Pilz PNOZ e2.2p User manual

PNOZ e2.2p
Operating Manual-21360-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 e2.2p
21360-EN-06 3
Introduction 5
Validity of documentation 5
Using the documentation 5
Definition of symbols 5
Safety 6
Intended use 6
Safety regulations 7
Safety assessment 7
Use of qualified personnel 7
Warranty and liability 7
Disposal 7
Unit features 8
Safety features 8
Block diagram/terminal configuration 8
Function description 9
Operating modes 9
Installation 10
Wiring 10
Preparing for operation 11
Supply voltage 11
Input circuit 11
Feedback loop 12
Logic connection between several units 13
Logic inputs S35 and S36 14
Examples 14
Operation 19
Status indicators 19
Faults - malfunctions 20
Dimensions in mm 25
Technical details 25
Safety characteristic data 28

Contents
Operating Manual PNOZ e2.2p
21360-EN-06 4
Remove plug-in terminals 29
Order reference 29
Product 29
Accessories 29

PNOZ e2.2p
Operating Manual PNOZ e2.2p
21360-EN-06 5
Introduction
Validity of documentation
This documentation is valid for the product PNOZ e2.2p. It is valid until new documentation
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.

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INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The two-hand control device PNOZ e2.2p meets the requirements of EN574 Type III A.
CAUTION!
The two-hand control device PNOZ e2.2p may not be used on press con-
trollers. For these we recommend the PNOZ e2.1p. It is only suitable for use
where the risk analysis has established a low level of risk (e.g. EN ISO
13849-1 Cat. 1).
The two-hand control device is used as a Type III A hand protection device on plant and
machinery, in accordance with EN 574. The unit forces the operator to keep his hands out
of the danger zone during dangerous movements. The unit is designed for use in two-hand
circuits. Please note the type of two-hand circuit as stated in the relevant C standard.
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 [ 25]).
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.

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Operating Manual PNOZ e2.2p
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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.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
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"
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific 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).

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Unit features
}Outputs using semiconductor technology:
– 2 safety outputs
– 1 auxiliary output
– 2 test pulse outputs
}Application: Two-hand monitoring
}LED display for:
– Supply voltage
– Switch state of safety outputs
}2 logic inputs (AND/OR) for logic connections between several units
}Feedback loops for monitoring external contactors
}Detection of shorts across contacts via test pulse outputs
Safety features
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 safety outputs are tested periodically using an off-test.
Block diagram/terminal configuration
InputInput &Feed-
back
Diag-
nostic
Power
Test
Pulse
Output
S14 S24 S35 S36 Y6 Y7
Y5 S13 S23 14 24Y32
A1 A2

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Function description
When supply voltage is applied and the set operating mode is detected (initialisation
phase), the "POWER" LED is lit. The unit is ready for operation when the feedback loops
are closed.
The two-hand control device is activated by simultaneously pressing two pushbuttons. It in-
terrupts the control command for the hazardous movement when one or both pushbuttons
are released. The movement can only be restarted when both pushbuttons have returned
to their start position (released) and are operated again.
}Both pushbuttons have been operated simultaneously, i.e. within 0.5 s:
– There are high signals at safety outputs 14 and 24 and auxiliary output Y32
– The LEDs "CH.1" and "CH.2" are lit.
}One pushbutton has been released following simultaneous operation:
– There are low signals at safety outputs 14 and 24 and auxiliary output Y32.
– The LEDs "CH.1" and "CH.2" go out.
}There are also low signals at safety outputs 14 and 24 and auxiliary output Y32 when:
– Only one control element is pressed,
– Simultaneity is not upheld,
– The feedback control loop is still open.
}The safety outputs will not return to a high signal until both control elements are re-
leased and then re-operated simultaneously.
Feedback loop
Before a safety output is switched on, a test is run to establish whether the contacts at
feedback loop inputs Y6 and Y7 are closed. If a contact is open, an error is detected and
LEDs CH.1 and CH.2 will flash alternately. It will not be possible to switch the unit back on
until the feedback loops are closed and the safety function has been reset.
The feedback loop contacts are also checked when the signal at the output changes from
high to low. After this signal change, the contacts at the feedback loop inputs must close
within 150 ms. If a contact is still open after 150 ms has elapsed, an error is detected and is
displayed as a flashing code 1,8 (see Faults - malfunctions [ 20]). It will not be possible
to switch the unit back on until the error has been rectified and the supply voltage has been
switched off and then on again.
AND/OR connection
The PNOZ e2.2p has two logic inputs S35 (OR) and S36 (AND) for logic connections
between several units.
Operating modes
}Automatic start: Unit is active once the input circuit has been closed within the simultan-
eity period.
}Increase in the number of available contacts by connecting contact expander modules
or external contactors/relays.

