Solid State Relays ISO 9001 N° 1993/1106b okpac range ® European Meeting Guy PONCET celduc 2006 1 Innovation 2004 ISO 9001 N° 1993/1106b Solid State Relays New range ? a) Manufacturing Cost Reduction b) Performances c) IP 20 = protection cover (mainly for Europe) SC range SC5 : 1980 SC8 : 1990 SV range SV8 : 1995 d) New look COMMERCIAL IMPACT SO range New 2004 ® okpac range Guy PONCET celduc 2006 2 ISO 9001 N° 1993/1106b ® okpac range Competition CARLO CRYDOM GAVAZZI CROUZET/ GORDOS OMRON Some Asian manufacturers NAIS, KYOTTO FOTEK WOONYOUNG …… Guy PONCET celduc 2006 3 ® ISO 9001 N° 1993/1106b okpac range Our main goals are : a) Innovation with Performances & Reliability - Electricals - Mechanical : terminals, IP 20 or not b) Look : New celduc design c) Lower price Guy PONCET celduc 2006 4 ISO 9001 N° 1993/1106b ® okpac range a) Construction : * New housing, new terminals, SMD LED,… LOW profile L= 58.5mm l = 44.5mm H = 29mm * Less mould mass : tropicalisation Environment friendly Weight = 20 to 25% less Higher life-time expectancy * IP20 or not. We can touch without any risk Easy screwing thanks to open flaps * Input connector in option Guy PONCET celduc 2006 5 ® ISO 9001 N° 1993/1106b okpac range a) Construction : Power thyristors (TMS2) on the aluminium base plate, nickel plated SMD components Screws are mounted on an encapsulated metallic base, (not a plastic base) Guy PONCET celduc 2006 6 ISO 9001 N° 1993/1106b ® okpac range b) Configurations : Without flaps With IP20 flaps on terminals Open flaps for easy screwing connector Guy PONCET celduc 2006 Pluggable spring connector for input 7 ® ISO 9001 N° 1993/1106b okpac range Terminals : The same screwdriver for input and output ! ( We are alone) The best terminals of the market ! Power conductors sizes according to permanent currents Guy PONCET celduc 2006 8 ® okpac range ISO 9001 N° 1993/1106b Power Terminals : The best terminals of the market ! Direct wiring or with ferrules 1 or 2 wires per terminal Wiring with power tabs Up to 2 x10 mm2 Wiring with a copper bar. Up to 50mm2 Means 150A Means up to 2 x 50 A Guy PONCET celduc 2006 9 ® okpac range ISO 9001 N° 1993/1106b Power Terminals : The best terminals of the market ! COPPER LUGS WITH CONTAINED PALM up to 50mm2 (AWG0) = 150A Washer FASTON terminals Very good in term of vibrations : Avionic, trains….. Guy PONCET celduc 2006 10 ISO 9001 N° 1993/1106b ® okpac range Control terminals Standard M4 terminals For direct wiring Or for flat tabs Pluggable. Spring terminals or diagnostic models : « Plug and Play » Guy PONCET celduc 2006 11 ISO 9001 N° 1993/1106b okpac® range Solid State Relay construction Input a da pta tion c irc uit INSULATION Input P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Cur re nt re gulator + voltage prote ction A C v ol tage i np u t Tria c 2 Rec tif ier + f ilte r 4 Bac k to ba ck thyr istor s 1 3 Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage 5 Protection Power Switching Opto Guy PONCET celduc 2006 Var istor (VDR) 12 ISO 9001 N° 1993/1106b ® okpac range Power thyristors Input Input a da pta tion c irc uit INSULATION 1 P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t Cur re nt re gulator + voltage prote ction Tria c C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Bac k to ba ck thyr istor s A C v ol tage i np u t Rec tif ier + f ilte r SSR construction Var istor (VDR) Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage Technology Comparison Life Time expectancy Chip size & Performances Guy PONCET celduc 2006 13 ISO 9001 N° 1993/1106b Chipset used by most competitors (CRYDOM, NAIS, OMRON…) Lot of layers: Connections, Solders, Molybdenum, silicon, …….. Guy PONCET celduc 2006 14 ® okpac range ISO 9001 N° 1993/1106b For I >32A Innovation in the substrate : Thanks to a high temperature (approx. 1000°C) diffusion process, a thick layer of copper (usually 0.4 mm) is directly imbedded onto the alumina substrate.