Protection devices
3RB24 solid-state overload relay for IO-Link
Manual • 12/2011
Industrial Controls
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3RB24 solid-state overload relay for IO-
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SIRIUS industrial controls
Protection devices
3RB24 solid-state overload relay for
IO-Link
Manual
12/2011
GWA 4NEB 969 1656-02 DS 02
Introduction
1
Safety information
2
Product description
3
Use planning
4
Configuring
5
Parameters
6
Process image of outputs
(PIQ) and inputs (PII)
7
Mounting/removal
8
Connecting
9
Operation
10
Diagnostics
11
Appendix
A
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 3ZX1012-0RB24-0AC0
Ⓟ 12/2011 Technical data subject to change
Copyright © Siemens AG 2011.
All rights reserved
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 5
Table of contents
1 Introduction...................................................................................................................................9
2 Safety information .......................................................................................................................11
3 Product description......................................................................................................................15
3.1 Properties .............................................................................................................................. 15
3.2 System structure .................................................................................................................... 16
3.3 Functions ............................................................................................................................... 17
3.4 Operator controls and display elements.................................................................................. 21
3.5 System components............................................................................................................... 23
3.6 Accessories............................................................................................................................ 26
3.7 Technical data........................................................................................................................ 30
3.7.1 3RB24 evaluation unit ............................................................................................................ 30
3.7.2 3RB29 current measuring module .......................................................................................... 36
4 Use planning...............................................................................................................................39
4.1 Applications............................................................................................................................ 39
4.2 Special application cases ....................................................................................................... 40
5 Configuring.................................................................................................................................43
5.1 Configuring in STEP 7............................................................................................................ 43
5.1.1 Requirements......................................................................................................................... 43
5.1.2 Configuration with STEP 7 and S7-PCT.................................................................................. 44
5.1.3 Configuration with STEP 7 and S7-PCT (GSD version)........................................................... 45
5.2 Configuring without STEP 7.................................................................................................... 46
5.2.1 Requirements......................................................................................................................... 46
5.2.2 Configuring without STEP 7.................................................................................................... 47
5.3 Module replacement............................................................................................................... 48
5.3.1 Module replacement (replacement of an IO-Link device)......................................................... 48
5.3.2 Module replacement with PG/PC............................................................................................ 48
5.3.3 Module replacement without PG/PC ....................................................................................... 49
5.4 Integration into the SIMATIC environment (3RB24)................................................................. 50
6 Parameters.................................................................................................................................51
6.1 Parameters ............................................................................................................................ 51
6.2 "Cold start" parameter ............................................................................................................ 52
6.3 "Ground fault detection" parameter......................................................................................... 53
6.4 "Rated operational current" parameter.................................................................................... 54
6.5 "Trip class [CLASS]" parameter.............................................................................................. 54
Table of contents
3RB24 solid-state overload relay for IO-Link
6 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
6.6 "Response to overload - thermal motor model" parameter .......................................................55
6.7 "Response to overload - thermistor" parameter........................................................................55
6.8 "Thermistor - monitoring" parameter........................................................................................55
6.9 Operation with operator panel .................................................................................................56
6.9.1 "Operator panel available" parameter ......................................................................................56
6.9.2 Parameter "Operation at Preset <> Actual Operation"..............................................................56
7 Process image of outputs (PIQ) and inputs (PII) ............................................................................. 59
8 Mounting/removal ....................................................................................................................... 63
8.1 Mounting options.....................................................................................................................63
8.2 Mounting position ....................................................................................................................63
8.3 Snapping onto/off DIN rail (snap-on mounting) ........................................................................64
8.4 Screw mounting ......................................................................................................................65
8.5 Mounting the sealing cover......................................................................................................65
8.6 Inserting the interface cover ....................................................................................................66
8.7 Installing an operator panel .....................................................................................................67
9 Connecting................................................................................................................................. 69
