21104_01

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<p>The spirit of safety.</p><p>PNOZmulti</p><p>Modular Safety System</p><p>PNOZmulti Range</p><p>Safety manual</p><p>Item no. 21 104-01</p><p>All rights to this operating manual are reserved by Pilz GmbH & Co. KG. Copies may be</p><p>made for internal use as required.</p><p>While every effort has been made to ensure that the information in this operating manual is</p><p>accurate, no responsibility can be accepted for errors or omissions contained within it.</p><p>The contents of this manual may be changed at any time without prior notice. We are</p><p>grateful for any feedback on the contents of this operating manual.</p><p>The names of products, goods and technologies used in this manual are trademarks of the</p><p>respective companies.</p><p>1PNOZmulti Safety Manual</p><p>Introduction 1-1</p><p>Overview of documentation 1-2</p><p>Definition of symbols 1-3</p><p>Safe Applications 2-1</p><p>Safety concept 2-1</p><p>Application area 2-1</p><p>General safety assessment 2-1</p><p>Safety assessment of the PNOZmulti modular safety system 2-2</p><p>Managing a safe application 2-3</p><p>Documentation of a safe application 2-4</p><p>Project Planning of a Process 3-1</p><p>Determining the application area 3-1</p><p>Specifying functions 3-1</p><p>Defining safety requirements 3-3</p><p>Planning operation and installation 3-4</p><p>Implementation of the Application 4-1</p><p>Assigning safety requirements 4-1</p><p>Safety in the project circuit diagram 4-1</p><p>Safety in the application 4-2</p><p>Safety requirements on sensors and actuators 4-2</p><p>Configuration in the PNOZmulti Configurator 4-3</p><p>Planning installation 4-3</p><p>Planning of commissioning and validity 4-4</p><p>Contents</p><p>Contents</p><p>2 PNOZmulti Safety Manual</p><p>Changes, Maintenance, Decommissioning 5-1</p><p>Changes 5-1</p><p>Maintenance 5-2</p><p>Decommissioning 5-2</p><p>Troubleshooting 6-1</p><p>Error stack 6-1</p><p>Diagnostics using the LEDs 6-2</p><p>Checklist 7-1</p><p>Note on the checklist 7-1</p><p>1-1PNOZmulti Safety Manual</p><p>This manual describes how to safely use the PNOZmulti modular safety</p><p>system. The manual assists you in project planning, installation, commis-</p><p>sioning, decommissioning and in dealing with possible problems.</p><p>After introducing you to the safety concept of the system, the measures</p><p>required to also safely create a process into which the safety system is</p><p>integrated will be explained.</p><p>WARNING!</p><p>Be sure to read this manual prior to commissioning the PNOZmulti modu-</p><p>lar safety system. Always comply with the specified safety requirements.</p><p>INFORMATION</p><p>The safety manual refers to the base units and expansion modules of the</p><p>PNOZmulti modular safety system. For the purpose of simplification, these</p><p>units and modules will be summarised under the term "safety system" in</p><p>the following text.</p><p>This safety manual for the PNOZmulti range, item no. 21 104-01, 04/05</p><p>was tested by the German trade association (BG).</p><p>Introduction</p><p>Introduction</p><p>1-2 PNOZmulti Safety Manual</p><p>Overview of documentation</p><p>1 Introduction</p><p>The introduction is designed to familiarise you with the contents,</p><p>structure and specific order of this manual.</p><p>2 Safe Applications</p><p>This chapter provides information on the safety concept of the units as</p><p>well as the handling of and documentation for a safe application.</p><p>3 Project Planning of a Process</p><p>This chapter describes the project planning of a process, subdivided</p><p>into its individual work stages and the respective safety requirements.</p><p>4 Implementation of the Application</p><p>This chapter explains the process for installation and commissioning.</p><p>5 Changes, Maintenance, Decommissioning</p><p>This chapter must be read and observed before changing a process.</p><p>6 Troubleshooting</p><p>This chapter describes possible system fault conditions and measures</p><p>to carry out in the event of a fault. This chapter primarily is intended</p><p>for service technicians.</p><p>7 Checklist</p><p>This chapter describes the safety-related process for implementing the</p><p>safety system based on a checklist.</p><p>1-3PNOZmulti Safety Manual</p><p>Definition of symbols</p><p>Information in this safety manual that is of particular importance can be</p><p>identified as follows:</p><p>DANGER!