Rockwell Automation Allen-Bradley 700-SA Application Manual Download Page 35 | Manualshive

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Publication 700-AT001A-EN-E June 2002

Considerations When Designing SSR Control Systems

2-19

SSR Failures

Short-circuit Protection (Fuse Selection) and Overcurrent
Protection

A short-circuit current or an overcurrent flowing through the load side
of the SSR will damage the output switching element of the SSR.
Connect a quick-break fuse in series with the load as an overcurrent
protection measure.

Design a circuit so that the protection coordination conditions for the
quick-break fuse satisfy the relationship between the SSR surge
resistance (I

S

), quick-break fuse current-limiting feature (I

F

), and the

load inrush current (I

L

), shown in the following chart.

Provide an appropriate circuit breaker for each machine to provide
overcurrent protection of the machine. Refer to page 4-5, “What is the
Meaning of I

2

t” for more details.

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Summary of Contents for Allen-Bradley 700-SA

Page 1: ...Solid State Relays 700 SA SC SE SF SH SK Application Guide ...

Page 2: ...adley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of t...

Page 3: ...rt documented in a technical construction file EN 61000 6 2 EMC Generic Standards Immunity for Industrial Environments This product is intended for use in an industrial environment Low Voltage Directive This product is tested to meet Council Directive 73 23 EEC as ammended by 93 68 EEC Low Voltage by applying the safety requirements of EN 60950 and safety requirements for Safety of Information Tec...

Page 4: ...plication 1 8 SSR Glossary 1 9 Chapter 2 Considerations When Designing SSR Control Systems Input Circuit 2 1 Input Noise 2 1 Input Conditions 2 3 Output Circuit 2 5 AC ON OFF SSR Output Noise Surges 2 5 DC ON OFF Output Noise Surges 2 6 Self Holding Latching Circuits 2 7 Selecting a SSR For Different Loads 2 7 Inrush Currents From Transformer Loads 2 11 Transformer Tap Selection 2 13 Controlling P...

Page 5: ...s and Wire Ducts 3 3 Ventilation 3 4 Confirmation after Installation 3 4 Operation and Storage Environment Precautions 3 5 Ambient Temperature Operating 3 5 Operation and Storage Locations 3 6 Vibration and Shock 3 6 Solvents 3 6 Oil 3 6 Handling the SSR 3 7 Chapter 4 Q and A What Is Zero Cross Function 4 1 Why Does the Input Current Vary With the SSR 4 2 What Is The Difference in Switching with a...

Page 6: ... Necessary to Apply Grease to the SSR Heat Sink 4 11 Available Silicon Grease Products for Heat Dissipation 4 12 What Output Configuration Is Suitable When the SSR Is Used in Combination With a Temperature Controller 4 12 What Precautions Are Necessary When Driving a Number of SSRs With a Temperature Controller Output 4 12 Examples of Connections Between Temperature Controllers and SSRs 4 13 What ...

Page 7: ...popular for the following reasons They provide a means of creating no contact relays in output power sections enabling conversion of control circuits to ICs They provide a means of increasing the service life of the application and reducing maintenance time and costs They provide a means of preventing operating errors caused through noise by isolating signal circuits and outputs They provide a mea...

Page 8: ...tput load signals Photocouplers change electric signals into optical signals and transmit the signals through space thus fully isolating the input and output sections while transferring the signals at high speed SSRs consist of electronic parts with no mechanical contacts Therefore SSRs have a variety of features that mechanical relays do not incorporate The greatest feature of SSRs is that SSRs d...

Page 9: ...riac coupler Photocoupler Diode capacitor resistor and varistor Resistor capacitor and varistor power transistor thyristor Output terminals SSR Component Configuration Power transistor for DC loads Thyristor for AC loads Triac for AC loads and triac Input Output Light Phototriac coupler Triac No operation noise Long life SSRs are SPST NO Input circuit Zero cross function Trigger circuit High speed...

