Pilz PNOZ s30 User manual

PNOZ s30
Operating Manual-1001715-EN-19
}Safety relays

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
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.
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 ............................................................................................................................7
1.1 Validity of documentation ..........................................................................................................7
1.2 Using the documentation ..........................................................................................................7
1.3 Definition of symbols .................................................................................................................7
2 Overview .................................................................................................................................9
2.1 Unit structure.............................................................................................................................9
2.1.1 Range........................................................................................................................................9
2.1.2 Unit features..............................................................................................................................9
2.2 Front/side view ..........................................................................................................................10
3 Safety ......................................................................................................................................12
3.1 Intended use .............................................................................................................................12
3.2 Safety regulations .....................................................................................................................12
3.2.1 Safety assessment....................................................................................................................12
3.2.2 Use of qualified personnel.........................................................................................................13
3.2.3 Warranty and liability.................................................................................................................13
3.2.4 Disposal ....................................................................................................................................13
3.2.5 For your safety ..........................................................................................................................13
4 Security ...................................................................................................................................14
5 Function description ..............................................................................................................15
5.1 Introduction ...............................................................................................................................15
5.2 Block diagram ...........................................................................................................................15
5.3 Functions...................................................................................................................................16
5.3.1 Standstill....................................................................................................................................16
5.3.2 Speed........................................................................................................................................17
5.3.3 Speed range..............................................................................................................................17
5.3.4 Position .....................................................................................................................................18
5.3.5 Direction ....................................................................................................................................20
5.3.6 2 encoder diagnostics / broken shearpin monitoring.................................................................21
5.3.7 Hysteresis .................................................................................................................................21
5.3.8 Frequency filtering.....................................................................................................................22
5.3.9 Start types .................................................................................................................................24
5.3.10 Start-up delay............................................................................................................................24
5.3.11 Synchronous start .....................................................................................................................25
5.3.12 Outputs......................................................................................................................................25
5.3.13 Switch delay ..............................................................................................................................26
5.3.14 Feedback loops.........................................................................................................................26
5.3.15 Analogue output........................................................................................................................27
5.3.16 Units ..........................................................................................................................................27
5.3.17 Timing diagram for speed monitoring........................................................................................28
5.4 Speed configuration ..................................................................................................................29
5.4.1 Select Inputs .............................................................................................................................31
5.4.2 Switch functions ........................................................................................................................33
5.4.3 Special functions .......................................................................................................................35
5.4.4 Basic configuration....................................................................................................................37

Contents
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5.4.5 Chip card...................................................................................................................................38
5.5 Input device types .....................................................................................................................39
5.5.1 Proximity switch ........................................................................................................................39
5.5.2 Rotary encoders........................................................................................................................40
5.5.2.1 Output signals ...........................................................................................................................41
5.5.2.2 Adapter for incremental encoders .............................................................................................42
6 Installation ..............................................................................................................................43
6.1 General installation guidelines ..................................................................................................43
6.1.1 Dimensions ...............................................................................................................................43
7 Wiring ......................................................................................................................................44
7.1 General wiring guidelines..........................................................................................................44
7.2 Pin assignment of RJ45 socket.................................................................................................44
7.3 Supply voltage...........................................................................................................................44
7.4 Connection of proximity switches..............................................................................................45
7.5 Connection of a rotary encoder.................................................................................................46
7.5.1 Connect rotary encoder to speed monitor.................................................................................47
7.5.2 Connect rotary encoder with Z index to speed monitor.............................................................47
7.5.3 Connect rotary encoder to the speed monitor via an adapter...................................................48
7.6 Connection of proximity switch and rotary encoder ..................................................................48
7.7 Reset circuit ..............................................................................................................................50
7.8 Feedback circuit ........................................................................................................................50
7.9 Select inputs..............................................................................................................................51
7.10 Semiconductor outputs .............................................................................................................51
7.11 Analogue output........................................................................................................................51
7.12 EMC-compliant wiring ...............................................................................................................51
8 Display menu - Configuration ...............................................................................................56
8.1 Create configuration overview...................................................................................................56
8.2 Operate rotary knob ..................................................................................................................57
8.3 Configure Speed Monitor ..........................................................................................................57
8.4 Password protection..................................................................................................................58
8.5 Use chip card ...........................................................................................................................59
8.5.1 Insert chip card .........................................................................................................................60
8.5.2 Write data to chip card .............................................................................................................60
8.5.3 Read data from chip card..........................................................................................................61
8.5.4 Transfer device parameters .....................................................................................................62
8.5.5 Duplicate chip card....................................................................................................................62
8.5.6 Compatibility with older device versions ...................................................................................63
8.5.7 Special cases and problem solving...........................................................................................64
8.6 Save configuration with Software SmartCardCommander........................................................65
8.7 Menu overview ..........................................................................................................................67
8.7.1 Permanent display ....................................................................................................................67
8.7.2 Basic settings Ini pnp pnp .........................................................................................................67
8.7.3 Basic settings for the rotary encoder.........................................................................................68
8.7.4 Settings .....................................................................................................................................70
8.7.5 Advanced settings.....................................................................................................................78

