Pilz PNOZ s30 User manual

PNOZ s30
Operating Manual-1001715-EN-13
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 internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
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

Content
Operating Manual PNOZ s30
1001715-EN-13 3
Section 1 Introduction 6
1.1 Validity of documentation 6
1.2 Retaining 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 Use of qualified personnel 11
3.2.2 Warranty and liability 11
3.2.3 Disposal 12
3.2.4 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 19
4.4 Speed configuration 19
4.4.1 Select Inputs 21
4.4.2 Switch functions 23
4.4.3 Basic configuration 23
4.4.4 Chip card 25
4.5 Input device types 25
4.5.1 Proximity switch 25
4.5.2 Rotary encoders 26
4.5.2.1 Output signals 27
4.5.2.2 Adapter for incremental encoders 28
Section 5 Installation 29
5.1 General installation guidelines 29
5.1.1 Dimensions 29
Section 6 Commissioning 30
6.1 Wiring 30
6.1.1 General wiring guidelines 30
6.1.2 Pin assignment of RJ45 socket 30
6.1.3 Supply voltage 30
6.1.4 Connection of proximity switches 31
6.1.5 Connection of a rotary encoder 32
6.1.5.1 Connect rotary encoder to speed monitor 32

Content
Operating Manual PNOZ s30
1001715-EN-13 4
6.1.5.2 Connect rotary encoder with Z index to speed monitor 33
6.1.5.3 Connect rotary encoder to the speed monitor via an adapter 33
6.1.6 Connection of proximity switch and rotary encoder 34
6.1.7 Reset circuit 35
6.1.8 Feedback circuit 36
6.1.9 Select inputs 36
6.1.10 Semiconductor outputs 36
6.1.11 EMC-compliant wiring 36
6.2 Display menu - Configuration 38
6.2.1 Create configuration overview 39
6.2.2 Operate rotary knob 39
6.2.3 Configure Speed Monitor 40
6.2.4 Password protection 40
6.2.5 Use chip card 41
6.2.5.1 Insert chip card 42
6.2.5.2 Write data to chip card 42
6.2.5.3 Read data from chip card 43
6.2.5.4 Transfer device parameters 43
6.2.5.5 Duplicate chip card 43
6.2.6 Menu overview 44
6.2.6.1 Permanent display 44
6.2.6.2 Basic settings Ini pnp pnp 44
6.2.6.3 Basic settings for the rotary encoder 45
6.2.6.4 Settings 47
6.2.6.5 Advanced settings 53
6.2.6.6 Information 55
6.2.7 Example: Configure basic configuration 2 58
Section 7 Operation 59
7.1 Display elements for device diagnostics 59
7.1.1 LEDs 59
7.1.2 Display 60
7.1.2.1 Error stack entries 60
7.1.2.2 Current error messages 60
7.1.2.3 Open circuit message 66
7.1.2.4 Frequency difference message on proximity switch 66
Section 8 Technical details 67
8.1 Safety characteristic data 71
Section 9 Supplementary data 72
9.1 Service life graph of output relays 72
9.2 Categories 72
9.2.1 Safety level 72
9.2.2 Safety functions 73
9.2.3 Safety-related characteristic data for operation with non-safety-related ro-
tary encoder without additional requirements 74

