Pilz PNOZ m1p base unit User Manual

Operating Manual PNOZmu lti Special Applica tions

Operating Manual PNOZmulti Special Applications
PNOZmulti Special Applications
Configurable Control System PNOZmulti
Operating Manual — No. 1002337-EN-02
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.
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.

Preface

Contents
Contents
Contents Page
Chapter 1 Introduction
1.1 Overview of documentation 1-1
1.2 Definition of symbols 1-2
Chapter 2 Muting
2.1 Introduction 2-1
2.2 Safety 2-2
2.2.1 Intended use 2-2
2.2.2 Standards 2-2
2.2.3 Safety guidelines 2-2
2.3 Configuration in the PNOZmulti Configura-
2-4
tor
2.3.1 Functions 2-4
2.3.2 Input parameters 2-4
2.3.3 Output parameters 2-4
2.3.4 Monitoring times 2-5
2.3.5 Suspension of muting (override) 2-5
2.3.6 Reset 2-6
2.3.7 Restarting the muting time 2-6
2.4 Operating modes 2-7
2.4.1 Terminology 2-7
2.4.2 Sequential muting 2-7
2.4.2.1 Position of the muting sensors 2-7
2.4.2.2 Switch conditions in sequential mode 2-8
2.4.2.3 Sequence errors 2-9
2.4.2.4 Diagnostic word 2-10
2.4.2.5 Timing diagram (example) 2-10
2.4.3 Parallel muting 2-11
2.4.3.1 Position of the muting sensors 2-11
2.4.3.2 Switch conditions in parallel mode 2-12
2.4.3.3 Diagnostic word 2-12
2.4.3.4 Timing diagram (example) 2-13
2.4.4 Cross muting 2-14
2.4.4.1 Position of the muting sensors 2-14
2.4.4.2 Switch conditions in cross mode 2-15
2.4.4.3 Diagnostic word 2-16
2.4.4.4 Timing diagram (example) 2-16
Chapter 3 Safety Mat/Safe Edge
3.1 Introduction 3-1
3.2 Safety 3-2
3.2.1 Intended use 3-2
3.2.2 Safety guidelines 3-2
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
1
Contents
3.3 Function description 3-3
3.4 Configuration in the PNOZmulti Configura-
3.4.1 Allocation of test pulses to inputs 3-4
3.5 Commissioning the safety system 3-5
3.5.1 Preparing for commissioning 3-5
3.5.2 Preparing for operation 3-5
3.6 Operation 3-7
3.6.1 Diagnostic word 3-7
3.7 Technical Details 3-8
Chapter 4 Burners
4.1 Introduction 4-1
4.2 Safety 4-2
4.2.1 Intended use 4-2
4.3 Configuration in the PNOZmulti Configura-
4.3.1 Functions 4-3
4.3.2 Monitoring functions/settings for the burn-
4.3.2.1 Combustion air pressure monitoring, acti-
4.3.2.2 Ignition 4-5
4.3.2.3 Flame monitoring 4-5
4.3.2.4 Compound controller 4-6
4.3.2.5 Tightness control 4-6
4.3.2.6 High temperature 4-7
4.3.2.7 Plant-dependent monitoring functions 4-8
4.3.2.8 Shutdown types 4-8
4.3.2.9 Step times 4-9
4.4 Burner cycle 4-11
4.4.1 Steps 4-11
4.4.2 Errors during the burner cycle 4-11
4.4.3 Master burner with direct ignition 4-12
4.4.4 Master burner with separate flame moni-
4.4.5 Master burner with joint flame monitoring 4-16
4.4.6 Slave burner with direct ignition 4-17
4.4.7 Slave burner with separate flame monitor-
4.4.8 Slave burner with joint flame monitoring 4-18
4.4.9 Example: Viewing the burner cycle in the
4.5 Inputs and outputs 4-22
4.5.1 Element's inputs 4-22
3-4
tor
4-3
tor
4-4
er cycle
4-4 vating the combustion air blower, com­pound controller monitoring
4-14 toring
4-17 ing
4-19 PNOZmulti Configurator
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
2
Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
Contents
4.5.1.1 Operation 4-22
4.5.1.2 Monitoring functions 4-22
4.5.2 Element's outputs 4-24
4.6 Configuration examples 4-26
4.6.1 Burner configuration 4-26
4.6.1.1 Burner structure 4-26
4.6.1.2 Burner properties 4-26
4.6.1.3 Configuration in the PNOZmulti Configura­tor
4.6.2 Connecting the safety valves 4-27
Chapter 5 Loop formation (LOOP)
5.1 Introduction 5-1
5.1.1 Intended use 5-1
5.2 Function description 5-2
5.3 Example configurations 5-3
5.3.1 Application using one loop 5-3
5.3.2 Application using two loops 5-3
4-26
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3
Contents
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
4
Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
1 Introduction