9.1 Connection via terminals .........................................................................................................69
9.2 Connecting the solid-state overload relay for IO-Link ...............................................................75
10 Operation................................................................................................................................... 79
10.1 Setting the current (rated operational current) and trip class ....................................................79
10.2 Activating/deactivating thermistor protection ............................................................................84
10.3 Outputting an analog signal.....................................................................................................85
10.4 Carrying out self-test ...............................................................................................................86
10.5 Performing a reset...................................................................................................................89
10.5.1 Manual reset ...........................................................................................................................91
10.5.2 Automatic reset .......................................................................................................................92
10.6 Operation using the operator panel..........................................................................................94
11 Diagnostics ...............................................................................................................................101
11.1 Indication of the operating state.............................................................................................101
11.2 Auxiliary contacts ..................................................................................................................103
11.3 Fault codes (only in the case of non-acknowledgeable faults)................................................104
11.4 IO-Link diagnostics................................................................................................................106
A Appendix ..................................................................................................................................109
A.1 Dimension drawings (dimensions in mm)...............................................................................109
A.1.1 Current measuring module ....................................................................................................111
A.1.1.1 Current measuring module 3RB2906-2BG1 and 3RB2906-2DG1 ..........................................111
A.1.1.2 Current measuring module 3RB2906-2JG1 ...........................................................................112
A.1.1.3 Current measuring module 3RB2956-2TG2...........................................................................113
Table of contents
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 7
A.1.1.4 Current measuring module 3RB2956-2TH2 ...........................................................................114
A.1.1.5 Current measuring module 3RB2966-2WH2..........................................................................115
A.2 Circuit diagrams ....................................................................................................................116
A.2.1 Internal circuit diagram ..........................................................................................................116
A.2.2 Sample circuit diagrams ........................................................................................................117
A.3 Data sets...............................................................................................................................120
A.3.1 Structure of the data sets.......................................................................................................120
A.3.2 IO-Link communication parameters .......................................................................................121
A.3.3 Identification data ..................................................................................................................122
A.3.4 Diagnostics - data set (index) 92............................................................................................123
A.3.5 Measured value - data set (index) 94.....................................................................................125
A.3.6 Preset configuration - data set (index) 130.............................................................................126
A.3.7 Technology functions - data set (index) 131...........................................................................127
A.4 References............................................................................................................................129
A.5 Correction sheet....................................................................................................................130
Index ....................................................................................................................................... 131
Table of contents
3RB24 solid-state overload relay for IO-Link
8 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 9
Introduction 1
Purpose of the manual
This manual describes the 3RB24 solid-state overload relay for IO-Link. The manual
supplies the following information:
● Information for integrating the solid-state overload relay into the system environment.
● Information about the necessary hardware and software components.
● Information about the parameters that can be set on the overload relay or via the IO-Link.
● Information on installing, connecting and operating the overload relay.
● Technical information such as dimension drawings, device circuit diagrams and data sets
in the appendix.
The information in this manual enables you to configure, commission and diagnose the
3RB24 solid-state overload relay.
Required basic knowledge
To understand these operating instructions you should have a general knowledge of
automation engineering and low-voltage switchgear.
Scope of the manual
This manual is valid for the 3RB24 solid-state overload relay for IO-Link. It describes the
components that are valid at the time of publication.
Further documentation
To install and connect the current measuring module, you require the operating instructions
of the current measuring module used. For additional information on the Siemens IO-Link
masters, please refer to the respective manuals for the electronic modules 4SI IO-Link and
4SI SIRIUS (IP20) and ET 200eco PN (IP65).
The Appendix "References (Page 129)" has a list of the operating instructions.
Recycling and disposal
The 3RB24 solid-state overload relays for IO-Link can be recycled, as they are low in
pollutants. For environmentally-friendly recycling and disposal of your electronic waste,
please contact a company certified for the disposal of electronic waste.
Introduction
3RB24 solid-state overload relay for IO-Link
10 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Up-to-the-minute information
You can obtain further assistance by calling the following numbers:
Technical Assistance:
Phone: +49 (0) 911-895-5900 (8 a.m. to 5 p.m. CET)
Fax: +49 (0) 911-895-5907
or on the Internet at:
E-mail: (mailto:technical-assistance@siemens.com)
Internet: (www.siemens.com/industrial-controls/technical-assistance)
Correction sheet
A correction sheet is included at the end of the manual. Please use it to record your
suggestions for improvements, additions and corrections, and return the sheet to us. This will
help us to improve the next edition of the manual.
