PILZ PNOZ XV2P Safety Relay Instruction Manual

PNOZ XV2P Safety Relay
Instruction Manual

PNOZ XV2P Safety Relay

PNOZ XV2P
Operating Manual-20095-EN-09
– Safety relays

This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when formulating this document. We do assure you that all persons are regarded without discrimination and on an equal basis.
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 documentation will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, Safety BUS p®, Safety EYE®, Safety NET p®, the spirit of safety® are registered and protected trademarks of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Introduction

Validity of documentation
This documentation is valid for the product PNOZ XV2P. 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 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 damaged and also provides information on preventive measures that can be taken. It also highlights areas within the text that are of particular importance.
INFORMATION
This gives advice on applications and provides information on special features.

Safety

Intended use
The safety relay PNOZ XV2P provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN 60947-5-1 and EN 60204-1 and may be used in applications with:

• E-STOP pushbuttons
• Safety gates

Improper use
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 operating manual,
• Use of the product outside the technical details (see chapter entitled Technical Details [ 16]).

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 interference.
Safety regulations
Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is required.
The product as an individual component fulfils the functional safety requirements in accordance with EN ISO 13849 and EN IEC 62061. However, this does not guarantee the functional safety of the overall  plant/machine. To achieve the relevant safety level of the overall  plant/machine’s required safety functions, each safety function needs to be considered separately.
Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated, maintained and decommissioned by persons who are competent to do so.
A competent person is a qualified and knowledgeable person who, because of their training, 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 prevention,
• 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 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-related 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.

Unit features

• Positive-guided relay outputs:
  – 2 safety contacts (N/O), instantaneous
  – 2 safety contacts (N/O), delay-on de-energization

• Connection options for:
  – E-STOP pushbutton
  – Safety gate limit switch
  – Start button

• LED display for:
  – Supply voltage
  – Switch state of the safety contacts
  – Start circuit

• Delay time fixed or selectable

• Possible to cancel delay time

• Plug-in connection terminals (either spring-loaded terminal or screw terminal)

• See order reference for unit types

Safety features
The safety relay meets the following safety requirements:

• The circuit is redundant with built-in self-monitoring.
• The safety function remains effective in the case of a component failure.
• The correct opening and closing of the safety function relays is tested automatically in each on-off cycle.

Block diagram/terminal configuration

*Insulation between the non-marked area and the relay contacts: Basic insulation (overvoltage category III), Protective separation (overvoltage category II)
Function Description
The safety relay PNOZ XV2P provides a safety-oriented interruption of a safety circuit.
When supply voltage is supplied the “POWER” LED is lit. The unit is ready for operation when the reset circuit Y39-Y40 and the start circuit S13-S14 are closed.

• Input circuit is closed (e.g. E-STOP pushbutton not operated):
  – The “START” LED is lit.
  – The LEDs “CH.1”, “CH.1 [t]” and “CH.2”, “CH.2 [t]” are lit.
  – The safety contacts 13-14, 23-24, 37-38 and 47-48 are closed. The unit is active.
  – The “START” LED goes out.

• Input circuit is opened (e.g. E-STOP pushbutton operated):
  – The LEDs “CH.1” and “CH.2” go out.
  – Safety contacts 13-14 and 23-24 are redundantly opened.
  – Safety contacts 37-38 and 47-48 open after the delay time has elapsed.
  – The LEDs “CH.1 [t]” and “CH.2 [t]” go out.

Before the unit can be restarted, the delay time must have elapsed and the unit must again be ready for operation.
Set delay time:
On units with selectable delay time, the delay time of the safety contacts 37-38 and 47-48 can be set on the front of the unit using a screwdriver.
Reset function:
The delay time cycle can be ended prematurely by opening the reset circuit Y39-Y40. For this purpose, one N/C contact is connected between Y39-Y40 instead of a link.
Operating modes

• Single-channel operation: No redundancy in the input circuit, earth faults in the start and input circuit are detected.

• Dual-channel operation with detection of shorts across contacts: Redundant input circuit, detects PNOZ XV2P
  – earth faults in the start and input circuit,
  – short circuits in the input circuit,
  – Shorts across contacts in the input circuit.

•  Automatic start: Unit is active once the input circuit has been closed.

• Monitored start: Unit is active once the input circuit is closed and once the start circuit is closed after the waiting period has elapsed (see Technical details [ 16]).

• Increase in the number of available contacts by connecting contact expansion modules or external contactors/relays.

Timing diagram

Legend

• Power: Supply voltage
•  Start: Start circuit
• Reset tv: Reset circuit
• Input: Input circuit
• Output safe: Safety contacts, instantaneous
•  Output safe delay: Safety contacts, delayed
• [1]: Automatic start
•  [2]: Monitored start
• t1: Switch-on delay
• t2: Delay-on de-energization
• t3: Waiting period with a monitored start
• t4: Recovery time
• tv: Delay time

NOTICE
At the latest, the delay-on de-energization safety contacts open after the set delay time + 50 ms + 15% 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 (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 [ 16]” must be followed.

• Delivery status of units with screw terminals: Link between S11-S12 (dual-channel input circuit) and link between Y39-Y40 (reset circuit)

• Outputs 13-14, 23-24 are instantaneous safety contacts, outputs 37-38, 47-48 are delay on de-energization safety contacts.

