PILZ PNOZ S4 Safety Relay User Manual

1. Introduction

This manual provides essential information for the safe and efficient operation of the PILZ PNOZ S4 Safety Relay. It covers product overview, installation, operation, maintenance, and troubleshooting. Please read this manual thoroughly before installation and operation to ensure proper use and to prevent potential hazards.

2. Safety Information

Safety is paramount when working with electrical components. Adhere to all local and national electrical codes and regulations. Only qualified personnel should install, operate, and maintain this device.

2.1 General Safety Instructions

• Disconnect all power before performing any installation, maintenance, or troubleshooting.
• Ensure proper grounding of the system.
• Do not operate the device if it is damaged.
• Use appropriate personal protective equipment (PPE).
• Refer to the wiring diagrams for correct connections.

2.2 Intended Use

The PILZ PNOZ S4 Safety Relay is designed for monitoring safety functions in industrial applications. Any use other than that specified in this manual is considered unintended and may lead to hazardous situations.

3. Product Overview

The PILZ PNOZ S4 is a standalone safety relay, part of the PNOZ Sigma series. It features a compact design and is suitable for various safety applications.

3.1 Key Features

• Voltage Rating: 24V DC / 240V AC
• Current Rating: 8 Amp
• Contact Configuration: 3 Normally Open (N/O) / 1 Normally Closed (N/C)
• 1/2 Channel operation
• Compact design for DIN rail mounting

3.2 Product Components

Figure 3.2.1: Front view of the PILZ PNOZ S4 Safety Relay. This image displays the main face of the relay, clearly showing the "PILZ" brand logo, "Made in Germany" text, and the model identification "PNOZ s4 24VDC 3n/o 1n/c Ident.No.: 750104". It also shows voltage specifications (24VDC -15% / +10%, 2.5W) and some AC/DC ratings.

Figure 3.2.2: Side view of the PILZ PNOZ S4 Safety Relay. This image provides a perspective of the relay's side, highlighting its compact form factor and the green casing. The yellow latch mechanism for DIN rail mounting is visible at the bottom.

Figure 3.2.3: Top view of the PILZ PNOZ S4 Safety Relay. This image shows the top surface of the relay, which includes a detailed wiring diagram, various certifications (CE, cULus listed), and additional product information like voltage ratings and reset options (Auto/Manual reset, Reset with start-up test).

4. Setup and Installation

The PNOZ S4 Safety Relay is designed for DIN rail mounting. Ensure the mounting surface is stable and free from excessive vibration.

4.1 Mounting

1. Ensure power is disconnected from the DIN rail.
2. Hook the top edge of the relay onto the DIN rail.
3. Press the bottom edge firmly until it clicks into place.
4. Verify the relay is securely fastened to the DIN rail.

4.2 Wiring

Refer to the wiring diagram printed on the top of the device (Figure 3.2.3) for correct terminal connections. Use appropriate wire gauges for the current rating.

• Power Supply: Connect 24V DC to the designated terminals.
• Input Circuits: Connect safety devices (e.g., emergency stop buttons, safety gates) to the input terminals.
• Output Circuits: Connect controlled devices (e.g., contactors) to the normally open (N/O) and normally closed (N/C) output terminals.
• Grounding: Ensure proper grounding of the system to prevent electrical hazards.

Note: The PNOZ S4 uses screw-type connectors. Ensure all connections are tight and secure to prevent loose contacts and potential failures.

5. Operating Instructions

Once installed and wired correctly, the PNOZ S4 Safety Relay operates by monitoring the input safety circuits and controlling the output circuits accordingly.

5.1 Initial Power-Up

1. Double-check all wiring connections.
2. Apply power to the system.
3. Observe the status indicators on the relay (if present) to confirm proper power and input status.

5.2 Functionality

The relay will activate its output contacts when all safety inputs are closed (safe state). If any safety input opens (unsafe state), the relay will de-energize its outputs, bringing the controlled machinery to a safe stop.

The PNOZ S4 supports both automatic and manual reset functions. Refer to the device labeling and system design for the configured reset method.

6. Maintenance

The PILZ PNOZ S4 Safety Relay is designed for minimal maintenance. However, regular inspections are recommended to ensure continued safe operation.

6.1 Routine Checks

• Visually inspect the relay for any signs of physical damage, discoloration, or loose connections.
• Ensure the operating environment is within specified temperature and humidity ranges.
• Periodically test the safety function by activating the connected safety devices (e.g., pressing an E-stop button) to confirm the relay de-energizes the outputs.

6.2 Cleaning

If cleaning is necessary, disconnect power and use a soft, dry cloth. Do not use abrasive cleaners or solvents.

7. Troubleshooting

This section provides basic troubleshooting steps for common issues. For complex problems, contact PILZ technical support.

8. Specifications

Detailed technical specifications for the PILZ PNOZ S4 Safety Relay.

9. Warranty and Support

For specific warranty information, please refer to the official PILZ website or contact your authorized PILZ distributor. PILZ products are known for their reliability and adherence to international safety standards.

9.1 Technical Support

If you encounter issues that cannot be resolved using the troubleshooting guide, or require further technical assistance, please contact PILZ technical support. Contact details can typically be found on the official PILZ website: www.pilz.com.

9.2 Product Documentation

Additional documentation, including detailed wiring diagrams, certification information, and software tools (if applicable), may be available on the PILZ website.