Pilz PU3Z User manual

PU3Z
Operating Manual-19093-EN-07
}Safe monitoring 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.
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 PU3Z
19093-EN-07 | 3
Introduction ............................................................................................................................5
Validity of documentation.......................................................................................................... 5
Using the documentation .......................................................................................................... 5
Definition of symbols................................................................................................................. 5
Safety ...................................................................................................................................... 6
Intended use ............................................................................................................................. 6
Safety regulations ..................................................................................................................... 6
Safety assessment ................................................................................................................... 6
Use of qualified personnel ........................................................................................................ 7
Warranty and liability ................................................................................................................ 7
Disposal .................................................................................................................................... 7
For your safety.......................................................................................................................... 7
Unit features ...........................................................................................................................7
Safety features ....................................................................................................................... 8
Block diagram/terminal configuration ................................................................................. 9
Types: AC ................................................................................................................................. 9
Types: DC................................................................................................................................. 9
Function description ............................................................................................................. 10
Operating modes ...................................................................................................................... 11
Timing diagram ......................................................................................................................... 12
Automatic start (S33-S34 linked) .............................................................................................. 12
Installation ..............................................................................................................................13
Wiring ......................................................................................................................................13
Preparing for Operation ........................................................................................................ 14
Operation ................................................................................................................................15
Status indicators ....................................................................................................................... 15
Faults – Interference .............................................................................................................. 16
Dimensions in mm .................................................................................................................16
Technical details ....................................................................................................................17
Safety characteristic data ......................................................................................................... 22
Supplementary data ..............................................................................................................23
Service life graph ...................................................................................................................... 23

Contents
Operating Manual PU3Z
19093-EN-07 | 4
Order reference ......................................................................................................................23
EC declaration of conformity ................................................................................................ 24

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Introduction
Validity of documentation
This documentation is valid for the product PU3Z. It is valid until new documentation is pub-
lished.
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.

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Operating Manual PU3Z
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Safety
Intended use
The voltage monitoring relay operates as a device for the safe monitoring of 3-phase sup-
plies with no voltage applied with neutral conductor. The three-phase network must be
earthed in the star point. It may be used in
}Safety circuits in accordance with EN60204-1
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 Technical details).
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, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 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 separ-
ately.

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Operating Manual PU3Z
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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 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 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 on the device there are voltages higher than 300 V
measured to the earth potential, connected control elements and sensors must have a
rated insulation voltage of at least 600V.
Unit features
}Redundant measuring inputs for 3-phase AC circuits
}Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
}7 semiconductor outputs
}LED display for:
– Supply voltage

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Operating Manual PU3Z
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– Error
– Status of measuring circuit
}Semiconductor outputs signal:
– Status of measuring circuit
– Error
}Feedback loop for monitoring external contactors
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.

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Block diagram/terminal configuration
Types: AC
}UB: 120 – 240 V AC; Order no. 775505
A1
Power
A2 S33
0V 24V Y41 Y42 Y43 Y44 Y46
Y45 FAULT
0 V 24 V
Start Input N
Input
L1
Input
L2
Input
L3
Input
Feed-
back
S34 Y4 Y5
Y1 Y2
N N* L1 L1* L2 L2* L3 L3* 13 23 33 41
14 24 34 42
**Insulation against the non-marked area and between the relay contacts: Basic insulation
(overvoltage category III), protective separation (overvoltage category II); at 250 V, 4 kV
***Insulation against the non-marked area and between the measurement connections:
L1(*), L2(*), L3(*): Basic insulation (overvoltage category III), protective separation (over-
voltage category II); at 600 V, 6 kV
Types: DC
}UB: 24 VDC; Order no. 775510
A1
Power
A2 S33
0V 24V Y41 Y42 Y43 Y44 Y45 Y46 FAULT
0 V 24 V
Start Input N
Input
L1
Input
L2
Input
L3
Input
Feed-
back
S34 Y4 Y5
Y1 Y2
N N* L1 L1* L2 L2* L3 L3* 13 23 33 41
14 24 34 42
**Insulation against the non-marked area and between the relay contacts: Basic insulation
(overvoltage category III), protective separation (overvoltage category II); at 250 V, 4 kV
***Insulation against the non-marked area and between the measurement connections:
L1(*), L2(*), L3(*): Basic insulation (overvoltage category III), protective separation (over-
voltage category II); at 600 V, 6 kV

