Pilz PNOZ m1p User manual

PNOZ m1p (ETH)
Operating Manual-20878-EN-16
}Configurable safety systems PNOZmulti

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
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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 Range 7
2.2 Unit features 7
2.3 Chip card 8
2.4 Front view 9
Section 3 Safety 11
3.1 Intended use 11
3.2 System requirements 11
3.3 Safety regulations 11
3.3.1 Safety assessment 11
3.3.2 Use of qualified personnel 12
3.3.3 Warranty and liability 12
3.3.4 Disposal 12
3.3.5 For your safety 12
Section 4 Function description 13
4.1 Integrated protection mechanisms 13
4.2 Functions 13
4.3 Block diagram 13
4.4 Diagnostics 14
4.5 Cascading 14
4.6 Safety mat, muting 14
4.7 Interfaces 14
Section 5 Installation 15
5.1 Control cabinet installation 15
5.2 Dimensions 16
5.3 Install base unit without expansion module 16
5.4 Connecting the base unit and expansion modules 17
Section 6 Commissioning 18
6.1 General wiring guidelines 18
6.2 Ethernet interfaces (ETH version only) 19
6.2.1 RJ45 interfaces ("Ethernet") 19
6.2.2 Requirements of the connection cable and connector 19
6.2.3 Interface configuration 19
6.2.4 RJ45 connection cable 20
6.2.5 Process data exchange 21
6.3 Function test during commissioning 21
6.4 Commissioning the PNOZmulti control system for the first time 22
6.4.1 Load project from chip card 22

Contents
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6.4.2 Load project via integrated interface 22
6.5 Download modified project to the PNOZmulti system 23
6.5.1 Load modified project from chip card 23
6.5.2 Load modified project via integrated interface 23
6.6 Connection 23
6.7 Connection example 26
Section 7 Operation 27
7.1 LED indicators 27
7.1.1 Indicators for the Ethernet connection (ETH version only) 28
7.2 Function test of the relay outputs 28
7.3 Reset Ethernet connection settings 29
Section 8 Technical Details 30
8.1 Safety characteristic data 38
Section 9 Supplementary data 40
9.1 Service life graph for the relay contacts 40
Section 10 Order reference 42
10.1 Product 42
10.2 Accessories 42

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ m1p. 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.
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 Range
}Base unit PNOZ m1p
}Terminator
}Documentation on data medium
2.2 Unit features
Application of the product PNOZ m1p:
Base unit from the configurable control system PNOZmulti
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Positive-guided relay outputs:
– 2 safety outputs
Depending on the application, up to PL e of EN ISO 13849-1 and up to SIL CL 3 of
EN IEC 62061
}Semiconductor outputs:
– 4 safety outputs
Depending on the application, up to PL e of EN ISO 13849-1 and up to SIL CL 3 of
EN IEC 62061
– 1 output for standard applications
}4 test pulse outputs
}1 cascading input and output;
can also be used as a standard output
}20 inputs for connecting, for example:
– E-STOP pushbuttons
– Two-hand pushbuttons
– Safety gate limit switches
– Start buttons
– Light beam devices
– Scanners
– Enabling switches
– PSEN
– Operating mode selector switches
– Safety mats
}Muting function

Overview
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}LED indicator for:
– Diagnostics
– Supply voltage
– Output circuits
– Input circuits
}Test pulse outputs used to monitor shorts across the inputs
}Monitoring of shorts between the safety outputs
}Expansion modules can be connected
(please refer to the document "PNOZmulti System Expansion" for details of the type
and number that can be connected)
}Integrated interfaces:
– PNOZ m1p: Serial interface RS232
– PNOZ m1pETH: 2 Ethernet interfaces
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see order
reference)
}Coated version:
Increased environmental requirements (see Technical details [ 30])
2.3 Chip card
To be able to use the product you will need a chip card.
Chip cards are available with memories of 8 kByte and 32 kByte. For large-scale projects
we recommend the 32 kByte chip card (see Technical Catalogue: Accessories chapter).

