Pilz PNOZ mml1p User manual

PNOZ mml1p
Operating Manual-1002233-EN-06
}Configurable, safe compact controllers PNOZmulti Mini

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 ............................................................................................................................4
1.1 Validity of documentation.......................................................................................................... 4
1.2 Using the documentation .......................................................................................................... 4
1.3 Definition of symbols................................................................................................................. 4
2 Overview .................................................................................................................................6
2.1 Scope of supply ........................................................................................................................ 6
2.2 Unit features ............................................................................................................................. 6
2.3 Front view ................................................................................................................................. 6
3 Safety ...................................................................................................................................... 8
3.1 Intended use ............................................................................................................................. 8
3.2 System requirements................................................................................................................ 8
3.3 Safety regulations ..................................................................................................................... 8
3.3.1 Safety assessment ................................................................................................................... 8
3.3.2 Use of qualified personnel ........................................................................................................ 9
3.3.3 Warranty and liability ................................................................................................................ 9
3.3.4 Disposal .................................................................................................................................... 9
3.3.5 For your safety.......................................................................................................................... 9
4 Function Description ............................................................................................................. 10
4.1 Integrated protection mechanisms............................................................................................ 10
4.2 Functions .................................................................................................................................. 10
4.3 Block diagram ........................................................................................................................... 12
5 Installation ..............................................................................................................................13
5.1 General installation guidelines.................................................................................................. 13
5.2 Dimensions ............................................................................................................................... 13
5.3 Connect the base unit and expansion modules........................................................................ 14
6 Commissioning ......................................................................................................................15
6.1 General wiring guidelines ......................................................................................................... 15
6.2 Download modified project to the PNOZmulti system .............................................................. 15
6.3 Connection................................................................................................................................ 16
6.4 Connection examples .............................................................................................................. 17
6.4.1 Example: Series connection of 3 base units............................................................................. 17
6.4.2 Example: Connection of 5 base units ....................................................................................... 18
7 Operation ................................................................................................................................19
7.1 LED indicators .......................................................................................................................... 19
7.2 Fault detection .......................................................................................................................... 19
8 Technical details ....................................................................................................................20
9 Order reference ......................................................................................................................22
9.1 Product ..................................................................................................................................... 22
9.2 Accessories .............................................................................................................................. 22

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ mml1p. 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 Scope of supply
}Expansion module PNOZ mml1p
}Jumper
2.2 Unit features
Application of the product PNOZ mml1p:
Link module to safely connect two configurable small control systems PNOZmulti.
The product has the following features:
}Connection options:
– Two PNOZmulti Mini base units
or
– One PNOZmulti Mini base unit with one PNOZmulti base unit
}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
}LED indicators for
– Operating status
– Error
– Connection status
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see Order ref-
erences for accessories).
2.3 Front view

Overview
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Key:
}X2:
– 0 V, 24 V:Supply connections
– FE: Functional earth
}Link:
Connection
}LEDs:
– Power
– Ready
– Link
– Fault

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 configurable system
PNOZmulti Mini (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 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 [ 20]).
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.
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 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 prevention,
}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-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. The expanded func-
tions 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 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.
4.2 Functions
The link module PNOZ mml1p 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 link modules. Two link modules are re-
quired for a connection between two base units. However, only a maximum of 4 link mod-
ules 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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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 under "Preparing for operation".
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.

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
4.3 Block diagram
Interface
to previous
module
Interface
to next
module
=
Power
24V 0V n.c.FE
=
CB- CGroundCA- CB+CA+

Installation
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5 Installation
5.1 General installation guidelines
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Fit the safety system to a horizontal mounting rail. The venting slots must face 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.
}The ambient temperature in the control cabinet must not exceed the figure stated in the
technical details. otherwise air conditioning may be required.
NOTICE
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
5.2 Dimensions
120 (4.72")
100 (3,94")
22,5
(0.88")

Installation
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5.3 Connect the base unit and expansion modules
Connect the base unit and the expansion module as described in the operating instructions
for the base units.
}Connect the black/yellow terminator to the expansion module.
}Install the expansion module in the position in which it is configured in the PNOZmulti
Configurator.
The position of the expansion modules is defined in the PNOZmulti Configurator. The ex-
pansion modules are connected to the left or right of the base unit, depending on the type.
Please refer to the document "PNOZmulti System Expansion" for details of the number of
modules that can be connected to the base unit and the module types.