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 11
Safety information 2
Working on the system
DANGER
Hazardous voltage!
Will cause death or serious injury.
Turn off and lock out power before working on this equipment.
Restricted touch protection
DANGER
Restricted touch protection!
Will cause death or serious injury.
The 3RB24 overload relay for IO-Link corresponds to degree of protection in accordance
with IP20 (IEC 60529) and is safe to touch in accordance with DIN VDE 0106, Part 100.
Touching the terminals can result in an electric shock.
Commissioning and maintenance must be carried out by qualified personnel only.
Cover the terminals of the current measuring module (size S6 and S10 / S12) with the
appropriate terminal covers.
Safety information
3RB24 solid-state overload relay for IO-Link
12 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Intended use
WARNING
Intended use
Can Cause Death, Serious Injury, or Property Damage.
The devices may only be used for the applications described in the catalog and the
technical description, and only in conjunction with equipment or components from other
manufacturers which have been approved or recommended by Siemens.
This product can function correctly and reliably only if it is transported, stored, assembled,
and installed correctly, and operated and maintained as recommended.
Before you run any sample programs or programs that you have written yourself, make
sure that running the plant cannot cause injury to anyone else or damage to the machine
itself.
EU note: Start-up/commissioning is absolutely prohibited until it has been ensured that the
machine in which the component described here is to be installed fulfills the
regulations/specifications of Machinery Directive 89/392/EEC.
Important note for maintaining the operational safety of your system
WARNING
Hazardous voltage!
Can Cause Death, Serious Injury, or Property Damage.
Please take note of our latest information
Systems with safety-related characteristics are subject to special operational safety
requirements on the part of the operator. The supplier is also obliged to comply with certain
actions when monitoring the product. For this reason, we publish a special newsletter
containing information on product developments and features that are (or could be) relevant
to operation of safety-related systems. You should subscribe to the corresponding
newsletter in order to obtain the latest information and to allow you to modify your plant
accordingly. Please go to the Internet
(http://www.automation.siemens.com/WW/newsletter/guiThemes2Select.aspx?subjectID=2
&lang=en)
There, you can register for the following newsletter:
• IO-Link (in the Automation folder).
To receive this newsletter, select the "Updates" check box.
Safety information
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 13
ESD guidelines
ESD components are destroyed by voltage and energy far below the limits of human
perception. Voltages of this kind occur as soon as a device or an assembly is touched by a
person who is not electrostatically discharged. ESD components which have been subject to
such voltage are usually not recognized immediately as being defective, because the
malfunction does not occur until after a longer period of operation.
CAUTION
Damage to the solid-state overload relay from electrostatic charging!
The solid-state overload relay contains components that are sensitive to electrostatic
discharge. These components will be destroyed or damaged by incorrect handling.
Observe ESD guidelines when handling and installing the devices.
Connection is only permitted when the power adapters have been deactivated (PELV
power adapter in accordance with IEC EN 50178).
• You must discharge your body electrostatically immediately before touching an
electronic component. To do this, touch a conductive, grounded object, e.g., a bare
metal part of a switch cabinet or the water pipe.
• Always hold the component by the plastic enclosure.
• Electronic modules should not be brought into contact with electrically insulating
materials such as plastic film, plastic parts, insulating table supports or clothing made of
synthetic fibers.
• Always place electrostatic sensitive devices on conductive bases.
• Always store and transport electronic modules or components in ESD-safe conductive
packaging, e.g. metallized plastic or metal containers. Leave the component in its
packaging until installation.
Safety information
3RB24 solid-state overload relay for IO-Link
14 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 15
Product description 3
3.1 Properties
Solid-state overload relay for IO-Link
The solid-state overload relay, comprising the 3RB24 evaluation module and a
3RB29 current measuring module, protects electrical equipment (e.g. three-phase motors)
with two different protection mechanisms: overload protection and thermistor protection.
Ground fault detection can also be enabled via IO-Link.