•  Do not connect undesignated terminals.

• To prevent contact welding, a fuse should be connected before the output contacts (see Technical details [ 16]).

• Calculation of the max. cable length lmax in the input circuit:
  Rlmax = max. overall cable resistance (see Technical details [ 16])
  Rl / km = cable resistance/km

• Use copper wiring with a temperature stability of 60/75 °C.

• To prevent EMC interferences (particularly common-mode interferences) the measures described in EN 60204-1 must be executed. This includes the separate routing of cables of the control circuits (input,  start and feedback loop) from other cables for energy transmission or the shielding of cables, for example.

• Adequate protection must be provided on all output contacts with capacitive and inductive loads.

• Do not switch low currents using contacts that have been used previously with high currents.

• When connecting magnetically operated, reed proximity switches, ensure that the max. peak inrush current (on the input circuit) does not overload the proximity switch.

• The power supply must comply with the regulations for extra low voltages with protective electrical separation (SELV, PELV) in accordance with VDE 0100, Part 410.

Important for detection of shorts across contacts:
As this function for detecting shorts across contacts is not failsafe, it is tested by Pilz during the final control check. If there is a danger of exceeding the cable length, we recommend the following test once the unit is installed:

1. Unit ready for operation (output contacts closed)
2. Short circuit the test terminals S22, S32 for detecting shorts across the inputs.
3. The unit‘s fuse must be triggered and the output contacts must open. Cable lengths in the scale of the maximum length can delay the fuse triggering for up to 2 minutes.
4. Reset the fuse: Remove the short circuit and switch off the supply voltage for approx. 1 minute.

Preparing for operation

Input circuit|

Single-channel

|

Dual-channel

---|---|---
E-STOP
without detection of shorts across contacts| **|
E-STOP
with detection of shorts across contacts| **|
Safety gate
without detection of shorts across contacts| |
Safety gate

with detection of shorts across contacts

| |

NOTICE
With single-channel wiring the safety level of your machine/plant may be lower than the safety level of the unit (see Safety characteristic data).

Start circuit| E-STOP wiring Safety gate without start-up test| Safety gate with start-up test
---|---|---
Automatic start| | Simultaneity S1 and S2: max. 3 s
Monitored start| |

NOTICE
With automatic start
The unit starts up automatically when the safeguard is reset, e.g. when the E-STOP pushbutton is released. Use external circuit measures to prevent an unexpected restart.

Reset delay time|

Without reset

|

With reset

---|---|---
Link or N/C contact| ****|

Legend

• S1/S2: E-STOP/safety gate switch
• S3: Reset button
• : Switch operated
• : Gate open
• : Gate closed

INFORMATION
With automatic start, S33 and S34 must not be linked; with monitored start, S13 and S14 must not be linked.

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 (switch off output) and start the device again, so that the internal diagnostics can check that the safety contacts open correctly

• for SIL 3/PL e at least 1x per month
• for SIL 3/PL d at least 1x per year

NOTICE
The safety functions 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.

• START
  Start circuit is closed.

• CH.1
  Safety contacts of channel 1 are closed.

• CH.2
  Safety contacts of channel 2 are closed.

• CH.1 [t] Channel 3 safety contacts are closed.

• CH.2 [t] Channel 4 safety contacts are closed.

Faults – Interference

• Earth fault: The supply voltage fails and the safety contacts open. Once the cause of the respective fault has been rectified and the supply voltage is switched off for approx.
  1 minute, the unit is ready for operation again.

• Contact malfunctions: If the contacts have welded, reactivation will not be possible after the input circuit has opened.

•  LED “POWER” does not light: Short circuit or no supply voltage.

• In the case of an error, the delay-on de-energization contacts may open before the delay time has elapsed.

