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Smartcards are the key to configurable safety

A Pilz Automation Technology product story
Edited by the Engineeringtalk editorial team Oct 29, 2003

The PNOZmulti is a novel cost-effective software-configurable safety controller for all safety functions in applications up to BS EN954-1 Category 4.

The PNOZmulti is a novel cost-effective software-configurable safety controller for all safety functions in applications up to BS EN954-1 Category 4.

This is designed for medium-complexity machinery for which conventional electromechanical relays or microprocessor-based electronic safety relays are unsuitable, and where the use of programmable safety systems would be excessive.

PNOZmulti is as simple to use as a traditional PNOZ electromechanical relay, with drag-and-drop configuration software that needs no specialist programming skills.

Furthermore, the modular nature of the controller means that the customer only has to purchase and install the required functionality, thereby saving both costs and cabinet space.

Using the modules already available, customers can employ a PNOZmulti controller for safety related control systems with emergency stop switches, gate switches, limit switches, light curtains, safety mats and two-handed starts.

More modules are planned for launch in the near future.

In operation, the PNOZmulti provides comprehensive diagnostics, either by using the multicoloured LEDs on the front of the unit or via a communications port that transmits diagnostic log files to the programming software; online diagnostics will be available in the next generation systems later this year.

Should the safety system ever need to be upgraded or modified, it is easily reconfigured in software - or the controller can be completely reused on a replacement machine.

Being entirely electronic, with no moving or wearing parts, means that the PNOZmulti is exceptionally reliable and long-lived, even in areas where shock or vibration cause difficulties for traditional electromechanical relays.

For many applications, the PNOZ m1p base unit alone is sufficient.

This has 20 freely configurable inputs, four test pulse outputs, one auxiliary output, four safe semiconductor outputs (or two for Category 4 applications) and two safe relay outputs (or one for Category 4 applications).

However, for more complex safety related control systems, customers can add up to eight of the available expansion modules.

These are the PNOZ mi1p eight-input module, the PNOZ mo1p with two safe semiconductor outputs, the PNOZ mo2p with one safe relay output (or this can be used to provide two auxiliary outputs), and the PNOZ mc1p communications module that has 16 auxiliary semiconductor outputs.

Each additional module is simply plugged into the adjacent module, with no need for wiring and, therefore, no risk of wiring errors being made.

Configuration is entirely in software, which can take place before any hardware has been purchased, thereby helping cashflow for machine builders.

Using the PNOZmulti Configurator software is very straightforward: first, the user defines the inputs and outputs, then the logic functions are specified and, finally, the links are made between the inputs, outputs and logic operators.

Comprehensive help files and application examples are provided to assist with the process, though the drag-and-drop software is very intuitive.

One of the most important aspects of the design of safety related control systems, namely documentation, is largely automated, which saves considerable time and effort for users and those assigned the task of checking and approving the designs.

When the configuration is programmed and approved, it can then be downloaded to the PNOZmulti hardware by using a smartcard (the same technology as a mobile telephone SIM card).

Smartcards can be quickly and securely written to, then the smartcard is installed in the PNOZmulti base unit.

Should modifications to the configuration ever be required, these can be made by reprogramming the smartcard.

The facility for writing smartcards is especially useful where series machines are being built.

In this case, the configuration need only be carried out once in software, then multiple smartcards produced.

Smartcards and a smartcard reader are included in the PNOZmulti Toolkit, which also contains the Configurator software, cables and manuals.

Additional smartcards may be ordered separately.

PNOZmulti configurable safety controller modules are available for immediate delivery direct from Pilz Automation.

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