Pilz PNOZ s30 User manual

PNOZ s30
Operating Manual 1001715-EN-15
}Safety relays

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
Operating Manual PNOZ s30
1001715-EN-15 3
Section 1 Introduction 6
1.1 Validity of documentation 6
1.2 Using the documentation 6
1.3 Definition of symbols 6
Section 2 Overview 8
2.1 Unit structure 8
2.1.1 Range 8
2.1.2 Unit features 8
2.2 Front/side view 9
Section 3 Safety 11
3.1 Intended use 11
3.2 Safety regulations 11
3.2.1 Safety assessment 11
3.2.2 Use of qualified personnel 11
3.2.3 Warranty and liability 12
3.2.4 Disposal 12
3.2.5 For your safety 12
Section 4 Function description 13
4.1 Introduction 13
4.2 Block diagram 13
4.3 Functions 14
4.3.1 Timing diagram for speed monitoring 20
4.4 Speed configuration 21
4.4.1 Select Inputs 23
4.4.2 Switch functions 25
4.4.3 Basic configuration 26
4.4.4 Chip card 27
4.5 Input device types 27
4.5.1 Proximity switch 27
4.5.2 Rotary encoders 28
4.5.2.1 Output signals 29
4.5.2.2 Adapter for incremental encoders 30
Section 5 Installation 31
5.1 General installation guidelines 31
5.1.1 Dimensions 31
Section 6 Commissioning 32
6.1 Wiring 32
6.1.1 General wiring guidelines 32
6.1.2 Pin assignment of RJ45 socket 32
6.1.3 Supply voltage 32
6.1.4 Connection of proximity switches 33
6.1.5 Connection of a rotary encoder 34

Contents
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6.1.5.1 Connect rotary encoder to speed monitor 34
6.1.5.2 Connect rotary encoder with Z index to speed monitor 35
6.1.5.3 Connect rotary encoder to the speed monitor via an adapter 36
6.1.6 Connection of proximity switch and rotary encoder 36
6.1.7 Reset circuit 38
6.1.8 Feedback circuit 38
6.1.9 Select inputs 38
6.1.10 Semiconductor outputs 38
6.1.11 EMC-compliant wiring 39
6.2 Display menu - Configuration 42
6.2.1 Create configuration overview 42
6.2.2 Operate rotary knob 42
6.2.3 Configure Speed Monitor 43
6.2.4 Password protection 44
6.2.5 Use chip card 44
6.2.5.1 Insert chip card 45
6.2.5.2 Write data to chip card 46
6.2.5.3 Read data from chip card 46
6.2.5.4 Transfer device parameters 47
6.2.5.5 Duplicate chip card 47
6.2.6 Save configuration with Software SmartCardCommander 48
6.2.7 Menu overview 49
6.2.7.1 Permanent display 49
6.2.7.2 Basic settings Ini pnp pnp 50
6.2.7.3 Basic settings for the rotary encoder 51
6.2.7.4 Settings 53
6.2.7.5 Advanced settings 59
6.2.7.6 Information 60
6.2.8 Example: Configure basic configuration 2 64
Section 7 Operation 65
7.1 Display elements for device diagnostics 65
7.1.1 LEDs 65
7.1.2 Display 66
7.1.2.1 Error stack entries 66
7.1.2.2 Current error messages 66
7.1.2.3 Open circuit message 73
7.1.2.4 Frequency difference message on proximity switch 73
Section 8 Technical details 75
8.1 Safety characteristic data 80
Section 9 Supplementary data 81
9.1 Service life graph of output relays 81
9.2 Categories 82
9.2.1 Safety level 82
9.2.2 Safety functions 83

