Pilz PNOZ po3.2p User manual

PNOZ po3.2p
Operating Manual 20677-EN-06
}Safety relays

Preface
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.
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
Operating Manual PNOZ po3.2p
20677-EN-06 3
Introduction 4
Validity of documentation 4
Using the documentation 4
Definition of symbols 4
Safety 5
Intended use 5
Safety regulations 5
Safety assessment 5
Use of qualified personnel 6
Warranty and liability 6
Disposal 6
For your safety 6
Unit features 7
Safety features 7
Block diagram/terminal configuration 7
Function Description 8
Installation 8
Wiring 9
Preparing for operation 10
Operation 10
Status indicators 10
Faults – Interference 11
Dimensions in mm 11
Technical details 11
Safety characteristic data 14
Supplementary data 14
Service life graph 15
Remove plug-in terminals 16
Order reference 16
EC declaration of conformity 17

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 4
Introduction
Validity of documentation
This documentation is valid for the product PNOZ po3.2p. It is valid until new documenta-
tion is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
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.
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.

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The PNOZ po3.2p is an expansion module of the safety system PNOZpower. It may only
be used with a base unit or a control module of the modular safety system PNOZpower.
The expansion module meets the requirements of EN60947-5-1, EN60204-1 and
VDE0113-1.
The max. achievable safety level depends on the base unit. The expansion module may not
exceed this. The safety-related characteristic values stated under safety-related character-
istic data [ 14] can only be achieved if the base unit also exhibits these safety charac-
teristic values.
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 [ 11]).
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 regulations
Safety assessment
Before using a unit 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.

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Operating Manual PNOZ po3.2p
20677-EN-06 6
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 preven-
tion
}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.
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.).
Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
For your safety
The unit meets all the necessary conditions for safe operation. However, please note the
following:
}Note for overvoltage category III: If voltages higher than low voltage (>50 VAC or >120
VDC) are present on the unit, connected control elements and sensors must have a
rated insulation voltage of at least 250 V.

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 7
Unit features
}Expansion module control inputs via PNOZpower bus
}Positive-guided relay outputs:
– 4 safety contacts (N/O)
}LED indicator for:
– Supply voltage
– Switch state of the safety contacts
– Error
}Plug-in connection terminals
Safety features
In conjunction with a base unit of the safety system PNOZpower, the expansion module ful-
fils 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 correct opening and closing of the safety device relays is tested automatically in
each on-off cycle.
Block diagram/terminal configuration
PNOZpower-Bus PNOZpower-Bus
13 23 33 43
14 24 34 44
95185
*Safe separation from non-marked area in accordance with EN 60947-1, 6 kV, basic insula-
tion between all safety contacts.

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Operating Manual PNOZ po3.2p
20677-EN-06 8
Function Description
The safety contacts are controlled by the base unit. The base unit controls the status of the
input circuits and the feedback loop. The supply voltage is fed via the PNOZpower bus.
When supply voltage is applied the "POWER" LED will light. The unit is ready for operation
when the feedback loop and the start circuit are closed at the base unit.
}Functional procedure after closing the input circuit of the base unit:
– The safety contacts 13-14, 23-24, 33-34 and 43-44 close.
– The LEDs "CH. 1" and "CH. 2" are lit.
}Functional procedure after opening the input circuit of the base unit:
– Safety contacts 13-14, 23-24, 33-34 and 43-44 are opened redundantly.
– The LEDs "CH. 1" and "CH. 2" go out.
NOTICE
When controlling an expansion module via the den PNOZpower bus the
switch-on delay/delay-on de-energisation of the controlling device (e.g base
unit, control module, ...) and the expansion module are added together.
Installation
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Use the notches on the rear of the unit to attach it to a DIN rail.
}Fit the unit to a horizontal DIN rail. If other mounting positions are used, the switching
capability values stated in the technical details cannot be maintained.
}There are 2 sockets on the rear of the PNOZ po3.2p.
The base unit/control module and the expansion modules are connected using the
jumpers supplied.
NOTICE
Always connect a terminator to the first and last device.
}Only use terminators, jumpers and terminals of the modular safety system PNOZpower.
}Layout:
– The base module and the expansion modules can be installed in any position on
the PNOZpower modular safety system.
}Maximum hardware:
– 1 base unit/control module
– 4 expansion modules
– 1 power supply unit