( No extra layers) The jumpers are replaced by a multitude of bonding wires with several anchor points to withstand significant overload currents. This technology brings the following assets : * Well improved thermal resistance (Rthj/c) * Thermal cycle stress divided by 2 or 3. * Simplified mounting, with automation giving rise to total control of the production process Guy PONCET celduc 2006 15 ® ISO 9001 N° 1993/1106b okpac range Chip size 35A : 5.6 x 5.6mm 50A : 7 x 7 mm 75A : 8.9 x 8.9mm 95A : 10.3 x 10.3mm 125A : 12.4 x 12.4mm Guy PONCET celduc 2006 16 ® ISO 9001 N° 1993/1106b okpac range Current range: 12A - 25A - 35A - 50A - 75A - 95A -125A Voltage range : 600V - (800V) - 1200V - 1600V The largest range of the market ! Guy PONCET celduc 2006 17 ISO 9001 N° 1993/1106b ® okpac range LIFE TIME EXPECTANCY Temperature variation 1 : standard product 2 : first generation of TMS2 3 : TMS2 second generation preheating regulation Variation of temperature (°C) Inrush current at starting Guy PONCET celduc 2006 18 ® ISO 9001 N° 1993/1106b okpac range Reliability / Thermal cycling results Tests made on a 50A model SCR B to B Thyristor CRYDOM tests : 500 cycles with a variation of temperature of 100°C CARLO tests : 5400 cycles with a variation of temperature of 100°C CROUZET : 5100 cycles with a variation of temperature of 100°C OMRON : 4500 cycles with a variation of temperature of 100°C celduc ® standard SC range: 5 400 cycles with a variation of temperature of 100°C celduc ® new okpac ® range: 10 000 cycles with a variation of temperature of 100°C Guy PONCET celduc 2006 19 ISO 9001 N° 1993/1106b ® okpac range Advantages to have high surge current SSRs Origin of overload current : Load Inrush current ORIGINS : - Motor starting, Overload currents Io RMS - Accidental mechanical load increase on the motor shaft, - Lamp load (IR lamps) at turn ON (cold state), - Transformer turn ON. } Io 5 to 10xIe Duration : 0,5s to 10s } Io 20 to 100xIe } Duration : 20 to 50ms Io 10 to 20xIe Duration : 20 to 100ms Load current RMS nominal load current Ie Big advantage to have high current SSR Guy PONCET celduc 2006 20 ISO 9001 N° 1993/1106b ® okpac range Advantages to have high surge current SSRs Origin of overload current short-circuit of the load Iq = prospective short-circuit current (current without protection on line) : can be > 1000x Ie Actual current limited by the short-circuit protection device correponding to the I2t applied to the SSR ORIGINS : - Ageing of heating resistors, - Ageing of insulating materials in motors ... - Accidental short-circuit made by the user. Advantages to have high I2t SSR : The capability to sustain overloads and inrush current is directly proportional with the size of the dices Guy PONCET celduc 2006 21 ISO 9001 N° 1993/1106b ® okpac range Advantages to have high surge current SSRs Short-circuit of the load :protection solution Fast Fuses Mains I> SSR 2 Or Short-circuit protection or I t fuse < I t SSR Fast Circuit Breakers Short circuit Load 2 2 2 SSR with I t > 5000A s Advantages to have high I2t SSR : Easy to protect even with a fast MCB Guy PONCET celduc 2006 22 ® okpac range ISO 9001 N° 1993/1106b Advantages to have high voltage SSRs World Electricity Supplies: Europe: 230VRMS & 400VRMS 50hz ±10% (690VRMS on few applications) USA: 120 VRMS & 240 VRMS 60hz 460 & 480VRMS (+6% max) Canada: 600VRMS (+4% max) Japan: 100VRMS 50 and 60Hz / 200VRMS 50 and 60hz Australia: 415 VRMS KOREA & China: 380VRMS & 220VRMS India: 220VRMS & 400VRMS 50hz (with lots of perturbations) ………. In sine wave : Vpeak = VRMS x square root 2 = VRMS x 1.414 Vpeak VRMS (Example 400VRMS + 10% 440 x 1.414 = 622Vpeak In power electronic and for a good reliability the rule is : Device Peak voltage > about 2 times the mains voltage Guy PONCET celduc 2006 23 ® ISO 9001 N° 1993/1106b okpac range Advantages to have high voltage SSRs 600Vpeak SSR Mains up to 275 / 280VRMS (Depends on the protection) 800Vpeak SSR Mains up to 440VRMS for mains without lots of perturbations !!! 