Contents
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1001715-EN-15 5
9.2.3 Safety-related characteristic data for operation with non-safety-related
rotary encoder without additional requirements
83
9.2.3.1 Permitted encoder types and output signals 83
9.2.3.2 Safety-related architecture 84
9.2.3.3 Achievable safety level 84
9.2.4 Safety-related characteristic data for operation with non-safety-related
rotary encoder with mechanical fault exclusion
84
9.2.4.1 Permitted encoder types and output signals 84
9.2.4.2 Safety-related architecture 85
9.2.4.3 Achievable safety level 85
9.2.5 Safety-related characteristic data for operation with non-safety-related
rotary encoder with diagnostics via the drive controller
85
9.2.5.1 Permitted encoder types and output signals 85
9.2.5.2 Requirements of the drive controller 86
9.2.5.3 Safety-related architecture 86
9.2.5.4 Achievable safety level 87
9.2.6 Safety-related characteristic data for operation with a safe rotary encoder 87
9.2.6.1 Permitted encoder types and output signals 87
9.2.6.2 Safety-related architecture 87
9.2.6.3 Achievable safety level 88
9.2.7 Safety-related characteristic data for operation with a safe rotary encoder
with Z index
88
9.2.7.1 Permitted encoder types and output signals 88
9.2.7.2 Safety-related architecture 88
9.2.7.3 Achievable safety level 89
9.2.8 Safety-related characteristic data for operation with non-safety-related
rotary encoder and proximity switch
89
9.2.8.1 Permitted encoder types and output signals 89
9.2.8.2 Safety-related architecture 90
9.2.8.3 Achievable safety level 90
9.2.9 Safety-related characteristic data for operation with 2 proximity switches 91
9.2.9.1 Permitted encoder types and output signals 91
9.2.9.2 Safety-related architecture 91
9.2.9.3 Achievable safety level 92
9.3 Examples 92
9.3.1 Connection of proximity switch 92
9.3.1.1 Features 92
9.3.1.2 Configuration overview 93
9.3.1.3 Connection 94
9.3.2 Incremental encoder connection 94
9.3.2.1 Features 94
9.3.2.2 Configuration overview 95
9.3.2.3 Connection 96
Section 10 Order reference 97
10.1 Product 97
10.2 Accessories 97

Introduction
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1001715-EN-15 6
1 Introduction
1.1 Validity of documentation
This documentation is valid for speed monitors PNOZ s30 from version 2.2. It is valid until
new documentation is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
This documentation is intended for instruction and should be retained for future reference.
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
Operating Manual PNOZ s30
1001715-EN-15 7
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
2.1 Unit structure
2.1.1 Range
Scope of supply:
}Speed monitor PNOZ s30
}Terminator
}Connection terminals
}Chip card
}Chip card holder
}Documentation on data medium
2.1.2 Unit features
Using the product PNOZ s30:
Speed monitor for safe monitoring of standstill, speed, speed range, position and direction.
The product has the following features:
}Measured value recorded by
– Incremental encoder
– Proximity switch
}Measured variables
– Standstill
– Speed
– Speed range
– Position
– Direction
– Analogue voltage (track S)
}Positive-guided relay outputs
– 2 safety contacts (NO)
– 2 auxiliary contacts (NC)
}Semiconductor outputs
– 4 auxiliary outputs
}Expansion interface for 2 more safe relay outputs that be controlled separately
}Can be configured via the display on the speed monitor
}Configuration is stored on a chip card

Overview
Operating Manual PNOZ s30
1001715-EN-15 9
}Display
– Current frequencies
– Current position
– Warning and error messages
}Status and fault LEDs
}Rotary encoder connection technology:
RJ45 socket
2.2 Front/side view
IN1 IN2
GND Y10
Y11
Y12Y13 Y30
A1 Y1
IY2 Y32
Y33
Y34Y35 Y31
X3X1
A2 S11
S21 11
23
13S34 21
12
24
14 22
PNOZ s30
X2X6
X4
A2 S11
S21 11
23
13S34 21
12
24
14 22
X4
X2X6
IN1 IN2
GND Y10
Y11
Y12Y13 Y30
A1 Y1
IY2 Y32
Y33
Y34Y35 Y31
X3X1
PNOZ s30
Power
In1
In2
Rel 1
Rel 2
Fault
X6
1
2
4
3
5
Fig.: Left: Side view, centre: Front view without cover, right: Front view with cover
Legend:
}A1, A2:
Supply connections
}In1, In2, GND:
Proximity switch 1 - In1 (track A) and 2 - In2 (track B) and GND
}Y10 ... Y13:
Select inputs (SEL1, SEL2, SEL4, SEL8)
}13-14 and 23-24:
Relay outputs (safety contacts)
}11-12 and 21-22:
Relay outputs (auxiliary contacts)

Overview
Operating Manual PNOZ s30
1001715-EN-15 10
}Y32 ... Y35: Semiconductor outputs (auxiliary outputs)
}S11: +24 V / 30 mA (supply for S34, Y1 and Y2)
}S21: 0 V (GND for S11, S34, Y1 and Y2)
}S34: Start input
}Y30: 0 V ext (GND for select input and semiconductor outputs)
}Y31: 24 V ext (supply for semiconductor outputs)
}Y1, Y2:
Y1: Feedback input for Rel. 1
Y2: Feedback input for Rel. 2
}X6: RJ45 socket for connecting the encoder
(tracks A, /A, B, /B, Z, /Z, S and GND). Proximity switches can be connected via RJ45
socket or connection terminals.
}1: Chip card
}2: Display format
}3: USB connection (service only)
}4: Rotary knob
}5: Expansion interface for 2 more external relay outputs
}LEDs:
– Power
– In1
– In2
– Rel 1
– Rel 2
– Fault

Safety
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1001715-EN-15 11
3 Safety
3.1 Intended use
The speed monitor monitors standstill, speed, speed range, position and direction in ac-
cordance with EN ISO 13849-1 up to PL e and EN IEC 62061 up to SIL CL 3.
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
– Z-frequency monitoring with an additional proximity switch (Ini pnp)
on the same axis
3.2 Safety regulations
3.2.1 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.
3.2.2 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.

