Pilz PNOZmulti User manual

PNOZmulti Installation Manual
Installation Manual 1002265-EN-02
}Configurable control systems PNOZmulti 2
}Configurable compact control systems PNOZmulti Mini
}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 the documentation 5
1.2 Definition of symbols 5
Section 2 Safety 7
2.1 General safety guidelines 7
2.2 Use of qualified personnel 7
2.3 Safety during installation 7
2.3.1 Power supply 7
2.3.2 Installation 8
2.3.3 Chip card 8
Section 3 Electromagnetic compatibility (EMC) 10
3.1 Overview 10
3.2 Making the installation EMC-compliant 11
3.2.1 Connecting the earth cables 11
3.2.2 Cable routing 11
3.2.3 Connecting the fieldbuses 12
3.2.4 Equipotential bonding 12
3.2.5 Shielding 12
3.2.6 Suppression on inductive loads 13
3.2.7 Lighting in the control cabinet 13
3.3 Testing the EMC-compliance of an installation 14
Section 4 Installation 16
4.1 Control cabinet installation 16
4.1.1 General installation guidelines 16
4.1.1.1 Positioning of units 16
4.1.2 Mounting distances 17
4.2 Install the control system PNOZmulti 18
4.2.1 Install base unit without expansion module 18
4.2.2 Connect the base unit and expansion modules 18
4.3 Install the control system PNOZmulti Mini 19
4.3.1 Install base unit without expansion module 19
4.3.2 Connect the base unit and expansion modules 20
4.4 Install the control system PNOZmulti 2 21
4.4.1 Install base unit without expansion module 21
4.4.2 Connecting the base unit and expansion modules 22
Section 5 Connecting the Control System PNOZmulti 23
5.1 General wiring guidelines 23
5.2 Supply voltage 23
5.3 Earthing 24
5.4 Cable requirements 24
5.5 Terminals 25
5.6 Connecting safety inputs and outputs 25
5.7 Example of EMC-compliant wiring 26

Contents
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5.8 Analogue input module 26
5.9 Motion monitoring modules 27
5.10 Connection example: analogue input module and speed monitor 29
5.11 Fieldbus modules 31
5.12 Link modules 31
5.13 Cascading 32
5.13.1 System requirements 33
5.13.2 Series connection 33
5.13.3 Tree structure 34
5.13.4 Supply voltage for the cascaded units 35
5.13.5 Installing the cascaded units 35
5.13.6 Wiring 36

Introduction
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1 Introduction
1.1 Validity of the documentation
This documentation is intended for instruction and should be retained for future reference.
This installation manual contains all the information you need to install the configurable
small control systems PNOZmulti.
Please also refer to the following documents:
}The respective operating manuals contain a description of the units' functionality and
guidelines on their operation.
}The document "PNOZmulti System Expansion" contains details of the maximum sys-
tem expansion.
This documentation is valid for the configurable small control systems PNOZmulti:
}Configurable control systems PNOZmulti 2
}Configurable compact control systems PNOZmulti Mini
}Configurable safety systems PNOZmulti.
The documentation is valid until new documentation is published.
1.2 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.

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

Safety
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2 Safety
2.1 General safety guidelines
Please note the following general safety guidelines:
}Ensure VDE, local and national regulations are met, especially those relating to safety.
The relevant safety regulations for the respective application must also be met.
}The product is designed exclusively for use in an industrial environment. It is not suit-
able for use in a domestic environment, as this can lead to interference. Additional sup-
pression measures may be required.
}The deciding factors in how to use the device are the requirements of the relevant certi-
fication body (e.g. BG or TÜV).
}In particular please observe the wiring regulations.
}If the devices are altered in any way, such as exchanging a component or carrying out
soldering work, the guarantee, and any approval, will be rendered invalid.
}Devices must be disposed of properly when they reach the end of their service life.
2.2 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.
2.3 Safety during installation
2.3.1 Power supply
The control system requires a 24 VDC supply. Check that the external power supply
provides this voltage.
The tolerance of the supply voltage must comply with the technical details. Safe operation
cannot be guaranteed outside this range.
Protect the external power supply by fitting a fuse between the external power supply and
the control system. The size of the fuse will depend on the specification of the external
power supply, the cable cross section and on local regulations.