1.1 Overview of documentation

11000IntroductionIntroduction1-1.1Overview of documentation1100Overview of documentation1-Einf_Uebersicht_über_die_Doku-spezielle Applikationen

1 Introduction

The introduction is designed to familiarise you with the contents, struc­ture and specific order of this manual.
2 Muting
This chapter describes the muting function with units from the config­urable control system PNOZmulti.
3 Safety Mat/Safe Edge
This chapter describes the use of pressure-sensitive protective devices with the PNOZmulti.
4 Burners
This chapter describes how to control and monitor burners with the con­figurable control system PNOZmulti.
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
1-1
1 Introduction

1.2 Definition of symbols

1.2Definition of symbols1200Definition of symbols1-Einfhrung Zeichen
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 unit(s) could be damaged and also provides information on preventive measures that can be taken. It also highlights areas within the text that are of partic­ular importance.
INFORMATION
This gives advice on applications and provides information on special features.
1-2
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2Muting

2.1 Introduction

22000MutingMuting2-2.1Introduction2100Introduc tion2-Muting_Einführung
This chapter describes the muting function with units from the config­urable control system PNOZmulti. The safe inputs and outputs from base units and expansion modules are suitable.
NOTICE
With a muting application, please refer to the operating manuals provided with the units. Please also refer to the PNOZmulti tech­nical catalogue.
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
2-1
2Muting

2.2 Safety

2.2Safety2200Safety2-

2.2.1 Intended use

Intended use2-Muting_Sicherheit_Bestimmungsgemäße Verwendung
The muting logic element is used to temporarily suspend safety func­tions (ESPE/AOPD) without interrupting the process (muting) in accord­ance with EN 61496-1. For a limited time period and a specific operational phase (e.g. when feeding materials), it will suspend the ef­fect of safety devices during the working process. Once completed, it will reset the safety function.
Use of this operating mode and the arrangement of the sensors are ma­chine or plant-specific and depend on the risk assessment of the ma­chine or plant.
Be sure that you observe the warning notes given in the other parts of this configuration guide and in the PNOZmulti technical catalogue. These are highlighted visually through the use of symbols.

2.2.2 Standards

Standards2-Muting_Sicherheit_Normen
CAUTION!
Failure to observe the safety regulations in this configuration guide and in the PNOZmulti technical catalogue will render the warranty invalid.
Knowledge of and compliance with the relevant standards and direc­tives are a prerequisite for using the muting function. The following gives an overview of the most important standards:
EN 61496-1: Safety of machinery – Electrosensitive protective equip-
ment
EN 60947-5-3: Low voltage switchgear and controlgear - Control cir-
cuit devices and switching elements
EN 999: Safety of machinery - The positioning of protective equip-
ment
Please note this is not an exhaustive list of safety standards and direc­tives.
2-2
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2Muting
2.2 Safety

2.2.3 Safety guidelines

Safety guidelines2-Muting_Sicherheit_Siche rheitshinweise
WARNING!
The following information must be heeded! Failure to comply with these guidelines could result in serious injury or death.
Refer to EN 61496-1 and EN 60947-5-3 when configuring, setting up
and operating the muting device.
Refer to EN 999 with regard to the positioning of the AOPD.Measures must be taken to exclude common cause failures, e.g. by
the use of non-equivalent signals or diverse sensors.
Muting switches should be positioned so that it is impossible for a
person to trigger the muting function.
The vehicle should be designed to make it impossible for people to
ride on it.
Limit the size of the entry area by applying appropriate safety meas-
ures. People must not be able to enter the danger zone during the muting phase.
If various transport speeds are being used, consider the total duration
of the muting phase.
Remember that a new muting phase can only be introduced once the
previous phase has been completed.
Maintenance gates should be provided if you secure equipment
through muting.
Please note that if the maintenance gates are opened, the plant ab-
solutely must be brought to a standstill in accordance with the risk
classification.
Use of muting sensors with contacts: Supply the contacts of the mut-
ing sensors via test pulse outputs (test pulses).
Use of ESPE as muting sensors: Test pulses cannot be used. For this
reason, be sure to use a N/O contact as sensor 1 and a N/C contact as sensor 2 for fault detection (shorts across contacts).
Laying the connection cable to the sensors in a way that is protected
against shorts (i.e. separate) may provide an alternative to non-equiv­alent sensors.
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
2-3
2Muting

