Pilz PNOZ c1 User manual

PNOZ c1
Operating Manual-22197-EN-06
}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 c1
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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 ...........................................................................................................................6
Safety features ....................................................................................................................... 7
Block diagram/terminal configuration ................................................................................. 7
Function description ............................................................................................................. 7
Installation ..............................................................................................................................8
Wiring ......................................................................................................................................8
Connect cable with crimp connector......................................................................................... 9
Connect cable without crimp connector.................................................................................... 10
Disconnect cable ...................................................................................................................... 10
Preparing for operation ......................................................................................................... 11
Operation ................................................................................................................................12
Status indicators ....................................................................................................................... 12
Error indicators ......................................................................................................................... 13
Faults - malfunctions ............................................................................................................. 13
Dimensions in mm .................................................................................................................13
Technical details ....................................................................................................................14
Safety characteristic data ......................................................................................................... 18
Supplementary data ..............................................................................................................18
Service life graph ...................................................................................................................... 19
Order reference ......................................................................................................................20
EC Declaration of Conformity ............................................................................................... 20

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Introduction
Validity of documentation
This documentation is valid for the product PNOZ c1. 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 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
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 [ 14]).
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.
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.

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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.
Unit features
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}Connection options for:
– Emergency stop pushbuttons
– Safety gate limit switches
– Reset buttons
– PSENmech, PSENmag

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}LED for:
– Supply voltage
– Switch status channel 1
– Switch status channel 2
Safety features
The 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
InputInput
A1 A2 S21 S22
=
Power
Start
S11 S12
=
K1
K2
13 23 33
24 34
14
41
42
*
S33 S34
14
24
34
42
41
33
23
13
S34
S33
S22
S21
S12
S11
A2
A1
PNOZ c1
Ch. 1
Power
Ch. 2
* Insulation from non-marked area: Safe separation (overvoltage category III),
Insulation between relay contacts: basic insulation (overvoltage category III), safe separa-
tion (overvoltage category II)
Function description
When the supply voltage is supplied, the "POWER" LED illuminates. The unit is ready for
operation when the start circuit is closed.
}Input circuits closed (e.g. the E-STOP button is not pressed): The safety contacts are
closed and the auxiliary contact is open.
}Input circuit open (e.g. E-STOP operated): The safety contacts are open and the auxiliary
contact is closed.

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}Dual-channel operation with detection of shorts across contacts: redundant input circuit,
detects
– earth faults in the start and input circuit,
– shorts between 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 is closed and then the start circuit is
closed.
}Increase in the number of available contacts by connecting contact expandsion modules
or external contactors/relays.
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).
Wiring
Please note:
}Information given in the "Technical details" 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!
}To prevent contact welding, a fuse should be connected before the output contacts (see
see technical details [ 14]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see see technical details [ 14])
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.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}The power supply must comply with the regulations for extra low voltages with protective
electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.

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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.
Connect cable with crimp connector
}Strip the cable [1] and apply a crimp connector.
}Insert the stripped cable with the crimp connector applied into the terminal point [2] [3] as
far as it will go.
NOTICE
Do not use a tool to connect the cable.
[1] [2] [3]
10 mm
Fig.: Connect cable with crimp connector

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Connect cable without crimp connector
}Strip the cable [1].
}Using the screwdriver, press the actuator button [2] and insert the stripped cable into the
terminal point [2] [3] as far as it will go.
We recommend you use a screw driver with a 0.4 x 2.5 mm (DIN 5264) blade!
[1] [2] [3]
10 mm
Fig.: Connect cable without crimp connector
Disconnect cable
We recommend you use a screw driver with a 0.4 x 2.5 mm (DIN 5264) blade!
}Using the screwdriver, press the actuator button and pull the cable out of the terminal
point [4].
[4]
Fig.: Disconnect cable

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Preparing for operation
Supply voltage AC DC
A1
A2
L+
L-
Input circuit Single-channel Dual-channel
E-STOP with detection of shorts
across contacts
S1
S22
S21
S12
S11
Safety gate with detection of
shorts across contacts
S1 S2
S12
S11
S22
S21
Start circuit/feedback loop Start circuit Feedback loop
automatic start
Manual start
S33
S34
S3

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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.
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.
The unit is ready for operation when the Power LED is permanently lit.
LEDs indicate the status and errors during operation:
Status indicators
Legend
LED on
LED off
POWER
Supply voltage is present.
CH.1
Input S21-S22 is closed.
CH.2
Input S11-S12 is closed.

