Pilz PNOZ m EF 4AI User manual

PNOZ m EF 4AI
Operating Manual-1004650-EN-02
}Configurable, safe small controllers PNOZmulti 2

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 Scope of supply ........................................................................................................................ 7
2.2 Unit features ............................................................................................................................. 7
2.3 Front view ................................................................................................................................. 8
3 Safety ...................................................................................................................................... 9
3.1 Intended use ............................................................................................................................. 9
3.2 System requirements................................................................................................................ 10
3.3 Safety regulations ..................................................................................................................... 10
3.3.1 Safety assessment ................................................................................................................... 10
3.3.2 Use of qualified personnel ........................................................................................................ 10
3.3.3 Warranty and liability ................................................................................................................ 11
3.3.4 Disposal .................................................................................................................................... 11
3.3.5 For your safety.......................................................................................................................... 11
4 Function Description ............................................................................................................. 12
4.1 Integrated protection mechanisms............................................................................................ 12
4.1.1 Measures for achieving process safety .................................................................................... 13
4.2 Analogue inputs ........................................................................................................................ 15
4.3 Monitoring functions.................................................................................................................. 15
4.3.1 Working range monitoring......................................................................................................... 15
4.3.2 Plausibility check ...................................................................................................................... 17
4.3.3 Scaling ...................................................................................................................................... 20
4.3.4 Mathematical operations........................................................................................................... 20
4.3.5 Constant ................................................................................................................................... 20
4.3.6 Threshold value monitoring ...................................................................................................... 20
4.3.7 Range monitoring ..................................................................................................................... 21
4.3.8 Diagnostics ............................................................................................................................... 22
4.4 Block diagram ........................................................................................................................... 23
5 Installation ..............................................................................................................................24
5.1 General installation guidelines.................................................................................................. 24
5.2 Dimensions in mm .................................................................................................................... 24
5.3 Connecting the base unit and expansion modules ................................................................... 24
6 Commissioning ......................................................................................................................26
6.1 Wiring........................................................................................................................................ 26
6.2 Connection................................................................................................................................ 26
6.3 Download modified project to the PNOZmulti system .............................................................. 31
7 Operation ................................................................................................................................32
7.1 LED indicators .......................................................................................................................... 32

Contents
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8 Technical details ....................................................................................................................34
8.1 Safety characteristic data ......................................................................................................... 37
9 Order reference ......................................................................................................................38
9.1 Product ..................................................................................................................................... 38
9.2 Accessories .............................................................................................................................. 38

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ m EF 4AI from Version HW:01,
FW:01.00.
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 m EF 4AI
}Jumper
2.2 Unit features
Application of the product PNOZ m EF 4AI:
Analogue input module for connection to a base unit from the PNOZmulti 2 system
The product has the following features:
}4 analogue inputs for current measurement
}Each input can be configured separately
}Current range: 0 ... 25 mA
}Resolution current measurement: 15 Bit + sign Bit
}Working range monitoring [ 15] in accordance with NAMUR NE43 recommendation
}Scaling function [ 20]
}Plausibility check [ 17]
}Mathematical operations [ 20]
}Constant [ 20]
}Threshold value monitoring [ 20]
}Range monitoring [ 21]
}Exact analogue value can be passed to a fieldbus or OPC server for diagnostic purposes
}LEDs [ 32] for
– Operating status
– Status of the input signals
– Error/diagnostics
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see Order ref-
erences for accessories [ 38]).
}Please refer to the document "PNOZmulti System Expansion" for details of the base units
PNOZmulti 2 that can be connected.

Overview
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2.3 Front view
Hardware version (HW)
Firmware version (FW)
Serial number
Legend
X1: Analogue inputs I0+, I0-, I1+, I1 -
X2: Analogue inputs I2+, I2-, I3+, I3-
X3: Supply connections 0 V, 24 V to supply the sensors
X4 Supply connections 0 V, 24 V, 0 V, 24 V to supply the analogue input module
and to supply the sensors
LEDs Power, Run, Diag, Fault, I Fault,

