Pilz PNOZ ml2p User manual

PNOZ ml2p
Operating Manual 1001642-EN-04
}Configurable safety systems PNOZmulti

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

Contents
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Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Scope 7
2.2 Unit features 7
2.3 Front view 8
Section 3 Safety 9
3.1 Intended use 9
3.2 System requirements 9
3.3 Safety regulations 10
3.3.1 Use of qualified personnel 10
3.3.2 Warranty and liability 10
3.3.3 Disposal 10
3.3.4 For your safety 10
Section 4 Function description 11
4.1 Integrated protection mechanisms 11
4.2 Operation 11
4.3 Block diagram 12
Section 5 Installation 13
5.1 General installation guidelines 13
5.2 Dimensions in mm 13
5.3 Connecting the base unit and expansion modules 14
Section 6 Commissioning 15
6.1 General wiring guidelines 15
6.1.1 Insulation voltage test 15
6.2 Preparing for operation 15
6.2.1 Download modified project to the PNOZmulti safety system 15
6.2.2 Connection 16
6.3 Series connection of 4 decentralised modules 17
6.4 Voltage drop 17
6.4.1 Guidelines for various cable types 17
6.4.2 Calculation example 18
Section 7 Operation 19
7.1 LED indicators 19
7.2 Fault detection 19
Section 8 Technical details 20
8.1 Safety characteristic data 22

Contents
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Section 9 Order reference 23
9.1 Products 23
9.2 Accessories 23

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ ml2p. 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 Scope
}Expansion module PNOZ ml2p
}Jumper
2.2 Unit features
Using the product PNOZ ml2p:
Link module to safely connect decentralised input/output modules to a configurable control
system PNOZmulti
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Max. 4 PNOZ ml2p can be connected to the base unit
}Max. 4 decentralised modules PDP67 F 8DI ION can be connected to the link module
PNOZ ml2p
}Plug-in connection terminals (either cage clamp terminal or screw terminal)
}LEDs for
– Operating status
– Fault
– Connection status
}Please refer to the document "PNOZmulti System Expansion" for the PNOZmulti base
units that can be connected.

Overview
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2.3 Front view
Key:
}0 V, 24 V:
Supply connections
}CAN+, CAN-, VCC, GND:
Connection for decentralised modules
}Shield:
Connection for the cable shield

Safety
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3 Safety
3.1 Intended use
The expansion module is used to connect decentralised input/output modules to a configur-
able control system PNOZmulti .
The expansion module may only be connected to a base unit from the configurable system
PNOZmulti (please refer to the document "PNOZmulti System Expansion" for details of the
base units that can be connected).
The configurable small control systems PNOZmulti are used for the safety-related interrup-
tion of safety circuits and are designed for use in:
}E-STOP equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
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 [ 20]).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
3.2 System requirements
Please refer to the "Product Modifications PNOZmulti" document in the "Version overview"
section for details of which versions of the base unit and PNOZmulti Configurator can be
used for this product.

Safety
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3.3 Safety regulations
3.3.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}Have read and understood the information provided in this description under "Safety"
}And have a good knowledge of the generic and specialist standards applicable to the
specific application.
3.3.2 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.).
3.3.3 Disposal
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3.4 For your safety
The unit meets all the necessary conditions for safe operation. However, you should always
ensure that the following safety requirements are met:
}This operating manual only describes the basic functions of the unit. The expanded
functions are described in the PNOZmulti Configurator's online help. Only use these
functions once you have read and understood the documentations.
}Do not open the housing or make any unauthorised modifications.
}Please make sure you shut down the supply voltage when performing maintenance
work (e.g. exchanging contactors).

Function description
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4 Function description
4.1 Integrated protection mechanisms
The relay conforms to the following safety criteria:
}The circuit is redundant with built-in self-monitoring.
}The safety function remains effective in the case of a component failure.
4.2 Operation
The link module PNOZ ml2p is used to safely transfer the input information from decentral-
ised modules to the safety system PNOZmulti.
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.
Data exchange:
}Communication with the decentralised modules is via a safe data link.
}The link module PNOZ ml2p reads the input information from the decentralised mod-
ules as part of each cycle and then forwards it to the base unit.
}At the end of a PNOZmulti cycle, the base unit sends its output data to its link module.
This output data is immediately sent to the decentralised modules.
Linking several decentralised modules:
}A maximum of 4 link modules can be connected to a PNOZmulti base unit.
}A maximum of 4 decentralised modules can be connected to a link module PNOZ ml2p.
}If a decentralised module receives data intended for a different decentralised module
that is connected, the data is forwarded without being processed.

