Pilz PNOZ po4p User manual

PNOZ po4p
Operating Manual-1003836-EN-10
}Safety relays

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
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.
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 po4p
1003836-EN-10 | 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 ....................................................................................................................12
Safety characteristic data ......................................................................................................... 15
Supplementary data ..............................................................................................................15
Service life graph ...................................................................................................................... 16
Remove plug-in terminals ..................................................................................................... 17
Order reference ......................................................................................................................17
EC declaration of conformity ................................................................................................ 18
UKCA-Declaration of Conformity ......................................................................................... 18

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Introduction
Validity of documentation
This documentation is valid for the product PNOZ po4p. 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 PNOZ po4p 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 and EN60204-1.
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 [ 15] can only be achieved if the base unit also exhibits these safety charac-
teristic values.
Improper use
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 operating manual,
}Use of the product outside the technical details (see Technical details [ 12]).
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 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.

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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).
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.

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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
*Safe separation from non-marked area in accordance with EN 60947-1,
6 kV, basic insulation between all safety contacts.

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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 po4p.
The base unit/control module and the expansion modules are connected using the jump-
ers 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

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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 po4p
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 [ 12]" 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 [ 12]).
}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.
}Adequate protection must be provided on all output contacts with capacitive and inductive
loads.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.

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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
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.
Open the safety contacts (switch off output) and start the device again, so that the internal
diagnostics can check that the safety contacts open correctly
}for SIL CL 3/PL e at least 1x per month
}for SIL CL 2/PL d at least 1x per year
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.
CH1
Channel 1 safety contacts are closed.

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CH2
Channel 2 safety contacts are closed.
FAULT
Contact malfunction
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 circuit
has opened.
Dimensions in mm
94 (3.70") 22,5
131 (5.16") 121 (4.76")
(0.88")

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Technical details
General
Certifications CCC, CE, EAC, TÜV, UKCA, cULus Listed
Electrical data
Supply voltage
Voltage 24 V
Kind DC
Power consumption 2 W
Duty cycle 100 %
Relay outputs
Number of output contacts
Safety contacts (N/O), instantaneous 4
Max. short circuit current IK 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1
Utilisation category of safety contacts
AC1 at 240 V
Min. current 0,03 A
Max. current 4 A
Max. power 960 VA
DC1 at 24 V
Min. current 0,03 A
Max. current 4 A
Max. power 96 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 240 V
Max. current 4 A
DC13 (6 cycles/min) at 24 V
Max. current 4 A
Utilisation category in accordance with UL
Voltage 240 V AC G. P.
With current 4 A
Voltage 24 V DC Resistive
With current 4 A
Pilot Duty B300, R300
External contact fuse protection, safety contacts
In accordance with the standard EN 60947-5-1
Blow-out fuse, quick 6 A
Blow-out fuse, slow 4 A
Blow-out fuse, gG 6 A
Circuit breaker 24V AC/DC, characteristic B/C 4 A
Conventional thermal current 4 A

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Relay outputs
Contact material AgSnO2 + 0,2 µm Au
Times
Switch-on delay
With automatic start typ. 22 ms
With automatic start max. 35 ms
Delay-on de-energisation
With E-STOP typ. 18 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 61000-6-3, 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
Housing IP30
Terminals IP20
Mounting area (e.g. control cabinet) IP54
Mechanical data
Mounting position horizontally on mounting rail
Mechanical life 10,000,000 cycles
Material
Bottom PPO UL 94 V1
Top ABS UL 94 V0
Connection type Screw terminal
Mounting type plug-in

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Operating Manual PNOZ po4p
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Mechanical data
Conductor cross section with screw terminals
1 core flexible 0,25 - 2,5 mm², 24 - 12 AWG
2 core with the same cross section, flexible with
crimp connectors, no plastic sleeve 0,25 - 1 mm², 24 - 16 AWG
2 core with the same cross section, flexible without
crimp connectors or with TWIN crimp connectors 0,2 - 2,5 mm², 24 - 16 AWG
Torque setting with screw terminals 0,5 Nm
Stripping length with screw terminals 8 mm
Dimensions
Height 94 mm
Width 22,5 mm
Depth 121 mm
Weight 230 g
Where standards are undated, the 2020-07 latest editions shall apply.

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Safety characteristic data
NOTICE
You must comply with the safety characteristic data in order to achieve the
required safety level for your plant/machine.
Operating
mode
EN ISO
13849-1:
2015
PL
EN ISO
13849-1:
2015
Category
EN62061
SIL CL
EN62061
PFHD [1/h]
IEC61511
SIL
IEC61511
PFD
EN ISO
13849-1:
2015
TM [year]
–PL e Cat. 4 SIL CL 3 2,31E-09 SIL 3 2,03E-06 20
Explanatory notes for the safety-related characteristic data:
}The SIL CL value in accordance with EN 62061 corresponds to the SIL value in accord-
ance with EN 61508.
}TM is the maximum mission time in accordance with EN ISO 13849-1. The value also ap-
plies as the retest interval in accordance with EN 61508-6 and IEC 61511 and as the
proof test interval and mission time in accordance with EN 62061.
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 switch frequency and the load of the relay output.
If the service life graphs are not accessible, the stated PFH value can be used irrespective
of the switch 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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1003836-EN-10 | 16
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.
Switching current (A)
Number of cycles
Example
}Inductive load: 1 A,
}Utilisation category: AC15
}Contact service life: 400 000 cycles
Provided the application to be implemented requires fewer than 400 000 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.

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1003836-EN-10 | 17
Remove plug-in terminals
Procedure
}Insert a suitable screwdriver into the housing recess behind the terminal.
Do not remove the terminals by pulling the cables!
}Lever the terminal out.
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 po4p Screw terminals 773635

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Operating Manual PNOZ po4p
1003836-EN-10 | 18
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
UKCA-Declaration of Conformity
This product(s) complies with following UK legislation: Supply of Machinery (Safety) Regu-
lation 2008.
The complete UKCA Declaration of Conformity is available on the Internet at www.pilz.com/
support/downloads.
Representative: Pilz Automation Technology, Pilz House, Little Colliers Field,
Corby, Northamptonshire, NN18 8TJ United Kingdom, eMail: [email protected]

We are represented internationally. Please refer to our homepage www.pilz.com
for further details or contact our headquarters.
Headquarters: Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: [phone], Telefax: [phone], E-Mail: [email protected], Internet: www.pilz.com
CECE®, CHRE®, CMSE®, InduraNET p®, Leansafe®, Master of Safety®, Master of Security®, PAS4000®, PAScal®, PASconfig®, Pilz®, PIT®, PLID®, PMCprimo®, PMCprotego®, PMCtendo®,
PMD®, PMI®, PNOZ®, PRBT®, PRCM®, Primo®, PRTM®, 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.
1800XXXX-en-0X, 2021-01 Printed in Germany
© Pilz GmbH & Co. KG, 2021
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1003836-EN-10, 2022-06 Printed in Germany © Pilz GmbH & Co. KG, 2019