Pilz PNOZ X4 User manual

PNOZ X4
Operating Manual 19894-EN-07
}Safety relays

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
Operating Manual PNOZ X4
19894-EN-07 3
Introduction 4
Validity of documentation 4
Using the documentation 4
Definition of symbols 4
Safety 5
Intended use 5
Safety regulations 5
Safety assessment 5
Use of qualified personnel 6
Warranty and liability 6
Disposal 6
For your safety 6
Unit features 7
Safety features 7
Block diagram/terminal configuration 7
Types: AC 7
Type: DC 8
Function Description 8
Operating modes 8
Timing diagram 9
Installation 9
Wiring 10
Preparing for operation 11
Operation 13
Status indicators 13
Faults – Interference 14
Dimensions in mm 14
Technical details 15
Safety characteristic data 30
Supplementary data 30
Service life graph 31
Order reference 31
EC declaration of conformity 32

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 4
Introduction
Validity of documentation
This documentation is valid for the product PNOZ X4. It is valid until new documentation is
published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The safety relay PNOZ X4 provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN60947-5-1, EN60204-1 and VDE0113‑1
and may be used in applications with
}E-STOP pushbuttons
}Safety gates
}Light grids and safety switches with detection of shorts across contacts
The following is deemed improper use in particular:
}Any component, technical or electrical modification to the product
}Use of the product outside the areas described in this manual
}Use of the product outside the technical details (see Technical details [ 15]).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
Safety regulations
Safety assessment
Before using a unit it is necessary to perform a safety assessment in accordance with the
Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 6
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}Have read and understood the information provided in this description under "Safety"
}And have a good knowledge of the generic and specialist standards applicable to the
specific application.
Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended
}Damage can be attributed to not having followed the guidelines in the manual
}Operating personnel are not suitably qualified
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
For your safety
The unit meets all the necessary conditions for safe operation. However, please note the
following:
}Note for overvoltage category III: If voltages higher than low voltage (>50 VAC or >120
VDC) are present on the unit, connected control elements and sensors must have a
rated insulation voltage of at least 250 V.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 7
Unit features
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}Connection options for:
– E-STOP pushbuttons
– Safety gate limit switches
– Start button
– Light guards and safety switches
}LED display for:
– Supply voltage
– Switch status of the safety contacts
}See order reference for unit types
Safety features
The safety relay meets the following safety requirements:
}The circuit is redundant with built-in self-monitoring.
}The safety function remains effective in the case of a component failure.
}The correct opening and closing of the safety function relays is tested automatically in
each on-off cycle.
Block diagram/terminal configuration
Types: AC
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 8
Type: DC
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Function Description
The safety relay PNOZ X4 provides a safety-oriented interruption of a safety circuit. When
supply voltage is supplied the "POWER" LED is lit. The unit is ready for operation when the
feedback loop Y1-Y2 and the start circuit S33-S34 are closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– LEDs "CH1" and "CH2" will light.
– Safety contacts 13-14, 23-24 and 33-34 are closed, auxiliary contact 41-42 is open.
The unit is active.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– The LEDs "CH1" and "CH2" go out.
– Safety contacts 13-14, 23-24 and 33-34 are opened redundantly, auxiliary contact
41-42 is closed.
Operating modes
}Single-channel operation: No redundancy in the input circuit, earth faults in the start
and input circuit are detected.
}Dual-channel operation without detection of shorts across contacts: Redundant input
circuit, detects PNOZ X4
– earth faults in the start and input circuit,
– short circuits in the input circuit.
}Dual-channel operation with detection of shorts across contacts: Redundant input cir-
cuit, PNOZ X4 detects
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– shorts across contacts in the input circuit.
}Automatic start: Unit is active once the input circuit has been closed.
}Manual start: Unit is active once the input circuit and the start circuit are closed.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 9
}Monitored start: Unit is active once the input circuit is closed and once the start circuit is
closed after the waiting period has elapsed (see Technical details [ 15]).
}Increase in the number of available contacts by connecting contact expander modules
or external contactors/relays.
Timing diagram
[1][1] [2][2] [3][3]
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}Output aux: Auxiliary contact
}[1]: Automatic start
}[2]: Manual start
}[3]: Monitored start
}a: Input circuit closes before start circuit
}b: Start circuit closes before input circuit
}t1: Switch-on delay
}t2: Delay-on de-energisation
}t3: Recovery time
}t4: Waiting period with a monitored start
Installation
}The unit should be installed in a control cabinet with a protection type of at least IP54.
}Use the notch on the rear of the unit to attach it to a DIN rail.
}Ensure the unit is mounted securely on a vertical DIN rail (35 mm) by using a fixing ele-
ment (e.g. retaining bracket or an end angle).