Content
Operating Manual PNOZ s30
1001715-EN-13 5
9.2.3.1 Permitted encoder types and output signals 74
9.2.3.2 Safety-related architecture 74
9.2.3.3 Achievable safety level 75
9.2.4 Safety-related characteristic data for operation with non-safety-related ro-
tary encoder with mechanical fault exclusion 75
9.2.4.1 Permitted encoder types and output signals 75
9.2.4.2 Safety-related architecture 75
9.2.4.3 Achievable safety level 76
9.2.5 Safety-related characteristic data for operation with non-safety-related ro-
tary encoder with diagnostics via the drive controller 76
9.2.5.1 Permitted encoder types and output signals 76
9.2.5.2 Requirements of the drive controller 76
9.2.5.3 Safety-related architecture 77
9.2.5.4 Achievable safety level 77
9.2.6 Safety-related characteristic data for operation with a safe rotary encoder 78
9.2.6.1 Permitted encoder types and output signals 78
9.2.6.2 Safety-related architecture 78
9.2.6.3 Achievable safety level 78
9.2.7 Safety-related characteristic data for operation with a safe rotary encoder
with Z index 79
9.2.7.1 Permitted encoder types and output signals 79
9.2.7.2 Safety-related architecture 79
9.2.7.3 Achievable safety level 80
9.2.8 Safety-related characteristic data for operation with non-safety-related ro-
tary encoder and proximity switch 80
9.2.8.1 Permitted encoder types and output signals 80
9.2.8.2 Safety-related architecture 81
9.2.8.3 Achievable safety level 81
9.2.9 Safety-related characteristic data for operation with 2 proximity switches 81
9.2.9.1 Permitted encoder types and output signals 81
9.2.9.2 Safety-related architecture 82
9.2.9.3 Achievable safety level 82
9.3 Examples 83
9.3.1 Connection of proximity switch 83
9.3.1.1 Features 83
9.3.1.2 Configuration overview 83
9.3.1.3 Connection 84
9.3.2 Incremental encoder connection 84
9.3.2.1 Features 84
9.3.2.2 Configuration overview 85
9.3.2.3 Connection 86
Section 10 Order reference 87

Introduction
Operating Manual PNOZ s30
1001715-EN-13 6
Introduction
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.
Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.
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.
ATTENTION!
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.
CAUTION!
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be tak-
en. It also highlights areas within the text that are of particular importance.
1
1.1
1.2
1.3

Introduction
Operating Manual PNOZ s30
1001715-EN-13 7
Information
This gives advice on applications and provides information on special fea-
tures.

Overview
Operating Manual PNOZ s30
1001715-EN-13 8
Overview
Unit structure
Range
Scope of supply:
}Speed monitor PNOZ s30
}Terminator
}Connection terminals
}Chip card
}Chip card holder
}Documentation on data medium
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
}Display
– Current frequencies
– Current position
– Warning and error messages
2
2.1
2.1.1
2.1.2

Overview
Operating Manual PNOZ s30
1001715-EN-13 9
}Status and fault LEDs
}Rotary encoder connection technology:
RJ45 socket
Front/side view
IN1 IN2 GND Y10
Y11
Y12Y13 Y30
A1 Y1 IY2 Y32
Y33
Y34Y35 Y31

A2 S11 S21 11
23
13S34 21
12
24
14 22
PNOZ s30


A2 S11 S21 11
23
13S34 21
12
24
14 22


IN1 IN2 GND Y10
Y11
Y12Y13 Y30
A1 Y1 IY2 Y32
Y33
Y34Y35 Y31

PNOZ s30
Power
In1
In2
Rel 1
Rel 2
Fault






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)
}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: Reset input
2.2

Overview
Operating Manual PNOZ s30
1001715-EN-13 10
}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
}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
Operating Manual PNOZ s30
1001715-EN-13 11
Safety
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
Safety regulations
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 safety guidelines given in this description
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific application.
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
3.1
3.2
3.2.1
3.2.2

Safety
Operating Manual PNOZ s30
1001715-EN-13 12
Disposal
}In safety-related applications, please comply with the mission time tMin the safety-relat-
ed characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
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.
3.2.3
3.2.4

Function description
Operating Manual PNOZ s30
1001715-EN-13 13
Function description
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.
Block diagram
 








 











 
 





 






4
4.1
4.2

Function description
Operating Manual PNOZ s30
1001715-EN-13 14
CAUTION!
The individual blocks are galvanically isolated from each other:
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 connect-
ed directly to the GNDs on the connected units, otherwise noise susceptibili-
ty may be increased significantly (conductor loops are not permitted).
– Supply voltage: A1, A2
– Encoder and initiator inputs: GND, In1, In2, RJ45 socket and shield
– Reset 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
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.
Timing diagram for standstill/speed monitoring:








4.3

Function description
Operating Manual PNOZ s30
1001715-EN-13 15
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:





 




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.