Dimensions in mm

• with spring-loaded terminals

Technical details Order no. 777500, 777502, 777503

Listed
Electrical data| 777500| 777502| 777503
Supply voltage| | |
Voltage| 24 V| 24 V| 24 V
Kind| DC| DC| DC
Voltage tolerance| -15 %/+10 %| -15 %/+10 %| -15 %/+10 %
Output of external power supply (DC)| 4,5 W| 4,5 W| 4,5 W
Residual ripple DC| 160 %| 160 %| 160 %
Duty cycle| 100 %| 100 %| 100 %
Max. inrush current im- pulse| | |
Current pulse, A1| 5 A| 5 A| 5 A
Pulse duration, A1| 1 ms| 1 ms| 1 ms
Inputs| 777500| 777502| 777503
Quantity| 2| 2| 2
Voltage at| | |
Input circuit DC| 24 V| 24 V| 24 V
Start circuit DC| 24 V| 24 V| 24 V
Feedback loop DC| 24 V| 24 V| 24 V
Current at| | |
Input circuit DC| 35 mA| 35 mA| 35 mA
Start circuit DC| 40 mA| 40 mA| 40 mA
Feedback loop DC| 3,5 mA| 3,5 mA| 3,5 mA
Min. input resistance at power-on| 143 Ohm| 143 Ohm| 143 Ohm
Max. overall cable resistance Rlmax| | |
Single-channel at UB DC| 100 Ohm| 100 Ohm| 100 Ohm
Dual-channel with detection of shorts across contacts at UB DC| 10 Ohm| 10 Ohm| 10 Ohm
Relay outputs| 777500| 777502| 777503
Number of output contacts| | |
Safety contacts (N/O), instantaneous| ****2| ****2| ****2
Safety contacts (N/O), delayed| ****2| ****2| ****2
Max. short circuit current IK| ****1 kA| ****1 kA| ****1 kA
Relay outputs| 777500| 777502| 777503
---|---|---|---
Utilization category| | |
in accordance with the| | |
standard| EN 60947-4-1| EN 60947-4-1| EN 60947-4-1
Utilization category of safety contacts| | |
AC1 at| 240 V| 240 V| 240 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 2000 VA| 2000 VA| 2000 VA
DC1 at| 24 V| 24 V| 24 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 200 W| 200 W| 200 W
Utilization category of safety contacts delayed| | |
AC1 at| 240 V| 240 V| 240 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 2000 VA| 2000 VA| 2000 VA
DC1 at| 24 V| 24 V| 24 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 200 W| 200 W| 200 W
Utilization category| | |
in accordance with the| | |
standard| EN 60947-5-1| EN 60947-5-1| EN 60947-5-1
Utilization category of safety contacts| | |
AC15 at| 230 V| 230 V| 230 V
Max. current| 5 A| 5 A| 5 A
DC13 (6 cycles/min) at| 24 V| 24 V| 24 V
Max. current| 7 A| 7 A| 7 A
Utilization category of safety contacts delayed| | |
AC15 at| 230 V| 230 V| 230 V
Max. current| 5 A| 5 A| 5 A
DC13 (6 cycles/min) at| 24 V| 24 V| 24 V
Max. current| 7 A| 7 A| 7 A
Utilization category in ac- accordance with UL| | |
Voltage| 240 V AC G. P.| 240 V AC G. P.| 240 V AC G. P.
with current| 8 A| 8 A| 8 A
Pilot Duty| C300, R300| C300, R300| C300, R300
Relay outputs| 777500| 777502| 777503
---|---|---|---
External contact fuse pro- section, safety contacts| | |
in accordance with the standard| EN 60947-5-1| EN 60947-5-1| ****EN 60947-5-1
Max. melting integral| 240 A²s| 240 A²s| 240 A²s
Blow-out fuse, quick| 10 A| 10 A| 10 A
Blow-out fuse, slow| 6 A| 6 A| 6 A
Blow-out fuse, gG| 10 A| 10 A| 10 A
Circuit breaker 24V AC/DC, characteristic B/C| 6 A| 6 A| 6 A**

External contact fuse pro- section, delayed safety contacts

Circuit breaker, 24
V AC/DC, character- istic B/C| 6 A| 6 A| 6 A
Contact material| AgSnO2 + 0,2 µm Au| AgSnO2 + 0,2 µm Au| **AgSnO2

