1. Introduction
The Pilz PNOZ s3 is a compact safety relay designed for monitoring safety functions in industrial applications. It is specifically engineered to monitor E-STOP pushbuttons, safety gates, and light grids, ensuring the safe operation of machinery by reliably detecting and reacting to hazardous conditions. This manual provides essential information for the proper installation, operation, and maintenance of the PNOZ s3 safety relay.
2. Safety Information
Important: Read and understand all safety instructions before installing, operating, or performing maintenance on the PNOZ s3 safety relay. Failure to comply with these instructions may result in serious injury or death, and/or damage to the equipment.
- Installation and commissioning must only be carried out by qualified and authorized personnel.
- Always disconnect power to the device and the machine before performing any installation, wiring, or maintenance work.
- Adhere to all local and national safety regulations, standards, and directives (e.g., EN ISO 13849-1, IEC 62061).
- Do not bypass or modify safety functions.
- Ensure proper grounding and protection against electrical hazards.
3. Product Overview
The Pilz PNOZ s3 safety relay features a compact design with clearly labeled terminals and status indicators on the front panel. It is designed for plug-in mounting, allowing for easy installation and replacement.
Figure 1: Front view of the Pilz PNOZ s3 Safety Relay, showing input/output terminals and status indicators.
3.1. Terminals
The relay is equipped with screw terminals for secure electrical connections. Key terminals include:
- A1, A2: Power supply connection (24VDC).
- S11, S12, S21, S22, S34: Input terminals for connecting safety devices such as E-STOP buttons, safety gates, or light grids.
- 13, 14; 23, 24; 33, 34: Safety output contacts (Normally Open, n/o) for controlling contactors or other safety-related parts of the control system.
- Y32: Reset input.
3.2. Indicators
The front panel includes LED indicators to provide status information:
- Power: Indicates power supply status.
- In1, In2: Indicate the status of the input circuits.
- Out: Indicates the status of the output contacts.
- Reset: Indicates the status of the reset function.
- Fault: Illuminates in case of an internal fault or wiring error.
4. Setup and Installation
4.1. Mounting
The PNOZ s3 is designed for plug-in mounting onto a compatible base or DIN rail adapter. Ensure the mounting location is free from excessive vibration, moisture, and extreme temperatures. Allow adequate space for ventilation and wiring.
- Ensure the mounting surface is clean and dry.
- Align the relay with the corresponding slots on the base unit or DIN rail adapter.
- Gently push the relay into place until it clicks securely.
4.2. Wiring
All wiring must be performed according to the provided wiring diagrams from PILZ and relevant electrical standards. Use appropriate wire gauges and ensure all connections are secure to prevent loose contacts.
- Connect the 24VDC power supply to terminals A1 (+) and A2 (-).
- Connect the safety device inputs (e.g., E-STOP, safety gate contacts) to the S11, S12, S21, S22, S34 terminals as per the application's safety circuit design.
- Connect the safety outputs (13/14, 23/24, 33/34) to the control circuit of the machine, typically to contactor coils or other safety-related components.
- Connect the reset circuit to terminal Y32 if an external manual reset is required.
- Verify all wiring connections for correctness and tightness before applying power.
5. Operating Instructions
Once properly installed and wired, the PNOZ s3 safety relay operates by monitoring the status of its input circuits. When all safety inputs are closed (e.g., E-STOP released, safety gate closed), and after a successful reset, the safety outputs will close, allowing the machine to operate. If any safety input opens, the outputs will immediately open, bringing the machine to a safe state.
5.1. Initial Power-Up and Reset
- Apply power to the PNOZ s3. The 'Power' LED should illuminate.
- Ensure all safety inputs are in their safe (closed) state. The 'In1' and 'In2' LEDs should indicate the status of the input circuits.
- If configured for manual reset, activate the reset button connected to Y32. The 'Reset' LED will briefly illuminate, and then the 'Out' LED should turn on, indicating the safety outputs are closed.
- If configured for automatic reset, the outputs will close automatically once all safety inputs are in their safe state.
5.2. Normal Operation
During normal operation, the 'Power', 'In1', 'In2', and 'Out' LEDs should be illuminated, indicating that the safety circuit is closed and the machine is enabled. If a safety function is activated (e.g., E-STOP pressed, safety gate opened), the corresponding input LED(s) will change state, and the 'Out' LED will turn off as the safety outputs open.
6. Maintenance
The Pilz PNOZ s3 safety relay is designed for minimal maintenance. Regular inspections are recommended to ensure continued safe operation.
- Visual Inspection: Periodically check the relay for any signs of physical damage, discoloration, or loose connections.
- Cleaning: If necessary, gently clean the exterior of the relay with a soft, dry cloth. Do not use abrasive cleaners or solvents.
- Functional Test: Regularly test the safety functions connected to the relay (e.g., activate E-STOP, open safety gate) to ensure the relay responds correctly and brings the machine to a safe state.
7. Troubleshooting
This section provides guidance for common issues encountered with the PNOZ s3 safety relay.
| Symptom | Possible Cause | Solution |
|---|---|---|
| Fault indicator (LED) is on. | Internal fault, wiring error, or short circuit in the safety circuit. | Check wiring for shorts or open circuits. Verify power supply. If fault persists, contact PILZ support. |
| No power LED illumination. | No power supply, incorrect voltage, or faulty wiring to A1/A2. | Verify 24VDC power supply. Check connections to A1 and A2. |
| Outputs not activating (Out LED off). | Safety inputs not closed, reset not performed, or internal fault. | Ensure all safety inputs are in their safe state. Perform a manual reset if required. Check input LEDs. |
| Inputs (In1, In2) LEDs not illuminating correctly. | Faulty safety device, wiring issue to input terminals, or incorrect input configuration. | Check the connected safety devices (E-STOP, safety gate). Verify wiring to S11, S12, S21, S22, S34. |
8. Specifications
Key technical specifications for the Pilz PNOZ s3 safety relay (Model: 750103):
- Model Number: 750103
- Brand: PILZ
- Product Dimensions: 4.72 x 5.51 x 13.78 inches; 3.49 ounces
- Input Voltage: 24VDC
- Connector Type: Plug-In
- Contact Material: Silver Tungsten
- Contact Type: 2 Normally Open (n/o) safety contacts
- Mounting Type: Plug In Mount
- Application: E-STOP, safety gates, light grids monitoring
9. Warranty and Support
For detailed warranty information, please refer to the official PILZ warranty policy available on their website or contact your authorized PILZ distributor. In case of technical issues or questions not covered in this manual, please contact PILZ technical support for assistance. Ensure you have the model number (750103) and serial number of your device ready when contacting support.
PILZ Official Website: www.pilz.com
