Pilz PNOZ X3.2 User manual

PNOZ X3.2
Operating Manual-21147-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 PNOZ X3.2
21147-EN-11 | 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 ......................................................................................................................................10
Preparing for operation .........................................................................................................11
Operation ................................................................................................................................13
Status indicators........................................................................................................................13
Faults – Interference ..............................................................................................................14
Dimensions in mm .................................................................................................................14
Technical details ....................................................................................................................15
Safety characteristic data..........................................................................................................19
Supplementary data ...............................................................................................................19
Service life graph ......................................................................................................................20
Order reference ......................................................................................................................20
EC declaration of conformity ................................................................................................21
UKCA-Declaration of Conformity .........................................................................................21

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Introduction
Validity of documentation
This documentation is valid for the product PNOZ X3.2. 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 safety relay PNOZ X3.2 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
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 [ 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 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.

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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.

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Unit features
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}1 semiconductor output
}Connection options for:
– E-STOP pushbutton
– Safety gate limit switch
– Start button
}LED display for:
– Supply voltage
– Switch status of the safety contacts
}Semiconductor output signals:
– Switch state of the safety contacts
}Extended supply interruption before de-energisation
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
* *
*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 safety relay PNOZ X3.2 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 S13-S14 is closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– Safety contacts 13-14, 23-24 and 33-34 are closed, auxiliary contact 41-42 is open.
The unit is active.
– The LEDs "CH.1" and "CH.2" are lit.
– A high signal is present at the semiconductor output switch state Y32.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– Safety contacts 13-14, 23-24 and 33-34 are opened redundantly, auxiliary contact
41-42 is closed.
– The LEDs "CH.1" and "CH.2" go out.
– A low signal is present at the semiconductor output switch state Y32.
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 circuit,
PNOZ X3.2 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.
}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 expandsion modules
or external contactors/relays.

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Timing diagram
[1] [2]
POWER
Start
Input
Output safe
Output aux.
Out semi OUT
Legend
}Power: Supply voltage
}Start: Start circuit
}Input: Input circuit
}Output safe: Safety contacts
}Output aux: Auxiliary contact
}Out semi OUT: Semiconductor output switch state
}[1]: Automatic start
}[2]: Monitored start
}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 (35 mm).
}When installed vertically: Secure the unit by using a fixing element (e.g. retaining bracket
or end angle).

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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!
}Delivery condition: Link between S11-S12 (dual-channel input circuit)
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 15]).
}Calculation of the max. cable length 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 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.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}Adequate protection must be provided on all output contacts with capacitive and inductive
loads.
}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 a 24 VDC supply voltage via terminals B1, B2, the power supply must comply with
the regulations for extra low voltages with safe electrical separation (SELV, PELV).
}When operated with AC voltage: Connect terminal B2 to the functional earth.
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 length, we recommend
the following test once the unit is installed:
1. Unit ready for operation (output contacts closed)
2. Short circuit the test terminals S22, S32 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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Preparing for operation
Supply voltage AC DC
FE
B1
B2
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 [ 19]).

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Start circuit E-STOP wiring
Safety gate without start-up
test
Safety gate with start-up test
Automatic start
S33
S34
S13
S14
S33
S13
S34
S14
Monitored start
S33
S34
S3
S14
S13
NOTICE
In the event of an automatic start:
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 Monitored start
Contacts from external contactors
K5 K6
K5
L1
N
K6
S13
13 (23, 33)
S14
14 (24, 34)
Semiconductor output
PLC
PLC
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed

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INFORMATION
With automatic start, S33 and S34 must not be linked; with monitored
start, S13 and S14 must not be linked.
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 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.
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.

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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
121 (4.76")
75 (2.95")
87 (3.42")
45
(1.77")

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Technical details
General
Certifications CCC, CE, EAC, TÜV, UKCA, cULus Listed
Electrical data
Supply voltage
Voltage 230 V
Kind AC
Voltage tolerance -15 %/+10 %
Output of external power supply (AC) 5 VA
Frequency range AC 50 - 60 Hz
Supply voltage
Voltage 24 V
Kind DC
Voltage tolerance -15 %/+10 %
Output of external power supply (DC) 2,5 W
Residual ripple DC 160 %
Duty cycle 100 %
Inputs
Quantity 2
Voltage at
Input circuit DC 24 V
Start circuit DC 24 V
Feedback loop DC 24 V
Current at
Input circuit DC 50 mA
Start circuit DC 35 mA
Feedback loop DC 20 mA
Min. input resistance at power-on 100 Ohm
Max. overall cable resistance Rlmax
Single-channel at UB DC 150 Ohm
Single-channel at UB AC 180 Ohm
Dual-channel with detection of shorts across con-
tacts at UB DC 15 Ohm
Dual-channel with detection of shorts across con-
tacts at UB AC 30 Ohm
Semiconductor outputs
Quantity 1
Voltage 24 V
Current 20 mA
External supply voltage 24 V
Voltage tolerance -20 %/+20 %
Residual current at "0" signal 0,1 mA
Max. internal voltage drop 4 V
Conditional rated short circuit current 100 A
Lowest operating current 0 mA