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 10
Wiring
Please note:
}Information given in the "Technical details [ 15]" must be followed.
}Outputs 13-14, 23-24, 33-34 are safety contacts; output 41-42 is an auxiliary contact
(e.g. for display).
}Auxiliary contact 41-42 shouldnot be used for safety circuits!
}Do not connect undesignated terminals.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 15]).
}Calculation of the max. cable runs lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 15])
Rl/km = cable resistance/km
}Use copper wire that can withstand 60/75°C.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}On 24 VDC devices:
The power supply must comply with the regulations for extra low voltages with protect-
ive electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.
}Ensure the wiring and EMC requirements of IEC 60204-1 are met.
Important for detection of shorts across contacts:
As this function for detecting shorts across contacts is not failsafe, it is tested by Pilz during
the final control check. If there is a danger of exceeding the cable runs, we recommend the
following test after the installation of the device:
1. Unit ready for operation (output contacts closed)
2. Short circuit the test terminals S12, S22 for detecting shorts across the inputs.
3. The unit's fuse must be triggered and the output contacts must open. Cable lengths in
the scale of the maximum length can delay the fuse triggering for up to 2 minutes.
4. Reset the fuse: remove the short circuit and switch off the supply voltage for approx. 1
minute.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 11
Preparing for operation
Supply voltage AC DC
A1
A2
L1
N
FE
A1
A2
L+
L-
Input circuit Single-channel Dual-channel
E-STOP
without detection of shorts
across contacts
S1
S22
S21
S11
S52
S12
S1
S11
S12
S52
S22
S21
E-STOP
with detection of shorts across
contacts
S1
S22
S21
S12
S11
S52
S11
Safety gate
without detection of shorts
across contacts
S1
S22
S21
S11
S52
S12
S1 S2
S22
S21
S11
S12
S52
Safety gate
with detection of shorts across
contacts
Light guard or safety switch, de-
tection of shorts across contacts
via ESPE (only when UB = 24
VDC)
NOTICE
With single-channel wiring the safety level of your machine/plant may be
lower than the safety level of the unit (see Safety characteristic
data [ 30]).

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 12
NOTICE
Operation with a light guard or safety switch
It must not be possible to switch off the supply voltage for the PNOZ X4
separately from the supply voltage for the light guard or safety switch.
Start circuit
E-STOP wiring, safety gate
(single-channel)
E-STOP wiring, safety gate (dual-
channel)
Automatic start
Manual start
S33
S34
S3
Y37
Y36
S33
S34
S3
Y37
Y36
Monitored start
S33
S34
S3
Y37
Y36
S33
S34
S3
Y37
Y36
NOTICE
In the event of an automatic start or manual start with bridged start contact
(fault):
The unit starts up automatically when the safeguard is reset, e.g. when the
E-STOP pushbutton is released. Use external circuit measures to prevent
an unexpected restart.
Feedback loop with feedback loop monitoring without feedback loop monitoring
Link or contacts from external
contactors

