Pilz PNOZ s7.2 User manual

PNOZ s7.2
Operating Manual-21866-EN-10
}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 s7.2
21866-EN-10 3
Introduction 4
Validity of documentation 4
Using the documentation 4
Definition of symbols 4
Safety 5
Intended use 5
Safety regulations 5
Safety assessment 5
Use of qualified personnel 6
Warranty and liability 6
Disposal 6
For your safety 6
Unit features 7
Safety features 7
Block diagram/terminal configuration 8
Function description 8
Installation 8
Wiring 10
Preparing for operation 11
Operation 11
Status indicators 11
Faults - malfunctions 12
Dimensions in mm 12
Technical details 12
Safety characteristic data 16
Supplementary data 17
Service life graph 17
Permitted operating height 19
Remove plug-in terminals 20
Order reference 20
EC declaration of conformity 20

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 4
Introduction
Validity of documentation
This documentation is valid for the product PNOZ s7.2. 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 s7.2
Operating Manual PNOZ s7.2
21866-EN-10 5
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.
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 [ 16] 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.
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.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 6
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).
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.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 7
Unit features
}Positive-guided relay outputs:
– 4 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}Connection option for expansion modules
}LED for:
– Input status, channel1
– Input status, channel2
– Switch status of the safety contacts
}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 s7.2
Operating Manual PNOZ s7.2
21866-EN-10 8
Block diagram/terminal configuration
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 insula-
tion between all safety contacts.
Function description
with PNOZsigma s7.1:
}Dual-channel operation and supply voltage via PNOZsigma connector
with PNOZsigma expander modules:
}Dual-channel operation and supply voltage via PNOZsigma connector
Installation
Connect contact expansion module PNOZ s7.2 to PNOZsigma contact expansion
modules
}Connect the contact expansion modules 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 s7.2
Operating Manual PNOZ s7.2
21866-EN-10 9
Expansion options
Please note the max. power consumption of the
contact expansion modules (see technical data
PNOZs7.1).
: Base unit
: Contact expansion module PNOZs7.1
: Contact expansion module PNOZs7.2
: Contact expansion module PNOZs7.2 with ter-
minator
: Base unit
: Contact expansion module PNOZs7.1
: Contact expansion module PNOZs7.2
: Expansion module PNOZ s7, s8, s9, s10, s11 as
a terminator
: Contact expansion module PNOZs7.1 with ter-
minator
: Contact expansion module PNOZs7.2
: Contact expansion module PNOZs7.2 with ter-
minator

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 10
Expansion options
Please note the max. power consumption of the
contact expansion modules (see technical data
PNOZs7.1).
: Contact expansion module PNOZs7.1 with ter-
minator
: Contact expansion module PNOZs7.2
: Expansion module PNOZ s7, s8, s9, s10, s11 as
a terminator
: Base unit
: Contact expansion module PNOZs7.1
: Contact expansion module PNOZs7.2
: Contact expansion module PNOZs7.1
: Contact expansion module PNOZs7.2
: Contact expansion module PNOZs7.2 with ter-
minator
Wiring
Please note:
}Information given in the "Technical details [ 12]" must be followed.
}Outputs 13-14, 23-24, 33-34, 43-44 are safety contacts; outputs 51 -52 are auxiliary
contacts (e.g. for display).
}Auxiliary contact 51-52 shouldnot 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.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 11
Preparing for operation
Supply voltage/input circuit/
feedback loop AC DC
Contact expansion module PNOZ
s7.2
Interface
PNOZsigma
PNOZs
expansion
module
PNOZs
expansion
module
Connection to PNOZsigma
base unit/PNOZmulti Mini base
unit
Base unit: Safety relay PNOZ-
sigma
Base unit: Small control system
PNOZmulti Mini
The feedback loop is connected
and evaluated via the connector
PNOZmulti Mini
base unit
PNOZsigma
expansion
module
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
IN1
Channel1 actuated.
IN2
Channel2 actuated.
IN1, IN2, OUT
Safety contacts are closed.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 12
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")
Technical details
General 750177 751177
Approvals
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
Electrical data 750177 751177
Supply voltage
Voltage 24 V 24 V
Kind DC DC
Power consumption 2 W 2 W
Duty cycle 100 % 100 %
Relay outputs 750177 751177
Number of output contacts
Safety contacts (N/O), instant-
aneous 4 4
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

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 13
Relay outputs 750177 751177
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 2 A 2 A
Max. power 500 VA 500 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 2 A 2 A
Max. power 50 W 50 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 2 A 2 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 2 A 2 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 s7.2
Operating Manual PNOZ s7.2
21866-EN-10 14
Relay outputs 750177 751177
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 4 A 4 A
Blow-out fuse, slow 2 A 2 A
Blow-out fuse, gG 4 A 4 A
Circuit breaker 24 V AC/DC,
characteristic B/C 2 A 2 A
Contact material AgCuNi + 0,2 µm Au AgCuNi + 0,2 µm Au
Conventional thermal current
while loading several contacts
750177 751177
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 6 A 6 A
Conv. therm. current with 2 con-
tacts 5,5 A 5,5 A
Conv. therm. current with 3 con-
tacts 4,5 A 4,5 A
Conv. therm. current with 4 con-
tacts 4 A 4 A
Times 750177 751177
Switch-on delay
With automatic start after power
on typ. 30 ms 30 ms
With automatic start after power
on max. 50 ms 50 ms
Delay-on de-energisation
With E-STOP typ. 18 ms 18 ms
With E-STOP max. 30 ms 30 ms
With power failure typ. 18 ms 18 ms
With power failure max. 30 ms 30 ms
Environmental data 750177 751177
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

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 15
Environmental data 750177 751177
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
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 750177 751177
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

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 16
Mechanical data 750177 751177
Dimensions
Height 98 mm 100 mm
Width 17,5 mm 17,5 mm
Depth 120 mm 120 mm
Weight 170 g 170 g
Where standards are undated, the 2017-01 latest editions shall apply.
Safety characteristic data
NOTICE
You must comply with the safety-related characteristic data in order to
achieve the required safety level for your plant/machine.
Operating
Mode
EN ISO
13849-1:
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
All the units used within a safety function must be considered when calculating the safety
characteristic data.
INFORMATION
A safety function's SIL/PL values are not identical to the SIL/PL values of
the units that are used and may be different. We recommend that you use
the PAScal software tool to calculate the safety function's SIL/PL values.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 17
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 V DC and 230 V AC

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 18
Cycles x 1000
Switching current (A)
Fig.: Service life graphs at 110 V DC
Example
}Inductive load: 0.2 A
}Utilisation category: AC15
}Contact service life: 2 000 000 cycles
Provided the application to be implemented requires fewer than 2 000 000 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 output
contacts. With capacitive loads, any power surges that occur must be noted. With DC con-
tactors, use flywheel diodes for spark suppression.

PNOZ s7.2
Operating Manual PNOZ s7.2
21866-EN-10 19
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 s7.2
Operating Manual PNOZ s7.2
21866-EN-10 20
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 s7.2 24 VDC Screw terminals 750 177
PNOZ s7.2 C 24 VDC Spring-loaded terminals 751 177
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
This manual suits for next models
3
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