• 0,2 µm Au
  Conventional thermal| 777500| 777502| 777503
  current while loading| | |
  several contacts| | |
  Ith per contact at UB DC; AC1: 240 V, DC1: 24 V| | |
  Conv. therm. current with 1 contact| 8 A| 8 A| 8 A
  Conv. therm. current with 2 contacts| 7 A| 7 A| 7 A
  Conv. therm. current with 3 contacts| 5,7 A| 5,7 A| 5,7 A
  Conv. therm. current with 4 contacts| 5 A| 5 A| 5 A
  Times| 777500| 777502| 777503
  Switch-on delay| | |
  with automatic start typ.| 350 ms| 350 ms| 350 ms
  with automatic start max.| 650 ms| 650 ms| 650 ms
  with automatic start after power on typ.| 385 ms| 385 ms| 385 ms
  with automatic start after power on max.| 700 ms| 700 ms| 700 ms
  with monitored start typ.| 35 ms| 35 ms| 35 ms
  with monitored start max.| 70 ms| 70 ms| 70 ms
  Times| 777500| 777502| 777503
  ---|---|---|---
  Delay-on de-energization| | |
  with E-STOP typ.| 15 ms| 15 ms| 15 ms
  with E-STOP max.| 30 ms| 30 ms| 30 ms
  with power failure typ.| 85 ms| 85 ms| 85 ms
  with power failure max.| 200 ms| 200 ms| 200 ms
  Recovery time at max. switching frequency 1/s| | |
  after E-STOP| 50 ms +tv| 50 ms +tv| 50 ms +tv
  after power failure| 250 ms| 250 ms| 250 ms
  Delay time tv| 0,1 s, 0,5 s, 1 s, 2 s, 4 s, 6 s, 8 s, 10 s,  15 s, 20 s, 25 s, 30 s| 0,1 s, 0,2 s, 0,3 s, 0,4 s, 0,5 s, 0,6 s,  0,7 s, 0,8 s, 1 s, 1,5 s, 2 s, 3 s| 1 s
  Time accuracy| -15 %/+15 % +50 ms| -15 %/+15 % +50 ms| -15 %/+15 % +50 ms
  Repetition accuracy| 2 %| 2 %| 2 %
  Waiting period with a monitored start| 300 ms| 300 ms| 300 ms
  Min. start pulse duration with a monitored start| 30 ms| 30 ms| 30 ms
  Supply interruption before energisation| 20 ms| 20 ms| 20 ms
  Simultaneity, channel 1 and 2 max.| ∞| ∞| ∞
  Environmental data| 777500| 777502| 777503
  Climatic suitability| EN 60068-2-78| EN 60068-2-78| EN 60068-2-78
  Ambient temperature| | |
  Temperature range| -10 – 55 °C| -10 – 55 °C| -10 – 55 °C
  Storage temperature| | |
  Temperature range| -40 – 85 °C| -40 – 85 °C| -40 – 85 °C
  Climatic suitability| | |
  Humidity| 93 % r. h. at 40 °C| 93 % r. h. at 40 °C| 93 % r. h. at 40 °C
  Condensation during operation| Not permitted| Not permitted| Not permitted
  EMC| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1
  Vibration| | |
  in accordance with the standard| EN 60068-2-6| EN 60068-2-6| EN 60068-2-6
  Frequency| 10 – 55 Hz| 10 – 55 Hz| 10 – 55 Hz
  Amplitude| 0,35 mm| 0,35 mm| 0,35 mm
  Airgap creepage| | |
  in accordance with the standard| EN 60947-1| EN 60947-1| EN 60947-1
  Overvoltage category| III / II| III / II| III / II
  Pollution degree| 2| 2| 2
  Rated insulation voltage| 250 V| 250 V| 250 V
  Rated impulse withstand voltage| 4 kV| 4 kV| 4 kV
  Environmental data| 777500| 777502| 777503
  ---|---|---|---
  Protection type| | |
  Housing| IP40| IP40| IP40
  Terminals| IP20| IP20| IP20
  Mounting area (e.g.| | |
  control cabinet)| IP54| IP54| IP54
  Mechanical data| 777500| 777502| 777503
  Mounting position| Any| Any| Any
  Mechanical life| 10,000,000 cycles| 10,000,000 cycles| 10,000,000 cycles
  Material| | |
  Bottom| PPO UL 94 V1| PPO UL 94 V1| PPO UL 94 V1
  Front| ABS UL 94 V0| ABS UL 94 V0| ABS UL 94 V0
  Top| PPO UL 94 V1| PPO UL 94 V1| PPO UL 94 V1
  Connection type| Screw terminal| Screw terminal| Screw terminal
  Mounting type| plug-in| plug-in| plug-in
  Conductor cross section| | |
  with screw terminals| | |
  1 core flexible| 0,25 – 2,5 mm², 24 – 12 AWG| 0,25 – 2,5 mm², 24 – 12 AWG| 0,25 – 2,5 mm², 24 – 12 AWG
  2 core with the same| | |
  cross section, flexible| | |
  with crimp connectors,| 0,25 – 1 mm², 24 – 16| 0,25 – 1 mm², 24 – 16| 0,25 – 1 mm², 24 – 16
  no plastic sleeve| AWG| AWG| AWG
  2 core with the same| | |
  cross section, flexible| | |
  without crimp connect-| | |
  ors or with TWIN crimp| 0,2 – 1,5 mm², 24 – 16| 0,2 – 1,5 mm², 24 – 16| 0,2 – 1,5 mm², 24 – 16
  connectors| AWG| AWG| AWG
  Torque setting with screw| | |
  terminals| 0,5 Nm| 0,5 Nm| 0,5 Nm
  Stripping length with| | |
  screw terminals| 8 mm| 8 mm| 8 mm
  Dimensions| | |
  Height| 94 mm| 94 mm| 94 mm
  Width| 45 mm| 45 mm| 45 mm
  Depth| 121 mm| 121 mm| 121 mm
  Weight| 360 g| 360 g| 350 g**

