Pilz PNOZ XV3.3P User manual

PNOZ XV3.3P
Operating Manual-20777-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 XV3.3P
20777-EN-09 | 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 ..............................................................................................................................10
Wiring ......................................................................................................................................10
Preparing for operation ......................................................................................................... 11
Operation ................................................................................................................................13
Status indicators ....................................................................................................................... 14
Faults – Interference .............................................................................................................. 14
Dimensions in mm .................................................................................................................15
Technical details ....................................................................................................................16
Safety characteristic data ......................................................................................................... 21
Supplementary data ..............................................................................................................21
Service life graph ...................................................................................................................... 22
Remove plug-in terminals ..................................................................................................... 23
Order reference ......................................................................................................................23
EC declaration of conformity ................................................................................................ 23

PNOZ XV3.3P
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Introduction
Validity of documentation
This documentation is valid for the product PNOZ XV3.3P. 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 XV3.3P 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
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 [ 16]).
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
– 2 safety contacts (N/O), delay-on de-energisation
}Connection options for:
– E-STOP pushbutton
– Safety gate limit switch
– Start button
}Selectable delay time
}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.
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 XV3.3P 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, 47-48 and 57-58 are closed. 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.
– Safety contacts 47-48 and 57-58 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 47-48 and 57-58
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 XV3.3P
– 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.
}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 [ 16]).
}Increase in the number of available contacts by connecting contact expandsion modules
or external contactors/relays.

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Timing diagram
[1] [2] [3]
v v v v vv
POWER
Start
Reset tv
Input
Output safe
Output safe delay
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
}[1]: Automatic start
}[2]: Manual start
}[3]: Monitored 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: 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 [ 16]" 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 47-48, 57-58 are
delay-on de-energisation safety contacts.
}Do not connect undesignated terminals.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 16]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 16])
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.
}When connecting magnetically operated, reed proximity switches, ensure that the max.
peak inrush current (on the input circuit) does not overload the proximity switch.
}Do not switch low currents using contacts that have been used previously with high cur-
rents.
}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 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

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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).
Start circuit Single-channel Dual-channel
Automatic start
S33
S34
S13
S14
S33
S34
S13
S14
Monitored start
S33
S34
S3
S14
S13
S33
S34
S3
S14
S13
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.
Reset Without reset With reset
Link or N/C contact
Y39
Y40

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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 and manual 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
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.

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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.
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.

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Dimensions in mm
*with spring-loaded terminals

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Technical details
General 777511 787511
Certifications CCC, CE, EAC (Eurasian), TÜV CCC, CE, EAC (Eurasian), TÜV
Electrical data 777511 787511
Supply voltage
Voltage 24 V 24 V
Kind DC DC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(DC) 4,5 W 4,5 W
Residual ripple DC 160 % 160 %
Duty cycle 100 % 100 %
Max. inrush current impulse
Current pulse, A1 5 A 5 A
Pulse duration, A1 1 ms 1 ms
Inputs 777511 787511
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 35 mA 35 mA
Start circuit DC 50 mA 50 mA
Feedback loop DC 3,5 mA 3,5 mA
Min. input resistance at power-on 135 Ohm 135 Ohm
Max. overall cable resistance Rl-
max
Single-channel at UB DC 100 Ohm 100 Ohm
Dual-channel with detection of
shorts across contacts at UB DC 10 Ohm 10 Ohm
Relay outputs 777511 787511
Number of output contacts
Safety contacts (N/O), instant-
aneous 3 3
Safety contacts (N/O), delayed 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

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Relay outputs 777511 787511
Utilisation category of safety con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 2000 VA 2000 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 200 W 200 W
Utilisation category of safety con-
tacts delayed
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 2000 VA 2000 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 8 A 8 A
Max. power 200 W 200 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 7 A 7 A
Utilisation category of safety con-
tacts delayed
AC15 at 230 V 230 V
Max. current 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 7 A 7 A
External contact fuse protection,
safety contacts
In accordance with the standard EN 60947-5-1 EN 60947-5-1
Max. melting integral 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A
Blow-out fuse, slow 6 A 6 A
Blow-out fuse, gG 10 A 10 A
Circuit breaker 24V AC/DC,
characteristic B/C 6 A 6 A

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Relay outputs 777511 787511
External contact fuse protection,
delayed safety contacts
Max. melting integral 240 A²s 240 A²s
Blow-out fuse, quick 10 A 10 A
Blow-out fuse, slow 6 A 6 A
Blow-out fuse, gG 10 A 10 A
Circuit breaker 24 V AC/DC,
characteristic B/C 6 A 6 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Conventional thermal current
while loading several contacts
777511 787511
Ith per contact at UB DC;
AC1:240V,DC1:24V
Conv. therm. current with 1 con-
tact 8 A 8 A
Conv. therm. current with 2 con-
tacts 6,8 A 6,8 A
Conv. therm. current with 3 con-
tacts 5,5 A 5,5 A
Conv. therm. current with 4 con-
tacts 4,8 A 4,8 A
Conv. therm. current with 5 con-
tacts 4,3 A 4,3 A
Times 777511 787511
Switch-on delay
With automatic start typ. 350 ms 350 ms
With automatic start max. 650 ms 650 ms
With automatic start after power
on typ. 385 ms 385 ms
With automatic start after power
on max. 700 ms 700 ms
With manual start typ. 220 ms 220 ms
With manual start max. 650 ms 650 ms
With monitored start typ. 35 ms 35 ms
With monitored start max. 70 ms 70 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. 85 ms 85 ms
With power failure max. 200 ms 200 ms
Recovery time at max. switching
frequency 1/s
After E-STOP 50 ms +tv 50 ms +tv
After power failure 250 ms 250 ms
Delay time tv 0,1 s, 0,5 s, 1 s, 2 s, 4 s, 6 s, 8 s,
10 s, 15 s, 20 s, 25 s, 30 s
0,1 s, 0,5 s, 1 s, 2 s, 4 s, 6 s, 8 s,
10 s, 15 s, 20 s, 25 s, 30 s
Time accuracy -15 %/+15 % +50 ms -15 %/+15 % +50 ms

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Times 777511 787511
Repetition accuracy 2 % 2 %
Waiting period with a monitored
start 300 ms 300 ms
Min. start pulse duration with a
monitored start 30 ms 30 ms
Supply interruption before de-ener-
gisation 20 ms 20 ms
Simultaneity, channel 1 and 2 max. ∞ ∞
Environmental data 777511 787511
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
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 777511 787511
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

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Mechanical data 777511 787511
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 –
Stripping length with screw termin-
als 8 mm –
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 45 mm 45 mm
Depth 121 mm 121 mm
Weight 370 g 370 g
Where standards are undated, the 2020-07 latest editions shall apply.