Pilz PNOZ s2 User manual

PNOZ s2
Operating Manual-21394-EN-11
}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 s2
21394-EN-11 | 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 ................................................................................. 9
Function description ............................................................................................................. 9
Timing diagram ......................................................................................................................... 10
Installation ..............................................................................................................................10
Wiring ......................................................................................................................................11
Preparing for operation ......................................................................................................... 12
Operating modes ...................................................................................................................... 12
Set operating modes................................................................................................................. 12
Connection................................................................................................................................ 13
Application example ..............................................................................................................15
Operation ................................................................................................................................15
Status indicators ....................................................................................................................... 16
Error indicators ......................................................................................................................... 16
Faults - malfunctions ............................................................................................................. 17
Dimensions in mm .................................................................................................................17
Technical Details ...................................................................................................................18
Safety characteristic data ......................................................................................................... 23
Classification according to ZVEI, CB24I ................................................................................... 24
Supplementary data ..............................................................................................................25
Service life graph ...................................................................................................................... 25

Contents
Operating Manual PNOZ s2
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Permitted operating height........................................................................................................ 27
Remove plug-in terminals ..................................................................................................... 28
Order reference ......................................................................................................................28
EC declaration of conformity ................................................................................................ 28

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Introduction
Validity of documentation
This documentation is valid for the product PNOZ s2. 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 [ 18]).
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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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:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}Protective separation of safety contacts from all other circuits
}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
}Operating modes can be set via rotary switch
}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 safety relay meets the following safety requirements:
}The circuit is internally redundant with built-in self-monitoring.
}The safety device remains effective in the case of a component failure.
}The correct opening and closing of the safety device 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
*Safe separation from non-marked area in accordance with EN 60947-1,
6 kV, basic insulation between all safety contacts.
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.
} Monitored start with falling edge: 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.
} Monitored start with rising edge: Unit is active once the input circuit is closed and
once the start circuit is closed after the waiting period has elapsed (seetechnical details).
}Increase in the number of available instantaneous safety contacts by connecting contact
expander modules or external contactors/relays;
A connector can be used to connect 1 PNOZsigma contact expansion module.

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Timing diagram
[1] [2] [4][3]
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuits
}Output safe: Safety contacts
}Output aux: Auxiliary contacts
}Out semi: Semiconductor output
}[1]: Automatic start
}[2]: Manual start
}[3]: Monitored start with rising edge
}[4]: Monitored start with falling edge
}a: Input circuit closes before start circuit
}b: Start circuit closes before input circuit
}t1: Switch-on delay
}t2: Delay-on de-energisation
}t3: Waiting period
}t4: Min. start pulse duration with a monitored start
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.

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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.
Wiring
Please note:
}Information given in the "Technical details [ 18]" 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and semiconductor output Y32 should not be used for safety cir-
cuits!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 18]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 18])
Rl/km = cable resistance/km
}Use copper wiring with a temperature stability of 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.
}Adequate protection must be provided on all output contacts with capacitive and inductive
loads.
}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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Preparing for operation
Operating modes
The operating mode is set via the rotary switch on the unit. You can do this by opening the
cover on the front of the unit.
NOTICE
Do not adjust the rotary switch during operation, otherwise an error mes-
sage will appear, the safety contacts will open and the unit will not be ready
for operation until the supply voltage has been switched off and then on
again.
Set operating modes
}Switch off supply voltage.
}Select operating mode via the operating mode selector switch "mode".
}If the operating mode selector switch "mode" is in its start position (vertical position), an
error message will appear.
Operating mode se-
lector switch "mode"
Automatic/manual
start
Monitored start rising
edge
Monitored start fall-
ing edge
without detection of
shorts across con-
tacts

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Connection
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
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 [ 23]).
Start circuit/feedback loop Without feedback loop monit-
oring
with feedback loop monitoring
Automatic start
K5 K6
K5
L1
N
K6
A1
13 (23,33)
S34
14 (24,34)
Monitored, manual start/restart
A1
S34
S3
K5 K6
K5 L1
K6
A1
S34
S3
N
13 (23,33)
14 (24,34)

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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.
Semiconductor output
*Connect together the 0V connections on all the external power supplies
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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Application example
Emergency stop
}Single-channel
}Monitored start
}falling edge with feedback loop monitoring
@

.
0
>
40
"8

 .
.-=2
-)
.-.)
)-))
-.-
 ..-=2
 &,%%.