Technical details Order no. 777504, 787500, 787502

Listed
Electrical data| 777504| 787500| 787502
Supply voltage| | |
Voltage| 24 V| 24 V| 24 V
Kind| DC| DC| DC
Voltage tolerance| -15 %/+10 %| -15 %/+10 %| -15 %/+10 %
Output of external power supply (DC)| 4,5 W| 4,5 W| 4,5 W
Residual ripple DC| 160 %| 160 %| 160 %
Duty cycle| 100 %| 100 %| 100 %
Max. inrush current im- pulse| | |
Current pulse, A1| 5 A| 5 A| 5 A
Pulse duration, A1| 1 ms| 1 ms| 1 ms
Inputs| 777504| 787500| 787502
Quantity| 2| 2| 2
Voltage at| | |
Input circuit DC| 24 V| 24 V| 24 V
Start circuit DC| 24 V| 24 V| 24 V
Feedback loop DC| 24 V| 24 V| 24 V
Current at| | |
Input circuit DC| 35 mA| 35 mA| 35 mA
Start circuit DC| 40 mA| 40 mA| 40 mA
Feedback loop DC| 3,5 mA| 3,5 mA| 3,5 mA
Min. input resistance at power-on| 143 Ohm| 143 Ohm| 143 Ohm
Max. overall cable resistance Rlmax| | |
Single-channel at UB DC| 100 Ohm| 100 Ohm| 100 Ohm
Dual-channel with detection of shorts across contacts at UB DC| 10 Ohm| 10 Ohm| 10 Ohm
Relay outputs| 777504| 787500| 787502
Number of output con- tacts| | |
Safety contacts (N/O), instantaneous| 2| 2| 2
Safety contacts (N/O), delayed| 2| 2| 2
Max. short circuit current IK| 1 kA| 1 kA| 1 kA
Relay outputs| 777504| 787500| 787502
---|---|---|---
Utilization category| | |
in accordance with the| | |
standard| EN 60947-4-1| EN 60947-4-1| EN 60947-4-1
Utilization category of safety contacts| | |
AC1 at| 240 V| 240 V| 240 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 2000 VA| 2000 VA| 2000 VA
DC1 at| 24 V| 24 V| 24 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 200 W| 200 W| 200 W
Utilization category of safety contacts delayed| | |
AC1 at| 240 V| 240 V| 240 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 2000 VA| 2000 VA| 2000 VA
DC1 at| 24 V| 24 V| 24 V
Min. current| 0,01 A| 0,01 A| 0,01 A
Max. current| 8 A| 8 A| 8 A
Max. power| 200 W| 200 W| 200 W
Utilization category| | |
in accordance with the| | |
standard| EN 60947-5-1| EN 60947-5-1| EN 60947-5-1
Utilization category of safety contacts| | |
AC15 at| 230 V| 230 V| 230 V
Max. current| 5 A| 5 A| 5 A
DC13 (6 cycles/min) at| 24 V| 24 V| 24 V
Max. current| 7 A| 7 A| 7 A
Utilization category of safety contacts delayed| | |
AC15 at| 230 V| 230 V| 230 V
Max. current| 5 A| 5 A| 5 A
DC13 (6 cycles/min) at| 24 V| 24 V| 24 V
Max. current| 7 A| 7 A| 7 A
Utilization category in ac- accordance with UL| | |
Voltage| 240 V AC G. P.| 240 V AC G. P.| 240 V AC G. P.
with current| 8 A| 8 A| 8 A
Pilot Duty| C300, R300| C300, R300| C300, R300
Relay outputs| 777504| 787500| 787502
---|---|---|---
External contact fuse pro- tection, safety contacts| | |
in accordance with the standard| EN 60947-5-1| EN 60947-5-1| EN 60947-5-1
Max. melting integral| 240 A²s| 240 A²s| 240 A²s
Blow-out fuse, quick| 10 A| 10 A| 10 A
Blow-out fuse, slow| 6 A| 6 A| 6 A
Blow-out fuse, gG| 10 A| 10 A| 10 A
Circuit breaker 24V AC/DC, characteristic B/C| 6 A| 6 A| 6 A**