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Function description
The voltage monitoring relay PU3Z operates as a threshold switch. It measures the three
phase voltages L1, L2, L3. The N/C contact of the contactor to be monitored must be con-
nected at the input circuit and the measuring voltages have to be connected to the measur-
ing circuit. The reset circuit must be closed. When the supply voltage is applied, the
"POWER” LED will light.
}Input circuit Y4-Y5 is open (contactor energised) or one of the measurements is greater
than the switching threshold Uf (see Technical details [ 17])
– The safety contacts 13-14, 23-24 and 33-34 are open.
– Auxiliary contact 41-42 is closed.
}Input circuit Y4-Y5 is closed (contactor de-energised) and all the measuring voltages are
smaller that the switching threshold Uf (see Technical details [ 17])
– The safety contacts 13-14, 23-24 and 33-34 are closed.
– Auxiliary contact 41-42 is open.
}Self test: An internal self test is carried out during initial commissioning and each time the
supply voltage is switched off and on. The process simulates switching all measuring
voltages on and then off again. Provided no error occurs during the self test, the unit will
then be ready for operation.
The status of the measuring circuits is displayed via the auxiliary outputs Y41 ... Y46 and
the relevant LEDs:
Measuring voltage Semiconductor LED
L1 - L2 Y41 VL1-L2 (Y41)
L2 - L3 Y42 VL2-L3 (Y42)
L1 - L3 Y43 VL1-L3 (Y43)
L1 - N Y44 VL1-N (Y44)
L2 - N Y45 VL2-N (Y45)
L3 - N Y46 VL3-N (Y46)
Measuring voltage Input circuit Y4-Y5 Semiconductor out-
put
LED indicator
All the measuring
ranges are in the
range of
110…600VAC
and/or
64…346VAC
(against N)
Input circuit is open
or closed.
High signal at all the
semiconductor out-
puts
All the relevant LEDs
illuminate.
A measuring voltage
<110VAC and/or
64VAC (against N)
Input circuit is open
or closed.
Low signal at the rel-
evant semiconductor
output
The relevant LED
goes out.
All the measuring
voltages <Uf (see
Technical
details [ 17])
Input circuit is open
or closed.
Low signal at all the
semiconductor out-
puts
All the relevant LEDs
go out.

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Measuring voltage Input circuit Y4-Y5 Semiconductor out-
put
LED indicator
At least one measur-
ing voltage <Uf (see
Technical
details [ 17])
Input circuit is closed
(contactor de-ener-
gised).
High signal at the
semiconductor out-
put "FAULT"
"VOLTAGE HAZARD
DETECTION" LED
will light.
At least one measur-
ing voltage is
<110VAC and/or
64VAC (against N)
Input circuit is closed
(contactor de-ener-
gised).
High signal at the
semiconductor out-
put "FAULT".
High signal at the rel-
evant semiconductor
output
"VOLTAGE HAZARD
DETECTION" LED
will light.
Relevant LED on.
Internal wiring diagram:
24 V 0 V
Operating modes
}Automatic start: Device becomes active after the input circuit has been closed and all the
measuring voltages are <Uf .
}Manual start: Device becomes active after the input circuit and the start circuit has been
closed and all the measuring voltages are <Uf .
}Increase in the number of safety contacts available by connecting external contactors.

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Timing diagram
Automatic start (S33-S34 linked)
**
ts
U1 ... U6 Ur
Uf
POWER
Input
110 (64) V AC
Output safe
Output aux
Output semi
Output semi FAULT
VOLTAGE HAZARD
DETECTION
SYSTEM FAULT
Legend:
}POWER: Supply voltage
}Input: Input circuit Y4-Y5
}U1 … U6: Measuring input voltage, phase voltages on the measuring circuit L1-L1*, L2-
L2*, L3-L3*, N-N*
– Ur: Upper switching threshold
– Uf: Lower switching threshold
}Output safe: Safety contacts 13-14, 23-24, 33-34
}Output aux: Auxiliary contacts 41-42
}Output semi: Semiconductor outputs Y41, Y42, Y43, Y44, Y45, Y46 indicate the status of
the measuring circuit.
}Output semi FAULT: "FAULT" semiconductor conducts when a "VOLTAGE HAZARD DE-
TECTION" error or "SYSTEM FAULT" occurs.
}VOLTAGE HAZARD DETECTION: LED lights when there is a measuring voltage of >10
VAC, although the input circuit is closed.
}SYSTEM FAULT: LED on: Open circuit on at least one measuring line or internal error.
}ts: Automatic test duration
}** Open circuit or internal error