Function description
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4.3 Block diagram
24V 24V
=
Power
=
0V 0V
Interface
to previous
module
Interface
to next
module
CAN+ CAN- VCC GND Shield

Installation
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5 Installation
5.1 General installation guidelines
}The control system should be installed in a control cabinet with a protection type of at
least IP54. Fit the control system to a horizontal mounting rail. The venting slots must
face upward and downward. Other mounting positions could destroy the control system.
}Use the notches on the rear of the unit to attach it to a mounting rail. Connect the con-
trol 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 PNOZmulti units in the control cabinet must not exceed
the figure stated in the technical details, otherwise air conditioning will be required.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
CAUTION!
Damage due to electrostatic discharge!
Electrostatic discharge can damage components. Ensure against discharge
before touching the product, e.g. by touching an earthed, conductive sur-
face or by wearing an earthed armband.
5.2 Dimensions in mm
94 (3.70")
22,5
(0.88")
121 (4.76")

Installation
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5.3 Connecting the base unit and expansion modules
Connect the base unit and the expansion module as described in the operating instructions
for the base units.
}Do not connect a terminator to the last expansion module on the left-hand side.
}Install the expansion module in the position in which it is configured in the PNOZmulti
Configurator.
The position of the expansion modules is defined in the PNOZmulti Configurator. The ex-
pansion modules are connected to the left or right of the base unit, depending on the type.
Please refer to the document "PNOZmulti System Expansion" for details of the number of
modules that can be connected to the base unit and the module types.

Commissioning
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6 Commissioning
6.1 General wiring guidelines
The wiring is defined in the circuit diagram of the PNOZmulti Configurator.
Please note:
}Information given in the Technical details [ 20] must be followed.
}Use copper wire that can withstand 75°C.
}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.
}Please refer to the technical details for information on the maximum cable length.
Please also read the section entitled Voltage drop [ 17].
}Shielded cable must be used from a cable length of 30 m.
}Pilz pre-assembled cable can be used to connect the decentralised modules (see Order
references [ 23]).
}The plug-in connection terminals are either designed as cage clamp terminals or screw
terminals (see Order references [ 23]).
CAUTION!
Only connect and disconnect the expansion module when the supply
voltage is switched off.
6.1.1 Insulation voltage test
The product PNOZ ml2p is connected to functional earth via protection elements on the
supply voltage. Insulation voltage tests are only possible with voltages up to ca. 42 V.
6.2 Preparing for operation
6.2.1 Download modified project to the PNOZmulti safety system
As soon as an additional expansion module has been connected to the system, the project
must be amended using the PNOZmulti Configurator. Proceed as described in the operat-
ing instructions for the base unit.
NOTICE
For the commissioning and after every program change, you must check
whether the safety devices are functioning correctly.

Commissioning
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6.2.2 Connection
Supply voltage AC DC
Supply voltage
Connection to a decentralised input module PDP67
CAN+
CAN-
VCC
GND
Shield
VCC
CAN-
GND
CAN+
Shield
PNOZ ml2p PDP67 F 8DI ION
1
2
3
4
5
Connection when using the PSS SB BUSCABLE LC in conjunction with a Pilz self-
assembly "PSS67 M12 connector" (see order reference in the Technical Catalogue)
CAN+
CAN-
VCC
GND
Shield
PNOZ ml2p PDP67 F 8DI ION
1
2
3
4
5
red
brown
white
green
VCC
CAN-
GND
CAN+
Shield

