Pilz PNOZ mm0.2p User manual

PNOZ mm0.2p
Operating Manual-1002235-EN-07
}Configurable, safe compact controllers PNOZmulti Mini

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
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.
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 ................................................................................................................................. 9
3 Safety ...................................................................................................................................... 10
3.1 Intended use ............................................................................................................................. 10
3.2 System requirements................................................................................................................ 10
3.3 Safety regulations ..................................................................................................................... 10
3.3.1 Safety assessment ................................................................................................................... 10
3.3.2 Use of qualified personnel ........................................................................................................ 11
3.3.3 Warranty and liability ................................................................................................................ 11
3.3.4 Disposal .................................................................................................................................... 11
3.3.5 For your safety.......................................................................................................................... 11
4 Function description ............................................................................................................. 12
4.1 Integrated protection mechanisms............................................................................................ 12
4.2 Functions .................................................................................................................................. 12
4.3 System reaction time ................................................................................................................ 12
4.4 Connection of two base units.................................................................................................... 12
4.5 Diagnostics ............................................................................................................................... 14
4.6 Block diagram ........................................................................................................................... 14
5 Installation ..............................................................................................................................15
5.1 Control cabinet installation........................................................................................................ 15
5.1.1 Mounting distances................................................................................................................... 15
5.2 Dimensions ............................................................................................................................... 16
5.3 Install base unit without expansion module ............................................................................. 17
5.4 Connecting the base unit and expansion modules ................................................................... 17
6 Commissioning ......................................................................................................................19
6.1 General wiring guidelines ......................................................................................................... 19
6.2 Preparing for operation ............................................................................................................. 20
6.2.1 Function test during commissioning ......................................................................................... 20
6.2.2 Using the chip card .................................................................................................................. 20
6.2.3 Commissioning the PNOZmulti safety system.......................................................................... 21
6.2.3.1 Load project from chip card ...................................................................................................... 21
6.2.3.2 Load project via USB port ........................................................................................................ 21
6.2.4 Connection................................................................................................................................ 22
6.2.5 Connection of two base units.................................................................................................... 24
6.2.5.1 Interface assignment ................................................................................................................ 24
6.2.5.2 Connection................................................................................................................................ 24

Contents
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1002235-EN-07 | 4
6.3 Connection examples .............................................................................................................. 25
6.3.1 Connection of multiple base units via the integrated interface ................................................. 25
6.3.1.1 Example 1: Series connection of 3 base units.......................................................................... 25
6.3.1.2 Example 2: Connection of 5 base units .................................................................................... 26
7 Operation ................................................................................................................................27
7.1 LED indicators .......................................................................................................................... 27
7.2 Display indicators...................................................................................................................... 28
7.2.1 Rotary knob .............................................................................................................................. 30
7.2.1.1 Function .................................................................................................................................... 30
7.2.1.2 Pull out and retract the knob .................................................................................................... 30
7.2.1.3 Rotate and press the knob ....................................................................................................... 30
7.2.2 Switch between menu levels ................................................................................................... 31
7.2.3 Unit diagnostics on the LC display............................................................................................ 31
7.2.4 Error stack on the LC display.................................................................................................... 32
8 Technical details ....................................................................................................................34
8.1 Safety characteristic data ......................................................................................................... 37
9 Supplementary data ..............................................................................................................39
9.1 Maximum capacitive load C (μF) with load current I (A) at the semiconductor outputs............ 39
9.2 Maximum permitted total current of the semiconductor outputs ............................................... 39
10 Order reference ...................................................................................................................... 40
10.1 Product ..................................................................................................................................... 40
10.2 Accessories .............................................................................................................................. 40
11 EC declaration of conformity ................................................................................................ 41
12 UKCA-Declaration of Conformity ......................................................................................... 42

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ mm0.2p. It is valid until new documenta-
tion 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 mm0.2p
}Right-hand terminator: (yellow)
}Left-hand terminator: (yellow/black)
2.2 Unit features
Application of the product PNOZ mm0.2p:
PNOZmulti Mini base unit
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}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
}12 inputs for connecting, for example:
– E-STOP pushbuttons
– Two-hand button
– Safety gate limit switches
– Start buttons
– Light beam devices
– Scanners
– Enabling switches
– PSEN
– Operating mode selector switches
– Safety mats
}8 configurable inputs/outputs
Can be configured as:
– Inputs (see above for connection options)
or
– Outputs for standard applications
}4 configurable outputs
Can be configured as:
– Outputs for standard applications
or
– Test pulse outputs
}LED indicator for:
– Error messages

Overview
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– Diagnostics
– Supply voltage
– Output circuits
– Input circuits
}Display for:
– Error messages
– State of supply voltage
– State of the inputs and outputs
– Status information
– Unit information
}Test pulse outputs used to monitor shorts across the inputs
}Monitoring of shorts between the safety outputs
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see order ref-
erence)
}Rotary knob for menu control
}Expansion modules can be connected
(please refer to the document "PNOZmulti System Expansion" for details of the type and
number that can be connected)
}Integrated interface (RJ45 socket) for safe connection of two configurable control sys-
tems:
– Connection options:
- Two PNOZmulti Mini base units
or
- One PNOZmulti Mini base unit with one PNOZmulti base unit
(both the units to be connected need either an integrated interface or a link module)
– Point-to-point connection via 4-core shielded, twisted-pair cable
– 32 virtual inputs and 32 virtual outputs for data transfer
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).