</p><p>This warning must be heeded! It warns of a hazardous situation that</p><p>poses an immediate threat of serious injury and death and indicates</p><p>preventive measures that can be taken.</p><p>WARNING!</p><p>This warning must be heeded! It warns of a hazardous situation which</p><p>could lead to serious injury or death and indicates preventive measures</p><p>that can be taken.</p><p>CAUTION!</p><p>This refers to a hazard that can lead to a less serious or minor injury plus</p><p>material damage, and also provides information on preventive measures</p><p>that can be taken.</p><p>NOTICE</p><p>This describes a situation in which the unit(s) could be damaged and also</p><p>provides information on preventive measures that can be taken.</p><p>INFORMATION</p><p>This gives advice on applications and provides information on special</p><p>features, as well as highlighting areas within the text that are of particular</p><p>importance.</p><p>Introduction</p><p>1-4 PNOZmulti Safety Manual</p><p>Notes</p><p>2-1PNOZmulti Safety Manual</p><p>Safe Applications</p><p>Safety concept</p><p>Application area</p><p>The PNOZmulti modular safety system is designed for use in the safety</p><p>circuits of plants and machinery, e.g. for</p><p>• Tooling, packaging and print machinery</p><p>• Robot cells and production lines</p><p>• Mechanical engineering, e.g. lathes, milling and drilling machines</p><p>• Plastics processing machines, e.g. blow moulding machines</p><p>• Laser machines, e.g. laser welding and laser punching machines</p><p>• Packaging machines, e.g. drink dispensing and palletising machines</p><p>• Forming technology: small and punch presses</p><p>• Robots: processing, welding and spraying robots</p><p>• Print and paper industry, e.g. printing, enveloping and paper machines</p><p>• Presses, e.g. eccentric presses</p><p>CAUTION!</p><p>The PNOZmulti modular safety system is only designed for safety func-</p><p>tions for which a safe condition is defined by shutting down the energy</p><p>supply.</p><p>General safety assessment</p><p>Before using the PNOZmulti modular safety system, it is necessary to</p><p>perform a safety assessment in accordance with the Machinery Directive.</p><p>The safety system as an individual component is geared toward safety. It</p><p>ensures functional safety, e.g. against errors in hardware and software. It</p><p>does not, however, ensure the safety of the entire process or project plan-</p><p>ning and configuration.</p><p>The user is responsible for the safety of configuration in the PNOZmulti</p><p>Configurator. Pay special attention when configuring and observe stand-</p><p>ards and regulations. A faulty configuration can jeopardize the safety of the</p><p>entire process!</p><p>Safe Applications</p><p>2-2 PNOZmulti Safety Manual</p><p>Define the safety requirements for the plant as a whole, and also define</p><p>how these will be implemented from a technical and organisational stand-</p><p>point. Among the technical measures are e.g. use of the PNOZmulti safety</p><p>system and the safety-related use of peripheral components as well as</p><p>project planning and configuration of the safety system. Organisational</p><p>measures are e.g. the specification of responsible personnel and the docu-</p><p>mentation of all work stages for commissioning. This also includes specifi-</p><p>cation regarding responsibilities and access rights.</p><p>Safety requirement is geared toward the function of the plant and the</p><p>resulting hazards. A safety assessment also must cover malfunctions,</p><p>faulty operation and the possible consequences.</p><p>Safety assessment of the PNOZmulti modular safety system</p><p>The modular safety system consists of a base module and several expan-</p><p>sion modules. The system performs fail-safe and standard functions. Only</p><p>safe inputs and outputs may process safety-related functions.</p><p>The safe parts of the safety system are redundant with built-in self monitor-</p><p>ing. The safety function remains effective even in the case of a component</p><p>failure. Semiconductor outputs that are switched on are tested periodically</p><p>using a disconnection test.</p><p>The expansion modules are subdivided into safe (yellow) and non-safe</p><p>(green).