2.3 Configuration in the PNOZmulti Configurator

2.3Configuration in the PNOZ multi Configurator2300Configurat ion in the PNOZmulti C onfigurator2-

2.3.1 Functions

Functions2-Muting_Konfiguration_Funktionen

2.3.2 Input parameters

Input parameters2-Muting_Konfiguration_Eingangsparameter
Muting via light beam devices or limit switchesOverride option in case of faultMax. muting time can be setMuting sensors can be monitored for simultaneityConfiguration of bounce time for contact-based muting sensorsSequence of the muting sensors can be monitoredOperating modes
– Sequential muting – Parallel muting –Cross muting
Muting sensor 1
N/O contact of muting sensor 1 Muting sensor 1 = 0: Not operated Muting sensor 1 = 1: Operated
Muting sensor 2
N/O contact of muting sensor 2 Muting sensor 2 = 0: Not operated Muting sensor 2 = 1: Operated
Light curtain
Light curtain = 0: Interrupted Light curtain = 1: Not interrupted Assign the light curtain input parameter to the output of the light cur­tain function element. The light curtain function element must be configured with an automatic reset.
Muting sensor 3
N/O contact of muting sensor 3 Muting sensor 3 = 0: Not operated Muting sensor 3 = 1: Operated
Muting sensor 4
N/O contact of muting sensor 4 Muting sensor 4 = 0: Not operated Muting sensor 4 = 1: Operated
Muting override
Muting override = 1: Suspend the muting function if a fault occurs (override) to override the muting channel.
Reset = 0/1 pulse edge: Reset muting after an error or start the muting
time.
2-4
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2Muting
2.3 Configuration in the PNOZmulti Configurator

2.3.3 Output parameters

Output parameters2-Muting_Konfiguration_Ausgangsparameter

2.3.4 Monitoring times

Monitoring times2-Muting_Konfiguration_Überwachungszeiten
Enable
Enable = 0: Error detected (e.g. simultaneity exceeded) Enable = 1: The enable is granted if no error has been detected.
Muting active
Display of muting status (e.g. for activating a lamp) Muting active = 0: No muting (light curtain not suspended) Muting active = 1: Muting active (light curtain suspended)
Maximum muting time
This setting is used to adjust the maximum permitted muting time. Permitted value range: 1 ... 900s (= 15 minutes)
Simultaneity
This setting is used to define the maximum time (synchronisation time) which is permitted to elapse between the actuation (0/1-pulse edge) of muting sensors 1 and 2 or muting sensors 3 and 4. Permissible value range for parallel muting and cross muting: 1 ... 3 s Permitted value range for sequential muting: 1 ... 30 s
Bounce time
This setting can be used to set the time up to the point at which the muting sensors finally make contact. Permitted value range: 50 ..0.800 ms

2.3.5 Suspension of muting (override)

Suspension of muting (override)2-Muting_Konfiguration_Muting-Überbrückung_Override
If there are faults, the muting station can be overridden via the muting override input parameter.
Start-up condition
Muting override can be switched on if at least one of the muting sen­sors is active. The enable output and are set during the override. The override is monitored and has a max­imum duration that corresponds to the set muting time.
Switch-off condition
Muting override is switched off if
– the muting time has elapsed
or
– no muting sensor is active and the light curtain is clear
or
– muting override is reset to 0 (release override button).
muting active
output parameter
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2-5
2Muting
2.3 Configuration in the PNOZmulti Configurator
CAUTION!
The following additional safety requirements apply to the muting override:
– The override switch must have a hold-to-run control device
(touch-operated switch).
– The override switch must be installed in a fixed position out-
side the danger zone.
– The danger zone and the muting station must be visible
from the override switch position.
– The danger zone must be identified as clear before the over-
ride switch is operated and while it is operated.

