Pilz P2HZ X4P User manual

P2HZ X4P
Operating Manual-20076-EN-11
-Safety relays

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
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 P2HZ X4P
20076-EN-11 | 3
Introduction ............................................................................................................................5
Validity of documentation ..........................................................................................................5
Using the documentation ..........................................................................................................5
Definition of symbols .................................................................................................................5
Safety ......................................................................................................................................6
Intended use .............................................................................................................................6
Safety regulations .....................................................................................................................7
Safety assessment....................................................................................................................7
Use of qualified personnel.........................................................................................................7
Warranty and liability.................................................................................................................7
Disposal ....................................................................................................................................7
For your safety ..........................................................................................................................8
Unit features ...........................................................................................................................8
Safety features .......................................................................................................................8
Block diagram/terminal configuration .................................................................................9
Types: DC .................................................................................................................................9
Types: AC .................................................................................................................................9
Function Description .............................................................................................................10
Operating modes.......................................................................................................................10
Timing diagram .........................................................................................................................11
Installation ..............................................................................................................................11
Wiring ......................................................................................................................................12
Preparing for operation .........................................................................................................13
Operation ................................................................................................................................13
Status indicators........................................................................................................................14
Faults – Interference ..............................................................................................................14
Dimensions in mm .................................................................................................................14
Technical details ....................................................................................................................15
Safety characteristic data..........................................................................................................19
Supplementary data ...............................................................................................................20
Service life graph ......................................................................................................................20

Contents
Operating Manual P2HZ X4P
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Order reference ......................................................................................................................21
EC declaration of conformity ................................................................................................21
UKCA-Declaration of Conformity .........................................................................................21

P2HZ X4P
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Introduction
Validity of documentation
This documentation is valid for the product P2HZ X4P. 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.

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INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The two-hand control relay P2HZ X4P meets the requirements of EN ISO 13851 Type IIIC
and EN 60204-1.
It forces an operator to keep his hands out of the hazardous area during the dangerous
movement.
The device is suitable as a block for simultaneity, for example for mounting in press control-
lers, woodworking machinery or machine tools.
Note the respective valid regulations for these machines.
Improper use
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 operating manual,
}Use of the product outside the technical details (see chapter entitled Technical
Details [ 19]).
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.

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Safety regulations
Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and ENIEC62061. However, this does not guarantee the func-
tional safety of the overall plant/machine. To achieve the relevant safety level of the overall
plant/machine’s required safety functions, each safety function needs to be considered sep-
arately.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. In
order to inspect, assess and handle products, devices, systems, plant and machinery, this
person must be familiar with the state of the art and the applicable national, European and
international laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident prevention,
}Have read and understood the information provided in the section entitled Safety
}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-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

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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.
Unit features
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}Connection options for:
– 2 control elements (pushbuttons)
}LED display for:
– Supply voltage
– Switch status of the safety contacts
}Plug-in connection terminals (either spring-loaded terminal or screw terminal)
Safety features
The two-hand control 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 circuit prevents a further press stroke in the case of:
– Relay failure
– Contact welding
– Coil defect on a relay
– Open circuit
– Short circuit

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Block diagram/terminal configuration
Types: DC
}UB: 24 VDC; Order no. 777355, 787355
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Types: AC
}UB: 24 VAC; Order no. 777354
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)

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Function Description
The two-hand control relay P2HZ X4P is activated by simultaneously pressing the two oper-
ator elements (simultaneity see Technical details [ 19]). If one or both of the operator
elements are released, it interrupts the control command to close the press. The device is
ready for operation when the supply voltage is applied and the feedback loop Y1-Y2 is
closed. The "POWER" LED lights up.
}Both operator elements are operated within the simultaneity:
– Safety contacts 13-14, 23-24 and 33-34 close, auxiliary contact 41-42 is opened, the
device is active.
– LEDs "CH1" and "CH2" will light.
}One operator element is released following simultaneous operation:
– Safety contacts 13-14, 23-24 and 33-34 are opened redundantly, auxiliary contact
41-42 is closed.
– The LED "CH1" or "CH2" goes out.
}To activate the device again, both operator elements have to be released and then oper-
ated again within the simultaneity.
Operating modes
}Dual-channel operation with detection of shorts across contacts: Redundant input circuit,
P2HZ X4P detects
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– shorts across contacts in the input circuit.