</p><p>The safety functions of the system (e.g. E-STOP, interlocks, enabling de-</p><p>vice of a two-hand circuit) are specified in a project via the PNOZmulti</p><p>Configurator. The PNOZmulti Configurator is a graphic tool which is used</p><p>to define the functions of the units. Using predefined</p><p>symbols, a circuit</p><p>diagram is created in the project showing how the units’ inputs and outputs</p><p>should be connected. The project is then downloaded to the base module.</p><p>The project can be certified. This rules out changes made to the project.</p><p>From the transferred data, the base module recognises the safety func-</p><p>tions it is to perform. Depending on the application area and its respective</p><p>regulations, the safety system is suitable for applications up to category 4</p><p>in accordance with EN 954-1. For any deviations, refer to the specifications</p><p>in the operating instructions of the respective units.</p><p>2-3PNOZmulti Safety Manual</p><p>CAUTION!</p><p>If a project was changed or recreated in the PNOZmulti Configurator, a</p><p>function test must be carried out after downloading to a base module. The</p><p>safety devices especially must be checked for proper operation.</p><p>The redundant design of the safety system provides a high level of safety.</p><p>During project planning and configuration, it is important to ensure that this</p><p>high level of safety is not compromised by errors and lack of attention.</p><p>Retain the high level of safety especially by specifying responsibilities,</p><p>writing comprehensible test logs and performing function tests.</p><p>Note that the diagnostic interface of the base module and the interfaces of</p><p>the fieldbus modules must not be used for safety-related communication.</p><p>Managing a safe application</p><p>Attention must be paid to ensuring safety throughout the entire service life</p><p>of a plant or a process. Service life is subdivided into the following phases:</p><p>• Planning, configuration</p><p>• Installation</p><p>• Commissioning</p><p>• Operation</p><p>• Maintenance</p><p>• Decommissioning</p><p>• Only if necessary: modification</p><p>An independent safety strategy should be created and documented for</p><p>each individual phase as part of a comprehensive safety plan. This safety</p><p>plan should, among other things, cover:</p><p>• Technical and organisational measures during each phase in order to</p><p>retain safety</p><p>• Responsible persons for the various phases</p><p>• Documents which are important for the respective phases</p><p>• Measures to retain the desired safety</p><p>• Techniques and measurements used</p><p>Safe Applications</p><p>2-4 PNOZmulti Safety Manual</p><p>• Analysis and minimisation of possible errors</p><p>• Audits for testing functional safety</p><p>• Process for modification</p><p>• List of all documents</p><p>An important aspect of safety is attributed to the responsible persons.</p><p>Specially trained professionals must be used for each lifecycle phase.</p><p>These professionals must have the required qualification, technical knowl-</p><p>edge and experience. Examples:</p><p>• Project planning</p><p>Requirements of a process engineer: Knowledge of the process and the</p><p>respective safety requirements, reading and understanding of the safety</p><p>system technical catalogue and the operating instructions for the units</p><p>used (base module and expansion modules).</p><p>• Configuration with the PNOZmulti Configurator</p><p>Requirements of a programmer: Knowledge of the project planning</p><p>plans, knowledge of safety technology, experience in the creation of</p><p>safety-related circuits, reading and understanding of the technical cata-</p><p>logue and the operating instructions for the safety system.</p><p>• Installation</p><p>Requirements of e.g. an electrician: Knowledge of project planning plans,</p><p>reading and understanding of the technical catalogue and the operating</p><p>instructions for the safety system, knowledge of accident prevention</p><p>regulations.</p><p>• Commissioning</p><p>Requirements: Knowledge of the project process, reading and under-</p><p>standing of the technical catalogue and the operating instructions for the</p><p>safety system.</p><p>Documentation of a safe application</p><p>All safe applications require documentation that defines application safety.</p><p>• The documentation should describe every lifecycle phase (see page 2-3)</p><p>and the functions of a plant (a process). A simple, comprehensible,</p><p>correct and complete description is satisfactory. Complete means that</p><p>e.g. all functions, signals, events and time sequences as well as the</p><p>respective tests can be tracked.