Safety
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WARNING!
Risk of electrocution!
Safe electrical isolation must be ensured for the external power supply that
generates the supply voltage. Failure to do so could result in electric shock.
The power supplies must comply with EN 60950-1:2006/A11:2009, EN
61558-2-6:11/1997.
WARNING!
Risk of electrocution!
When voltage is applied, contact with live components could result in seri-
ous or even fatal injury from an electric shock.
If voltages higher than 50VAC or 120VDC are connected to the control
systems PNOZmulti or PNOZmulti Mini, e.g. to switch contacts on relay
modules, please note the following:
– Specific accident prevention regulations apply.
2.3.2 Installation
Please note:
}The control systems should be installed in an enclosure, e.g. control cabinet.
}The control cabinet must conform to the protection class required for the environment.
}Please refer to the technical details of the relevant devices when installing them in the
control cabinet.
}Ensure there is sufficient ventilation to prevent heat building up within the control cab-
inet. Monitor the ambient temperature of 0...60 °C.
}In extreme ambient conditions, additional measures such as control cabinet air condi-
tioning may be required in order to keep within the prescribed value range.
2.3.3 Chip card
The base units for the PNOZmulti and PNOZmulti Mini and the base units PNOZ m B0 from
the PNOZmulti 2 range have a chip card for saving and downloading projects.
NOTICE
The chip card contact is only guaranteed if the contact surface is clean and
undamaged. For this reason please protect the chip card's contact surface
from
– Contamination
– Contact
– Mechanical impact, such as scratches.

Safety
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The base units PNOZ m B1 have a USB memory for saving and downloading projects.

Electromagnetic compatibility (EMC)
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3 Electromagnetic compatibility (EMC)
3.1 Overview
The PNOZmulti systems are designed for use within an electromagnetic industrial environ-
ment. To ensure electromagnetic compatibility the correct procedures must be carried out
during installation.
A device is electromagnetically compatible if
}It functions without error in a given electromagnetic environment.
}It does not adversely affect its own environment.
Electromagnetic interference can reach the devices through:
}Fields
}Power supplies
}Earth cabling
}Bus connections
}Interfaces
}Input and output cables
The interference can be transferred from the source to the receiver (interference sink) via
the coupling routes.
Interference reaches the interference sink (e.g. the control system devices) in various ways:
}DC coupling:
DC coupling occurs if the source and sink of interference have common cable connec-
tions. The common cable presents complex resistances, inducing potential differences.
– Typical sources of interference are switches/relays, running motors or varying po-
tentials for other systems on the same power supply.
}Capacitive (electrical) coupling
A different potential between the source and interference sink (e.g. two cables) creates
an electrical field. Coupling is proportional to the rate of voltage change.
– Typical sources of interference are contactors, static discharge, parallel signal
cables.
}Inductive (magnetic) coupling
A live cable produces a magnetic field which also surrounds adjacent cables. Interfer-
ence voltage is induced. Coupling is proportional to the rate of current change.
– Typical sources of interference are mains cables running in parallel, live cables,
high frequency cables, inductors, transformers, motors.
}Electromagnetic coupling
A cable can emit a signal as a radio wave. This wave is then picked up by another
cable.
– Typical sources of interference are transmitters such as radios, sparks from spark
plugs, welding equipment, etc.

Electromagnetic compatibility (EMC)
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NOTICE
Powerful HF transmitters should only be operated at a distance of more
than 0.6 m.
}Static discharge:
Static discharge occurs where there are very high differences in potential between two
points. If the two points are brought closer together or if the potential difference is in-
creased, discharges can occur in the air gaps.
– Typical source of interference: people who are statically charged from a synthetic
carpet, for example.
3.2 Making the installation EMC-compliant
3.2.1 Connecting the earth cables
Please note:
}A conductor cross section of at least 2.5 mm2 should be used for the connection to the
central earth bar. Connections should be kept as short as possible.
}Connections to the earth bar should always be in star form.
}Connect together the 0V connections on all the 24 V power supplies and earth the 0 V
mains at a single point, or ensure that measures are in place to monitor for earth faults.
}Earthed supply voltages offer the best noise immunity.
}The connection of the 0 V supply to the central earth bar or earth fault monitor must be
in accordance with relevant national regulations (such as EN60204-1, NFPA 79:17-7,
NEC: Article 250).
}Define a central earthing point.
}Make sure that the control system and motor are earthed correctly.
}Earth the mounting plate.
}Connections should be protected from corrosion.
}Flexible earthing straps should be used on moving earth parts (e.g. machine parts,
gates). Ensure these earthing straps are as short and wide as possible.
3.2.2 Cable routing
It is possible to differentiate between cables according to their function. The following
groups exist:
}Group 1: Data and supply lines for DC voltages below 60 V and AC voltages below 25
V
}Group 2: Data and supply lines for DC voltages from 60 V to 400 V and AC voltages
from 25 V to 400 V.
}Group 3: Supply lines above 400 V
Cabling inside buildings
}The cable groups listed above should be laid separately.

