Pilz PZE X5 User manual

PZE X5
Operating Manual-1003301-EN-08
}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 X5
1003301-EN-08 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 14
Supplementary data 15
Service life graph 15
Order reference 16
EC declaration of conformity 16

PZE X5
Operating Manual PZE X5
1003301-EN-08 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.
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 X5
Operating Manual PZE X5
1003301-EN-08 5
INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The contact expansion module PZE X5 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 [ 14] 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 X5
Operating Manual PZE X5
1003301-EN-08 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 X5
Operating Manual PZE X5
1003301-EN-08 7
Unit features
}Positive-guided relay outputs:
– 5 safety contacts (N/O), instantaneous
}LED display for:
– Supply voltage
– Switch status of the safety contacts
}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.
}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)

PZE X5
Operating Manual PZE X5
1003301-EN-08 8
Function description
The contact expansion module PZE X5 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). When operating voltage is supplied the "POWER"
LED will light.
}Functional procedure once the input circuit is closed (safety contacts on the base unit
are closed):
– Safety contacts 13-14, 23-24, 33-34, 43-44 and 53-54 close.
– The LEDs "CH.1" and "CH.2" are lit.
}Functional procedure once the input circuit is opened (safety contacts on the base unit
are opened):
– Safety contacts 13-14, 23-24, 33-34, 43-44 and 53-54 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).
Wiring
Please note:
}Information given in the "Technical details [ 11]" 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 [ 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.
}Ensure the wiring and EMC requirements of EN 60204-1 are met.

PZE X5
Operating Manual PZE X5
1003301-EN-08 9
Preparing for operation
Supply voltage AC DC
A1
A2
L+
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

PZE X5
Operating Manual PZE X5
1003301-EN-08 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
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:
}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)

PZE X5
Operating Manual PZE X5
1003301-EN-08 11
Dimensions in mm
121 (4.76")
75 (2.95")
87 (3.42")
45
(1.77")
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) 3,5 W
Residual ripple DC 20 %
Duty cycle 100 %
Max. inrush current impulse
Current pulse, A1 10 A
Pulse duration, A1 0,5 ms
Inputs
Number 2
Voltage at
Input circuit DC 24 V
Current at
Input circuit DC 35 mA
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
Relay outputs
Number of output contacts
Safety contacts (N/O), instantaneous 5

PZE X5
Operating Manual PZE X5
1003301-EN-08 12
Relay outputs
Max. short circuit current IK 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1
Utilisation category of safety contacts
AC1 at 240 V
Min. current 0,01 A
Max. current 8 A
Max. power 2000 VA
DC1 at 24 V
Min. current 0,01 A
Max. current 8 A
Max. power 200 W
Utilisation category
In accordance with the standard EN 60947-5-1
Utilisation category of safety contacts
AC15 at 230 V
Max. current 5 A
DC13 (6 cycles/min) at 24 V
Max. current 7 A
Utilisation category in accordance with UL
Voltage 240 V AC G. P.
With current 8 A
Voltage 24 V DC G. P. Resistive
With current 5 A
Pilot Duty B300, R300
External contact fuse protection, 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 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
Ith per contact at UB DC; AC1:240V,DC1:24V
Conv. therm. current with 1 contact 8 A
Conv. therm. current with 2 contacts 8 A
Conv. therm. current with 3 contacts 6,5 A
Conv. therm. current with 4 contacts 5,6 A
Conv. therm. current with 5 contacts 5 A

PZE X5
Operating Manual PZE X5
1003301-EN-08 13
Times
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. 15 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 ms
Supply interruption before de-energisation 20 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
Protection type
Housing IP40
Terminals IP20
Mounting area (e.g. control cabinet) IP54
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

PZE X5
Operating Manual PZE X5
1003301-EN-08 14
Mechanical data
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 270 g
Where standards are undated, the 2017-01 latest editions shall apply.
Safety characteristic data
NOTICE
You must comply with the safety characteristic data in order to achieve the
required safety level for your plant/machine.
Operating
mode
EN ISO
13849-1:
2015
PL
EN ISO
13849-1:
2015
Category
EN62061
SIL CL
EN62061
PFHD [1/h]
IEC 61511
SIL
IEC 61511
PFD
EN ISO
13849-1:
2015
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.

PZE X5
Operating Manual PZE X5
1003301-EN-08 15
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.
Number of cycles x 1000
Switching current (A)
Example
}Inductive load: 0.2 A
}Utilisation category: AC15
}Contact service life: 4 000 000 cycles
Provided the application to be implemented requires fewer than 4 000 000 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.

PZE X5
Operating Manual PZE X5
1003301-EN-08 16
Order reference
Product
type Features Connection type Order no.
PZE X5 24 VDC Screw terminals 774595
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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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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200XXXX-EN-0X
0-0-2-3-000, 2017-00 Printed in Germany
© Pilz GmbH & Co. KG, 2017
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1003301-EN-08, 2018-02 Printed in Germany © Pilz GmbH & Co. KG, 2015