</p><p>2-5PNOZmulti Safety Manual</p><p>• The description can comprise one or more parts, depending on the</p><p>scope. Each document must be labelled with one name and one version</p><p>number.</p><p>• Project data can be entered in the PNOZmulti Configurator. These data</p><p>specify the created project. The project data are printed out together with</p><p>the circuit diagram.</p><p>• Additional documents are required for communication between the</p><p>lifecycle phases. For example, the programmer requires information</p><p>about the necessary functions from the project planner or the installer</p><p>requires a wiring plan from the project planner etc.</p><p>Safe Applications</p><p>2-6 PNOZmulti Safety Manual</p><p>Notes</p><p>3-1PNOZmulti Safety Manual</p><p>Project Planning of a Process</p><p>Determining the application area</p><p>Prior to project planning, determine</p><p>• the exact purpose of the application,</p><p>• the limits of the application,</p><p>• the goal for using the safety system.</p><p>Exact knowledge of the process and the plant are required in order to</p><p>execute the project.</p><p>Specifying functions</p><p>The following questions must be answered after determining the applica-</p><p>tion area:</p><p>• Which safety-relevant functions must be fulfilled?</p><p>• Which safety-relevant operating states can occur?</p><p>• Which interfaces and inputs/outputs (safety-relevant and non-safety-</p><p>relevant) are required?</p><p>Specify the exact definitions of the functions, operating statuses and inter-</p><p>faces used. Use logic diagrams to illustrate the functions and operating</p><p>statuses.</p><p>Example: E-STOP circuit (see also examples in the modular safety system</p><p>technical catalogue)</p><p>• Function: To switch off a plant after actuating an E-STOP button</p><p>• Operating statuses can be defined in a logic diagram via the switch</p><p>statuses of the E-STOP button.</p><p>• Specify inputs and outputs for connecting the E-STOP buttons e.g. via</p><p>wiring sketches.</p><p>Project Planning of a Process</p><p>3-2 PNOZmulti Safety Manual</p><p>Defining safety requirements</p><p>The first two sections of this chapter cover "what needs to be done". The</p><p>following sections will focus on "how this must be done". Define the safety</p><p>requirements for the safety system:</p><p>• Determine the tasks of the safety system in order to achieve the required</p><p>safety.</p><p>Example: What must the safety system do to monitor the safe operating</p><p>statuses of the process?</p><p>• Specify how the safety system is to react to an error.</p><p>Example: The safety system must switch the process to a safe status in</p><p>the event of an error.</p><p>• Define the input and output signals.</p><p>Example: number of safety-related inputs</p><p>• Define the time requirements of the safety-related tasks.</p><p>Example: consideration of delay times, processing times etc., specifica-</p><p>tion of the process error tolerance (period during which the process</p><p>tolerates an error without a danger occurring).</p><p>• Define the risk and the appropriate requirement class or category e.g. in</p><p>accordance with EN 954-1.</p><p>We recommend that you have the defined safety requirements checked</p><p>and approved.</p><p>3-3PNOZmulti Safety Manual</p><p>Planning operation and installation</p><p>No special measures are required for the safe operation of the safety</p><p>system itself. The safety system immediately switches to the safe status in</p><p>the event of an error (e.g. internal error) or an external fault (e.g. EMC</p><p>influence).</p><p>NOTICE</p><p>Ensure that you observe the operating instructions for the units and the</p><p>PNOZmulti technical catalogue. The instructions also contain important</p><p>information on electromagnetic compatibility (EMC), wiring and connection</p><p>of the inputs and outputs for planning.</p><p>The maximum permissible ambient temperature of the PNOZmulti "coated</p><p>version" units can deviate from that of the other units. Note that the maxi-</p><p>mum permitted ambient temperature of the overall system in a mixed</p><p>mode is determined by the unit with the lowest ambient temperature.</p><p>Project Planning of a Process</p><p>3-4 PNOZmulti Safety Manual</p><p>Notes</p><p>4-1PNOZmulti Safety Manual</p><p>Implementation of the Application</p><p>Assigning safety requirements</p><p>A requirement class or category must be assigned to every</p><p>safety function</p><p>after you have defined the required level of safety and the necessary</p><p>safety-relevant functions:</p><p>• Define the category according to EN 954-1.