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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 (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" must be followed.
}Outputs 13-14, 23-24, 33-34 are safety contacts; output 41-42 is an auxiliary contact (e.g.
for display).
}Auxiliary contact 41-42 shouldnot be used for safety circuits!
}Semiconductor outputs should not be used for safety circuits!
}To prevent contact welding, a fuse should be connected before the output contacts (see
Technical details).
}Do not connect undesignated terminals.
}Calculation of the max. cable length lmax in the input circuit:
Rlmax
Rl / km
Imax =
Rlmax = max. overall cable resistance (see Technical details)
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 trans-
mission 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 cur-
rents.
}Connect the measuring voltages L1 and L1*, L2 and L2* and L3 and L3*, and N and N*
each to separate terminals on the plant, so that at least one measuring voltage will be
present if a terminal screw should come away unintentionally (single fault tolerance).
}To meet the requirements of the safety circuits, separate wires in separate multicore
cables must be used for the measuring voltages L1, L2, L3, N and the measuring
voltages L1*, L2*, L3*, N*.
}The three-phase network must be earthed in the star point.

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Preparing for Operation
Supply voltage AC DC
A1
A2
L1
N
A1
A2
L+
L-
Input circuit
Contactor to be monitored
Measuring circuit
Measuring voltage L1
Measuring voltage L2
Measuring voltage L3
Measuring voltage N
Start circuit Automatic start Manual start
S33
S34
S3
Feedback loop with feedback loop monitoring without feedback loop monitoring
Contacts from external contactors
or link

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Semiconductor output
PLC
PLC
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 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.
SYSTEM FAULT*
Open circuit on at least one measuring circuit or internal error.
VOLTAGE HAZARD DETECTION
Input circuit closes and a measuring voltage >10 V AC.
VL1-L2(Y41) … VL3-N(Y46)
Status of the measuring voltage (s. chapter "Function Description [ 10]")

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Faults – Interference
}The "SYSTEM FAULT" LED will light: Open circuit on at least one measuring line or in-
ternal error.
}The "VOLTAGE HAZARD DETECTION" LED will light: A measuring voltage >10 V AC is
present, although the input circuit Y4-Y5 is closed.
}Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.
Dimensions in mm
112,5 (4.41")
121 (4.76")
75 (2.95")
87 (3.42")

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Operating Manual PU3Z
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Technical details
General 775505 775510
Certifications
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
CCC, CE, EAC (Eurasian), TÜV,
cULus Listed
Electrical data 775505 775510
Supply voltage
Voltage 120 - 240 V 24 V
Kind AC DC
Voltage tolerance -15 %/+10 % -15 %/+10 %
Output of external power supply
(AC) 12 VA –
Output of external power supply
(DC) – 7 W
Frequency range AC 50 - 60 Hz –
Residual ripple DC – 20 %
Duty cycle 100 % 100 %
Measuring circuit 775505 775510
Min. measuring voltage 110 V 110 V
Max. measuring voltage 600 V 600 V
Min. measuring voltage against N
(N*) 64 V 64 V
Max. measuring voltage against N
(N*) 346 V 346 V
Tolerance, measuring voltage 85 - 110 % 85 - 110 %
Frequency range 50 - 60 Hz 50 - 60 Hz
Upper switching threshold Ur 15 V 15 V
Lower switching threshold Uf 10 V 10 V
Hysteresis 50 % 50 %
Input resistance 320 kOhm 320 kOhm
Inputs 775505 775510
Number 6 6
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 80 mA 80 mA
Start circuit DC 40 mA 40 mA
Feedback loop DC 0,5 mA 0,5 mA
Max. inrush current impulse
Current pulse, input circuit 0,1 A 0,1 A
Pulse duration, input circuit 200 ms 200 ms
Current pulse, feedback loop 0,1 A 0,1 A
Pulse duration, feedback loop 150 ms 150 ms