2.3.6 Reset

Reset2-Muting_Konfiguration _Reset
Reset resets the muting element after a fault or during start-up if
no muting sensor is operated
and
the light curtain is clear.

2.3.7 Restarting the muting time

Restarting the muting time2-Muting_Konfiguration_Neu start der Muting-Zeit
Reset resumes muting and restarts the muting time if
muting was ended as a result of the muting time having elapsed (e.g.
by the conveyor feed stopping)
and
the muting sensors are returning feasible signals and the light curtain
has not been interrupted.
CAUTION!
The following additional safety requirements apply for the reset button:
– The danger zone and the muting station must be visible
from the reset button position.
– The reset button may not be operated until the danger zone
has been viewed and has been identified as clear.
2-6
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2Muting

2.4 Operating modes

2.4Operating modes2400Operating modes2-Muting_Betriebsarten
The following operating modes can be implemented:
Sequential mutingParallel mutingCross muting
WARNING!
"During muting safe conditions shall be provided by other means" (EN 954-1). For example, this may be achieved by the conveyed item blocking access to the danger zone. Even open­ings in or between the individual parts of the conveyor flow must never enable access.

2.4.1 Terminology

Terminology2-Muting_Betriebsarten_Begriffsbestimmungen
Muting On
"Muting On" is the switch condition for switching on the muting func­tion. When muting is switched on, the
Muting active
output parame-
ter has a 1 signal and time monitoring runs.
Muting Off
"Muting Off" is the switch condition for ending the muting function. When the muting function is ended, output parameter
Muting active
has a 0 signal.
INFORMATION
You will find important additional information on the use of sen­sors or contacts in the section entitled "Safety".
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2-7
2Muting
MS1
MS2 MS3 MS4
AOPD
AOPD
W
A
B
2.4 Operating modes

2.4.2 Sequential muting

Sequential muting2-
2.4.2.1 Position of the muting sensors
Position of the muting sensors2-Muting_Betriebsarten_sequenzielles Muting-Anordnung der Muting-Sensoren
The distance between the muting sensors MS1 and MS2 / MS3 and
MS4 should be as large as possible.
Vehicle length W must be greater than the distance between MS1 and
MS3 or MS2 and MS4 (W > A and W > B).
MS2 and MS3 must be positioned as close as possible in front of/be-
hind the AOPD.
2-8
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2Muting
2.4 Operating modes
2.4.2.2 Switch conditions in sequential mode
Switch conditions in sequential mode2-Muting_Betriebsarten_sequenzielles Muting-Schaltbedingungen
Muting On
Entering the danger zone:
1. Muting sensors MS1 and MS2 must be operated consecutively (first MS1, then MS2) within the configured simultaneity period. Muting is activated by operating MS2.
2. Muting sensors MS3 and MS4 must be operated consecutively (first MS3, then MS4) within the configured simultaneity period.
3. MS1 and MS2 must be cleared consecutively (first MS1, then MS2).
4. MS3 and MS4 must be cleared consecutively (first MS3, then MS4).
Leaving the danger zone:
1. Muting sensors MS4 and MS3 must be operated consecutively (first MS4, then MS3) within the configured simultaneity period. Muting is activated by operating MS3.
2. MS2 and MS1 must be operated consecutively (first MS2, then MS1).
3. MS4 and MS3 must be cleared consecutively (first MS4, then MS3).
4. MS2 and MS1 must be cleared consecutively (first MS2, then MS1).
Muting Off
Suspension of the safety function is cancelled as soon as the penulti­mate muting sensor, MS2 or MS3, is no longer operated, i.e. only one muting sensor remains operated.
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2-9
2Muting
MS1
MS2
MS3 MS4
AOPD
W > C
A
B
C
2.4 Operating modes
2.4.2.3 Sequence errors
Sequence errors2-Muting_Betriebsarten_sequenzielles Muting-Sequenzfehler
The muting sensors must be operated in a specific sequence in sequen­tial mode. Once a particular directional movement has started (entry or exit), it must be fully completed. Any deviation from the sequence shown causes the enable output (enable = 0) and the output parameter
active
Vehicle length W greater than distance C between MS1 and MS4
All sensors are temporarily operated as the vehicle passes through. The first muting sensor (MS1 upon entering, MS4 upon exiting) only be­comes clear once all muting sensors have been operated.
Muting
to reset.
2-10
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2Muting
MS1
MS2
MS3 MS4
AOPD
W < C
A
B
C
2.4 Operating modes
Vehicle length W less than distance C between MS1 and MS4
As the vehicle passes through, the first muting sensor becomes clear (MS1 upon entering, MS4 upon exiting) before the last muting sensor has been operated.
MS1 MS2 MS3 MS4 Travel direction
0000 1000 1100 1110 1/0 1 1 1/0 0111 0011 0001 0000
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2-11
2Muting
1 0
1
Reset
1 0
1 0
1 0
1 0
1 0
32 4
MS1
MS2
Mut ing
Enabl e
AOPD
t
sync
t
sync
t
MUT
MS4
MS3
1 0
1 0
2.4 Operating modes
2.4.2.4 Diagnostic word
Diagnostic word2-Muting_Betriebsarten_Muting-Diagnosewort
Muting_Betriebsarten_Muting-Diagnosewort-bit10-para-sequ
2.4.2.5 Timing diagram (example)
Timing diagram (example)2-Muting_Betriebsarten_sequenzielles Muting-Zeitdiagramm
Messages can be queried in the PNOZmulti Configurator in bit mode and linked further within the program.
Bit 1: Light curtain, interrupted (without active muting)Bit 2: Waiting for reset (reset)Bit 3: Sensor status unfeasible, override requiredBit 8: Muting time exceededBit 9: Feasibility error, simultaneity period exceeded on muting sen-
Bit 10: Feasibility error, simultaneity period exceeded on muting sen-
sors 1 and 2, only one sensor operated
sors 3 and 4, only one sensor operated
Vehicle length W less than distance C between MS1 and MS4
Key: t
= Simultaneity
sync
t
= Muting time
MUT
: Set enable with reset: Start muting via MS1/MS2: End muting by clearing MS3: Restart muting via MS1/MS2
2-12
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2Muting
MS3
AOPD
AOPD
MS1
MS2
MS4
W
A
2.4 Operating modes

