Reliable solid-state switching devices for frequent switching of resistive or motor loads SIRIUS Answers for industry. High switching frequencies, long service life: Solid-State Switching Devices with Added Value Multiple individual assembly options: Switching of Resistive Loads Maximum reliability in every respect: Motor Switching Extended functionality, improved options: Function Modules 4 6 8 9 For resistive and inductive loads: Optimized Control Principles 10 Variable Connection Technology 10 Overview table: The SIRIUS Solid-State Switching Devices Portfolio 11 Your project in perfect company: Solid-State Switching Devices in Practical Applications 12 Service and Support 2 14 Control room Press shop Final assembly Powertrain/ assembly Body shop Power distribution Paint shop In the automotive industry just like in numerous further sectors, SIRIUS switching devices ensure reliable operation throughout all automation levels Everything. Easy. SIRIUS Industrial Controls. For more than 110 years now, we have been developing and manufacturing industrial control products for you. We have always followed the philosophy to make it easier for you by using innovative industrial controls – whether they are in the electrical cabinet, in the field or directly on the machine. This is the reason that today we have combined our complete range of industrial controls under just one star – SIRIUS®. Everything required to switch, protect and start loads is now in the SIRIUS portfolio. The breath of products includes those which monitor, control, command, signal, detect and supply. Combining our portfolio with higher-level, seamless concepts such as Totally Integrated AutomationTM, Safety Integrated® and ECOFAST® enable the user to create optimized systems. The result is that you obtain reliable and innovative industrial controls that utilize state-of-the-art features – for instance, communications and safety systems are integrated – as basis for leading-edge and seamless solutions. 3 The extensive range that we offer for switching motors and equipment is an important part of our SIRIUS industrial controls. Starting with well-proven and reliable contactors through simple-to-handle relays up to our innovative solid-state switching devices for use in the most rugged of applications – with SIRIUS, you simply always switch safely and reliably. With SIRIUS industrial controls, you can look forward to the future with confidence. High switching frequencies, long service life: Solid-State Switching Devices with Added Value To improve the competitiveness of industrial systems and plants, the increasing of productivity is becoming more and more important. The result: rising switching frequencies, which can often no longer be mastered by conventional switching devices. A clean-cut case for our SIRIUS solid-state switching devices – once installed, they offer almost unlimited activity. Regular time- and cost-intensive device replacements are thus a thing of the past. Using SIRIUS solid-state switching devices for tasks requiring high switching frequencies is therefore profitable. See for yourself! Sustainable improvements – solid-state switching technology Expenditures/ costs Conventional switching devices Costs for new devices, device replacement, etc. SIRIUS 3RF Costs for new devices, device replacement, etc. SIRIUS 3RT Device replacement after approx. 3 million switching cycles 4 Device replacement after approx. 6 million switching cycles Solid-state switching devices Switching frequency Compared to conventional switching devices, our SIRIUS solid-state switching devices stand out with their wear-free and quiet switching behavior. Despite the high switching frequencies, these characteristics are aided by the use of powerful semiconductors, which means that the devices do not use any mechanically moving parts. Where conventional electromechanical devices fail and need to be replaced after a certain number of switching cycles, the SIRIUS solid-state switching devices continue their reliable operation. Single- and three-phase solid-state relays for resistive loads Single- and three-phase solid-state contactors for resistive loads SIRIUS solid-state switching devices – a wide range of advantages No matter how complex and diversified your tasks may be: Our seamless and integrated product range for frequent switching offers the ideal solution for all applications. We offer single- and three-phase solid-state contactors and relays for resistive loads. For switching of motor loads, we also offer three-phase solid-state contactors – as well as solidstate reversing contactors. Furthermore, we offer function modules which allow easy and highly flexible responses to new requirements. Three-phase solid-state contactors and reversing contactors for motors of control cabinets and distribution boards. Ease of mounting and rapid commissioning provide substantial time and cost savings. product standard. In addition, due to the power semiconductors’ maximum blocking capacity, additional protective circuits can be eliminated. Convincing, manifold and proven