Pilz PNOZ s4 User manual

PNOZ s4
Operating Manual-21396-EN-21
-Safety relays

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
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.
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 s4
21396-EN-21 | 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
Unit types with UB 24 VDC .......................................................................................................9
Unit types with UB 48 - 240 VAC/DC ........................................................................................9
Function description ..............................................................................................................10
Timing diagram .........................................................................................................................11
Installation ..............................................................................................................................11
Wiring ......................................................................................................................................12
Preparing for operation .........................................................................................................13
Operating modes.......................................................................................................................13
Set operating modes .................................................................................................................13
Connection ................................................................................................................................14
Application examples ............................................................................................................16
Operation ................................................................................................................................19
Status indicators........................................................................................................................19
Error indicators..........................................................................................................................20

Contents
Operating Manual PNOZ s4
21396-EN-21 | 4
Faults - malfunctions .............................................................................................................21
Dimensions in mm .................................................................................................................21
Technical details Order no. 750104, 750134, 751104 ..........................................................22
Technical details Order no. 751134, 751184 ........................................................................29
Safety characteristic data ......................................................................................................35
Classification according to ZVEI, CB24I ..............................................................................36
Supplementary data ...............................................................................................................37
Service life graph ......................................................................................................................37
Permitted operating height........................................................................................................41
Remove plug-in terminals .....................................................................................................42
Order reference ......................................................................................................................42
EC declaration of conformity ................................................................................................42
UKCA-Declaration of Conformity .........................................................................................43

PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 5
Introduction
Validity of documentation
This documentation is valid for the product PNOZ s4. 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 s4
Operating Manual PNOZ s4
21396-EN-21 | 6
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
}Light grids and safety switches with detection of shorts across contacts
Improper use
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 operating manual,
}Use of the product outside the technical details (see Technical details [ 22]).
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 s4
Operating Manual PNOZ s4
21396-EN-21 | 7
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.
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).

PNOZ s4
Operating Manual PNOZ s4
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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
}1 semiconductor output
}Connection options for:
– E-STOP pushbuttons
– Safety gate limit switches
– Start buttons
– Light grids and safety switches with detection of shorts across contacts
}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 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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Operating Manual PNOZ s4
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Block diagram/terminal configuration
Unit types with UB 24 VDC
}UB: 24 VDC; Order no. 750104, 751104, 751184
*
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)
Unit types with UB 48 - 240 VAC/DC
}UB: 48 - 240 VAC/DC; Order no. 750134, 751134
*
*
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)

PNOZ s4
Operating Manual PNOZ s4
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Function description
}
In2+
Single-channel operation: no redundancy in the input circuit, earth faults in the start
circuit and input circuit are detected.
}Dual-channel operation without detection of shorts across contacts: Redundant input cir-
cuit, detects PNOZ s4
– earth faults in the start and input circuit,
– short circuits in the input circuit and, with a monitored start, in the start circuit too.
}
In2-
Dual-channel operation with detection of shorts across contacts: Redundant input cir-
cuit, detects PNOZ s4
– earth faults in the start and input circuit,
– Short circuits in the input circuit and, with a monitored start, in the start circuit too,
– Shorts across 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 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).
} Start with start-up test: The unit checks whether safety gates that are closed are
opened and then closed again when supply voltage is applied.
}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.

PNOZ s4
Operating Manual PNOZ s4
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Timing diagram
[1] [2] [3] [4]
Legend
}POWER: Supply voltage
}Start: Start circuit
}Input: Input circuit
}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 with a monitored start
}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.
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).

PNOZ s4
Operating Manual PNOZ s4
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}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 [ 22]" 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 [ 22]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 22])
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.
}With UB 48 – 240 VAC/DC: Connect S21 to the functional earth.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}On 24 VDC devices:
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.
NOTICE
If you connect contact expansion modules to a base unit with a universal
power supply, you will need to limit the conventional thermal current at the
contact expansion modules' safety contacts to 70% of the stated current
(see technical details for contact expansion module).

PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 13
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
Always carry out the following steps before the unit is set for the first time
and with each change of the rotary switch.
Check that the rotary switch locks into position correctly:
}Turn the rotary switch as far as it will go to the left and right.
}Check the click sound and "click feel" in each individual position.
When you bring the rotary switch to the desired position, make sure that the rotary switch
locks in position (click feel). The actual lock-in position may vary slightly from the labelling,
as there are minor manufacturing tolerances.
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
selector switch
"mode"
Automatic or
manual start
Monitored start
rising edge
Monitored start
falling edge
Automatic start
with start-up test
Without detec-
tion of shorts
across contacts
In2-
In2+
In2-
In2+
In2-
In2+
In2-
In2+
With detection of
shorts across
contacts
In2-
In2+
In2-
In2+
In2-
In2+
In2-
In2+
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.

PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 14
Connection
Supply voltage Unit types with
UB 24 VDC
Unit types with
UB 48 - 240 VAC/DC
A1 L+
A2 L-
Input circuit Single-channel Dual-channel
Emergency stop
without detection of shorts
across contacts
S1
S11
S22
S12
S1
S11
S12
S22
Emergency stop
with detection of shorts
across contacts
S1
S22
S21
S12
S11
Safety gate
without detection of shorts
across contacts
S1
S22
S11
S12
S1 S2
S11
S12
S22
Safety gate
with detection of shorts
across contacts
S1 S2
S12
S11
S22
S21
Light beam device or safety
switch, detection of shorts
across contacts via ESPE,
operating mode selector
switch in the position
"without detection of shorts
across contacts"
(only for unit types with
UB = 24 VDC)
A1
A2 S12
S22
24 V DC
GND
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 [ 35]).

PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 15
NOTICE
When operated with a light grid or sensor
– It must not be possible to switch off the supply voltage for the
PNOZsigma separately from the supply voltage for the light grid or
safety switch.
– The operating mode selector switch must be set to "Without detection
of shorts across contacts", as shorts across contacts are detected by
the ESPE.
Start circuit/feedback loop Without feedback loop
monitoring
with feedback loop monit-
oring
Automatic start
K5 K6
K5
L1
N
K6
S12
13 (23,33)
S34
14 (24,34)
Monitored, manual start/re-
start
S12
S34
S3
K5 K6
K5 L1
K6
S12
S34
S3
N
13 (23,33)
14 (24,34)
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.
Unit types with UB 24 VDC Unit types with UB 48 - 240 VAC/DC
*Connect together the 0V connections on all
the external power supplies
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated

PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 16
}: Gate open
}: Gate closed
Application examples
Emergency stop
}Dual-channel
}with detection of shorts across contacts
}Monitored start
}falling edge with feedback loop monitoring
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PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 17
Safety gate
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}with detection of shorts across contacts
}Monitored start
}falling edge with feedback loop monitoring
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PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 18
OSSD signals
}Dual-channel
}without detection of shorts across contacts of PNOZ - detection of shorts across contacts
by sensor technology
}Automatic start
}with feedback loop monitoring
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PNOZ s4
Operating Manual PNOZ s4
21396-EN-21 | 19
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 functions 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
LED off
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
Supply voltage is present.
IN1
Input circuit at S12 is closed.
IN2
Input circuit at S22 is closed.
OUT
Safety contacts are closed and semiconductor output Y32 carries a high signal.
START
24 VDC is present at S34.

PNOZ s4
Operating Manual PNOZ s4
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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.
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.
IN1, IN2 alternately FAULT
Diagnostics: Connection error (possibly: cable resistance in the input circuit is
too high) or short detected between S12 and S22
}Remedy: Rectify connection error or short across contacts, switch supply
voltage off and then on again.
IN1 FAULT
Diagnostics: Power-up blocked due to short-term interruption at S12; channels
in the input circuit not opened simultaneously.
}Remedy: Open S11-S12 and S21-S22 simultaneously and then close again.
IN2 FAULT
Diagnostics: Power-up blocked due to short-term interruption at S22; channels
in the input circuit not opened simultaneously.
}Remedy: Open S11-S12 and S21-S22 simultaneously and then close again.