Pilz PNOZ 16 User manual

PNOZ 16
Operating Manual-1003517-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 16
1003517-EN-09 | 3
Introduction ............................................................................................................................5
Validity of documentation.......................................................................................................... 5
Using the documentation .......................................................................................................... 5
Definition of symbols................................................................................................................. 5
Safety ...................................................................................................................................... 6
Intended use ............................................................................................................................. 6
Safety regulations ..................................................................................................................... 6
Safety assessment ................................................................................................................... 6
Use of qualified personnel ........................................................................................................ 7
Warranty and liability ................................................................................................................ 7
Disposal .................................................................................................................................... 7
For your safety.......................................................................................................................... 7
Unit features ...........................................................................................................................8
Safety features ....................................................................................................................... 8
Block diagram/terminal configuration ................................................................................. 8
Function Description ............................................................................................................. 9
Operating modes ...................................................................................................................... 9
Timing diagram ......................................................................................................................... 10
Installation ..............................................................................................................................10
Wiring ......................................................................................................................................11
Preparing for operation ......................................................................................................... 12
Operation ................................................................................................................................14
Status indicators ....................................................................................................................... 14
Faults – Interference .............................................................................................................. 14
Dimensions in mm .................................................................................................................15
Technical Details Order No. 774060-774062 ........................................................................ 15
Technical details Order no. 774063-774064 ........................................................................ 19
Technical Details Order No. 774066-774067 ........................................................................ 24
Safety characteristic data ..................................................................................................... 28
Supplementary data ..............................................................................................................29
Service life graph ...................................................................................................................... 29

Contents
Operating Manual PNOZ 16
1003517-EN-09 | 4
Order reference ......................................................................................................................30
EC declaration of conformity ................................................................................................ 30

PNOZ 16
Operating Manual PNOZ 16
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Introduction
Validity of documentation
This documentation is valid for the product PNOZ 16. 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 16 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:
}E-STOP pushbuttons
}Safety gates
}Pressure sensitive mats
}Pressure sensitive edges
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).
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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Operating Manual PNOZ 16
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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
}Positive-guided relay outputs:
– 2 safety contacts (N/O), instantaneous
}Connection options for:
– E-STOP pushbuttons
– Safety gate limit switches
– Start button
– Pressure sensitive edges
– Pressure sensitive mats
}LED indicator for:
– Supply voltage
– Switch state of the safety contacts
– Detection of shorts across contacts, pressure sensitive mat
}See order reference for unit types
Safety features
The safety relay meets the following safety requirements:
}The circuit is redundant with built-in self-monitoring.
}The safety function remains effective in the case of a component failure.
}The correct opening and closing of the safety function relays is tested automatically in
each on-off cycle.
Block diagram/terminal configuration
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)

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Function Description
The safety relay PNOZ 16 provides a safety-oriented interruption of a safety circuit. When
supply voltage is supplied the "POWER" LED is lit. The unit is ready for operation when the
feedback loop Y1-Y2 and the start circuit S33-S34 are closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– The LEDs "CH.1" and "CH.2" are lit.
– Safety contacts 13-14 and 23-24 are closed. The unit is active.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– The LEDs "CH.1" and "CH.2" go out.
– Safety contacts 13-14 and 23-24 are redundantly opened.
Operating modes
}Single-channel operation: No redundancy in the input circuit, earth faults in the start and
input circuit are detected.
}Dual-channel operation with detection of shorts across contacts: Redundant input circuit,
PNOZ 16 detects
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– shorts across contacts in the input circuit.
}Automatic start: Unit is active once the input circuit has been closed.
}Manual start: Unit is active once the input circuit and the start circuit are closed.
}Operating with pressure sensitive mat: When the pressure sensitive mat is actuated, a
short is formed between the inputs and internal fault detection is energised. Safety con-
tacts open and the "EXT.FAULT" LED is lit. If the pressure sensitive mat is cleared and
supply voltage is maintained, the unit is ready for operation again once the recovery time
has elapsed.
}Increase in the number of available contacts by connecting contact expandsion modules
or external contactors/relays.

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Timing diagram
[1] [2]
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}FAULT: Short across contacts in the input circuit due to actuation of pressure sensitive
mat
}[1]: Automatic start
}[2]: Manual start
}a: Input circuit closes before start circuit
}b: Start circuit closes before input circuit
}t1: Switch-on delay
}t2: Delay-on de-energisation
}t3: Recovery time after short across contacts
Installation
}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).

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Wiring
Please note:
}Information given in the "Technical details" must be followed.
}The outputs 13-14, 23-24 are safety contacts.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details)
Rl/km = cable resistance/km
}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.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}Adequate protection must be provided on all output contacts with capacitive and inductive
loads.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}With a 24 VDC supply voltage via terminals B1, B2, the power supply must comply with
the regulations for extra low voltages with safe electrical separation (SELV, PELV).
Important for detection of shorts across contacts:
As this function for detecting shorts across contacts is not failsafe, it is tested by Pilz during
the final control check. If there is a danger of exceeding the cable length, we recommend
the following test once the unit is installed:
1. Unit ready for operation (output contacts closed)
2. Short circuit the test terminals S22, S32 for detecting shorts across the inputs.
3. The unit‘s fuse must be triggered and the output contacts must open. Cable lengths in
the scale of the maximum length can delay the fuse triggering for up to 2 minutes.
4. Reset the fuse: Remove the short circuit and switch off the supply voltage for approx. 1
minute.

