Pilz PNOZX4 User manual

PZE X4
Operating Manual-1003199-EN-11
}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 PZE X4
1003199-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
Installation 8
Wiring 8
Preparing for operation 9
Operation 10
Status indicators 10
Faults – Interference 10
Dimensions in mm 11
Technical details 11
Safety characteristic data 15
Supplementary data 15
Service life graph 16
Order reference 17
EC declaration of conformity 17

PZE X4
Operating Manual PZE X4
1003199-EN-11 4
Introduction
Validity of documentation
This documentation is valid for the product PZE X4. 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.

PZE X4
Operating Manual PZE X4
1003199-EN-11 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The contact expansion module PZE X4 meets the requirements of EN 60947-5-1, EN
60204-1 and VDE 0113-1. It is an expansion module for increasing the number of contacts
available on a base unit. Base units are all safety relays with feedback loop.
The max. achievable safety level depends on the base unit. The expansion module may not
exceed this. The safety-related characteristic values stated under Safety-related character-
istic data [ 15] can only be achieved if the base unit also exhibits these values.
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 [ 11]).
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 it is necessary to perform a safety assessment in accordance with
the Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.

PZE X4
Operating Manual PZE X4
1003199-EN-11 6
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion,
}Have read and understood the information provided in the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific application.
Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended,
}Damage can be attributed to not having followed the guidelines in the manual,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
For your safety
The unit meets all the necessary conditions for safe operation. However, please note the
following:
}Note for overvoltage category III: If voltages higher than low voltage (>50 VAC or >120
VDC) are present on the unit, connected control elements and sensors must have a
rated insulation voltage of at least 250 V.

PZE X4
Operating Manual PZE X4
1003199-EN-11 7
Unit features
}Positive-guided relay outputs:
– 4 safety contacts (N/O), instantaneous
}LED display for:
– Switch status of the safety contacts
}Connection for feedback loop
}Operation: single-channel
Safety features
The unit meets the following safety requirements:
}The contact expander module expands an existing circuit. As the output relays are
monitored via the base unit's feedback loop, the safety functions on the existing circuit
are transferred to the contact expander module.
}The safety function remains effective in the case of a component failure.
}Earth fault in the feedback loop:
Detected, depending on the base unit that is used.
}Earth fault in the input circuit:
The output relays de-energise and the safety contacts open.
Block diagram/terminal configuration
A1 A2 Y1 13 23 33 43
14Y2 24 34 44
K1
K2
Power
Input
PZE X4
CH. 1
43
14 24 34
44 A2
13
A1 Y1 Y2
23 33
13 23 33 43
14 24 34 44
CH. 2
*Safe separation from non-marked area in accordance with EN 60947-1, 6 kV, basic insula-
tion between all safety contacts.

PZE X4
Operating Manual PZE X4
1003199-EN-11 8
Function description
The contact expansion module PZE X4 is an add-on device without delay-on de-energisa-
tion, and it is used to expand a safety circuit. The contact expansion module is driven by a
base unit (e. g. emergency stop relay).
}Functional procedure once the input circuit is closed (e.g. safety contacts on the base
unit are closed):
– The supply voltage is present at input (A1) of the contact expansion module.
– The safety contacts 13-14, 23-24, 33-34 and 43-44 close.
– The LEDs "CH.1" and "CH.2" are lit.
}Functional procedure once the input circuit is opened (e.g. safety contacts on the base
unit are opened):
– The supply voltage is not present at input (A1) of the contact expansion module.
– Safety contacts 13-14, 23-24, 33-34 and 43-44 are opened redundantly.
– The LEDs "CH.1" and "CH.2" go out.
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).
}If more than 2 units are installed next to each other in the control cabinet, leave a dis-
tance of at least 6 mm between the units.
Wiring
Please note:
}Information given in the "Technical details [ 11]" must be followed.
}The outputs 13-14, 23-24, 33-34 and 43-44 are safety contacts.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 11]).
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 11])
Rl/km = cable resistance/km
}Use copper wire that can withstand 60/75°C.
}Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
}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 protect-
ive electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.

PZE X4
Operating Manual PZE X4
1003199-EN-11 9
}Ensure the wiring and EMC requirements of EN 60204-1 are met.
Preparing for operation
Supply voltage AC DC
A1
A2 PZE
24 V DC
0 V
Input circuit Single-channel Dual-channel
Base unit:
PNOZX
Driven via safety contacts
A1
A2 PZE
24 V DC
0 V
Base unit:
PNOZmulti or PNOZelog
Driven via semiconductor outputs
(24 V DC)
A1
PZE
A20 V
O1
L-
Feedback loop Base unit: PNOZX
Base unit: PNOZmulti or
PNOZelog
Y1, Y2 and Input are inputs on
the base unit; they evaluate the
feedback loop

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Operating Manual PZE X4
1003199-EN-11 10
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 of the contact expansion module (switch off outputs of the base
unit) and start the base unit again so that the internal diagnostics can check that the safety
contacts open correctly
}for SIL CL 3/PL e at least 1x per month
}for SIL CL 2/PL d at least 1x per year
NOTICE
The safety function should be checked after initial commissioning and each
time the plant/machine is changed. The safety functions may only be
checked by qualified personnel.
Status indicators
LEDs indicate the status and errors during operation:
LED on
CH.1
Safety contacts of channel 1 are closed.
CH.2
Safety contacts of channel 2 are closed.
Faults – Interference
By closing or interrupting the input circuit you can check whether the unit switches on or off
correctly.
For safety reasons, the unit cannot be started if the following faults are present:
}Contact malfunction: As the contact block is connected to a base unit,
reactivation will not be possible if the contacts have welded after the input circuit has
opened.
}Open circuit, short circuit or earth fault ( e.g. in the input circuit)