Pilz PZE x4p User manual

PZEX4P
OperatingManual1003201EN08
Safetyrelays

Preface
Thisdocumentisatranslationoftheoriginaldocument.
AllrightstothisdocumentationarereservedbyPilzGmbH&Co.KG.Copiesmaybemade
forinternalpurposes.Suggestionsandcommentsforimprovingthisdocumentation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

Content
OperatingManualPZEX4P
1003201EN08 3
Introduction 4
Validityofdocumentation 4
Retainingthedocumentation 4
Definitionofsymbols 4
Intendeduse 5
Foryoursafety 5
Unitfeatures 5
Safetyfeatures 5
Blockdiagram/terminalconfiguration 6
Functiondescription 6
Installation 6
Wiring 7
Preparingforoperation 7
Operation 8
Statusindicators 8
Faults–Interference 8
Dimensionsinmm 8
Technicaldetails 9
Safetycharacteristicdata 12
Supplementarydata 12
Servicelifegraph 12
Removepluginterminals 14
Orderreference 14
ECdeclarationofconformity 15

PZEX4P
OperatingManualPZEX4P
1003201EN08 4
Introduction
Validityofdocumentation
ThisdocumentationisvalidfortheproductPZEX4P.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.
Retainingthedocumentation
Thisdocumentationisintendedforinstructionandshouldberetainedforfuturereference.
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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OperatingManualPZEX4P
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INFORMATION
Thisgivesadviceonapplicationsandprovidesinformationonspecialfea
tures.
Intendeduse
TheunitmeetstherequirementsofEN6094751,EN602041andVDE01131.Thecon
tactexpansionmoduleisusedtoincreasethenumberofinstantaneoussafetycontacts
availableonabaseunit.Baseunitsareallsafetyrelayswithfeedbackloopmonitoring.
ThecategorythatcanbeachievedinaccordancewithENISO138491dependsonthe
categoryofthebaseunit.Thecontactexpansionmodulemaynotexceedthis.
Foryoursafety
}Onlyinstallandcommissiontheunitifyouhavereadandunderstoodtheseoperating
instructionsandarefamiliarwiththeapplicableregulationsforhealthandsafetyatwork
andaccidentprevention.
EnsureVDEandlocalregulationsaremet,especiallythoserelatingtosafety.
}Anyguaranteeisrenderedinvalidifthehousingisopenedorunauthorisedmodifica
tionsarecarriedout.
}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.
Unitfeatures
}Positiveguidedrelayoutputs:
– 4safetycontacts(N/O),instantaneous
}LEDdisplayfor:
– Switchstatuschannel1/2
}Connectionforfeedbackloop
}Operation:singlechannel
}Pluginconnectionterminals(eitherspringloadedterminalorscrewterminal)
}Seeorderreferenceforunittypes
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.

PZEX4P
OperatingManualPZEX4P
1003201EN08 6
}Earthfaultintheinputcircuit:
Theoutputrelaysdeenergiseandthesafetycontactsopen.
Blockdiagram/terminalconfiguration
CH.2
CH.1
PNOZ X4P
P1
13A1
Y1 Y2 43
2414A2
P1
P2
23
14
13
34
3323
24
33
43
44
34
44
PZE X4P
*
*Insulationbetweenthenonmarkedareaandtherelaycontacts:Basicinsulation(over
voltagecategoryIII),Protectiveseparation(overvoltagecategoryII)
Functiondescription
Thecontactexpansionmoduleisanaddondevicewithoutdelayondeenergisation,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afterclosingthesafetycontactsofthebaseunit:
– Thesupplyvoltageispresentattheinput(A1)ofthecontactexpansionmodule.
– Closethesafetycontacts1314,2324,3334and4344.
– TheLEDs"CH.1"and"CH.2"arelit.
}Functionalprocedureafteropeningthesafetycontactsofthebaseunit:
– Thereisnotsupplyvoltageatinput(A1)ofthecontactexpansionmodule.
– Openthesafetycontacts1314,2324,3334and4344.
– 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.
}EnsuretheunitismountedsecurelyonaverticalDINrail(35mm)byusingafixingele
ment(e.g.retainingbracketoran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.