1200Vpeak SSR Mains up to 510 / 600VRMS (Depends on the protection) 1600Vpeak SSR up to 690VRMS We accept 10% more for the mains tolerance Take Precautions for loads with overvoltage at turn OFF Guy PONCET celduc 2006 Vpeak SSR Vpeak mains VRMS mains 24 ISO 9001 N° 1993/1106b ® okpac range Input Input a da pta tion c irc uit INSULATION 2 Optocouplers P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t Cur re nt re gulator + voltage prote ction Tria c C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Bac k to ba ck thyr istor s A C v ol tage i np u t Var istor (VDR) Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage Rec tif ier + f ilte r SSR construction Performances Guy PONCET celduc 2006 25 ISO 9001 N° 1993/1106b ® okpac range 2 OPTOISOLATOR Typically Insulation Level : 5kV Internal distances in compliance with VDE Creepage & Clearance distances : 8mm In/Out High level SO8 Standard SO9 Zero Cross Level Turn ON time Coupler Immunity Means low EMI in commutation Means like competitors Random SO7 <12V <35V - 10ms @ 50hz 10ms @ 50hz 0,050 ms 10 000V/microsecond 500V/microsecond 10 000V/microsecond Means high Immunity Guy PONCET celduc 2006 Means very fast answer 26 ISO 9001 N° 1993/1106b ® okpac range Input Input a da pta tion c irc uit INSULATION 3 Input P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t Cur re nt re gulator + voltage prote ction Tria c C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Bac k to ba ck thyr istor s A C v ol tage i np u t Var istor (VDR) Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage Rec tif ier + f ilte r DC control range AC control range Input current SSR construction LED Guy PONCET celduc 2006 27 ISO 9001 N° 1993/1106b ® okpac range 3 Input LEDs on Input with current regulator Large input voltage DC input : 3-32 VDC with a limited current and a voltage protection A1 AC input : 20-265VAC or DC with a limited current 3+ V1 filter A2 4- Guy PONCET celduc 2006 1 6 2 4 28 ISO 9001 N° 1993/1106b ® okpac range Switching 4 Input Input a da pta tion c irc uit INSULATION Zero Cross P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t Cur re nt re gulator + voltage prote ction Tria c C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Bac k to ba ck thyr istor s A C v ol tage i np u t Var istor (VDR) Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage Random Rec tif ier + f ilte r SSR construction How to choose ? Type of loads ? Guy PONCET celduc 2006 29 ISO 9001 N° 1993/1106b ® okpac range 4 Switching Zero Cross SSR AC-51 Heating loads (Non Inductive or slightly inductive loads, resistance furnaces) AC-55b Lamps, Infrared lamps. Switching of incandescent lamps Inrush current No Inrush current ( 8 to 10 times nominal current) No overvoltage No overvoltage SO9 Guy PONCET celduc 2006 SO8 (with In SSR = 8 x In load) 30 ISO 9001 N° 1993/1106b ® okpac range 4 Switching Zero Cross SSR AC-55a Discharges Lamps, Switching of electric discharge lamp controls Inrush current Inrush current ( 8 to 10 times nominal current) Overvoltages One pole asynchronous motors with capacitor (exemple compressor = AC-58) Inrush current ( 8 to 10 times nominal current) Overvoltages SO8 (with In SSR = 8 x In load SO8 (with In SSR = 8 x In load and U SSR = 2 x U mains) Guy PONCET celduc 2006 and U SSR = 2 x U mains) 31 ISO 9001 N° 1993/1106b ® okpac range 4 Switching Random SSR AC-53 : Three pole asynchronous motors AC-56a : Transformers Control of squirrel cage motors with two or three one pole SSRs = up to 100 times nominal current Inrush current = 8 times nominal current ( 8 to 10 times nominal current) Few Overvoltages SO7 (with In SSR =8 x In load) Guy PONCET celduc 2006 Inrush current No overvoltage High Inductive Loads SO7 ! To choose consult celduc SOP possible: (peak turn ON) but on request 32 ® okpac range ISO 9001 N° 1993/1106b Switching 4 Other loads : SSRs for UPS Uninterrupted Power Supply Capacitors for Power Factor Correctors K2 rectifier bypass SSR mains Inverter IGBT High voltage (1600V) Zero Cross SSR with some precautions : SO88xxx K1 user Output SSR Battery Random SSR (S07) high voltage In any case consult celduc for these specific loads Guy PONCET celduc 2006 33 