EPA PECON+ User manual

Protective earth monitoring for single and three phase networks
P
0
2
I
PECON+®
For mobile use of
frequency inverters
and servo drives
The 3.5 mA-limit as per
DIN EN 50178 / VDE 0160
may be exceeded
For networks with rated
voltages of 100 VAC
up to 480 VAC with or
without neutral*
Instruction manual

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Thank you for choosing the PECON+® protective earth monitoring system from EPA!
If you have any technical questions, please give us a call:
Phone: [phone] - 0
For the latest information on this product, visit www.epa.de.

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Contents
1 Important basic information ........................................................................................... 4
1.1 Publication details .................................................................................................. 4
1.2 Target group........................................................................................................... 5
1.3 Liability ................................................................................................................... 5
1.4 General equal treatment ......................................................................................... 5
1.5 Registered trademarks ........................................................................................... 5
1.6 Symbols and signal words ...................................................................................... 6
1.7 Marking on the product ........................................................................................... 7
1.8 CE mark ................................................................................................................. 8
1.9 EMC Limit Class ..................................................................................................... 8
1.10 Declaration of conformity ........................................................................................ 9
1.11 Product description............................................................................................... 10
1.12 Area of application ............................................................................................... 11
1.13 Delivery contents .................................................................................................. 12
2 Safety instructions ...................................................................................................... 13
2.1 Intended use ........................................................................................................ 13
2.2 Inadmissible operating conditions......................................................................... 13
2.3 Requirements for personnel ................................................................................. 14
2.4 Responsibility: ...................................................................................................... 14
2.5 Connection ........................................................................................................... 15
2.6 Follow the operating instructions .......................................................................... 16
3 Technical data ................................................................................................................ 17
3.1 Rating data PECON+
®
......................................................................................... 17
3.2 Rating data PECON+
®
S1 / S2 ............................................................................. 18
3.3 Rating data PECON+
®
S3 / S4 ............................................................................. 19
3.4 Rating data PECON+
®
NVT-1 / NVF-1 ................................................................. 20
3.5 Rating data PECON+
®
NVT-2 / NVF-2 ................................................................. 21
3.6 Rating data PECON+
®
IT ..................................................................................... 22
3.7 Dimensions .......................................................................................................... 23
4 Function ......................................................................................................................... 24
4.1 Operating principle ............................................................................................... 24
4.2 Normal state ......................................................................................................... 24
4.3 Fault ..................................................................................................................... 25
4.4 Additional functions .............................................................................................. 25
4.5 Type overview ...................................................................................................... 29
5 Delivery, internal transport, unpacking ........................................................................ 32
5.1 Delivery ................................................................................................................ 32
5.2 Internal transport .................................................................................................. 32
5.3 Unpacking ............................................................................................................ 32

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6 Storage and transport ................................................................................................... 33
6.1 Ambient conditions ............................................................................................... 33
6.2 Storage ................................................................................................................ 33
6.3 Transport .............................................................................................................. 33
7 Installation ..................................................................................................................... 34
7.1 Safety instructions for installation ......................................................................... 34
7.2 Installation conditions ........................................................................................... 35
7.3 Operating conditions ............................................................................................ 35
7.4 Connection conditions .......................................................................................... 35
7.5 Overload protection .............................................................................................. 36
7.6 Connections ......................................................................................................... 36
7.7 Wiring diagram ..................................................................................................... 39
8 Startup / Operation ........................................................................................................ 45
8.1 Switching on ......................................................................................................... 45
8.2 Shutdown ............................................................................................................. 45
8.3 LED display elements ........................................................................................... 45
9 Troubleshooting ............................................................................................................ 46
9.1 All LEDs remain dark ............................................................................................ 46
9.2 Red LED is illuminated ......................................................................................... 46
9.3 Service address ................................................................................................... 46
10 System inspection and maintenance ........................................................................... 47
11 Repairs ........................................................................................................................... 48
12 Disposal ......................................................................................................................... 48