Safety
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3 Safety
3.1 Intended use
The expansion module PNOZ m EF 4AI is an analogue input module. It provides 4 safe
analogue inputs for current measurement. The analogue inputs are designed as differential
inputs. Each analogue input has a measuring range from 0 mA to 25 mA.
The expansion module may only be connected to a base unit from the configurable system
PNOZmulti 2 (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 product PNOZ m EF 4AI meets the requirements of the standards EN 81-20, EN
81-22 and EN 81-50, harmonised under the Lifts Directive 2014/33/EU, and the require-
ments of the standard EN 115-1, harmonised under the Machinery Directive 2006/42/EC.
}The programmable safety system should be installed in a protected environment that
meets at least the requirements of pollution degree 2.
Example: Protected inside space or control cabinet with protection type IP54 and corres-
ponding air conditioning.
The product PNOZ m EF 4AI can be used in furnaces in accordance with EN 298. You
must make sure that there is sufficient overvoltage protection.
}You must use only symmetrically operated cables that are protected with an appropriate
filter (z. B. Dehn overvoltage filter Type DCO SD2 E12, order number 917 987 or Type
DCO SD2 ME12, order number 917 920).
}Ensure that the folder has the required SIL classification in accordance with your applica-
tion.
}Use the external protection elements in accordance with the manufacturer and installation
manual for limiting overvoltages.
Please note the following when configuring the analogue input module PNOZ m EF 4AI:
}With 1-channel operation, check the measured value with an anticipated measured value
to detect measurement errors and offset errors on the sensor, or to detect open circuit
and short circuit between sensor and module.
}With 2-channel operation, perform a plausibility check of two inputs and two sensors (see
chapter Plausibility check [ 17]). Take appropriate measures to avoid common cause
errors in the sensor technology, by using diverse sensors or a separate supply voltage for
the sensors, for example.
}Monitor a defined working range to detect open circuit or short circuit; we recommend 3.8
… 20.5 mA in accordance with NE 43.
}The measured value is attenuated through the input filter. At the cutoff frequency, the
amplitude of the measured value is 70 % of the amplitude of the input signal.

Safety
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CAUTION!
Hazard due to the destruction of the device
Measured values may not leave the positive current range. This could des-
troy the device.
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 [ 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 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.
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.

Safety
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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.
The analogue input module can be used for applications up to SIL3.
Applications in accordance with SIL 2:
When the analogue input module for applications in accordance with SIL2 is to be used,
sensors must be connected that comply with EN IEC 62061: SIL2.
Scaling Threshold
value
Sensor
SIL 2
Applications in accordance with SIL 3:
When the analogue input module for applications in accordance with SIL3 is to be used,
two sensors must be connected that comply with EN IEC 62061: SIL CL 2.
Two inputs have to be configured and checked for plausibility (see Plausibility
check [ 17]).
Plausibility Scaling Threshold
value
Channel 1
Channel 2
Sensor
SIL 2
Sensor
SIL 2

Function Description
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NOTICE
For SIL 3 applications, set a maximum permitted deviation between the
measured values of both input signals (tolerance) in the PNOZmulti Config-
urator. A tolerance is only entered to balance out the imprecision of the sig-
nal recording, the encoder and the analogue input module. To maintain
safety, the tolerance should be set as low as possible. Please note that the
maximum safety-related measurement error for the overall system is
composed of the following measurement errors:
Error during signal recording
+ Sensor measurement error
+ Max. measurement error in the event of an error at the module Measures
for achieving process safety [ 13]
To ensure that your application switches off safely in the event of a critical
process variable, the configuration of the range limits/threshold values must
be increased/decreased.
4.1.1 Measures for achieving process safety
The module will detect internal module errors. Sensor errors and wiring errors can be de-
tected using the function Working range monitoring.
Please note that the overall accuracy must be considered when defining monitored limit val-
ues in the user program. The calculation of the overall accuracy is described in the follow-
ing examples
Example for calculating the overall measuring accuracy with 1-channel operation
The overall accuracy in % is calculated by adding the following values:
}Module's safety-related accuracy of 1% (see Technical details [ 34]).
}Module's measuring accuracy
This value is calculated by adding all deviations from the measuring range limit value
(see Technical details [ 34]).
The value Greatest transient deviation during el. interference test need only be con-
sidered in environments with strong EMC interference.
A measuring accuracy of 0.5% is assumed for this example.
}Sensor's measuring accuracy
This value is taken from the sensor's technical details.
A measurement accuracy of 0.5% is assumed for this example (in relation to the overall
measuring range of 0…25mA).
Calculation of the monitored limit values, taking into account the overall accuracy:
}Overall accuracy in %:
1 % + 0.5 % + 0.5 % = 2 %.
The overall accuracy refers to the overall measuring range of 0 ... 25 mA
}Overall accuracy in mA in relation to the overall measuring range:
25mA * 2% = 0.5mA