Global application The use of our SIRIUS solid-state switching devices is great for multiple application cases: particularly for the control of electric heat, the actuation of valves and motors in conveyor technology or for reversing applications. Due to their quiet switching capability, they are suitable for noise-sensitive areas such as offices or hospitals. SIRIUS solid-state switching devices are equipped with particularly powerful semiconductors, thanks to which they offer an enormous short-circuit rating. They can therefore be employed in ULcompliant control cabinets without any problems and offer a high SCCR value (short-circuit current rating). Accurate, reliable and cost-effective Maximum quality SIRIUS solid-state switching devices are accurate and reliable. Their compact design assures safe operation up to an ambient temperature of 60 °C (140 °F). Variable connection technologies and a wide control voltage range provide for universal application and variant reduction. The connection technology with removable control terminal further ensures fast and uncomplicated assembly The fully automatic production of our SIRIUS solid-state switching devices forms the basis for their unique quality. Due to special carrier materials and selected semiconductors, the technical data such as heat transition and power loss is optimized. Therefore, the solid-state relays can be easily mounted onto diverse cooling surfaces while mastering the rated currents specified by the EN 60947-4-3 5 Standardized function modules for various applications In addition to UL approval, the SIRIUS solid-state switching devices of course also meet all other important standards and approvals such as IEC, CSA, CCC, C-Tick and GOST and are thus globally applicable. Multiple individual assembly options: Switching of Resistive Loads Even maximum switching frequencies are easily handled by our solid-state switching devices. In addition to their basic application area, the switching of heaters, they can also be employed for valves or other inductive loads. Depending on the respective application, “zero-point switching” or “instantaneous switching” variants are available. Besides simple on- and off-switching, the load circuits are monitored by retrofittable function modules, allowing even heating power to be controlled. SIRIUS solid-state relays SIRIUS solid-state relays are suitable for assembly on existing cooling surfaces. The mounting process is completed quickly and easily with only two screws. The power semiconductor’s special technology ensures a perfect thermal contact with the heat sink. Depending on the heat sink‘s characteristics, the devices offer a capacity of up to 88 A for resistive loads. If very many resistive loads have to be controlled, the relays can be mounted on a large group heat sink. With a dissipation of the power loss to the outside, the control cabinet’s heating is minimized. For individual adjustments, the solid-state relays can be extended by various function modules. 3RF21 single-phase solid-state relay Single-phase versions Three-phase versions Solid-state relays 22.5 mm With its narrow width of 22.5 mm, our 3RF21 solid-state relay saves space. The logical connection technology, the power supply from the top and the load connection from the bottom ensure a structured assembly inside the control cabinet. With their compact width of 45 mm, the 3RF22 three-phase solid-state relays offer a space-saving and cost-affordable solution for the operation of three-phase loads. Depending on the employed heat sink, loads of up to 55 A can be switched. You can also choose between two- and three-phase controlled versions. The twophase controlled version distinguishes itself as a result of having the lowest power loss; the three-phase version can be used when all three phases need to be switched operationally. Similarly to the 3RF21 solid-state relays, the power supply line is connected from the top and the load from the bottom. The removable control plug allows for prewiring of the circuit. Solid-state relays 45 mm The 45 mm standard version 3RF20 offers a top connection of the power supply line and the load. This facilitates easy replacement of available solid-state relays in existing assemblies. As with the 22.5 mm version, the control line is simply plugged on. 6 3RF20 single-phase solid-state relay 3RF22 three-phase solid-state relay SIRIUS solid-state contactors SIRIUS solid-state contactors The complete devices consist of a solid-state relay plus an optimized heat sink and are “ready to use”. Due to the heat sink’s exact matching to the power semiconductor, defined rated currents are realized. This way, solid-state switching devices which are accurately matched to the respective load can be selected rapidly and easily. Depending on the version, current strengths of up to 88 A are supported. Like all of our solid-state switching devices, our SIRIUS solid-state contactors stand out with their compact and space-saving design. The devices can be mounted closely, side by side, due to the special design of their terminals which are