Important basic information
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1 Important basic information
1.1 Publication details
Published by:
EPA GmbH
Fliederstr. 8
63486 Bruchköbel
Germany
Phone: [phone] - 9704- 0
Fax: [phone] - 9704- 99
E-mail: [e-mail]
Web: www.epa.de
Author:
T. Bozem
Photos:
A. Mayer
Implementation:
K. Bonkosch
Issue number:
1.6 / 11/2018
Validity of device version:
PECON+®
PECON+® S1 / S2 / S3 / S4
PECON+® NVT-1 / -2
PECON+® NVF-1 / -2
PECON+® IT
© EPA GmbH
All rights, including the rights to photomechanical reproduction and storage in electronic
media, are reserved by EPA GmbH. Commercial use or distribution of the text, models,
drawings and photos used in this product is not permitted. No part of this publication may
be reproduced, stored or transferred, distributed or translated in any form or using any
medium without prior written permission.

Important basic information
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®
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1.2 Target group
This documentation is intended for qualified personnel as defined in IEC 60364.
Qualified personnel are persons who have the appropriate qualifications for the work to be
performed during the installation, assembly, startup and operation of the product.
1.3 Liability
The common names, trade names, descriptions of goods and other designations used in
this publication may be legally protected even if not specifically marked as such (for
example as trademarks). EPA GmbH accepts no liability or warranty for their free
availability.
The illustrations and text were compiled with the utmost care. Nevertheless, errors cannot
be excluded.
The publication is provided without guarantee.
The information it contains is provided solely for the purpose of customer information and
contains no representations or binding warranties. Binding statements are possible only in
response to specific inquiries.
The contents of this instruction manual are accurate at the date of printing. Because it is
under continuous development, the manufacturer reserves the right to change the
specification of the product and its performance data as well as the contents of this
instruction manual, in both technical and commercial terms, without prior notice. The
current version is available at www.epa.de.
Liability of the company EPA GmbH for any damage resulting from incorrect use of this
instruction manual or incorrect, erroneous or inappropriate installation or adjustment is
excluded. Interruptions to operation, loss of profit as well as loss of information and data or
consequential damages are excluded insofar as liability is not mandatory in accordance
with the law on product liability or in cases of intent, gross negligence or breach of
fundamental contractual obligations.
1.4 General equal treatment
EPA GmbH is aware of the importance of language with respect to the equal rights of
women and men and makes every effort to take this into account. To ensure better
readability, however, it was necessary to abstain from the consistent use of differentiated
formulations.
1.5 Registered trademarks
Brand names and trademarks are the property of their respective owners and are not
generally marked as such in this manual.
The absence of such marking does not mean that a name is free within the meaning of
brand and trademark law.

Important basic information
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®
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1.6 Symbols and signal words
The following symbols and signal words are used in this documentation to indicate hazards
and important information:
Symbol/signal word
Meaning
Warning of hazardous electrical voltage
DANGER
Draws your attention to a hazardous situation that will
result in serious injury or death if not avoided.
WARNING
Draws your attention to a hazardous situation that may
result in serious injury or death if not avoided.
CAUTION
Draws your attention to a hazardous situation that may
result in minor to moderate injury if not avoided.
IMPORTANT NOTE
Draws your attention to the handling and impact of safety
information.
NOTE
Draws your attention to the handling and impact of safety
information.
Draws your attention to possible damage to property and
other important information.
The installation must be carried out by a qualified
electrician (IEC 60417-6182).

Important basic information
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1.7 Marking on the product
The marking on the device may vary depending on the product version.
Illustration Description
Fig. 1: Example: PECON+®
Front panel
LED status displays
Labelling of terminals
Test key
Fig. 2: Example: PECON+®
Type plate
Technical data and manufacturer
information
Fig. 3: Example: PECON+®
Terminal assignment
Product-specific terminal assignment

Important basic information
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1.8 CE mark
The CE mark is on the device nameplate.
The device complies with the relevant essential requirements of all applicable EU
directives. The declaration of conformity can be found in the section "Declaration of
conformity" or downloaded from www.epa.de.
1.9 EMC Limit Class
The device complies with the limits for emitted interference according to DIN EN 55011
class B group 1.
The device's interference immunity corresponds to DIN EN 61000-6-2 for the industrial
environment.
The device is classified in accordance with DIN EN 61326-1 (VDE 0843-20-1) and is
suitable for use in residential, business and commercial areas as well as in industrial
environments.

