ZIEHL-ABEGG U-EK230E User manual

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Operating Instructions English
Type U-EK230E Part.-No. 382008
Motor protection- and releasing unit with thermistors “TP” (PTC thermistor relay)
0102

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Contents
Contents ....................................................................................................................................2
1. General Notes...................................................................................................................3
2. Application.........................................................................................................................3
3. Approvals ..........................................................................................................................3
4. Features............................................................................................................................3
5. Connection proposal .........................................................................................................4
6. Display- and control elements...........................................................................................4
7. Detailed description...........................................................................................................5
8. Function diagram...............................................................................................................5
9. Installation / commissioning...............................................................................................5
10. Trouble-shooting and remedies.........................................................................................6
11. Technical data...................................................................................................................7
12. Enclosure V2.....................................................................................................................8
13. Safety instructions and references for putting into operation.............................................9
14. Safety characteristics of the safety device.........................................................................9
15. Proof testing of the safety functions ................................................................................11
16. Maintenance and repair...................................................................................................12
17. Manufacturer reference...................................................................................................12
18. Service information.......................................................................................................... 12

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1. General Notes
Compliance with the following instructions is mandatory to ensure the functionality and safety
of the product. If the following instructions given especially but not limited for general safety,
transport, storage, mounting, operating conditions, start-up, maintenance, repair, cleaning and
disposal / recycling are not observed, the product may not operate safely and may cause a
hazard to the life and limb of users and third parties.
Deviations from the following requirements may therefore lead both to the loss of the statutory
material defect liability rights and to the liability of the buyer for the product that has become
unsafe due to the deviation from the specifications.
2. Application
Ziehl-Abegg PTC thermistor relays protect motors, transformers, machines and equipment
against thermal overload. These are according to EN 60947-8 and are thus exchangeable.
Used in conjunction with respective PTC thermistors they provide a reliable temperature
protection in the temperature range 60 °C up to 180 °C.
PTC thermistors according to DIN 44081 and DIN 44082 shall be connected. PTC thermistors
are suitable for the installation into windings of electrical machines, bearings and transformers
as well as to monitor the temperature of liquid media, airflow and gases.
With ATEX approval, explosion-protected equipment in explosive gas atmospheres (marking
G: gas) or in areas with combustible dust (marking D: dust) can be protected.
3. Approvals
ATEX approval under directive 2014/34/EU
Marking see type plate on the device
4. Features
•for 1…6 temperature sensors “TP” (PTC thermistors)
•Short-circuit detection within the thermistor circuit
•Output relay with 1 change-over contact (co)
•Operating status display with LED

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5. Connection proposal
6. Display- and control elements
1 = LED red „ALARM“
2 = LED green „Power ON“
3 = built-in key button “Reset”
Us = supply voltage H1 = indicator lamp fault
S1 = off-switch F1-F4 = fuses
S2 = push-button on K1 = contactor
S3 = push-button external reset TP = PTC thermistor

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7. Detailed description
A current monitors continuously the resistance of the PTC thermistors. In cold state, the
resistance is ≤250 Ω per thermistor (thermistor circuit ≤1.5 kΩ). The relay has picked up and
contacts 11/14 are closed. The resistance of the thermistor rises rapidly at detector operating
temperature TNF. The relay releases at a resistance of 3…4 kΩ and the contacts 11/12 close.
The device also switches off in the case of detector or line short-circuit (< approx. 20 Ω). The
device stores the switch-off and must be reset (to be acknowledged) manually with the built-in
key button or an external push-button. Power-on is recognized as an automatic reset. With
bridged terminals Y1 and Y2, the function reclosing-lock is disabled.
With a bridge at the RESET inputs (Y1/Y2) the reclosing lock is out of
operation. The device switches back automatically, when the temperature of
the thermistor circuit has fallen below the switchback value.
Depending on the number of PTC thermistors the following tripping temperatures and reset
temperatures arise related to TNF (detector operating temperature):
Tripping temperature
Reset temperature
1 PTC thermistor
TNF + 15 K
TNF + 5 K
3 PTC thermistors in series
TNF + 5 K
TNF –5 K
6 PTC thermistors in series
TNF
TNF –20 K
8. Function diagram
9. Installation / commissioning
Attention!
Observe safety rules and standards. Notice safety remarks!
•The applicant must observe safety rules and standards.
!
!