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Installation
CAUTION!
Electrostatic discharge can damage components on the safety system!
Ensure against discharge before touching the safety system, e.g. by touch-
ing an earthed, conductive surface or by wearing an earthed armband.
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Use the notch on the rear of the unit to attach it to a DIN rail (35 mm).
}When installed vertically: Secure the unit by using a fixing element (e.g. retaining
bracket or end angle).
NOTICE
The distance of the pushbutton on the two-hand control device from the
nearest danger zone must be large enough so that if one of the pushbuttons
is released, the hazardous movement is interrupted before the operator
reaches the danger zone or can reach into the danger zone (see EN 999
"Hand-arm speed").
NOTICE
If you are connecting several units logically, please note the guidelines in
the section entitled Logic connection between several units [ 13].
Wiring
Please note:
}Information given in the "Technical details [ 25]" must be followed.
}Use copper wire that can withstand 60/75°C.
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 25])
Rl/km = cable resistance/km
}Cables that have to be laid outside the control cabinet must be protected from mechan-
ical damage, e.g. by installing them in a conduit.
}The unit and the input circuits must always be supplied by a single power supply.
}The connection cables between the PNOZ e2.2p and the pushbuttons should not be
laid directly next to power cables, otherwise inductive and capacitive interference coup-
ling can result.
}Safety outputs 14 and 24 should exclusively be used for safe applications.
}The safety outputs must not be connected to control inputs.

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}To suppress the pulse on switching off at safety outputs 14 and 24, use the terminal
block with filter (see Order reference [ 29]).
}You must comply with the idling capacity at safety outputs 14 and 24 (see Technical
details [ 25]).
}Do not connect undesignated terminals.
}Only contactors with positive-guided contacts should be used for safety functions.
}Output Y32 is an auxiliary output, e.g. for communication with a PLC or text display.
}Auxiliary output Y32 shouldnot be used for safety circuits!
}Use freewheel diodes to drive inductive loads (e.g. contactors or relays) with the safety/
auxiliary outputs.
}The operating voltage for the two-hand control device must only be connected after the
shutdown device in accordance with §9VBG7n5.1/2.
}The power supply must comply with the regulations for extra low voltages with protect-
ive electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.
}Ensure the wiring and EMC requirements of EN 60204-1 are met.
}Terminal Y5 is provided for Pilz-internal diagnostic purposes.
Preparing for operation
Supply voltage
Supply voltage AC DC
A1
F1
A2
L+
L-
Input circuit
The N/O contacts on the two-hand button must be connected to the input circuits. The input
circuit may only be wired as shown in the following diagram.

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Feedback loop
The unit has two feedback loop inputs, one (Y6) for safety output 14 and one (Y7) for safety
output 24.
The wiring of the feedback loop depends on the unit's logic links:
}Unit is used as a single unit (no logic links) or is only OR-linked:
– Safety output 14:
Connect the contacts from external contactors between terminals Y6 and S13.
– Safety output 24:
Connect the contacts from external contactors to terminals Y7 and A1.
}Unit is AND-linked:
– Safety output 14:
Connect the contacts from external contactors between terminals Y6 and A1.
– Safety output 24:
Connect the contacts from external contactors to terminals Y7 and A1.
}Feedback loop unconnected:
If you do not wish to connect any contacts to the feedback loop, bridge the terminals as
described in the table below.
OR/no
logic connection
AND + OR/AND
logic connection
without feedback loop monit-
oring
Y7
Y6
A1
S13
Y7
Y6
A1
with feedback loop monitor-
ing
Y7
A1 K3 K4
Y6
S13 K1 K2
14
24
K1 K2
K3 K4
Y7
A1
K3 K4
Y6 K1 K2
14
24
K1 K2
K3 K4

