Pilz PNOZ e3.1p User manual

PNOZ e3.1p
Operating Manual-21240-EN-09
}Safety relays

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
Operating Manual PNOZ e3.1p
21240-EN-09 | 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
Start circuit................................................................................................................................ 12
Feedback loop .......................................................................................................................... 12
Logic connection between several units ............................................................................. 13
Logic input S35 and S36........................................................................................................... 14
Examples .................................................................................................................................. 15
Operation ................................................................................................................................19
Status indicators ....................................................................................................................... 19
Faults – Interference .............................................................................................................. 20
Dimensions in mm .................................................................................................................25
Technical details ....................................................................................................................25
Safety characteristic data ......................................................................................................... 29

Contents
Operating Manual PNOZ e3.1p
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Remove plug-in terminals ..................................................................................................... 30
Order reference ......................................................................................................................30
Product ..................................................................................................................................... 30
Accessories .............................................................................................................................. 30

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Introduction
Validity of documentation
This documentation is valid for the product PNOZ e3.1p. 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 safety relay PNOZ e3.1p provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN 60947-5-1 and EN 60204-1 and may be
used in applications with:
}the safety sensors PSEN 2.1p-10 and PSEN 2.1p-11 in safety circuits in accordance with
EN60947-5-3:2005, PDF-M
}as an evaluation device for position switches with N/C/N/O combination
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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Safety regulations
Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 62061. However, this does not guarantee the functional
safety of the overall plant/machine. To achieve the relevant safety level of the overall plant/
machine’s required safety functions, each safety function needs to be considered separ-
ately.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
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 prevention,
}Have read and understood the information provided in the section entitled Safety
}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-related
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
}Connection options:
– Safety sensors PSEN2.1p-10 and PSEN2.1p-11
– Position switch with N/C / N/O combination
}LED display for:
– Supply voltage
– Switch state of safety outputs
}2 logic inputs (AND/OR) for logic connections between several units
}Feedback loop 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
Input &Feed-
back
Diag-
nostic
Power
Test
Pulse
Output
S12 S35 S36 Y6
Y5 S11 S23 14 24Y32
A1 A2 S24
Input
Y4
Start
S34

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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 loop is
closed.
}Input circuit: Contact at S12 closed and contact at S24 open (e.g. safety gate closed)
– There are high signals at safety outputs 14 and 24 and auxiliary output Y32.
– LEDs "CH.1" and "CH.2" are lit.
}Input circuit: Contact at S12 open and contact at S24 closed (e.g. safety gate open)
– There are low signals at safety outputs 14 and 24 and auxiliary output Y32.
– LEDs "CH.1" and "CH.2" go out.
Feedback loop
Before a safety output is switched on, a test is run to establish whether the contacts ahead
of feedback loop input Y6 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 loop is 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 input 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 – Interference [ 20]). It will not be pos-
sible 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 e3.1p has two logic inputs S35 (OR) and S36 (AND) for logic connections
between several units.
Operating modes
}Dual-channel operation: Earth faults in the input circuit and shorts between the input cir-
cuit contacts will be detected.
}Automatic start: Unit becomes active once the contact at S12 has been closed and the
contact at S24 has been opened in the input circuit.
}Monitored start: Unit is not active until the start button has been operated and then re-
leased.
}The start-up test prevents automatic restarting after a power failure and subsequent re-
turn of voltage. The unit checks whether safety gates that are closed have been opened
and then closed again when supply voltage is applied.
}Increase in the number of available contacts by connecting contact expandsion modules
or external contactors/relays.

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Installation
CAUTION!
Electrostatic discharge can damage components on the safety sys-
tem!
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
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 wiring with a temperature stability of 60/75 °C.
}To prevent EMC interferences (particularly common-mode interferences) the measures
described in EN60204-1 must be executed. This includes the separate routing of cables
of the control circuits (input, start and feedback loop) from other cables for energy trans-
mission or the shielding of cables, for example.
}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.
}Safety outputs 14 and 24 should exclusively be used for safe applications.
}The safety outputs must not be connected to control inputs.
}To suppress the pulse on switching off at safety outputs 14 and 24, use the terminal block
with filter (see Order reference [ 30]).
}You must comply with the idling capacity at safety outputs 14 and 24 (see Technical
details [ 25]).
}Do not connect undesignated terminals.
}Output Y32 is an auxiliary output, e.g. for communication with a PLC or text display.

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}Auxiliary output Y32 shouldnot be used for safety circuits!
}Only contactors with positive-guided contacts should be used for safety functions.
}Use freewheel diodes to drive inductive loads (e.g. contactors or relays) with the safety/
auxiliary outputs.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}The power supply must comply with the regulations for extra low voltages with protective
electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.
}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
Connect the N/C and N/O contact from the trigger element to the input circuit.
The table describes how the input circuit is wired when the unit is used individually (without
logic input). If units are linked together logically, Y4 must be wired as described in the table
in the section entitled "Logic connection between several units [ 14]".
Input circuit Dual-channel
without detection of shorts across contacts
PNOZelog PSENmag
Brown
White
Blue
Black
with detection of shorts across contacts
PNOZelog PSENmag
Brown
White
Blue
Black

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Start circuit
The unit can be started automatically or manually with monitoring.
Automatic start Monitored start
Safety gate
without start-up
test
Safety gate with
start-up test
NOTICE
With automatic start
The unit starts up automatically when the safeguard is reset, e.g. when the
E-STOP pushbutton is released. Use external circuit measures to prevent
an unexpected restart.
Feedback loop
Contacts from external contactors can be connected between Y6 and A1.
}Feedback loop unconnected:
If you do not wish to connect any contacts to the feedback loop, Y6 must be connected to
A1.
CAUTION!
Do not connect the contacts from external contactors in series to the start
circuit.

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Example
The positive-guided contacts of contactors K1 and K2 control the feedback loop
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 cas-
cading 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 connec-
ted 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 re-
sponse time in the Technical details [ 25]). These are added up with each unit that is
logically linked (Example 3 [ 18]).

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}Install all the logically linked units in the same control cabinet or ensure that faults regard-
ing the units' connection are excluded, e.g. via protected installation of the connection
cables.
}All linked units must be connected to the same supply voltage.
Logic input S35 and S36
The logic inputs are connected to each other as follows:
Input circuit
Safety outputs
Logic inputs S35 and S36 from the PNOZ e3.1p enable additional PNOZelog or PNOZmulti
units to be logically AND/OR connected.
Input circuit Logic AND + OR
connection
Logic AND connec-
tion
Logic OR connec-
tion
without detection of
shorts across con-
tacts
with detection of
shorts across con-
tacts
∗1 Where units are linked logically, Y4 must be wired as shown here (differs from the por-
trayal on the input circuit).

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Examples
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.
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.
}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.

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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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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 – Interference
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"). 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 flash-
ing. The entire sequence is constantly repeated.
INFORMATION
Error code 0: 16 flashes