Pilz PNOZ X2.8P User manual

PNOZ X2.8P
Operating Manual-1004082-EN-20
}Safety relays

Preface
This document is the original document.
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.
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 X2.8P
1004082-EN-20 | 3
Introduction ............................................................................................................................5
Validity of documentation.......................................................................................................... 5
Using the documentation .......................................................................................................... 5
Definition of symbols................................................................................................................. 5
Safety ...................................................................................................................................... 6
Intended use ............................................................................................................................. 6
Safety regulations ..................................................................................................................... 6
Safety assessment ................................................................................................................... 6
Use of qualified personnel ........................................................................................................ 7
Warranty and liability ................................................................................................................ 7
Disposal .................................................................................................................................... 7
For your safety.......................................................................................................................... 7
Unit features ...........................................................................................................................8
Safety features ....................................................................................................................... 8
Block diagram/terminal configuration ................................................................................. 9
Type: 24 VAC/DC ..................................................................................................................... 9
Type: 24 - 240 V AC/DC ........................................................................................................... 9
Function Description ............................................................................................................. 10
Operating modes ...................................................................................................................... 10
Timing diagram ......................................................................................................................... 10
Installation ..............................................................................................................................11
Wiring ......................................................................................................................................12
Preparing for operation ......................................................................................................... 13
Operation ................................................................................................................................15
Status indicators ....................................................................................................................... 16
Faults – Interference .............................................................................................................. 16
Dimensions in mm .................................................................................................................16
Technical details ....................................................................................................................17
Safety characteristic data ......................................................................................................... 27
Supplementary data ..............................................................................................................27
Service life graph ...................................................................................................................... 28

Contents
Operating Manual PNOZ X2.8P
1004082-EN-20 | 4
Remove plug-in terminals ..................................................................................................... 31
Order reference ......................................................................................................................31
EC declaration of conformity ................................................................................................ 31

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 5
Introduction
Validity of documentation
This documentation is valid for the product PNOZ X2.8P. 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 X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 6
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The safety relay PNOZ X2.8P provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN 60947-5-1 and EN 60204-1 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 [ 17]).
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 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 62061. However, this does not guarantee the functional
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 separ-
ately.

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 7
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. 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 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).
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 X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 8
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
}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.

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 9
Block diagram/terminal configuration
Type: 24 VAC/DC
}UB: 24 VAC/DC; Order no. 777301, 787301
S11 S52 S21 S22 S12 S34
PNOZ X2.8P
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Type: 24 - 240 V AC/DC
}UB: 24 – 240 VAC/DC; Order no. 777302, 787302
S11 S52 S21 S22 S12 S34
PNOZ X2.8P
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 10
Function Description
The safety relay PPNOZ X2.8P 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 S12-S34 is 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 cir-
cuit, detects PNOZ X2.8P
– 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 circuit,
PNOZ X2.8P 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 expandsion modules
or external contactors/relays.
Timing diagram
[1][1] [2][2]
3 3

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 11
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}Output aux: Auxiliary contact
}[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).

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 12
Wiring
Please note:
}Information given in the "Technical details [ 17]" 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 [ 17]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 17])
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.
}Adequate protection must be provided on all output contacts with capacitive and inductive
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.
}With 24 V AC/DC units:
The power supply must meet the regulations for extra low voltages with protective elec-
trical separation (SELV, PELV).
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 X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 13
Preparing for operation
Supply voltage AC DC
UB = 24 VAC/DC;
Order no. 777301, 787301
A1
A2
L1
N
A1
A2
L+
L-
UB = 24 - 240 VAC/DC;
Order no. 777302, 787302
A1
A2
L1
N
S21
A1
A2
L+
L-
S21
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 guards or safety switch, de-
tection of shorts across contacts
via ESPE
(only when UB = 24 VDC);
Order no. 777301, 787301)

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 14
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 [ 27]).
NOTICE
Operation with a light guard or safety switch
It must not be possible to switch off the supply voltage for the PNOZ X2.8P
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
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.

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 15
Feedback loop Automatic start Manual start
Contacts from external contactors
K5 K6
K5
L1
N
K6
S12
13 (23,33)
S34
14 (24,34)
K5 K6
K5 L1
K6
S12
S34
S3
N
13 (23, 33)
14 (24 ,34)
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed
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.

