Pilz PZE X4V8 User manual

PZE X4V8
Operating Manual 1003204-EN-07
}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.
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 X4V8
1003204-EN-07 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 5
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 11
Faults – Interference 11
Dimensions in mm 11
Technical details 12
Safety characteristic data 14
Supplementary data 15
Service life graph 15
Order reference 16
EC declaration of conformity 16

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 4
Introduction
Validity of documentation
This documentation is valid for the product PZE X4V8. 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 X4V8
Operating Manual PZE X4V8
1003204-EN-07 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The contact expansion module PZE X4V8 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 [ 12]).
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 unit 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.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 6
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
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 this description under "Safety"
}And 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-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 X4V8
Operating Manual PZE X4V8
1003204-EN-07 7
Unit features
}Positive-guided relay outputs:
– 4 safety contacts (N/O), delay-on de-energisation
}LED display for:
– Switch status of the safety contacts
}Connection for feedback loop
}Operation: single-channel
}Selectable delay time
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
8A 8B 4A 7B5A6A
6A7A
Delay
*
6B
6B 5B 4B
*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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Operating Manual PZE X4V8
1003204-EN-07 8
Function description
The contact expansion module PZE X4V8 is an add-on device with selectable 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 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 17-18, 27-28, 37-38 and 47-48 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.
– The LEDs "CH.1" and "CH.2" go out.
– Safety contacts 17-18, 27-28, 37-38 and 47-48 are opened redundantly once the
delay time has elapsed.
NOTICE
At the latest the safety contacts open after the set delay time tv + 50% of the
set value, even in the case of a component failure.
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).
Wiring
Please note:
}Information given in the "Technical details [ 12]" must be followed.
}Outputs 17-18, 27-28, 37-38 and 47-48 are delay-on de-energisation safety contacts.
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details [ 12]).
}Calculation of the max. cable runs lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details [ 12])
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.

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 9
}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.
}Ensure the wiring and EMC requirements of IEC 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:
Safety relay PNOZX
Driven via safety contacts
A1
A2 PZE
24 V DC
0 V
Feedback loop Base unit: Safety relay PNOZ X
Y1 and Y2 are inputs on the base
unit; they evaluate the feedback
loop

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 10
Setting the delay time
Operation
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.

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 11
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)
}In the case of an error, the delay-on de-energisation safety contacts may open before
the delay time has elapsed.
Dimensions in mm
121 (4.76")
75 (2.95")
87 (3.42")
45
(1.77")

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 12
Technical details
General
Approvals CCC, CE, EAC (Eurasian), TÜV, cULus Listed
Electrical data
Supply voltage
Voltage 24 V
Kind DC
Voltage tolerance -15 %/+10 %
Output of external power supply (DC) 2,5 W
Residual ripple DC 20 %
Duty cycle 100 %
Max. inrush current impulse
Current pulse, A1 1,7 A
Pulse duration, A1 280 ms
Inputs
Number 1
Voltage at
Input circuit DC 24 V
Current at
Input circuit DC 70 mA
Max. overall cable resistance Rlmax
Single-channel at UB DC 30 Ohm
Relay outputs
Number of output contacts
Safety contacts (N/O), delayed 4
Max. short circuit current IK 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1
Utilisation category of safety contacts delayed
AC1 at 240 V
Min. current 0,01 A
Max. current 5 A
Max. power 1200 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 5 A
Max. power 120 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts delayed
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 4 A

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 13
Relay outputs
Utilisation category in accordance with UL
Voltage 240 V AC G.U. (same polarity)
With current 5 A
Voltage 24 V DC Resistive
With current 5 A
Pilot Duty B300, R300
External contact fuse protection, safety contacts
In accordance with the standard EN 60947-5-1
External contact fuse protection, delayed safety con-
tacts
Max. melting integral 100 A²s
Blow-out fuse, quick 6 A
Blow-out fuse, slow 4 A
Blow-out fuse, gG 6 A
Circuit breaker 24 V AC/DC, characteristic B/C 4 A
Conventional thermal current 5 A
Contact material AgSnO2 + 0,2 µm Au
Times
Switch-on delay
With automatic start after power on typ. 320 ms
With automatic start after power on max. 500 ms
Delay time tv 4 s, 5 s, 6 s, 7 s, 8 s
Time accuracy -50 %/+50 %
Supply interruption before de-energisation 2.000 ms
Environmental data
Climatic suitability EN 60068-2-78
Ambient temperature
Temperature range -10 - 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

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 14
Environmental data
Protection type
Mounting area (e.g. control cabinet) IP54
Housing IP40
Terminals IP20
Mechanical data
Mounting position Any
Mechanical life 10,000,000 cycles
Material
Bottom PPO UL 94 V0
Front ABS UL 94 V0
Top PPO UL 94 V0
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 0,6 Nm
Dimensions
Height 87 mm
Width 45 mm
Depth 121 mm
Weight 345 g
Where standards are undated, the 2014-07 latest editions shall apply.
Safety characteristic data
NOTICE
You must comply with the safety-related characteristic data in order to
achieve the required safety level for your plant/machine.
Operating
mode
EN ISO
13849-1:
2008
PL
EN ISO
13849-1:
2008
Category
EN 62061
SIL CL
EN 62061
PFHD [1/h]
IEC 61511
SIL
IEC 61511
PFD
EN ISO
13849-1:
2008
TM [year]
Safety con-
tacts,
delayed <30
sPL d Cat. 3 SIL CL 2 2,48E-09 SIL 2 1,47E-05 20

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 15
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.
Cycles x 1000
Switching current (A)

PZE X4V8
Operating Manual PZE X4V8
1003204-EN-07 16
Example
}Inductive load: 2 A
}Utilisation category AC15
}Contact service life: 400 000 cycles
Provided the application to be implemented requires fewer than 400 000 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
Type Features Connection type Order no.
PZE X4V8 24 V DC
tv: 4 - 8 s, selectable
Screw terminals 774 584
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/downloads.
Representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2, 73760 Ost-
fildern, Germany

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CMSE®, InduraNET p®, PAS4000®, PAScal®, PASconfig®, Pilz®, PIT®, PLID®, PMCprimo®, PMCprotego®, PMCtendo®, PMD®, 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.
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100XXXX-DE-0X
0-0-1-3-000, 2015-00 Printed in Germany
© Pilz GmbH & Co. KG, 2015
1003204-EN-07, 2016-07 Printed in Germany © Pilz GmbH & Co. KG, 2015
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