In conjunction with the 3RT contactors, the solid-state overload relay for IO-Link can be used
as a direct-on-line starter, reversing starter or, with the help of an additional circuit, as a star-
delta (wye-delta) starter. It is possible to read out diagnostics data, such as the current, via
IO-Link and to further process this data in the higher-level controller.
Product description
3.2 System structure
3RB24 solid-state overload relay for IO-Link
16 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3.2 System structure
Device concept
The 3RB24 solid-state overload relay has a modular device concept. Each device consists of
a motor-current-independent evaluation module, and a motor-current-dependent current
measuring module. Both modules are connected electrically to each other by connecting
cable via the interface.
Optionally, the 3RA6935-0A operator panel can be connected to the front of the evaluation
module.
Requirements
You require the following tools for system setup:
● 1 x evaluation module 3RB2483-4A .1
● 1 x current measuring module 3RB29.6-2...
● 1 x connecting cable 3RB2987-2.
Note
The connecting cable 3RB2987-2B for linking the evaluation module and the current
measuring module is only to be used when the evaluation module is mounted direct on
the current measuring module.
System structure
The following graphic illustrates the design principle of a system.
...
3
1
2
① Evaluation module 3RB2483-4A .1
② Current measuring module 3RB29.6-2...
③ Connecting cable 3RB2987-2.
Figure 3-1 System structure
You can find information on the evaluation module, current measuring module, and
connecting cables in the Chapter "Accessories (Page 26)".
Product description
3.3 Functions
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 17
3.3 Functions
Overview of the basic functions
The 3RB24 solid-state overload relay for IO-Link offers the following basic functions:
Protective function:
● Current-dependent protection of loads against overload
● Current-dependent protection of loads against phase asymmetry
● Current-dependent protection of loads against phase failure
● Cold conductor (PTC) sensor circuit (thermistor protection)
● Protection of loads against incomplete ground faults
Motor starter function:
● Control of the relay contacts for operating the connected contactors via IO-Link
Diagnostics and monitoring:
● Output of an analog signal DC 4 mA to DC 20 mA as an image of the flowing motor
current
● Diagnostics via IO-Link for further processing in the higher-level controller, e.g. device
status with regard to protective functions, parameterization and transfer of the measured
current value
Note
Fuses or circuit breakers must be used for short-circuit protection.
Product description
3.3 Functions
3RB24 solid-state overload relay for IO-Link
18 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Overload protection/phase asymmetry/phase failure
The 3RB24 solid-state overload relays for IO-Link are modular in design and are supplied
with power via the IO-Link master. The associated 3RB29 current measuring modules can
be ordered in different sizes and cover a current range of 0.3 to 630 A. This means the right
current measuring module can be selected for every application. A current setting up to
820 A is possible in conjunction with a series transformer. The solid-state overload relays
have been designed to provide current-dependent protection for loads with normal starting
and heavy starting against impermissibly high temperature rises due to overload, phase
asymmetry or phase failure. The devices can be used as direct-on-line starters, reversing
starters or, with the help of an additional circuit, as star-delta (wye-delta) starters.
Overload, phase asymmetry or phase failure results in an increase of the motor current
beyond the set rated operational current of the motor. This increase in current is detected
using a current measuring module, and electronically analyzed by a connected 3RB24
evaluation module. The evaluation electronics send a signal to the auxiliary contacts. The
auxiliary contacts then disconnect the contactor and the load. The break time depends on
the ratio of the tripping current to the rated operational current Ie and is stored in the form of
a tripping characteristic with long-term stability (see Setting the current (rated operational
current) and trip class (Page 79)).
The status "Tripped" is signaled by an "OVERLOAD" LED showing a permanently red light
and a "DEVICE / IO-Link" LED showing a permanently red light. The "OVERLOAD" LED
flickers to indicate an imminent relay trip following violation of a limit current resulting from
overload, phase asymmetry or phase failure. This overload warning is reported as a general
warning via the IO-Link to the higher-level controller.
If, after a tripping operation, the voltage supply of the overload relay is interrupted within the
recovery time of 3 minutes, the time starts again when the supply is restored, and a period of
3 minutes must elapse before the device is ready for service again.