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Logic connection between several units
Units from the PNOZelog product range can be logically connected to each other and to
units from the PNOZmulti product range. On the PNOZelog, input S35 is intended for the
logic OR connection and input S36 for the logic AND connection. Safety outputs 14 and 24
on the PNOZelog are suitable for logic connections.
When linking several units logically, please note:
}When PNOZelog units are linked logically to each other, a safety output from a
PNOZelog unit may be connected to logic inputs from one or more PNOZelog units.
}When linking PNOZelog units logically to PNOZmulti units
– a cascading output from PNOZmulti units may be connected to logic inputs on
PNOZelog units
or
– a safety output from PNOZelog units may be connected to cascading inputs on
PNOZmulti units.
}The unit with the lowest SIL/PL value determines the SIL/PL value of the entire circuit.
}PNOZ e1p, PNOZ e8.1p: These units do not have logic inputs. Their safety outputs can
be used to logically link the units to the logic inputs of other PNOZelog units or to the
cascading inputs from PNOZmulti units.
}Safety outputs from the PNOZ e1p are suitable for logic connections from unit version
3.0.
}Each safety output on a PNOZelog unit that is connected to the load may also be con-
nected to the logic inputs of a maximum of four PNOZelog units (Example 1 [ 15]).
}Up to 50 logic inputs from PNOZelog units can be connected to safety outputs with no
load.
}Logically linking the units leads to delays when switching on and off (see on-delay and
response time in the Technical details [ 25]). These are added up with each unit
that is logically linked (Example 3 [ 17]).
}Install all the logically linked units in the same control cabinet or ensure that faults re-
garding the units' connection are excluded, e.g. via protected installation of the connec-
tion cables.
}All linked units must be connected to the same supply voltage.
WARNING!
Muting the safety function
A valid signal at the OR input of a PNOZelog unit mutes its safety function
and can lead to the most serious injuries and death.
– Before using the OR function, carry out a risk analysis and use other
measures to establish a safe condition.

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NOTICE
Logic AND connection
The high signal must always be present at the AND input before the two-
hand pushbutton is operated. If the AND input switches from a low to a high
signal while the two-hand pushbutton is operated, you will need to release
the pushbutton and press it again.
Logic inputs S35 and S36
Logic inputs S35 and S36 from the PNOZ e2.2p enable additional PNOZelog or PNOZmulti
units to be logically AND/OR connected.
Logic AND + OR connec-
tion
Logic AND connection Logic OR connection
PNOZ e2.2p
PNOZ e2.2p
PNOZ e2.2p
Examples
The following examples represent various ways in which PNOZelog units can be logically
connected. In all the application examples, 2 loads may also be connected to the safety
outputs.

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}Example 1:
Loads are connected to the safety outputs of Unit 1. In addition, a safety output is AND-
linked to 4 other PNOZelog units via the logic input S36.
14

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}Example 2:
Loads are connected to the safety outputs of Unit 1. In addition, a safety output is AND-
linked to another PNOZelog unit via the logic input S36.

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}Example 3
The logic connection line between Unit 1 and Unit 2 contains contacts from the external
contactors on Unit 4. This means that Unit 4 and Unit 1 can set the outputs on Unit 2 and
Unit 3 to low.
A short circuit between +24 VDC and a safety output must be excluded!
K5 K6 K3 K4
K7 K8
K7
K1 K2
K8

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}Example 4
Unit 1 and Unit 2 are OR-linked via Unit 3. If the output from Unit 2 has a low signal, Unit 1
alone will control the status of the outputs on Unit 3. If Unit 2 sends a high signal to the OR
input on Unit 3, a high signal will be present at the outputs on Unit 3, irrespective of the
status of its input circuit.

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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.
INFORMATION
The safety outputs are constantly checked via test pulses. This may gener-
ate a humming noise on the connected contactors, which does not affect
the function. The test pulses also mean that, when measured with a multi-
meter, the voltage at the safety outputs is displayed to be less than it actu-
ally is.
The unit detects the set operating mode once supply voltage is applied. During this time
(initialisation phase) the "POWER" LED will flash. The unit is ready for operation when the
"POWER" LED is lit continuously.
LEDs indicate the status and errors during operation:
LED on
LED flashes
Status indicators
POWER
Supply voltage is present, operating mode is detected.
POWER
Initialisation phase
CH.1
There is a high signal at safety output 14.
CH.2
There is a high signal at safety output 24.

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Faults - malfunctions
INFORMATION
Supply interruptions lasting longer than 20 ms are detected as an error. The
LEDs indicate an error and the safety outputs carry a low signal. The plant
or machinery driven via the safety outputs will be shut down. The unit can
only be restarted when the supply voltage is switched off for at least 1 s and
then switched on again.
Fault
Fault conditions are indicated by flashing the LEDs. There are faults that are displayed via
periodic flashing (see table "Display of fault conditions") and faults where an error code can
be determined via the number of flashes (see table "Relationship between the number of
flashes and the decimal error code [ 22]"). These faults are always indicated by three
short flashes at LED CH.1 or CH.2. After a longer pause, the LED will then flash at one
second intervals. The number of LED flashes corresponds to a digit in the error code. The
error code can consist of up to 4 digits. The digits are separated by a longer period without
flashing. The entire sequence is constantly repeated.
INFORMATION
Error code 0: 16 flashes