Pilz PNOZ s22 Series User manual

PNOZ s22
Operating Manual-22170-EN-04
}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 s22
22170-EN-04 3
Introduction 5
Validity of documentation 5
Using the documentation 5
Definition of symbols 5
Safety 6
Intended use 6
Safety regulations 7
Safety assessment 7
Use of qualified personnel 7
Warranty and liability 7
Disposal 7
For your safety 8
Unit features 8
Safety features 8
Block diagram/terminal configuration 9
Function description 9
Installation 9
Wiring 10
Preparing for operation 10
Operation 11
Status indicators 11
Faults - malfunctions 11
Dimensions in mm 12
Technical details 12
Safety characteristic data 16
Supplementary data 17
Service life graph 17

Contents
Operating Manual PNOZ s22
22170-EN-04 4
Permitted operating height 19
Remove plug-in terminals 20
Order reference 20
EC declaration of conformity 20

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 5
Introduction
Validity of documentation
This documentation is valid for the product PNOZ s22. 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.

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 6
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The unit meets the requirements of EN 60947-5-1, EN 60204-1 and VDE 0113-1. The con-
tact expansion module is used to increase the number of instantaneous safety contacts
available on a base unit. Base units are
}Speed monitor PNOZ s30
}PNOZmulti Mini base units PNOZ mm0.1p, PNOZ mm0.2p
The max. achievable safety level depends on the base unit. The expansion module may not
exceed this. The safety-related characteristic values stated under safety-related character-
istic data can only be achieved if the base unit also exhibits these values.
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 [ 12]).
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.

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 7
Safety regulations
Safety assessment
Before using a device 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.
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 preven-
tion,
}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 spe-
cific 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).

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 8
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:
– 6 safety contacts (N/O), instantaneous
– 2 auxiliary contacts (N/C), instantaneous
}3 safety contacts and 1 auxiliary contact each; these can be controlled separately
}LED indicator for:
– Input state of channel Ext.1/O0
– Input state of channel Ext.2/O1
}Plug-in connection terminals (either spring-loaded terminal or screw terminal)
}See order reference for unit types
Safety features
The unit meets the following safety requirements:
}The contact expander module expands an existing circuit. As the output relays are
monitored via the base unit's feedback loop, the safety functions on the existing circuit
are transferred to the contact expander module.
}The safety function remains effective in the case of a component failure.
}Earth fault in the feedback loop:
Detected, depending on the base unit that is used.
}Earth fault in the input circuit:
The output relays de-energise and the safety contacts open.

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 9
Block diagram/terminal configuration
*Safe separation from non-marked area in accordance with EN 60947-1, 6 kV, basic insula-
tion between all safety contacts.
Function description
}Dual-channel operation and supply voltage via PNOZsigma connector
}3 safety contacts and 1 auxiliary contact each; these can be controlled separately
Installation
Connect the contact expansion block to the PNOZ s30 or base unit PNOZ mm0.1p/
PNOZmm0.2p
}Connect the contact expansion block using the connector supplied.
Control cabinet installation
}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.
}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).
Push the unit upwards or downwards before lifting it from the DIN rail.

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 10
Wiring
Please note:
}Information given in the "Technical details [ 12]" must be followed.
}The wiring guidelines in the base units' operating instructions must be taken into ac-
count.
}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
Technical details [ 12]).
}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 wiring and EMC requirements of EN 60204-1 are met.
Preparing for operation
Connection
AC DC
Supply voltage/input circuit/feed-
back loop
Interface
PNOZsigma
PNOZ s30/
PNOZ mm0.1p
PNOZ mm0.2p PNOZs22
Connection to speed monitor
PNOZ s30/PNOZmulti Mini
base unit
Base unit: Speed monitor PNOZ
s30
Base unit: Small control system
PNOZmulti Mini
The feedback loop is connected
and evaluated via the connector
PNOZ s30
PNOZmulti Mini
base unit
PNOZsigma
expansion
module

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Operating Manual PNOZ s22
22170-EN-04 11
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.
LEDs indicate the status and errors during operation:
LED on
Status indicators
EXT.1/O0
Channel Ext.1/O0 activated.
EXT.2/O1
Channel Ext.2/O1 activated.
Faults - malfunctions
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.