Page 10: ... device such as a heater is turned ON or OFF by turning a SSR ON or OFF in response to voltage output signals from a Temperature Controller The same kind of control is also possible with an electromagnetic relay but if the heater is turned ON and OFF at intervals of a few seconds high frequency switching over a period of several years then an SSR must be used UF JHQHUDWLRQ RQWDFW IDLOXUHV PD UHVXO...

Page 11: ...ric machines and devices SSR Classifications SSRs can be classified by appearance such as panel mounting models socket models or by applications as shown below The optimum SSR can be selected depending on the purpose ON OFF 2 s SSR 7HPSHUDWXUH RQWUROOHU 9ROWDJH RXWSXW QDEOHV ORZ FRVW QRLVHOHVV RSHUDWLRQ ZLWK UHGXFHG PDLQWHQDQFH UHTXLUHPHQWV ...

Page 12: ...achines e g molding machines Food related machines e g packaging machines Industrial robots Industrial machines and control equipment e g programmable controllers Medical equipment e g CT scanners Physical and chemical equipment e g temperature controlled baths Automatic vending machines Amusement machines Railroad related applications e g lamp and seat heaters Traffic signals ...

Page 13: ...d for inching and reversible operation I O These SSRs meet the requirements for isolated transmission of control output from PCs and Position Controllers to an actuator Amusement Machines These SSRs have high ON OFF frequency noiseless operation and when compared to mechanical relays have greater resistance to vibration shock dust and dirt and gas making them ideal for situations where these facto...

Page 14: ...ecessary to electrically isolate internal circuits and external circuits output circuits An isolated input circuit is a circuit that isolates inputs and outputs by using components that are not connected electrically but that can transmit signals such as contact relays or photocouplers Photocoupler A component that runs the electric signal into a light emitter e g LED changes it to a light signal ...

Page 15: ...conductor output element load switching device This is a generic name for semiconductors such as the thyristor triac and power transistor In particular triacs are often used in SSRs because they allow switching to be performed with one element Repetitive peak OFF state voltage VDRM This is a rating for an output semiconductor that is used in a SSR for AC loads Collector emitter voltage VCEO This i...

Page 16: ...e which occurs when the load switched or turned OFF Recommended applicable load The recommended load capacity which takes into account the safety factors of ambient temperature and inrush current Bleeder resistance The resistance connected in parallel to the load in order to increase apparently small load currents so that the ON OFF of minute currents functions normally It is also used to shunt le...

Page 17: ...l pulse noise and inductive noise 3XOVH 1RLVH A combination of capacitor and resistor on the input control circuit can absorb pulse noise effectively The following is an example of a noise absorption circuit with capacitor C and resistor R connected to an SSR The value of R and C must be decided carefully The value of R must not be too large or the supply voltage E will not be able to satisfy the ...

Page 18: ...ines Inductive noise may cause the SSR to malfunction turn off unexpectedly or both If inductive noise is imposed on the input terminals of the SSR use the following cables according to the type of inductive noise to help reduce the noise level to less than the reset voltage of the SSR Twisted pair wires For electromagnetic noise Shielded cable For static noise A filter consisting of a combination...

Page 19: ...g power OFF To counteract this connect a bleeder resistance R as shown in the diagram below and set the resistance so that the voltage applied to both ends of the resistance is less than half of the reset voltage of the SSR The bleeder resistance R can be obtained in the way shown below E Voltage applied at both ends of the bleeder resistance half of the reset voltage of the SSR IL Leakage current...

Page 20: ...d changes in the input current If the input voltage is low the influence of the voltage drop for the input LED is large and the input impedance will be higher than expected If the voltage is so high that the LED voltage drop can be ignored the input impedance will be close to the resistance R For semiconductor driven SSRs changes in voltage can cause malfunction of the semiconductor so be sure to ...

Page 21: ... Refer to the SSR s datasheet for details When switching an inductive load ON and OFF be sure to take countermeasures against surge such as adding a surge absorbing element In the following example a surge voltage absorbing element is added Basically if the SSR does not have a built in varistor circuit A will be effective and if the SSR does have a built in varistor circuit B will be effective In ...

