About Pilz
Pilz Industrial Safety & Automation Control
Pilz GmbH & Co. KG is an automation technology company founded in 1948 by Hermann Pilz and headquartered in Ostfildern, Germany. The company has 42 subsidiaries and branches on all continents and employs 2,504 people as of 2024. Pilz began as a glass-blowing business producing medical laboratory equipment, then pivoted to electronic control and monitoring devices, and ultimately became a world leader in industrial safety control systems and programmable logic controllers for manufacturing automation.
The core product portfolio spans four integrated families: sensor technology (safety switches, optical sensors, area/zone monitoring, safe radar and camera systems per ISO 13849-1 and IEC 61348-3), motion control (precision servo drives and positioning controllers), safety relays (the flagship PNOZ emergency stop and guarding relays certified per DIN EN 954-1 and ISO 13849-1), and programmable safety controllers (PSS 4000 and PSS 67 integrated hardware/software platforms for multi-axis machine safety logic).
The safety relay PNOZ, launched in 1987, revolutionized the industry by combining relays, emergency-stop logic, and guard-locking sequencing into a single module, eliminating the need for complex hardwired relay cabinets. Today, PNOZ variants cover diagnostic emergency-stop functions, enabling-switch monitoring, and output force-guided relays for maximum diagnostic coverage per ISO 13849-1 Performance Level d and SIL 1. The PSS 4000 control system, developed in the 1990s, extends safety logic to complex multi-machine coordinated operations, supporting PL e (ISO 13849-1) and SIL 3 (IEC 62061) architectures with integrated testing and validation tools.
Industries served include automotive manufacturing (press lines, assembly robots, paint booths), food and beverage processing (conveyor interlocks, packaging machinery guarding), heavy machinery and construction equipment (bulldozer blade controls, crane hoist safety), pharmaceuticals (aseptic clean-room equipment), and textile manufacturing (loom stop-motion systems). Every product is engineered to comply with the Machinery Directive (2006/42/EC) and relevant harmonized standards (EN 61508, EN 62061, EN 954-1, ISO 13849-1).
ChatMRO instantly maps your machine's hazard analysis (guard locations, emergency-stop distribution, sensor topology) and required safety level (PL a–e per ISO 13849-1, or SIL 1–3 per IEC 62061) to Pilz's modular safety controller and relay components, enabling rapid certification and commissioning without manual standards research or third-party safety engineering.
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Frequently asked questions
What is the difference between ISO 13849-1 Performance Level (PL) and IEC 62061 Safety Integrity Level (SIL), and which standard applies to my machinery?
Both standards define safety system reliability, but differ in scope: ISO 13849-1 (Performance Levels a–e, driven by ISO 12100 machinery risk assessment) is a control-architecture standard covering emergency stop, guard interlocks, and motion safety for all types of machinery and applies by default to EU Machinery Directive (2006/42/EC) compliance. IEC 62061 (Safety Integrity Levels 1–3, used in process industries and functional safety) applies to machinery with independent high-risk subsystems (pressure vessels, chemical reactors). Most factory automation (presses, conveyors, robots) uses ISO 13849-1; chemical plants and process equipment more commonly cite IEC 62061. Pilz products support both; ChatMRO's compliance matrix helps select the applicable standard for your machinery category.
How do I choose between a hardwired PNOZ emergency-stop relay versus a PSS 4000 programmable safety controller?
PNOZ relays (hardwired logic) are ideal for simple, fixed-function safety tasks: single emergency stop, guard interlocks on 1–3 doors, basic enable/disable sequencing. They require no programming, are inherently fail-safe if properly wired (wire-break detection is built-in), and cost less than software-based systems. PSS 4000 controllers are necessary for complex machinery with multiple hazard zones, coordinated motion sequences across axes, conditional logic (e.g., 'stop press if door opens AND brake fails'), or frequent logic changes. A single press line might use PNOZ; a full automotive assembly plant with dozens of coordinated robots typically uses PSS 4000.
Do Pilz safety sensors (e.g., PSENmag magnetic switches) require separate safety-rated wiring, or can they connect to standard PLCs?
Pilz sensors can connect to either hardwired PNOZ relays or the PSS 4000 safety controller via safe I/O modules. If safety-critical (guarding a hazard), the wiring must be certified safe (typically two independent monitored channels per ISO 13849-1) and certified components must be used throughout the signal chain. Pilz sensors and controllers are pre-certified as a system; if you mix Pilz sensors with third-party PLCs, you must independently verify that the combined architecture meets your target PL/SIL and obtain certification from a notified body (an expensive, time-consuming process). ChatMRO recommends staying within Pilz's certified ecosystem for faster compliance and warranty coverage.
What is the difference between emergency-stop relays and guard-locking relays in Pilz's PNOZ line?
Emergency-stop relays (e.g., PNOZ e1 series) monitor emergency-stop buttons and distribute de-energized stop signals to machinery drives; they don't actively lock guards. Guard-locking relays (e.g., PNOZ e2 series, PNOZ e4 series) combine emergency-stop with an electromechanical latch that holds a door/gate closed, preventing operator access to hazardous areas until the system is explicitly reset—essential for press guards and automated machinery. Many systems use both: a guard-locking relay on the access door and an emergency-stop relay on the main control cabinet.
How often must a Pilz safety system be tested and validated to maintain compliance?
Initial validation occurs during commissioning: a Functional Safety Assessment (FSA) per ISO 13849-1 or IEC 62061 is performed by the machine builder or a notified body to verify PL/SIL achievement. Ongoing compliance requires periodic testing: daily visual checks (e.g., emergency-stop buttons are accessible and clearly marked), quarterly functional tests (e.g., press stops within 500 ms of E-stop press), and annual comprehensive system audits per the machine's risk assessment. Pilz's diagnostic safety relays auto-test internal circuit functions during operation, logging results; machinery with PSS 4000 can automate self-test routines. ChatMRO's maintenance schedules align Pilz system testing with OSHA/ISO audit requirements.