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Semiconductor outputs
Utilisation category in accordance with EN 60947-1 DC-12
Relay outputs
Number of output contacts
Safety contacts (N/O), instantaneous 3
Auxiliary contacts (N/C) 1
Max. short circuit current IK 1 kA
Utilisation category
in accordance with the standard EN 60947-4-1
Utilisation category of safety contacts
AC1 at 240 V
Min. current 0,01 A
Max. current 8 A
Max. power 2000 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 8 A
Max. power 200 W
Utilisation category of auxiliary contacts
AC1 at 240 V
Min. current 0,01 A
Max. current 8 A
Max. power 2000 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 8 A
Max. power 200 W
Utilisation category
in accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 6 A
Utilisation category of auxiliary contacts
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 6 A
Utilisation category in accordance with UL
Voltage 240 V AC G. P.
with current 8 A
Voltage 24 V DC Resistive
with current 5 A
Pilot Duty B300, R300

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Relay outputs
External contact fuse protection, safety contacts
in accordance with the standard EN 60947-5-1
Max. melting integral 240 A²s
Blow-out fuse, quick 10 A
Blow-out fuse, slow 6 A
Blow-out fuse, gG 10 A
Circuit breaker 24V AC/DC, characteristic B/C 6 A
External contact fuse protection, auxiliary contacts
Max. melting integral 240 A²s
Blow-out fuse, quick 10 A
Blow-out fuse, slow 6 A
Blow-out fuse, gG 10 A
Circuit breaker, 24 VAC/DC, characteristic B/C 6 A
Contact material AgSnO2 + 0,2 µm Au
Conventional thermal current while loading sev-
eral contacts
Ith per contact at UB AC; AC1:240V,DC1:24V
Conv. therm. current with 1 contact 8 A
Conv. therm. current with 2 contacts 7,5 A
Conv. therm. current with 3 contacts 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
Switch-on delay
with automatic start typ. 250 ms
with automatic start max. 500 ms
with automatic start after power on typ. 500 ms
with automatic start after power on max. 1.000 ms
with monitored start typ. 35 ms
with monitored start max. 50 ms
Delay-on de-energisation
with E-STOP typ. 15 ms
with E-STOP max. 30 ms
with power failure typ. 850 ms
with power failure max. 1500 ms
Recovery time at max. switching frequency 1/s
after E-STOP 50 ms
after power failure 1500 ms
Waiting period with a monitored start 300 ms
Min. start pulse duration with a monitored start 30 ms
Supply interruption before de-energisation 650 ms
Simultaneity, channel 1 and 2 max. ∞

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Environmental data
Climatic suitability EN 60068-2-78
Ambient temperature
Temperature range -20 - 55 °C
Storage temperature
Temperature range -40 - 85 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C
Condensation during operation Not permitted
EMC EN 60947-5-1, EN 61000-6-2, EN 61326-3-1
Vibration
in accordance with the standard EN 60068-2-6
Frequency 10 - 55 Hz
Amplitude 0,35 mm
Airgap creepage
in accordance with the standard EN 60947-1
Overvoltage category III / II
Pollution degree 2
Rated insulation voltage 250 V
Rated impulse withstand voltage 4 kV
Protection type
Housing IP40
Terminals IP20
Mounting area (e.g. control cabinet) IP54
Mechanical data
Mounting position Any
Mechanical life 10,000,000 cycles
Material
Bottom PPO UL 94 V1
Front ABS UL 94 V0
Top PPO UL 94 V1
Connection type Screw terminal
Mounting type Fixed
Conductor cross section with screw terminals
1 core flexible 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
2 core with the same cross section, flexible without
crimp connectors or with TWIN crimp connectors 0,2 - 2,5 mm², 24 - 14 AWG
Torque setting with screw terminals 0,5 Nm
Stripping length with screw terminals 6 mm
Dimensions
Height 87 mm
Width 45 mm
Depth 121 mm
Weight 390 g

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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 2,31E-09 SIL 3 2,03E-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.
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.

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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.
Number of cycles x 1000
Switching current (A)
Example
}Inductive load: 0.2 A
}Utilisation category: AC15
}Contact service life: 4 000 000 cycles
Provided the application to be implemented requires fewer than 4 000 000 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 X3.2 230 VAC; 24 VDC Screw terminals 774309