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Danger!
Hazardous voltage!
Will cause death or serious injury. Turn off and lock out all power supplying this
device before working on this device.
•The device can be mounted on 35 mm rail EN 60715 or with screws M4 (Option)
•The devices must be installed in a closed switchgear cabinet or in an enclosure of
international protection class IP5X according EN 60529 or higher.
When installing the device into the switchgear cabinet, please observe the max.
admissible temperature. Care for both, sufficient clearance to other devices or
sources of heat or enough forced draught. If cooling is made more difficult, e.g.
close devices with increased surface temperature or by handicap of airflow cooling
the permissible ambient temperature has to be reduced.
Attention!
Before switching on make sure that the operational voltage Us of the type
plate and the mains voltage are the same!
•After installation and before commissioning the correct function of the tripping device
must be checked by resistance simulation at terminals T1 and T2. This check is also
performed after changes to the installation.
10. Trouble-shooting and remedies
Relay does not pick up. Please check:
•The supply voltage Us at terminals A1-A2 (green LED lights-up).
•The thermistors at terminals T1-T2. In the case of disturbance the red LED lights-up.
•The resistance of a thermistor circuit must be at 50 Ω < R < 1500 Ω. The terminal voltage
T1-T2 is to be measured < 2.5 Vdc with connected thermistors.
•Push the key button “Reset”. The relay can pick up at resistance R < 1650 Ω. LED
changes from red to green. Alternatively reset can be done with closing an external
contact at terminals Y1-Y2 or with power recovery.
Relay does not release. Please check:
•With no thermistors connected the relay must release. The voltage at terminals T1-T2
must be approx. 8 V. In case of any other malfunctions, replace device. Please add a
description of the occurred malfunction when sending back for repair.
!

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11. Technical data
Power supply
Rated supply voltage Us AC 220-240 V
Tolerance voltage Us 0.9 Us - 1.1 Us
Frequency (AC) 50 / 60 Hz
Tolerance frequency 45 Hz - 65 Hz
Power consumption < 2 VA
Thermistor connection PTC thermistor according DIN 44081/DIN 44082
Number 1…6 thermistors in series
Cut-out-point 3.3 kΩ…3.65 kΩ…3.85 kΩ
Reclosing point 1.7 kΩ…1.8 kΩ …1.95 kΩ
Response tolerance ±6 °C
Collective resistance cold thermistors ≤ 1.65 kΩ
Terminal voltage (PTC thermistor) ≤ 2.5 Vdc at R ≤ 3.65 kΩ, ≤ 9 Vdc at R = 
Terminal current (PTC thermistor) ≤ 1 mA
Short circuit 20 Ω ≤ R ≤ 40 Ω
Power consumption ≤ 2 mW
Relay output EN 60947-5-1
Contacts 1 change-over contact
Switching voltage max. AC 415 V
Switching current max. 5 A
Switching power AC cos = 1 max. 1250 VA (ohm resistive load)
max. 120 W at DC 24 V
Rated operational current (Ie) AC15 Ie = 3 A Ue = 250 V
DC13 Ie = 2 A Ue = 24 V
Recommended fuse 4 A (gG)
Mechanical contact life 3 x 107operations
Electrical contact life 1 x 105operations at 240 V / 5 A
Testing conditions EN 60947
Rated impulse voltage 4000 V
Overvoltage category III
Contamination level 3 2
Rated insulation voltage Ui 250 V 415 V
Transformer EN 61558-2-6
On-period 100 %
Rated ambient temperature range -20 °C ... +55 °C
EMC - Immunity EN 61000-6-2
EMC - Emission EN 61000-6-4
Vibration resistance EN 60068-2-6 2…13.2 Hz ± 1 mm
13.2 ... 100 Hz 1 g

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48
58
45
3
61,8
16,5
(90)
Option
98
116
35
3
4
12
5
7
6
Enclosure Form V2
Dimensions (H x W x D) mm 90 x 35 x 58
Line connection solid wire 1 x 0.5 ... 2.5 mm2(AWG 22 –14)
Stranded wire with insulated ferrules 1 x 0.14 mm2up to 1.5 mm2
Insulation strip length min. 8 mm
Torque 0.5 Nm (3.6 lb.in)
Protection class enclosure EN 60529 IP30
Protection class terminals EN 60529 IP20
Fitting position any
Mounting EN 60715 standard rail 35 mm
Optional: Screw mounting M4, only with additional bolt
(Not part of delivery)
Weight approx. 117 g
Subject to technical modifications
12. Enclosure V2
Dimensions in mm
1 Top
2 Bottom
3 Bolt
4 Seal mounting link
5 Front plate element
6 Characteristic for bottom
7 Extensible bolt for wall fastening with screws. Bolt bore Ø 4.2 mm.

