Pilz PNOZ mo5p User manual

PNOZ mo5p
Operating Manual-1001353-EN-05
}Configurable safety systems PNOZmulti

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 mo5p
1001353-EN-05 3
Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Scope 7
2.2 Unit features 7
2.3 Front view 7
Section 3 Safety 8
3.1 Intended use 8
3.2 System requirements 8
3.3 Safety regulations 8
3.3.1 Safety assessment 8
3.3.2 Use of qualified personnel 9
3.3.3 Warranty and liability 9
3.3.4 Disposal 9
3.3.5 For your safety 9
Section 4 Function description 10
4.1 Integrated protection mechanisms 10
4.2 Operation 10
4.3 System reaction time 10
4.4 Block diagram 10
Section 5 Installation 11
5.1 General installation guidelines 11
5.2 Dimensions in mm 11
5.3 Connecting the base unit and expansion modules 12
Section 6 Commissioning 13
6.1 General wiring guidelines 13
6.2 Connection 13
6.3 Connection example 14
6.4 Download modified project to the PNOZmulti system 15
Section 7 Operation 16
7.1 LED indicators 16
7.2 Function test of the relay outputs 16
Section 8 Technical details 17
8.1 Safety characteristic data 20
Section 9 Supplementary data 21
9.1 Service life graph for the relay contacts 21

Contents
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Section 10 Order reference 23
10.1 Product 23
10.2 Accessories 23

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PNOZ mo5p. 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.
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
}Expansion module PNOZ mo5p
}Jumper
2.2 Unit features
The product has the following features:
}Can be configured in the PNOZmulti Configurator
}Positive-guided relay outputs, diverse:
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
}Suitable for controlling the safety valves on a burner in accordance with EN 50156
}Status indicators
}Plug-in connection terminals (either cage clamp terminal or screw terminal)
}Max. 8 expansion modules and one fieldbus module can be connected to a base unit. A
max. 6 of these may be the expansion modules PNOZ mo5p, PNOZ mo4p, PNOZ
mo2p and PNOZ mo1p.
2.3 Front view
77353
5
Key:
}O0 – O3
Relay outputs

Safety
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3 Safety
3.1 Intended use
The expansion module may only be connected to a base unit from the PNOZmulti system
(please refer to the document "PNOZmulti System Expansion" for details of the base units
that can be connected).
The configurable small control systems PNOZmulti are used for the safety-related interrup-
tion of safety circuits and are designed for use in:
}E-STOP equipment
}Safety circuits in accordance with VDE0113 Part 1 and EN60204-1
The relay outputs are diverse in design and so are also suitable for controlling safety valves
on a burner in accordance with EN 50156.
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 [ 17]).
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.
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.

Safety
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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 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.
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-re-
lated 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:
}This operating manual only describes the basic functions of the unit. The expanded
functions 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
insulation compared with all other circuits in the safety system.
}A defective relay contact will be detected during switching.
}The relays are diverse in design.
4.2 Operation
The expansion module provides additional relay outputs.
The function of the outputs on the safety system depends on the safety circuit created us-
ing the PNOZmulti Configurator. A chip card 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 safety 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
Interface
to previous
module
Interface
to next
module
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 control system should be installed in a control cabinet with a protection type of at
least IP54. Fit the control system to a horizontal mounting rail. The venting slots must
face upward and downward. Other mounting positions could destroy the control system.
}Use the locking elements on the rear of the unit to attach it to a mounting rail. Connect
the control system to the mounting rail in an upright position, so that the earthing
springs on the control system are pressed on to the mounting rail.
}The ambient temperature of the devices in the control cabinet must not exceed the fig-
ure stated in the technical details. Air conditioning may otherwise be required.
}To comply with EMC requirements, the mounting rail must have a low impedance con-
nection to the control cabinet housing.
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
94 (3.70")
22,5
(0.88")
121 (4.76")

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 [ 17] must be followed.
}The position of the expansion module is specified in the Hardware configuration of the
PNOZmulti Configurator.
}Use copper wire that can withstand 75°C.
6.2 Connection
Redundant
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
single
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
Feedback loop Redundant output
Contacts from external contactors
O1 (3) K1
L1
N
K2
14 (34)
13 (33)
23 (43)
24 (44)
O0 (2)
L+
I0