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection Input Input a da pta tion c irc uit INSULATION 5 P rotec tion c irc uit Driving c irc uit P owe r switching device Output D C v ol tage i np u t R Zer o m a ins volta ge switch ON Serial re sistor + re ve rse pr ote ction D C v ol tage i np u t Cur re nt re gulator + voltage prote ction Tria c C RC ne twor k Opto- isola tion Alte rnistor Random m a ins voltage switch ON Bac k to ba ck thyr istor s A C v ol tage i np u t Var istor (VDR) Tra nsils on the ga tes. Tur n ON the SSR in c ase of ove rvoltage Rec tif ier + f ilte r Overvoltage origins EMC standards (*) Solutions SSR construction (*) : EMC = ElectroMagnetic Compatibility. Guy PONCET celduc 2006 34 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection IMMUNITY : (Overvoltages) High Energy overvoltage IEC/EN1000-4-5 (EMC standard) High energy / medium frequency mains overvoltage ORIGIN : Mains voltage LIGHTNINGS In case of overvoltage due to lightnings, the SSR can turn ON without control. The high energy of this overvoltage can damage a SSR ! Guy PONCET celduc 2006 35 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection IEC/EN1000-4-5 Immunity EMC: High Energy overvoltage solutions: VDR : Transils on the gate : Overvoltage clamped by VDR The SSR is turned ON. Mai n s Mai n s VDR Load Load In option for SO9 In option for SO9 In standard for SO7, SO8, SOR. Guy PONCET celduc 2006 36 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection IMMUNITY : (dv/dt) Fast Transient bursts Low energy / high frequency mains overvoltage Mains voltage IEC/EN1000-4-4 (EMC standard) dV/dt during commutations on inductive load Mains voltage dv/dt Time ORIGIN : ORIGIN : Load current ON-->OFF In case of overvoltage or dv/dt due to perturbations on the mains, the SSR can turn ON without control. Generally, the low energy of this overvoltage doesn’t damage the SSR, but during few milliseconds, the load is ON without control (can be acceptable for an heating load, not for a lamp or a motor) Guy PONCET celduc 2006 37 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection IEC/EN1000-4-4 Immunity EMC : Fast Transient bursts solution Adding a RC snubber SSR with high immunity components Mai n s R C Load In option for SO9 In standard for SO7 (Inductive loads) SO8 use high immunity components. So RC is not necessary (except for some inductive loads where random SO7 range with RC is adapted) Guy PONCET celduc 2006 38 ISO 9001 N° 1993/1106b ® okpac range Voltage Protection Other Type of overvoltages Overvoltages due to the loads Hi gh e n ergy / l on g du rati on ove rvol tage s O RIGINS : Afte r tu rn O FF Use SSRs with adapted voltages : µF celduc : up to 1600V S S R voltage Nomi n al mai n s vol tage Guy PONCET celduc 2006 39 ISO 9001 N° 1993/1106b ® okpac range okpac with output status yellow celduc Patented ! Guy PONCET celduc 2006 40 ® okpac range ISO 9001 N° 1993/1106b okpac with status celduc Patented ! Mains ON No M ains or fus e ope n Mains Failure Load Failure SSR Failure Control O FF Load current O pe n C l ose d Status output t o1 t o2 Short-circuit S SR OPEN LOAD t on t c1 t off t o1 t o2 t c2 t o1 t o2 t c1 C on trol LED S tatu s LED Guy PONCET celduc 2006 41 ® okpac range ISO 9001 N° 1993/1106b okpac with status Status output is normally closed without failure on the mains, the relay and/or the load . The yellow LED is switched ON In case of failure on the mains (missed), the load (opened) or on the SSR (short-circuited), the status is opened . status The yellow LED is switched OFF. Advantages : • No power supply required • Outputs Status can be chained Guy PONCET celduc 2006 status celduc Patented ! 