Pilz 535012

Name: Pilz 535012
Brand: Pilz
SKU: 535012
Availability: InStock

€ 150,00

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Condition

Clear

SKU: 535012 Category: Other Brand: Pilz

Description
Additional information

The Pilz 535012 is a safety relay module belonging to the PNOZsigma series manufactured by Pilz, a specialist in safety technology and automation. This part number identifies a configurable safety relay designed to monitor safety functions such as emergency stop circuits, safety gates, and two-hand control systems. The PNOZsigma family is widely recognized in industrial safety applications for providing reliable, certified safety switching functions in compact DIN-rail mountable housings.

The 535012 module provides safety-rated inputs for connecting safety sensors, E-stop buttons, and guard door switches, with redundant internal relay contacts rated for safety-critical switching. The device is designed to meet Performance Level PL e (EN ISO 13849-1) and Safety Integrity Level SIL 3 (IEC 62061), making it suitable for the highest risk categories in machinery safety. It features automatic and manual reset modes, cross-circuit detection on input channels, and LED status indicators for power, output state, and fault diagnostics. The compact design allows side-by-side mounting with minimal spacing requirements on standard 35 mm DIN rails.

The Pilz 535012 is commonly deployed in machinery manufacturing, automotive production lines, press and stamping equipment, packaging machinery, and robotic work cells where personnel protection is mandatory. It is used wherever safety gates, light curtains, or emergency stop devices must be integrated into a machine control system with certified safety performance. The module is also found in material handling systems, conveyor lines, and process automation environments where compliance with EN ISO 13849 and IEC 62061 safety standards is required by regulation or customer specification.

Technical Specifications

Series/Product Family	PNOZsigma
Input/Operating Voltage	24 V DC
Safety Category	Category 4 (EN ISO 13849-1)
Performance Level	PL e (EN ISO 13849-1)
Safety Integrity Level	SIL 3 (IEC 62061)
Number of Safety Inputs	2 (dual-channel)
Safety Output Contacts	2 NO (normally open) safety contacts
Auxiliary Output	1 NC (normally closed) signaling contact
Operating Temperature	-10 °C to +55 °C
Storage Temperature	-25 °C to +70 °C
Relative Humidity	15 % to 95 % (non-condensing)
IP/Protection Rating	IP40 (housing)
Mounting	35 mm DIN rail (EN 60715)
Certifications	CE, TUV, UL, cUL
Reset Mode	Automatic and manual selectable
Cross-Circuit Detection	Yes

Common Fault Conditions and Diagnostic Indicators

LED PWR off: No supply voltage detected at the module input terminals.
Check 24 V DC supply wiring to the module. Verify fuse integrity and power supply output voltage.
LED OUT off (inputs active): Output relay has not energized despite inputs being closed, indicating a detected fault condition.
Check for cross-circuit faults on input wiring. Verify both input channels are correctly connected and that the reset input has been triggered if manual reset is configured.
Cross-Circuit Fault: A short circuit between the two input channels has been detected, indicating a wiring fault.
Inspect and separate input channel wiring. Ensure cables for channel 1 and channel 2 are routed independently to prevent cross-circuit conditions.
Simultaneous Discrepancy Fault: The two input channels did not switch within the permitted discrepancy time window, indicating a faulty safety device or wiring issue.
Test the connected safety device (E-stop, gate switch) for correct simultaneous switching. Replace the safety device if one contact is slower or fails to close.
Reset Fault: Manual reset input signal was present before the safety inputs were closed, or reset pulse duration was outside the permitted range.
Ensure the reset button is pressed only after the safety inputs are closed. Verify reset pulse duration meets the module specification (typically 0.05 s to 5 s).
Output Welding Fault: Internal monitoring has detected that one or more output relay contacts may be welded closed, preventing safe de-energization.
Remove power and inspect output relay contacts. If welding is confirmed, the module must be replaced. Do not attempt to repair internal relay contacts.
Internal Device Fault: An internal self-test has detected a hardware fault within the safety relay module.
Power cycle the module. If the fault persists, the module must be replaced and returned for repair or evaluation. Do not continue operating the machine with a faulty safety relay.

Frequently Asked Questions

What supply voltage does the Pilz 535012 require?

The Pilz 535012 operates on a 24 V DC supply voltage. Ensure the power supply is within the specified tolerance range as defined in the PNOZsigma datasheet for this variant.

What safety standard certifications does the 535012 hold?

The module is certified to Performance Level PL e per EN ISO 13849-1 and Safety Integrity Level SIL 3 per IEC 62061. It also carries CE, TUV, UL, and cUL certifications.

Can the 535012 be used with light curtains and safety gate switches?

Yes, the module supports dual-channel safety inputs compatible with OSSD outputs from light curtains, as well as mechanically linked safety gate switches and emergency stop buttons.

Does the 535012 support both automatic and manual reset modes?

Yes, the module can be configured for either automatic reset or monitored manual reset depending on the wiring configuration, allowing compliance with different machine safety requirements.

Is the Pilz 535012 suitable for use in Category 4 safety circuits?

Yes, when correctly wired in a dual-channel configuration with cross-circuit detection enabled, the 535012 supports Category 4 / PL e applications as defined by EN ISO 13849-1.

Troubleshooting

Module does not power on and PWR LED remains off

Measure 24 V DC at the supply input terminals of the module using a multimeter. Check for blown fuse or open circuit in the supply wiring.

Restore correct 24 V DC supply. Replace any blown fuse in the supply circuit and verify wiring connections at the module terminals are secure and correctly torqued.

Output relay does not energize after closing safety inputs

Check the status of the input channel LEDs. If they indicate a fault, inspect input wiring for cross-circuit conditions or discrepancy between channels. Verify the reset input is being triggered correctly.

Separate input channel cables to eliminate cross-circuit faults. Test the connected safety device for simultaneous contact closure. Apply a valid reset pulse if manual reset mode is configured.

Module triggers a fault immediately after reset

Verify that the safety inputs are fully closed and stable before the reset signal is applied. Check reset button wiring and pulse duration.

Ensure the safety device contacts are fully closed before pressing reset. Adjust reset button wiring so the pulse duration falls within the specified range. Replace the reset button if contact bounce is suspected.

Intermittent nuisance tripping of the safety relay

Inspect input channel wiring for loose connections, cable damage, or electromagnetic interference from adjacent power cables. Check the safety device contacts for wear or contamination.

Re-terminate all input connections and ensure cables are routed away from high-voltage or high-current conductors. Replace worn or contaminated safety device contacts. Consider shielded cable for long input cable runs.

Module fails to reset after replacing a connected safety device

Verify that the new safety device wiring matches the original dual-channel configuration. Check that both output contacts of the new device are connected to the correct input channels on the module.

Review the PNOZsigma wiring diagram for the 535012 and confirm channel 1 and channel 2 connections are correctly assigned. Power cycle the module after correcting the wiring and apply a valid reset signal.

Condition	Repair, Used, Refurbished, New in box (sealed)