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 9
Power supply Base unit Expansion module 1 Expansion module 4
95579
Terminator
95579
Terminator
95425
Jumper
Order no: 779120 Order no: 779120Order no: 774639
PNOZ po3.2p
WARNING!
Risk of electrocution!
When voltage is applied, contact with live components could result in seri-
ous or even fatal injury from an electric shock.
The plug-in connection terminals should only be connected and disconnec-
ted when the voltage is switched off.
Wiring
Please note:
}Information given in the "Technical details [ 11]" must be followed.
}The outputs 13-14, 23-24, 33-34 and 43-44 are safety contacts.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 11]).
}Use copper wire that can withstand 60/75°C.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}Ensure the wiring and EMC requirements of IEC 60204-1 are met.

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Operating Manual PNOZ po3.2p
20677-EN-06 10
Preparing for operation
The expansion module is ready for operation when it is connected to a base unit via the
PNOZpower bus.
If the contactors are to be controlled directly, we recommend the following wiring:
Feedback loop
Contacts from external contactors
K5 N
L1
K6
13 (23 ...)
14 (24 ...)
Y1 K5 K6
Y2
Base unit
Expansion module
Operation
NOTICE
The safety function should be checked after initial commissioning and each
time the plant/machine is changed. The safety functions may only be
checked by qualified personnel.
Status indicators
LEDs indicate the status and errors during operation:
LED on
POWER
Supply voltage is present.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
FAULT
Contact malfunction

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 11
Faults – Interference
By closing or interrupting the input circuit you can check whether the unit switches on or off
correctly.
For safety reasons, the expansion module cannot be started if the following faults are
present:
}Contact malfunction: As the expansion module is connected to a base unit or a control
module, reactivation will not be possible if the contacts have welded after the input cir-
cuit has opened.
Dimensions in mm
Technical details
General
Approvals CCC, CE, EAC (Eurasian), TÜV, cULus Listed
Electrical data
Supply voltage
Voltage 24 V
Kind DC
Power consumption 4 W
Duty cycle 100 %
Relay outputs
Number of output contacts
Safety contacts (N/O), instantaneous 4
Utilisation category
In accordance with the standard EN 60947-4-1

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 12
Relay outputs
Utilisation category of safety contacts
AC1 at 400 V
Min. current 0,01 A
Max. current 10 A
Max. power 4000 VA
AC1 at 240 V
Min. current 0,01 A
Max. current 16 A
Max. power 4000 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 16 A
Max. power 400 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 230 V
Max. current 6 A
DC13 (6 cycles/min) at 24 V
Max. current 7,5 A
Utilisation category in accordance with UL
Voltage 240 V AC G. P.
With current 16 A
Voltage 24 V DC Resistive
With current 16 A
External contact fuse protection, safety contacts
In accordance with the standard EN 60947-5-1
Max. melting integral 640 A²s
Blow-out fuse, quick 16 A
Blow-out fuse, slow 16 A
Blow-out fuse, gG 16 A
Circuit breaker 24V AC/DC, characteristic B/C 16 A
Contact material AgSnO2 + 0,2 µm Au
Conventional thermal current while loading sev-
eral contacts
Ith per contact at UB DC; AC1:240V,DC1:24V
Conv. therm. current with 1 contact 16 A
Conv. therm. current with 2 contacts 16 A
Conv. therm. current with 3 contacts 12 A
Conv. therm. current with 4 contacts 10 A
Times
Switch-on delay
With automatic start typ. 30 ms
With automatic start max. 50 ms

