Pilz PNOZ XV3.1P User manual

PNOZ XV3.1P
Operating Manual-20516-EN-09
}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 XV3.1P
20516-EN-09 | 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
Types: AC/DC........................................................................................................................... 9
Types: DC................................................................................................................................. 9
Function Description ............................................................................................................. 10
Operating modes ...................................................................................................................... 10
Timing diagram ......................................................................................................................... 11
Installation ..............................................................................................................................12
Wiring ......................................................................................................................................12
Preparing for operation ......................................................................................................... 13
Operation ................................................................................................................................15
Status indicators ....................................................................................................................... 16

Contents
Operating Manual PNOZ XV3.1P
20516-EN-09 | 4
Faults – Interference .............................................................................................................. 17
Dimensions in mm .................................................................................................................17
Technical details Order no. 777520-777525 ........................................................................ 18
Technical details Order no. 777530-777538 ........................................................................ 23
Technical details Order no. 787520-787530 ........................................................................ 30
Technical details Order no. 787532-787538 ........................................................................ 37
Safety characteristic data ..................................................................................................... 43
Supplementary data ..............................................................................................................44
Service life graph ...................................................................................................................... 44
Remove plug-in terminals ..................................................................................................... 45
Order reference ......................................................................................................................46
EC declaration of conformity ................................................................................................ 46

PNOZ XV3.1P
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Introduction
Validity of documentation
This documentation is valid for the product PNOZ XV3.1P. It is valid until new documenta-
tion 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 XV3.1P 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 [ 18]).
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 XV3.1P
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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
– 2 safety contacts (N/O), delay-on de-energisation
– 1 auxiliary contact (N/C), instantaneous
}Connection options for:
– E-STOP pushbuttons
– Safety gate limit switches
– Start buttons
– Light grids and safety switches with detection of shorts across contacts
}Delay time fixed or selectable
}Possible to cancel delay time
}LED display for:
– Supply voltage
– Switch state of the safety contacts
– Start circuit
}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.

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Block diagram/terminal configuration
Types: AC/DC
}UB: 24 - 240 VAC/DC; Order no. 777530, 787530, 777532, 787532, 777538, 787538
*Insulation between the non-marked area and the relay contacts: Basic insulation (over-
voltage category III), Protective separation (overvoltage category II)
Types: DC
}UB: 24 VDC; Order no. 777520, 787520, 777522, 787522, 777525
*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 XV3.1P 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 reset circuit Y39-Y40 and the start circuit S13-S14 are closed.
}Input circuit is closed (e.g. E-STOP pushbutton not operated):
– The "START" LED is lit.
– The LEDs "CH.1", "CH.1 [t]", "CH.2" and "CH.2 [t]" are lit.
– Safety contacts 13-14, 23-24, 33-34, 57-58 and 67-68 are closed, auxiliary contact
41-42 is opened. The unit is active.
– The "START" LED goes out.
}Input circuit is opened (e.g. E-STOP pushbutton operated):
– The LEDs "CH.1" and "CH.2" go out.
– Safety contacts 13-14, 23-24 and 33-34 are opened redundantly, auxiliary contact
41-42 is closed.
– Safety contacts 57-58 and 67-68 open after the delay time has elapsed.
– The LEDs "CH.1 [t]" and "CH.2 [t]" go out.
Before the unit can be restarted, the delay time must have elapsed and the unit must again
be ready for operation.
Set delay time:
On units with selectable delay time, the delay time of the safety contacts 57-58 and 67-68
can be set on the front of the unit using a screwdriver.
Reset function:
The delay time cycle can be ended prematurely by opening the reset circuit Y39-Y40. For
this purpose, one N/C contact is connected between Y39-Y40 instead of a link.
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,
detects PNOZ XV3.1P
– earth faults in the start and input circuit,
– short circuits in the input circuit,
– Shorts across contacts in the input circuit.
}Dual-channel operation without detection of shorts across contacts: Redundant input cir-
cuit, detects PNOZ XV3.1P
– earth faults in the start and input circuit,
– short circuits 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 [ 18]).

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}Increase in the number of available contacts by connecting contact expandsion modules
or external contactors/relays.
Timing diagram
v
Output safe delay
Output aux
Output safe
[1] [2]
v
v
v
Legend
}Power: Supply voltage
}Start: Start circuit
}Reset tv: Reset circuit
}Input: Input circuit
}Output safe: Safety contacts, instantaneous
}Output safe delay: Safety contacts, delayed
}Output aux: Auxiliary contact
}[1]: Automatic start
}[2]: Monitored start
}t1: Switch-on delay
}t2: Delay-on de-energisation
}t3: Waiting period with a monitored start
}t4: Recovery time
}tv: Delay time
NOTICE
At the latest, the delay-on de-energisation safety contacts open after the set
delay time + 50 ms + 15% of the set value, even in the case of a component
failure.

