Pilz myPNOZ User manual

Modular safety relay
myPNOZ
Getting started-1005615-EN-02
}Safety relays

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 The modular safety relay myPNOZ ...................................................................................... 4
2 Introduction to Getting Started manual ............................................................................... 5
3 Task ......................................................................................................................................... 6
4 Safety functions ..................................................................................................................... 7
5 Configure myPNOZ with myPNOZ Creator ......................................................................... 9
5.1 Create logic configuration ......................................................................................................... 9
5.2 Hardware configuration............................................................................................................. 11
5.3 Display, save and order myPNOZ configuration....................................................................... 13
6 Calculating the safety-related characteristic data .............................................................. 14
7 Wire myPNOZ ......................................................................................................................... 17
8 Install myPNOZ ...................................................................................................................... 18
9 Commission myPNOZ ........................................................................................................... 19
10 Change configuration ............................................................................................................ 20
11 Diagnostics ............................................................................................................................ 21
11.1 Status messages ...................................................................................................................... 21
11.2 Error messages ........................................................................................................................ 24
11.3 Errors on the safe outputs ........................................................................................................ 30

The modular safety relay myPNOZ
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1 The modular safety relay myPNOZ
myPNOZ is a modular safety relay, which can be used to implement various safety func-
tions without the need for programming. A safety function can be achieved through the
combination and wiring of the respective myPNOZ components. The “plug and play” prin-
ciple was in the foreground during development, without compromising on safety require-
ments. With myPNOZ it is easy to implement safety functions up to PL e of EN ISO 13849
and SIL CL 3 of EN 62061 and SIL 3 of IEC 61508.
You create your individual myPNOZ using the web application myPNOZ Creator. It’s a
simple process requiring no knowledge of programming. All you need to do is define the re-
quired safety functions and how they are linked.
Pilz then assembles your myPNOZ from the various modules, before setting it up and test-
ing it.
Your myPNOZ arrives “ready-to-install”. All you need to do is install it in the control cabinet
and wire it up. After testing the safety functions, myPNOZ is operational.
User:
Simple configuration
Pilz: Assembly, settings and delivery User:
Installation and
function test

Introduction to Getting Started manual
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2Introduction to Getting Started manual
This Getting Started manual uses an example to describe how to create and commission a
myPNOZ. The Getting Started manual shows you the elementary steps and familiarises
you with the myPNOZ.
A detailed description of the myPNOZ and the individual modules can be found in the
myPNOZ System Description.
WARNING!
Loss of safety function due to incorrect use of the myPNOZ
This Getting Started manual does not contain the safety guidelines needed
for safe installation and operation.
You must read the myPNOZ System Description.

Task
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3 Task
}A processing machine has two protection zones. One processing unit and a packaging
unit with inspection area.
}In an emergency it should be possible to stop the whole machine. It should be possible to
trigger the emergency stop from both units.
}Staff must be able to reach into the processing unit to change the tool or for cleaning
work.
It must be guaranteed that the processing unit is in a stop state whenever a staff member
reaches into the danger zone.
}Maintenance staff must be able to reach into the inspection area for maintenance work.
It must be guaranteed that the conveyor is stopped whenever a staff member reaches
into the danger zone.
}Only the unit on which work needs to be carried out should be stopped. The other unit
should continue running.
}After a stop, the units should only restart following confirmation on the operator panel.
}It must be guaranteed that nobody reaches into the product outlet area while the produc-
tion unit is running. However, products must be able to exit.

Safety functions
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4 Safety functions
Global E-STOP function
In an emergency, the whole machine (processing unit and conveyor) can be stopped from
both areas via the E-STOP pushbuttons (ES1 and ES2).
Monitored start with rising and falling edge
If the E-STOP function has been triggered, confirmation must be given on the operator
panel in order for the machine to restart.
Zone 1: Processing unit
The processing unit is secured using a safety gate and light curtain.
}Safety gate safety function (SG1)
If the safety gate is opened, then the processing unit is stopped.
The safety function is started with a monitored start with rising and falling edge. If the
safety function has been triggered, confirmation must be given on the operator panel in
order for the processing unit to restart.
}Light curtain safety function (LC)
If the light curtain is interrupted, then the processing unit is stopped.
The safety function of the light curtain is temporarily suspended through integrated L-mut-
ing, so that the products can exit the processing area without the processing unit being
stopped.
The safety function is started with a monitored start with rising and falling edge. If the
safety function has been triggered, confirmation must be given on the operator panel in
order for the processing unit to restart.
Zone 2: Packaging unit with inspection area
The inspection area is equipped with a hatch for maintenance work. The hatch is secured
using a safety switch.
}Safety gate safety function (SG2)
The conveyor is stopped via a safety switch as soon as the hatch is opened.
The safety function is started with a monitored start with rising and falling edge. If the
safety function has been triggered, confirmation must be given on the operator panel in
order for the conveyor to restart.