Safety
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1001715-EN-15 12
3.2.3 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.).
3.2.4 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).
3.2.5 For your safety
}The device is designed exclusively for use in an industrial environment. It is not suitable
for use in a domestic environment, as this can lead to interference.
}The guarantee is rendered invalid if the housing is opened or unauthorised modifica-
tions are carried out.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.

Function description
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1001715-EN-15 13
4 Function description
4.1 Introduction
Proximity switches or rotary encoders record measured values, which are evaluated in the
speed monitor PNOZ s30. There are 9 monitoring functions (F1 ... F9), which are per-
formed simultaneously.
Up to 16 different parameter sets (P0 ... P15) for the monitoring functions can be selected
via the select inputs.
Configuration of the monitoring functions is menu-driven, using a rotary knob. The outputs
switch depending on the configuration.
An interface is available to connect a contact expansion module PNOZsigma, enabling the
number of outputs to be expanded.
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 Block diagram
A1 A2
Y10 Y11 Y12 Y13 Y30 Y31
Power
Reset/
Start
S34
=
~
Rel. 1
13 11
12
14
23
24
21
22
Feed-
back
Y32 Y33 Y34 Y35
Initiator
Input
In1 In2 GND
24 V 0 V
S11 S21
Inputs (SEL)
Select
Interface
Extended Relais
24 V ext 0 V ext
X6
RJ45
Y1 Y2
Rel. 2
Relay
Control

Function description
Operating Manual PNOZ s30
1001715-EN-15 14
NOTICE
The individual blocks are galvanically isolated from each other:
– Supply voltage: A1, A2
– Encoder and initiator inputs: GND, In1, In2, RJ45 socket and shield
– Start and feedback circuits: S21, S11, S34, Y1, Y2
– Semiconductor outputs and select inputs: Y30, Y31, Y32, Y33, Y34,
Y35, Y10, Y11, Y12, Y13
– Relay output 13, 14
– Relay output 11, 12
– Relay output 23, 24
– Relay output 21, 22
If possible, the connections for the various earth potentials (GND, S21, Y30
und A2) should not be connected on the PNOZ s30 but should be connec-
ted directly to the GNDs on the connected units, otherwise noise susceptib-
ility may be increased significantly (conductor loops are not permitted).
4.3 Functions
The following monitoring functions can be configured:
Standstill
With standstill monitoring, the output is switched on when the value falls below the stated
standstill value; if the standstill value is exceeded, the output switches off.
Speed
With speed monitoring, the output switches off when the configured value is exceeded.

Function description
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Timing diagram for standstill/speed monitoring:
v
t
Hys. F2
vmax (F2)
vmax (F2) - Hys. F2
F2
t
0
Speed range
With range monitoring, the output switches off if the rotational speed (velocity, frequency) is
outside the configured range.
Timing diagram for speed range monitoring:
v
t
Hys. F3
vmax (F3)
vmax (F3) - Hys. F3
vmax (F2) + Hys. F2 Hys. F2
F2-F3
t
vmax (F2)
0

Function description
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1001715-EN-15 16
Position
Position monitoring is activated via a rising edge at the start input. The current position is
adopted as a reference position in the middle of the position window (configured window
width) and the assigned output is switched on.
The output will stay switched on provided the current position is within the position window.
Timing diagram for position monitoring:
v
s
Reference position
(rising edge at
S34)
Configured
window width
Position
window
F2
s
AB
0°
Position
Reference position
(rising edge at
S34)
B
A
If the position moves outside the configured range, position monitoring is reset and the as-
signed outputs are switched off. Position monitoring can be restarted via a rising edge at
the start input
A max. of 4 positions can be configured to be monitored simultaneously.
Please note:
}Active position monitoring is not started again by another rising edge at the start input.
}Active position monitoring continues unchanged even if a different parameter set is se-
lected, which also uses position monitoring. This also applies if position monitoring is
used in a different switch function.
}Active position monitoring is reset if another parameter set is selected, which does not
use position monitoring.
}Position monitoring cannot be used if proximity switches are employed.