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Timing diagram
POWER
Feedback loop
Output safe
Button 1
t0t1t2t3t3t1
Button 2
Output aux.
t1
Legend
}POWER: Supply voltage
}Button 1/Button 2: Input circuits S11, S21, S32, S33
}Feedback loop: Feedback loop Y1-Y2
}Output safe: Safety outputs 13-14, 23-24, 33-34
}Output aux: Auxiliary contacts 41-42
}t0: Recovery time after power on
}t1: Simultaneity, channel 1 and 2
}t2: Operating cycle ended through pushbutton 1 or 2
}t3: Y1-Y2 must be closed before the button is operated (recovery time)
Shaded area: State irrelevant
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 (35 mm).
}When installed vertically: Secure the unit by using a fixing element (e.g. retaining bracket
or end angle).
}Fit the input terminal block of the control cabined with additional terminals for the supply
voltage.
WARNING!
Loss of the safety function due to too short distance of the operator
elements to the hazardous area!
The distance of the two-hand control relay to the nearest hazardous area
must be large enough so that if one of the operator elements is released,
the hazardous movement is interrupted before the operator reaches the
hazardous area or can reach into the hazardous area. You must maintain
the minimum distance in accordance with EN ISO 13855.
Depending on the application, serious injury or death may result.

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Wiring
Please note:
}Information given in the "Technical details [ 19]" 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!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 19]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 19])
Rl/km = cable resistance/km
}Use copper wiring with a temperature stability of 60/75 °C.
}To prevent EMC interferences (particularly common-mode interferences) the measures
described in EN60204-1 must be executed. This includes the separate routing of cables
of the control circuits (input, start and feedback loop) from other cables for energy trans-
mission or the shielding of cables, for example.
}The supply voltage must be switched off with the operating energy of the machine.
}The connection cables between the P2HZ X4P and the pushbuttons should not be laid
directly next to power cables, otherwise inductive and capacitive interference coupling
can result.
}On account of the low currents you should use gold-plated pushbutton contacts.
}Only contactors with positive-guided contacts should be used for safety functions.
}Adequate protection circuit 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.
}On 24 VDC devices:
The power supply must comply with the regulations for extra low voltages with protective
electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.

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Preparing for operation
Supply voltage AC DC
A1
A2
L1
N
F1
A1
A2
L+
L-
F1
Input circuit Single-channel Dual-channel
Two-hand pushbutton
with detection of shorts across
contacts
S33
S11
S32
S21
S1
S2
Feedback loop without feedback loop monitor-
ing
with feedback loop monitoring
Link or contacts from external con-
tactors
Legend
}S1/S2: Two-hand pushbuttons
Operation
When the relay outputs are switched on, the mechanical contact on the relay cannot be
tested automatically. Depending on the operational environment, measures to detect the
non-opening of switching elements may be required under some circumstances.
When the product is used in accordance with the European Machinery Directive, a check
must be carried out to ensure that the safety contacts on the relay outputs open correctly.
Open the safety contacts (switch off output) and start the device again, so that the internal
diagnostics can check that the safety contacts open correctly
}for SIL 3/PL e at least 1x per month
}for SIL 2/PL d at least 1x per year
NOTICE
The safety functions should be checked after initial commissioning and each
time the plant/machine is changed. The safety functions may only be
checked by qualified personnel.