42 ISO 9001 N° 1993/1106b Complete ® okpac range Guy PONCET celduc 2006 43 ISO 9001 N° 1993/1106b ® okpac o Market Entry SO9 range for resistive loads With input current regulator Input resistor = Lower price Output voltage Output current Vpeak (V) Control Voltage Type Reference 12-280VAC 12A 600V 3-32VDC zero cross 12-280VAC 25A 600V 3-32VDC zero cross 12-280VAC 50A 600V 3-32VDC zero cross 24-600VAC 35A 1200V 3.5-32VDC zero cross 24-600VAC 50A 1200V 3.5-32VDC zero cross 24-600VAC 75A 1200V 3.5-32VDC zero cross SO941460 SO942460 SO945460 SO963460 SO965460 SO967460 12-280VAC 25A 600V 7-30VDC zero cross 12-280VAC 35A 600V 8-30VDC zero cross 12-280VAC 50A 600V 8-30VDC zero cross 24-600VAC 75A 1200V Flaps on request : Minimum 1 flap for power . Normally not necessary for DC control 8-30VDC zero cross SO942560 SO963560 SO965560 SO967560 Output VDR on request Guy PONCET celduc 2006 44 okpac® range Output voltage o SO8 range for most of loads Universal Output current ISO 9001 N° 1993/1106b Vpeak (V) Control Voltage Type Reference 3-32VDC zero cross SO842074 SO842974 SO843070 SO843970 SO845070 SO847070 SO848070 SO849070 SO863070 SO863970 SO865070 SO865970 SO867070 SO867970 SO868070 SO868970 SO869070 SO869970 12-275VAC 25A 600V 12-275VAC 25A 600V 12-275VAC 35A 600V 12-275VAC 35A 600V 12-275VAC 50A 600V 3-32VDC zero cross 12-275VAC 75A 600V 3-32VDC zero cross 12-275VAC 95A 600V 3-32VDC zero cross 12-275VAC 125A 600V 3-32VDC zero cross 24-510VAC 35A 1200V 3.5-32VDC zero cross 24-510VAC 35A 1200V 24-510VAC 50A 1200V 24-510VAC 50A 1200V 24-510VAC 75A 1200V 24-510VAC 75A 1200V 24-510VAC 95A 1200V 24-510VAC 95A 1200V 24-510VAC 125A 1200V 24-510VAC 125A 1200V 20-265VAC/DC zero cross 3-32VDC zero cross 20-265VAC/DC zero cross 20-265VAC/DC zero cross 3.5-32VDC zero cross 20-265VAC/DC zero cross 3.5-32VDC zero cross 20-265VAC/DC zero cross 3.5-32VDC zero cross 20-265VAC/DC zero cross 3.5-32VDC zero cross 20-265VAC/DC zero cross Guy PONCET celduc 2006 45 ® okpac range ISO 9001 N° 1993/1106b o SO8 range 1600 Volts High voltage range Output voltage Output current Vpeak (V) Control Voltage Type Reference 24-690VAC 50A 1600V 3.5-32VDC zero cross 24-690VAC 75A 1600V 3.5-32VDC zero cross 24-690VAC 95A 1600V 3.5-32VDC zero cross 24-690VAC 125A 1600V 3.5-32VDC zero cross SO885060 SO887060 SO888060 SO889060 Guy PONCET celduc 2006 46 ® okpac range ISO 9001 N° 1993/1106b o Random SO7 range Random range Output voltage Output current Vpeak (V) Control Voltage Type Reference 12-275VAC 50A 600V 3-32VDC Random 12-275VAC 75A 600V 3-32VDC Random 24-510VAC 35A 1200V 3.5-32VDC Random 24-510VAC 50A 1200V 3.5-32VDC Random 24-510VAC 75A 1200V 3.5-32VDC Random 24-510VAC 95A 1200V 3.5-32VDC Random 24-510VAC 125A 1200V 3.5-32VDC Random SO745090 SO747090 SO763090 SO765090 SO767090 SO768090 SO769090 Guy PONCET celduc 2006 47 ® okpac range ISO 9001 N° 1993/1106b o SOD range Diagnostic Range with Diagnostic Output voltage Output current Vpeak (V) Control Voltage Type Reference SOD843180 SOD845180 SOD865180 SOD867180 70-275VAC 35A 600V 7-30 VDC zero cross 70-275VAC 50A 600V 7-30 VDC zero cross 150-510VAC 50A 1200V 7-30 VDC zero cross 150-510VAC 75A 1200V 7-30 VDC zero cross Guy PONCET celduc 2006 48 ® okpac range ISO 9001 N° 1993/1106b o Input connector SOR range Range with Input connector Output voltage Output current Vpeak (V) Control Voltage Type Reference 3-32 VDC zero cross 3.5-32 VDC zero cross SOR842074 SOR863070 SOR865070 SOR867070 12-275VAC 25A 600V 24-510VAC 35A 1200V 24-510VAC 50A 1200V 3,5-32 VDC zero cross 24-510VAC 75A 1200V 3,5-32 VDC zero cross Guy PONCET celduc 2006 49 ISO 9001 N° 1993/1106b ® okpac range ACCESSORIES Heatsinks : New versions Thermal pads Flaps WF151200 WF108100 for SO9 Power terminals Standard model : 5TH21000 or With adhesive on the SSRs base Guy PONCET celduc 2006 50 ® ISO 9001 N° 1993/1106b okpac range NEW THERMAL PADs 5THxxxx thermal PAD is a thermally conductive phase change material coated on both sides of aluminium foil. At temperatures greater than 52°C, 5THxxxx changes into a molten state and, under low closure force, wets the heat sink and component surfaces to create a very thin, low thermal resistance interface. 5THxxxx has great heat spreading characteristics and won’t flow from the interface. 5THxxxx has superior thermal performance comparable to the highest performing grease and phase change products available Guy PONCET celduc 2006 51