1. Introduction
This manual provides essential information for the safe and efficient installation, operation, and maintenance of the Pilz PNOZsigma Configurable Safety Relay, model 751104. Please read this manual thoroughly before attempting to install or operate the device.
2. Safety Information
Safety relays are critical components in safety-related control systems. Incorrect installation or operation can lead to serious injury or death. Observe all local and international safety regulations, standards, and directives.
- Qualified Personnel: Installation, commissioning, and maintenance must only be performed by qualified and authorized personnel.
- Power Disconnection: Always disconnect power before performing any installation, wiring, or maintenance tasks.
- Wiring: Ensure all wiring is correct and securely connected according to the wiring diagrams and local electrical codes.
- Testing: Thoroughly test the safety function after installation and any modifications.
- Original Condition: Do not modify the device. Use only genuine Pilz accessories and spare parts.
3. Product Overview
The Pilz PNOZsigma 751104 is a configurable safety relay designed for monitoring safety functions in industrial applications. It is a standalone unit featuring a compact design with plug-in spring-loaded terminals for easy installation.
Key Features:
- Inputs: Supports 1-channel or 2-channel wiring with or without detection of shorts across contacts.
- Start Options: Configurable for manual or automatic start.
- Outputs: Features 3 Normally Open (N/O) safety outputs, 1 Normally Closed (N/C) auxiliary output, and 1 Safety Contact (SC) output.
- Power Supply: Operates on 24 V DC.
- Monitoring: Capable of monitoring E-STOP pushbuttons, safety gates, and light curtains.
- Compact Design: With a width of 22.5 mm, it saves space in control cabinets.
Figure 1: Pilz PNOZsigma 751104 Safety Relay. This image displays the front view of the Pilz PNOZsigma 751104 safety relay. Visible are the top and bottom plug-in spring-loaded terminals. The front panel is yellow and features the 'PILZ PNOZ s4' branding. Indicator LEDs for 'Power', 'In1', 'In2', 'Out', 'Start', and 'Fault' are present. Terminal markings include A1, 13, 23, 33, S12, S22, S34, 41 at the top, and S11, S21, Y32, 42, A2, 14, 24, 34 at the bottom.
4. Setup
4.1. Installation
The PNOZsigma 751104 is designed for plug-in mounting. It should be installed in a control cabinet or enclosure that provides adequate protection against environmental factors and unauthorized access. Ensure sufficient ventilation to prevent overheating.
- Mount the device on a DIN rail.
- Ensure proper clearance around the device for air circulation and ease of wiring.
4.2. Wiring
All wiring must comply with the provided wiring diagrams and relevant electrical standards. Refer to Figure 1 for terminal identification.
- Power Supply: Connect the 24 V DC power supply to terminals A1 (+) and A2 (-).
- Inputs: Connect safety input devices (e.g., E-STOP, safety gate switches) to the S11, S12, S21, S22, S34 terminals as per your safety circuit design. The device supports 1-channel or 2-channel wiring.
- Outputs: Connect the safety outputs (13-14, 23-24, 33-34) to the control circuit of contactors or other safety-related components. The auxiliary output (41-42) can be used for signaling. The SC output (Y32) is also available.
- Start Circuit: Depending on the configuration (manual or automatic start), connect the start button or bridge the start circuit accordingly.
After wiring, double-check all connections for correctness and tightness to prevent loose contacts or short circuits.
5. Operating Instructions
Once installed and wired correctly, the PNOZsigma 751104 monitors the connected safety devices. The operational status is indicated by the LEDs on the front panel.
- Power LED: Illuminates when the device is supplied with power.
- In1/In2 LEDs: Indicate the status of the safety inputs.
- Out LED: Illuminates when the safety outputs are closed (enabled).
- Start LED: Indicates the status of the start circuit.
- Fault LED: Illuminates in case of an internal fault or a fault in the safety circuit.
Starting the System:
After power-up and with all safety inputs closed, the device will be ready to enable the safety outputs. Depending on the configuration:
- Automatic Start: The safety outputs will close automatically if all safety inputs are closed.
- Manual Start: Acknowledge the start condition by pressing the connected start button.
6. Maintenance
The Pilz PNOZsigma 751104 is designed for minimal maintenance. However, regular inspections are recommended to ensure continued safe operation.
- Visual Inspection: Periodically check the device for any signs of damage, discoloration, or loose connections.
- Function Test: Regularly test the complete safety function, including the connected safety devices and the PNOZsigma relay, according to your risk assessment and local regulations.
- Cleaning: If necessary, clean the device with a dry, lint-free cloth. Do not use abrasive cleaners or solvents.
7. Troubleshooting
If the system does not operate as expected, refer to the following troubleshooting guide. The Fault LED provides a primary indication of issues.
| Symptom | Possible Cause | Action |
|---|---|---|
| Fault LED is ON | Internal fault, wiring error, or fault in the safety circuit (e.g., short circuit, open circuit in input). | Check all wiring connections. Verify the integrity of connected safety devices. Consult the detailed product manual for specific fault codes if available. |
| Out LED does not illuminate (outputs not enabled) | Safety inputs not closed, start condition not met (for manual start), or internal fault. | Ensure all safety devices are in their safe (closed) state. If manual start, press the start button. Check input LEDs (In1, In2) for status. |
| Power LED is OFF | No power supply or incorrect voltage. | Verify 24 V DC power supply to terminals A1 and A2. Check fuses and circuit breakers. |
For complex issues or persistent faults, contact Pilz technical support.
8. Specifications
| Parameter | Value |
|---|---|
| Model Number | 751104 |
| Manufacturer | Pilz |
| Power Supply | 24 V DC |
| Outputs | 3 N/O (Safety), 1 N/C (Auxiliary), 1 SC (Safety Contact) |
| Current Rating | 6 Amps |
| Contact Material | Silver |
| Connector Type | Plug-In |
| Mounting Type | Plug In Mount (DIN Rail) |
| Width | 22.5 mm |
| Product Dimensions | 0.31 x 0.31 x 0.24 inches (approximate) |
| Weight | 1.67 Pounds (approximate) |
9. Warranty and Support
For detailed warranty information, please refer to the official Pilz website or contact your authorized Pilz distributor. Warranty terms typically cover defects in materials and workmanship under normal use.
For technical support, product inquiries, or to report issues, please visit the official Pilz website or contact their customer service department. You can also visit the PILZ Store on Amazon for more information.
