Pilz PMI 6 primo User manual

PMI 6 primo
Operating Manual-1004647-EN-02
}Operator terminals

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 6
1.1 Validity of documentation 6
1.2 Using the documentation 6
1.3 Definition of symbols 6
Section 2 Overview 8
2.1 Device structure 8
2.1.1 Device features 8
2.2 Front view 9
2.3 Scope of supply 9
Section 3 Safety 10
3.1 Intended use 10
3.2 Safety regulations 11
3.2.1 Use of qualified personnel 11
3.2.2 Warranty and liability 11
3.2.3 Disposal 11
3.3 Standards 11
3.4 Unit-specific safety regulations 11
3.4.1 Installation site 12
3.4.2 Measures to protect against interference 12
3.4.3 Voltage supply 12
3.4.4 Operation 12
3.4.5 Maintenance 13
Section 4 Function description 14
4.1 Device properties 14
4.1.1 Controller 14
4.1.2 Visualisation 14
4.2 Side view 15
4.3 Rear view 16
4.4 Interfaces 16
4.4.1 Overview 16
4.4.2 CANopen 18
4.4.3 PROFIBUS DP 18
4.4.4 Ethernet 19
4.4.5 EtherCAT 19
4.5 Reset pushbutton 20
4.6 Software 20
Section 5 Installation 21
5.1 Safety 21
5.1.1 Installation site and unit surroundings 21
5.2 Dimensions 22
5.3 Installing the unit 23
5.4 Installation 23

Contents
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Section 6 Wiring 25
6.1 General wiring guidelines 25
6.1.1 Shielding 25
6.1.2 Measures to protect against interference voltages 25
6.2 Supply voltage 26
6.3 Connection example 26
6.4 Interfaces 27
6.4.1 Overview 27
6.4.2 CANopen, PROFIBUS DP 27
6.4.2.1 Wiring guidelines for the CANopen interface 27
6.4.2.2 CANopen/PROFIBUS DP interface 29
6.4.3 Ethernet 29
6.4.4 EtherCAT 30
6.4.5 RS232 interface (COM1) 30
Section 7 Commissioning 31
7.1 Safety guidelines 31
7.2 Activating setup 31
7.3 Commissioning motion control software 32
7.3.1 Preparing for commissioning 32
7.3.2 Create communication PMI 6 primo with PC 32
7.3.3 Adapt the base configuration of the motion control software 35
7.3.4 Configure servo amplifier 37
7.3.5 Operate motion control software 37
7.4 Install CODESYS 39
7.5 Control Panel 40
7.5.1 Backup and Restore 40
7.5.2 Password settings 41
7.5.3 Date/time 43
7.5.4 Display 43
7.5.5 Keyboard & soft keyboard 44
7.5.6 Regional settings 44
7.5.7 Storage Manager 44
7.5.8 System 44
7.5.9 Edit PMI Start 44
7.5.10 Taskbar and desktop 44
7.5.11 Network servers 45
7.5.12 Internet options 45
7.6 Start behaviour 45
7.6.1 Automatically copy to system folder (\windows) 45
7.6.2 Batch file PMIStart.cmd 45
7.6.3 Running services 46
7.6.4 Network settings 46
7.6.5 Various basic settings 46
Section 8 Operation 47
8.1 Operating states and changes in operating status 47

Contents
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8.1.1 Status graph 47
8.1.2 Operating states 48
8.1.2.1 "Power Off" operating status 48
8.1.2.2 "Startup Operating System" operating status 48
8.1.2.3 "PMI Assistant" operating status 48
8.1.2.4 "Startup Motion Control Software" operating status 48
8.1.2.5 "Boot Menu" operating status 48
8.1.2.6 "RUN" operating status 49
8.1.2.7 "STOP" operating status 49
8.1.2.8 "Fatal Error" operating status 49
8.1.3 Change in operating status 49
8.2 Reset, restart, start and stop options 52
8.2.1 Overview 52
8.2.2 Cold start, "Startup" 52
8.2.3 Reset commands 53
8.2.3.1 Warm reset 53
8.2.3.2 Cold reset 53
8.2.3.3 Original Reset 53
8.2.4 Start and stop commands 54
8.3 Functions of the reset button 54
8.4 Messages 55
8.5 Display elements 56
Section 9 Care and maintenance 57
9.1 Cleaning the touch-screen 57
Section 10 Attachment 58
10.1 Supported Windows components 58
10.2 Windows CE Shell commands 63
10.3 Windows CE Shell commands - Pilz expansions 64
Section 11 Technical details 69
Section 12 Order reference 72
12.1 Product 72

Introduction
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1 Introduction
1.1 Validity of documentation
This operating manual is valid for the following products
}PMI 607 primo
}PMI 612 primo
}PMI 638 primo
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.
Please also refer to the following documents from the motion control range:
}The configuration and programming software for motion control devices (e.g.
CODESYS, PASmotion) can be found on the Internet at www.pilz.com.
}The manuals for Pilz products from the PMC product area are available on the supplied
DVD "Drive technology PMC – Operating manuals".
You will need to be conversant with the information in these documents in order to fully un-
derstand this operating manual.
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.