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13. Safety instructions and references for putting into operation
- please read carefully!
Special remarks for hazardous areas (Zone 0, Zone 1 and Zone 2)
•The increased danger within hazardous areas requires the careful attention of the
safety instructions and references for putting into operation. Observe the national safety
rules and regulations for prevention of accidents as well as the European standard EN
60079-14 „Electrical apparatus for explosive gas atmospheres - Part 14: Electrical
installations in hazardous areas (other than mines)”. All work for the connection, for
putting into operation and maintenance is to be implemented by qualified, responsible
technical personnel. Inappropriate behaviour can cause heavy personal damage and
damages to property.
•The response of the thermal motor protection must directly switch off the motor, also
when used together with frequency inverters. This must be realized in the logic section
or configuration in the inverter.
•The tripping device may be installed only outside potentially explosive atmospheres for
the protection of explosive-protected motors. When used in potentially atmospheres, the
device must comply with the required type of protection.
Special remarks for use in the presence of combustible dust (Zone 20, Zone 21 and
Zone 22)
•The increased danger within hazardous areas of combustible dust requires the careful
attention of the safety instructions and references for putting into operation. Observe the
national safety rules and regulations for prevention of accidents as well as the European
Standard EN 61241-14 „Electrical apparatus for use in the presence of combustible dust
–Part 14: Selection and installation”(new in EN 60079-14). Installation, electrical
connection and commissioning to be carried out by trained service personnel only.
Inappropriate behaviour can cause heavy personal damage and damages to property.
•The relay may be installed only outside potentially explosive atmospheres for the
protection of explosive-protected motors. Within potentially explosive atmospheres the
equipment is to be provided with a dust proofed enclosure according EN 60529.
14. Safety characteristics of the safety device
Safety Integrity Level (EN 61508) and safety related parameters
Operating mode
Hardware architecture
HFT
Safety Integrity Level
low demand mode
1001
0
SIL 1
Type
MTBF
PFH
SFF
SD
SU
DD
DU
U-EK230E
52 years
4.26E-07
55 %
4.52E-07
6.10E-08
0
4.26E-07
Type
Proof test
interval T1
1year
3 years
5 years
10 years
U-EK230E
PFDavg
1.87E-03
5.60E-03
9.33E-02
1.87E-02
Observe proof test interval according EN 60079-17 for electrical equipment ≤ 3 years.
!

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Category and Performance-Level (EN ISO 13849-1)
The devices fulfil the requirements of category 1 and PL = c.
MTTFd= 268 years.
The data of the functional safety stated above are valid for an ambient temperature of 40 °C.
Data for additional ambient temperatures can be obtained on request.
Application of the safety device used with equipment category (EN 50495/VDE 0171-18)
This standard describes the minimum requirements of safety integrity level and fault tolerance
of a safety device in the application together with the category of the Equipment Ander Control
(EUC).
EUC
Safety device
no safety device
SIL 1
SIL 2
Category 2
(2G, 2D)
EPL = Gb, Db
Zone 1, Zone 21
Zone 0, Zone 20
Zone 0, Zone 20
Category 3
(3G, 3D)
EPL = Gc, Dc
Zone 2, Zone 22
Zone 1, Zone 21
Zone 0, Zone 20
The tripping relay thus is suitable as safety device for Equipment Under Control (EUC)
Category 3 (HFT = 0) in Zone 1 and Zone 21 and for Equipment Under Control (EUC)
Category 2 (HFT = 1) in Zone 0 and Zone 20.
The combined equipment shall comply with the relevant standards EN 60079-0 respectively
EN 61241 according to the categories to match.
Wiring
•The lines of the thermistor circuit are to be routed as separate control lines as far as to
the motor line. The use of lines of the supply cable or other mainstream lines is not
permissible. If extreme inductive or capacitive stray effects are to be expected by parallel
cables of the power installation, protected control lines should be used.
•Used with electronic speed regulation the thermistor lines must be routed separately
from the power lines as far as to the motor line, in order to avoid EMC distortion and
thus false signal release.
•The terminals Y1, Y2 may be attached parallel to a common resetting mechanism.
Thermistor lines may not be connected together.
•The line resistance within the thermistor circuit may not exceed a value of 20 Ω.
•Maximum of permissible length for thermistor lines:
Wire cross section
Wire length
2.5 mm 2
2 x 1000 m
1.5 mm 2
2 x 800 m
1.0 mm 2
2 x 500 m
0.75 mm 2
2 x 300 m
0.5 mm 2
2 x 250 m
•With commissioning and after modification of the plant the thermistor resistance should
be measured with a suitable measuring instrument. With a resistance <50 Ω the
thermistor circuit is to be examined for short-circuit.
Attention! Check PTC thermistors only with measuring voltages of <2.5 V.
!