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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 [ 18]" must be followed.
}Delivery status of units with screw terminals: Link between S11-S12 (dual-channel input
circuit) and link between Y39-Y40 (reset circuit)
}Outputs 13-14, 23-24, 33-34 are instantaneous safety contacts, outputs 57-58, 67-68 are
delay-on de-energisation safety contacts, output 41-42 is an instantaneous auxiliary con-
tact (e.g. for display).
}Auxiliary contact 41-42 shouldnot be used for safety circuits!
}Do not connect undesignated terminals.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 18]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 18])
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.
}On units with UB 24 – 240 VAC/DC: Connect operational earth terminal to functional
earth.
}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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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.
Preparing for operation
Supply voltage UB 24 - 240 VAC/DC UB 24 VDC
FE
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
S1
S11
S12
S32
S22
S21
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
S1 S2
S22
S21
S11
S12
S32
Safety gate
with detection of shorts across
contacts

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Input circuit Single-channel Dual-channel
Light guard or safety switch, de-
tection of shorts across contacts
via ESPE
(only when UB = 24 VDC); Order
no. 7777520, 787520, 777522,
787522, 777525)
A2
GND
S21
S22
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).
NOTICE
Operation with a light guard or safety switch
It must not be possible to switch off the supply voltage for the PNOZ
XV3.1P separately from the supply voltage for the light grid or safety switch.
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.

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Reset delay time Without reset With reset
Link or N/C contact
Y39
Y40
Feedback loop Automatic start Monitored start
Contacts from external contactors
K5 K6
K5
L1
N
K6
S13
13 (23, 33)
S14
14 (24, 34)
Legend
}S1/S2: E-STOP/safety gate switch
}S3: Reset button
}: Switch operated
}: Gate open
}: Gate closed
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 3/PL d at least 1x per year

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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.
START
Start circuit is closed.
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
CH.1 [t]
Channel 3 safety contacts are closed.
CH.2 [t]
Channel 4 safety contacts 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.
}In the case of an error, the delay-on de-energisation contacts may open before the delay
time has elapsed.
Dimensions in mm
* with spring-loaded terminals

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Technical details Order no. 777520-777525
General 777520 777522 777525
Certifications
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
CCC, CE, EAC (Euras-
ian), TÜV, cULus Listed
Electrical data 777520 777522 777525
Supply voltage
Voltage 24 V 24 V 24 V
Kind DC DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external
power supply (DC) 4,5 W 4,5 W 4,5 W
Residual ripple DC 160 % 160 % 160 %
Duty cycle 100 % 100 % 100 %
Max. inrush current im-
pulse
Current pulse, A1 5 A 5 A 5 A
Pulse duration, A1 1 ms 1 ms 1 ms
Inputs 777520 777522 777525
Number 222
Voltage at
Input circuit DC 24 V 24 V 24 V
Start circuit DC 24 V 24 V 24 V
Feedback loop DC 24 V 24 V 24 V
Current at
Input circuit DC 50 mA 50 mA 50 mA
Start circuit DC 40 mA 40 mA 40 mA
Feedback loop DC 3 mA 3 mA 3 mA
Max. overall cable resist-
ance Rlmax
Single-channel at UB
DC 100 Ohm 100 Ohm 100 Ohm
Dual-channel without
detection of shorts
across contacts at UB
DC 120 Ohm 120 Ohm 120 Ohm
Dual-channel with de-
tection of shorts across
contacts at UB DC 10 Ohm 10 Ohm 10 Ohm
Relay outputs 777520 777522 777525
Number of output con-
tacts
Safety contacts (N/O),
instantaneous 333
Safety contacts (N/O),
delayed 222
Auxiliary contacts (N/C) 111

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Relay outputs 777520 777522 777525
Max. short circuit current
IK 1 kA 1 kA 1 kA
Utilisation category
In accordance with the
standard EN 60947-4-1 EN 60947-4-1 EN 60947-4-1
Utilisation category of
safety contacts
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W
Utilisation category of
safety contacts delayed
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W
Utilisation category of
auxiliary contacts
AC1 at 240 V 240 V 240 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 2000 VA 2000 VA 2000 VA
DC1 at 24 V 24 V 24 V
Min. current 0,01 A 0,01 A 0,01 A
Max. current 8 A 8 A 8 A
Max. power 200 W 200 W 200 W
Utilisation category
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
Utilisation category of
safety contacts
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 7 A 7 A 7 A

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Relay outputs 777520 777522 777525
Utilisation category of
safety contacts delayed
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 7 A 7 A 7 A
Utilisation category of
auxiliary contacts
AC15 at 230 V 230 V 230 V
Max. current 5 A 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V 24 V
Max. current 7 A 7 A 7 A
Utilisation category in ac-
cordance with UL
Voltage 240 V AC G. P. 240 V AC G. P. 240 V AC G. P.
With current 8 A 8 A 8 A
Voltage 24 V DC Resistive 24 V DC Resistive 24 V DC Resistive
With current 5 A 5 A 5 A
Pilot Duty C300, R300 C300, R300 C300, R300
External contact fuse pro-
tection, safety contacts
In accordance with the
standard EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
Max. melting integral 240 A²s 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A 10 A
Blow-out fuse, slow 6 A 6 A 6 A
Blow-out fuse, gG 10 A 10 A 10 A
Circuit breaker 24V
AC/DC, characteristic
B/C 6 A 6 A 6 A
External contact fuse pro-
tection, delayed safety
contacts
Max. melting integral 240 A²s 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A 10 A
Blow-out fuse, slow 6 A 6 A 6 A
Blow-out fuse, gG 10 A 10 A 10 A
Circuit breaker 24 V
AC/DC, characteristic
B/C 6 A 6 A 6 A