Pilz PNOZ ms2p HTL User manual

PNOZ ms2p HTL
Operating Manual-1001401-EN-04
}Configurable safety systems PNOZmulti

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation 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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Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Scope 7
2.2 Unit features 7
2.3 Front view 8
Section 3 Safety 9
3.1 Intended use 9
3.2 System requirements 10
3.3 Safety regulations 11
3.3.1 Safety assessment 11
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 12
Section 4 Function description 13
4.1 Integrated protection mechanisms 13
4.2 Operation 13
4.3 Block diagram 13
4.4 Input device types 14
4.4.1 Proximity switch 14
4.4.1.1 Requirements of the proximity switches 14
4.4.2 Incremental encoders 14
4.4.2.1 Requirements of the incremental encoders 14
4.4.2.2 Adapter for incremental encoders 15
4.4.3 Incremental encoder and proximity switch on one axis 15
Section 5 Installation 16
5.1 General installation guidelines 16
5.2 Dimensions 16
5.3 Connecting the base unit and expansion modules 17
Section 6 Commissioning 18
6.1 General wiring guidelines 18
6.2 Pin assignment of RJ45 socket 19
6.3 Connection of proximity switches 19
6.4 Connection of the incremental encoder 20
6.4.1 Connect signals of the incremental encoder to the speed monitor 20
6.4.2 Connect incremental encoder to the speed monitor via an adapter 20
6.5 Connection of proximity switches and incremental encoder 22
6.5.1 Proximity switch and incremental encoder on various axes 22
6.5.2 Proximity switch and incremental encoder on one axis 23

Contents
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6.6 Connection examples 24
6.6.1 Connection of 2 proximity switches and an incremental encoder 24
6.6.2 Connection of 4 proximity switches 25
6.6.3 Connection of an incremental encoder and proximity switch on an axis 26
Section 7 Operation 27
7.1 LED indicators 27
7.2 Signal statuses 28
7.3 Faults - malfunctions 28
Section 8 Technical details 29
8.1 Safety characteristic data 31
Section 9 Order reference 32
9.1 Product 32
9.2 Accessories 32
Section 10 Application Examples 33

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ ms2p HTL. It is valid until new document-
ation 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
}Expansion module PNOZ ms2p HTL
}Jumper
2.2 Unit features
Using the product PNOZ ms2p HTL:
Speed monitor for connection to a base unit from the configurable control system
PNOZmulti
The product has the following features:
}Monitoring of 2 independent axes
}Connection per axis
– 1 incremental encoder
or
– 2 proximity switches
or
– 1 incremental encoder and 1 proximity switch
}Measured variables:
– Standstill
– Speed (8 values can be set)
– Direction of rotation
}Axis types, input device types and start mode can be selected in the PNOZmulti Config-
urator
}Status indicators for
– Supply voltage
– Incremental encoder
– Proximity switch
– Axis status, standstill and excess speed
– Faults on the system
}Proximity switch connection technology: Plug-in connection terminals (either cage
clamp terminal or screw terminal)
}Incremental encoder connection technology:
RJ45 female connector
}Galvanic isolation between the connections X1, X12 and X22
}Max. 4 speed monitors can be connected to the base unit

Overview
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2.3 Front view
HTL
15
Legend:
}X1:
– I10, I11:
Connection terminals for proximity switch at axis1
– I20, I21:
Connection terminals for proximity switch at axis2
– 0 V, 24 V:
Supply connections
}X12:
– female connector for the connection of an incremental encoder at axis1
}X22:
– female connector for the connection of an incremental encoder at axis2
}LEDs:
– POWER
– FAULT
– SHAFT 1
– SHAFT 2
– X12
– X22

Safety
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3 Safety
3.1 Intended use
The expansion module monitors standstill, speed and direction of rotation in accordance
with EN ISO 13849-1 up to PL e and EN IEC 62061 up to SIL CL 3.
The expansion module may only be connected to a base unit from the PNOZmulti system
(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
WARNING!
Users must take appropriate measures to detect or exclude errors (e.g. slip-
page or broken shearpin) which cause the frequency of the encoder signal
to no longer be proportional to the monitored speed.
Appropriate measures are:
– Using the monitored encoder to also control the drive
– Mechanical solutions
– Monitoring for broken shearpin by means of the speed monitor
WARNING!
A single-channel open circuit/input device error is recognised and leads to a
safe condition of the outputs at the relevant axis.
For applications in accordance with PL e and SIL CL 3, the "Overspeed"
output must be integrated into the safety function in every operating mode
and evaluated so that a shutdown occurs if the output switches to a safe
condition ("Overspeed" output = "0").