PZEX4P
OperatingManualPZEX4P
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Wiring
Pleasenote:
}Informationgiveninthe"Technicaldetails[ 9]"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).
}Calculationofthemax.cablerunslmaxintheinputcircuit:
Rlmax
Rl / km
Imax =
Rlmax=max.overallcableresistance(seeTechnicaldetails)
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.
Preparingforoperation
Supplyvoltage AC DC
A1
A2 PZE
24 V DC
0 V
Inputcircuit Singlechannel Dualchannel
Baseunit:
SafetyrelayPNOZX
Drivenviasafetycontacts
A1
A2 PZE
24 V DC
0 V
Baseunit:
SafetyrelayPNOZmulti
Drivenviasemiconductoroutputs
(24VDC)
A1
PZE
A20 V
O1
L-
Feedbackloop Baseunit:SafetyrelayPNOZX Baseunit:SafetyrelayPNOZmulti
Y1,Y2andInputareinputson
thebaseunit;theyevaluatethe
feedbackloop

PZEX4P
OperatingManualPZEX4P
1003201EN08 8
Operation
Statusindicators
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)
Dimensionsinmm
*withspringloadedterminals
121 (4.76")
22,5
(0.88")
* 101 (3.98")
94 (3.70")

PZEX4P
OperatingManualPZEX4P
1003201EN08 9
Technicaldetails
General 777585 787585
Approvals
CCC,CE,GOST,TÜV,cULusLis
ted
CCC,CE,GOST,TÜV,cULusLis
ted
Electricaldata 777585 787585
Supplyvoltage
Voltage 24V 24V
Kind DC DC
Voltagetolerance 15%/+10% 15%/+10%
Outputofexternalpowersupply
(DC) 2,5W 2,5W
ResidualrippleDC 20% 20%
Continuousduty 100% 100%
Max.inrushcurrentimpulse
Currentpulse,inputcircuit 2,00A 2,00A
Pulseduration,inputcircuit 2,0ms 2,0ms
Max.overallcableresistanceRl
max
SinglechannelatUBDC 30Ohm 30Ohm
Voltageat
InputcircuitDC 24,0V 24,0V
Currentat
InputcircuitDC 95,0mA 95,0mA
Numberofoutputcontacts
Safetycontacts(N/O),instant
aneous 4 4
Inputs 777585 787585
Number 1 1
Relayoutputs 777585 787585
Max.shortcircuitcurrentIK 1kA 1kA
Utilisationcategory
Inaccordancewiththestandard EN6094741 EN6094741
Safetycontacts,AC1at 240V 240V
Max.current 6,0A 6,0A
Min.current 0,01A 0,01A
Max.power 1500VA 1500VA
Safetycontacts,DC1at 24V 24V
Max.current 6,0A 6,0A
Min.current 0,01A 0,01A
Max.power 150W 150W

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1003201EN08 10
Relayoutputs 777585 787585
Utilisationcategory
Inaccordancewiththestandard EN6094751 EN6094751
Safetycontacts,AC15at 230V 230V
Max.current 5,0A 5,0A
SafetycontactsDC13(6cycles/
min)at 24V 24V
Max.current 5,0A 5,0A
Utilisationcategoryinaccordance
withUL
Voltage 240VACG.U.(samepolarity) 240VACG.U.(samepolarity)
Withcurrent 6,0A 6,0A
Voltage 24VDCG.U. 24VDCG.U.
Withcurrent 6,0A 6,0A
PilotDuty R300 R300
Contactfuseprotectionexternal,
safetycontacts
Inaccordancewiththestandard EN6094751 EN6094751
Max.meltingintegral 260A²s 260A²s
Blowoutfuse,quick 10A 10A
Blowoutfuse,slow 6,00A 6,00A
Blowoutfuse,gG 10A 10A
Circuitbreaker,24VAC/DC,
characteristicB/C 6A 6A
Contactmaterial AgCuNi+0,2µmAu AgCuNi+0,2µmAu
Conventionalthermalcurrent
whileloadingseveralcontacts
777585 787585
IthpercontactatUBDC
Conv.therm.currentwith1con
tact 6,00A 6,00A
Conv.therm.currentwith2con
tacts 6,00A 6,00A
Conv.therm.currentwith3con
tacts 5,00A 5,00A
Conv.therm.currentwith4con
tacts 4,00A 4,00A
Times 777585 787585
Switchondelay
Withautomaticstartafterpower
ontyp. 30ms 30ms
Withautomaticstartafterpower
onmax. 50ms 50ms
Delayondeenergisation
WithESTOPtyp. 30ms 30ms
WithESTOPmax. 50ms 50ms
Withpowerfailuretyp. 30ms 30ms
Withpowerfailuremax. 50ms 50ms
Supplyinterruptionbeforedeener
gisation 20ms 20ms