protected against direct touch. The insulated mounting foot allows for the devices’ easy snap-on installation on the mounting rail or fitting to mounting plates using fixation screws. This insulation facilitates the contactors’ application in circuits accommodating extra-low protective or function voltages in building technology. For other application cases, e.g. extended personal protection, the heat sink can be grounded by means of screwtype connections. Optionally, SIRIUS solid-state relays and contactors can be installed in fuseless or fused load feeders. Our single-phase solid-state contactors are furthermore available in a “shortcircuit-proof” special version. This way, semiconductor protection is also assured in fuseless assemblies. Due to a convenient matching of the power semiconductor to the solidstate contactor’s power rating, short-circuit-proof functionality is attained with a standard supplementary protector. When combined with a B-type supplementary protector or a conventional line protection fuse, a short-circuit-proof load feeder is assembled. 3RF23 single-phase solid-state contactor 3RF24 three-phase solid-state contactor 7 Single-phase versions Three-phase versions With seven versions, the 3RF23 singlephase solid-state contactors cover a current range up to 88 A. The 10.5 A and 20 A versions have a narrow width of 22.5 mm. Special versions facilitate the devices’ application in public mains or a short-circuit-proof assembly using a supplementary protector up to 25 A. The 3RF24 three-phase solid-state contactors are typically used in three-phase applications. With five versions, offered in two- and three-phase-controlled versions, a current range from 10 to 50 A is covered. As with the three-phase solidstate relays, they serve a voltage range from 48 to 600 V AC and are offered as “zero-point switching” version. The wide control voltage range from 4 to 30 V DC allows for the devices’ operation on digital controls (PLC) or simple temperature controllers. Maximum reliability in every respect: Motor Switching Ever increasing productivity requirements are driving an increase in the switching frequency requirements for motor applications. This challenge poses no problem for our SIRIUS solid-state contactors for motor switching. With threephase motors up to 7.5 kW (5 hp), they reliably operate even the maximum switching frequencies. The application of solid-state reversing contactors allows for a continuous reversal of the motor rotation. The typical application examples include conveyor belts in parcel distribution systems or palletizing machines. 3RF34 three-phase solid-state contactor Three-phase solid-state contactors These two-phase-controlled, instantaneous switching solid-state contactors embedded in an insulated enclosure are rated up to 5 A in a width of 45 mm and up to 16 A in a width of 90 mm. Motors of up to 7.5 kW (5 hp) can be operated. Three-phase solid-state reversing contactors The integration of four current paths in a reversing circuit accommodated in a single enclosure turns this device into a particularly compact solution. Compared to conventional systems, for which two contactors are required, the three-phase reversing contactors facilitate space savings of up to 50 % of the width. Devices with a width of 45 mm cover motors up to 2.2 kW (3 hp) and the 90 mm width design serves motor applications up to 3 kW (3 hp). 3RF34 three-phase solid-state reversing contactor Systematic combination and mounting The SIRIUS solid-state contactors and reversing contactors are designed to be easily combined with components of the SIRIUS modular system. Connection with SIRIUS motor starter protectors, SIRIUS overload relays or current monitoring relays is effortlessly possible. This saves time in the assembly of fuseless and fused motor feeders for frequently switching applications. Fuseless and fused motor feeders 8 Extended functionality, improved options: Function Modules In the industrial world, challenges form part of everyday business. Production capacities need to be adjusted to the respective requirements with even more flexibility. This presents a clean-cut case for our SIRIUS solid-state switching devices for the switching of resistive loads. Combined with standardized function modules, these devices can be quickly and reliably extended and adapted to individual requirements. Simply snap on and work away Single-phase solid-state contactor with load monitoring Three-phase solid-state contactor with converter 9 Assembly of our function modules is completed in quickly. By simply snapping them on, all connections to the solid-state relay or contactor are established. The plug connection for the control of the solidstate switching devices can be used. It could hardly be simpler. The function extension of the singlephase solid-state relays with a width of 22.5 mm and the single-phase solid-state contactors by the function modules’ simple plug-on installation supports numerous different applications. With three-phase applications, the threephase solid-state contactors and relays can be extended