.
)-
A).

.
#
)
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#)
>

.
48*
.-=2
%=
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.

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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.
POWER
Diagnostics: Supply voltage too low
}Remedy: Check supply voltage and increase if necessary.
RESET FAULT

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Diagnostics: Position of rotary switch is not permitted or rotary switch was ad-
justed during operation.
}Remedy: Switch supply voltage off and then on again.
POWER, IN1, IN2, OUT, RESET, FAULT
Diagnostics: The operating mode selector switch "mode" is in its start position
(vertical position)
}Remedy: Switch off the supply voltage and set the required operating mode
on operating mode selector switch "mode".
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")
17,5
(0.69")

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Technical Details
General 750102 751102
Certifications
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
Electrical data 750102 751102
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 750102 751102
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
Current at
Input circuit DC 75 mA 75 mA
Start circuit DC 7 mA 7 mA
Feedback loop DC 7 mA 7 mA
Max. inrush current impulse
Current pulse, input circuit 0,5 A 0,5 A
Pulse duration, input circuit 7 ms 7 ms
Current pulse, feedback loop 0,5 A 0,5 A
Pulse duration, feedback loop 30 ms 30 ms
Current pulse, start circuit 0,5 A 0,5 A
Pulse duration, start circuit 30 ms 30 ms
Max. overall cable resistance Rl-
max
Single-channel at UB DC 30 Ohm 30 Ohm
Semiconductor outputs 750102 751102
Number 1 1
Voltage 24 V 24 V
Current 20 mA 20 mA
Residual current at "0" signal 0,1 mA 0,1 mA
Max. internal voltage drop 5 V 5 V
Conditional rated short circuit cur-
rent 100 A 100 A
Lowest operating current 0 mA 0 mA
Utilisation category in accordance
with EN 60947-1 DC-12 DC-12

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Relay outputs 750102 751102
Number of output contacts
Safety contacts (N/O), instant-
aneous 3 3
Auxiliary contacts (N/C) 1 1
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 0,003 A 0,003 A
Max. current 6 A 6 A
Min. output 0,04 VA 0,04 VA
Max. power 1500 VA 1500 VA
DC1 at 24 V 24 V
Min. current 0,003 A 0,003 A
Max. current 6 A 6 A
Min. output 0,04 W 0,04 W
Max. power 150 W 150 W
Utilisation category of auxiliary con-
tacts
AC1 at 240 V 240 V
Min. current 0,003 A 0,003 A
Max. current 6 A 6 A
Min. output 0,04 VA 0,04 VA
Max. power 1500 VA 1500 VA
DC1 at 24 V 24 V
Min. current 0,003 A 0,003 A
Max. current 6 A 6 A
Min. output 0,04 W 0,04 W
Max. power 150 W 150 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 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 5 A
Utilisation category of auxiliary con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 5 A

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Relay outputs 750102 751102
Utilisation category in accordance
with UL
Voltage 240 V AC G.U. (same polarity) 240 V AC G.U. (same polarity)
With current 6 A 6 A
Voltage 24 V DC G. U. 24 V DC G. U.
With current 6 A 6 A
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 260 A²s 260 A²s
Blow-out fuse, quick 10 A 10 A
Blow-out fuse, slow 6 A 6 A
Blow-out fuse, gG 10 A 10 A
Circuit breaker 24V AC/DC,
characteristic B/C 6 A 6 A
External contact fuse protection,
auxiliary contacts
Max. melting integral 160 A²s 160 A²s
Blow-out fuse, quick 10 A 10 A
Blow-out fuse, slow 6 A 6 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24 V AC/DC,
characteristic B/C 6 A 6 A
Contact material AgCuNi + 0,2 µm Au AgCuNi + 0,2 µm Au
Conventional thermal current
while loading several contacts
750102 751102
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 6 A 6 A
Conv. therm. current with 2 con-
tacts 6 A 6 A
Conv. therm. current with 3 con-
tacts 5 A 5 A