Function description
Operating Manual PNOZ s30
1001715-EN-13 16
Timing diagram for position monitoring:
v
s
Reference position
(rising edge at
S34)
Configured
window width
Position
window
F2
s
AB

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 restarted 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.
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.

Function description
Operating Manual PNOZ s30
1001715-EN-13 17
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
0 0 0 0...
0 0 0 1 2 3 4 4 ...
1 2 3 4 4 ...
3 2 1 0 0 ...
3 2 1 2 1 0 0 ...
1 2 3 2 3 4 4 ...
1 2 3 3 ... 4 4 ... 4 4 ... 3 2 1 0 0 . ..
Wrong
direction:
Wrong
direction: s
3 2 1 1 1 ... 0 0 ... 0 0 ... 1 2 3 4 4 . ..
Configuration in the example:
}Wrong direction in anti-clockwise rotation
Max. right: 3 pulses
}Wrong direction in clockwise rotation
Max. left: 3 pulses
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.
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

Function description
Operating Manual PNOZ s30
1001715-EN-13 18
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 is 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 is detected at S34.
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 acti-
vated 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-13 19
Timing diagram for speed monitoring









 

 












  





Configuration in the example:
}Switch function: F2
}Assigned output: Rel. 1
}Delay effect on outputs: On + Off
}Reset mode: Monitored /
Speed configuration
The speed monitor is configured using the rotary knob on the device.
Up to 16 parameter sets (P0 ... P15), each with a max. of 9 switch functions (F1 ... F9) can
be configured to monitor various operating modes, for example.
One of the 16 parameter sets is selected via 4 select inputs SEL1 (Y10), SEL2 (Y11), SEL4
(Y12), SEL8 (Y13).
4.3.1
4.4

Function description
Operating Manual PNOZ s30
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The switch functions are monitored simultaneously.
Each of a switch function's 16 parameters can be configured as
}Standstill limit
}Speed limit
}Upper or lower limit of speed range
}Right-hand direction monitoring
}Left-hand direction monitoring
}Position monitoring 1 to 4 with width of position window 1 to 4
Exactly one switch function can be assigned to each output. The same switch function can
be assigned to several outputs. With range monitoring, a range is assigned to an output
(F2-F3, F4-F5, F6-F7 or F8-F9).
A switch delay and start mode can be configured for each output.
If only one parameter set is used, configure the mode "Select inputs: None". The select in-
puts will then be ignored.
Information
2 basic configurations are available for standard applications, for simple
configuration within the display menu. A basic configuration contains limited
menu functions adapted for standard applications, with partly pre-defined
parameters. Further information about basic configurations can be found in
this chapter, under "Basic configuration".
Example configuration:
2 parameter sets for 2 operating modes are configured:
}Set-up: P1
}Automatic mode: P2
The parameter set P1 is used to monitor a reduced speed.
The parameter set P2, "Automatic mode", is selected for speed monitoring (selection via
the select inputs, see next chapter "Select inputs").
The following switch functions are configured for the parameter set P1:
}F1: Standstill 2 Hz
}F2: Overspeed: 50 Hz
}F3: Warning threshold: 50 Hz
The following switch functions are configured for the parameter set P2:
}F1: Standstill 2 Hz
}F2: Overspeed: 3000 Hz
}F3: Warning threshold: 2800 Hz
The following outputs are assigned to the switch functions:
}F1: Relay output Rel. 1
}F2: Relay output Rel. 2
}F3: Semiconductor output Out 1