by converters to assemble a simple power control. For resistive and inductive loads: Variable Connection Technology Optimized Control Principles uMains uMains iLoad iLoad tON t tON t Zero-point switching: Switching of resistive loads, e.g. heating circuits Instantaneous switching: Switching of inductive loads, e.g. motors Version for resistive loads: “zero-point switching” Version for inductive loads: “instantaneous switching” To assure an optimized control principle for various loads, the functionality of our single- and three-phase solid-state switching devices has been adapted. For resistive loads, the “zero-point switching” principle is best. This means: The power semiconductor is controlled exactly when the voltage passes through zero. For inductive loads, such as valves, the “instantaneous switching” principle is a better solution. Due to the distribution of the switch-on point over the complete sinusoidal curve of the mains voltage, disturbances are minimized. This version of the solid-state switching devices is specifically matched to inductive loads. Tasks such as the frequent operation of valves in a filling system as well as the start-up and shutdown of small drives in parcel distribution systems are reliably and quietly completed. Special version for resistive loads: “low-noise” Due to a special control circuit, this version of the single-phase solid-state contactor can be used in public mains up to 16 A without additional measures such as noise suppression filters. Thus, the emitted interference does not exceed the limit value curve Class B in accordance with EN 60947-4-3. 10 Variable connection technology: Screw-type connection, spring-loaded or ring cable lug connection: SIRIUS solid-state switching devices offer the optimum technology for all applications All SIRIUS solid-state switching devices are characterized by a large number of available connection technologies. You can choose between screw-type connection, the industrial standard for loads up to 50 A, or the innovative spring-loaded technology for loads up to 20 A, which requires no screw connections while guaranteeing a high vibration resistance. Another option is the ring cable lug connection technology for safe attachment of large cross-sections with currents up to 88 A. SIRIUS solid-state switching devices offer the best suited main current connection for all assembly types including protection against direct touch. Overview table: The SIRIUS Solid-State Switching Devices Portfolio Function Applications Frequent switching of resistive and inductive loads Solid-state relay or solid-state contactor Operation of individual heating elements with constant resistance Operation of valves Starting and stopping small single-phase motors Frequent switching of motors Solid-state contactor or solid-state reversing contactor, three-phase units with two or three phase control S tarting and stopping small three- phase motors – Connection to the 3RV motor starter protector via link module – Capable of attaching to the 3RB2 solid-state overload relay Frequent switching and load monitoring of solid-state relays/solid-state contactors Solid-state relay or solid-state contactor plus load or heat monitoring module Operation of several heating elements with constant resistance at a solid-state relay or solid-state contactor Operation and monitoring of critical heating systems Control of the heating power through ON/OFF ratio Solid-state relay or solid-state contactor plus converter module Distributed autonomous temperature control (the temperature controller directly cooperates with the SIRIUS solid-state switching device) Control of the heating power through ON/OFF ratio (or phase angle control) Solid-state relay or solid-state contactor plus power controller module Power control through analog signal Power control Solid-state relay or solid-state contactor plus power regulator module Complex heating systems Heating elements with temperature-dependent resistance Heating elements with long-time aging Simple indirect temperature control through power control 11 Solid-State Switching Devices in Practical Application Resistive loads Solid-state relays Solid-state contactors Function modules Future-safe control of plastic injection machines Optimized bumper production in the automotive industry Easy heating zone monitoring of gluing robots in the automotive industry Challenge A monitoring option for the individual heating zones is required for the efficient control of plastic injection machines. Also a cost-favorable and space-saving assembly as well as optimum stability, even with high switching frequencies, represent further crucial aspects. Challenge The retrofit process for bumper production machines amongst others aims at the target of increased temperature control quality. For this purpose, conversions must be realized rapidly, effortlessly and with minimum cost expenditures. Solution The ideal devices for these requirements: SIRIUS solid-state relays 3RF2130 with a maximum load current of 30 A and a width of 22.5 mm. As an alternative, the application