Electromagnetic compatibility (EMC)
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}Cables of the same group can be laid within the same cable duct.
}Cables from group 1 and group 2 should be laid in separate groups or in cable ducts
which are at least 10 cm apart.
}Cables from group 1 and group 3 should be laid in separate groups or in cable ducts
which are at least 50 cm apart.
}Data and signal lines should be laid as close as possible to an earthed surface.
Cabling to open air systems
}As far as possible use metal conduits. These should be electrically connected and
earthed.
}Ensure there is sufficient protection against lightning by using metal conduits earthed at
both ends, or concrete cable ducts with reinforcements connected across the joints.
3.2.3 Connecting the fieldbuses
To connect the available fieldbus systems, please refer to the
}Operating manual for the respective fieldbus module.
}Guidelines published by the user group or manufacturer of the respective fieldbus.
}"Communication interfaces PNOZmulti" document
3.2.4 Equipotential bonding
Potential differences can occur if the devices are connected to different earth or ground
connections. Even cable shields that are connected at either end and have different earth
connections can cause potential differences. In order to avoid interference, equipotential
bonding cables must be installed. Please note:
}Select a low impedance equipotential bonding cable.
}Select the following as standard values for the cross section of the equipotential bond-
ing cables:
– 16 mm2 for equipotential bonding cable up to 200m in length
– 25 mm2 for equipotential bonding cable over 200m in length
}If the devices of the control system PNOZmulti are connected with shielded signal
cables which are earthed at either end, the impedance is calculated as follows:
– Impedance equipotential bonding cable = 10 % of shield impedance
}Use copper or galvanised steel equipotential bonding cable.
}Connect equipotential bonding cables to the earth bar over as wide a surface area as
possible.
}As short a distance as possible should be kept between the equipotential bonding cable
and signal cable.
3.2.5 Shielding
Interference currents must be diverted to cable shields via shield bars.
Please note:
}Connect the shields with low impedance to the shield bar or earth bar.
}Use cables with a braided shield, with a minimum coverage of 80 %.

Electromagnetic compatibility (EMC)
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}When laying cables without equipotential bonding or using foil shields: Connect the
shield at one end.
}If possible, use metal or metallised plugs to connect cables for serial data transfer. Al-
ways refer to the regulations relating to the fieldbus systems.
}If the shield is not to be connected at the end of the cable, it must have no connection
to the connector housing.
}If the shield is to be connected, connect it to the shield bar at the point where the cable
enters the cabinet, without making a break in the cable. Use metal cable clamps which
cover the shield over a wide surface area. Route the shield as far as the units, but do
not connect it to the units.
Digital inputs and outputs do not need shielded cables. However, if the connection cables
have a shield, it should be connected at one end.
Analogue inputs and inputs on the incremental encoder on the speed monitors should al-
ways be connected using shielded cables.
INFORMATION
A connection example is available in the chapter entitled "Connecting the
Control System", under "Analogue input module".
3.2.6 Suppression on inductive loads
Adequate protection must be provided for all inductive consumers.
3.2.7 Lighting in the control cabinet
Use low interference panel lighting for inside the control cabinet.

Electromagnetic compatibility (EMC)
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3.3 Testing the EMC-compliance of an installation
You can use the list below to check that the installation of the control systems PNOZmulti
and PNOZmulti Mini is EMC-compliant.
Check Action Done
Are there areas with a high
probability of interference?
(e.g. computers running,
process control areas, distri-
bution cabinets, cable cas-
ing, frequency converters,
hand-held radios etc.)
EMC protection in these areas should be
planned with particular care.
Are areas where computers
are running or areas such as
process control rooms suffi-
ciently shielded from electro-
magnetic coupling?
If necessary shield the whole area.
Does the cable layout take
into account the principles of
EMC compliance?
Some important points: Lay cables close to
earth, keep clear of other electrical equipment,
keep cables in ducts separate from other parts
of the installation, keep cables as short as pos-
sible, avoid multiple crossovers
Is the supply voltage free of
interference?
Supplies with interference voltages should be
fitted with a mains filter.
EMC characteristics of indi-
vidual units / all units tested
once installed?
Test EMC characteristics under operating con-
ditions, e.g. while hand-held radios are in use,
or HF frequency generators are close by. Test
static discharge with operating personnel, test
mutual interference between units under differ-
ent operating conditions.
Earthed parts connected
correctly?
Most important are the connections between
the units, racking bars, earth conductors and
shield bars; inactive metal parts should be con-
nected over a wide surface area and earthed at
a central point; with insulated metal: Remove
insulation or use special contact fixings; protect
the connection from corrosion; connect the cab-
inet doors to the body of the cabinet using
earthing straps
Cable groups laid separ-
ately?
Separate cables into groups. Supply and signal
leads should be laid separately
Are the shields connected
correctly?
Use shielded cables for analogue and data
leads; use metallic plugs; connect cable shields
to shield bar at point of entry to cabinet; con-
nect cable shields over a wide surface area and
with low impedance
Equipotential bonding car-
ried out?
If the installation extends over a wide area:
Equipotential bonding cables should be laid.
Are inductive loads
switched?
Sufficient fuse protection should be provided
with inductive loads