Overview
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2.4 Front view
PNOZ m1p
CHIP-Card

Overview
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PNOZ m1p ETH
CHIP-Card
TRF
LNK
TRF
LNK
MAC ADD_00-02-47-MAC-VAR
Legend:
CHIP card Chipkarte interface
X1 Cascading inputs and outputs CI and CO,
Test pulse outputs T0 ... T3
X2 Semiconductor outputs O0 ... O3,
Auxiliary output OA0,
Supply connections
X3 Relay outputs O4 and O5
X4 RS232 interface / Ethernet interface
X5, X6 Inputs I0 ... I19
X7 Power supply
LEDs: PWR
RUN
DIAG
FAULT
I FAULT
O FAULT

Safety
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3 Safety
3.1 Intended use
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
CAUTION!
Inputs and outputs for standard functions must not be used for safety-re-
lated applications.
The coated version of the product PNOZ m1p is suitable for use where there are increased
environmental requirements (see Technical details [ 30]).
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 [ 30]).
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" document in the "Version overview" section for
details of which versions of the PNOZmulti Configurator can be used for this product.
3.3 Safety regulations
3.3.1 Safety assessment
Before using a device 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.

Safety
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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 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 preven-
tion,
}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 spe-
cific 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).
3.3.5 For your safety
The device meets all the necessary conditions for safe operation. However, you should al-
ways ensure that the following safety requirements are met:
}This operating manual only describes the basic functions of the device. Advanced func-
tions are described in the online help for the PNOZmulti Configurator, in the
"PNOZmulti Communication Interfaces" document and in "PNOZmulti Special Applica-
tions". Only use these functions once you have read and understood the documenta-
tion.
}You must note the information stated in the PNOZmulti Safety Manual.
}Adequate protection must be provided for all inductive consumers.
}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 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.
}The relay contacts meet the requirements for protective separation through increased
insulation compared with all other circuits in the safety system.
}The safety outputs are tested periodically using a disconnection test.
4.2 Functions
The function of the inputs and outputs on the control system depends on the safety circuit
created using the PNOZmulti Configurator. A chip card is used to download the safety cir-
cuit to the base unit. The base unit has 2 microcontrollers that monitor each other. They
evaluate the input circuits on the base unit and expansion modules and switch the outputs
on the base unit and expansion modules accordingly.
The LEDs on the base unit and expansion modules indicate the status of the configurable
control system PNOZmulti.
The online help on the PNOZmulti Configurator contains descriptions of the operating
modes and all the functions of the control system, plus connection examples.
4.3 Block diagram
Interface
fieldbus,
expansion
module
Interface
chip card
Ethernet/
RS 232
Interface
expansion
module
O4 O5
A1 A2 I0 I14I6 I11I9 I10 I13I8I7 I16I12 I18I15I2 I4 I5I1 I3 I17 I19
Input
Power
Cascading Test pulse
output 24 V 0 V
24 V 0 V
1323
CI+ CI- CO+ CO- T0 T1 T2 T3 O0 O1 O2 O3 OA0 14 24

Function description
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4.4 Diagnostics
The status and error messages displayed by the LEDs are saved in an error stack. This er-
ror stack can be read from the PNOZmulti Configurator via the interfaces (RS232 or Ether-
net). More comprehensive diagnostics are possible via the interfaces or one of the fieldbus
modules, e.g. the PROFIBUS module.
4.5 Cascading
The cascading inputs and outputs enable several PNOZmulti and PNOZelog units to be
connected in series or as a tree structure.
INFORMATION
Detailed information on these functions and connection examples can be
found in the online help for the PNOZmulti Configurator and in the
PNOZmulti Installation Manual.
4.6 Safety mat, muting
INFORMATION
Detailed information on these functions and connection examples can be
found in the online help for the PNOZmulti Configurator and in the docu-
ment entitled "PNOZmulti - Special Applications".
4.7 Interfaces
The product PNOZ m1p ETH has two Ethernet interfaces, the product PNOZ m1p has one
serial interface to
}Project download
}Read the diagnostic data
}Set virtual inputs for standard functions
}Read virtual outputs for standard functions.
Information on diagnostics via the interfaces can be found in the document "PNOZmulti
communication interfaces".
The connection to Ethernet is made via the two 8-pin RJ45 sockets.
The Ethernet interface is configured in the PNOZmulti Configurator and is described in the
online help for the PNOZmulti Configurator.

Installation
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5 Installation
5.1 Control cabinet installation
}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.

