Pilz PNOZ 8 User manual

PNOZ 8
Operating Manual 22152-EN-03
}Safety relays

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
Operating Manual PNOZ 8
22152-EN-03 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 5
Warranty and liability 6
Disposal 6
For your safety 6
Unit features 7
Safety features 7
Block diagram/terminal configuration 8
Types: AC 8
Type: DC 8
Function Description 9
Operating modes 9
Timing diagram 10
Installation 10
Wiring 11
Preparing for operation 12
Operation 14
Status indicators 15
Faults – Interference 15
Dimensions in mm 15
Technical details 16
Safety characteristic data 20
Supplementary data 21
Service life graph 22
Order reference 22
EC declaration of conformity 22

PNOZ 8
Operating Manual PNOZ 8
22152-EN-03 4
Introduction
Validity of documentation
This documentation is valid for the product PNOZ 8. 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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Operating Manual PNOZ 8
22152-EN-03 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The safety relay PNOZ 8 provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN 60947-5-1, EN 60204-1 and VDE 0113-1
and may be used in applications with
}E-STOP pushbuttons
}Safety gates
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 [ 16]).
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 unit it is necessary to perform a safety assessment in accordance with the
Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.

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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.
Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended
}Damage can be attributed to not having followed the guidelines in the manual
}Operating personnel are not suitably qualified
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
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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Operating Manual PNOZ 8
22152-EN-03 7
Unit features
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}2 semiconductor outputs
}Connection options for:
– E-STOP pushbutton
– Safety gate limit switch
– Start button
}Reset button for resetting after a short circuit
}LED indicator for:
– Supply voltage
– Switch state of the safety contacts
– Error
}Semiconductor outputs signal:
– Switch state of the safety contacts
– Error
}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.

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Block diagram/terminal configuration
Types: AC
}UB: 110 VAC; Order no. 774764
}UB: 230 VAC; Order no. 774768
Y37
Y36
A1 A2 S52
Feed-
back/
Start
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Type: DC
}UB: 24 VDC; Order no. 774760
Y37
A1 A2 Y36 S52
A3
Feed-
back/
Start
*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 8 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 S12-Y1 are closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– Safety contacts 13-14, 23-24 and 33-34 are closed, auxiliary contact 41-42 is open.
The unit is active.
– The LEDs "CH.1" and "CH.2" are lit.
– A high signal is present at the semiconductor output switch state Y32.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– Safety contacts 13-14, 23-24 and 33-34 are opened redundantly, auxiliary contact
41-42 is closed.
– The LEDs "CH.1" and "CH.2" go out.
– A low signal is present at the semiconductor output switch state Y32.
Semiconductor output fault Y35
}A low signal is present at semiconductor output Y35 if the supply voltage is present and
the internal fuse (circuit breaker) has not blown. If there is a fault on the safety relay, a
high signal is present at Y35, the "FAULT" LED lights. Once the cause of the fault has
been removed, the fuse must be reset via the reset pushbutton.
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 cir-
cuit, PNOZ 8 detects
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– shorts across contacts in the input circuit.
}Dual-channel operation without detection of shorts across contacts: Redundant input
circuit, detects PNOZ 8
– earth faults in the start and input circuit,
– short circuits 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.
}Monitored start: Unit is active once
– the input circuit is closed and then the start circuit is closed and opened again.
– the start circuit is closed and then opened again once the input circuit is closed.
}Increase in the number of available contacts by connecting contact expander modules
or external contactors/relays.

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Timing diagram
Out semi OUT
Out semi FAULT
[2] [3][1]
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}Output aux: Auxiliary contacts
}Out semi FAULT: Semiconductor output fault
}Out semi OUT: Semiconductor output switch state
}[1]: Automatic start
}[2]: Manual start
}[3]: Monitored 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
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.
}Ensure the unit is mounted securely on a vertical DIN rail (35 mm) by using a fixing ele-
ment (e.g. retaining bracket or an end angle).

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Wiring
Please note:
}Information given in the "Technical details [ 16]" must be followed.
}Outputs 13-14, 23-24, 33-34 are safety contacts; output 41-42 is an auxiliary contact
(e.g. for display).
}Auxiliary contact 41-42 shouldnot be used for safety circuits!
}Do not connect undesignated terminals.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 16]).
}Calculation of the max. cable runs lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 16])
Rl/km = cable resistance/km
}Use copper wire that can withstand 60/75°C.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}Ensure the wiring and EMC requirements of IEC 60204-1 are met.
}On 24 VDC devices:
The power supply must comply with the regulations for extra low voltages with protect-
ive electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.
}Terminals S11 and Y36 are linked internally and either can be used.
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 runs, we recommend the
following test after the installation of the device:
1. Unit ready for operation (output contacts closed)
2. Short circuit the test terminals S12, S22 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
A1
A2
L1
N
FE
A1
A2
L+
L-
Input circuit Single-channel Dual-channel
E-STOP
without detection of shorts
across contacts
S1
S22
S21
S11
S52
S12
S11
E-STOP
with detection of shorts across
contacts
S1
S22
S21
S12
S11
S52
Y36
Safety gate
without detection of shorts
across contacts
S1
S22
S21
S11
S52
S12
S1 S2
S22
S21
S11
S12
S52
Safety gate
with detection of shorts across
contacts
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 [ 20]).