External contact fuse protection, delayed safety contacts

A
Contact material| AgSnO2 + 0,2 µm Au| AgSnO2 + 0,2 µm Au| AgSnO2

• 0,2 µm Au
  Conventional thermal| 777504| 787500| 787502
  current while loading| | |
  several contacts| | |
  Ith per contact at UB DC; AC1: 240 V, DC1: 24 V| | |
  Conv. therm. current with 1 contact| 8 A| 8 A| 8 A
  Conv. therm. current with 2 contacts| 7 A| 7 A| 7 A
  Conv. therm. current with 3 contacts| 5,7 A| 5,7 A| 5,7 A
  Conv. therm. current with 4 contacts| 5 A| 5 A| 5 A
  Times| 777504| 787500| 787502
  Switch-on delay| | |
  with automatic start typ.| 350 ms| 350 ms| 350 ms
  with automatic start max.| 650 ms| 650 ms| 650 ms
  with automatic start after power on typ.| 385 ms| 385 ms| 385 ms
  with automatic start after power on max.| 700 ms| 700 ms| 700 ms
  with monitored start typ.| 35 ms| 35 ms| 35 ms
  with monitored start max.| 70 ms| 70 ms| 70 ms
  Times| 777504| 787500| 787502
  ---|---|---|---
  Delay-on de-energisation| | |
  with E-STOP typ.| 15 ms| 15 ms| 15 ms
  with E-STOP max.| 30 ms| 30 ms| 30 ms
  with power failure typ.| 85 ms| 85 ms| 85 ms
  with power failure max.| 200 ms| 200 ms| 200 ms
  Recovery time at max. switching frequency 1/s| | |
  after E-STOP| 50 ms +tv| 50 ms +tv| 50 ms +tv
  after power failure| 250 ms| 250 ms| 250 ms
  Delay time tv| 0,5 s| 0,1 s, 0,5 s, 1 s, 2 s, 4 s, 6 s, 8 s, 10 s, 15 s, 20 s, 25 s, 30 s| 0,1 s, 0,2 s, 0,3 s, 0,4 s, 0,5 s, 0,6 s, 0,7 s, 0,8 s, 1 s, 1,5 s, 2 s, 3 s
  Time accuracy| -15 %/+15 % +50 ms| -15 %/+15 % +50 ms| -15 %/+15 % +50 ms
  Repetition accuracy| 2 %| 2 %| 2 %
  Waiting period with a monitored start| 300 ms| 300 ms| 300 ms
  Min. start pulse duration with a monitored start| 30 ms| 30 ms| 30 ms
  Supply interruption before de-energisation| 20 ms| 20 ms| 20 ms
  Simultaneity, channel 1 and 2 max.| ∞| ∞| ∞
  Environmental data| 777504| 787500| 787502
  Climatic suitability| EN 60068-2-78| EN 60068-2-78| EN 60068-2-78
  Ambient temperature| | |
  Temperature range| -10 – 55 °C| -10 – 55 °C| -10 – 55 °C
  Storage temperature| | |
  Temperature range| -40 – 85 °C| -40 – 85 °C| -40 – 85 °C
  Climatic suitability| | |
  Humidity| 93 % r. h. at 40 °C| 93 % r. h. at 40 °C| 93 % r. h. at 40 °C
  Condensation during operation| Not permitted| Not permitted| Not permitted
  EMC| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1| EN 60947-5-1, EN 61000-6-2, EN 61326-3-1
  Vibration| | |
  in accordance with the standard| EN 60068-2-6| EN 60068-2-6| EN 60068-2-6
  Frequency| 10 – 55 Hz| 10 – 55 Hz| 10 – 55 Hz
  Amplitude| 0,35 mm| 0,35 mm| 0,35 mm
  Airgap creepage| | |
  in accordance with the standard| EN 60947-1| EN 60947-1| EN 60947-1
  Overvoltage category| III / II| III / II| III / II
  Pollution degree| 2| 2| 2
  Rated insulation voltage| 250 V| 250 V| 250 V
  Rated impulse withstand voltage| 4 kV| 4 kV| 4 kV
  Environmental data| 777504| 787500| 787502
  ---|---|---|---
  Protection type| | |
  Housing| IP40| IP40| IP40
  Terminals| IP20| IP20| IP20
  Mounting area (e.g.| | |
  control cabinet)| IP54| IP54| IP54
  Mechanical data| 777504| 787500| 787502
  Mounting position| Any| Any| Any
  Mechanical life| 10,000,000 cycles| 10,000,000 cycles| 10,000,000 cycles
  Material| | |
  Bottom| PPO UL 94 V1| PPO UL 94 V1| PPO UL 94 V1
  Front| ABS UL 94 V0| ABS UL 94 V0| ABS UL 94 V0
  Top| PPO UL 94 V1| PPO UL 94 V1| PPO UL 94 V1
  Connection type| Screw terminal| Spring-loaded terminal| Spring- loaded terminal
  Mounting type| plug-in| plug-in| plug-in
  Conductor cross section| | |
  with screw terminals| | |
  1 core flexible| 0,25 – 2,5 mm², 24 – 12 AWG| –| –
  2 core with the same| | |
  cross section, flexible| | |
  with crimp connectors,| 0,25 – 1 mm², 24 – 16| |
  no plastic sleeve| AWG| –| –
  2 core with the same| | |
  cross section, flexible| | |
  without crimp connect-| | |
  ors or with TWIN crimp| 0,2 – 1,5 mm², 24 – 16| |
  connectors| AWG| –| –
  Torque setting with screw| | |
  terminals| 0,5 Nm| –| –
  Stripping length with| | |
  screw terminals| 8 mm| –| –
  Conductor cross section| | |
  with spring-loaded terminals:| | |
   Flexible with/without| | 0,2 – 1,5 mm², 24 – 16| 0,2 – 1,5 mm², 24 – 16
  crimp connector| –| AWG| AWG
  Spring-loaded terminals:| | |
  Terminal points per connection| | |
  | –| 2| 2
  Stripping length with| | |
  spring-loaded terminals| –| 8 mm| 8 mm
  Dimensions| | |
  Height| 94 mm| 101 mm| 101 mm
  Width| 45 mm| 45 mm| 45 mm
  Depth| 121 mm| 121 mm| 121 mm
  Weight| 350 g| 355 g| 355 g
  General| 787503| 787504
  ---|---|---