Thermistor protection
The 3RB24 solid-state overload relays for IO-Link offer the option of direct temperature
monitoring of the motor windings. Full motor protection is implemented by connection of a
cold conductor (PTC) sensor circuit monitored for short-circuit and wire break.
With this temperature-dependent protection, the loads can be protected against
overtemperature resulting indirectly from restricted coolant flow, for example, and
undetectable by current measurement. In the case of overtemperature, the devices shut
down the contactor and thus the loads via the auxiliary contact.
The status "Tripped" is signaled by a "THERMISTOR" LED showing a permanently red light
and a "DEVICE / IO-Link" LED showing a permanently red light.
NOTICE
To guarantee sure functioning of the short-circuit detection in the thermistor circuit, the line
resistance must not exceed 10 Ω in the case of a short-circuited thermistor.
Product description
3.3 Functions
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 19
Ground fault protection
To also protect the loads against high-resistance short circuits due to damage to the
insulation, humidity or condensation the solid-state overload relays for IO-Link offer the
possibility of internal ground fault detection.
Note
Internal ground fault detection is not possible in conjunction with contactor assemblies for
star-delta (wye-delta) start.
In the event of a ground fault, the relays trip instantaneously.
The "Tripped" status is signaled by means of a "GND FAULT" LED showing a permanently
red light and a "DEVICE / IO-Link" LED showing a permanently red light, and it can also be
signaled via IO-Link.
Ground fault detection can be enabled or parameterized in the solid-state overload relay
when using with motors with 3-conductor connection (without N connection). Ground fault
detection is disabled in the delivery state.
Self-monitoring
The 3RB24 solid-state overload relay for IO-Link has a self-monitoring feature. The overload
relay constantly monitors its own basic functions and trips if an internal fault is detected.
Electrical interlock
The electrical interlock prevents simultaneous selection of direction of rotation 1 and
direction of rotation 2. If direction of rotation 1 and direction of rotation 2 are selected
simultaneously, the overload relay outputs a process image error.
The switchover time is the time provided for changing the direction of rotation. The
switchover time is 0.5 s and cannot be parameterized. The electrical interlock is also active
during the switchover time, in other words, selection of a direction of rotation only becomes
effective 0.5 s after revoking a selection signal for the other direction of rotation.
Product description
3.3 Functions
3RB24 solid-state overload relay for IO-Link
20 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Residual current detection
The 3RB24 solid-state overload relay for IO-Link has internal residual current detection and
checks for a current-free state with regard to an active or non-active control command. If not,
the device switches off and signals a fault.
A current flow is detected if the current is greater than 12% of the rated operational current.
Detection takes place 1.5 s after switching the overload relay on or off.
The table below represents the different states.
Table 3- 1 Residual current detection
Switch-on command … Current flow … Response/state Message
pending detected Device ready for service No fault message
pending not detected Residual current tripping Fault message and shutdown of the
auxiliary contacts
not pending detected Switching element defective Fault message (no further response
possible)
not pending not detected Device ready for service No fault message
You can find further information on residual current detection in the Chapter "IO-Link
diagnostics (Page 106)".
Product description
3.4 Operator controls and display elements
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 21
3.4 Operator controls and display elements
Equipment features of the evaluation module
OVERLOAD
RESET
MAN
AUTO
Y1 T1
CLASS/I
I(-)
T2
I(+)
L+
SIRIUS
DEVICE /
IO-LINK
GND FAULT
THERMISTOR
3RB2483-4AA1
G/JJMMTT *Exx*
10
20 30
40
50
60
70
80
90
100
15
x I
MAX
%
20
10
5
30
20
10 5 30 20
10
5
30
10
5
30
20
1
0
0
A
1
0
0
0
A
A
0
1
1
A
TEST/
RESET
Y2
MAX
C/Q L-
96 9895
96 95 98
Q1
Q2
5$$RQO\
① Interface for operator panel:
Enables connection of the 3RA6935-0A operator panel (optional accessory).