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Start circuit
E-STOP wiring/safety gate
(single-channel, dual-channel
without detection of shorts
across contacts)
E-STOP wiring/safety gate (dual-
channel without detection of
shorts across contacts)
Automatic start
S12 (Y36)
Y1
S12
Y1
Automatic start, Safety gate dual-
channel, simultaneity: ∞
S11
S12
Y37Y1
S11
S12
Y37Y1
Manual start
S12 (Y36)
Y1
S12
Y1
Monitored start
S12 (Y36)
Y37
Y1
Y2
S12
Y37
Y1
Y2
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 with feedback loop monitoring without feedback loop monitoring
Link or contacts from external
contactors

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Semiconductor output
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed
Operation
NOTICE
Check each safety function
– after initial commissioning and after each change of the machine/
plant
– for SIL CL 3/PL e at least 1x per month, for SIL CL 2/PL d at least 1x
per year
Follow the instructions below:
– Activate the safety function and check whether all the used safety
contacts open.
– Prepare for operation again and start the unit. All the used safety
contacts must be closed again.
The safety functions may only be checked by qualified personnel.

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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.
FAULT
Short circuit: internal fuse has blown.
Faults – Interference
}Earth fault/short circuit: an internal fuse interrupts the supply voltage, the safety con-
tacts are opened and the "FAULT" LED is lit. Once the cause of the fault has been re-
moved, press the reset button to reset the fuse. On AC units, a magnetic circuit breaker
is used as an internal fuse; on DC units, a thermal circuit breaker is used as an internal
fuse.
}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.
Dimensions in mm
121 (4.76")
75 (2.95")
87 (3.42")
90 (3.54")

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Technical details
Order no. 774760 – 774768
General 774760 774764 774768
Approvals
CCC, EAC (Eurasian),
TÜV, cULus Listed
CCC, EAC (Eurasian),
TÜV, cULus Listed
CCC, EAC (Eurasian),
TÜV, cULus Listed
Electrical data 774760 774764 774768
Supply voltage
Voltage 24 V 110 V 230 V
Kind DC AC AC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (AC) – 6 VA 6 VA
Output of external
power supply (DC) 4,5 W – –
Frequency range AC – 50 - 60 Hz 50 - 60 Hz
Residual ripple DC 160 % – –
Duty cycle 100 % 100 % 100 %
Max. inrush current im-
pulse
Current pulse, A1 11 A – –
Pulse duration, A1 0,5 ms – –
Inputs 774760 774764 774768
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
Current at
Input circuit DC 30 mA 30 mA 30 mA
Start circuit DC 40 mA 40 mA 40 mA
Feedback loop DC 40 mA 40 mA 40 mA
Max. overall cable resist-
ance Rlmax
Single-channel at UB
DC 100 Ohm – –
Single-channel at UB
AC – 200 Ohm 200 Ohm
Dual-channel with de-
tection of shorts across
contacts at UB DC 8 Ohm – –
Dual-channel with de-
tection of shorts across
contacts at UB AC – 20 Ohm 20 Ohm
Semiconductor outputs 774760 774764 774768
Number 222
Voltage 24 V 24 V 24 V

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Semiconductor outputs 774760 774764 774768
Current 50 mA 50 mA 50 mA
External supply voltage 24 V 24 V 24 V
Voltage tolerance -20 %/+20 % -20 %/+20 % -20 %/+20 %
Short circuit-proof yes yes yes
Relay outputs 774760 774764 774768
Number of output con-
tacts
Safety contacts (N/O),
instantaneous 333
Auxiliary contacts (N/C) 111
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 of
auxiliary 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
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 7 A 7 A 7 A

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Relay outputs 774760 774764 774768
Utilisation category of
auxiliary 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 7 A 7 A 7 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
Voltage 24 V DC Resistive 24 V DC Resistive 24 V DC Resistive
With current 5 A 5 A 5 A
Pilot Duty B300, R300 B300, R300 B300, 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
External contact fuse pro-
tection, auxiliary contacts
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 24 V
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
774760 774764 774768
Ith per contact at UB AC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact – 8 A 8 A
Conv. therm. current
with 2 contacts – 8 A 8 A
Conv. therm. current
with 3 contacts – 7 A 7 A

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Conventional thermal
current while loading
several contacts
774760 774764 774768
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact 8 A – –
Conv. therm. current
with 2 contacts 8 A – –
Conv. therm. current
with 3 contacts 7 A – –
Times 774760 774764 774768
Switch-on delay
Typ. switch-on delay 150 ms 150 ms 150 ms
Max. switch-on delay 350 ms 350 ms 350 ms
Delay-on de-energisation
With E-STOP typ. 15 ms 15 ms 15 ms
With E-STOP max. 30 ms 30 ms 30 ms
With power failure typ. 100 ms 100 ms 100 ms
With power failure max. 200 ms 200 ms 200 ms
Recovery time at max.
switching frequency 1/s
After E-STOP 300 ms 300 ms 300 ms
Supply interruption before
de-energisation 20 ms 20 ms 20 ms
Fuse trigger delay 150 ms 350 ms 350 ms
Environmental data 774760 774764 774768
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

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Environmental data 774760 774764 774768
Rated insulation voltage 250 V 250 V 250 V
Rated impulse withstand
voltage 4 kV 4 kV 4 kV
Protection type
Mounting area (e.g.
control cabinet) IP54 IP54 IP54
Housing IP40 IP40 IP40
Terminals IP20 IP20 IP20
Mechanical data 774760 774764 774768
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
Dimensions
Height 87 mm 87 mm 87 mm
Width 90 mm 90 mm 90 mm
Depth 121 mm 121 mm 121 mm
Weight 450 g 600 g 600 g
Where standards are undated, the 2014-07 latest editions shall apply.
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.