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 13
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed
Operation
NOTICE
Check each safety function
– after initial commissioning and after each change of the machine/
plant
– for SIL CL 3/PL e at least 1x per month, for SIL CL 2/PL d at least 1x
per year
Follow the instructions below:
– Activate the safety function and check whether all the used safety
contacts open.
– Prepare for operation again and start the unit. All the used safety
contacts must be closed again.
The safety functions may only be checked by qualified personnel.
Status indicators
LEDs indicate the status and errors during operation:
LED on
POWER
Supply voltage is present.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 14
Faults – Interference
}Earth fault: The supply voltage fails and the safety contacts open. Once the cause of
the respective fault has been rectified and the supply voltage is switched off for approx.
1minute, the unit is ready for operation again.
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
}LED "POWER" does not light: Short circuit or no supply voltage.
Dimensions in mm
45 ( 1,77 ")
121 (4.76")
75 (2.95")
87 (3.42")

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 15
Technical details
Order no. 774730 – 774734
See below for more order numbers
General 774730 774731 774734
Approvals
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
Electrical data 774730 774731 774734
Supply voltage
Voltage 24 V 24 V 110 V
Kind DC AC AC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (AC) – 5 VA 5 VA
Output of external
power supply (DC) 2,5 W – –
Frequency range AC – 50 - 60 Hz 50 - 60 Hz
Residual ripple DC 160 % – –
Duty cycle 100 % 100 % 100 %
Max. inrush current im-
pulse
Current pulse, A1 1,7 A – –
Pulse duration, A1 1,5 ms – –
Inputs 774730 774731 774734
Number 222
Voltage at
Input circuit DC 24 V 24 V 24 V
Start circuit DC 24 V 24 V 24 V
Feedback loop DC 24 V 24 V 24 V
Current at
Input circuit DC 40 mA 40 mA 40 mA
Start circuit DC 70 mA 90 mA 90 mA
Feedback loop DC 70 mA 90 mA 90 mA
Min. input resistance at
power-on 165 Ohm 165 Ohm 165 Ohm

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 16
Inputs 774730 774731 774734
Max. overall cable resist-
ance Rlmax
Single-channel at UB
DC 20 Ohm – –
Single-channel at UB
AC – 150 Ohm 150 Ohm
Dual-channel without
detection of shorts
across contacts at UB
DC 20 Ohm – –
Dual-channel without
detection of shorts
across contacts at UB
AC –150 Ohm 150 Ohm
Dual-channel with de-
tection of shorts across
contacts at UB DC 15 Ohm – –
Dual-channel with de-
tection of shorts across
contacts at UB AC – 100 Ohm 100 Ohm
Relay outputs 774730 774731 774734
Number of output con-
tacts
Safety contacts (N/O),
instantaneous 333
Auxiliary contacts (N/C) 111
Max. short circuit current
IK 1 kA 1 kA 1 kA
Utilisation category
In accordance with the
standard EN 60947-4-1 EN 60947-4-1 EN 60947-4-1
Utilisation category of
safety contacts
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 17
Relay outputs 774730 774731 774734
Utilisation category of
auxiliary contacts
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W
Utilisation category
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
Utilisation category of
safety contacts
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 7 A 7 A 7 A
Utilisation category of
auxiliary contacts
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 7 A 7 A 7 A
Utilisation category in ac-
cordance with UL
Voltage 240 V AC G. P. 240 V AC G. P. 240 V AC G. P.
With current 8 A 8 A 8 A
Voltage 24 V DC Resistive 24 V DC Resistive 24 V DC Resistive
With current 5 A 5 A 5 A
Pilot Duty B300, R300 B300, R300 B300, R300
External contact fuse pro-
tection, safety contacts
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
Max. melting integral 240 A²s 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A 10 A
Blow-out fuse, slow 6 A 6 A 6 A
Blow-out fuse, gG 10 A 10 A 10 A
Circuit breaker 24V
AC/DC, characteristic
B/C 6 A 6 A 6 A