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Error indicators
All LEDs off
Diagnostics: Short across contacts/earth fault; unit switched off
}Remedy: Rectify short across contacts/earth fault, switch off supply voltage
for 1 min.
LED Power off
Diagnostics: Short circuit or supply voltage failure
}Remedy: Rectify short circuit or connect supply voltage.
Faults - malfunctions
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
Dimensions in mm
100
94.5
22.5

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Technical details
General
Certifications CCC, CE, EAC (Eurasian), TÜV, cULus Listed
Electrical data
Supply voltage
Voltage 24 V
Kind DC
Voltage tolerance -15 %/+10 %
Output of external power supply (DC) 2,5 W
Residual ripple DC 160 %
Duty cycle 100 %
Max. inrush current impulse
Current pulse, A1 1,8 A
Pulse duration, A1 4 ms
Inputs
Number 2
Voltage at
Input circuit DC 24 V
Start circuit DC 24 V
Feedback loop DC 24 V
Current at
Input circuit DC 30 mA
Start circuit DC 40 mA
Feedback loop DC 40 mA
Max. inrush current impulse
Current pulse, input circuit 0,35 A
Pulse duration, input circuit 25 ms
Current pulse, feedback loop 0,15 A
Pulse duration, feedback loop 2 ms
Current pulse, start circuit 0,15 A
Pulse duration, start circuit 2 ms
Min. input resistance at power-on 88 Ohm
Max. overall cable resistance Rlmax
Dual-channel with detection of shorts across con-
tacts at UB DC 15 Ohm
Relay outputs
Number of output contacts
Safety contacts (N/O), instantaneous 3
Auxiliary contacts (N/C) 1
Max. short circuit current IK 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1

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Relay outputs
Utilisation category of safety contacts
AC1 at 240 V
Min. current 0,01 A
Max. current 6 A
Max. power 1500 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 6 A
Max. power 150 W
Utilisation category of auxiliary contacts
AC1 at 240 V
Min. current 0,01 A
Max. current 6 A
Max. power 1500 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 6 A
Max. power 150 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 5 A
Utilisation category of auxiliary contacts
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 5 A
Utilisation category in accordance with UL
Voltage 240 V AC G.U. (same polarity)
With current 6 A
Voltage 24 V DC G. U.
With current 6 A
External contact fuse protection, safety contacts
In accordance with the standard EN 60947-5-1
Max. melting integral 260 A²s
Blow-out fuse, slow 6 A
Blow-out fuse, gG 6 A
Circuit breaker 24V AC/DC, characteristic B/C 6 A

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Relay outputs
External contact fuse protection, auxiliary contacts
Max. melting integral 260 A²s
Blow-out fuse, slow 6 A
Blow-out fuse, gG 6 A
Circuit breaker 24 V AC/DC, characteristic B/C 6 A
Contact material AgCuNi + 0,2 µm Au
Conventional thermal current while loading sev-
eral contacts
Ith per contact at UB DC; AC1:240V,DC1:24V
Conv. therm. current with 1 contact 6 A
Conv. therm. current with 2 contacts 6 A
Conv. therm. current with 3 contacts 5 A
Times
Switch-on delay
With automatic start typ. 250 ms
With automatic start max. 450 ms
With automatic start after power on typ. 250 ms
With automatic start after power on max. 450 ms
With manual start typ. 125 ms
With manual start max. 450 ms
Delay-on de-energisation
With E-STOP typ. 15 ms
With E-STOP max. 30 ms
With power failure typ. 60 ms
With power failure max. 100 ms
Recovery time at max. switching frequency 1/s
After E-STOP 300 ms
After power failure 300 ms
Supply interruption before de-energisation 20 ms
Simultaneity, channel 1 and 2 max. ∞
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 61000-6-4, EN
61326-3-1
Vibration
In accordance with the standard EN 60068-2-6
Frequency 10 - 55 Hz
Amplitude 0,35 mm

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Environmental data
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 IP40
Terminals IP20
Mounting area (e.g. control cabinet) IP54
Mechanical data
Mounting position Any
Mechanical life 10,000,000 cycles
Material
Bottom PC
Top PC
Connection type Spring-loaded terminal
Mounting type Fixed
Conductor cross section with spring-loaded terminals
1 core flexible without crimp connector 0,25 - 1,5 mm², 24 - 16 AWG
1 core flexible with crimp connector 0,25 - 0,75 mm², 24 - 20 AWG
Spring-loaded terminals: Terminal points per connec-
tion 1
Stripping length with spring-loaded terminals 10 mm
Dimensions
Height 105 mm
Width 22,5 mm
Depth 100 mm
Weight 160 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]
Safety con-
tacts, in-
stantaneous 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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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.
Cycles x 1000
Switching current (A)
Fig.: Service life graphs at 24 V DC and 230 V AC
Cycles x 1000
Switching current (A)
Fig.: Service life graphs at 110 V DC

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Example
}Inductive load: 0.2 A
}Utilisation category: AC15
}Contact service life: 2 000 000 cycles
Provided the application to be implemented requires fewer than 2 000 000 cycles, the PFH
value (see Technical details [ 14]) 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.
Order reference
Product type Features Terminals Order no.
PNOZ c1 24 V DC With spring-loaded terminals 710001
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/downloads.
Authorised representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2,
73760 Ostfildern, Germany