541080 - Dual Safety Channels Start Interlock - SIL 3 Metal Industrial Safety Relay
1. Product Overview
The Pilz PNOZ s4 541080 is a high-performance safety relay designed for advanced emergency stop (E-stop) and guard door monitoring applications. This robust DIN-rail module features dual-channel contact monitoring with force-guided contacts certified to ISO 13849-1 PL e (Category 4) and IEC 62061 SIL CL 3. Engineered for universal voltage compatibility (24-240V AC/DC), it provides reliable safety switching for machines operating in harsh industrial environments (-25°C to +60°C). The compact 17.5mm-wide housing integrates LED status indicators for real-time diagnostics and includes an auto/manual reset selector for flexible system recovery. Its screw terminal connections and IP20 rating make it ideal for control cabinet installation in manufacturing, robotics, and material handling systems where fail-safe E-stop functionality is critical.
2. Key Technical Parameters
- Safety Ratings:
- PL e per ISO 13849-1 (Cat. 4, DCavg=99%, MTTFd=150yr)
- SIL 3 per IEC 62061
- Performance Data: PFHD = 3.7×10⁻⁹/h
- Electrical Specifications:
- Voltage Range: 24-240V AC/DC (auto-sensing)
- Max Load: 6A resistive (AC1) / 4A inductive (AC15)
- Safety Outputs: 2× N/O contacts (force-guided)
- Response Times:
- Switch-off delay: ≤100ms
- Reset time: ≤1s
- Mechanical:
- Dimensions: 17.5×90×103mm (W×H×D)
- Weight: 180g
- Environmental:
- Temperature: -25°C to +60°C
- Humidity: ≤95% (non-condensing)
- Altitude: ≤2000m
- Certifications:
- CE, UL 508, CSA 22.2 No. 14
- RoHS, REACH
3. Primary Applications
The PNOZ s4 is engineered for mission-critical safety functions:
- Press Brakes: Dual-channel E-stop monitoring with contactor control
- Robotic Cells: Safety gate interlocking with position verification
- Conveyor Systems: Emergency stop cord monitoring
- Packaging Machinery: Two-hand control systems
- CNC Equipment: Protective door monitoring with guard locking
- Automated Warehouses: AGV emergency stop circuits
- Plastics Injection: Mold area access control
- Power Presses: Light curtain integration
Its universal voltage compatibility and SIL 3 certification make it indispensable for safeguarding hazardous machinery in automotive, aerospace, and pharmaceutical industries.
4. Functional Advantages
- Diagnostic Intelligence:
- Tri-color LEDs visualize circuit status (green/red/yellow)
- Contact monitoring detects welding/faults
- Versatile Reset Options:
- Selectable manual/auto reset modes
- Key-operated reset security
- Installation Efficiency:
- 17.5mm width saves panel space
- Tool-free terminal marking
- Global Compatibility:
- Wide voltage range eliminates need for converters
- Integrated surge protection
- Compliance Readiness:
- Pre-certified to ISO 13849-1 PL e
- Compliant with EN 60204-1 Stop Category 0
- Lifecycle Durability:
-
100,000 electrical cycles
- Corrosion-resistant terminals
-
5. Safety Functionality
The relay operates through a dual-channel safety concept:
- Input Monitoring:
- Cross-comparison of S11/S12 and S21/S22 contacts
- Detects faults like contact welding within 100ms
- Force-Guided Contacts:
- EN 50205 certified mechanical linkage
- Guaranteed contact separation ≥0.5mm
- Startup Test:
- Automatic contact verification upon power-up
- Prevents restart with undetected faults
- Output Control Logic:
- Closed safety circuit activates K1/K2 contacts
- Auxiliary contact (13-14) provides external signaling
- Reset Protocols:
- Manual: Requires pushbutton after fault clearance
- Auto: Automatic reset when contacts reclose
- Voltage Independence:
- Internal rectifier handles AC/DC inputs
- Maintains safety performance at voltage dips
Failure Management:
- Detected fault: Forces outputs open and LED indication
- Undervoltage lockout below 20V prevents partial operation
- 200ms startup delay prevents nuisance tripping
| Parameter Category | Specification Details |
|---|---|
| Manufacturer & Model | Pilz 541080 (PNOZ X3 1P 24VDC) |
| Product Type | Compact Modular Safety Relay (Single-channel base unit) |
| Safety Standards | ISO 13849-1, IEC 62061, EN 60947-5-1, EN 60204-1 |
| Safety Level | PL e (ISO 13849-1), SIL 3 (IEC 62061) |
| Input Channels | 1 dual-channel safety input • Start/Reset: 1 N/O contact + 1 N/C contact |
| Safety Outputs | 1 N/O contact (Force-guided relay per EN 60947-5-1) |
| Auxiliary Outputs | 1 N/O + 1 N/C (Non-safety rated, for status indication) |
| Contact Rating (Safety) | 6 A @ 250 VAC / 24 VDC (Resistive load) |
| Max. Switching Capacity | 1,500 VA / 180 W |
| Supply Voltage | 24 VDC (Rated), Range: 19.2–28.8 VDC |
| Power Consumption | ≤ 3 W (Typical) |
| Response Time | ≤ 20 ms (Safety output release after valid start) ≤ 100 ms (Fault detection) |
| Reset Modes | Manual (M), Automatic (A), Monitor (S) Configurable via rotary switch |
| Diagnostic Indicators | Multi-color LEDs: • Power (green) • Input status (yellow) • Fault (red) • Ready (green) |
| Expansion Capability | Up to 4 modules via PNOZ X Interface (e.g., timers, I/O modules) |
| Terminal Type | Pluggable screw terminals (Spring-cage optional) |
| Operating Temperature | -25°C to +55°C |
| Protection Rating | IP20 (DIN rail mounted) |
| Housing Material | Polycarbonate (UL94 V-0 flame-retardant) |
| Mounting | 35 mm DIN rail (EN 60715) |
| Dimensions (W×H×D) | 22.5 mm × 99 mm × 121 mm (0.5 TE width) |
| Weight | ≈ 200 g |
| Approvals/Certifications | CE, cULus, TÜV, EAC, UKCA, KOSHA |
| Key Features | • Force-guided contacts (EN 60947-5-1) • Cross-monitoring diagnostics • Short-circuit protection • Tool-free module expansion • Auto-adaptive input technology |
Packaging & Shipping
Company Information
Xiamen ZhiCheng Automation Technology Co., Ltdit is a leading global supplier of control system components. We specialize in control systems and drives.
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