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Semiconductor outputs 775505 775510
Number 6 6
Voltage 24 V 24 V
Current 50 mA 50 mA
External supply voltage 24 V 24 V
Voltage tolerance -20 %/+20 % -20 %/+20 %
Residual current at "0" signal 0,1 mA 0,1 mA
Max. internal voltage drop 4 V 4 V
Conditional rated short circuit cur-
rent 100 A 100 A
Lowest operating current 0 mA 0 mA
Utilisation category in accordance
with EN 60947-1 DC-12 DC-12
Relay outputs 775505 775510
Number of output contacts
Safety contacts (N/O), instant-
aneous 3 3
Auxiliary contacts (N/C) 1 1
Max. short circuit current IK 1 kA 1 kA
Utilisation category
In accordance with the standard EN 60947-4-1 EN 60947-4-1
Utilisation category of safety con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 1200 VA 1200 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 120 W 120 W
Utilisation category of auxiliary con-
tacts
AC1 at 240 V 240 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 1200 VA 1200 VA
DC1 at 24 V 24 V
Min. current 0,01 A 0,01 A
Max. current 5 A 5 A
Max. power 120 W 120 W
Utilisation category
In accordance with the standard EN 60947-5-1 EN 60947-5-1

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Relay outputs 775505 775510
Utilisation category of safety con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 5 A
Utilisation category of auxiliary con-
tacts
AC15 at 230 V 230 V
Max. current 5 A 5 A
DC13 (6 cycles/min) at 24 V 24 V
Max. current 5 A 5 A
Utilisation category in accordance
with UL
Voltage 240 V AC G. P. 240 V AC G. P.
With current 5 A 5 A
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 6 A 6 A
Blow-out fuse, slow 4 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24V AC/DC,
characteristic B/C 4 A 4 A
External contact fuse protection,
auxiliary contacts
Max. melting integral 240 A²s 240 A²s
Blow-out fuse, quick 6 A 6 A
Blow-out fuse, slow 4 A 4 A
Blow-out fuse, gG 6 A 6 A
Circuit breaker 24 V AC/DC,
characteristic B/C 4 A 4 A
Conventional thermal current 5 A 5 A
Contact material AgSnO2 + 0,2 µm Au AgSnO2 + 0,2 µm Au
Times 775505 775510
Switch-on delay
With automatic start typ. 2 s 2 s
With automatic start max. 3 s 3 s
With automatic start after power
on typ. 2.700 ms 2.700 ms
With automatic start after power
on max. 4.000 ms 3.500 ms
With manual start typ. 20 ms 20 ms
With manual start max. 3.000 ms 3.000 ms

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Times 775505 775510
Delay-on de-energisation
With power failure typ. – 100 ms
With power failure max. – 200 ms
With power failure typ. UB 240 V 250 ms –
With power failure max. UB 240
V350 ms –
With power failure typ. UB 120 V 85 ms –
With power failure max. UB 120
V110 ms –
After safety function is triggered
typ. 50 ms 50 ms
After safety function is triggered
max. 60 ms 60 ms
Recovery time at max. switching
frequency 1/s
After power failure 1500 ms 1500 ms
After safety function is triggered 1000 ms 1000 ms
Supply interruption before de-ener-
gisation 20 ms 20 ms
Simultaneity, channel 1 and 2 max. 3 s 3 s
Environmental data 775505 775510
Climatic suitability EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature range -10 - 55 °C -10 - 55 °C
Storage temperature
Temperature range -40 - 70 °C -40 - 70 °C
Climatic suitability
Humidity 93 % r. h. at 40 °C 93 % r. h. at 40 °C
Condensation during operation Not permitted Not permitted
EMC EN 60947-5-1, EN 61000-6-2, EN
61000-6-4, EN 61326-3-1
EN 60947-5-1, EN 61000-6-4, 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 600 V 600 V
Rated impulse withstand voltage 6 kV 6 kV
Protection type
Housing IP40 IP40
Terminals IP20 IP20
Mounting area (e.g. control cab-
inet) IP54 IP54