Function Description
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}Sensor's measuring range: 0 ...100 °C at 4...20mA.
Resolution of the sensor: 100°C / (20 – 4mA) = 6.25°C per mA.
The overall accuracy in °C is therefore: 0.5mA * 6.25°C per mA = 3.125°C.
This overall accuracy must be considered when defining monitored limit values in the user
program.
For example, if a hazardous situation should arise at a temperature above 80°C, a safe re-
action must occur in the user program at a temperature above 80°C-3.125°C=
76.875°C.
Example for calculating the overall measuring accuracy with 2-channel operation
With 2-channel operation, two inputs and two sensors must be used, as well as the Plaus-
ibility test function.
The overall accuracy in % is calculated by adding the following values:
}Empirically established tolerance
Instead of the module's safety-related accuracy, an empirically established tolerance is
used with 2-channel operation.
Enter in the PNOZmulti Configurator in the element Plausibility a percentage tolerance
at which availability is still maintained.
This tolerance value defines the maximum permitted deviation between the two analogue
input signals.
In the example, a tolerance of 2 % has been determined.
If as set tolerance is exceeded, the analogue value is signalised as invalid. For availability
reasons we therefore recommend that you use a slightly higher value for the tolerance
than the empirically established deviation.
For the example, a tolerance of 3% was therefore set for the plausibility monitoring.
}Module's measuring accuracy
}This value is calculated by adding all deviations from the measuring range limit value
(see Technical details [ 34]).
The value Greatest transient deviation during el. interference test needs only be con-
sidered in environments with strong EMC interference.
A measuring accuracy of 0.5% is assumed for this example.
}Sensor's measuring accuracy
This value is taken from the sensor's technical details. A value of 0.5% is assumed for
this example (in relation to the overall measuring range of 0…20 mA).
Calculation of the monitored limit values, taking into account the overall accuracy:
}Overall accuracy in %:
3 % + 0.5 % + 0.5 % = 4 %.
The overall accuracy refers to the overall measuring range of 0 ... 25 mA
}Overall accuracy in mA in relation to the overall measuring range:
25mA * 4% = 1mA
}Sensor's measuring range: 0 ...500 mbar at 4 ...20mA.
Resolution of the sensor: 500mbar / (20 – 4mA) = 31.25 mbar per mA.
The overall accuracy in mbar is therefore: 1mA * 31.25mbar per mA = 31.25mbar.

Function Description
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This overall accuracy must be considered when defining monitored limit values in the user
program.
For example, if a hazardous situation should arise at a pressure above 300mbar, a safe re-
action must occur in the user program at a pressure above 300mbar–31.25mbar=
268.75mbar.
WARNING!
Loss of the safety function by limit values that have been set too high
or too low!
You must take into account the overall accuracy when setting the limit val-
ues in the user program.
4.2 Analogue inputs
The module has 4 analogue inputs. This is to monitor analogue input current signals.
The input signals are recorded and read in at each input through two channels and are con-
verted into digital signals.
The measured value resolution is 15 Bit plus sign Bit.
The measuring range is 0 … 25 mA
4.3 Monitoring functions
In the PNOZmulti Configurator you can configure the following limit values and monitoring
functions.
4.3.1 Working range monitoring
With the working range monitoring you define the valid working or measuring range. The
working range monitoring is used to detect sensor errors or errors in the wiring.
You can define 4 limit values (R1 … R4) that define the working range and the failure in-
formation area.
If you do not configure a working range, the working range will be 0 … 25 mA.
The default settings are in accordance with NAMUR NE 43 recommendation to simplify the
signal level for the failure information. We recommend compliance with NAMUR recom-
mendation NE 43.
WARNING!
Potential loss of safety function if the working range monitoring is not
used
It must be ensured that open circuits and sensor errors are detected. If you
do not use working range monitoring, other suitable measures must be
taken.
}Lower failure information range (0 mA… R1)
Default: 0 … 3.6 mA
(e.g. circuit interrupted)