Overview
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2.4 Front view
X3
X1
X4
X2
PNOZ mm0.2p
IM0 IM1
IM2 I6
I5
I4IM3 I7
I8 I9
I10 I14
I13
I12I11 I15
X3
X1
X4
X2
PNOZ mm0.2p
T0 T1
T2 O2
O1
O0T3 O3
IM16 IM17
IM18 0 V
A2
A1IM19 24 V
M20 M21 M22 M23
IM0 IM1
IM2 I6
I5
I4IM3 I7
I8 I9
I10 I14
I13
I12I11 I15
T0 T1
T2 O2
O1
O0T3 O3
IM16 IM17
IM18 0 V
A2
A1IM19 24 V
M20 M21 M22 M23
Safe Link
RJ45
Safe Link
RJ45
Front view with and without cover
Legend
X1: Inputs I8 ... I15
X2: Configurable test pulse/auxiliary outputs T0M20 ... T3M23
Semiconductor outputs O0 ... O3
X3: Configurable inputs/outputs IM0 – IM3
Inputs I4 ... I7
X4: Configurable inputs/outputs IM16 – IM19
Supply connections
LEDs: PWR
RUN
DIAG
FAULT
I FAULT
O FAULT
}Safe Link RJ45
RJ45 socket for connection of 2 base units

Safety
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3 Safety
3.1 Intended use
The configurable system is used for the safety-related interruption of safety circuits and is
designed for use in:
}Emergency stop equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
CAUTION!
Inputs and outputs for standard functions must not be used for safety-re-
lated applications.
Improper use
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 operating manual,
}Use of the product outside the technical details (see Technical details [ 34]).
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, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 62061. However, this does not guarantee the functional
safety of the overall plant/machine. To achieve the relevant safety level of the overall plant/
machine’s required safety functions, each safety function needs to be considered separ-
ately.

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 persons who are competent to do so.
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 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 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 Connection of two base units
The integrated interface for connection of 2 base units is used to safely transfer the input in-
formation from 32 virtual inputs and 32 virtual outputs between two PNOZmulti systems.
Each base unit needs either an integrated interface or a link module for the connection.
Data exchange:
}Data is exchanged cyclically.
}At the end of the PNOZmulti cycle, each base unit sends its output data to the other base
unit or to the link module on the other base unit.
}At the same time the base unit reads the input data from the other base unit.
Connection of multiple base units:
Any number of base units can be connected via link modules or via the integrated interface.
Each base unit needs a link module or an integrated interface 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 tBUS data transmission time 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").

Function description
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1002235-EN-07 | 13
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 or interface, 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 is multiplied by the number of connections.
}Please refer to the connection examples under "Preparing for operation".
CAUTION!
For signals that are forwarded or received via the link module or interface,
the overall reaction time, e.g. the maximum reaction time of the series con-
nection 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.

Function description
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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.
Base unit 1
Virtual outputs
o0
...
o31
Virtual inputs
i0
...
i31
Base unit 2
Virtual inputs
i0
...
i31
Virtual outputs
o0
...
o31
4.5 Diagnostics
The status and error messages displayed by the LEDs are saved in an error stack. This er-
ror stack can be shown on the display or can be read from the PNOZmulti Configurator via
the USB port.
4.6 Block diagram
=
Power
A1 A2
=
Input
Configurable
output 24 V 0 V
24 V 0 V
T0M21 O2
O0 O1 O3
IM1 I8I5 I11
I4 I9 I12 I13 I14 I15I7I6 I10
IM2IM0 IM3IM16 IM18IM17 IM19
Interface
extension
module
USB
Interface
extension
module
Configurable
input/output
T0M22 T0M23T0M20 CA+ CA- CB+ CB- CGround
RJ45
Safe Link Interface

Installation
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1002235-EN-07 | 15
5 Installation
5.1 Control cabinet installation
}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 upwards
and downwards. Other mounting positions could destroy the safety system.
}Use the notch 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 ele-
ment (e.g. retaining bracket or end angle).
}Push the unit upwards or downwards before lifting it from the mounting rail.
}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.
5.1.1 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.

Installation
Operating Manual PNOZ mm0.2p
1002235-EN-07 | 16
Mounting distances:
Heat-producing unit
Heat-producing unit
5.2 Dimensions
*with spring-loaded terminals
120 (4.72")
* 100 (3,94")
98 (3.86")
45
(1.77")

Installation
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1002235-EN-07 | 17
5.3 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
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.
}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 expan-
sion 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

Installation
Operating Manual PNOZ mm0.2p
1002235-EN-07 | 18
Left terminator Right terminator
Jumper
CAUTION!
Only connect the base unit and expansion modules when the supply voltage
is switched off.

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:
}Information given in the Technical details [ 34] must be followed.
}Outputs O0 to O3 are semiconductor outputs
}Use copper wiring with a temperature stability of 75 °C.
}Adequate protection must be provided on all output contacts with inductive loads.
}The safety 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.
}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.
When connecting two base units via the integrated interface please note:
}The max. cable length between two base units on a connection with
– one link module PNOZ ml1p <V2.0: 100 m
– one link module PNOZ ml1p from V2.0, PNOZ mml1p or one base unit PNOZ
mm0.2p: 1000 m
}Connect the inputs and outputs via the two interfaces using 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.

Commissioning
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6.2 Preparing for operation
6.2.1 Function test during commissioning
CAUTION!
It is essential to check that the safety devices operate correctly
– after the chip card has been exchanged
– after a project has been downloaded
– when the project has been deleted from the base unit's memory ("Re-
set Project" menu)
6.2.2 Using the chip card
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.
NOTICE
Switch off the product before inserting or exchanging the chip card.
Make sure that you do not bend the chip card as you insert it into the chip card slot.