Electromagnetic compatibility (EMC)
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Check Action Done
24 VDC power supply? Power supplies must conform to EN
60742:9/1995, EN 60950-1:2006/A11:2009 or
EN 50178: 10/97
Mains in accordance with
TN-S system?
This guarantees that there is no connection
between the neutral conductor and protective
conductor within the machine. With unbalanced
loads, e.g. TN-C systems, currents can be fed
back to the source via the PEN conductor and
the currents on the PEN are not zero. This can
lead to EMC problems.

Installation
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4 Installation
4.1 Control cabinet installation
4.1.1 General installation guidelines
Please note during installation:
}The unit 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. If other mounting positions are used there will be insufficient ventilation.
}Use the locking element on the rear of the unit to attach it to a mounting rail.
}In environments exposed to heavy vibration, the unit should be secured against lateral
movement by using a fixing element (e.g. retaining bracket or end angle).
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
}The coated versions of the PNOZmulti units are suitable for use where there are in-
creased environmental requirements on temperature and humidity. Please refer to the
technical details.
}Note the relevant standards when wiring the control cabinet. For example:
– DIN EN 61439-1 (VDE 0660-600-1):2012-06 Low-voltage switchgear and control-
gear assemblies – Part 1 General rules,
– DIN EN 61439-2 (VDE 0660-600-2):2012-06 Low-voltage switchgear and control-
gear assemblies – Part 2: Power switchgear and controlgear assemblies,
– DIN EN 60204-1, DIN EN 69439-1,
– Machinery Directive 2006/42/EC,
– EMC Directive 2004/108/EC.
}Please note the guidelines given under Electromagnetic compatibility [ 10].
4.1.1.1 Positioning of units
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.
}Install the expansion module in the position in which it is configured in the PNOZmulti
Configurator.
For module selection please refer to the online help for 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.

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4.1.2 Mounting distances
With control cabinet installation it is essential to maintain a certain distance from the top
and bottom, as well as to other heat-producing devices (see diagram). The values stated
for the mounting distances are minimum specifications.
The ambient temperature in the control cabinet must not exceed the figure stated in the
technical details. Air conditioning may otherwise be required.
Mounting distances:
30 mm
(1.181")
30 mm
(1.181")
20 mm
(0.787")
20 mm
(0.787")
IM0 IM1
IM2 I6
I5
I4IM3 I7
I8
I10 I14
I13
I12I11 I15
X3
X1
X4
X2
PNOZ mm0.1p
T0 T1
T2 O2
O1
O0T3 O3
IM16 IM17
IM18 0 V
A2
A1IM19 24 V
M20 M21 M22 M23
Heat-producing device
Heat-producing device

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4.2 Install the control system PNOZmulti
4.2.1 Install base unit without expansion module
When installed on its own, a base unit from the configurable control system PNOZmulti
must be fitted with a terminator:
}The terminator must be fitted to the side of the base unit marked “Termination/Link”.
}Do not fit a terminator on the left hand side of the base unit.
Terminator Termination/Link
4.2.2 Connect the base unit and expansion modules
The modules are linked via jumpers.
There are 2 pin connectors on the rear of the base unit.
}Make sure that no terminator is fitted.
}Connect the base unit, expansion modules and fieldbus module using the jumpers sup-
plied.
}The terminator must be fitted to the last expansion module to the right of the base unit.
}A terminator must not be fitted to the last expansion module to the left of the base unit.
Expansion module 1 ... 8
Jumpers Terminator
Fieldbus module
Base unit
Expansion module 1 ... 4 Power supply

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4.3 Install the control system PNOZmulti Mini
4.3.1 Install base unit without expansion module
Make sure that the terminators are inserted on the top left and right of the unit :
}Left: Black/yellow terminator
}Right: Yellow terminator
Left:
Black/yellow
terminator
Right:
Yellow
terminator

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4.3.2 Connect the base unit and expansion modules
The modules are linked via jumpers.
}Remove the terminator on the side of the base unit and on the expansion module.
}Before installing the units on the mounting rail, connect the base unit to the expansion
module using the jumper supplied .
}Fit the appropriate terminator to the unconnected interfaces on the base unit and ex-
pansion module.
– Left-hand side on the base unit and expansion modules to the left of the base unit:
Black/yellow terminator
– Right-hand side on the base unit and expansion modules to the right of the base
unit: Yellow terminator
Left terminator Right terminator
Jumper