Installation
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5.2 Dimensions
94 (3.70")
121 (4.76")
135 (5.31")
5.3 Install base unit without expansion module
}The terminator must be fitted to the side of the base unit marked “Termination/Link”.
}Do not fit a terminator on the left hand side of the base unit.
Terminator Termination/Link

Installation
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5.4 Connecting the base unit and expansion modules
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.
The modules are linked via jumpers.
There are 2 pin connectors on the rear of the base unit.
A max. of 12 expansion modules plus one fieldbus module may be connected to one base
unit.
}Ensure that no terminator is connected.
}Connect the base unit, the expansion modules and the fieldbus module using the jump-
ers supplied.
}The terminator must be fitted to the last expansion module to the right of the base unit.
}A terminator must not be fitted to the last expansion module to the left of the base unit.
Expansion module 1 ... 8
Jumpers Terminator
Fieldbus module
Base unit
Expansion module 1 ... 4 Power supply

Commissioning
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6 Commissioning
6.1 General wiring guidelines
The wiring is defined in the circuit diagram in the Configurator. There you can select the in-
puts that are to perform a safety function and the outputs that are to switch this safety func-
tion.
Please note:
CAUTION!
The plug-in connection terminals on the relay outputs carry mains voltage
and should only be connected and disconnected when the voltage is
switched off.
}Information given in the Technical details [ 30] must be followed.
}Outputs:
– O0 to O5 are safety outputs
– O4 and O5 are relay outputs
– O0 to O3 are semiconductor outputs
– OA0 is an output to delete a project from the base unit (see online help for the
PNOZmutli Configurator).
}To prevent contact welding, a fuse should be connected before the output contacts (see
technical details).
}Use copper wiring with a temperature stability of 75°C.
}Sufficient fuse protection must be provided on all output contacts with inductive loads.
}The control system and input circuits must always be supplied by a single power sup-
ply. The power supply must meet the regulations for extra low voltages with protective
separation.
}Two connection terminals are available for each of the supply connections 24 V and 0 V
(semiconductor outputs), plus A1 and A2 (power supply). This means that the supply
voltage can be looped through several connections. When the supply voltage is looped,
the current at each terminal may not exceed 3A.
}Test pulse outputs must exclusively be used to test the inputs. They must not be used
to drive loads.
Do not route the test pulse lines together with actuator cables within an unprotected
multicore cable.
}Test pulse outputs are also used to supply safety mats that trigger a short circuit.
Test pulses that are used for the safety mat may not be reused for other purposes.

Commissioning
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6.2 Ethernet interfaces (ETH version only)
6.2.1 RJ45 interfaces ("Ethernet")
Two free switch ports are provided as Ethernet interfaces via an internal autosensing
switch. The autosensing switch automatically detects whether data transfer is occurring at
10 Mbit/s or 100 Mbit/s.
INFORMATION
The connected subscribers must support the autosensing/autonegotiation
function. If not, the communication partner must be set permanently to "10
Mbit/s, half duplex".
The switch's automatic crossover function means there is no need to distinguish on the
connection cable between patch cable (uncrossed data line connection) and crossover
cable (crossover data line connection). The switch automatically creates the correct data
line connection internally. Patch cable can therefore be used as the connection cable for
end devices as well as cascading.
Both Ethernet interfaces use RJ45 technology.
6.2.2 Requirements of the connection cable and connector
The following minimum requirements must be met:
}Ethernet standards (min. Category 5) 10BaseT or 100BaseTX
}Double-shielded twisted pair cable for industrial Ethernet use
}Shielded RJ45 connectors (industrial connectors)
6.2.3 Interface configuration
RJ45 socket
8-pin PIN Standard Crossover
8 1
1 TD+ (Transmit+) RD+ (Receive+)
2 TD- (Transmit-) RD- (Receive-)
3 RD+ (Receive+) TD+ (Transmit+)
4 n.c. n.c.
5 n.c. n.c.
6 RD- (Receive-) TD- (Transmit-)
7 n.c. n.c.
8 n.c. n.c.

Commissioning
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6.2.4 RJ45 connection cable
RJ45 connector
8-pin
8
1
10BaseT cable or 100BaseTX cable
max. 100 m
NOTICE
With the plug-in connection please note that the data cable and connector
have a limited mechanical load capacity. Appropriate design measures
should be used to ensure that the plug-in connection is insensitive to in-
creased mechanical stress (e.g. through shock, vibration). Such measures
include fixed routing with strain relief, for example.