</p><p>• Determine the safety-relevant reaction times and minimum distances.</p><p>Check if there are any regulations on the max. reaction time for your</p><p>application. The reaction time always must be smaller than this max.</p><p>value. Note the relevant standards (e.g. EN 999) for the resulting calcula-</p><p>tion and maintenance of the required minimum distances from the dan-</p><p>ger zone.</p><p>• Assign every safety function the necessary hardware, software and</p><p>documentation.</p><p>• Ensure that you maintain the safety guidelines and follow the wiring</p><p>examples in the operating instructions of the respective units.</p><p>Safety in the project circuit diagram</p><p>The circuit diagram created in the PNOZmulti Configurator contains safety-</p><p>related and non-safety-related parts:</p><p>• The safety-related part processes the safety functions; the non-safety-</p><p>related part processes all functions that do not influence the safety of the</p><p>process.</p><p>• Safety-related functions and non-safety-related functions can be clearly</p><p>identified in the circuit diagram of the PNOZmulti Configurator.</p><p>Incorrect entries, e.g. invalid loops when connecting logic elements, are</p><p>detected by the PNOZmulti Configurator either at the point of entry or</p><p>when downloading the project to the base module.</p><p>The project can be certified prior to downloading it to the base module.</p><p>After certification, the executable project is explicitly protected from</p><p>changes.</p><p>Different authorisations can be assigned with the assignment of passwords</p><p>(e.g. all editing features for the project are enabled or read access only).</p><p>Implementation of the Application</p><p>4-2 PNOZmulti Safety Manual</p><p>CAUTION!</p><p>It must be checked that the safety program is properly operating by carry-</p><p>ing out comprehensive function tests in order to ensure that entry errors</p><p>and incorrect functionalities also will be detected.</p><p>Safety in the application</p><p>• Data from standard functions of the safety system are not safe, e.g.</p><p>fieldbus outputs. They may only have one additional criterion for an</p><p>action (e.g. start or stop) and may not block safety measures (e.g. a non-</p><p>activated stop signal or a continuously activated start signal, for any</p><p>reason, in the standard application must not compromise the safety of</p><p>the plant or process).</p><p>• The communication interfaces on the base module or on the expansion</p><p>modules may only be used for non-safety-related communication.</p><p>• The test pulse outputs may only be used for test pulses or as a 24 VDC</p><p>terminal.</p><p>CAUTION!</p><p>Control of safety-related machine functions via test pulse outputs is not</p><p>permitted.</p><p>Safety requirements on sensors and actuators</p><p>The failure of a sensor in the "OK state" must be detected for analogue</p><p>sensors (e.g. incremental encoders) or static binary sensors (e.g. E-STOP)</p><p>in safety-relevant functions. This can be achieved with respect to the haz-</p><p>ard analysis and the resulting safety category by way of:</p><p>• Type-approved sensors</p><p>• Diverse sensors or actuators with regular tests</p><p>• Redundant sensors or actuators with regular tests</p><p>• Internal or external tests for automatic fault detection</p><p>• Design of the sensors or actuators that excludes physical faults (product</p><p>certificate with respect to constant production)</p><p>• Measuring and regularly monitoring diverse process data</p><p>4-3PNOZmulti Safety Manual</p><p>Examples for connecting actuators and sensors are described in the oper-</p><p>ating instructions for the units and in the PNOZmulti technical catalogue.</p><p>Some actuators must be controlled by auxiliary contactors. Additional</p><p>safety measures must be carried out when implementing auxiliary contac-</p><p>tors.</p><p>Configuration in the PNOZmulti Configurator</p><p>Configuration in the PNOZmulti Configurator can only be started when</p><p>configuration of the modular safety system (i.e. assignment of the slots) is</p><p>fixed. Record which units are mounted to which slots. Assign the inputs</p><p>and outputs to the safety functions. Then create a structured flow chart.