2.4.3 Parallel muting

Parallel muting2-
2.4.3.1 Position of the muting sensors
Position of the muting sensors2-Muting_Betriebsarten_paralleles Muting-Anordnung der Muting-Sensoren
Muting sensors MS1 and MS2/MS3 and MS4 must be positioned at
the same height to the left and right of the vehicle.
The vehicle length W must be greater than distance A between MS1
and MS3/MS2 and MS4.
The distance between the light curtain and the muting sensor must be
as short as possible.
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2-13
2Muting
2.4 Operating modes
2.4.3.2 Switch conditions in parallel mode
Switch conditions in parallel mode2-Muting_Betriebsarten_paralleles Muting-Schaltbedingungen
Muting On
Entering the danger zone:
1. Muting sensors MS1 and MS2 must be operated within the config­ured simultaneity period. Muting is activated.
2. Muting sensors MS3 and MS4 must be operated within the config­ured simultaneity period, before MS1 and MS2 are cleared.
Leaving the danger zone:
1. Muting sensors MS3 and MS4 must be operated within the config­ured simultaneity period. Muting is activated.
2.4.3.3 Diagnostic word
Diagnostic word2-Muting_Betriebsarten_Muting-Diagnosewort
Muting_Betriebsarten_Muting-Diagnosewort-bit10-para-sequ
2. Muting sensors MS1 and MS2 must be operated before MS3 and MS4 are cleared.
Muting Off
Suspension of the safety function is cancelled as soon as the penulti­mate muting sensor, MS3/MS4 upon entering or MS1/MS2 upon exiting, is no longer operated. In other words, only one muting sensor remains operated.
Messages can be queried in the PNOZmulti Configurator in bit mode and linked further within the program.
Bit 1: Light curtain, interrupted (without active muting)Bit 2: Waiting for reset (reset)Bit 3: Sensor status unfeasible, override requiredBit 8: Muting time exceededBit 9: Feasibility error, simultaneity period exceeded on muting sen-
sors 1 and 2, only one sensor operated
Bit 10: Feasibility error, simultaneity period exceeded on muting sen-
sors 3 and 4, only one sensor operated
2-14
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