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 18
Relay outputs 774730 774731 774734
External contact fuse pro-
tection, auxiliary contacts
Max. melting integral 240 A²s 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A 10 A
Blow-out fuse, slow 6 A 6 A 6 A
Blow-out fuse, gG 10 A 10 A 10 A
Circuit breaker 24 V
AC/DC, characteristic
B/C 6 A 6 A 6 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Conventional thermal
current while loading
several contacts
774730 774731 774734
Ith per contact at UB AC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact – 8 A 8 A
Conv. therm. current
with 2 contacts – 7,5 A 7,5 A
Conv. therm. current
with 3 contacts – 6,5 A 6,5 A
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current
with 1 contact 8 A – –
Conv. therm. current
with 2 contacts 8 A – –
Conv. therm. current
with 3 contacts 7 A – –
Times 774730 774731 774734
Switch-on delay
With automatic start
typ. 270 ms 210 ms 210 ms
With automatic start
max. 600 ms 350 ms 350 ms
With automatic start
after power on typ. 270 ms 240 ms 240 ms
With automatic start
after power on max. 600 ms 390 ms 390 ms
With manual start typ. 70 ms 55 ms 55 ms
With manual start max. 600 ms 350 ms 350 ms
With monitored start
typ. 40 ms 30 ms 30 ms
With monitored start
max. 70 ms 50 ms 50 ms

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 19
Times 774730 774731 774734
Delay-on de-energisation
With E-STOP typ. 15 ms 15 ms 15 ms
With E-STOP max. 30 ms 30 ms 30 ms
With power failure typ. 50 ms 55 ms 55 ms
With power failure max. 70 ms 80 ms 80 ms
Recovery time at max.
switching frequency 1/s
After E-STOP 50 ms 50 ms 50 ms
After power failure 100 ms 100 ms 100 ms
Waiting period with a
monitored start 250 ms 150 ms 150 ms
Min. start pulse duration
with a monitored start 30 ms 30 ms 30 ms
Supply interruption before
de-energisation 20 ms 20 ms 20 ms
Simultaneity, channel 1
and 2 max. ∞∞∞
Environmental data 774730 774731 774734
Climatic suitability EN 60068-2-78 EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C -10 - 55 °C -10 - 55 °C
Storage temperature
Temperature range -40 - 85 °C -40 - 85 °C -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during op-
eration Not permitted Not permitted Not permitted
EMC EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
EN 60947-5-1, EN
61000-6-2, EN 61326-3-1
Vibration
In accordance with the
standard EN 60068-2-6 EN 60068-2-6 EN 60068-2-6
Frequency 10 - 55 Hz 10 - 55 Hz 10 - 55 Hz
Amplitude 0,35 mm 0,35 mm 0,35 mm
Airgap creepage
In accordance with the
standard EN 60947-1 EN 60947-1 EN 60947-1
Overvoltage category III / II III / II III / II
Pollution degree 222
Rated insulation voltage 250 V 250 V 250 V
Rated impulse withstand
voltage 4 kV 4 kV 4 kV
Protection type
Mounting area (e.g.
control cabinet) IP54 IP54 IP54
Housing IP40 IP40 IP40
Terminals IP20 IP20 IP20

PNOZ X4
Operating Manual PNOZ X4
19894-EN-07 20
Mechanical data 774730 774731 774734
Mounting position Any Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles 10,000,000 cycles
Material
Bottom PPO UL 94 V0 PPO UL 94 V0 PPO UL 94 V0
Front ABS UL 94 V0 ABS UL 94 V0 ABS UL 94 V0
Top PPO UL 94 V0 PPO UL 94 V0 PPO UL 94 V0
Connection type Screw terminal Screw terminal Screw terminal
Mounting type Fixed Fixed Fixed
Conductor cross section
with screw terminals
1 core flexible 0,2 - 4 mm², 24 - 10 AWG 0,2 - 4 mm², 24 - 10 AWG 0,2 - 4 mm², 24 - 10 AWG
2 core with the same
cross section, flexible
with crimp connectors,
no plastic sleeve
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
2 core with the same
cross section, flexible
without crimp connect-
ors or with TWIN crimp
connectors
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
0,2 - 2,5 mm², 24 - 14
AWG
Torque setting with screw
terminals 0,6 Nm 0,6 Nm 0,6 Nm
Dimensions
Height 87 mm 87 mm 87 mm
Width 45 mm 45 mm 45 mm
Depth 121 mm 121 mm 121 mm
Weight 270 g 370 g 370 g
Where standards are undated, the 2014-07 latest editions shall apply.