</p><p>General errors such as supply interruptions, short circuits and periphery</p><p>errors must be taken into consideration in the flow chart.</p><p>The circuit diagram in the PNOZmulti Configurator contains safety-related</p><p>and non-safety-related parts. Only the safety-related part executes the</p><p>required safety functions.</p><p>In order to avoid errors and allow for simple tests, the project must be</p><p>subdivided into function blocks. Each function block contains an elemen-</p><p>tary task. The individual functions can be distributed across different pages</p><p>of the project in the PNOZmulti Configurator.</p><p>This makes the circuit diagram</p><p>• readily understood,</p><p>• logically structured,</p><p>• and easy to test.</p><p>After the project has been created, use a printout to check it for errors</p><p>such as incorrect setting of connection points, invalid logic connections etc.</p><p>Checking using a printout also covers possible PNOZmulti Configurator</p><p>errors.</p><p>Implementation of the Application</p><p>4-4 PNOZmulti Safety Manual</p><p>Planning installation</p><p>Installation of the safety system always must be carried out based on the</p><p>information in the operating instructions for the respective units and based</p><p>on the information in the PNOZmulti technical catalogue. This information</p><p>includes regulations, notes and measures for the safe installation and</p><p>wiring of the safety system.</p><p>A report should be be created that covers all activities, reactions and</p><p>solutions during the installation. The report especially must contain the:</p><p>• Version of the hardware and software</p><p>• Checksum (CRC) for the project</p><p>• Name, job title and signature of the tester</p><p>Planning of commissioning and validity</p><p>Commissioning should be analysed and noted step-by-step. Create an</p><p>exact description of the</p><p>• Necessary commissioning activities (tasks, responsibilities, solutions)</p><p>• Acceptance tests (according to the specification for acceptance tests)</p><p>• Expected reactions (documented in the respective test protocols)</p><p>From this, create a checklist for commissioning. The commissioning engi-</p><p>neer uses the checklist to verify that he has carried out all measures to</p><p>ensure safe commissioning, i.e. the engineer commissions based on the</p><p>checklist.</p><p>The higher the safety requirement class, the higher the requirements</p><p>placed on the skills of the commissioning engineer. The commissioning</p><p>engineer must have:</p><p>• An understanding of the system behaviour of the safety system</p><p>• Exact knowledge of the overall process (entire plant)</p><p>• A knowledge of the safety function and the dangers associated with the</p><p>process and the plant</p><p>4-5PNOZmulti Safety Manual</p><p>All units that are required for commissioning (e.g. measuring devices) must</p><p>be calibrated.</p><p>A report should be be created for commissioning that covers all activities,</p><p>reactions, problems and solutions as well as the test results of the test</p><p>specification(s).</p><p>The PNOZmulti modular safety system offers some important resources</p><p>for problems experienced during commissioning:</p><p>• Status information, e.g.</p><p>- Status of the inputs and outputs</p><p>- Operating statuses: START/STOP, online</p><p>• Messages: e.g. number of open connections</p><p>• Dynamic program display</p><p>shows the status of the inputs and outputs on the elements as well as</p><p>the connections between the elements on the interface of the PNOZmulti</p><p>Configurator. Inputs, outputs and connections that are active are high-</p><p>lighted in colour.</p><p>• Error stack</p><p>The error stack of the PNOZmulti unit contains important information for</p><p>diagnostics and troubleshooting. The error stack is read out by the</p><p>PNOZmulti Configurator.</p><p>• The checksum for the project</p><p>can be read out to identify the loaded project. The checksums for the</p><p>project which is open in the PNOZmulti Configurator and for the project</p><p>which is loaded in the base module can be compared. Differences in the</p><p>checksums are displayed.</p><p>Implementation of the Application</p><p>4-6 PNOZmulti Safety Manual</p><p>Notes</p><p>5-1PNOZmulti Safety Manual</p><p>Changes, Maintenance, Decommissioning</p><p>Changes</p><p>It may be</p><p>Select and configure output elements (relays,</p><p>semiconductors etc.)</p><p>Select and configure connections, time elements etc.