Commissioning
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6.3 Series connection of 4 decentralised modules
You can connect up to 4 decentralised modules in series to a PNOZmulti link module.
PNOZ ml2p
6.4 Voltage drop
The max. cable length depends on the voltage drop in the supply voltage cables. The level
of voltage drop is determined by the:
}Cable resistance on the supply voltage cables
}Operating current of the modules
}Load on the modules
To increase the max. cable length, the input voltage can be permanently increased by the
voltage tolerance (see Technical Details).
6.4.1 Guidelines for various cable types
Cable type Voltage drop per 10 m and per 100 mA
PSS SB BUSCABLE LC 0.1 V
Sensor cable 0.25 mm20.15 V
Sensor cable 0.34 mm20.11 V
Sensor cable 0.5 mm20.07 V

Commissioning
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6.4.2 Calculation example
}The PSS SB BUSCABLE LC is used in accordance with the pin assignment in section
6.2.2.
Voltage drop per 10 m and per 100 mA: 0.1 V
PNOZmulti Base Unit
4*I0+I1+I2+I3+I4
650 mA
U1 = 1,3 V
I0+I4
100 mA
U4 = 0,10 V
2*I0+I3+I4
250 mA
U3 = 0,5 V
3*I0+I2+I3+I4
550 mA
U2 = 0,825 V
20 m
20 m 15 m 10 m
I0=50 mA
I4 = 50 mA I3 =100 mA I2 = 250 mA I1 = 50 mA
Link
Module
PNOZ
ml2p
PDP67 F 8DI ION
I0=50 mA
PDP67 F 8DI ION
I0=50 mA
PDP67 F 8DI ION
I0=50 mA
PDP67 F 8DI ION
Key:
}I0: Module's consumption.
}I1 ... I5: Load current taken from the module
}U1 … U4: Voltage drop on the respective connection path
Total voltage drop from the link module PNOZ ml2p to the final PDP67 F 8DI ION:
Utotal = U1 + U2 + U3 + U4
Utotal = 1.3 V + 0.825 V + 0.5 V + 0.10 V = 2.725 V

Operation
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7 Operation
When the supply voltage is switched on, the PNOZmulti safety system copies the configur-
ation from the chip card.
The LEDs “POWER”, “DIAG”, “FAULT”, “IFAULT” and “OFAULT” will light up on the base
unit.
The PNOZmulti safety system is ready for operation when the "POWER" and "RUN" LEDs
on the base unit and the "READY" LED on the PNOZ ml2p are lit continuously.
7.1 LED indicators
Legend
LED on
LED flashes
LED off
LED LED status Meaning
READY Gree
n
The unit is ready for operation
The unit is not ready for operation
FAULT Red External error
Red Internal error
No error
TR Yel-
low
Connection to a decentralised module avail-
able
Yel-
low
Connection is not available to all decentralised
modules.
No connection to a decentralised module
7.2 Fault detection
The base unit contains information about the
}Link module (in order, defective, no supply voltage)
}Status of communication with the decentralised modules (data valid, data invalid)
If the connection to a decentralised module is interrupted or there is a major error on the
decentralised module, the inputs on the devices connected to the link module are set to
zero. The base unit remains in a RUN condition.

Technical details
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8 Technical details
General
Approvals
BG, CCC, CE, EAC (Eurasian), KCC, TÜV, cULus
Listed
Electrical data
Supply voltage
for Module supply
Voltage 24,0 V
Kind DC
Voltage tolerance -15 %/+20 %
Output of external power supply (DC) 5,0 W
Residual ripple DC 5 %
Status indicator LED
Inputs
Maximum input delay 15 ms
Semiconductor outputs
Switch-off delay 35 ms
Test pulse outputs
Maximum output current, decentralised module sup-
ply 4 A
Short circuit protection of decentralised module sup-
ply yes
Times
Switch-on delay 5,00 s
Supply interruption before de-energisation 20 ms
Environmental data
Ambient temperature
In accordance with the standard EN 60068-2-14
Temperature range 0 - 60 °C
Storage temperature
In accordance with the standard EN 60068-2-1/-2
Temperature range -25 - 70 °C
Climatic suitability
In accordance with the standard EN 60068-2-30, EN 60068-2-78
Humidity 93 % r. h. at 40 °C
Condensation during operation Not permitted
EMC EN 61131-2
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10,0 - 150,0 Hz
Acceleration 1g
Shock stress
In accordance with the standard EN 60068-2-27
Acceleration 15g
Duration 11 ms