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Status indicators
LEDs indicate the status and errors during operation:
LED on
POWER
Supply voltage is present and E-STOP pushbutton not operated.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
Faults – Interference
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
Dimensions in mm
* with spring-loaded terminals

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Technical details
General 777354 777355 787355
Certifications
CCC, CE, EAC, KOSHA,
TÜV, UKCA, cULus Lis-
ted
CCC, CE, EAC, KOSHA,
TÜV, UKCA, cULus Lis-
ted
CCC, CE, EAC, KOSHA,
TÜV, UKCA, cULus Lis-
ted
Electrical data 777354 777355 787355
Supply voltage
Voltage 24 V 24 V 24 V
Kind AC DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (AC) 4 VA – –
Output of external
power supply (DC) – 2,5 W 2,5 W
Frequency range AC 50 - 60 Hz – –
Residual ripple DC – 10 % 10 %
Duty cycle 100 % 100 % 100 %
Current at
N/O contact 15 mA 15 mA 15 mA
N/C contact 25 mA 20 mA 20 mA
Max. overall cable resist-
ance Rlmax per input cir-
cuit 14 Ohm 14 Ohm 14 Ohm
External unit fuse protec-
tion F1 min. 1 A 1 A 1 A
External unit fuse protec-
tion F1 max.
Max. conductor cross
section
Max. conductor cross
section
Max. conductor cross
section
Two-hand control relay
type
in accordance with the
standard EN ISO 13851 EN ISO 13851 EN ISO 13851
Type III C III C III C
Inputs 777354 777355 787355
Quantity 222
Voltage at
Input circuit DC 24 V 24 V 24 V
Feedback loop DC 24 V 24 V 24 V
Current at
Feedback loop DC 25 mA 30 mA 30 mA
Relay outputs 777354 777355 787355
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

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Relay outputs 777354 777355 787355
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 5 A 5 A 5 A
Max. power 1250 VA 1250 VA 1250 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 5 A 5 A 5 A
Max. power 125 W 125 W 125 W
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 2,5 A 2,5 A 2,5 A
Max. power 600 VA 600 VA 600 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 2,5 A 2,5 A 2,5 A
Max. power 60 W 60 W 60 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 2,5 A 2,5 A 2,5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 1,5 A 1,5 A 1,5 A
Utilisation category of
auxiliary contacts
AC15 at 230 V 230 V 230 V
Max. current 2,5 A 2,5 A 2,5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 1,5 A 1,5 A 1,5 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 5 A 5 A 5 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

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Relay outputs 777354 777355 787355
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 100 A²s 100 A²s 100 A²s
Blow-out fuse, quick 6 A 6 A 6 A
Blow-out fuse, slow 4 A 4 A 4 A
Blow-out fuse, gG 6 A 6 A 6 A
Circuit breaker 24V
AC/DC, characteristic
B/C 4 A 4 A 4 A
External contact fuse pro-
tection, auxiliary contacts
Max. melting integral 100 A²s 100 A²s 100 A²s
Blow-out fuse, quick 4 A 4 A 4 A
Blow-out fuse, slow 2 A 2 A 2 A
Blow-out fuse, gG 4 A 4 A 4 A
Circuit breaker, 24
VAC/DC, character-
istic B/C 2 A 2 A 2 A
Conventional thermal cur-
rent 5 A 5 A 5 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Times 777354 777355 787355
Delay-on de-energisation
(response time tA in ac-
cordance with EN ISO
13851)
N/O contact 15 ms 15 ms 15 ms
N/C contact 30 ms 30 ms 30 ms
Recovery time 250 ms 250 ms 250 ms
Simultaneity, channel 1
and 2 max. 500 ms 500 ms 500 ms
Environmental data 777354 777355 787355
Climatic suitability EN 60068-2-78 EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -25 - 55 °C -25 - 55 °C -25 - 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 60947-5-1, EN
61000-6-2
EN 60947-5-1, EN
61000-6-2

