Pilz PNOZ s1 User manual

PNOZ s1
Operating Manual-21393-EN-08
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.
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

Content
Operating Manual PNOZ s1
21393-EN-08 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 6
Warranty and liability 7
Disposal 7
For your safety 7
Unit features 8
Safety features 8
Block diagram/terminal configuration 9
Function description 9
Timing diagram 10
Installation 10
Wiring 11
Preparing for operation 11
Operation 13
Status indicators 13
Error indicators 13
Faults - malfunctions 14
Dimensions in mm 14
Technical Details 14
Safety characteristic data 18
Supplementary data 18
Service life table 19
Remove plug-in terminals 19
Order reference 19

Content
Operating Manual PNOZ s1
21393-EN-08 4
EC declaration of conformity 20

PNOZ s1
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Introduction
Validity of documentation
This documentation is valid for the product PNOZ s1. 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, 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 [ 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 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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Unit features
}Relay outputs:
– 2 safety contacts (N/O), instantaneous
}1 semiconductor output
}Connection options for:
– E-STOP pushbutton
– Safety gate limit switch
– Start button
}A connector can be used to connect 1 PNOZsigma contact expansion module
}LED indicator for:
– Supply voltage
– Input status, channel1
– Input status, channel2
– Switch status of the safety contacts
– Start circuit
– Errors
}Plug-in connection terminals (either spring-loaded terminal or screw terminal)
}See order reference for unit types
Safety features
The relay meets the following safety requirements:
}The circuit is internally 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
Interface
expansion
module
Fig.: Centre: Front view with cover, right: Front view without cover
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Function description
}Single-channel operation: No redundancy in the input circuit, earth faults in the start
and input circuit are detected.
}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.
}Increase in the number of available instantaneous safety contacts by connecting con-
tact expander modules or external contactors/relays;
A connector can be used to connect 1 PNOZsigma contact expander module.

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Timing diagram
[1][1] [2][2]
Reset/Start
Legend
}POWER: Supply voltage
}Start: Start circuit
}Input: Input circuits
}Output safe: Safety contacts
}Semi: Semiconductor output
}[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
Installation
Install base unit without contact expansion module:
}Ensure that the plug terminator is inserted at the side of the unit.
Connect base unit and PNOZsigma contact expansion module:
}Remove the plug terminator at the side of the base unit and at the contact expansion
module.
}Connect the base unit and the contact expansion module to the supplied connector be-
fore mounting the units to the DIN rail.
Installation in control cabinet
}The safety relay 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).
}Push the device upwards or downwards before lifting it from the DIN rail.

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Wiring
Please note:
}Information given in the "Technical details [ 14]" must be followed.
}Outputs 13-14 and 23-24 are safety contacts, the semiconductor output Y32 is an auxil-
iary output (e.g. for display).
}Semiconductor output Y32 should not be used for safety circuits!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 14]).
}Calculation of the max. cable runs lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 14])
Rl/km = cable resistance/km
}Use copper wire that can withstand 60/75°C.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}Ensure the EMC requirements of IEC 60204-1 are met.
}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.
Preparing for operation
Supply voltage AC DC
S1
L+
A1
A2 L-
Input circuit Single-channel Dual-channel
E-STOP
without detection of shorts
across contacts
S1
A1 L+
Safety gate
without detection of shorts
across contacts
A1 L+
S1

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Start circuit/feedback loop Start circuit Feedback loop
Automatic start
K5 K6
K5
L1
N
K6
A1
13 (23)
S34
14 (24)
Manual start
A1
S34
S3
K5 K6
K5 L1
K6
A1
S34
S3
N
13 (23)
14 (24)
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.
Semiconductor output
*Connect together the 0V connections on all the external power supplies
Key
}S1: E-STOP pushbutton
}S3: Start button
}: Switch operated
}: Gate open
}: Gate closed
INFORMATION
If a base unit and a contact expansion module from the PNOZsigma range
are connected via the connector, no additional wiring is necessary.

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Operation
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:
LED on
LED flashes
INFORMATION
Status indicators and error indicators may occur independently. In the case
of an error display, the "Fault" LED will light or flash (exception: "Supply
voltage too low"). An LED that is also flashing indicates the potential cause
of the error. An LED that is lit and is static indicates a normal operating
status. Several status indicators and error indicators may occur simultan-
eously.
Status indicators
POWER, IN1, IN2
Input circuit is closed.
OUT
Safety contacts are closed and semiconductor output Y32 carries a high signal.
RESET
24 VDC is present at S34.
Error indicators
FAULT
Diagnostics: Plug terminator not connected
}Remedy: Insert plug terminator, switch supply voltage off and then on
again.
FAULT
Diagnostics: Internal error, unit defective
}Remedy: Switch supply voltage off and then on again, change unit if neces-
sary.

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POWER
Diagnostics: Supply voltage too low
}Remedy: Check supply voltage and increase if necessary.
Faults - malfunctions
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
Dimensions in mm
*with spring-loaded terminals
120 (4.72")
* 100 (3,94")
98 (3.86")
12,5 (0.69")
Technical Details
General 750101 751101
Approvals
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
Electrical data 750101 751101
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 %
Continuous duty 100 % 100 %
Inputs 750101 751101
Number 1 1
Voltage at
Input circuit DC 24 V 24 V
Start circuit DC 24 V 24 V
Feedback loop DC 24 V 24 V

