Pilz PZE X5 User manual

PZEX5
OperatingManual1003301EN05
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X5
1003301EN05 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 7
Wiring 7
Preparingforoperation 8
Operation 8
Statusindicators 8
Faults–Interference 8
Dimensionsinmm 9
Technicaldetails 9
Safetycharacteristicdata 12
Supplementarydata 12
Servicelifegraph 13
Orderreference 13
ECdeclarationofconformity 14

PZEX5
OperatingManualPZEX5
1003301EN05 4
Introduction
Validityofdocumentation
ThisdocumentationisvalidfortheproductPZEX5.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.

PZEX5
OperatingManualPZEX5
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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:
– 5safetycontacts(N/O),instantaneous
}LEDdisplayfor:
– Switchstatuschannel1/2
– Supplyvoltage
}Connectionforfeedbackloop
}Operation:singleordual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.

PZEX5
OperatingManualPZEX5
1003301EN05 6
}Earthfaultintheinputcircuit:
Theoutputrelaysdeenergiseandthesafetycontactsopen.
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)
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whenthesupplyvoltageisappliedandtheinputcircuitschannel
1and2areclosed(safetycontactsofthebaseunitareclosed):
– Closethesafetycontacts1314,2324,3334,4344and5354.
– TheLEDs"CH.1"and"CH.2"arelit.
}Functionalprocedureafteroneorbothinputcircuitsareopen(safetycontactsofthe
baseunitareopen):
– Openthesafetycontacts1314,2324,3334,4344and5354.
– TheLEDs"CH.1"and"CH.2"goout.

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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.
}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[ 9]"mustbefollowed.
}Theoutputs1314,2324,3334,4344,5354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.

PZEX5
OperatingManualPZEX5
1003301EN05 8
Preparingforoperation
Supplyvoltage AC DC
A1 L+
A2 L-
Inputcircuit Singlechannel Dualchannel
withoutdetectionofshorts
acrosscontacts
K1
K2
U
Y4
Y3
PZE
K1
K2
U
Y4
Y3
PZE
U
withdetectionofshortsacross
contacts
K1
K2
U
Y4
Y3
PZE
U
Feedbackloop
Y1andY2arefeedbackloopin
putsonthebaseunit
Operation
Statusindicators
Power
Supplyvoltageispresent.
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:

PZEX5
OperatingManualPZEX5
1003301EN05 9
}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
121 (4.76")
75 (2.95")
87 (3.42")
45
(1.77")
Technicaldetails
General 774595
Approvals CCC,CE,EAC(Eurasian),TÜV,cULusListed
Electricaldata 774595
Supplyvoltage
Voltage 24V
Kind DC
Voltagetolerance 15%/+10%
Outputofexternalpowersupply(DC) 3,5W
ResidualrippleDC 20%
Continuousduty 100%
Max.overallcableresistanceRlmax
SinglechannelatUBDC 120Ohm
Dualchannelwithoutdetectionofshortsacross
contactsatUBDC 240Ohm
Dualchannelwithdetectionofshortsacrosscon
tactsatUBDC 4Ohm
Voltageat
InputcircuitDC 24,0V
Currentat
InputcircuitDC 35,0mA
Numberofoutputcontacts
Safetycontacts(N/O),instantaneous 5

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1003301EN05 10
Inputs 774595
Number 2
Relayoutputs 774595
Max.shortcircuitcurrentIK 1kA
Utilisationcategory
Inaccordancewiththestandard EN6094741
Safetycontacts,AC1at 240V
Max.current 8,0A
Min.current 0,01A
Max.power 2000VA
Safetycontacts,DC1at 24V
Max.current 8,0A
Min.current 0,01A
Max.power 200W
Utilisationcategory
Inaccordancewiththestandard EN6094751
Safetycontacts,AC15at 230V
Max.current 5,0A
SafetycontactsDC13(6cycles/min)at 24V
Max.current 7,0A
UtilisationcategoryinaccordancewithUL
Voltage 240VACG.P.
Withcurrent 8,0A
Voltage 24VDCG.P.Resistive
Withcurrent 5,0A
PilotDuty B300,C600,R300
Contactfuseprotectionexternal,safetycontacts
Inaccordancewiththestandard EN6094751
Max.meltingintegral 240A²s
Blowoutfuse,quick 10A
Blowoutfuse,slow 6,00A
Blowoutfuse,gG 10A
Circuitbreaker,24VAC/DC,characteristicB/C 6A
Contactmaterial AgSnO2+0,2µmAu
Conventionalthermalcurrentwhileloadingsev
eralcontacts
774595
IthpercontactatUBDC
Conv.therm.currentwith1contact 8,00A
Conv.therm.currentwith2contacts 8,00A
Conv.therm.currentwith3contacts 6,50A
Conv.therm.currentwith4contacts 5,60A
Conv.therm.currentwith5contacts 5,00A

PZEX5
OperatingManualPZEX5
1003301EN05 11
Times 774595
Switchondelay
Withautomaticstarttyp. 15ms
Withautomaticstartmax. 30ms
Withautomaticstartafterpowerontyp. 15ms
Withautomaticstartafterpoweronmax. 30ms
Delayondeenergisation
WithESTOPtyp. 13ms
WithESTOPmax. 30ms
Withpowerfailuretyp. 110ms
Withpowerfailuremax. 150ms
Supplyinterruptionbeforedeenergisationintheinput
circuit 8,0ms
Supplyinterruptionbeforedeenergisation 20ms
Environmentaldata 774595
Climaticsuitability EN60068278
Ambienttemperature
Temperaturerange 1055°C
Storagetemperature
Temperaturerange 4085°C
Condensationduringoperation Notpermitted
EMC EN6094751,EN6100062
Vibration
Inaccordancewiththestandard EN6006826
Frequency 10,055,0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 4,00kV
Protectiontype
Mountingarea(e.g.controlcabinet) IP54
Housing IP40
Terminals IP20
Mechanicaldata 774595
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

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Mechanicaldata 774595
Conductorcrosssectionwithscrewterminals
1coreflexible 0,204,00mm²,2410AWG
2corewiththesamecrosssection,flexiblewith
crimpconnectors,noplasticsleeve 0,202,50mm²,2414AWG
2corewiththesamecrosssection,flexiblewithout
crimpconnectorsorwithTWINcrimpconnectors 0,202,50mm²,2414AWG
Torquesettingwithscrewterminals 0,50Nm
Connectiontype Screwterminal
Mountingtype Fixed
Dimensions
Height 87,0mm
Width 45,0mm
Depth 121,0mm
Weight 270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.

PZEX5
OperatingManualPZEX5
1003301EN05 13
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.
Example
}Inductiveload:0,2A
}Utilisationcategory:AC15
}Contactservicelife:4,000,000cycles
Providedtheapplicationrequiresfewerthan4,000,000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.
Orderreference
Type Features Connectiontype Orderno.
PZEX5 24VDC Screwterminals 774595

PZEX5
OperatingManualPZEX5
1003301EN05 14
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

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100XXXX-DE-0X
0-0-2-3-000, 2014-00 Printed in Germany
© Pilz GmbH & Co. KG, 2014
1003301EN05,201405PrintedinGermany ©PilzGmbH&Co.KG,2011
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