Page 22: ...e load as shown in the following diagram and table As an absorption element the diode is the most effective at suppressing the counter electromotive force The release time for the solenoid or electromagnetic valve will however increase with a diode Be sure to check the circuit before use To shorten the time connect a Zener diode and a regular diode in series The release time will be shortened at t...

Page 23: ... provides examples of the inrush currents for different loads AC Loads and Inrush Current HDWHU RDG 5HVLVWLYH RDG A resistive load is essentially a load without an inrush current The SSR is generally used together with a voltage output temperature controller for heater ON OFF switching When used with an SSR with a zero cross function it suppresses most noise generated by the load This type of load...

Page 24: ...waveform of the power supply voltage will be distorted and flickering will occur Fluorescent lamps are discharge tubes and have transformers for producing high voltages For this reason noise and harmonics are generated as a result of distortions in the power supply voltage small phase gaps and differences in positive and negative ON voltages 0RWRU RDG When a motor is started an inrush current of 5...

Page 25: ...ge does not reach the SSR output For SSRs with the zero cross function this can cause them not to turn ON Two methods for counteracting this problem are described below a Connect a bleeder resistance with approximately 20 of the SSR load current b Use SSRs without the zero cross function XOO ZDYH 5HFWLILHG RDGV Some AC electromagnetic counters and solenoids have built in diodes which act as full w...

Page 26: ...less than the load s reset voltage QYHUWHU RDG Do not use an inverter controlled power supply as the load power supply for the SSR Waveforms for inverter controlled voltages are rectangular Semiconductor output elements triac thyristor may not be able to respond to the steep voltage increases dV dt becomes extremely large and the SSR may fail to reset also called turn OFF problem or commutating dV...

Page 27: ... the transformer Due to the self reactance of the transformer in actual operation the actual inrush current will be less than the calculated value I peak V peak R V R If the transformer has a DC resistance of 3 Ω and the load power supply voltage is 220 V the following inrush current will flow I peak 1 414 220 3 103 7 A The inrush current resistance of Bulletin 700 S_ SSRs is specified on conditio...

Page 28: ...r Supply Voltage 480 V RDG SRZHU VXSSO YROWDJH QUXVK FXUUHQW 665 LQUXVK FXUUHQW UHVLVWDQFH SSOLFDEOH 665 9 9 9 7UDQVIRUPHU UHVLVWDQFH Ω DW 1R DW 1R PLQ PLQ PLQ 6 B 6 B 6 B 6 B 6 B 6 B 6 B RDG SRZHU VXSSO YROWDJH QUXVK FXUUHQW 665 LQUXVK FXUUHQW UHVLVWDQFH SSOLFDEOH 665 9 9 9 7UDQVIRUPHU UHVLVWDQFH Ω DW 1R DW 1R PLQ PLQ PLQ 6 B 6 B 6 B 6 B 6 B 6 B 6 B 7UDQVIRUPHU UHVLVWDQFH Ω QUXVK FXUUHQW 665 LQUX...

Page 29: ...pply is used in place of a DC supply be sure that the peak load current does not exceed the maximum usage load power specification of the SSR Otherwise overvoltage will cause damage to the output element of the SSR Operating Frequency for AC Load Power Supply The SSR operating frequency range for AC load power supply is 47 63 Hz This is due to the response speed of the internal triac or thyristor ...

Page 30: ...tage falls below the trigger voltage the SSR will not turn ON so be sure to set the load voltage to no lower than the minimum for the SSR e g 75V AC minimum for the 700 SH_ SSR Phase controlled AC Power Supplies Do not use a phase controlled power supply for SSRs that have triac or thyristor output Trigger voltage Trigger voltage An inductive L load causes a current phase delay as shown above Ther...