Important basic information
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1.10 Declaration of Conformity

Important basic information
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1.11 Product description
A familiar problem for manufacturers of machinery and pluggable devices:
Due to modern drive regulators such as frequency converters or servo controllers, the
operational leakage current of the device or machine may increase.
However, DIN EN 50178/VDE 0160 only permits an operational leakage current of up to 3.5
mA AC. If this value is exceeded, the standard stipulates that the protective earth requires a
fixed connection. This limits the mobility of the machines or devices.
However, this leakage current can be minimised through the careful arrangement of the
individual components as well as with complex network filters. Unfortunately, this
implementation is usually too expensive, and in many cases the operational leakage current
is still above 3.5 mA due to the system.
The notion of the standard is reasonable and understandable as it protects the users of the
machines or devices from electric shock if such a device is disconnected from the
protective earth system due to a defective connection cable, plug or extension cable. But in
addition, the standard expressly allows higher leakage currents if the availability of the
protective earth system is permanently monitored. This is where the PECON+® comes in.
The PECON+® is a monitoring device that is installed directly at the feed point of the mobile
machine.
The quality of the protective earth is permanently monitored by the PECON+®. If it is
working flawlessly, the integrated signal contact of the PECON+® releases the main
contactor of the machine.
The device, which is only 45 mm wide, is mounted on a DIN rail and reliably monitors all
common voltage ranges.
The PECON+® is used for monitoring the protective earth of single phase and 3-phase
pluggable consumers. Depending on the product, polarity reversal of phase (L) and neutral
conductor (N) is also monitored. Other product variants with special functions are also
available.
The PECON+® IT is available for networks without neutral conductor (N).

Important basic information
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1.12 Area of application
Leakage current >3.5 mA = danger to life!?
Manufacturers and operators of machinery as well as portable or mobile electrical devices
are equally affected. If an electrical device continuously exceeds a leakage current of AC
3.5 mA (in some regulations the limit is set to AC 10 mA) during normal use, it is subject to
special regulations.
Why this strict limit?
When a residual current circuit breaker (RCCB) is used, you can rest assured that the
personnel is adequately protected. Or are they?
Of course not every instance of touching electricity leads to injury or even death. If a live
object is merely touched, the person generally removes the affected body part from the
danger by virtue of the natural muscle reflex.
A more critical danger presents itself when we clasp a live machine part. Door handles,
control levers, climbing aids etc. present typical risks. Internationally recognised standards
already define body currents of only 15 mA as a "release limit", meaning that the muscles of
the energised body part cramp and render the victim unable to release their grip.
All is well for the residual current circuit breaker!
Innovative machine concepts and electromobility often cannot be realised without inverters,
frequency converters, servo drives or intelligent charging concepts.
In most instances, mains filters with Y capacitors (C between outer conductor and PE) are
used for EMC reasons. However, two small Y-suppressor capacitors of only 100 nF can
already cause leakage currents well above the 10 mA limit.
This is where VDE, TÜV and BG come in:
Producing leakage currents for trouble-free operation is generally permitted. However,
developers are obliged to ensure that the electrical equipment is equipped with suitable
protective earthing. Only then can the risk of a dangerous potential increase of touchable,
conductive parts of the machine be safely ruled out.
In general, the relevant standards (e.g. DIN EN 50178) equally permit the following
solutions for leakage currents AC > 3.5 mA:
- Installation of a second protective earth
- Installation of a separate isolating transformer
- Automatic disconnection of the power supply if the protective earth is interrupted

Important basic information
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1.13 Delivery contents
Protective earth monitoring
PECON+®
Instruction manual
PECON+®

