Pilz PNOZ m EF 4DI4DOR User manual

PNOZ m EF 4DI4DOR
Operating Manual-1002702-EN-08
}Configurable, safe small controllers PNOZmulti 2

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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1 Introduction ............................................................................................................................5
1.1 Validity of documentation.......................................................................................................... 5
1.2 Using the documentation .......................................................................................................... 5
1.3 Definition of symbols................................................................................................................. 5
2 Overview .................................................................................................................................7
2.1 Scope of supply ........................................................................................................................ 7
2.2 Unit features ............................................................................................................................. 7
2.3 Front view ................................................................................................................................. 8
3 Safety ...................................................................................................................................... 9
3.1 Intended use ............................................................................................................................. 9
3.2 System requirements................................................................................................................ 9
3.3 Safety regulations ..................................................................................................................... 10
3.3.1 Safety assessment ................................................................................................................... 10
3.3.2 Use of qualified personnel ........................................................................................................ 10
3.3.3 Warranty and liability ................................................................................................................ 10
3.3.4 Disposal .................................................................................................................................... 10
3.3.5 For your safety.......................................................................................................................... 10
4 Function description ............................................................................................................. 12
4.1 Integrated protection mechanisms............................................................................................ 12
4.2 Functions .................................................................................................................................. 12
4.3 System reaction time ................................................................................................................ 12
4.4 Block diagram ........................................................................................................................... 12
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
6 Commissioning ......................................................................................................................15
6.1 General wiring guidelines ......................................................................................................... 15
6.2 Connection................................................................................................................................ 15
6.3 Download modified project to the PNOZmulti system .............................................................. 16
7 Operation ................................................................................................................................17
7.1 LED indicators .......................................................................................................................... 17
7.2 Function test of the relay outputs.............................................................................................. 18
8 Technical details ....................................................................................................................19
8.1 Safety characteristic data ......................................................................................................... 22
8.2 Classification according to ZVEI, CB24I ................................................................................... 23
9 Supplementary data ..............................................................................................................24
9.1 Service life graph for the relay contacts.................................................................................... 24
9.2 Permitted ambient temperature Tamb dependent on the total current Isum ............................ 26

Contents
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10 Order reference ......................................................................................................................27
10.1 Product ..................................................................................................................................... 27
10.2 Accessories .............................................................................................................................. 27

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ m EF 4DI4DOR. It is valid until new doc-
umentation 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 of supply
}Expansion module PNOZ m EF 4DI4DOR
}Jumper
2.2 Unit features
Application of the product PNOZ m EF 4DI4DOR:
Expansion module for connection to a base unit from the PNOZmulti 2 system.
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Positive-guided relay outputs:
4 safety outputs
Depending on the application, up to PL e of EN ISO 13849-1 and up to SIL CL 3 of EN
IEC 62061
}4 inputs for connecting, for example:
– E-STOP pushbutton
– Two-hand button
– Safety gate limit switch
– Start button
– Light beam devices
– Scanner
– Enabling switch
– PSEN
– Operating mode selector switch
}LED for:
– Error messages
– Diagnostics
– Supply voltage
– Output circuits
– Input circuits
}Test pulse outputs used to monitor shorts across the inputs
}Monitoring of shorts between the safety outputs
}Plug-in connection terminals:
Either spring-loaded terminal or screw terminal available as an accessory (see order ref-
erence)
}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
Legend:
}Inputs I0 – I3
}Outputs O0 – O3
}LEDs:
– POWER
– Run
– Diag
– Fault
– I Fault
– O Fault