Commissioning
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6 Commissioning
6.1 General wiring guidelines
The wiring is defined in the circuit diagram of the PNOZmulti Configurator.
Please note:
}Information given in the Technical details [ 20] must be followed.
}The position of the expansion module is specified in the Hardware configuration of the
PNOZmulti Configurator.
}Use copper wiring with a temperature stability of 75 °C.
}The power supply must meet the regulations for extra low voltages with safe separation
(SELV, PELV).
}2 connection terminals are available for each of the supply connections 24 V and 0 V.
This means that the supply voltage can be looped through several connections. The cur-
rent at each terminal may not exceed 3A.
}The max. cable length between two link modules on a connection with one link module
– PNOZ ml1p <V2.0: 100 m
– PNOZ ml1p from V2.0, PNOZ mml1p: 1000 m
}Connect the inputs and outputs from two link modules with 4-core shielded cable. The
cables must be twisted in pairs.
}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.
CAUTION!
Only connect and disconnect the expansion module when the supply
voltage is switched off.
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 in the PNOZmulti Configurator and downloaded back into the base unit.
Proceed as described in the operating manual for the base unit.
NOTICE
For the commissioning and after every user program change, you must
check whether the safety devices are functioning correctly.

Commissioning
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6.3 Connection
RJ45 socket
8-pin
PIN Layout
8 1
1 CA+
2 CA-
3 CB+
4 n.c.
5 n.c.
6 CB-
7 n.c.
8 n.c.
Shield CGround
Supply voltage AC DC
Supply voltage
CA+
CA-
CB+
CB-
CGround
CA+
CA-
CB+
CB-
PNOZ mml1p PNOZ mml1p
1
2
3
6
CGround
1
2
3
6
Connection of two base units PNOZmulti Mini via PNOZmml1p

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 I4 and I6 + data transmission time1 * tBUS through link module/interface +
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 I4 und I6 + data transmission time 2 * tBUS through link modules/interfaces
+ 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
K2
I3 I6
Base 1 Base 2 Base 3
S1
K3

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 2: 69 ms
O1 on Base 3: 104 ms
O0 on Base 4: 139 ms
O0 on Base 5: 104 ms
I3 I6
Base 1 Base 2 Base 3
S1
K3
Base 4 Base 5
I4 I6
K2
O0 O1
K4
O0
K5
O0

Operation
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7 Operation
When the supply voltage is switched on, the PNOZmulti copies the configuration from the
chip card.
The PNOZmulti safety system is ready for operation when the "POWER" and "RUN" LEDs
on the base unit and the "READY" LED on the PNOZ mml1p are lit continuously.
7.1 LED indicators
Legend
LED on
LED flashes
LED off
LED LED status Meaning
Power No supply voltage
Gree
n
Supply voltage is present
Ready Gree
n
The unit is ready for operation
The unit is not ready for operation
Fault Red External fault
Red Internal fault
No fault
Link Yel-
low
Connection available to another link module
No connection available to another link module
7.2 Fault detection
Each base unit contains information about
}its own link module (in order, defective, no supply voltage)
}the status of the connection (yes, no)
}the operating status of the connected base unit (RUN, STOP)
When the connection is interrupted, the base units switch the virtual inputs to zero. The
base units remains in a RUN condition.
Defective link module:
}The corresponding base unit switches to a STOP condition. The virtual outputs on the link
module are set to zero.
}The connected base unit remains in a RUN condition.

Technical details
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8 Technical details
General
Certifications BG, CCC, CE, EAC (Eurasian), TÜV, cULus Listed
Electrical data
Supply voltage
for Module supply
Voltage 24,0 V
Kind DC
Voltage tolerance -15 %/+20 %
Output of external power supply (DC) 5,0 W
Residual ripple DC 5 %
Status indicator LED
Virtual inputs
Number of virtual inputs 32
Virtual outputs
Number of virtual outputs 32
Times
Switch-on delay 5,00 s
Supply interruption before de-energisation 20 ms
Max. data transmission time 35 ms
Environmental data
Ambient temperature
In accordance with the standard EN 60068-2-14
Temperature range 0 - 60 °C
Storage temperature
In accordance with the standard EN 60068-2-1/-2
Temperature range -25 - 70 °C
Climatic suitability
In accordance with the standard EN 60068-2-30, EN 60068-2-78
Humidity 93 % r. h. at 40 °C
Condensation during operation Not permitted
EMC EN 61131-2
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10,0 - 150,0 Hz
Acceleration 1g
Shock stress
In accordance with the standard EN 60068-2-27
Acceleration 15g
Duration 11 ms
Max. operating height above sea level 2000 m