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8.7.6 Information ................................................................................................................................81
8.7.7 Restart.......................................................................................................................................82
8.7.8 Menu messages........................................................................................................................83
8.8 Example: Configure basic configuration 2.................................................................................86
9 Create configuration in PNOZsigma Configurator ..............................................................87
9.1 Download project from the PNOZsigma Configurator to the PNOZs30...................................87
9.2 Transfer project from PNOZs30 to the PNOZsigma Configurator............................................88
10 Function test during commissioning ...................................................................................90
11 Operation and diagnostics ....................................................................................................91
11.1 LED indicators...........................................................................................................................91
11.2 Display ......................................................................................................................................92
11.2.1 Error stack entries .....................................................................................................................92
11.2.2 Current error messages ............................................................................................................92
11.2.3 Open circuit message ...............................................................................................................100
11.2.4 Frequency difference message on proximity switch .................................................................100
11.3 Function test of the relay outputs..............................................................................................101
12 Technical details ....................................................................................................................102
12.1 Safety characteristic data..........................................................................................................108
12.2 Signal level of the encoders......................................................................................................109
13 Supplementary data ...............................................................................................................110
13.1 Service life graph of output relays.............................................................................................110
13.2 Permitted operating height........................................................................................................111
13.3 Categories.................................................................................................................................112
13.3.1 Safety level................................................................................................................................112
13.3.2 Safety functions.........................................................................................................................114
13.3.3 Safety-related characteristic data for operation with non-safety-related rotary encoder
without additional requirements ................................................................................................
114
13.3.3.1 Permitted encoder types and output signals.............................................................................114
13.3.3.2 Safety-related architecture ........................................................................................................115
13.3.3.3 Achievable safety level..............................................................................................................115
13.3.4 Safety-related characteristic data for operation with non-safety-related rotary encoder with
mechanical fault exclusion ........................................................................................................
115
13.3.4.1 Permitted encoder types and output signals.............................................................................115
13.3.4.2 Safety-related architecture ........................................................................................................116
13.3.4.3 Achievable safety level..............................................................................................................116
13.3.5 Safety-related characteristic data for operation with non-safety-related rotary encoder with
diagnostics via the drive controller ............................................................................................
116
13.3.5.1 Permitted encoder types and output signals.............................................................................116
13.3.5.2 Requirements of the drive controller .........................................................................................117
13.3.5.3 Safety-related architecture ........................................................................................................117
13.3.5.4 Achievable safety level..............................................................................................................118
13.3.6 Safety-related characteristic data for operation with a safe rotary encoder..............................118
13.3.6.1 Permitted encoder types and output signals.............................................................................118

