Pilz PNOZ m3p (ETH) User manual

PNOZ m3p (ETH)
Operating Manual-1001352-EN-09
}Configurable, safe small controllers PNOZmulti Classic

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion 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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1 Introduction ............................................................................................................................ 5
1.1 Validity of documentation.......................................................................................................... 5
1.2 Using the documentation .......................................................................................................... 5
1.3 Definition of symbols................................................................................................................. 5
2 Overview ................................................................................................................................. 7
2.1 Range ....................................................................................................................................... 7
2.2 Unit features ............................................................................................................................. 7
2.3 Chip card .................................................................................................................................. 8
2.4 Front view ................................................................................................................................. 8
3 Safety ...................................................................................................................................... 11
3.1 Intended use ............................................................................................................................. 11
3.2 System requirements................................................................................................................ 12
3.3 Safety regulations ..................................................................................................................... 12
3.3.1 Safety assessment ................................................................................................................... 12
3.3.2 Use of qualified personnel ........................................................................................................ 13
3.3.3 Warranty and liability ................................................................................................................ 13
3.3.4 Disposal .................................................................................................................................... 13
3.3.5 For your safety.......................................................................................................................... 13
4 Function description ............................................................................................................. 14
4.1 Integrated protection mechanisms............................................................................................ 14
4.2 Functions .................................................................................................................................. 14
4.3 Application for furnaces ............................................................................................................ 14
4.4 Block diagram ........................................................................................................................... 15
4.5 Diagnostics ............................................................................................................................... 15
4.6 Cascading................................................................................................................................. 15
4.7 Safety mat, muting.................................................................................................................... 16
4.8 Interfaces ................................................................................................................................. 16
5 Installation .............................................................................................................................. 17
5.1 Control cabinet installation........................................................................................................ 17
5.2 Dimensions ............................................................................................................................... 18
5.3 Install base unit without expansion module ............................................................................. 18
5.4 Connecting the base unit and expansion modules ................................................................... 19
6 Commissioning ...................................................................................................................... 20
6.1 General wiring guidelines ......................................................................................................... 20
6.2 Ethernet interfaces (ETH version only)..................................................................................... 21
6.2.1 RJ45 interfaces ("Ethernet") ..................................................................................................... 21
6.2.2 Requirements of the connection cable and connector.............................................................. 21
6.2.3 Interface configuration .............................................................................................................. 21
6.2.4 RJ45 connection cable ............................................................................................................. 22
6.2.5 Process data exchange ............................................................................................................ 23
6.3 Function test during commissioning ......................................................................................... 23
6.4 Commissioning the PNOZmulti control system for the first time............................................... 24
6.4.1 Load project from chip card ...................................................................................................... 24

Contents
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6.4.2 Load project via integrated interface......................................................................................... 24
6.5 Download modified project to the PNOZmulti system .............................................................. 25
6.5.1 Load modified project from chip card........................................................................................ 25
6.5.2 Load modified project via integrated interface .......................................................................... 25
6.6 Connection................................................................................................................................ 25
6.7 Connection example ................................................................................................................. 28
7 Operation ................................................................................................................................ 29
7.1 LED indicators .......................................................................................................................... 29
7.1.1 Display elements for the Ethernet connection (only PNOZ m3p ETH) ..................................... 30
7.2 Function test of the relay outputs.............................................................................................. 30
7.3 Reset Ethernet connection settings .......................................................................................... 31
8 Technical Details ................................................................................................................... 32
8.1 Safety characteristic data ......................................................................................................... 37
9 Supplementary data .............................................................................................................. 39
9.1 Service life graph for the relay contacts.................................................................................... 39
10 Order reference ...................................................................................................................... 41
10.1 Product ..................................................................................................................................... 41
10.2 Accessories .............................................................................................................................. 41

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ m3p. 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 Range
}Base unit PNOZ m3p
}Terminator
}Documentation on data medium
2.2 Unit features
Application of the product PNOZ m3p:
Base unit from the configurable control system PNOZmulti
The product has the following features:
}Designed to monitor and control furnaces
}Can be configured in the PNOZmulti Configurator
}Positive-guided relay outputs:
– 2 safety outputs
Depending on the application, up to PL e of EN ISO 13849-1 and up to SIL CL 3 of
EN IEC 62061
}Semiconductor outputs:
– 4 safety outputs
Depending on the application, up to PL e of EN ISO 13849-1 and up to SIL CL 3 of
EN IEC 62061
– 1 output for standard applications
}4 test pulse outputs
}1 cascading input and output;
can also be used as a standard output
}20 inputs for connecting, for example:
– E-STOP pushbuttons
– Two-hand pushbuttons
– Safety gate limit switches
– Start buttons
– Light beam devices
– Scanners
– Enabling switches
– PSEN
– Operating mode selector switches
– Safety mats
}Muting function
}LED indicator for:
– Diagnostics