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Environmental data 777354 777355 787355
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
Housing IP40 IP40 IP40
Terminals IP20 IP20 IP20
Mounting area (e.g.
control cabinet) IP54 IP54 IP54
Mechanical data 777354 777355 787355
Mounting position Any Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles 10,000,000 cycles
Material
Bottom PPO UL 94 V1 PPO UL 94 V1 PPO UL 94 V1
Front ABS UL 94 V0 ABS UL 94 V0 ABS UL 94 V0
Top PPO UL 94 V1 PPO UL 94 V1 PPO UL 94 V1
Connection type Screw terminal Screw terminal Spring-loaded terminal
Mounting type plug-in plug-in plug-in
Conductor cross section
with screw terminals
1 core flexible 0,25 - 2,5 mm², 24 - 12
AWG
0,25 - 2,5 mm², 24 - 12
AWG –
2 core with the same
cross section, flexible
with crimp connectors,
no plastic sleeve
0,25 - 1 mm², 24 - 16
AWG
0,25 - 1 mm², 24 - 16
AWG –
2 core with the same
cross section, flexible
without crimp connect-
ors or with TWIN crimp
connectors
0,2 - 1,5 mm², 24 - 16
AWG
0,2 - 1,5 mm², 24 - 16
AWG –
Torque setting with screw
terminals 0,5 Nm 0,5 Nm –
Stripping length with
screw terminals 8 mm 8 mm –
Conductor cross section
with spring-loaded termin-
als: Flexible with/without
crimp connector – –
0,2 - 1,5 mm², 24 - 16
AWG

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Mechanical data 777354 777355 787355
Spring-loaded terminals:
Terminal points per con-
nection – – 2
Stripping length with
spring-loaded terminals – – 8 mm
Dimensions
Height 94 mm 94 mm 101 mm
Width 22,5 mm 22,5 mm 22,5 mm
Depth 121 mm 121 mm 121 mm
Weight 215 g 210 g 210 g
Where standards are undated, the 2022-09 latest editions shall apply.
Safety characteristic data
NOTICE
You must comply with the safety characteristic data in order to achieve the
required safety level for your plant/machine.
Operating
mode
EN ISO
13849-1:
2015
PL
EN ISO
13849-1:
2015
Category
EN IEC
62061
SIL CL/
maximum
SIL
EN IEC
62061
PFHD [1/h]
EN/IEC
61511
SIL
EN/IEC
61511
PFD
EN ISO
13849-1:
2015
TM [year]
–PL e Cat. 4 SIL 3 3,01E-09 SIL 3 3,24E-06 20
Explanatory notes for the safety-related characteristic data:
}Safety characteristic data in accordance with EN IEC 62061 and EN/IEC 61511 was cal-
culated based on EN/IEC 61508.
}TM is the maximum mission time in accordance with EN ISO 13849-1. The value also ap-
plies as the retest interval in accordance with EN/IEC 61508-6 and EN/IEC 61511 and as
the proof test interval and mission time in accordance with EN IEC 62061.
All the units used within a safety function must be considered when calculating the safety
characteristic data.
INFORMATION
A safety function's SIL/PL values are not identical to the SIL/PL values of
the units that are used and may be different. We recommend that you use
the PAScal software tool to calculate the safety function's SIL/PL values.

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Supplementary data
CAUTION!
It is essential to consider the relay's service life graphs. The relay outputs'
safety-related characteristic data is only valid if the values in the service life
graphs are met.
The PFH value depends on the switch frequency and the load of the relay output.
If the service life graphs are not accessible, the stated PFH value can be used irrespective
of the switch frequency and the load, as the PFH value already considers the relay's B10d
value as well as the failure rates of the other components.
Service life graph
The service life graphs indicate the number of cycles from which failures due to wear must
be expected. The wear is mainly caused by the electrical load; the mechanical load is negli-
gible.
Cycles x 1000
Switching current (A)
Example
}Inductive load: 2 A
}Utilisation category AC15
}Contact service life: 400 000 cycles
Provided the application to be implemented requires fewer than 400 000 cycles, the PFH
value (see Technical details) can be used in the calculation.
To increase the service life, sufficient spark suppression must be provided on all output
contacts. With capacitive loads, any power surges that occur must be noted. With DC con-
tactors, use flywheel diodes for spark suppression.