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Preparing for operation
Supply voltage AC DC
FE
B1
B2
L+
L-
Input circuit Single-channel Dual-channel
E-STOP
without detection of shorts across
contacts
S1
S22
S21
S12
S32
S11
S31
E-STOP
with detection of shorts across
contacts
S1
S22
S31
S32
S21
S12
S11
Safety gate
without detection of shorts across
contacts
S1
S22
S21
S12
S32
S11
S31
Safety gate
with detection of shorts across
contacts
Short circuit-forming pressure
sensitive mat/edge
S12
S11
S22
S32
S21
S31

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NOTICE
With single-channel wiring the safety level of your machine/plant may be
lower than the safety level of the unit (see Safety characteristic data).
NOTICE
The overall system PNOZ 16 and the short circuit-forming pressure sensit-
ive mat or edge has to be assessed in accordance with the product stand-
ard EN ISO 13856-1 and/or EN ISO 13856-2.
Start circuit Automatic start Manual start
S33
S34
S3
NOTICE
In the event of an automatic start or manual start with bridged start
contact (fault):
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 Without feedback loop monitor-
ing
With feedback loop monitoring
Link or contacts from external
contactors
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed

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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.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
EXT. FAULT
Short across contacts when operating with pressure sensitive mat.
Faults – Interference
}Earth fault: The supply voltage fails and the safety contacts open. Once the cause of the
respective fault has been rectified and the supply voltage is switched off for approx.
1minute, the unit is ready for operation again.
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
}LED "POWER" does not light: Short circuit or no supply voltage.

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Dimensions in mm
121 (4.76")
75 (2.95")
87 (3.42")
45
(1.77")
Technical Details Order No. 774060-774062
General 774060 774061 774062
Certifications
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
Electrical data 774060 774061 774062
Supply voltage
Voltage 24 V 42 V 48 V
Kind AC AC AC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (AC) 3,5 VA 3,5 VA 3,5 VA
Frequency range AC 50 - 60 Hz 50 - 60 Hz 50 - 60 Hz
Supply voltage
Voltage 24 V 24 V 24 V
Kind DC DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (DC) 2 W 2 W 2 W
Residual ripple DC 20 % 20 % 20 %
Duty cycle 100 % 100 % 100 %
Inputs 774060 774061 774062
Number 222
Voltage at
Input circuit DC 24 V 24 V 24 V
Start circuit DC 24 V 24 V 24 V
Feedback loop DC 24 V 24 V 24 V

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Inputs 774060 774061 774062
Current at
Input circuit DC 25 mA 25 mA 25 mA
Start circuit DC 25 mA 25 mA 25 mA
Feedback loop DC 25 mA 25 mA 25 mA
Min. input resistance at
power-on 49 Ohm 49 Ohm 49 Ohm
Max. overall cable resist-
ance Rlmax
Single-channel at UB
DC 40 Ohm 40 Ohm 40 Ohm
Single-channel at UB
AC 40 Ohm 40 Ohm 40 Ohm
Dual-channel with de-
tection of shorts across
contacts at UB DC 80 Ohm 80 Ohm 80 Ohm
Dual-channel with de-
tection of shorts across
contacts at UB AC 80 Ohm 80 Ohm 80 Ohm
Max. safety mat resist-
ance 80 Ohm 80 Ohm 80 Ohm
Relay outputs 774060 774061 774062
Number of output con-
tacts
Safety contacts (N/O),
instantaneous 222
Max. short circuit current
IK 1 kA 1 kA 1 kA
Utilisation category
In accordance with the
standard EN 60947-4-1 EN 60947-4-1 EN 60947-4-1
Utilisation category of
safety contacts
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W
Utilisation category
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1

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Relay outputs 774060 774061 774062
Utilisation category of
safety contacts
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 6 A 6 A 6 A
Utilisation category in ac-
cordance with UL
Voltage 240 V AC G. P. 240 V AC G. P. 240 V AC G. P.
With current 8 A 8 A 8 A
Pilot Duty C300, R300 C300, R300 C300, R300
External contact fuse pro-
tection, safety contacts
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
Max. melting integral 240 A²s 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A 10 A
Blow-out fuse, slow 6 A 6 A 6 A
Blow-out fuse, gG 10 A 10 A 10 A
Circuit breaker 24V
AC/DC, characteristic
B/C 6 A 6 A 6 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Conventional thermal
current while loading
several contacts
774060 774061 774062
Ith per contact at UB AC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact 8 A 8 A 8 A
Conv. therm. current
with 2 contacts 6 A 6 A 6 A
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact 8 A 8 A 8 A
Conv. therm. current
with 2 contacts 6 A 6 A 6 A