Overview
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– Supply voltage
– Output circuits
– Input circuits
}Test pulse outputs used to monitor shorts across the inputs
}Monitoring of shorts between the safety outputs
}Integrated interfaces:
– PNOZ m3p: Serial interface RS232
– PNOZ m3pETH: 2 Ethernet interfaces
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see Order ref-
erences for accessories).
2.3 Chip card
To be able to use the product you will need a chip card.
Chip cards are available with memories of 8 kByte and 32 kByte. For large-scale projects
we recommend the 32 kByte chip card (see Technical Catalogue: Accessories chapter).
2.4 Front view
PNOZ m3p
CHIP-Card

Overview
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PNOZ m3p ETH
CHIP-Card
TRF
LNK
TRF
LNK
MAC ADD_00-02-47-MAC-VAR
Legend:
}CHIP card:
– Interface chip card
}X1:
– Cascading inputs and outputs CI and CO,
– Test pulse outputs T0 ... T3
}X2:
– Semiconductor outputs O0 ... O3,
– Auxiliary output OA0,
– Supply connections
}X3:
– Relay outputs O4 and O5
}X4:
– RS232 interface / Ethernet interface
}X5, X6:
– Inputs I0 ... I19
}X7:
– Power supply

Overview
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}LEDs:
– PWR
– RUN
– DIAG
– FAULT
– I FAULT
– O FAULT

Safety
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3 Safety
3.1 Intended use
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 unit is designed to control and monitor furnaces in accordance with the standards:
}EN 12953-7: Shell boilers
}EN 12952-8: Water-tube boilers and auxiliary installations
}EN 61508: SIL 3: Functional safety of safety-related electrical/electronic/programmable
electronic systems
}EN 230: Automatic burner control systems for oil burners
}EN 267: Automatic forced draught burners for liquid fuels (draft)
}EN 298: Automatic gas burner control systems for gas burners and gas burning appli-
ances with or without fans
}EN 676: Automatic forced draught burners for gaseous fuels
}EN 746-2: Industrial thermoprocessing equipment
}EN 1643: Valve proving systems for automatic shut-off valves for gas burners and gas
appliances
These include:
Monitoring of:
}Safety chains
}Combustion air pressure
}Ignition
}Flame monitoring
}External compound controller
}Tightness control
And control of:
}Safety valves
}Ignition valves
}Vent valve
}Ignition
}External compound controller
}Combustion air blower
The following oil and gas burner types can be monitored:
}Master burner with direct ignition
}Master burner with indirect ignition and joint flame monitoring
}Master burner with indirect ignition and separate flame monitoring
}Slave burner with direct ignition

Safety
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}Slave burner with indirect ignition and joint flame monitoring
}Slave burner with indirect ignition and separate flame monitoring
CAUTION!
Inputs and outputs for standard functions must not be used for safety-re-
lated applications.
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 [ 32]).
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" document in the "Version overview" section for
details of which versions of the PNOZmulti Configurator can be used for this product.
3.3 Safety regulations
3.3.1 Safety assessment
Before using a device 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.

Safety
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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 a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident prevention,
}Have read and understood the information provided in the section entitled Safety
}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-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
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. Advanced functions
are described in the online help for the PNOZmulti Configurator, in the "PNOZmulti Com-
munication Interfaces" document and in "PNOZmulti Special Applications". Only use
these functions once you have read and understood the documentation.
}Please note the "PNOZmulti Installation Manual".
}You must note the information stated in the "PNOZmulti Safety Manual".
}Adequate protection must be provided for all inductive consumers.
}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 meets the following safety requirements:
}The circuit is redundant with built-in self-monitoring.
}The safety device remains effective in the case of a component failure.
}The relay contacts meet the requirements for protective separation through increased in-
sulation compared with all other circuits in the safety system.
}The safety outputs are tested periodically using a disconnection test.
4.2 Functions
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.
4.3 Application for furnaces
The base unit PNOZ m3p is designed for controlling and monitoring furnaces (see online
help for the PNOZmulti Configurator).
These include:
Monitoring:
}Safety chains
}Combustion air pressure
}Ignition
}Flame monitoring
}External compound controller
}Tightness control
and controlling:
}Safety valves
}Ignition valves
}Vent valve
}Ignition
}External compound controller
}Combustion air blower

