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Last call for Pilz PSENslock: Phase-out deadline approaches
September 16, 2025
Pilz announces December 2025 phase-out deadline for first-generation safety locks
By 31st December 2025, Pilz will Phase-out the original PSENslock [1]. For manufacturers still using the first-generation unit, the phase-out marks a turning point. Safety locking mechanisms are essential for protecting operators and ensuring stable operations.
They prevent entry mid-cycle and keep gates locked until machinery is in a safe state. Planning your next steps now is essential to avoiding supply chain pressure and last-minute scrambles for stock.
At EU Automation, we assist manufacturers in sourcing phased-out PSENslock components. This support continues even after OEM production ceases. We also facilitate early migration support to the replacement part, PSENslock 2.
Part numbers affected by PSENslock Phase-out
Pilz has confirmed that a range of PSENslock safety locking device part numbers are entering their Phase-out stage.
These include:
- 570500
- 570501
- 570502
- 570503
- 570504
- 570505
- 570510
- 570511
- 570513
- 570514
- 570520
- 570521
- 570522
- 570523
- 570560
- 570561
- 570562
- 570563
- 570564
- 570565
- 570570
- 570571
- 570572
- 570573
- 570574
- 570575
- 570577
- 570578
- 570581
- 570584
- 570588
According to Pilz, these part numbers are listed as Phase-out with a planned lifecycle close of 31st December 2025 [1]. At EU Automation we supply an extensive catalogue of Pilz parts. This allows manufacturers to keep lines running while potentially planning migration to PSENslock 2.
What PSENslock and PSENslock 2 do
The PSENslock family combines RFID (Radio Frequency Identification) safety gate monitoring with electromagnetic guard locking [2]. This dual approach means the device can secure sliding or hinged gates, covers and flaps. This system is designed for process guarding. It operates at Performance Level e (PL e), Category 4, which represents the highest level for this function.
The second-generation PSENslock 2 offers higher holding forces, more durable housing and advanced diagnostics. It also introduces configuration options that reduce commissioning effort.
Holding force options
PSENslock 2 is available in 1,000 N or 2,000 N versions [3]. Smaller packaging machines may require only 1,000 N. In contrast, heavy doors or gates that are subject to vibration benefit from 2,000 N. The original PSENslock was limited to 500 N or 1,000 N, so the new range expands its usability without changing footprint.
Migration from PSENslock to PSENslock 2
Pilz designed the new unit as a drop-in replacement. Dimensions and drill holes remain the same, allowing direct substitution [1]. This makes the transition manageable during scheduled downtime.
Migration checklist
The migration checklist below aligns with Pilz’s public specifications [4]:
- Holding force: Choose between 1 000 N or 2 000 N
- Ingress protection: Consider IP67/IP6K9K or stainless versions for hygiene-critical areas
- Series wiring: Specify SDD to enable safe series connection and diagnostics
- Latching adjustment: Plan for Config Key commissioning
- Mechanical compatibility: Dimensionally identical replacement ensures easy swap
- Controller integration: Ensure compatibility with PITgatebox and PNOZmulti
Updating documentation is essential. Validation should confirm that the new device achieves at least the same performance level as the original system. This will also satisfy audit requirements.
Integration with Pilz gate solutions
PSENslock 2 forms part of Pilz’s modular safety-gate portfolio. It can be combined with PITgatebox operator terminals. This provides clear user interfaces and includes PITreader, which adds access permissions. Only trained staff can operate the gates [5].
At system level, it integrates seamlessly with the PNOZmulti 2 configurable safety controller. This provides logic, diagnostics and easy configuration within a single vendor ecosystem. For manufacturers, that means fewer integration headaches and a more coherent safety architecture.
We can assist manufacturers in maintaining continuity. We source phased-out parts that are compatible with existing safety controllers. This ensures that systems remain functional, even while migration plans are being discussed.
Hygiene and durability
Manufacturers in the food, beverage and pharmaceutical sectors face strict hygiene demands. PSENslock 2 addresses these with IP67 and IP6K9K protection ratings.
These prevent dust ingress and allow the lock to withstand high-pressure washdowns. Stainless steel variants add resistance to corrosion and aggressive cleaning agents. The device’s smooth housing also reduces dirt traps and simplifies cleaning.
PSENslock 2 is particularly suited for packaging lines. It is ideal in situations where contamination must be avoided. Additionally, it is well-suited for pharmaceutical production, where equipment is frequently sanitised.
Case examples
Packaging lines
Wächter GmbH integrated PSENslock with PNOZmulti 2 to secure its Tablomat LE case erector [6]. The solution allowed frequent format changes while keeping the line safe. This demonstrates how interlocks can support both safety and operational flexibility.
Pharmaceutical environments
The stainless steel PSENslock consists of 2 units. They are specifically designed for regular high-pressure cleaning. These units assist manufacturers in maintaining compliance with GMP (Good Manufacturing Practice) and HACCP (Hazard Analysis and Critical Control Points) requirements. This makes them ideal for cleanroom and regulated facilities where hygiene failures are costly.
Diagnostics and day-to-day operation
Production downtime is costly. According to Siemens’ True Cost of Downtime 2024 report, Fortune Global 500 companies face significant financial losses. The report estimates that these companies lose $1.4 trillion each year due to unplanned stoppages, which amounts to 11% of their revenue.
In automotive, a single outage can cost up to $2.3 million per hour [7]. Advanced diagnostics at the machine level are one way to cut this risk.
PSENslock 2 offers LED status indicators on all sides for quick visual feedback. The addition of Safety Device Diagnostics (SDD) enables devices to be connected in series while maintaining PL e [8]. Each unit communicates its individual status, making troubleshooting faster and reducing the need for complex point-to-point wiring.
Conclusion
As the original Pilz PSENslock Phase-out date (31st December 2025) approaches, EU Automation can support both paths by supplying a wide range of Pilz safety components. This includies PSENslock and PSENslock 2 related controllers. Early action reduces compliance risks, prevents last-minute downtime and ensures production stays on track.
Citations
[3] https://www.lcautomation.com/wb_documents/Pilz/Pilz%20PSENslock%202%20Flyer.pdf
[6] https://www.pilz.com/en-US/products/success-stories/articles/200535