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Times 774060 774061 774062
Switch-on delay
With automatic start
typ. 230 ms 230 ms 230 ms
With automatic start
max. 350 ms 350 ms 350 ms
With automatic start
after power on typ. 310 ms 310 ms 310 ms
With automatic start
after power on max. 450 ms 450 ms 450 ms
With manual start typ. 230 ms 230 ms 230 ms
With manual start max. 350 ms 350 ms 350 ms
Delay-on de-energisation
With E-STOP typ. 18 ms 18 ms 18 ms
With E-STOP max. 30 ms 30 ms 30 ms
With power failure typ. 50 ms 50 ms 50 ms
With power failure max. 100 ms 100 ms 100 ms
Recovery time at max.
switching frequency 1/s
After E-STOP 50 ms 50 ms 50 ms
After power failure 100 ms 100 ms 100 ms
Supply interruption before
de-energisation 20 ms 20 ms 20 ms
Simultaneity, channel 1
and 2 max. ∞∞∞
Environmental data 774060 774061 774062
Climatic suitability EN 60068-2-78 EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C -10 - 55 °C -10 - 55 °C
Storage temperature
Temperature range -40 - 85 °C -40 - 85 °C -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during op-
eration Not permitted Not permitted Not permitted
EMC EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
Vibration
In accordance with the
standard EN 60068-2-6 EN 60068-2-6 EN 60068-2-6
Frequency 10 - 55 Hz 10 - 55 Hz 10 - 55 Hz
Amplitude 0,35 mm 0,35 mm 0,35 mm
Airgap creepage
In accordance with the
standard EN 60947-1 EN 60947-1 EN 60947-1
Overvoltage category III / II III / II III / II
Pollution degree 222
Rated insulation voltage 250 V 250 V 250 V

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Environmental data 774060 774061 774062
Rated impulse withstand
voltage 4 kV 4 kV 4 kV
Protection type
Housing IP40 IP40 IP40
Terminals IP20 IP20 IP20
Mounting area (e.g.
control cabinet) IP54 IP54 IP54
Mechanical data 774060 774061 774062
Mounting position Any Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles 10,000,000 cycles
Material
Bottom PPO UL 94 V0 PPO UL 94 V0 PPO UL 94 V0
Front ABS UL 94 V0 ABS UL 94 V0 ABS UL 94 V0
Top PPO UL 94 V0 PPO UL 94 V0 PPO UL 94 V0
Connection type Screw terminal Screw terminal Screw terminal
Mounting type Fixed Fixed Fixed
Conductor cross section
with screw terminals
1 core flexible 0,2 - 4 mm², 24 - 10 AWG 0,2 - 4 mm², 24 - 10 AWG 0,2 - 4 mm², 24 - 10 AWG
2 core with the same
cross section, flexible
with crimp connectors,
no plastic sleeve
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
2 core with the same
cross section, flexible
without crimp connect-
ors or with TWIN crimp
connectors
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
Torque setting with screw
terminals 0,6 Nm 0,6 Nm 0,6 Nm
Stripping length with
screw terminals 8 mm 8 mm 8 mm
Dimensions
Height 87 mm 87 mm 87 mm
Width 45 mm 45 mm 45 mm
Depth 121 mm 121 mm 121 mm
Weight 335 g 335 g 335 g
Where standards are undated, the 2020-07 latest editions shall apply.
Technical details Order no. 774063-774064
General 774063 774064
Certifications
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed

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Electrical data 774063 774064
Supply voltage
Voltage 110 V 115 V
Kind AC AC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(AC) 3,5 VA 3,5 VA
Frequency range AC 50 - 60 Hz 50 - 60 Hz
Supply voltage
Voltage 24 V 24 V
Kind DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(DC) 2 W 2 W
Residual ripple DC 20 % 20 %
Duty cycle 100 % 100 %
Inputs 774063 774064
Number 2 2
Voltage at
Input circuit DC 24 V 24 V
Start circuit DC 24 V 24 V
Feedback loop DC 24 V 24 V
Current at
Input circuit DC 25 mA 25 mA
Start circuit DC 25 mA 25 mA
Feedback loop DC 25 mA 25 mA
Min. input resistance at power-on 49 Ohm 49 Ohm
Max. overall cable resistance Rl-
max
Single-channel at UB DC 40 Ohm 40 Ohm
Single-channel at UB AC 40 Ohm 40 Ohm
Dual-channel with detection of
shorts across contacts at UB DC 80 Ohm 80 Ohm
Dual-channel with detection of
shorts across contacts at UB AC 80 Ohm 80 Ohm
Max. safety mat resistance 80 Ohm 80 Ohm
Relay outputs 774063 774064
Number of output contacts
Safety contacts (N/O), instant-
aneous 2 2
Max. short circuit current IK 1 kA 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1 EN 60947-4-1