Introduction
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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.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
2.1 Device structure
The PMI 6 primo
}is an operator terminal that is used to operate and monitor technical processes
}is a motion controller used to automate multi-axis motion sequences. The device con-
tains a PLC with the functionality of a logic and motion controller.
2.1.1 Device features
}Touch-screen
– Capacitive (PMI 607 primo, PMI 612 primo)
– Resistive (PMI 638 primo)
}Character set: Unicode
}Memory:
512 MB DDR SDRAM
}Real-time clock, battery-buffered
}User-specific applications and various visualisation software packages can be installed
}Logic controller universally programmable in accordance with IEC61131-3
}Motion controller
– Speed axes
– Positioning axes
– Synchronisation axes (electrical cam disk)
– Path axes (interpolation)
– Technology functions (CNC, curve calculation)
}Interfaces
– Ethernet TCP/IP
- Modbus TCP
– EtherCAT
– 1 CANopen/ 1 PROFIBUS DP interface
– 1 SD card slot
– 1 serial interface
– 2 USB host interfaces
}Supply voltages for
– Device
}Memory for
– Operating system
– Data
– Device project with user program

Overview
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}Reset pushbutton
– To change between operating states
– For a hardware reset (cold start)
}LED display for device's operating status
2.2 Front view
[1]
Legend
[1] Touchscreen (see Technical details [ 69])
2.3 Scope of supply
}Operator terminal
}Retaining clamps
}Connector plug for power supply
}Projection stand
}RJ45 cable for fieldbus junction box
}SD card as application memory
}DVD "Drive technology PMC – Operating manuals"
}Additionally on PMI 612 primo:
Press-in frame PMI X12

Safety
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3 Safety
3.1 Intended use
This device is used to operate and monitor technical processes.
The PMI provides the opportunity to install third-party software. This may also have an ef-
fect on the operation of motion control functions. Pilz GmbH & Co. KG accepts no liability
for any damages, nor does it provide support or any guarantee for the functional efficiency
of the installed software.
INFORMATION
Ensure that the visualisation software is suitable for the processor type X86
and the operating system Windows Embedded Compact 7.
CAUTION!
The unit is not designed for use in applications with stringent safety require-
ments (e.g. E-STOP).
The PMI 6 primo is suitable for use in logic and motion control applications.
Examples of typical application areas for the product are
}Clocked production machinery
}Continuous manufacturing processes (winding, flying saw, cross cutter)
}Machine tools
}Packaging machines
}Pick and place applications
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 [ 69]).
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.

Safety
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3.2 Safety regulations
3.2.1 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is 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.
3.2.2 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.).
3.2.3 Disposal
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3 Standards
To use the device correctly you will need to have a good knowledge of the relevant stand-
ards and directives. The following standards are relevant:
}EN 61131-1: Programmable controllers – Part 1: General information
}EN 61131-2: Programmable controllers – Part 2: Equipment requirements and tests
}EN 61131-3: Programmable controllers – Part 3: Programming languages
Please note this is not an exhaustive list of safety standards and directives.
Where standards are undated, the 2014-08 latest editions shall apply.
3.4 Unit-specific safety regulations
Before you install or commission the system, you should refer to any guidelines laid down
by the control manufacturer or operator.

Safety
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3.4.1 Installation site
}Do not position the device close to highly flammable materials.
}When installing the device within a control cabinet, you must ensure the ventilation slots
are not obstructed. otherwise the device could be damaged through overheating.
}Protect the device from direct sunlight and dust.
}Please note the guidelines given under “Installation”.
3.4.2 Measures to protect against interference
}If necessary, use bulkhead separators to protect the unit from sources of interference.
}Inductive loads within the environment (e.g. contactor, relay and solenoid valve coils)
should be wired using suppression elements (e.g. RC elements). This is particularly im-
portant if these inductive loads are fed from the same supply.
}The power cables and the data cables should be physically separated from each other
in their own conduits (recommended minimum distance: 10 cm/3.94"). This will avoid in-
ductive and capacitive interference.
}The prescribed earth point for the functional earth guarantees compliance with
noise immunity requirements.
Connect the functional earth to the central earth point in star form. A cable cross sec-
tion of at least 1.5mm² should be used for the connection. Connections should be kept
as short as possible.
3.4.3 Voltage supply
}The supply voltage must be +24VDC
CAUTION!
Safe electrical isolation must be ensured for the external power supply gen-
erating the 24V voltage supply. Failure to do so could result in electric
shock. Power supplies must conform to DINVDE0551/EN60742 and
EN50178.
3.4.4 Operation
}Plan the system correctly to ensure that a communication error between the PMI and
the host computer does not cause a malfunction.
}Do not operate the touchscreen interface using hard or heavy objects or apply excess-
ive pressure.
}The maximum ambient temperature must not be exceeded when using the unit.
}Do not pour liquids over the unit or insert any objects into the unit.
}When in storage and during operation, protect the unit from vibration and shock.
}Avoid using chemicals close to the system.