</p><p>Create circuit diagram according to application</p><p>Note the safety requirements specified in the</p><p>planning phase</p><p>Recognisably distinguish between safe and</p><p>not safety-related parts of the circuit diagram</p><p>Testing the project</p><p>Transfer project to the hardware.</p><p>Use test means: start/stop PNOZmulti, dynamic</p><p>program display, error stack</p><p>Documenting and certifying the project</p><p>Enter project data</p><p>Secure project from being changed (certify)</p><p>Determine passwords for access rights</p><p>Completed</p><p>Checklist</p><p>7-6 PNOZmulti Safety Manual</p><p>Range</p><p>Installation</p><p>Tasks</p><p>Note installation guidelines</p><p>Maintain wiring plan</p><p>Note regulations for health and safety at work and</p><p>accident prevention, VDE and local safety measures</p><p>Completed</p><p>Range</p><p>Commissioning</p><p>Tasks</p><p>Carry out a comprehensive function test</p><p>Carry out commissioning based on the test</p><p>specification</p><p>A function test must be performed for all specified</p><p>safety functions before the plant is re-enabled.</p><p>Check fault detection equipment (e.g. switch</p><p>redundant sensors differently, simulate short circuits</p><p>and interruptions on the lines)</p><p>Check regulation compliance</p><p>Check whether the technical details specified in the</p><p>operating instructions are maintained</p><p>Document commissioning</p><p>Completed</p><p>7-7PNOZmulti Safety Manual</p><p>Range</p><p>Maintenance/change</p><p>Tasks</p><p>Switch off the safety system before changing units!</p><p>A function test must be performed for all specified</p><p>safety functions before the plant is re-enabled.</p><p>If a project was changed or recreated in the</p><p>PNOZmulti Configurator, a function test must be</p><p>carried out after downloading to a base unit.</p><p>In particular, the safety devices must be checked for</p><p>proper operation.</p><p>Maintain safety requirements</p><p>Store changes in a changes catalogue</p><p>Carry out and check change</p><p>Document changes</p><p>Completed</p><p>Checklist</p><p>7-8 PNOZmulti Safety Manual</p><p>Notes</p><p>7-9PNOZmulti Safety Manual</p><p>Notes</p><p>Checklist</p><p>7-10 PNOZmulti Safety Manual</p><p>Notes</p><p>... www</p><p>Hotline</p><p>Pilz GmbH & Co. KG</p><p>Sichere Automation</p><p>Felix-Wankel-Straße 2</p><p>73760 Ostfildern, Germany</p><p>Telephone: +49 711 3409-0</p><p>Telefax: +49 711 3409-133</p><p>E-Mail: pilz.gmbh@pilz.de</p><p>www.pilz.com</p><p>+49 711 3409-444</p><p>In many countries we are</p><p>represented by sales partners.</p><p>Please refer to our Homepage</p><p>for further details or contact our</p><p>headquarters.</p><p>21</p><p>1</p><p>04</p><p>-0</p><p>1-</p><p>04</p><p>/0</p><p>5</p><p>P</p><p>ri</p><p>nt</p><p>ed</p><p>in</p><p>G</p><p>er</p><p>m</p><p>an</p><p>y</p><p>PNOZmulti Range Safety manual</p><p>Contents</p><p>Introduction</p><p>Overview of documentation</p><p>Definition of symbols</p><p>Safe Applications</p><p>Safety concept</p><p>Application area</p><p>General safety assessment</p><p>Safety assessment of the PNOZmulti modular safety system</p><p>Managing a safe application</p><p>Documentation of a safe application</p><p>Project Planning of a Process</p><p>Determining the application area</p><p>Specifying functions</p><p>Defining safety requirements</p><p>Planning operation and installation</p><p>Implementation of the Application</p><p>Assigning safety requirements</p><p>Safety in the project circuit diagram</p><p>Safety in the application</p><p>Safety requirements on sensors and actuators</p><p>Configuration in the PNOZmulti Configurator</p><p>Planning installation</p><p>Planning of commissioning and validity</p><p>Changes, Maintenance, Decommissioning</p><p>Changes</p><p>Maintenance</p><p>Decommissioning</p><p>Troubleshooting</p><p>Error stack</p><p>Diagnostics using the LEDs</p><p>Checklist</p><p>Note on the checklist</p><p>Planning of the plant</p><p>Determining the application area</p><p>Specifying functions</p><p>Defining safety requirements</p><p>Creating a safety plan</p><p>Creating a wiring plan</p><p>Documenting a safe application</p><p>Planning operation and installation</p><p>Configuration</p><p>Requirements</p><p>Creating a circuit diagram</p><p>Testing the project</p><p>Documenting and certifying the project</p><p>Installation</p><p>Commissioning</p><p>Maintenance/change</p><p>Addresses</p>Select and configure output elements (relays,
semiconductors etc.)