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Inputs 750101 751101
Current at
Input circuit DC 60 mA 60 mA
Start circuit DC 20 mA 20 mA
Feedback loop DC 20 mA 20 mA
Max. inrush current impulse
Current pulse, input circuit 1 A 1 A
Pulse duration, input circuit 5 ms 5 ms
Current pulse, feedback loop 0,2 A 0,2 A
Pulse duration, feedback loop 0,5 ms 0,5 ms
Current pulse, start circuit 0,2 A 0,2 A
Pulse duration, start circuit 0,5 ms 0,5 ms
Max. overall cable resistance Rl-
max
Single-channel at UB DC 30 Ohm 30 Ohm
Semiconductor outputs 750101 751101
Number 1 1
Voltage 24 V 24 V
Current 20 mA 20 mA
Relay outputs 750101 751101
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
Utilisation category of safety con-
tacts
AC1 at 240 V 240 V
Min. current 0,02 A 0,02 A
Max. current 3 A 3 A
Max. power 720 VA 720 VA
DC1 at 24 V 24 V
Min. current 0,02 A 0,02 A
Max. current 3 A 3 A
Max. power 72 W 72 W
Utilisation category
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Utilisation category of safety con-
tacts
AC15 at 230 V 230 V
Max. current 1,5 A 1,5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 1,5 A 1,5 A

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Relay outputs 750101 751101
Utilisation category in accordance
with UL
Voltage 240 V AC G. P. 240 V AC G. P.
With current 3 A 3 A
Voltage 24 V DC G. P. 24 V DC G. P.
With current 3 A 3 A
Pilot Duty B300, R300 B300, R300
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Blow-out fuse, quick 4 A 4 A
Blow-out fuse, slow 2 A 2 A
Blow-out fuse, gG 4 A 4 A
Circuit breaker 24V AC/DC,
characteristic B/C 2 A 2 A
Conventional thermal current 3 A 3 A
Contact material AgSnO2 AgSnO2
Times 750101 751101
Switch-on delay
With automatic start typ. 100 ms 100 ms
With automatic start max. 150 ms 150 ms
With automatic start after power
on typ. 100 ms 100 ms
With automatic start after power
on max. 150 ms 150 ms
With manual start typ. 50 ms 50 ms
With manual start max. 60 ms 60 ms
Delay-on de-energisation
With E-STOP typ. 30 ms 30 ms
With E-STOP max. 40 ms 40 ms
With power failure typ. 30 ms 30 ms
With power failure max. 40 ms 40 ms
Recovery time at max. switching
frequency 1/s
After E-STOP 100 ms 100 ms
After power failure 100 ms 100 ms
Supply interruption before de-ener-
gisation 10 ms 10 ms
Environmental data 750101 751101
Climatic suitability EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C -10 - 55 °C
Storage temperature
Temperature range -40 - 85 °C -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during operation Not permitted Not permitted

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Environmental data 750101 751101
EMC EN 60947-5-1, EN 61000-6-2, EN
61000-6-4, EN 61326-3-1
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 EN 60068-2-6
Frequency 10 - 55 Hz 10 - 55 Hz
Amplitude 0,35 mm 0,35 mm
Airgap creepage
In accordance with the standard EN 60947-1 EN 60947-1
Overvoltage category III / II III / II
Pollution degree 2 2
Rated insulation voltage 250 V 250 V
Rated impulse withstand voltage 4 kV 4 kV
Protection type
Mounting area (e.g. control cab-
inet) IP54 IP54
Housing IP40 IP40
Terminals IP20 IP20
Mechanical data 750101 751101
Mounting position Any Any
Mechanical life 5,000,000 cycles 5,000,000 cycles
Material
Bottom PC PC
Front PC PC
Top PC PC
Connection type Screw terminal Spring-loaded terminal
Mounting type plug-in plug-in
Conductor cross section with screw
terminals
1 core flexible 0,25 - 2,5 mm², 24 - 12 AWG –
2 core with the same cross sec-
tion, flexible with crimp connect-
ors, no plastic sleeve 0,25 - 1 mm², 24 - 16 AWG –
2 core with the same cross sec-
tion, flexible without crimp con-
nectors or with TWIN crimp con-
nectors 0,2 - 1,5 mm², 24 - 16 AWG –
Torque setting with screw terminals 0,5 Nm –
Conductor cross section with
spring-loaded terminals: Flexible
with/without crimp connector – 0,2 - 2,5 mm², 24 - 12 AWG
Spring-loaded terminals: Terminal
points per connection – 2
Stripping length with spring-loaded
terminals – 9 mm

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Mechanical data 750101 751101
Dimensions
Height 98 mm 100 mm
Width 12,5 mm 12,5 mm
Depth 120 mm 120 mm
Weight 105 g 105 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.
Operating
mode
EN ISO
13849-1:
2008
PL
EN ISO
13849-1:
2008
Category
EN 62061
SIL CL
EN 62061
PFHD [1/h]
IEC 61511
SIL
IEC 61511
PFD
EN ISO
13849-1:
2008
TM [year]
Safety con-
tacts, in-
stantaneous PL c Cat. 3 SIL CL 2 2,00E-07 SIL 2 5,95E-03 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.
Supplementary data
CAUTION!
It is essential to consider the values in the relays' service life table. The re-
lay outputs' safety-related characteristic data is only valid if the values in the
service life table are met.
The PFH value depends on the switching frequency and the load on the relay output.
If the values in the service life table 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.

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Service life table
The service life table indicates 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.
Load type Switching current Number of cycles
DC1 3 A 200,000
DC13 1.5 A 75,000
AC1 3 A 50,000
AC15 1.5 A 50,000
Remove plug-in terminals
Procedure: Insert the screwdriver into the housing recess behind the terminal and lever the
terminal out.
Do not remove the terminals by pulling the cables!
Order reference
Product type Features Connection type Order No.
PNOZ s1 24 VDC Screw terminals 750 101
PNOZ s1 C 24 VDC Spring-loaded terminals 751 101

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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.
Representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2, 73760 Ost-
fildern, Germany