Safety
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CAUTION!
If there are frequency differences between tracks A and B of the incre-
mental encoder and/or between the proximity switches on inputs I10 (I20)
and I11 (I21), the PNOZmulti switches to a safe state if a frequency ex-
ceeds the configured standstill frequency and is greater than 2 Hz. If the
speed monitor detects different directions of rotation, please note:
– With version 1.X devices the PNOZmulti changes to STOP.
– With devices from version 2.0, the axis in question switches to a safe
condition. The safe condition is cleared again as soon as the error is
remedied. Hazards that can arise through an automatic restart must
be excluded within the user program.
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 [ 29]).
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.

Safety
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3.3 Safety regulations
3.3.1 Safety assessment
Before using a unit 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.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}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-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Safety
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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
functions 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 conforms to the following safety criteria:
}The circuit is redundant with built-in self-monitoring.
}The safety function remains effective in the case of a component failure.
4.2 Operation
The speed monitor can independently monitor two axes for standstill, speed and direction
of rotation. The speed monitor signals the status of the monitored values to the base unit.
Depending on the safety circuit loaded, the values can be transferred from the base unit,
e.g. to a relay output on the safety system. Incremental encoders and/or proximity detectors
can be used to record the values.
The configuration of the speed monitor is described in detail in the PNOZmulti Configur-
ator's online help.
4.3 Block diagram
RJ45 RJ45

Function description
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4.4 Input device types
4.4.1 Proximity switch
4.4.1.1 Requirements of the proximity switches
}Only "pnp" type proximity switches may be used (N/O contact, switching to positive).
}The proximity switches require a 24 VDC supply.
}The proximity switches must be fitted so that at least one is always activated (carries a
high signal).
}The proximity switches must be fitted so that the recorded signals overlap.
}When monitoring with proximity switches we recommend you use proximity switches
with hysteresis in order to prevent bounce and therefore incorrect measurements.
Proximity switch 1
Proximity switch 2
Fig.: Example proximity switch signal behaviour
CAUTION!
Appropriate installation measures should be taken to prevent a foreign body
coming between the signal encoder and the proximity switch. The foreign
body could cause one of the proximity switches to be constantly energised
(constant high signal).
}Please note the values stated in the technical details
4.4.2 Incremental encoders
4.4.2.1 Requirements of the incremental encoders
}Only incremental encoders with a differential output of the following type are permitted
– HTL (12 V – 30 V)
}Please note the values stated in the technical details

Function description
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4.4.2.2 Adapter for incremental encoders
The adapter records the data between the encoder and drive and makes it available to the
PNOZ ms2p HTL via the RJ45 socket.
Pilz supplies complete adapters as well as ready-made cable with RJ45 connector, which
can be used when making your own adapter. The range of products in this area is con-
stantly being expanded. Please contact us about the range of adapters that is currently
available.
4.4.3 Incremental encoder and proximity switch on one axis
In order to increase the availability, a proximity switch and an incremental encoder can be
configured on one axis for the speed monitor. The speed monitor then monitors 3 signals
on an axis: Track A and track B of the incremental encoder and the proximity switch
Standstill monitoring
Standstill is detected when at least two of these signals fall below the standstill frequency.
Monitoring for broken shearpins
If the Broken shearpin monitoring option is activated, a shearpin break is recognised if
}both signals of the incremental encoder fall below the set standstill frequency (stand-
still)
and
}the proximity switch exceeds the set standstill frequency (rotating shaft).
The recognised broken shearpin leads to safe condition (see status B2 in "Signal statuses"
table in Chapter 8 of the operating manual). If individual or multiple signals change, the sys-
tem may leave a safe state (see "Signal statuses" table).
Hazards that can arise through an automatic restart must be excluded from the user pro-
gram.