Safety functions
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Zone 2
Zone 1
ES1
ES2
LC
SG2
SG1
Global E-STOP function

Configure myPNOZ with myPNOZ Creator
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5 Configure myPNOZ with myPNOZ Creator
The safety functions and their logic connections are now mapped out in the myPNOZ Cre-
ator.
The web application myPNOZ Creator enables configuration to be carried out based on a
logic plan or through the combination of modules. Based on this system configuration, the
web application automatically assembles an individual myPNOZ.
It selects the required modules, defines the sequence and defines the position of the rotary
switches. The result is a pre-configured myPNOZ, which can be ordered directly.
5.1 Create logic configuration
Open the web application myPNOZ Creator (http://mypnoz.com/creator) and map out the
safety functions and their logic connections.
}Global E-STOP function
Each myPNOZ contains the global safety function. It affects the outputs in each zone and
is AND-linked to the inputs on the input modules. The global safety function is pre-con-
figured as an input in each zone; changes to the properties affect all zones.
So the global E-STOP function ES is only configured once for ES1 and ES2.
}Zone 1:
– Global E-STOP function
Monitored start with rising and falling edge
with test pulse evaluation for detection of shorts across contacts
– Safety gate input function (SG1),
Monitored start with rising and falling edge
with test pulse evaluation for detection of shorts across contacts
– Light curtain input function (LC),
Monitored start with rising and falling edge
– Relay output, instantaneous

Configure myPNOZ with myPNOZ Creator
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}Zone 2:
– Global E-STOP function
Monitored start with rising and falling edge
with test pulse evaluation for detection of shorts across contacts
– Safety gate input function (SG2),
Monitored start with rising and falling edge
with test pulse evaluation for detection of shorts across contacts
– 2 semiconductor outputs, instantaneous
Simulate configuration
A simulation can then be started for test purposes, during which the potential interactions
can be simulated.
Click on an input in simulation view and the switching outputs will be highlighted.

Configure myPNOZ with myPNOZ Creator
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5.2 Hardware configuration
When you have created the logic configuration, the logic structure is optimised and auto-
matically converted into the appropriate hardware system.
The hardware configuration is mapped out in the myPNOZ Creator. It contains all the ne-
cessary modules and the corresponding settings.
If you already know which hardware modules you need prior to configuration, you can as-
semble and configure your myPNOZ here directly from the various modules.
The following hardware configuration was generated for this example:
Head
}Head module PNOZ yh1 for the two E-STOP pushbuttons ES1 and ES2 (connected in
series)
Zone 1
}Input module PNOZ yi1 for the safety gate SG1 and the light curtain LC
}Output module PNOZ yo2 for the relay output
Zone 2
}Input and output module PNOZ yio1 for the safety gate switch SG2 and the semicon-
ductor outputs

Configure myPNOZ with myPNOZ Creator
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The head module and expansion modules are connected in the above sequence using the
bus connectors. Through this sequence, the input on the head module is AND-liked to the
inputs on the expansion module PNOZ yi1. The link affects the safe relay output on the ex-
pansion module PNOZ yo2. Likewise, the input on the head module is AND-linked to the in-
put on the expansion module PNOZ yio1 and affects the safe semiconductor output on the
PNOZ yio1.
You can check the settings of the rotary switch for the start type
Monitored start
with rising and falling edge
with test pulse evaluation
Monitored start
with rising and falling edge
with test pulse evaluation
Monitored start
with rising and falling edge
without test pulse evaluation

Configure myPNOZ with myPNOZ Creator
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5.3 Display, save and order myPNOZ configuration
The pre-configured myPNOZ is mapped out in the myPNOZ Creator, including parts list,
and can be saved, shared, printed as a PDF and ordered.
}Wiring
A diagram in the myPNOZ Creator shows how to wire your myPNOZ (see Wire
myPNOZ [ 17]).
}Shutdown matrix
The shutdown matrix shows how the outputs switch depending on the inputs
Save and share configuration
You can create a URL for the project and save or share it. This will enable you to load the
whole project and all its parameters at another time.
What’s more, each configuration has a unique type code. Our example has the type code:
myPNOZ.72.CKA380EB820AD000XB800
The type code can be used to call up the configuration again at any time.
However, only the modules and the settings on the rotary switches are saved.
All other details, such as any descriptions that have been entered, are not included in the
type code.
}Create PDF
You can create a PDF file, which contains all the information about your configuration.
}Display order overview, select connection terminals
All the modules in your myPNOZ are displayed in the order overview.
You can choose between 2 different plug-in connection terminals for the wiring
– Spring-loaded terminals
– Screw terminals
}Submit order
You can then place an order directly via the Pilz E-Shop.
Once you’ve ordered you’ll receive a fully configured and tested myPNOZ, which you can
wire and install and then put into service directly. There is a QR code on the left-hand side
of the head module so that you can change or re-order the configuration at a later date. The
QR code leads you directly to your configuration in the myPNOZ Creator.

