Pilz PNOZ X2.5P Series User manual

PNOZ X2.5P
Operating Manual-20407-EN-10
}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 X2.5P
20407-EN-10 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
Function Description 8
Operating modes 8
Timing diagram 9
Installation 9
Wiring 9
Preparing for operation 11
Operation 13
Status indicators 13
Faults – Interference 13
Dimensions in mm 14
Technical details 14
Safety characteristic data 18
Supplementary data 18
Service life graph 19
Order reference 19
EC declaration of conformity 19

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 4
Introduction
Validity of documentation
This documentation is valid for the product PNOZ X2.5P. 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 X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The safety relay PNOZ X2.5P 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
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 [ 14]).
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 X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 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 a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of 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 preven-
tion,
}Have read and understood the information provided in this description under "Safety"
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific 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 X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 7
Unit features
}Positive-guided relay outputs:
– 2 safety contacts (N/O), instantaneous
}1 semiconductor output
}Connection options for:
– E-STOP pushbutton
– Safety gate limit switch
– Start button
}LED display for:
– Supply voltage
– Switch state of the safety contacts
– State of semiconductor output
}Semiconductor output signals:
– Switch state of the safety contacts
}Plug-in connection terminals (either spring-loaded terminal or screw terminal)
}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
Y11 Y12
*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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Operating Manual PNOZ X2.5P
20407-EN-10 8
Function Description
The safety relay PNOZ X2.5P 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 start circuit S33-S34 is closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– The LEDs "CH.1" and "CH.2" are lit.
– Safety contacts 23-24 and 33-34 are closed. The unit is active.
– The semiconductor output Y11-Y12 is enabled.
– The LED "Y11/Y22" will light.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– The semiconductor output Y11-Y12 is disabled.
– The LED "Y11/Y22" goes out.
– Safety contacts 23-24 and 33-34 are redundantly opened.
– The LEDs "CH.1" and "CH.2" go out.
Operating modes
}Single-channel operation: No redundancy in the input circuit, earth faults in the start
and input circuit are detected.
}Dual-channel operation with detection of shorts across contacts: Redundant input cir-
cuit, PNOZ X2.5P 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.
}Increase in the number of available contacts by connecting contact expander modules
or external contactors/relays.

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Operating Manual PNOZ X2.5P
20407-EN-10 9
Timing diagram
[1][1] [2][2]
Start
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}Semi: Semiconductor output
}[1]: Automatic start
}[2]: Manual 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
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).
Wiring
Please note:
}Information given in the "Technical details [ 14]" must be followed.
}Outputs 23-24, 33-34 are safety contacts.
}Semiconductor output Y11-Y12 shouldnot be used for safety circuits!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 14]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 10
Rlmax = max. overall cable resistance (see Technical details [ 14])
Rl/km = cable resistance/km
}Use copper wire that can withstand 60/75°C.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}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.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}Ensure the wiring and EMC requirements of EN 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.

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Operating Manual PNOZ X2.5P
20407-EN-10 11
Preparing for operation
Supply voltage AC DC
A1
A2
L+
L-
Input circuit Single-channel Dual-channel
E-STOP
without detection of shorts
across contacts
S1
S22
S21
S12
S32
S11
S31
E-STOP
with detection of shorts across
contacts
S1
S22
S31
S32
S21
S12
S11
Safety gate
without detection of shorts
across contacts
S1
S22
S21
S12
S32
S11
S31
Safety gate
with detection of shorts across
contacts
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 [ 18]).

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Operating Manual PNOZ X2.5P
20407-EN-10 12
Start circuit Automatic start Manual start
S33
S34
S3
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 Automatic start Manual start
Contacts from external contactors
K5 K6
K5
L1
N
K6
S33
23 (33)
S34
24 (34)
K5 K6
K5 L1
K6
S33
S34
S3
N
23 (33)
24 (34)
Semiconductor output
Low level at the input of the
driven unit
High level at the input of the
driven unit
After opening the input circuit
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed

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Operating Manual PNOZ X2.5P
20407-EN-10 13
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 CL 3/PL e at least 1x per month
}for SIL CL 2/PL d at least 1x per year
NOTICE
The safety function should be checked after initial commissioning and each
time the plant/machine is changed. 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.
Y11/Y12
Semiconductor output is active.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
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.

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 14
Dimensions in mm
* with spring-loaded terminals
Technical details
General 777308 787308
Approvals
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
Electrical data 777308 787308
Supply voltage
Voltage 24 V 24 V
Kind DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(DC) 1,5 W 1,5 W
Residual ripple DC 20 % 20 %
Duty cycle 100 % 100 %
Max. inrush current impulse
Current pulse, A1 1,7 A 1,7 A
Pulse duration, A1 1,5 ms 1,5 ms
Inputs 777308 787308
Number 2 2
Voltage at
Input circuit DC 24 V 24 V
Start circuit DC 24 V 24 V
Feedback loop DC 24 V 24 V
Current at
Input circuit DC 25 mA 25 mA
Start circuit DC 50 mA 50 mA
Feedback loop DC 50 mA 50 mA
Min. input resistance at power-on 64 Ohm 64 Ohm

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 15
Inputs 777308 787308
Max. overall cable resistance Rl-
max
Single-channel at UB DC 50 Ohm 50 Ohm
Dual-channel with detection of
shorts across contacts at UB DC 20 Ohm 20 Ohm
Semiconductor outputs 777308 787308
Number 1 1
Voltage 24 V 24 V
Current 100 mA 100 mA
External supply voltage 24 V 24 V
Voltage tolerance -20 %/+20 % -20 %/+20 %
Relay outputs 777308 787308
Number of output contacts
Safety contacts (N/O), instant-
aneous 2 2
Max. short circuit current IK 1 kA 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1 EN 60947-4-1
Utilisation category of safety con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
Max. power 1500 VA 1500 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 6 A 6 A
Max. power 150 W 150 W
Utilisation category
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Utilisation category of safety con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 4 A 4 A
Utilisation category in accordance
with UL
Voltage 240 V AC G. P. 240 V AC G. P.
With current 6 A 6 A
Voltage 24 V DC Resistive 24 V DC Resistive
With current 6 A 6 A
Pilot Duty B300, R300 B300, R300

