CB+ CB- Shield

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 in mm
94 (3.70")
22,5
(0.88")
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 General wiring guidelines
The wiring is defined in the circuit diagram of the PNOZmulti Configurator.
Please note:
}Information given in the Technical details [ 22] must be followed.
}Use copper wire that can withstand 75°C.
}Two connection terminals are available for each of the supply connections 24 V and 0 V
(semiconductor outputs), plus A1 and A2 (power supply). This means that the supply
voltage can be looped through several connections. When the supply voltage is looped,
the current at each terminal may not exceed 3A.
}The max. cable length between two link modules may be max. 1000 m.
Please note:
When connecting to a PNOZ ml1p with a version < 2.0, the cable length may be max.
100 m. The reduced cable length must be configured in the PNOZmulti Configurator.
}Connect the inputs and outputs from two PNOZ ml1p with a 4-core shielded cable. The
cables must be twisted in pairs (see "Preparing for operation").
}Note the crossover cabling, e.g. CA+ with CB+.
}The cables must be classified into a minimum of Category 5 in accordance with ISO/
IEC 11801.
}You can use ready-made cable from Pilz to connect two PNOZ ml1p. The plug-in con-
nection terminals are either designed as cage clamp terminals or screw terminals (see
order reference).
}Cable shield:
– Please note: Always connect the shield to both link modules (Shield terminal).
– The shield of the connection cable may only be connected to the Shield terminals
on both PNOZml1p. Do not connect the shield to the equipotential bonding bar, for
example.
CAUTION!
Only connect and disconnect the expansion module when the supply
voltage is switched off.

Commissioning
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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.
6.3 Connection
Supply voltage AC DC
Connection of two PNOZmulti base units via the module PNOZ ml1p

Commissioning
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6.4 Connection examples
6.4.1 Example: Series connection of 3 base units
Reaction time tSUM between base unit Base 1 and Base 2:
Input delay tON at I3 and I6 + data transmission time1 * tBUS through link module + switch-off
delay tCOND of the semiconductor output at O0
tSUM = tON + (n * tBUS) + tCOND
tSUM = 4 ms + (1 * 35 ms ) + 30 ms = 69 ms
Reaction time tSUM between base unit Base 1 and Base 3:
Input delay tON at I3 und I6 + data transmission time 2 * tBUS through link modules + switch-
off delay tCOND of the semiconductor output at O1
tSUM = tON + (n * tBUS ) + tCOND
tSUM = 4 ms + (2 * 35 ms ) + 30 ms = 104 ms
CHIP-Card
Shield
CHIP-Card CHIP-Card
Shield Shield Shield
S1
K2 K3
I3 I6
O0 O1
Base 1 Base 2 Base 3

Commissioning
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6.4.2 Example: Connection of 5 base units
The reaction times are calculated in the same way as application example 1. After pressing
S1 on Base 1, the semiconductor outputs switch after the following reaction times tSUM:
O0 on Base 1: 69 ms
O1 on Base 3: 104 ms
O0 on Base 4: 139 ms
O0 on Base 5: 104 ms
CHIP-Card
Shield
CHIP-Card CHIP-Card
Shield Shield Shield
Shield
CHIP-Card
Shield
CHIP-Card
Shield
Shield
Base 1 Base 2 Base 3
Base 4 Base 5
S1
I3 I6
K2
O0
K3
O1
K4
O0
K5
O0