Safety
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3 Safety
3.1 Intended use
The expansion module may only be connected to a base unit from the configurable system
PNOZmulti 2 (please refer to the document "PNOZmulti System Expansion" for details of
the base units that can be connected).
The configurable system PNOZmulti 2 is used for the safety-related interruption of safety
circuits and is designed for use in:
}Emergency stop equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
}The product PNOZ m EF 4DI4DOR meets the requirements of the standards EN 81-20,
EN 81-22 and EN 81-50, harmonised under the Lifts Directive 2014/33/EU, and the re-
quirements of the standard EN 115-1, harmonised under the Machinery Directive
2006/42/EC.
}The programmable safety system should be installed in a protected environment that
meets at least the requirements of pollution degree 2.
Example: Protected inside space or control cabinet with protection type IP54 and corres-
ponding air conditioning.
The module PNOZ m EF 4DI4DOR can be used in furnaces in accordance with EN 298. If
the module's relay outputs shut down the entire fuel supply and the furnace is used in con-
tinuous operation, appropriate external measures must be used to establish diversity of the
shutdown elements (requirement of EN 50156-1). For example, an appropriate measure
may be an additional, monitored switching element (contactor or relay), which is controlled
by a safe semiconductor output and is switched in series with both relay outputs.
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 [ 19]).
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 Safety assessment
Before using a device it is necessary to perform a safety assessment in accordance with
the Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
3.3.2 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 prevention,
}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.
3.3.3 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.).
3.3.4 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3.5 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:

Safety
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}This operating manual only describes the basic functions of the unit. The expanded func-
tions 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 meets the following safety requirements:
}The circuit is redundant with built-in self-monitoring.
}The safety device remains effective in the case of a component failure.
}The relay contacts meet the requirements for protective separation through increased in-
sulation compared with all other circuits in the safety system.
4.2 Functions
The expansion module provides additional inputs and additional relay outputs.
The function of the inputs and outputs on the control system depends on the safety circuit
created using the PNOZmulti Configurator. A removable data medium is used to download
the safety circuit 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 online help on the PNOZmulti Configurator contains descriptions of the operating
modes and all the functions of the PNOZmulti control system, plus connection examples.
4.3 System reaction time
Calculation of the maximum reaction time between an input switching off and a linked out-
put in the system switching off is described in the document "PNOZmulti System Expan-
sion".
4.4 Block diagram
Module
Supply
Data
(FS)
Interface
to previous
module
Interface
tonext
module
I0
Input
I1
Input
I2
Input
I3
Input
O0 O1
13 23
14 24
O2 O3
33 43
34 44

Installation
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5 Installation
5.1 General installation guidelines
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Fit the safety system to a horizontal mounting rail. The venting slots must face upward
and downward. Other mounting positions could damage the safety system.
}Use the locking elements on the rear of the unit to attach it to a mounting rail.
}In environments exposed to heavy vibration, the unit should be secured using a fixing ele-
ment (e.g. retaining bracket or end angle).
}Open the locking slide before lifting the unit from the mounting rail.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
}The ambient temperature of the PNOZmulti units in the control cabinet must not exceed
the figure stated in the technical details. Air conditioning may otherwise be required.
NOTICE
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
22,5
(0.88")

Installation
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5.3 Connecting the base unit and expansion modules
Connect the base unit and the expansion modules as described in the operating manuals
for the base modules.
}The terminator must be fitted to the last expansion module
}Install the expansion module in the position 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 [ 19] must be followed.
}The position of the expansion module is specified in the Hardware configuration of the
PNOZmulti Configurator.
}Use copper wiring with a temperature stability of 75 °C.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 19]).
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
6.2 Connection
Input circuit Single-channel Dual-channel
Example:
E-Stop
without detection of shorts across
contacts
S1
I0 L+
S1
I1
I0 L+
L+
Example:
E-Stop
with detection of shorts across
contacts
I0
T0
S1
S1
T1
I1
T0
I0

Commissioning
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Relay outputs
Dual output
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
Single output
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
Feedback loop Dual output
Contacts from external contactors
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
L+
I0
6.3 Download modified project to the PNOZmulti system
As soon as an additional expansion module has been connected to the system, the project
must be amended in the PNOZmulti Configurator and downloaded back into the base unit.
Proceed as described in the operating manual for the base unit.
NOTICE
For the commissioning and after every user program change, you must
check whether the safety devices are functioning correctly.