Safety instructions
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2 Safety instructions
2.1 Intended use
The EPA PECON+® is used to safely monitor and automatically disconnect the power
supply in the event of interruption of the protective earth (PE) in single and 3-phase
networks in accordance with standard DIN EN 50178 / VDE 0160:1998-04.
The PECON+® determines the availability of the protective earth of consumers (usually
pluggable connected) by measurement and actuates an internal release relay if the
protective earth is present.
The monitoring device must be installed directly on the feed point of the machine/system.
Depending on the product, the polarity reversal of phase (L) and neutral conductor (N) is
also monitored and reported. Other product variants with special functions are available,
e.g. for switching phases and the neutral conductor after release (for all PECON+® NV
variants).
The PECON+® IT is available for networks without neutral conductor.
NOTE
Particular attention should be paid to the safety instructions and the technical data
setting out the ambient conditions.
2.2 Inadmissible operating conditions
CAUTION
The PECON+® must only be used under the conditions and for the purposes for which
it was designed (see section "Intended use").
Operational safety is not guaranteed in the event of modification or improper use.
The device is not suitable for reducing leakage currents.*
The PECON+® does not replace a residual current device.
High voltage differences between the neutral conductor and the protective earth
conductor can overload or destroy the device.
Strong electromagnetic fields can affect the function of the device.
External mechanical loads are not allowed.
Use in potentially explosive atmospheres is prohibited.
*
EPA GmbH offers various other products for this purpose.

Safety instructions
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2.3 Requirements for personnel
WARNING
Installation and work on the PECON+® 1C may only be carried out by
qualified personnel.
Qualified personnel as defined by this instruction manual are
electricians who are familiar with the installation, assembly, startup and operation of
the device, with the hazards involved, and who, based on their technical training, are
also familiar with the relevant standards and provisions.
Repairs may only be carried out by authorised repair centres. Unauthorised tampering
can lead to property damage and will void the warranty provided by EPA GmbH.
2.4 Responsibility:
WARNING
Electronic devices are never fail-safe. The installer and/or operator of the machine or
system is responsible for ensuring that the system/machine is restored to a safe state
if the device fails.
The safety requirements for electrical controllers are set out in DIN EN 60204-1; VDE
0113-1 "Safety of machinery" in the section titled "Electrical equipment of machines".
These provisions ensure the safety of persons and machines as well as the
maintenance of the functional capability of the machine or system and must be
observed.

Safety instructions
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2.5 Connection
WARNING of hazardous electrical voltage
Risk to life from electric shocks! Death or serious injury!
To avoid electric shock, take appropriate precautions.
Follow the accident prevention regulations for electrical systems and equipment when
carrying out all work.
WARNING
The terminals are intended solely for the purpose for which they are defined in the
connection description. These must not be used for any other purpose.
The potential at the terminals can be at the mains voltage level under certain
circumstances. For safety reasons, the connecting cables must therefore have a
corresponding dielectric strength and be sufficiently insulated.
CAUTION
The device must be supplied with the voltage specified in the technical data. Higher
voltages can destroy the device.
Surge voltages between the terminals can destroy the device.
The device must be fixed firmly into place while the power supply is disconnected
and no parts are live.
A fixed, low-impedance connection is required between the PE connection and the
protective earth.
The PECON+® may only be operated in TN-S systems (separate neutral and protective
earth throughout the system; grounded star point).

Safety instructions
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2.6 Follow the operating instructions
IMPORTANT NOTE
Please read this manual carefully. It contains important information about the
installation and operation of the PECON+®.
The PECON+® has been subjected to extensive testing and left the factory in a
technically and operationally safe condition. To maintain this condition, the user must
follow the safety instructions in this manual.
We assume no liability for damage caused by failure to follow these instructions.
This manual is an integral part of the product and is valid only for the
PECON+® protective earth monitoring device manufactured by EPA GmbH.
Please pass this manual on to the system operator / end customer / service technician
so that it is available when required.
Keep these operating instructions and all other applicable documents in a safe place to
ensure that they are available when required.
This is a translation of the original German instruction manual.
The current edition of this operating manual can be downloaded from www.epa.de.