Page 31: ...5 Application Circuit Examples Connection to a Sensor The SSR connects directly to the Proximity Sensor and Photoelectric sensor Switching Control of an Incandescent Lamp Sensor Load power supply Fuse or breaker Input signal source Incandes cent lamp Load power supply Fuse or breaker Varistor ...

Page 32: ...l with a rated output voltage of at least twice the supply voltage 1 For example if the motor operates at a supply voltage of 100 V AC the SSR must have an output voltage of 200 V AC or higher 2 Make sure that there is a time lag of 30 milliseconds or more to switch over SW1 and SW2 ON OFF Control of a Three phase Inductive Motor Single SSRs in Combination Input signal source and Temperature Contr...

Page 33: ...Therefore make sure that there is a time lag of 30 milliseconds or more to switch over SW1 and SW2 The SSR may be damaged due to phase short circuiting if the SSR malfunctions with noise in the input circuit of the SSR To protect the SSR from phase short circuiting damage the protective resistance R may be inserted into the circuit The value of the protective resistance R must be determined accord...

Page 34: ...esult in short circuit of the SSR whereby the load cannot be turned OFF Therefore to provide a fail safe feature for a load using an SSR a control circuit should be designed in which a contactor or circuit breaker on the load power supply side will turn OFF the load when the SSR causes an error Do not design a circuit that only turns OFF the load power supply with the SSR as the control element Fo...

Page 35: ...ection coordination conditions for the quick break fuse satisfy the relationship between the SSR surge resistance IS quick break fuse current limiting feature IF and the load inrush current IL shown in the following chart Provide an appropriate circuit breaker for each machine to provide overcurrent protection of the machine Refer to page 4 5 What is the Meaning of I2t for more details RFDWLRQ DXV...

Page 36: ...ula SSR Heating Value P W SSR Output ON voltage drop V x SSR Carry current A For example if a load current of 8 A flows through Bulletin 700 SH the following heating value will be obtained P 1 6 V 8 A 12 8 W The SSR in typical normal operation switches a current of approximately 5 A with no heat sink required If the SSR must switch a higher current a heat sink will be required The higher the load ...

Page 37: ...le the standard heat sink can be used for Bulletin 700 SH_ Thermal resistance indicates a temperature rise per unit W Heat radiation efficency increases with a decrease in thermal resistance Calculating Heat Sink Area An SSR that uses an external heat sink can be directly mounted to control panels under the following conditions If the heat sink is made of steel used for standard panels do not appl...

Page 38: ...00 or equivalent non silicon recommended for automotive plant applications Designing for Control Panel Heat Radiation Control equipment using semiconductors will generate heat regardless of whether SSRs are used or not The failure rate of semiconductors greatly increases when the ambient temperature rises It is said that the failure rate of semiconductors will be doubled when the temperature rises...

Page 39: ...e tightening torque shown in the following table SSR Terminal Screw Tightening Torque SSR Panel Mounting Quality If Bulletin 700 SH or Bulletin 700 SE SSRs are to be mounted directly on the control panel without the use of a heat sink be sure to use a panel material with low thermal resistance such as aluminum or steel refer to page 2 20 Do not mount the SSR on a panel with high thermal resistance...

Page 40: ...IURP WKH VRFNHW LI DQ H FHVVLYH YLEUDWLRQ RU VKRFN LV DSSOLHG SSR Insertion and Removal Direction Insert and remove the SSR from the Socket perpendicular to the Socket surface If it is inserted and removed with an inclination from the diagonal line terminals of the SSR may bend and the SSR may not be properly inserted in the socket Socket Mounted SSR Panel Mounting When SSRs are mounted inside an ...

Page 41: ...ng surface Duct Vertical direction Duct Do not enclose the SSR with the duct in the depth direction or otherwise the heat radiation of the SSR will be adversely affected 50 mm max The recommended width is half as large as the depth of SSR or less Mounting surface Duct Use a short duct in the depth direction 100 mm 100 mm SSR SSR Duct Mounting surface Duct SSR Duct Wire Vertical direction Better Be...