Installation
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5 Installation
5.1 General installation guidelines
}The control system should be installed in a control cabinet with a protection type of at
least IP54. Fit the control system to a horizontal mounting rail. The venting slots must
face upward and downward. Other mounting positions could destroy the control system.
}Use the locking elements on the rear of the unit to attach it to a mounting rail. Connect
the control system to the mounting rail in an upright position, so that the earthing
springs on the control system are pressed on to the mounting rail.
}The ambient temperature of the devices in the control cabinet must not exceed the fig-
ure stated in the technical details. Air conditioning may otherwise be required.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
NOTICE
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
5.2 Dimensions
94 (3.70")
45
(1.77")
121 (4.76")

Installation
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5.3 Connecting the base unit and expansion modules
Connect the base unit and the expansion modules as described in the operating manuals
for the base modules.
}The terminator must be fitted to the last expansion module
}Install the expansion module in the position 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.
Details of the input type, axis type and reset mode, plus the values for standstill, speed
monitoring and direction of rotation are also defined in the PNOZmulti Configurator.
Please note:
}Information given in the Technical details [ 29] must be followed.
}Use copper wiring with a temperature stability of 75 °C.
CAUTION!
The configurable switch-off delay when reaching the overspeed increases
the reaction time of the system of base unit and speed monitor by the
entered value (see technical details). This must not delay the arrival of a
safe condition by more than the permitted time. The configuration of the
switch-off delay must be considered in the risk assessment as regards haz-
ards, reaction time and safety distance.
On each of the 2 axes you can connect as required:
}1incremental encoder
or
}2proximity switches
or
}1 incremental encoder and 1 proximity switch
Incremental encoder Proximity switch
Connection axis 1 X12 -
- I10, I11, 0 V
X12 I10, 0 V
Connection axis 2 X22 -
- I20, I21, 0 V
X22 I20, 0 V

Commissioning
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6.2 Pin assignment of RJ45 socket
RJ45 socket
8-pin PIN Track
8 1
1 n.c.
2 0 V
3 n.c.
4 A
5 /A
6 n.c.
7 B
8 /B
6.3 Connection of proximity switches
Proceed as follows when connecting proximity switches:
}Terminals I10 and I11: connect the proximity switch for axis 1
}Terminals I20 and I21: connect the proximity switch for axis 2.
}If only one axis is to be monitored, either terminals I10 and I11 or terminals I20 and I21
will remain free.
}When connecting incremental encoders and proximity switches on one axis:
– Terminals I10: connect proximity switch for axis 1 (I11 is not used)
– Terminals I20: connect proximity switch for axis 2 (I21 is not used)
}The proximity switch must always be connected to a 0 V terminal of the speed monitor.
The 0 V terminals are connected internally.
}Connect proximity switch to 24 VDC of the power supply or the speed monitor (the 24V
terminals of the speed monitor are connected internally)
I20
I11
I21
I10
0 V
L+
L-

Commissioning
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6.4 Connection of the incremental encoder
Proceed as follows when connecting the incremental encoder:
}The incremental encoder may be connected via an adapter or directly to the speed
monitor.
}The incremental encoder on connector X12 monitors axis 1; the incremental encoder
on connector X22 monitors axis 2.
}Use only shielded cables for all connections
}0 V from the incremental encoder and speed monitor should always be connected.
}Position the terminating resistors of the signal lines as close as possible to the speed
monitor input.
6.4.1 Connect signals of the incremental encoder to the speed monitor
Encoder types: 24 V-HTL
}Apply 24 VDC supply voltage to incremental encoder only
}Do not terminate incremental encoder with Z0=120 Ohm
X12
X22
Speed monitor
24 V DC
0 V
2
4
5
7
8
A
/A
B
/B
24 V
0 V
Incremental
encoder
Fig.: Connection to incremental encoder type 24 V-HTL
6.4.2 Connect incremental encoder to the speed monitor via an adapter
}The adapter is connected between the incremental encoder and the drive. The output
on the adapter is connected to the female RJ45 connector on the speed monitor.
}The adapter can also be used without connecting to a drive.
}The signals relevant for the speed monitor are utilised in parallel by the adapter. The in-
formation stated under "Connect incremental encoder signals to the speed monitor" and
in the adapter operating manual must be observed when connecting the supply voltage.
}Supply voltage (12 V – 30 V) to incremental encoder only.
}HTL signals may not be fitted with a terminating resistor.