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13.3.6.2 Safety-related architecture ........................................................................................................118
13.3.6.3 Achievable safety level..............................................................................................................119
13.3.7 Safety-related characteristic data for operation with a safe rotary encoder with Z index..........119
13.3.7.1 Permitted encoder types and output signals.............................................................................119
13.3.7.2 Safety-related architecture ........................................................................................................120
13.3.7.3 Achievable safety level..............................................................................................................120
13.3.8 Safety-related characteristic data for operation with non-safety-related rotary encoder and
proximity switch.........................................................................................................................
120
13.3.8.1 Permitted encoder types and output signals.............................................................................120
13.3.8.2 Safety-related architecture ........................................................................................................121
13.3.8.3 Achievable safety level..............................................................................................................121
13.3.9 Safety-related characteristic data for operation with 2 proximity switches................................122
13.3.9.1 Permitted encoder types and output signals.............................................................................122
13.3.9.2 Safety-related architecture ........................................................................................................122
13.3.9.3 Achievable safety level..............................................................................................................123
13.3.10 Safety characteristic data for operation with 2 proximity switches with reduced diagnostics ...123
13.3.10.1 Permitted encoder types and output signals.............................................................................123
13.3.10.2 Safety-related architecture ........................................................................................................124
13.3.10.3 Achievable safety level..............................................................................................................124
13.4 Examples ..................................................................................................................................125
13.4.1 Connection of proximity switch..................................................................................................125
13.4.1.1 Features ....................................................................................................................................125
13.4.1.2 Configuration overview..............................................................................................................125
13.4.2 Incremental encoder connection...............................................................................................127
13.4.2.1 Features ....................................................................................................................................127
13.4.2.2 Configuration overview..............................................................................................................127
14 Order reference ......................................................................................................................129
14.1 Product......................................................................................................................................129
14.2 Accessories...............................................................................................................................129
15 EC declaration of conformity ................................................................................................132
16 UKCA-Declaration of Conformity .........................................................................................133

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ s30 from Version 3.1.
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 Unit structure
2.1.1 Range
Scope of supply:
}Speed monitor PNOZ s30
}Terminator
}Connection terminals
}Chip card
}Chip card holder
2.1.2 Unit features
Application of 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, one output configurable as an analogue output
}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
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}Display
– Current frequencies
– Current position
– Warning and error messages
}Status and fault LEDs
}Encoder connection technology:
RJ45 socket
2.2 Front/side view
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 REL 1 and REL 2 (safety contacts)
}11-12 and 21-22:
Relay outputs REL 1 and REL 2 (auxiliary contacts)

Overview
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}Y32 ... Y34: Semiconductor outputs OUT 1 …- OUT 3 (auxiliary outputs)
}Y35: Semiconductor output OUT 4 (auxiliary output or analogue 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
}Y1, Y2:
Y1: Feedback input for Rel. 1
Y2: Feedback input for Rel. 2
}Y30: 0 V ext (GND for select input and semiconductor outputs)
}Y31: 24 V ext (supply for semiconductor outputs)
}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
}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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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.
The safety controller 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 appropriate air conditioning.
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
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 Safety regulations
3.2.1 Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 62061. However, this does not guarantee the functional
safety of the overall plant/machine. To achieve the relevant safety level of the overall plant/
machine’s required safety functions, each safety function needs to be considered separ-
ately.

Safety
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3.2.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
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 the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the specific
application.
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-related
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 modifications
are carried out.
}Adequate protection must be provided on all output contacts with capacitive and inductive
loads.

Security
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4 Security
}The product is not protected from physical manipulation or from reading of memory con-
tents during physical access. Use appropriate measures to ensure that there is no phys-
ical access by unauthorised persons. You should also use security seals so that you can
detect any manipulation of the product or interfaces. Installation inside a lockable control
cabinet is recommended as a minimum measure.
}To protect against unauthorised access, no cable may be plugged into the USB connec-
tion during normal operation.
}The configuration computer that accesses the product has to be protected from attacks
by a firewall or other suitable measures. We recommend that a virus scanner is used on
this configuration computer and updated regularly.

Function description
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5 Function description
5.1 Introduction
Proximity switches or encoders record measured values, which are evaluated in the speed
monitor PNOZ s30. Up to 9 monitoring functions can be configured (F1 ... F9) which are run
at a time.
Via the Select inputs, up to 16 different parameter sets (P0 ... P15) of the monitoring func-
tion can be chosen, e.g. to monitor various operating modes.
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 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.
5.2 Block diagram

Function description
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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).
5.3 Functions
The following monitoring functions can be configured:
5.3.1 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.