of 3-phase solid-state relays 3RF2230 supports even further space savings. With these devices, for example three loads respectively can be operated in three-phase circuit with only one solidstate relay – with a width of only 45 mm. Advantages Easy mounting directly on group heat sink thanks to compact design Easy plug-on retrofitting of load monitoring modules (e.g. 3RF29) on 1-phase devices Virtually unlimited service life for high system availability 12 Solution Predestined for application in injection molding plants: SIRIUS solid-state contactors. These extremely rugged devices facilitate particularly fast switching and ensure the required temperature quality at all times. Advantages Silent and wear-free switching – even with high switching frequencies Immediate applicability – thanks to optimally adjusted heat sink Improved quality and cycle time reduction from 80 to 54 seconds – thanks to optimized temperature control Power setting in percentage – conversion of analog into pulse width-modulated digital signals by means of plugon converter module Challenge Hot glue is applied by a gluing robot for disk mounting. For this purpose, the glue is transported from the drum pump to the dosing head via a heated line system. During this process, monitoring of the individual heating zones is of vital importance. The current limit value must be easily adjustable. Solution First choice for this application case: SIRIUS solid-state contactors 3RF23 in connection with the function module load monitoring basic 3RF2920-0FA. Every module is able to monitor up to six sub-loads per solid-state switching device. Besides sub-load failure, the load monitoring also signals mains failure as well as thyristor faults to the control – at a fault response rate of 100 ms. Advantages Easy and flexible teach-in of the setpoint current via the teach button Immediate display of radiator faults or failures via the load monitoring module – short response times for prevention of downtimes Easy and space-saving plug-on mounting of the load monitoring modules on a SIRIUS solid-state contactor Motor loads Heating control SIPLUS HCS300I Solid-state contactors/reversing contactors Reliable and precise control of resistive loads: Modular, easy and flexible Compact, extremely durable reversing circuit in solar plants Challenge Whether in automotive production or in the plastics industry: Heating controls have to ensure the right temperature at the right location at all times. This necessitates systems which are characterized by maximum reliability and flexible adjustability to individual requirements. Challenge The following installation alternatives are available for the configuration of photovoltaics plants: fixed installation or tracking of the solar panels in one or two axes. The tracking of these modules is controlled via solid-state contactors 3RF24. The plant’s automation has to be realized with minimum expenditures. The special maintenance situation calls for a service-friendly and particularly durable solution. Solution Together with the solid-state switching devices SIRIUS 3RF2, the modular heating control SIPLUS HCS300I represents the ideal solution for such applications. The switching devices can be easily connected to the HCS300I via pre-assembled cables. This considerably reduces wiring expenditures in the control circuit and minimizes mounting times. Every basic device of the SIPLUS HCS300I is able to control maximally 24 solid-state switching devices via 6-channel digital outputs and to operate four 4-channel temperature detections. The current and voltage of the loads can be monitored. Communication to the superior control is realized via PROFIBUS DP. Advantages Flexible, modular heating control of resistive loads Easy integration in existing automation systems such as SIMATIC and SIMOTION Flexible wiring and commissioning Further information is available at: www.automation.siemens.com/_en/heating-control 13 Solution The rugged and compact SIRIUS solid-state reversing contactors represent the perfect solution for these requirements. Thanks to their minimum dimensions, they reduce space requirements and thus minimize the control cabinet. Advantages Considerably increased plant availability and reduced service costs – thanks to extremely long service life Perfect combination options with components from the SIRIUS modular system (e.g. with SIRIUS circuit breakers or SIRIUS overload relays) Access to all important and up-to-date information: From the website to the newsletter, down to the download of complete brochures Ordering and information platform for all products and systems Efficient tools for increased productivity, e.g. CAx DVD for your configuration process Service & Support Portal for comprehensive technical information on configuration and system documentation Promotion website Newsletter portal Service Operation Commissioning Ordering Configuration Planning As competent and reliable partner, we not only offer tried-and-tested products and systems, but also comprehensive support – from initial information to planning, configuration