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Safe separation
•Line circuits (A1, A2, 11, 12, 14) have a safe separation to low-voltage electric circuits
(T1, T2, Y1, Y2).
Stop Function
•A stop function released by the protection device must transfer the machine after
manipulation of this function as fast as possible into a safe condition. The stop function
must have priority before an operating stop.
•In case of failure the relay switches off the contactor/circuit breaker and so prevents an
overheating of the isolation system and/or the surface temperature. The protective
function of the equipment is guaranteed only if wiring is done directly into the control
circuit of the motor/machine in accordance with the connection diagram. The contacts
must be protected, in order to prevent welding.
Start and restart
A restart may take place automatically only if no dangerous condition can be
present. With a bridge at terminals Y1, Y2 (auto reset) the tripping devices
switch-on automatically after cooling down. This function may not be used,
where an unexpected restart can lead to damages to property or person.
Manual resetting
•After introducing a stop instruction by the protection device this must be maintained,
until the manual resetting mechanism is operated and safe conditions for a renewed
start are given. The manual resetting may be only possible, if all safety functions and
protection device are effective.
•Trip devices types U-EK230E have an interlock function. The stop instruction remains,
until pressing the push-button „Reset“ a reset is made. A start-up is only possible, if no
case of failure occurs and the motor is cooled down to a sufficient value of temperature.
Trip devices type U-EK230E switch on automatically with return of mains voltage. The
user must guarantee by external interlock (see connection diagram) so the supervised
motor/machine does not start again independently or monitor the power supply.
Attention!
Safety circuits according to EN 60204/EN 62061.
The tripping devices must not be used alone for functions, where an
automatic Restart must be prevented.
15. Proof testing of the safety functions
•The safety function shall be tested at regular intervals. It is recommended to carry out
the proof-test once a year. Depending on the zone risk, tests should be conducted
more frequently. A fault is recognized by the safety test. A fault between safety tests
could cause loss of protection.
•The safety function must be tested by interrupt the thermistor circuit wire at terminals
T1, T2.
•The short circuit monitoring function must be tested by bridging the thermistor circuit
wires at terminals T1, T2.
!
!

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•The safety function must be tested by changing the resistance from 1500 Ohm to 4000
Ohm at terminals T1, T2.
•The function of the electronic interlock must be tested additionally.
•If an error is detected no restart must be induced until the error is cleared.
16. Maintenance and repair
The devices are maintenance-free. Only the manufacturer may accomplish repairs. We
recommend testing within the regular maintenance intervals of the plant, where the device is
used. EN 60079-17 is to be observed.
17. Manufacturer reference
Our products are manufactured in accordance with the relevant international regulations. If you
have any questions concerning the use of our products or plan special uses, please contact:
ZIEHL-ABEGG SE
Heinz-Ziehl-Straße
74653 Künzelsau
Telephone: [phone]
[email protected]
http://www.ziehl-abegg.com
18. Service information
If you have any technical questions while commissioning or regarding malfunctions, please
contact our support department for control systems - ventilation technology.
phone: [phone]
Email: [email protected]
Our worldwide contacts are available in our subsidiaries for deliveries outside of Germany
see www.ziehl-abegg.com