PZEX4P
OperatingManualPZEX4P
1003201EN08 11
Environmentaldata 777585 787585
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
EMC EN6094751,EN6100062 EN6094751,EN6100062
Vibration
Inaccordancewiththestandard EN6006826 EN6006826
Frequency 10,055,0Hz 10,055,0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 4,00kV 4,00kV
Protectiontype
Mountingarea(e.g.controlcab
inet) IP54 IP54
Housing IP40 IP40
Terminals IP20 IP20
Mechanicaldata 777585 787585
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
Conductorcrosssectionwithscrew
terminals
1coreflexible 0,252,50mm²,2412AWG –
2corewiththesamecrosssec
tion,flexiblewithcrimpconnect
ors,noplasticsleeve 0,251,00mm²,2416AWG –
2corewiththesamecrosssec
tion,flexiblewithoutcrimpcon
nectorsorwithTWINcrimpcon
nectors 0,201,50mm²,2416AWG –
Torquesettingwithscrewterminals 0,50Nm –
Connectiontype Screwterminal Cageclampterminal
Mountingtype plugin plugin
Conductorcrosssectionwith
springloadedterminals:Flexible
with/withoutcrimpconnector – 0,201,50mm²,2416AWG
Springloadedterminals:Terminal
pointsperconnection – 2
Strippinglength – 8mm

PZEX4P
OperatingManualPZEX4P
1003201EN08 12
Mechanicaldata 777585 787585
Dimensions
Height 94,0mm 101,0mm
Width 22,5mm 22,5mm
Depth 121,0mm 121,0mm
Weight 175g 175g
Thestandardscurrenton200912apply.
Safetycharacteristicdata
Operating
mode
ENISO
138491:
2008
PL
ENISO
138491:
2008
Category
ENIEC
62061
SILCL
ENIEC
62061
PFHD[1/h]
IEC61511
SIL
IEC61511
PFD
ENISO
138491:
2008
TM[year]
–PLe Cat.4 SILCL3 2,31E09 SIL3 2,03E06 20
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switchingfrequencyandtheloadontherelayoutput.Ifthe
servicelifegraphsarenotaccessible,thestatedPFHvaluecanbeusedirrespectiveofthe
switching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.
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.

PZEX4P
OperatingManualPZEX4P
1003201EN08 13
Servicelifegraphsat24VDCand230VAC
Servicelifegraphsat110VDC
Example
}Inductiveload:0,2A
}Utilisationcategory:AC15

PZEX4P
OperatingManualPZEX4P
1003201EN08 14
}Contactservicelife:2,000,000cycles
Providedtheapplicationrequiresfewerthan2,000,000cycles,thePFHvalue(seetech
nical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contact
ors,usefreewheeldiodesforsparksuppression.
Removepluginterminals
Procedure:Insertthescrewdriverintothehousingrecessbehindtheterminalandleverthe
terminalout.
Donotremovetheterminalsbypullingthecables!
Orderreference
Type Features Connectiontype Orderno.
PZEX4P 24VDC Screwterminals,plugin 777585
PZEX4PC 24VDC Springloadedterminals,plugin 787585

PZEX4P
OperatingManualPZEX4P
1003201EN08 15
ECdeclarationofconformity
Thisproduct/theseproductsmeettherequirementsofthedirective2006/42/ECforma
chineryoftheEuropeanParliamentandoftheCouncil.ThecompleteECDeclarationof
ConformityisavailableontheInternetatwww.pilz.com/support/downloads.
Representative:NorbertFröhlich,PilzGmbH&Co.KG,FelixWankelStr.2,73760Ost
fildern,Germany

...
Sachnummer Printed in Germany
© Pilz GmbH & Co. KG, 2011
[phone]
[email protected]
Pilz GmbH & Co. KG
Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Telephone: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.pilz.com
Technical support
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Please refer to our homepage
for further details or contact our
headquarters.
InduraNET p®, Pilz®, PIT®, PMCprotego®, 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. We would point out that product features may vary from the details stated in this document, depending on the status at the time of publication and the scope of the equipment. We accept no responsibility for the validity, accuracy and entirety of the text and graphics presented in this information. Please contact our Technical Support if you have any questions.
1003201EN08,201402PrintedinGermany ©PilzGmbH&Co.KG,2011
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