Page 42: ...erature ratings are satisfied for your system 50 x h Max h Duct SSR Ventilation Wire Duct Height Clean air inlet filter regularly if one is used Air Flow If the air inlet or air outlet has a filter clean the filter regularly to prevent it from clogging and ensure an efficient flow of air Do not locate any objects around the air inlet or air outlet otherwise the objects may obstruct the proper vent...

Page 43: ...mbient temperature of an SSR is determined with proper ventilation conditions If the heat radiation conditions of the SSR such as fresh air supply or ventilation is improper the operating ambient temperature will exceed the rated value As a result the SSR may fail prematurely When using SSRs check that the circuits are designed to satisfy the conditions specified under Load Currents vs Ambient Tem...

Page 44: ...Shock Do not subject the SSR to excessive vibration or shock Refer to the SSRs shock and vibration specifications pages in pub no 700 SG003B EN P otherwise the SSR will malfunction and may cause damage to the internal components To prevent the SSR from abnormal vibration do not install the Unit in locations or by means that will subject it to the severe vibrations from other devices such as motors...

Page 45: ...fer to pub 700 SG003B EN P The SSR cannot maintain its full performance capability if it is dropped or subjected to excessive vibration or shock resulting in possible damage to its internal components The impact of shock given to the SSR that is dropped varies upon the case and depends on the floor material the angle of collision with the floor and the dropping height For example if a single SSR i...

Page 46: ...ill reduce suppress the inrush current more than SSRs without the zero cross function It is ideal for the load current to start from 0 V when the zero cross function is used Due to circuit restrictions however the load current will start from a point that is 0 20 V The difference in voltage between this point and the 0 V point is called zero cross voltage ON ON ON ON OFF ON OFF OFF QSXW RQWURO 2XW...

Page 47: ...ent What Is The Difference in Switching with a Thyristor and a Triac There is no difference between them as long as resistive loads are switched For inductive loads however thyristors are superior to triacs due to the back to back connection of the thyristors For the switching element an SSR uses either a triac or a pair of thyristors connected back to back There is a difference between thyristors...

Page 48: ...cannot be turned OFF when the gate signal turns OFF The triacs and thyristors are kept ON until the output current is turned OFF at zero cross point These semiconductor elements are easy to break when they are short circuited Be aware of these characteristics from a viewpoint of safety when designing equipment or systems that employ SSRs What Is a Snubber Circuit When SSRs with triac or thyristor ...

Page 49: ...an SSR The relationship between the snubber circuit and current leakage is like balancing a seesaw With the snubber effect increased the leakage current will increase With the leakage current suppressed the SSR will be adversely affected by noise Are There Any SSRs With Normally Closed Contacts An SSR with a triac or thyristor output cannot have normally closed contacts unless a drive power supply...

Page 50: ... the direction required to maintain the magnetic flux even though the switch is already closed Therefore the counter electromotive force has no way to escape and a very high voltage is generated The counter electromotive force may cause contact friction damage and fatal element damage Pay utmost attention when using DC inductive loads As shown below the power supply voltage and counter electromoti...

Page 51: ...SSR connected in series shares the surge voltage Therefore both SSRs require protection from overvoltage However a high operating voltage cannot be applied to the SSRs connected in series The reason is that the SSRs cannot share the burden of the load voltage due to the difference between the SSRs in operating time and reset time when the load is switched Is It Possible to Connect Two 200V AC SSRs...

Page 52: ...o connect the load with the polarities corresponding in the way shown below Make sure you follow national and local codes when wiring electrical equipment What Portion of the Power Factor of the Load Is Practically Applicable A power factor range between COSφ 1 and about 0 4 is available If the power factor is less than 0 4 the phase gap between the current and the voltage will become large and ev...