Function Description
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}Working range (R2 … R3)
Default: 3.8 … 20.5 mA
(valid measuring range, upper and lower range limit)
}Upper failure information range (R4 … 25 mA)
Default: 21 … 25 mA
(e.g. short circuit or transducer error)
}Hysteresis (R1 … R2, R3 … R4)
–Upper hysteresis R3 ... R4:
The numerical value is invalid, when R4 is exceeded.
The numerical value is valid again when R3 is undershot.
–Lower hysteresis R1 … R2:
The numerical value is invalid, when R1 is undershot.
The numerical value is valid again when R2 is exceeded.
Example: Numerical value undershoots the working range
mA
t
R1
R4
R2
R3
0
1
Failure information
Failure information
Hysteresis
Hysteresis
Workspace
Numerical value
valid

Function Description
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Example: Numerical value exceeds the working range
mA
t
R1
R4
R2
R3
0
1
Failure information
Failure information
Hysteresis
Hysteresis
Workspace
Numerical value
valid
4.3.2 Plausibility check
In the plausibility check, a leading signal (L) is checked with a reference signal (P).
When the deviation of both values is greater than the configured tolerance, the numerical
value will be signalised as invalid.
The reference signal is used to calculate the tolerance.
WARNING!
Loss of the safety function with large tolerances
Depending on the application, serious injury or death may result.
When configuring a high tolerance time and simultaneously a small toler-
ance period, the result may be a tolerance of approximately 100 %.
Select the tolerance value as small as possible.

Function Description
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The following tolerances can be configured:
Difference tolerance
The tolerance value defines the maximum permitted deviation between the two numerical
values. There are three different types of tolerance determination:
Absolute tolerance Percentage tolerance Absolute/percentage toler-
ance
Absolute value by which the
signals can deviate from
each other as a maximum.
Max. percentage by which
the signals may differ. Combined tolerance. Both an
absolute value and a percent-
age value are configured.
The higher tolerance value is
valid, respectively.
Peak tolerance
Peak values can be tolerated, that exceed the permitted deviation configured above for a
short period.
}Tolerance time (t1)
Maximum time for which the tolerance value may be exceeded
}Tolerance period (t2)
Minimum time that may elapse from one limit value overshoot to the next
Plausibility signal
Leading signal
Analogue value valid
mA
t
0
1
t1
t2
t1
Deviation
tolerance
Fig.: Leading signal remains within the tolerance limits

Function Description
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mA
t
0
1
Plausibility signal
Leading signal
Analogue value valid
t1
t2
t1
Deviation
tolerance
Fig.: Leading signal exceeds the tolerance time (t1)
mA
t
0
1
Plausibility signal
Leading signal
Analogue value valid
t1
t2
t1
Deviation
tolerance
Fig.: Leading signal does not maintain the duration of the tolerance period (t2)

Function Description
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4.3.3 Scaling
The scaling function can be used to convert the analogue measured value (mA) to another
numerical value (physical measured value of the transducer, e.g. in litres). The scaling can
only be used with linear input variables
To do this, you define an upper and lower value each for the input value (current value) and
for the scaled value, and you specify the unit of the scaled value.
bar
mA
2000
5
420
4.3.4 Mathematical operations
You can perform a mathematical operation with two numerical values:
}Addition
The sum of two numerical values is calculated (X + Y).
}Subtraction
The difference of two numerical values is calculated (X – Y).
}Average
The average value of two numerical values is calculated ((X + Y) / 2).
The result of the mathematical operation can be issued as an amount (without sign).
4.3.5 Constant
A constant numerical value can be defined. The value is without dimensions and it can also
be negative. It can be linked in the user program and used e.g. as an offset.
4.3.6 Threshold value monitoring
You can define switching thresholds, which can be used to monitor certain process vari-
ables (e.g. temperature values).
You can monitor whether a numerical value is greater or less than a configured switching
threshold.