and ordering, down to commissioning, ongoing operation and technical service: Information Support Product information Information and Download Center Product selection Industry Mall Software for Low-Voltage Controls and Distribution Product & system engineering Service & Support Portal CAx DVD Product documentation Image database We thus provide you with a comfortable basis for optimizing your processes. In short: Support for improved efficiency! SITRAIN Portal Product training Technical Assistance Product hotline Product information Comprehensive information on Low-Voltage Controls and Power Distribution Amongst others, rapid and targeted provision of information on: SIRIUS industrial controls Ensure your success with our trendsetting system solutions! www.siemens.com/sirius Newsletter: always up to date Constantly updated information on the subjects of industrial controls www.siemens.com/industrialcontrols/newsletter Product information Product selection Easy download of catalogs and information material Our Information and Download Center offers all current Catalogs Customer magazines Brochures for download www.siemens.com/industrialcontrols/infomaterial Industry Mall: platform for e-business and product information Benefit from 24/7 access to our comprehensive information and ordering platform for the complete Low-Voltage Controls and Distribution portfolio, including: Selection tools, product and system configurators Availability check Order tracking www.siemens.com/industrialcontrols/mall Product selection 14 Product & system engineering Software for Low-Voltage Controls and Distribution: easy, fast and safe Our software supports you throughout all project phases – from planning to parametrization, down to operation. Parametrization and Configuration with SIRIUS Industrial Controls Planning and Dimensioning of electrical power distribution systems with SIMARIS www.siemens.com/industrialcontrols/mall Online support: full-range technical product information 24/7 access to comprehensive technical information on our products and systems to support you from the planning to the configuration down to the operation phase. Product data sheets, manuals/operating instructions Certificates, characteristic curves, downloads FAQs www.siemens.com/industrialcontrols/support Technical Product Data for CAx Applications: immediate availability of configuration-relevant CAx data types for your CAD/CAE system This DVD provides you with a comprehensive pool of configurationrelevant CAx data types. Commercial and technical product master data 2D dimension drawings, isometric illustrations and 3D models Product data sheets Tender specifications Order number E86060-D1000-A207-* (via Industry Mall) Easy download of product image material Our image database contains all current Product images 2D dimension drawings, isometric illustrations and 3D models internal circuit diagrams Symbols in diverse versions for free download. www.siemens.com/industrialcontrols/picdb Training: knowledge expansion Our Low-Voltage Controls and Distribution training offer both comprises an overview as well as detailed competencies regarding selected products and systems. Amongst others, you can expand your product and system know-how of SIRIUS. www.siemens.com/sitrain Or contact us personally via the information hotline: via infoline telephone: +49 1805 23 56 11* or via fax: +49 1805 23 56 12* www.siemens.com/simaris Product documentation Product training *0,14 €/min. from German landline network, deviating mobile communications prices are possible Product hotline Technical Assistance: competent Low-Voltage Controls and Distribution expert consulting We support you with all technical enquiries regarding our products and systems – both before and after delivery. Product selection Old/new conversions, competitor conversions Special versions, special requirements Commisioning, operation Tip: the Service & Support Portal, including the FAQ database, can be called up via www.siemens.com/industrial-controls/technical-assistance. You can also directly submit your support request to a technical consultant. 15 www.siemens.com/industrialcontrols/technical-assistance Personally from Mo. through Fr. 8.00 am to 5.00 pm (CET) via telephone: +49 911 895 5900 via e-mail: [email protected] via fax: +49 911 895 5907 Siemens Industry, Inc. Industry Automation 3333 Old Milton Parkway Alpharetta, GA 30005 1-800-964-4114 [email protected] www.usa.siemens.com/controls Subject to change without prior notice Order No.: GCBR-A640P-0510 E20001-A640-P302-V7-7600 All rights reserved Printed in USA © 2010 Siemens Industry, Inc. The information provided in this brochure contains descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Availability and technical specifications are subject to change without prior notice. Any product names mentioned may be trademarks or product designations of Siemens or their suppliers, whose use by third parties for their own purposes may infringe the rights of the trademark owners.
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project