  ** Certifications| CCC, CE, EAC, TÜV, cULus Lis- ted| CCC, CE, EAC, TÜV, cULus Lis- ted
  Electrical data| 787503| 787504
  Supply voltage| |
  Voltage| 24 V| 24 V
  Kind| DC| DC
  Voltage tolerance| -15 %/+10 %| -15 %/+10 %
  Output of external power supply (DC)| **4,5 W| ****4,5 W
  Residual ripple DC| 160 %| 160 %
  Duty cycle| 100 %| 100 %
  Max. inrush current impulse| |
  Current pulse, A1| 5 A| 5 A
  Pulse duration, A1| 1 ms| 1 ms
  Inputs| 787503| 787504
  Quantity| 2| 2
  Voltage at| |
  Input circuit DC| 24 V| 24 V
  Start circuit DC| 24 V| 24 V
  Feedback loop DC| 24 V| 24 V
  Current at| |
  Input circuit DC| 35 mA| 35 mA
  Start circuit DC| 40 mA| 40 mA
  Feedback loop DC| 3,5 mA| 3,5 mA
  Min. input resistance at power-on| 143 Ohm| 143 Ohm
  Max. overall cable resistance Rl- max| |
  Single-channel at UB DC| 100 Ohm| 100 Ohm
  Dual-channel with detection of| |
  shorts across contacts at UB DC 10 Ohm 10 Ohm
  Relay outputs| 787503| 787504
  Number of output contacts| |
  Safety contacts (N/O), instantaneous| 2| 2
  Safety contacts (N/O), delayed| 2| 2
  Max. short circuit current IK| 1 kA| 1 kA
  Utilization category| |
  in accordance with the standard| EN 60947-4-1| EN 60947-4-1
  Relay outputs| 787503| 787504
  ---|---|---
  Utilization category of safety contacts| |
  | |
  AC1 at| 240 V| 240 V
  Min. current| 0,01 A| 0,01 A
  Max. current| 8 A| 8 A
  Max. power| 2000 VA| 2000 VA
  DC1 at| 24 V| 24 V
  Min. current| 0,01 A| 0,01 A
  Max. current| 8 A| 8 A
  Max. power| 200 W| 200 W
  Utilization category of safety contacts delayed| |
  AC1 at| 240 V| 240 V
  Min. current| 0,01 A| 0,01 A
  Max. current| 8 A| 8 A
  Max. power| 2000 VA| 2000 VA
  DC1 at| 24 V| 24 V
  Min. current| 0,01 A| 0,01 A
  Max. current| 8 A| 8 A
  Max. power| 200 W| 200 W
  Utilization category| |
  in accordance with the standard| EN 60947-5-1| EN 60947-5-1
  Utilization category of safety contacts| |
  AC15 at| 230 V| 230 V
  Max. current| 5 A| 5 A
  DC13 (6 cycles/min) at| 24 V| 24 V
  Max. current| 7 A| 7 A
  Utilisation category of safety contacts delayed| |
  AC15 at| 230 V| 230 V
  Max. current| 5 A| 5 A
  DC13 (6 cycles/min) at| 24 V| 24 V
  Max. current| 7 A| 7 A
  Utilisation category in accordance with UL| |
  Voltage| 240 V AC G. P.| 240 V AC G. P.
  with current| 8 A| 8 A
  Pilot Duty| C300, R300| C300, R300
  Relay outputs| 787503| 787504
  ---|---|---
  External contact fuse protection,| |
  safety contacts| |
  in accordance with the standard| EN 60947-5-1| EN 60947-5-1
  Max. melting integral| 240 A²s| 240 A²s
  Blow-out fuse, quick| 10 A| 10 A
  Blow-out fuse, slow| 6 A| 6 A
  Blow-out fuse, gG| 10 A| 10 A
  Circuit breaker 24V AC/DC,| |
  characteristic B/C| 6 A| 6 A
  External contact fuse protection, delayed safety contacts| |
  Max. melting integral| 240 A²s| 240 A²s
  Blow-out fuse, quick| 10 A| 10 A
  Blow-out fuse, slow| 6 A| 6 A
  Blow-out fuse, gG| 10 A| 10 A
  Circuit breaker, 24 V AC/DC,| |
  characteristic B/C| 6 A| 6 A
  Contact material| AgSnO2 + 0,2 µm Au| AgSnO2 + 0,2 µm Au
  Conventional thermal current| 787503| 787504
  while loading several contacts| |
  Ith per contact at UB DC;| |
  AC1: 240 V, DC1: 24 V| |
  Conv. therm. current with 1 con-| |
  tact| 8 A| 8 A
  Conv. therm. current with 2 contacts| |
  | 7 A| 7 A
  Conv. therm. current with 3 contacts| |
  | 5,7 A| 5,7 A
  Conv. therm. current with 4 contacts| |
  | 5 A| 5 A
  Times| 787503| 787504
  Switch-on delay| |
  with automatic start typ.| 350 ms| 350 ms
  with automatic start max.| 650 ms| 650 ms
  with automatic start after power| |
  on typ.| 385 ms| 385 ms
  with automatic start after power| |
  on max.| 700 ms| 700 ms
  with monitored start typ.| 35 ms| 35 ms
  with monitored start max.| 70 ms| 70 ms
  Delay-on de-energisation| |
  with E-STOP typ.| 15 ms| 15 ms
  with E-STOP max.| 30 ms| 30 ms
  with power failure typ.| 85 ms| 85 ms
  with power failure max.| 200 ms| 200 ms
  Times| 787503| 787504
  ---|---|---
  Recovery time at max. switching frequency 1/s| |
  after E-STOP| 50 ms +tv| 50 ms +tv
  after power failure| 250 ms| 250 ms
  Delay time tv| 1 s| 0,5 s
  Time accuracy| -15 %/+15 % +50 ms| -15 %/+15 % +50 ms
  Repetition accuracy| 2 %| 2 %
  Waiting period with a monitored start| 300 ms| 300 ms
  Min. start pulse duration with a monitored start| 30 ms| 30 ms
  Supply interruption before de-energisation| ****20 ms| ****20 ms
  Simultaneity, channel 1 and 2 max.| ∞| ∞
  Environmental data| 787503| 787504
  Climatic suitability| EN 60068-2-78| EN 60068-2-78
  Ambient temperature| |
  Temperature range| -10 – 55 °C| -10 – 55 °C**