Select and configure connections, time elements etc.
Create circuit diagram according to application
Note the safety requirements specified in the
planning phase
Recognisably distinguish between safe and
not safety-related parts of the circuit diagram
Testing the project
Transfer project to the hardware.
Use test means: start/stop PNOZmulti, dynamic
program display, error stack
Documenting and certifying the project
Enter project data
Secure project from being changed (certify)
Determine passwords for access rights
Completed
Checklist
7-6 PNOZmulti Safety Manual
Range
Installation
Tasks
Note installation guidelines
Maintain wiring plan
Note regulations for health and safety at work and
accident prevention, VDE and local safety measures
Completed
Range
Commissioning
Tasks
Carry out a comprehensive function test
Carry out commissioning based on the test
specification
A function test must be performed for all specified
safety functions before the plant is re-enabled.
Check fault detection equipment (e.g. switch
redundant sensors differently, simulate short circuits
and interruptions on the lines)
Check regulation compliance
Check whether the technical details specified in the
operating instructions are maintained
Document commissioning
Completed
7-7PNOZmulti Safety Manual
Range
Maintenance/change
Tasks
Switch off the safety system before changing units!
A function test must be performed for all specified
safety functions before the plant is re-enabled.
If a project was changed or recreated in the
PNOZmulti Configurator, a function test must be
carried out after downloading to a base unit.
In particular, the safety devices must be checked for
proper operation.
Maintain safety requirements
Store changes in a changes catalogue
Carry out and check change
Document changes
Completed
Checklist
7-8 PNOZmulti Safety Manual
Notes
7-9PNOZmulti Safety Manual
Notes
Checklist
7-10 PNOZmulti Safety Manual
Notes
 ... www
 Hotline
Pilz GmbH & Co. KG
Sichere Automation
Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Telephone: +49 711 3409-0
Telefax: +49 711 3409-133
E-Mail: pilz.gmbh@pilz.de
www.pilz.com
+49 711 3409-444
In many countries we are
represented by sales partners.
Please refer to our Homepage
for further details or contact our
headquarters.
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	PNOZmulti Range Safety manual
	Contents
	Introduction
	Overview of documentation
	Definition of symbols
	Safe Applications
	Safety concept
	Application area
	General safety assessment
	Safety assessment of the PNOZmulti modular safety system
	Managing a safe application
	Documentation of a safe application
	Project Planning of a Process
	Determining the application area
	Specifying functions
	Defining safety requirements
	Planning operation and installation
	Implementation of the Application
	Assigning safety requirements
	Safety in the project circuit diagram
	Safety in the application
	Safety requirements on sensors and actuators
	Configuration in the PNOZmulti Configurator
	Planning installation
	Planning of commissioning and validity
	Changes, Maintenance, Decommissioning
	Changes
	Maintenance
	Decommissioning
	Troubleshooting
	Error stack
	Diagnostics using the LEDs
	Checklist
	Note on the checklist
	Planning of the plant
	Determining the application area
	Specifying functions
	Defining safety requirements
	Creating a safety plan
	Creating a wiring plan
	Documenting a safe application
	Planning operation and installation
	Configuration
	Requirements
	Creating a circuit diagram
	Testing the project
	Documenting and certifying the project
	Installation
	Commissioning
	Maintenance/change
	Addresses