Pilz PST 4 User manual

PST 4
Operating Manual-18436-EN-06
}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 PST 4
18436-EN-06 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 7
Types: AC 7
Type: DC 8
Function Description 8
Operating modes 9
Timing diagram 9
Installation 9
Wiring 10
Preparing for operation 11
Operation 12
Status indicators 14
Faults – Interference 14
Dimensions in mm 14
Technical details 15
Safety characteristic data 25
Supplementary data 25
Service life graph 26
Order reference 26
EC declaration of conformity 27

PST 4
Operating Manual PST 4
18436-EN-06 4
Introduction
Validity of documentation
This documentation is valid for the product PST 4. 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.

PST 4
Operating Manual PST 4
18436-EN-06 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The safety relay PST 4 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
}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 [ 15]).
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.

PST 4
Operating Manual PST 4
18436-EN-06 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.

PST 4
Operating Manual PST 4
18436-EN-06 7
Unit features
}Positive-guided relay outputs:
– 6 safety contacts (N/O), instantaneous
– 4 auxiliary contacts (N/C), instantaneous
}Connection options for:
– Safety gate limit switches
– Start button
}LED indicator for:
– Supply voltage
– Input state channel 1/2
– Output state channel 1/2
}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.
Block diagram/terminal configuration
Types: AC
}UB: 24 VAC; Order no. 720301
}UB: 110 VAC; Order no. 720308
}UB: 230 VAC; Order no. 720309
PST 4
S11 S12 S13 S24 S33 S34 Y1 Y2
A1 13 23 33 43 53 63 71 81 91 01
CH.1 IN
POWER
CH.2 IN
CH.1 OUT
CH.2 OUT
14 24 34 44 54 64 72 82 92 02 A2
S23 S24S12S11
S33 S34Y2Y1
13 23 33 43
14 24 34 44
53 63
54 64
71
72
81
82
91
92
01
02
~
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)

PST 4
Operating Manual PST 4
18436-EN-06 8
Type: DC
}UB: 24 VDC; Order no. 720300
S23 S24S12S11
S33 S34Y2Y1
13 23 33 43
14 24 34 44
53 63
54 64
71
72
81
82
91
92
01
02
PST 4
S11 S12 S13 S24 S33 S34 Y1 Y2
A1 13 23 33 43 53 63 71 81 91 01
CH.1 IN
POWER
CH.2 IN
CH.1 OUT
CH.2 OUT
14 24 34 44 54 64 72 82 92 02 A2
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Function Description
The safety gate monitor PST 4 provides a safety-oriented interruption of a safety circuit.
When operating voltage is supplied the "POWER" LED will light. The unit is ready for oper-
ation when the feedback loop Y1-Y2 and the start circuit S33-S34 are closed.
}Input circuit closed within the simultaneity period (safety gate closed)
– The LEDs "CH.1 IN", "CH.2 IN" and "CH.1 OUT" and "CH.2 OUT" are lit
– Safety contacts 13-14, 23-24, 33-34, 43-44, 53-54 and 63-64 are closed, auxiliary
contacts 71-72, 81-82, 91-92 and 01-02 are opened. The unit is active.
}Input circuit is opened (safety gate opened)
– The LEDs "CH.1IN" and "CH.2 IN" go out.
– Safety contacts 13-14, 23-24, 33-34, 43-44, 53-54 and 63-64 are opened redund-
antly, auxiliary contacts 71-72, 81-82, 91-92 and 01-02 are closed.
– The LEDs "CH.1 OUT" and "CH.2 OUT" go out.
If the input circuits have already switched before supply voltage is applied, the PST 4 stops
the plant being enabled, to prevent an automatic start-up in accordance with
EN60204Pt7.5.
Reset function
The safety contacts and auxiliary contacts remain in rest condition (safety contacts are
open and auxiliary contacts are closed) if the supply voltage is applied when the safety gate
is closed. The safety and auxiliary contacts are not activated until the safety gate has been
opened and then closed again. N/C contacts in series with the safety gate limit switches S1
and S2 can simulate the opening of the safety gate.

PST 4
Operating Manual PST 4
18436-EN-06 9
Operating modes
}Dual-channel operation with detection of shorts across contacts: Redundant input cir-
cuit, PST 4 detects
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– 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.
}Increase in the number of available contacts by connecting contact expander modules
or external contactors/relays.
Timing diagram
[1] [2]
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuits
}Output safe: Safety contacts
}[1]: Automatic start
}[2]: Manual start
}a: Input circuit closes before start circuit
}b: Start circuit closes before input circuit
}t1: Switch-on delay
}t2: Delay-on de-energisation
}t3: Recovery time
Installation
}The unit 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).