Safety
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3.4.5 Maintenance
}Do not use thinners or organic solvents to clean the device and touch-screen user inter-
face.
Further information on care and maintenance of the touch-screen can be found in the
chapter Care and maintenance [ 57].

Function description
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4 Function description
4.1 Device properties
4.1.1 Controller
The device includes a programmable logic controller with motion control functionalities.
These functionalities are described as "motion control software" in the following text. The
controller has volatile and non-volatile memory for the operating system, the data and the
device project with the user program.
It can be used for logic and motion control of intelligent drives.
User programs can be programmed in the main IEC61131-3 languages. The software
CODESYS is used to program the PLC functionality. The motion control software runs as a
stand-alone task.
The motion control software can also access inputs and outputs on networked servo ampli-
fiers from the PMC product area.
The device has fieldbus interfaces for communication with the periphery.
An LED provides information about the controller's operating states.
4.1.2 Visualisation
The device has a memory in which visualisation software can be installed. With the help of
this software, processes can be shown on the display and directly influenced via the touch-
screen. A fieldbus interface (CANopen), Ethernet (e.g.: Modbus), PROFIBUS, EtherCAT
and a RS232 interface are available for the transfer of data, e.g. diagnostic data, and for
communication with other subscribers.
The device is equipped with a battery-buffered real-time clock. Only Pilz can exchange the
battery.

Function description
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4.2 Side view
[1] [2] [3] [4] [5] [6]
[5] [7]
[7]
[8] [9] [10] [11] [12] [13]
Legend
[1] SD/SDHC card slot
[2] Reset pushbutton
[3] Status LED
[4] Reserved
[5] EtherCAT interface
[6] Ethernet interface
[7] Fieldbus junction box (PROFIBUS DP-Slave interface and CANopen interface, see
Rear view [ 16])
[8] Supply voltage +24 V DC
[9] Serial interface COM1 (RS232)
[10] USB Slave
[11] USB Host 1
[12] USB Host 2
[13] Functional earth

Function description
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4.3 Rear view
[1] [2]
[3]
Legend
[1] PROFIBUS DP-Slave interface
[2] CANopen interface
[3] Switch for the terminating resistors
4.4 Interfaces
4.4.1 Overview
The PMI 6 primo has various fieldbuses for communication with the periphery. The inter-
faces are suitable for the following applications:
}CANopen as a drive bus
– Real-time capable networking between CAN devices and the motion control soft-
ware
– Suitable for applications
– with ≤ 16 subscribers
– with cycle time of ≥1ms
}PROFIBUS DP Slave
– Networking between the motion control software and a PROFIBUS Master.
– Suitable for data exchange with a third party controller.
}Ethernet
–Ethernet TCP/IP

Function description
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– Communication between the programming device and the motion control software
– Suitable for configuration, programming, commissioning
–Modbus/TCP
– Communications protocol based on Industrial Ethernet (TCP/IP over Ethernet).
– Suitable for networking between the motion control software and a PSS4000, for
example.
}EtherCAT as a drive bus
– EtherCAT is an Ethernet-based master bus system suitable for industrial use. It is
suitable for real-time capable networking between the motion control software and
the servo amplifier PMCprotegoD.
– The PMI 6 primo acts as Master
– Suitable for applications
– with ≤ 32 subscribers
– with cycle time of1ms
}RS232 interface (COM1)
– Communication between the programming device and the motion control software
– Suitable for configuration, programming, commissioning