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 16
Relay outputs 777308 787308
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 100 A²s 100 A²s
Blow-out fuse, quick 6 A 6 A
Blow-out fuse, slow 4 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24V AC/DC,
characteristic B/C 4 A 4 A
Conventional thermal current 6 A 6 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Times 777308 787308
Switch-on delay
With automatic start typ. 90 ms 90 ms
With automatic start max. 180 ms 180 ms
With automatic start after power
on typ. 90 ms 90 ms
With automatic start after power
on max. 180 ms 180 ms
With manual start typ. 35 ms 35 ms
With manual start max. 180 ms 180 ms
Delay-on de-energisation
With E-STOP typ. 15 ms 15 ms
With E-STOP max. 30 ms 30 ms
With power failure typ. 60 ms 60 ms
With power failure max. 90 ms 90 ms
Recovery time at max. switching
frequency 1/s
After E-STOP 50 ms 50 ms
After power failure 150 ms 150 ms
Supply interruption before de-ener-
gisation 20 ms 20 ms
Simultaneity, channel 1 and 2 max. ∞ ∞
Environmental data 777308 787308
Climatic suitability EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C -10 - 55 °C
Storage temperature
Temperature range -40 - 85 °C -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during operation 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

PNOZ X2.5P
Operating Manual PNOZ X2.5P
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Environmental data 777308 787308
Vibration
In accordance with the standard EN 60068-2-6 EN 60068-2-6
Frequency 10 - 55 Hz 10 - 55 Hz
Amplitude 0,35 mm 0,35 mm
Airgap creepage
In accordance with the standard EN 60947-1 EN 60947-1
Overvoltage category III / II III / II
Pollution degree 2 2
Rated insulation voltage 250 V 250 V
Rated impulse withstand voltage 4 kV 4 kV
Protection type
Housing IP40 IP40
Terminals IP20 IP20
Mounting area (e.g. control cab-
inet) IP54 IP54
Mechanical data 777308 787308
Mounting position Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles
Material
Bottom PPO UL 94 V0 PPO UL 94 V0
Front ABS UL 94 V0 ABS UL 94 V0
Top PPO UL 94 V0 PPO UL 94 V0
Connection type Screw terminal Spring-loaded terminal
Mounting type plug-in plug-in
Conductor cross section with screw
terminals
1 core flexible 0,25 - 2,5 mm², 24 - 12 AWG –
2 core with the same cross sec-
tion, flexible with crimp connect-
ors, no plastic sleeve 0,25 - 1 mm², 24 - 16 AWG –
2 core with the same cross sec-
tion, flexible without crimp con-
nectors or with TWIN crimp con-
nectors 0,2 - 1,5 mm², 24 - 16 AWG –
Torque setting with screw terminals 0,5 Nm –
Conductor cross section with
spring-loaded terminals: Flexible
with/without crimp connector –0,2 - 1,5 mm², 24 - 16 AWG
Spring-loaded terminals: Terminal
points per connection –2
Stripping length with spring-loaded
terminals –8 mm
Dimensions
Height 94 mm 101 mm
Width 22,5 mm 22,5 mm
Depth 121 mm 121 mm
Weight 190 g 190 g

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 18
Where standards are undated, the 2017-01 latest editions shall apply.
Safety characteristic data
NOTICE
You must comply with the safety-related 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 62061
SIL CL
EN 62061
PFHD [1/h]
IEC 61511
SIL
IEC 61511
PFD
EN ISO
13849-1:
2015
TM [year]
–PL e Cat. 4 SIL CL 3 2,31E-09 SIL 3 2,03E-06 20
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.
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 switching frequency and the load on the relay output.
If the service life graphs are not accessible, the stated PFH value can be used irrespective
of the switching 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.

PNOZ X2.5P
Operating Manual PNOZ X2.5P
20407-EN-10 19
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.
Order reference
Product type Features Connection type Order no.
PNOZ X2.5P C 24 VDC Spring-loaded terminals 787 308
PNOZ X2.5P 24 VDC Screw terminals 777 308
EC declaration of conformity
This product/these products meet the requirements of the directive 2006/42/EC for ma-
chinery of the European Parliament and of the Council. The complete EC Declaration of
Conformity is available on the Internet at www.pilz.com/support/downloads.
Representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2, 73760 Ost-
fildern, Germany

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CMSE®, InduraNET p®, PAS4000®, PAScal®, PASconfig®, Pilz®, PIT®, PLID®, PMCprimo®, PMCprotego®, PMCtendo®, PMD®, 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. We would point out that product features may vary
from the details stated in this document, depending on the status at the time of publication and the scope of the equipment. We accept no responsibility for the validity, accuracy and entirety of the text and graphics presented in this information. Please contact our Technical Support if you have any questions.
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Offices and production facilities are ecologically designed,
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sustainability, plus the security of using energy-efficient
products and environmentally-friendly solutions.
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Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Tel.: [phone]
Fax: [phone]
[email protected]
www.pilz.com
200XXXX-EN-0X
0-0-2-3-000, 2017-00 Printed in Germany
© Pilz GmbH & Co. KG, 2017
Back cover
20407-EN-10, 2017-09 Printed in Germany © Pilz GmbH & Co. KG, 2015