PST 4
Operating Manual PST 4
18436-EN-06 10
Wiring
Please note:
}Information given in the "Technical details [ 15]" must be followed.
}Outputs 13-14, 23-24, 33-34, 43-44, 53-54, 63-64 are safety contacts; outputs 71-72,
81-82, 91-92, 01-02 are auxiliary contacts (e.g. for display).
}Do not use auxiliary contacts 71-72, 81-82, 91-92, 01-02 for safety circuits!
}Do not connect undesignated terminals.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 15]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 15])
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.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}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.
}Ensure the wiring and EMC requirements of EN 60204-1 are met.

PST 4
Operating Manual PST 4
18436-EN-06 11
Preparing for operation
Supply voltage AC DC
A1
A2
L1
N
FE
A1
A2
L+
L-
Input circuit Dual-channel Dual-channel with reset function
Safety gate
with detection of shorts across
contacts
S11 S1 S2
S12
S23
S24
S11 S1
S3
S2
S12
S23
S24
Start circuit Automatic start Manual start
S33
S34
S3
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.

PST 4
Operating Manual PST 4
18436-EN-06 12
Feedback loop
Without feedback loop monitor-
ing With feedback loop monitoring
Link or contacts from external con-
tactors
Y1
13 (23 ... 63)
14 (24 ... 64)
K3 K4
K3
K4
N
L1
Y2
Start-up testing
Y1
Y2
INFORMATION
The feedback circuit must be closed at least 500 ms before limit switch S1
is operated and may only be opened once limit switch S1 has been oper-
ated.
Legend
}S1/S2: Safety gate switch
}S3: Start button
}: Switch operated
}: Gate open
}: Gate closed
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

PST 4
Operating Manual PST 4
18436-EN-06 13
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.

PST 4
Operating Manual PST 4
18436-EN-06 14
Status indicators
LEDs indicate the status and errors during operation:
LED on
POWER
Supply voltage is present.
CH.1 IN
Channel 1 input circuit is closed.
CH.2 IN
Channel 2 input circuit is closed.
CH.1 OUT
Channel 1 safety contacts are closed.
CH.2 OUT
Channel 2 safety contacts are closed.
Faults – Interference
}Earth fault: The supply voltage fails and the safety contacts open. Once the cause of
the respective fault has been rectified and the supply voltage is switched off for approx.
1minute, the unit is ready for operation again.
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
}LED "POWER" does not light: Short circuit or no supply voltage.
}CH.1 OUT and CH.2 OUT do not light:
Only one limit switch is closed. Simultaneity was not maintained.
Dimensions in mm

PST 4
Operating Manual PST 4
18436-EN-06 15
Technical details
Order no. 720300 – 720301
See below for more order numbers
General 720300 720301
Approvals
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
Electrical data 720300 720301
Supply voltage
Voltage 24 V 24 V
Kind DC AC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(AC) – 12 VA
Output of external power supply
(DC) 5,5 W –
Frequency range AC – 50 - 60 Hz
Residual ripple DC 20 % –
Duty cycle 100 % 100 %
Max. inrush current impulse
Current pulse, A1 10 A –
Pulse duration, A1 0,5 ms –
Inputs 720300 720301
Number 2 2
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 30 mA 30 mA
Start circuit DC 30 mA 30 mA
Feedback loop DC 30 mA 30 mA
Max. overall cable resistance Rl-
max
Dual-channel with detection of
shorts across contacts at UB DC 100 Ohm –
Dual-channel with detection of
shorts across contacts at UB AC –100 Ohm
Relay outputs 720300 720301
Number of output contacts
Safety contacts (N/O), instant-
aneous 6 6
Auxiliary contacts (N/C) 4 4
Max. short circuit current IK 1 kA 1 kA

PST 4
Operating Manual PST 4
18436-EN-06 16
Relay outputs 720300 720301
Utilisation category
In accordance with the standard EN 60947-4-1 EN 60947-4-1
Utilisation category of safety con-
tacts
AC1 at 400 V 400 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 2000 VA 2000 VA
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 2000 VA 2000 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 200 W 200 W
Utilisation category of auxiliary con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 2000 VA 2000 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 200 W 200 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 7 A 7 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 7 A 7 A