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Operating Manual PNOZ po3.2p
20677-EN-06 13
Times
Delay-on de-energisation
With E-STOP typ. 20 ms
With E-STOP max. 30 ms
Environmental data
Climatic suitability EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C
Storage temperature
Temperature range -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C
Condensation during operation Not permitted
EMC EN 60947-5-1, EN 61000-6-2, EN 61326-3-1
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10 - 55 Hz
Amplitude 0,35 mm
Airgap creepage
In accordance with the standard EN 60947-1
Overvoltage category III
Pollution degree 2
Rated insulation voltage 250 V
Rated impulse withstand voltage 6 kV
Protection type
Mounting area (e.g. control cabinet) IP54
Housing IP30
Terminals IP20
Mechanical data
Mounting position Horizontal on top hat rail
Mechanical life 10,000,000 cycles
Material
Bottom PPO UL 94 V0
Top ABS UL 94 V0
Connection type Screw terminal
Mounting type plug-in
Conductor cross section with screw terminals
1 core flexible 0,5 - 4 mm², 20 - 10 AWG
Torque setting with screw terminals 0,5 Nm
Dimensions
Height 94 mm
Width 90 mm
Depth 135 mm
Weight 490 g
Where standards are undated, the 2014-07 latest editions shall apply.

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 14
Safety characteristic data
NOTICE
You must comply with the safety-related characteristic data in order to
achieve the required safety level for your plant/machine.
Operating
mode
EN ISO
13849-1:
2008
PL
EN ISO
13849-1:
2008
Category
EN 62061
SIL CL
EN 62061
PFHD [1/h]
IEC 61511
SIL
IEC 61511
PFD
EN ISO
13849-1:
2008
TM [year]
–PL e Cat. 4 SIL CL 3 2,31E-09 SIL 3 2,03E-06 20
All the units used within a safety function must be considered when calculating the safety
characteristic data.
INFORMATION
A safety function's SIL/PL values are not identical to the SIL/PL values of
the units that are used and may be different. We recommend that you use
the PAScal software tool to calculate the safety function's SIL/PL values.
Supplementary data
CAUTION!
It is essential to consider the relay's service life graphs. The relay outputs'
safety-related characteristic data is only valid if the values in the service life
graphs are met.
The PFH value depends on the switching frequency and the load on the relay output.
If the service life graphs are not accessible, the stated PFH value can be used irrespective
of the switching frequency and the load, as the PFH value already considers the relay's
B10d value as well as the failure rates of the other components.

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Operating Manual PNOZ po3.2p
20677-EN-06 15
Service life graph
The service life graphs indicate the number of cycles from which failures due to wear must
be expected. The wear is mainly caused by the electrical load; the mechanical load is negli-
gible.
Cycles x 1000
Switching current (A)
Example
}Inductive load: 2 A
}Utilisation category: AC15
}Contact service life: 300 000 cycles
Provided the application to be implemented requires fewer than 300 000 cycles, the PFH
value (see Technical details) can be used in the calculation.
To increase the service life, sufficient spark suppression must be provided on all output
contacts. With capacitive loads, any power surges that occur must be noted. With DC con-
tactors, use flywheel diodes for spark suppression.

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 16
Remove plug-in terminals
Procedure: Insert the screwdriver into the housing recess behind the terminal and lever the
terminal out.
Do not remove the terminals by pulling the cables!
WARNING!
Risk of electrocution!
When voltage is applied, contact with live components could result in seri-
ous or even fatal injury from an electric shock.
The plug-in connection terminals should only be connected and disconnec-
ted when the voltage is switched off.
Order reference
Product type Connection type Order No.
PNOZ po3.2p Screw terminals 773 631

PNOZ po3.2p
Operating Manual PNOZ po3.2p
20677-EN-06 17
EC declaration of conformity
This product/these products meet the requirements of the directive 2006/42/EC for ma-
chinery of the European Parliament and of the Council. The complete EC Declaration of
Conformity is available on the Internet at www.pilz.com/support/downloads.
Representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2, 73760 Ost-
fildern, Germany

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CMSE®, InduraNET p®, PAS4000®, PAScal®, PASconfig®, Pilz®, PIT®, PLID®, PMCprimo®, PMCprotego®, PMCtendo®, PMD®, 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. We would point out that product features may vary
from the details stated in this document, depending on the status at the time of publication and the scope of the equipment. We accept no responsibility for the validity, accuracy
and entirety of the text and graphics presented in this information. Please contact our Technical Support if you have any questions.
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100XXXX-DE-0X
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© Pilz GmbH & Co. KG, 2015
20677-EN-06, 2016-07 Printed in Germany © Pilz GmbH & Co. KG, 2015
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