Technical data
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3 Technical data
3.1 Rating data PECON+®
Testable networks
Single phase: L / N / PE
3-phase with N: L1 / L2 / L3 / N / PE
Network configuration
TN-S system
Rated voltage
200..230 VAC (±10%)
Rated frequency
50 / 60 Hz (±5%)
Response lag
<0.4 s
Response threshold
<1000 Ω
Power loss
5 VA
Ambient temperature
Operation: -15...+40ºC
Storage: -25...+70ºC
Transport: -25...+70ºC
Rel. humidity
max. 98%, without condensation
Atmospheric pressure
70..106ºC,
Dimensions
75 x 45 x 125 mm
Weight
Approx. 400 g
Mounting / fitting
on TS35 mounting rail according to DIN EN 50022, installation
position as required
Connections
Mains connection: L / N
Protective earth terminal: PE
Release relay: Alarm/operation (change-over
contact)
Other connections: External Test key (break contact)
Contact rating
max. 250 VAC / 5 A; 30 VDC / 2 A
Cable cross-section max. 4.0 mm² (12 AWG) solid
max. 2.5 mm² (14 AWG) flexible with sleeve
Tightening torque
max. 0.8 Nm
LED displays
green: OK (operating mode display)
yellow: Phase an N (polarity reversal L / N)
red: Alarm (PE interruption)
_
Function test
via test key on front cover or ext. test key
Protection class
IP20 (terminals), IP40 (housing)
Direct contact protection
DGUV V3 (BGV A3)
Flammability
UL94 V-0
Housing material
PC-GF
Normative basis
DIN EN 50178 / VDE 0160:1998-04
Safety
DIN EN 61010-1, DIN EN 60204-1
EMC
DIN EN 61326-1, DIN EN 55011
Conformity
CE, RoHS (2011/65/EU),
LVD (2006/95/EG), EMCD (2004/108/EG), MD (2006/42/EG)

Technical data
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3.2 Rating data PECON+® S1 / S2
Testable networks
Single phase: L / N / PE
3-phase with N: L1 / L2 / L3 / N / PE
Network configuration
TN-S system
Rated voltage
200..230 VAC (±10%)
Rated frequency
50 / 60 Hz (±5%)
Response lag
<0.4 s
Response threshold
<1000 Ω
Power loss
5 VA
Ambient temperature
Operation: -15...+40ºC
Storage: -25...+70ºC
Transport: -25...+70ºC
Rel. humidity
max. 98%, without condensation
Atmospheric pressure
70..106 kPa
Dimensions
75 x 45 x 125 mm
Weight
Approx. 400 g
Mounting / fitting
on TS35 mounting rail according to DIN EN 50022, installation
position as required
Connections
Mains connection:
L / N
Protective earth terminal: PE
Release relay: Alarm/operation (change-over
contact)
Other connections:
Polarity reversal L / N (normally
open)
Contact rating
max. 250 VAC / 5 A; 30 VDC / 2 A
Cable cross-section max. 4.0 mm² (12 AWG) solid
max. 2.5 mm² (14 AWG) flexible with sleeve
Tightening torque
max. 0.8 Nm
LED displays
green: OK (operating mode display)
yellow: Phase an N (polarity reversal L / N)
red: Alarm (PE interruption)
_
Function test
via test key on front cover
Protection class
IP20 (terminals), IP40 (housing)
Direct contact protection
DGUV V3 (BGV A3)
Flammability
UL94 V-0
Housing material
PC-GF
Normative basis
DIN EN 50178 / VDE 0160:1998-04
Safety
DIN EN 61010-1, DIN EN 60204-1
EMC
DIN EN 61326-1, DIN EN 55011
Conformity
CE, RoHS (2011/65/EU),
LVD (2006/95/EG), EMCD (2004/108/EG), MD (2006/42/EG)