PNOZ s22
Operating Manual PNOZ s22
22170-EN-04 12
Dimensions in mm
*with spring-loaded terminals
Technical details
General 750132 751132
Approvals
CCC, EAC (Eurasian), TÜV, cU-
Lus Listed
CCC, EAC (Eurasian), TÜV, cU-
Lus Listed
Electrical data 750132 751132
Supply voltage
Voltage tolerance -15 %/+20 % -15 %/+20 %
Supply voltage
Voltage 24 V 24 V
Kind DC DC
Power consumption 1,5 W 1,5 W
Duty cycle 100 % 100 %
Relay outputs 750132 751132
Number of output contacts
Safety contacts (N/O), instant-
aneous 6 6
Auxiliary contacts (N/C) 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

PNOZ s22
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Relay outputs 750132 751132
Utilisation category of safety con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
Max. power 1500 VA 1500 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
Max. power 150 W 150 W
Utilisation category of auxiliary con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
Max. power 1500 VA 1500 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
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 3 A 3 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 4 A 4 A
Utilisation category of auxiliary con-
tacts
AC15 at 230 V 230 V
Max. current 4 A 4 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 4 A 4 A
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

PNOZ s22
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Relay outputs 750132 751132
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 66 A²s 66 A²s
Blow-out fuse, quick 6 A 6 A
Blow-out fuse, slow 4 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24V AC/DC,
characteristic B/C 4 A 4 A
External contact fuse protection,
auxiliary contacts
Max. melting integral 66 A²s 66 A²s
Blow-out fuse, quick 6 A 6 A
Blow-out fuse, slow 4 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24 V AC/DC,
characteristic B/C 4 A 4 A
Contact material AgCuNi + 0,2 µm Au AgCuNi + 0,2 µm Au
Conventional thermal current
while loading several contacts
750132 751132
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 5 A 5 A
Conv. therm. current with 3 con-
tacts 4 A 4 A
Times 750132 751132
Switch-on delay
With automatic start typ. 11 ms 11 ms
With automatic start max. 20 ms 20 ms
Delay-on de-energisation
With E-STOP typ. 12 ms 12 ms
With E-STOP max. 20 ms 20 ms
Environmental data 750132 751132
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
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

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Environmental data 750132 751132
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 III
Pollution degree 2 2
Rated insulation voltage 250 V 250 V
Rated impulse withstand voltage 6 kV 6 kV
Protection type
Housing IP40 IP40
Terminals IP20 IP20
Mounting area (e.g. control cab-
inet) IP54 IP54
Mechanical data 750132 751132
Mounting position Any Any
Mechanical life 10,000,000 cycles 10,000,000 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
Dimensions
Height 98 mm 100 mm
Width 22,5 mm 22,5 mm
Depth 120 mm 120 mm
Weight 265 g 265 g

PNOZ s22
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Where standards are undated, the 2017-01 latest editions shall apply.
The values for conventional thermal current stated in the technical details apply when the
contacts from Ext.1/O0 and Ext.2/O1 are under load simultaneously.
Conventional thermal current when either the contacts from Ext.1/O0 or the contacts from
Ext.2/O1 are under load:
Number of contacts
in total Ith [A] per contact
1 6 A
2 6 A
3 5 A
Safety characteristic data
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
NOTICE
The safety-related characteristic data applies per channel of the contact ex-
pansion block. The safety-related characteristic data of the base unit and all
other devices that are used must be taken into account when calculating the
safety function. We recommend that you use the PAScal software tool to
calculate the safety function's SIL/PL values.

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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 switching frequency and the load on the relay output.
If the service life graphs 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.
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 VDC and 230 VAC

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Number of cycles x 1000
Switching current (A)
Fig.: Service life graphs at 110 VDC
Example
}Inductive load: 0.2 A
}Utilisation category: AC15
}Contact service life: 1 000 000 cycles
Provided the application to be implemented requires fewer than 1 000 000 cycles, the PFH
value (see Technical details [ 12]) can be used in the calculation.
To increase the service life, sufficient spark suppression must be provided on all relay con-
tacts. With capacitive loads, any power surges that occur must be noted. With DC contact-
ors, use flywheel diodes for spark suppression.

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Permitted operating height
The values stated in the technical details apply to the use of the device in operating heights
up to max. 2000 m above sea level. When used in greater heights, constraints have to be
taken into account:
}Permitted maximum operating height 5000 m
}Reduction of rated insulation voltage and rated impulse withstand voltage for applica-
tions with safe separation:
Maximum operation
height
Rated insulation
voltage Overvoltage category
Max. rated impulse
withstand voltage
3000 m 150 V II 2.5 kV
100 V III 2.5 kV
4000 m 150 V II 2.5 kV
100 V III 2.5 kV
5000 m 150 V II 2.5 kV
100 V III 2.5 kV
}Reduction of rated insulation voltage and rated impulse withstand voltage for applica-
tions with basic insulation:
Maximum operation
height Rated insulation voltage Overvoltage category
Max. rated impulse
withstand voltage
3000 m 250 V II 2.5 kV
150 V III 2.5 kV
4000 m 250 V II 2.5 kV
150 V III 2.5 kV
5000 m 250 V II 2.5 kV
150 V III 2.5 kV
}From an operating height of 2000 m the max. permitted ambient temperature is re-
duced by 0.5 °C/100 m
Operating height Permitted ambient temperature
3000 m 50 °C
4000 m 45 °C
5000 m 40 °C

PNOZ s22
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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 s22 24 VDC Screw terminals 750 132
PNOZ s22 C 24 VDC Spring-loaded terminals 751 132
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