Pilz PNOZ s4.1 User manual

PNOZ s4.1
Operating Manual 21890-EN-07
}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.
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 s4.1
21890-EN-07 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
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 13
Operation 16
Status indicators 16
Error indicators 17
Faults - malfunctions 18
Dimensions in mm 18
Technical details 19
Safety characteristic data 28
Supplementary data 28
Service life graph 29

Contents
Operating Manual PNOZ s4.1
21890-EN-07 4
Remove plug-in terminals 30
Order reference 30
EC declaration of conformity 31

PNOZ s4.1
Operating Manual PNOZ s4.1
21890-EN-07 5
Introduction
Validity of documentation
This documentation is valid for the product PNOZ s4.1. 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 s4.1
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21890-EN-07 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, EN60204-1 and VDE 0113-1
and may be used in applications with
}E-STOP pushbuttons
}Safety gates
}Light beam devices
It is suitable for use in furnaces in accordance with EN 50156-1.
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 [ 19]).
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.

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Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
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
}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
– PSEN
– Safety valves for furnaces
}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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Block diagram/terminal configuration
Unit types with UB 24 VDC
}UB: 24 VDC; Order no. 750124, 751124
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)
Unit types with UB 48 - 240 VAC/DC
}UB: 48 - 240 VAC/DC; Order no. 750154, 751154
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)

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21890-EN-07 10
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
circuit, detects PNOZ s4.1
– 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
circuit, detects PNOZ s4.1
– 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 de-
tails).
} 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 con-
tact expander modules or external contactors/relays;
A connector can be used to connect 1 PNOZsigma contact expander module.

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21890-EN-07 11
Timing diagram
[1] [2] [3] [4]
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 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 s4.1
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21890-EN-07 12
}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 [ 19]" 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
circuits!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 19]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 19])
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.
}With UB 48 – 240 VAC/DC: Connect S21 to the functional earth.
}Ensure the wiring and EMC requirements of IEC 60204-1 are met.
}On 24 VDC devices:
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.
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).

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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
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+
Connection
}Supply voltage
Supply voltage
Unit types with
UB 48 - 240 VAC/DC
Unit types with
UB 24 VDC
A1 L+
A2 L-

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}Input circuit
Input circuit Single-channel Dual-channel
E-Stop
without detection of shorts
across contacts
S1
S11
S22
S12
S1
S11
S12
S22
E-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 with detection of
shorts across contacts via
ESPE
(only when UB = 24 VDC)
A1
A2 S12
S22
24 V DC
GND
NOTICE
When operated with a light grid or sensor
– It must not be possible to switch off the supply voltage for the PNOZ-
sigma 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.

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}Start circuit/feedback loop
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.
}Semiconductor output
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
INFORMATION
If a base unit and a contact expansion module from the PNOZsigma range
are connected via the connector, no additional wiring is necessary.
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open

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}: Gate closed
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
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.
RESET
24 VDC is present at S34.

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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; input cir-
cuits not operated simultaneously
}Remedy: Open both input circuits, S12 and S22, simultaneously and then
close again.
IN2 FAULT
Diagnostics: Power-up blocked due to short-term interruption at S22; input cir-
cuits not operated simultaneously
}Remedy: Open both input circuits, S12 and S22, simultaneously and then
close again.

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RESET FAULT
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

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Technical details
General 750124 750154 751124 751154
Approvals
CCC, CE, EAC
(Eurasian), TÜV,
cULus Listed
CCC, CE, EAC
(Eurasian), TÜV,
cULus Listed
CCC, CE, EAC
(Eurasian), TÜV,
cULus Listed
CCC, CE, EAC
(Eurasian), TÜV,
cULus Listed
Electrical data 750124 750154 751124 751154
Supply voltage
Voltage 24 V 48 - 240 V 24 V 48 - 240 V
Kind DC AC/DC DC AC/DC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply
(AC) –5 VA –5 VA
Output of external
power supply
(DC) 2,5 W 2,5 W 2,5 W 2,5 W
Frequency range
AC –50 - 60 Hz –50 - 60 Hz
Residual ripple
DC 20 % 160 % 20 % 160 %
Duty cycle 100 % 100 % 100 % 100 %
Inputs 750124 750154 751124 751154
Number 2222
Voltage at
Input circuit DC 24 V 24 V 24 V 24 V
Start circuit DC 24 V 24 V 24 V 24 V
Feedback loop
DC 24 V 24 V 24 V 24 V
Current at
Input circuit DC 50 mA 50 mA 50 mA 50 mA
Start circuit DC 50 mA 50 mA 50 mA 50 mA
Feedback loop
DC 50 mA 50 mA 50 mA 50 mA

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Inputs 750124 750154 751124 751154
Max. inrush current
impulse
Current pulse, in-
put circuit 0,2 A 0,2 A 0,2 A 0,2 A
Pulse duration, in-
put circuit 100 ms 100 ms 100 ms 100 ms
Current pulse,
feedback loop 0,2 A 0,2 A 0,2 A 0,2 A
Pulse duration,
feedback loop 15 ms 15 ms 15 ms 15 ms
Current pulse,
start circuit 0,2 A 0,2 A 0,2 A 0,2 A
Pulse duration,
start circuit 15 ms 15 ms 15 ms 15 ms
Max. overall cable
resistance Rlmax
Single-channel at
UB DC 30 Ohm 30 Ohm 30 Ohm 30 Ohm
Single-channel at
UB AC –30 Ohm –30 Ohm
Dual-channel
without detection
of shorts across
contacts at UB
DC 60 Ohm 60 Ohm 60 Ohm 60 Ohm
Dual-channel
without detection
of shorts across
contacts at UB
AC –60 Ohm –60 Ohm
Dual-channel with
detection of
shorts across
contacts at UB
DC 30 Ohm 30 Ohm 30 Ohm 30 Ohm
Dual-channel with
detection of
shorts across
contacts at UB
AC –30 Ohm –30 Ohm
Semiconductor
outputs
750124 750154 751124 751154
Number 1111
Voltage 24 V 24 V 24 V 24 V