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 16
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.
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
* with spring-loaded terminals

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 17
Technical details
Order no. 777301 – 777302
See below for more order numbers
General 777301 777302
Certifications
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
CCC, CE, EAC (Eurasian),
KOSHA, TÜV, cULus Listed
Electrical data 777301 777302
Supply voltage
Voltage 24 V 24 - 240 V
Kind AC/DC AC/DC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(AC) 5,5 VA 4,5 VA
Output of external power supply
(DC) 2,5 W 2 W
Frequency range AC 50 - 60 Hz 50 - 60 Hz
Residual ripple DC 160 % 160 %
Duty cycle 100 % 100 %
Max. inrush current impulse
Current pulse, A1 1,7 A –
Pulse duration, A1 3,3 ms –
Inputs 777301 777302
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 30 mA 25 mA
Start circuit DC 40 mA 50 mA
Feedback loop DC 40 mA 50 mA
Min. input resistance at power-on 88 Ohm 209 Ohm

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 18
Inputs 777301 777302
Max. overall cable resistance Rl-
max
Single-channel at UB DC 30 Ohm 45 Ohm
Single-channel at UB AC 100 Ohm 45 Ohm
Dual-channel without detection
of shorts across contacts at UB
DC 50 Ohm 80 Ohm
Dual-channel without detection
of shorts across contacts at UB
AC 100 Ohm 80 Ohm
Dual-channel with detection of
shorts across contacts at UB DC 15 Ohm 15 Ohm
Dual-channel with detection of
shorts across contacts at UB AC 15 Ohm 15 Ohm
Relay outputs 777301 777302
Number of output contacts
Safety contacts (N/O), instant-
aneous 3 3
Auxiliary contacts (N/C) 1 1
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 of auxiliary 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

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 19
Relay outputs 777301 777302
Utilisation category of safety con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 3 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 4 A
Utilisation category of auxiliary con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 3 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 4 A
Utilisation category in accordance
with UL
Voltage 240 V AC G.U. (same polarity) 250 V AC G.U. (same polarity)
With current 6 A 6 A
Voltage 24 V DC G. P. 24 V DC G. P.
With current 6 A 6 A
Pilot Duty R300 B300, R300
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 260 A²s 66 A²s
Blow-out fuse, quick 10 A 6 A
Blow-out fuse, slow 6 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24V AC/DC,
characteristic B/C 6 A 4 A
External contact fuse protection,
auxiliary contacts
Max. melting integral 160 A²s 66 A²s
Blow-out fuse, quick 10 A 6 A
Blow-out fuse, slow 6 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24 V AC/DC,
characteristic B/C 6 A 4 A
Contact material AgCuNi + 0,2 µm Au AgCuNi + 0,2 µm Au
Conventional thermal current
while loading several contacts
777301 777302
Ith per contact at UB AC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 6 A 6 A
Conv. therm. current with 2 con-
tacts 4 A 6 A
Conv. therm. current with 3 con-
tacts 3,5 A 4,5 A

PNOZ X2.8P
Operating Manual PNOZ X2.8P
1004082-EN-20 | 20
Conventional thermal current
while loading several contacts
777301 777302
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 6 A 6 A
Conv. therm. current with 2 con-
tacts 6 A 6 A
Conv. therm. current with 3 con-
tacts 5 A 4,5 A
Times 777301 777302
Switch-on delay
With automatic start typ. 250 ms 340 ms
With automatic start max. 450 ms 400 ms
With automatic start after power
on typ. 250 ms 600 ms
With automatic start after power
on max. 450 ms 800 ms
With manual start typ. 125 ms 180 ms
With manual start max. 450 ms 400 ms
Delay-on de-energisation
With E-STOP typ. 15 ms 10 ms
With E-STOP max. 30 ms 20 ms
With power failure typ. 60 ms –
With power failure max. 100 ms –
With power failure typ. UB 240 V – 1100 ms
With power failure max. UB 240
V – 1500 ms
With power failure typ. UB 24 V – 180 ms
With power failure max. UB 24 V – 230 ms
Recovery time at max. switching
frequency 1/s
After E-STOP 50 ms 50 ms
After power failure 200 ms 1500 ms
Supply interruption before de-ener-
gisation 20 ms 20 ms
Simultaneity, channel 1 and 2 max. ∞ ∞
Environmental data 777301 777302
Climatic suitability EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -35 - 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
61000-6-4, EN 61326-3-1
EN 60947-5-1, EN 61000-6-2, EN
61000-6-4, EN 61326-3-1