Page 53: ...rent of 50 mA is used the leakage current with the SSR turned OFF will be 20 of the rated value This may cause reset failures depending on the load Why Can Most SSRs Not Switch Micro loads SSRs with AC Outputs Presently the minimum load current of most SSRs is limited to 100 mA 0 1 A At an ambient temperature of 25 C or higher this value will be a maximum of 50 mA There are two reasons for this On...

Page 54: ...st no current flows and periods where the capacitance changes quickly When the voltage is supplied to the SSR the SSR will turn ON Around point a refer to above graph where there is virtually no current flow however the SSR will turn OFF The moment the charge current starts flowing at point b the SSR will turn ON At point c the SSR will turn ON If the SSR does not turn ON at point b in time the ca...

Page 55: ...n the Back Junction refers to the PN junction of the semiconductor element and is used as a representative point on the element to express temperature Refer to pub 700 SG003B EN P for further details Can A Panel Frame Be Used in Place of Heat Sink Yes but steel plates used for standard panels have lower heat conductivity than aluminum plates and thus is not suitable for high current applications I...

Page 56: ...n silicon grease is used to aid heat dissipation The heat conduction of this special compound is five to ten times higher than standard silicon grease This special grease is used to fill the space between a heat radiating part such as an SSR and the heat sink to improve the heat conduction of the SSR Unless special grease is applied the generated heat of the SSR will not be radiated properly As a ...

Page 57: ...age output What Precautions Are Necessary When Driving a Number of SSRs With a Temperature Controller Output Refer to the diagrams below for the number of SSRs that can be connected to an Allen Bradley temperature controller Interface SSRs will be required to drive more SSRs With SSRs leakage currents can cause reset failures 7HPSHUDWXUH FRQWUROOHU QSXW YROWDJH 665 SRZHU VXSSO RDG RDG RDG SRZHU VX...

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Page 60: ...g In the case of high density or gang mounting of SSRs check the relevant data in Publication 700 SG003B EN P If there are no data check that the load current applied is 70 of the rated load current If the SSRs are mounted in two or more rows it is necessary to confirm the temperature rise of the SSR separately With side by side high density or gang mounting of SSRs with heat sinks reduce the load...

Page 61: ... repetitive inrush current and greater than the repetitive inrush current can be withstood once or twice a day e g this level of inrush current can be withstood in cases where power is supplied to devices once a day What Kind of Failure Do SSRs Have Most Frequently Data indicates that most failures are caused by overvoltage or overcurrent resulting in a short circuited SSR This data is based on SS...

Page 62: ...ds 264V AC Is It Possible to Replace a Defective Part in a SSR No parts of any SSR are replaceable because the SSR is sealed with plastic resin How Can We Use a Multimeter to Check If the SSR is ON or OFF The resistance of the load terminals of the SSR does not make clear changes when the input turns ON and OFF Connect a dummy load to the output terminals and check the voltage of the load terminal...

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Page 65: ...SSR limit the inrush current to 1 2 of the maximum rated value to be applied to the SSR 7KH PD LPXP 665 ORDG FXUUHQW ZDV GHWHUPLQHG DVVXPLQJ WKDW D VLQJOH UHVLVWDQFH ORDG LV LQVWDOOHG W LV H SHFWHG KRZHYHU WKDW WKH 665 ZLOO EH H SRVHG WR KDUVKHU FRQGLWLRQV LQ DFWXDO RSHUDWLRQ WKDQ LQ WKH WULDO WHVWLQJ EHFDXVH RI SRZHU YROWDJH IOXFWXDWLRQV DQG FRQWURO SDQHO VSDFH OLPLWDWLRQV 7R DOORZ IRU D VXIILFLH...

Page 66: ...ler Triac Snub ber circuit Output terminals Trigger circuit Zero cross circuit Trigger circuit Input circuit Input terminals Phototriac coupler Triac Snub ber circuit Output terminals Trigger circuit Zero cross circuit Input terminals Input circuit Snub ber circuit Output terminals Triac Phototriac coupler Input circuit Snub ber circuit Thyristor module Output terminals Input terminals Photocouple...

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