Operation
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7 Operation
The PNOZmulti system is ready for operation when the "POWER" and "RUN" LEDs on the
base unit are lit continuously.
7.1 LED indicators
Legend
LED on
LED flashes
LED off
LED Error
POWER Ru
n
Diag Fault IFaul
t
OFault
No supply voltage
Expansion module PNOZ m EF 4DI4DOR running without er-
ror.
Expansion module PNOZ m EF 4DI4DOR is in a STOP condi-
tion.
Internal error on the expansion module PNOZ m EF
4DI4DOR or on the overall system. Expansion module is in a
safe condition.
External error on the expansion module PNOZ m EF
4DI4DOR or on the overall system. Expansion module is in a
safe condition.
Internal error on the inputs of the expansion module PNOZ m
EF 4DI4DOR. Expansion module is in a safe condition, e.g.
pulse error.
Internal error on the outputs of the expansion module PNOZ
m EF 4DI4DOR. Expansion module is in a safe condition.
External error on the inputs of the expansion module PNOZ m
EF 4DI4DOR. Expansion module is in a safe condition.
External error on the outputs of the expansion module PNOZ
m EF 4DI4DOR. Expansion module is in a safe condition, e.g.
defective feedback loop.

Operation
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7.2 Function test of the relay outputs
When the relay outputs are switched on, the mechanical contact on the relay cannot be
tested automatically. Depending on the operational environment, measures to detect the
non-opening of switching elements may be required under some circumstances.
When the product is used in accordance with the European Machinery Directive, a check
must be carried out to ensure that the safety contacts on the relay outputs open correctly.
Start the device again or open the safety contacts (switch off output), so that the internal
diagnostics can check the correct opening of the safety contacts
}for SIL CL 3/PL e at least 1x per month
}for SIL CL 2/PL d at least 1x per year

Technical details
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8 Technical details
General
Certifications CCC, CE, EAC (Eurasian), KOSHA, TÜV, cULus
Listed
Application range Failsafe
Module's device code 00E1h
Electrical data
Supply voltage
for Module supply
internal Via base unit
Voltage 24 V
Kind DC
Current consumption 122 mA
Power consumption 3 W
Max. power dissipation of module 6,5 W
Status indicator LED
Permitted loads inductive, resistive
Inputs
Number 4
Input voltage in accordance with EN 61131-2 Type 1 24 V DC
Input current at rated voltage 5 mA
Input current range 2,5 - 5,3 mA
Pulse suppression 0,5 ms
Maximum input delay 8 ms
Potential isolation No
Relay outputs
Number of relay outputs 4
Utilisation category
In accordance with the standard EN 60947-4-1
Utilisation category of safety contacts
AC1 at 250 V
Min. current 10 mA
Max. current 6 A
Max. power 1500 VA
DC1 at 24 V
Min. current 10 mA
Max. current 6 A
Max. power 144 W
Utilisation category
In accordance with the standard EN 60947-5-1

Technical details
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Relay outputs
Utilisation category of safety contacts
AC15 at 230 V
Max. current 3 A
Max. power 690 W
DC13 (6 cycles/min) at 24 V
Max. current 3 A
Max. power 72 W
Utilisation category in accordance with UL
Voltage 240 V AC G.U. Resistive
With current 6 A
Voltage 24 V DC G. U. Resistive
With current 6 A
Pilot Duty; R300 24 V DC
With current 3 A
Pilot Duty; B300 230 V AC
With current 3 A
Airgap creepage between
Relay contacts 3 mm
Relay contacts and other circuits 5,5 mm
External contact fuse protection, safety contacts
In accordance with the standard VDE 0660
Blow-out fuse, quick 10 A
Blow-out fuse, slow 6 A
Switch-off delay 22 ms
Contact material AgCuNi + 0,2 µm Au
Potential isolation yes
Environmental data
Ambient temperature
In accordance with the standard EN 60068-2-14
Temperature range 0 - 60 °C
Forced convection in control cabinet off 55 °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
Condensation during operation Not permitted
Max. operating height above sea level 2000 m
EMC EN 61131-2
Vibration
In accordance with the standard EN 60068-2-6
Frequency 5 - 150 Hz
Acceleration 1g