Commissioning
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1001353-EN-05 14
Connecting the safety valves on a burner in accordance with EN 50156
230 V AC
Interface
to previous
module
Interface
to next
module
O0 O1
13 23
14 24
O2 O3
33 43
34 44
6.3 Connection example
I0 I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 I13 I14 I15 I16 I17 I18 I19 A1 A1 A2 A2
CI+ CI- CO- CO+ T0 T1 T2 T3 O0 O1 O2 O3 OA0 24V 24V 0V 0V 13 14 23 24
K3
K4
S1
K2
K1
S3
L+
L-
13 14 23 24
S2
PNOZ m1p
PNOZ mo5p
K1
K2
K4
K3
33 34 43 44
K6
K5
K5
K6

Commissioning
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1001353-EN-05 15
6.4 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 using the PNOZmulti Configurator. Proceed as described in the operat-
ing 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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1001353-EN-05 16
7 Operation
When the supply voltage is switched on, the PNOZmulti safety system copies the configur-
ation from the chip card.
The LEDs “POWER”, “DIAG”, “FAULT”, “IFAULT” and “OFAULT” will light up on the base
unit.
The PNOZmulti safety 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
Basis PNOZ mo5p
Error
Input Ix
Run
Diag
Fault
IFAULT
OFAULT
CI
CO
Fault
IN/OUT
External error on the output, e.g. defective feed-
back loop
Internal error on the expansion module
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
Approvals BG, CCC, CE, EAC (Eurasian), TÜV, cULus Listed
Electrical data
Supply voltage
for Module supply
internal Via base unit
Voltage 5,0 V
Kind DC
Voltage tolerance -2 %/+2 %
Power consumption 3,5 W
Status indicator LED
Relay outputs
Utilisation category
In accordance with the standard EN 60947-4-1
Utilisation category of safety contacts
AC1 at 240 V
Min. current 10,00 mA
Max. current 1,5 A
Max. power 360 VA
DC1 at 24 V
Min. current 10,00 mA
Max. current 6,0 A
Max. power 144 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 230 V
Max. current 0,6 A
Max. power 138 W
DC13 (6 cycles/min) at 24 V
Max. current 0,4 A
Max. power 9 W
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 EN 60947-5-1
Blow-out fuse, quick 6 A
Blow-out fuse, slow 6,00 A
Circuit breaker 24V AC/DC, characteristic B/C 6 A
Switch-off delay 50 ms
Conventional thermal current 12,0 A

Technical details
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Times
Switch-on delay 5,00 s
Supply interruption before de-energisation 20 ms
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
Humidity 93 % r. h. at 40 °C
Condensation during operation Not permitted
EMC EN 61131-2
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10,0 - 150,0 Hz
Acceleration 1g
Shock stress
In accordance with the standard EN 60068-2-27
Acceleration 15g
Duration 11 ms
Max. operating height above sea level 2000 m
Airgap creepage
In accordance with the standard EN 61131-2
Overvoltage category III
Pollution degree 2
Rated insulation voltage 250 V
Rated impulse withstand voltage 6,00 kV
Protection type
In accordance with the standard EN 60529
Mounting area (e.g. control cabinet) IP54
Housing IP20
Terminals IP20
Mechanical data
Mounting position Horizontal on top hat rail
DIN rail
Top hat rail 35 x 7,5 EN 50022
Recess width 27 mm
Material
Bottom PPO UL 94 V0
Front ABS UL 94 V0
Connection type Spring-loaded terminal, screw terminal

Technical details
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Mechanical data
Conductor cross section with screw terminals (relay
outputs)
1 core flexible 0,25 - 2,50 mm², 24 - 12 AWG
2 core with the same cross section, flexible without
crimp connectors or with TWIN crimp connectors 0,25 - 1,50 mm², 24 - 16 AWG
Torque setting with screw terminals (relay outputs) 0,50 Nm
Stripping length with screw terminals (relay outputs) 8 mm
Conductor cross section with spring-loaded terminals
(relay outputs)
1 core flexible without crimp connector 0,25 - 2,50 mm², 24 - 12 AWG
1 core flexible with crimp connector 0,25 - 1,50 mm², 24 - 16 AWG
Spring-loaded terminals: Terminal points per connec-
tion 1
Stripping length with spring-loaded terminals (relay
outputs) 10 mm
Dimensions
Height 94,0 mm
Width 22,5 mm
Depth 121,0 mm
Weight 198 g
Where standards are undated, the 2009-01 latest editions shall apply.

Technical details
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8.1 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:
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]
1-channel PL c Cat. 1 - 2,90E-08 - 2,60E-03 20
2-channel PL e Cat. 4 SIL CL 3 3,00E-10 SIL 3 5,20E-07 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.
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.