Storage temperature
Temperature range    Climatic suitability                  -40 – 85 °C -40 – 85 °C

61000-6-2, EN 61326-3-1
Vibration| |
in accordance with the standard| EN 60068-2-6| EN 60068-2-6
Frequency| 10 – 55 Hz| 10 – 55 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 kV| 4 kV
Protection type| |
Housing| IP40| IP40
Terminals| IP20| IP20
Mounting area (e.g. control cab- inet)| IP54| IP54
Mechanical data| 787503| 787504
Mounting position| Any| Any
Mechanical life| 10,000,000 cycles| 10,000,000 cycles
Mechanical data| 787503| 787504
---|---|---
Material| |
Bottom| PPO UL 94 V1| PPO UL 94 V1
Front| ABS UL 94 V0| ABS UL 94 V0
Top| PPO UL 94 V1| PPO UL 94 V1
Connection type| Spring-loaded terminal| Spring-loaded terminal
Mounting type| plug-in| plug-in
Conductor cross section with spring-loaded terminals: Flexible with/without crimp connector| 0,2 – 1,5 mm², 24 – 16 AWG| 0,2 – 1,5 mm², 24 – 16 AWG
Spring-loaded terminals: Terminal points per connection| 2| 2
Stripping length with spring-loaded terminals| 8 mm| 8 mm
Dimensions| |
Height| 101 mm| 101 mm
Width| 45 mm| 45 mm
Depth| 121 mm| 121 mm
Weight| 345 g| 345 g**

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 IEC 62061 SIL CL/maximum SIL| EN IEC 62061

PFH D [1/h]

| EN ISO 13849-1: 2015 T M [year]
---|---|---|---|---|---
Safety contacts, instantaneous| PL e| Cat. 4| SIL 3| 2,31E-09| 20
Safety contacts, delayed <30 s| PL d| Cat. 3| SIL 3| 2,64E-09| 20
Safety contacts, delayed ≥30 s| PL c| Cat. 1| SIL 1| **2,87E-09| ****20**

Explanatory notes for the safety-related characteristic data:

• Safety characteristic data in accordance with EN IEC 62061 and EN/IEC 61511 was calculated based on EN/IEC 61508.

• TM is the maximum mission time in accordance with EN ISO 13849-1. The value also applies as the retest interval in accordance with EN/IEC 61508-6 and EN/IEC 61511 and
  as the proof test interval and mission time in accordance with EN IEC 62061.

• 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 switch frequency and the load of the relay output.
If the service life graphs are not accessible, the stated PFH value can be used irrespective of the switch 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 negligible.

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 contactors, use flywheel diodes for spark
suppression.
Remove plug-in terminals
Procedure

• Insert a suitable screwdriver into the housing recess behind the terminal. Do not remove the terminals by pulling the cables!
• Lever the terminal out.

Order reference

EC declaration of conformity
This product/these products meet the requirements of the directive 2006/42/EC for machinery of the European Parliament and of the Council. The complete EC Declaration of Conformity is available on the Internet at www.pilz.com/downloads.
Authorised representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel- Str.2, 73760 Ostfildern,  Germany
UKCA-Declaration of Conformity
This product(s) complies with following UK legislation: Supply of Machinery (Safety) Regulation 2008.
The complete UKCA Declaration of Conformity is available on the Internet at www.pilz.com/downloads.
Representative: Pilz Automation Technology, Pilz House, Little Colliers Field, Corby, Northampton shire, NN18 8TJ United Kingdom, eMail: [email protected]
Support
Technical support is available from Pilz round the clock.

Americas
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+81 45 471-2281
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+82 31 778 3300| Australia and Oceania
Australia
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Europe
Austria
+43 1 7986263-0
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+33 3 88104003
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+49 711 3409-444
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+353 21 4804983
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+39 0362 1826711| Scandinavia
+45 74436332
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+34 938497433
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+41 62 88979-32
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+31 347 320477
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+90 216 5775552
United Kingdom
+44 1536 462203
You can reach our international hotline on:
+49 711 3409-222
[email protected]
---|---|---

Pilz develops environmentally-friendly products using ecological materials and energy-saving technologies. Offices and production facilities are ecologically designed, environmentally-aware and energy-saving. So  Pilz offers sustainability, plus the security of using energy-efficient products and environmentally-friendly solutions.

We are represented internationally. Please refer to our homepage www.pilz.com for further details or contact our headquarters.
Headquarters: Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany
Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: [email protected], Internet: www.pilz.com

CECE ® , CHRE ® , CMSE ® , InduraNET p ® , Leansafe ® , Master of Safety ® , Master of Security ® , PAS4000 ® , PAScal ® , PASconfig ® , Pilz ® , PIT ® , PLID ® , PMCprimo ® , PMCprotego ® , PMCtendo ® , PMD ® , PMI ® , PNOZ ® , PRBT ® , PRCM ® , Primo ® , PRTM ® , PSEN ® , PSS ® , PVIS ® , Safety BUS p ® , Safety EYE ® , 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.

20095-EN-09, 2023-06 Printed in Germany
© Pilz GmbH & Co. KG, 2019

References

• Pilz – Safe automation, automation technology - Pilz INT
• Pilz – Safe automation, automation technology - Pilz INT
• Downloads - Pilz INT
• Downloads - Pilz INT

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