Function description
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4.4.2 CANopen
The CANopen interface is suitable for networking drive components at field level. It meets
the requirements defined in the communications protocol DS-301.
The following device classes with CANopen device profiles are supported:
}I/O modules DS-401
}Electrical drives DS-402
}Encoder DS-406
The CAN network is designed as a linear structure. The CANopen communication protocol
is based on CAN.
}CAN networking with the motion control software is suitable for applications with a max-
imum subscriber number of ≤ 16 and a cycle time ≥ 1ms.
}Only CAN devices that are known to the controller or support a corresponding device
profile can be operated in the motion control software's CAN network.
}CAN devices detected by the motion control software are ready for operation immedi-
ately after the initial network run-up. No complex configuration of the CAN devices is re-
quired.
}The overall cable length and the length of the stub lines depend on the transmission
rate.
}Process data objects (PDO) are defined for each CAN device type and cannot be cus-
tomised by the user.
}For servo amplifiers, the "FS" command can be used to set which process data is to be
exchanged between the motion control software and the servo amplifier (see "PM-
Cprimo Programming Manual").
}The signal lines must be terminated with resistors (120 Ohm) on the first and last sub-
scriber. The resistors are generally integrated within the connected devices and can be
activated there. For a PMI 6 primo a terminating resistor can be activated in the fieldbus
junction box.
4.4.3 PROFIBUS DP
PROFIBUS is an open fieldbus standard. Communication is defined in IEC 61158 and IEC
61784. Further provisions have been defined in specifications published by the PROFIBUS
User Group. These specifications are available from PROFIBUS International.
On a certain unit type, the PROFIBUS interface is available together with a CANopen inter-
face on an RJ45 socket (X7).
Properties:
}The PROFIBUS is configured using the CD command: Slave address, address range,
see PMCprimo Programming Manual.
}A total of up to 108 bus variables can be read and written (see PMCprimo Programming
Manual):
– Address space of bus variables: $B1 to $Bx108 (can be set using the CD com-
mand).
– Data width: 16 Bit including sign
– Value range: -32768 to 32767 (Hex: 0x0000 bis 0x7FFF).

Function description
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}When changing the variable content, any programs can be started if the bus variables
have been defined as trigger variables.
INFORMATION
The GSD file is available on the supplied CD-ROM. The name of the de-
scription file can be found in the chapter Technical details [ 69].
INFORMATION
Please also refer to the installation guidelines published by the PROFIBUS
User Group.
4.4.4 Ethernet
The Gigabit Ethernet interface (X8) connects the PMI 6 primo to a programming device for
configuration, programming and commissioning. The interface can also be used to connect
a visualisation device.
The Gigabit Ethernet interface is compatible with 1000Base-T (Standard Gigabit Ethernet).
Data exchange is possible via Modbus/TCP.
4.4.5 EtherCAT
EtherCAT uses the Ethernet Standard (IEEE 802.3) without modifications.
The PMI 6 primo does not require a setting (CD command) to use the EtherCAT master as
a drive bus.
To do this, a CODESYS project has to be active (Boot project), where all the EtherCAT
devices are configured.
Before the CODESYS project starts, all the devices must be operational so that they are
detected by the EtherCAT master.
The address assignment of the network subscribers is performed automatically in the se-
quence of the physical arrangement. The sequence of the inserted devices in the device
tree with the physical arrangement has to match.
Please note the following during operation:
}The device sequence may no longer be modified.
}It is not permitted to add or remove devices.
The PMI 6 primo is an EtherCAT master which is the subscriber in the segment that can
actively send an EtherCAT frame, all the other subscribers only forward the frames. This
prevents unforeseeable delays and it guarantees real-time capability.
Bit errors in the transmission are reliably detected in the evaluation of CRC check sums.
Rare interferences can be detected and localised with EtherCAT even if the interference
does not influence the functionality of the machine.

Function description
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4.5 Reset pushbutton
The "RESET" pushbutton is mounted in a recess on the front of the device. It can only be
accessed using an appropriate tool (e.g. a pin).
The following actions can be triggered by pressing the "RESET" pushbutton:
}Change from "Startup" operating status to "Boot Menu"
}Hardware reset (cold start): Change from operating states "RUN" or "STOP" to "Star-
tup" (if a USB stick is inserted, any device data present will be copied, see Functions of
the reset button.)
}Change from "RUN" operating status to "STOP"
}Change from "STOP" operating status to "RUN"
INFORMATION
For further information on the reset pushbutton see Operation.
4.6 Software
Various tools are available for planning, configuration, programming and commissioning.
They are used to create a project:
}PASmotion
PASmotion is used to parametrise and commission the motion controller and the servo
amplifier PMCprotego D.
– Terminal program: The terminal can be used to send commands directly to the
hardware. It can also be used for firmware updates and for basic configuration of
the motion control software.
– Oscilloscope function: PScope is a PC-based oscilloscope with up to 4 channels. It
can be used to record and visualise signals from controllers and servo amplifiers.
– Elliptical curve tool: PMotion is a tool for constructing elliptical curves.
}Development environment in accordance with IEC 61131-3
CODESYS is a development environment for programming controllers in accordance
with IEC61131-3. Additional commands for motion sequences have been added. In ad-
dition to core CODESYS packages the "PMC Programming Tool" also contains the tar-
get support packages.
The software tools are available on the Internet at www.pilz.com.
INFORMATION
The "PMC Programming Tool" for IEC 61131-3 programming contains the
CODESYS Version 3.5.