PST 4
Operating Manual PST 4
18436-EN-06 17
Relay outputs 720300 720301
Utilisation category in accordance
with UL
Voltage 240 V AC G. P. 240 V AC G. P.
With current 8 A 8 A
Voltage 24 V DC Resistive 24 V DC Resistive
With current 5 A 5 A
Pilot Duty B300, R300 B300, R300
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 240 A²s 240 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 240 A²s 240 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 24 V AC/DC,
characteristic B/C 6 A 6 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Conventional thermal current
while loading several contacts
720300 720301
Ith per contact at UB AC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 8 A 8 A
Conv. therm. current with 2 con-
tacts 7 A 7 A
Conv. therm. current with 3 con-
tacts 5,7 A 5,7 A
Conv. therm. current with 4 con-
tacts 5 A 5 A
Conv. therm. current with 5 con-
tacts 4,4 A 4,4 A
Conv. therm. current with 6 con-
tacts 4 A 4 A

PST 4
Operating Manual PST 4
18436-EN-06 18
Conventional thermal current
while loading several contacts
720300 720301
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 8 A 8 A
Conv. therm. current with 2 con-
tacts 7 A 7 A
Conv. therm. current with 3 con-
tacts 5,7 A 5,7 A
Conv. therm. current with 4 con-
tacts 5 A 5 A
Conv. therm. current with 5 con-
tacts 4,4 A 4,4 A
Conv. therm. current with 6 con-
tacts 4 A 4 A
Times 720300 720301
Switch-on delay
Typ. switch-on delay 100 ms 100 ms
Delay-on de-energisation
With E-STOP typ. 30 ms 30 ms
With E-STOP max. 50 ms 50 ms
Supply interruption before de-ener-
gisation 10 ms 10 ms
Simultaneity, channel 1 and 2 max. 4 s 4 s
Environmental data 720300 720301
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
61326-3-1
EN 60947-5-1, EN 61000-6-2, 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 / II III / II
Pollution degree 2 2
Rated insulation voltage 400 V 400 V
Rated impulse withstand voltage 4 kV 4 kV

PST 4
Operating Manual PST 4
18436-EN-06 19
Environmental data 720300 720301
Protection type
Housing IP40 IP40
Terminals IP20 IP20
Mounting area (e.g. control cab-
inet) IP54 IP54
Mechanical data 720300 720301
Mounting position Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles
Material
Bottom PPO UL 94 V0 PPO UL 94 V0
Front PMMA PMMA
Top PPO UL 94 V0 PPO UL 94 V0
Connection type Screw terminal Screw terminal
Mounting type Fixed Fixed
Conductor cross section with screw
terminals
1 core flexible 0,2 - 4 mm², 24 - 10 AWG 0,2 - 4 mm², 24 - 10 AWG
2 core with the same cross sec-
tion, flexible with crimp connect-
ors, no plastic sleeve 0,2 - 2,5 mm², 24 - 14 AWG 0,2 - 2,5 mm², 24 - 14 AWG
2 core with the same cross sec-
tion, flexible without crimp con-
nectors or with TWIN crimp con-
nectors 0,2 - 2,5 mm², 24 - 14 AWG 0,2 - 2,5 mm², 24 - 14 AWG
Torque setting with screw terminals 0,6 Nm 0,6 Nm
Dimensions
Height 87 mm 87 mm
Width 90 mm 90 mm
Depth 121 mm 121 mm
Weight 530 g 790 g
Where standards are undated, the 2017-01 latest editions shall apply.
Order no. 720308 – 720309
General 720308 720309
Approvals
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed

PST 4
Operating Manual PST 4
18436-EN-06 20
Electrical data 720308 720309
Supply voltage
Voltage 110 V 230 V
Kind AC AC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(AC) 12 VA 12 VA
Frequency range AC 50 - 60 Hz 50 - 60 Hz
Duty cycle 100 % 100 %
Inputs 720308 720309
Number 2 2
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 30 mA 30 mA
Start circuit DC 30 mA 30 mA
Feedback loop DC 30 mA 30 mA
Max. overall cable resistance Rl-
max
Dual-channel with detection of
shorts across contacts at UB AC 100 Ohm 100 Ohm
Relay outputs 720308 720309
Number of output contacts
Safety contacts (N/O), instant-
aneous 6 6
Auxiliary contacts (N/C) 4 4
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 400 V 400 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 2000 VA 2000 VA
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 2000 VA 2000 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 200 W 200 W