Function description
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1001715-EN-15 17
Direction
If the direction is to be detected safely, this function must be linked to a safety contact.
}If "Direct. Right" is configured, the safety output is switched on during normal operation
in clockwise rotation.
}If "Direct. Left" is configured, the safety output is switched on during normal operation in
anti-clockwise rotation.
For both directions, a tolerance can be entered for the wrong direction. In other words, the
drive can run in the wrong direction up to the set tolerance value, without the assigned out-
put switching off.
If an output has been switched off, it cannot switch back on again until the drive has been
run in the right direction up to the tolerance value.
Please note:
}Direction monitoring is always active, irrespective of whether it is used in the selected
parameter set.
}Direct.Right and Direct.Left are active when the PNOZ s30 is started up.
}Direction cannot be detected if proximity switches are used.
Timing diagram for direction monitoring:
UB
Direction s
Direct.Right
Right
Left
Standstill
Direct.Left
s
s
0000...
00012344...
12344...
32100...
32 1 2 1 0 0 ...
12 3 2 3 4 4 ...
1 2 3 3 ... 4 4 ... 4 4 ... 32100...
Wrong
direction:
Wrong
direction: s
32111... 0 0 ... 0 0 ... 12344...
Configuration in the example:
}Wrong direction in anti-clockwise rotation
Max. right: 3 pulses
}Wrong direction in clockwise rotation
Max. left: 3 pulses

Function description
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1001715-EN-15 18
Monitoring for broken shearpins
An additional proximity switch or an HTL signal from an additional rotary encoder can be
connected to track Z to monitor for broken shearpins. These must both be configured as Z-
frequency monitoring.
Please note:
Monitoring for broken shearpins does not become active until
}The minimum speed has been exceeded and
}The tolerance for detecting feasibility errors has elapsed.
The minimum speed and tolerance depend on the ratio of the frequency at tracks AB "fAB"
to the frequency at track Z "fZ" in your configuration (fAB/fZ Verh. setting in the menu).
Minimum speed:
}when fAB/fZ Verh. ≥ 1.0
fZ = 70 mHz or fAB = (fAB/fZ) x 70 mHz
}when fAB/fZ Verh. < 1.0
fAB = 70 mHz or fZ = 70 mHz/(fAB/fz)
Tolerance for detecting feasibility errors:
}when fAB/fZ Verh. ≥ 1.0
7.5 Z-pulses or 7.5 x (fAB/fZ ) AB-pulses
}when fAB/fZ Verh. < 1.0
4.5 AB-pulses or 4.5/(fAB/fZ) Z-pulses
Hysteresis
For each switch function F1 ... F9 (with the exception of direction and position), a hysteresis
can be configured. This prevents the outputs on the speed monitor from bouncing if there
are fluctuations around the response value. The hysteresis becomes effective when the
output is switched on:
Switch-on value = switching threshold – hysteresis
For the lower range limit:
Switch-on value = switching threshold + hysteresis
Start modes
You can choose between the following start modes:
}Automatic start
If an automatic start is configured, the output switches on automatically if the speed
does not reach the limit value, for example.
}Monitored start with rising edge
If a monitored start with rising edge is configured, the output switches on if the speed
does not reach the limit value and then a rising edge was detected at S34.
}Monitored start with falling edge
If a monitored start with falling edge is configured, the output switches on if the speed
does not reach the limit value and then a falling edge was detected at S34.

Function description
Operating Manual PNOZ s30
1001715-EN-15 19
Switch delay
A delay time can be set for each output (see technical details). The outputs will not switch
until the set time has elapsed. It is possible to configure whether the delay time is to be ac-
tivated when switching on, switching off, or switching on and off.
WARNING!
Potential loss of safety function due to increased reaction time
The output switch-off delay (tdo,Off) when overspeed is reached will in-
crease the speed monitor's reaction time by the stated 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 hazards, reaction time and safety dis-
tance.
Feedback loops
Feedback loops are used to monitor external contactors or relays. The corresponding feed-
back loop must be closed before starting.
Start-up delay
A start-up delay time can be configured, which prevents the evaluation of the encoder sig-
nals for the configured time period after the supply voltage is switched on.
Switching direction on semiconductor outputs
The semiconductor outputs can be operated in normally de-energised or normally ener-
gised mode.
Units
The values to be configured can be entered in various units. Depending on the axis type
(linear or rotational axis), various units can be selected for speed and distance (see chapter
entitled "Menu overview").

Function description
Operating Manual PNOZ s30
1001715-EN-15 20
4.3.1 Timing diagram for speed monitoring
t
F2
Delay time (tv)
Rel. 1
Delay effect:
On Off
t
t
Delayed (+filtered)
On Off Off
Reset mode monitored/
On Off
Rel. 1
Feedback loop
t
t
t
Example: Rel. 1
Switch-on
delay
Switch-off
delay
Too short
Start
pulse duration Too short Too short
v
Hys. F2
vmax (F2)
vmax (F2) - Hys. F2
0
Configuration in the example:
}Switch function: F2
}Assigned output: Rel. 1
}Delay effect on outputs: On + Off
}Reset mode: Monitored /