Function description
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The following oil and gas burner types can be monitored:
}Master burner with direct ignition
}Master burner with indirect ignition and joint flame monitoring
}Master burner with indirect ignition and separate flame monitoring
}Slave burner with direct ignition
}Slave burner with indirect ignition and joint flame monitoring
}Slave burner with indirect ignition and separate flame monitoring
4.4 Block diagram
Interface
fieldbus,
expansion
module
Interface
chip card
Ethernet/
RS 232
Interface
expansion
module
O4 O5
A1 A2 I0 I14I6 I11I9 I10 I13I8I7 I16I12 I18I15I2 I4 I5I1 I3 I17 I19
Input
Power
Cascading Test pulse
output 24 V 0 V
24 V 0 V
2313
CI+ CI- CO+ CO- T0 T1 T2 T3 O0 O1 O2 O3 OA0 14 24
4.5 Diagnostics
The status and error messages displayed by the LEDs are saved in an error stack. This er-
ror stack can be read from the PNOZmulti Configurator via the interfaces (RS232 or Ether-
net). More comprehensive diagnostics are possible via the interfaces or one of the fieldbus
modules, e.g. the PROFIBUS module.
4.6 Cascading
The cascading inputs and outputs enable several PNOZmulti and PNOZelog units to be
connected in series or as a tree structure.
INFORMATION
Detailed information on these functions and connection examples can be
found in the online help for the PNOZmulti Configurator and in the
PNOZmulti Installation Manual.

Function description
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4.7 Safety mat, muting
INFORMATION
Detailed information on these functions and connection examples can be
found in the online help for the PNOZmulti Configurator and in the docu-
ment entitled "PNOZmulti - Special Applications".
4.8 Interfaces
The product PNOZ m3p ETH has two Ethernet interfaces, the product PNOZ m3p has one
serial interface to
}Project download
}Read the diagnostic data
}Set virtual inputs for standard functions
}Read virtual outputs for standard functions.
Information on diagnostics via the interfaces can be found in the document "PNOZmulti
communication interfaces".
The connection to Ethernet is made via the two 8-pin RJ45 sockets.
The Ethernet interface is configured in the PNOZmulti Configurator and is described in the
online help for the PNOZmulti Configurator.

Installation
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5 Installation
5.1 Control cabinet installation
}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 locking elements on the rear of the unit to attach it to a mounting rail. Connect
the control 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 devices in the control cabinet must not exceed the figure
stated in the technical details. Air conditioning may otherwise be required.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
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.

Installation
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5.2 Dimensions
94 (3.70")
121 (4.76")
135 (5.31")
5.3 Install base unit without expansion module
}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

Installation
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5.4 Connecting the base unit and expansion modules
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.
The modules are linked via jumpers.
There are 2 pin connectors on the rear of the base unit.
A max. of 12 expansion modules plus one fieldbus module may be connected to one base
unit.
}Ensure that no terminator is connected.
}Connect the base unit, the expansion modules and the fieldbus module using the jumpers
supplied.
}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

Commissioning
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6 Commissioning
6.1 General wiring guidelines
The wiring is defined in the circuit diagram in the Configurator. There you can select the in-
puts that are to perform a safety function and the outputs that are to switch this safety func-
tion.
Please note:
CAUTION!
The plug-in connection terminals on the relay outputs carry mains voltage
and should only be connected and disconnected when the voltage is
switched off.
}Information given in the Technical details [ 32] must be followed.
}Outputs:
– O0 to O5 are safety outputs
– O4 and O5 are relay outputs
– O0 to O3 are semiconductor outputs
– OA0 is an output to delete a project from the base unit (see online help for the
PNOZmutli Configurator).
}To prevent contact welding, a fuse should be connected before the output contacts (see
technical details).
}Use copper wiring with a temperature stability of 75°C.
}Adequate protection must be provided on all output contacts with inductive loads.
}The control system and input circuits must always be supplied by a single power supply.
The power supply must meet the regulations for extra low voltages with protective separ-
ation.
}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.
}Test pulse outputs must exclusively be used to test the inputs. They must not be used to
drive loads.
Do not route the test pulse lines together with actuator cables within an unprotected mul-
ticore cable.
}Test pulse outputs are also used to supply safety mats that trigger a short circuit.
Test pulses that are used for the safety mat may not be reused for other purposes.
The base unit PNOZ m3p is not suitable for connection to DC supplies.