Calculating the safety-related characteristic data
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6 Calculating the safety-related characteristic data
The safety-related characteristic values of the input, logic and output must always be taken
into account for calculating the safety-related characteristic data of a safety function on the
myPNOZ. The safety-related characteristic data of the connected sensors and actuators
must also be taken into account. They are not considered here, as they depend on the re-
spective application.
}All inputs of the same type have identical safety-related characteristic data.
}All outputs of the same type have identical safety-related characteristic data.
}The head module specifies the safety-related characteristic data of the logic.
}The input on the head module is evaluated as any other input of the same type.
}Each safety function is considered separately.
}A module’s position has no influence on the safety-related characteristic data
Calculating the safety-related characteristic data for the safety functions
The safety level of a safety function on the myPNOZ is always the result of the values for
input + logic + output, irrespective of the position of the modules. If all the inputs and out-
puts shown in the examples were of the same type, then the safety level of the safety func-
tion for all examples would also be identical.
Global E-STOP safety function – Relay output
When the global E-STOP is triggered, the relay output switches and the processing unit
goes to stop state.
PNOZ yh1 PNOZ yi1 PNOZ yo2 PNOZ yio1
Input
Logic
Output

Calculating the safety-related characteristic data
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Global E-STOP safety function – Semiconductor outputs
When the global E-STOP is triggered, the semiconductor outputs switch and the packaging
unit goes to stop state.
PNOZ yh1 PNOZ yi1 PNOZ yo2 PNOZ yio1
Input
Logic
Output
Safety gate/light curtain safety functions – Relay output
When the safety gate is opened or the light curtain is interrupted, the relay output switches
and the processing unit goes to stop state.
PNOZ yh1 PNOZ yi1 PNOZ yo2 PNOZ yio1
Input
Logic
Output

Calculating the safety-related characteristic data
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Safety gate safety function – Semiconductor outputs
When the hatch is opened, the semiconductor outputs switch and the packaging unit goes
to stop state.
PNOZ yh1 PNOZ yi1 PNOZ yo2 PNOZ yio1
Input
Logic
Output

Wire myPNOZ
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7 Wire myPNOZ
A wiring diagram for your myPNOZ is generated in the myPNOZ Creator.

Install myPNOZ
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8 Install myPNOZ
The modules are supplied pre-connected. All that’s needed is to install the myPNOZ on the
mounting rail.
Prerequisites
}The control cabinet must be at least protection type IP54.
Procedure
}Open the locking slides on the back of the modules
}Place the modules on the mounting rail and attach them to the mounting rail using the
locking slides.
}Install fixing element
When installed vertically or in environments exposed to heavy vibration, the myPNOZ
should be secured using a fixing element (e.g. retaining bracket or end angle).

Commission myPNOZ
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9 Commission myPNOZ
Prerequisites:
}The myPNOZ is installed and wired correctly.
Procedure:
1. Switch on the supply voltage.
2. Move the rotary switch System to the Run position.
The myPNOZ runs through an initialisation phase. It carried out self checks, establishes the
connection between the modules and tests the configuration. The Module LED on the head
module flashes green. Once initialisation is completed successfully, the myPNOZ goes into
operation and switches all the outputs in accordance with the configured logic. The Module
LEDs light up green. Potential status and error messages can be found under
Diagnostics [ 21].
NOTICE
The safety function should be checked after initial commissioning and each
time the plant/machine is changed. The safety functions may only be
checked by qualified personnel.

Change configuration
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10 Change configuration
Expansion modules can be exchanged or expansion modules can be removed or added.
The settings on the rotary switches can be changed. Always refer to the rules for the struc-
ture of the myPNOZ.
Procedure:
1. Set the rotary switch System on the head module to Conf. All the outputs are switched
off.
2. You can now make the following changes:
– Exchange expansion modules or insert new expansion modules
– Change or reset the start type on the rotary switch mode
3. If you have not already done so, switch on the supply voltage.
4. Save the configuration: If the rotary switch System on the head module is set to Conf,
the changed configuration will automatically be saved if no changes are made for 5 s. If
the set configuration is faulty, all the module LEDs will flash orange-green and the func-
tion LEDs will indicate the reason for the faulty configuration (see
Diagnostics [ 21]). The configuration was not saved. Correct the configuration and
save it again.
5. Set the rotary switch System to Run and check the safety functions.