Function description
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5.3.2 Speed
With speed monitoring, the output switches off when the configured value is exceeded.
v
t
Hys. F2
vmax (F2)
vmax (F2) - Hys. F2
F2
t
0
Fig.: Sequence of standstill and speed monitoring process
5.3.3 Speed range
With range monitoring, the output switches off if the rotational speed (velocity, frequency) is
outside the configured range.
v
t
Hys. F3
vmax (F3)
vmax (F3) - Hys. F3
vmax (F2) + Hys. F2 Hys. F2
F2-F3
t
vmax (F2)
0
Fig.: Sequence of speed range monitoring process

Function description
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5.3.4 Position
When position monitoring is active, the current position is taken 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 po-
sition window. A max. 4 positions to be monitored can configured at the same time.
If the position moves outside the configured range, position monitoring is deactivated and
the assigned outputs are switched off.
Position monitoring can be started (activated) automatically or monitored:
}Monitored start (default)
– Position monitoring is started when a rising edge has been detected at the start input.
– Active position monitoring is not started again by another rising edge at the start input
(retriggering is not possible).
– Active position monitoring continues unchanged even if a different parameter set is
selected, 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.
t0t1t2t3t4
x0
s [inc]
t
Pos.Monitoring
Lpos
Fig.: Sequence of position monitoring with monitored start
Legend
x0 Reference position
Lpos Position window
t0Device on
t1Start of position monitoring by rising edge at the start input (S34)
t2Position leaves the position window, assigned outputs will switch off
t3Restart of position monitoring by rising edge at the start input (S34)
t4Position leaves the position window, assigned outputs will switch off

Function description
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}Automatic start
– Position monitoring is started when a rising edge has been detected at the start input.
– Position monitoring is started when the parameter set has been switched over and
position monitoring is used in the current parameter set.
– Position monitoring is restarted when the limit value has been exceeded and a rising
edge has been detected at the start input.
– Active position monitoring is not started again by another rising edge at the start in-
put.
– Active position monitoring is restarted if another parameter set is selected, which also
uses position monitoring. This also applies if position monitoring is used in a different
switch function.
– Active position monitoring is deactivated if another parameter set is selected, which
does not use this position monitoring.
t0t1t2t3t4
x0
s [inc]
t
Pos. Monitoring
Lpos
Fig.: Sequence of position monitoring with automatic start
Legend
x0Reference position
Lpos Position window
t0Device on
t1Start of position monitoring by selecting a parameter set via the Select inputs
t2Position monitoring is restarted by selecting a different parameter set
t3Position leaves the position window, assigned outputs will switch off
t4Restart of position monitoring by rising edge at the start input (S34)
Please note:
}Position monitoring cannot be used if proximity switches are employed.
}Managing the start type of the outputs is independent of the start type of the position
monitoring.
}In the event of an open circuit, position monitoring is automatically deactivated

Function description
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5.3.5 Direction
If the direction is to be detected safely, this function must be linked to a safety contact.
}Clockwise
If "Direct. Right" is configured, the safety output is switched on during normal operation in
clockwise rotation.
}Counter-clockwise
If "Direct. Left" is configured, the safety output is switched on during normal operation in
anti-clockwise rotation.
}Tolerance
For both directions, a tolerance can be entered for the wrong direction. This means that
the drive may run in the incorrect direction until it reaches the set tolerance value without
the assigned output switching off.
A switched off output cannot switch on again until the drive has moved up to the toler-
ance value in the correct direction.
The tolerance is also taken into account following an automatic reset.
}Automatic reset
For both directions, a joint automatic reset can be configured.
– If no automatic reset is configured, the direction monitoring is reset only by switching
off the supply voltage.
– When automatic reset is configured, the direction monitoring is reset when a para-
meter set is switched over.
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...
1 23 4 4 ...
3 21 0 0 ...
3 2 1 21 0 0 ...
1 2 3 23 4 4 ...
1 2 3 3 ... 4 4 ... 4 4 ... 32 1 0 0...
Wrong
direction:
Wrong
direction: s
3 21 1 1 ... 0 0 ... 0 0 ... 12 3 4 4...