② Rotary switches for rated operational current and trip class:
With the two rotary switches, you set the overload relay to the rated operational current of the
motor and the required trip class depending on the startup conditions.
③ Connecting terminals (removable joint block):
The generously dimensioned terminals permit connection of two conductors with different
cross-sections for the auxiliary circuits, control circuits, and sensor circuits. Connection is
possible using screw terminals or spring-loaded terminals.
④ Interface for current measuring module:
Enables the connection of a current measuring module (device required for system setup).
⑤ TEST/RESET button:
Enables self-testing of all important device components and device functions as well as
resetting of the device after a trip when manual RESET is selected.
⑥ Slide switch for AUTO/MAN-RESET:
Enables selection between manual and automatic reset.
Automatic reset is only possible after overload tripping and thermistor tripping.
⑦ Red "OVERLOAD" LED:
A continuous red light signals an active overload trip; a flickering red light signals an imminent
trip (overload warning).
⑧ Red "THERMISTOR" LED:
A continuous red light signals an active thermistor trip.
⑨ Red "GND FAULT" LED:
A continuous red light signals an active ground fault trip.
Product description
3.4 Operator controls and display elements
3RB24 solid-state overload relay for IO-Link
22 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
⑩ Green "DEVICE/IO-LINK" LED:
A continuous green light signals that the device is working correctly; an interrupted continuous
light (interrupted for 200 ms every 3 s) indicates communication via IO-Link.
Continuous red light indicates a trip or a fault.
You can find more information in Chapter "Fault codes (only in the case of non-
acknowledgeable faults) (Page 104)" and Chapter "IO-Link diagnostics (Page 106)".
Figure 3-2 Operator controls and display elements of the evaluation module
Note
Connection of the solid-state overload relay for IO-Link is described in Chapter "Connecting
(Page 69)".
Product description
3.5 System components
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 23
3.5 System components
The necessary components for setting up a system are described in Chapter "System
structure (Page 16)".
The components below can be ordered individually using the order numbers.
Table 3- 2 Scope of supply of the solid-state overload relay for IO-Link
Order number Scope of supply Image
3RB2483-4AA1 Solid-state overload relay for
IO-Link:
1 x evaluation module with screw-
type terminals
3RB2483-4AC1 Solid-state overload relay for
IO-Link:
1 x evaluation module with spring-
loaded terminals
3RB2906-2BG1 1 x current measuring module
(0.3 to 3 A)
3RB2906-2DG1 1 x current measuring module
(2.4 to 25 A)
Product description
3.5 System components
3RB24 solid-state overload relay for IO-Link
24 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Order number Scope of supply Image
3RB2906-2JG1 1 x current measuring module
(10 to 100 A)
3RB2956-2TG2 1 x current measuring module
(20 to 200 A) for contactors of
size S6 with box terminals
3RB2956-2TH2 1 x current measuring module
(20 to 200 A) for contactors of
size S6 with busbar connection
3RB2966-2WH2 1 x current measuring module
(63 to 630 A)
3UF1868-3GA00 1 x series transformer
(820 A / 1 A)
Product description
3.5 System components
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 25
Order number Scope of supply Image
3RB2987-2B 1 x connecting cable for linking the
evaluation module and the current
measuring module (length 0.1 m);
only for the following current
measuring modules:
3RB2906-2BG1, 3RB2906-2DG1,
3RB2906-2JG1
3RB2987-2D 1 x connecting cable for linking the
evaluation module and the current
measuring module (length 0.5 m);
Note
The connecting cable 3RB2987-2B for linking the evaluation module and the current
measuring module is only to be used when the evaluation module is mounted direct on the
current measuring module.
Product description
3.6 Accessories
3RB24 solid-state overload relay for IO-Link
26 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3.6 Accessories
Accessories for the evaluation modules
In addition, you can order the following components for the evaluation module:
Table 3- 3 Accessories for the evaluation module
Order number Components supplied Image
3RP1903 Push-in lugs for screw mounting
3RB2984-2 Sealable cover
Product description
3.6 Accessories
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 27
Accessories for the current measuring modules
In addition, you can order the following components for the current measuring modules:
● Box terminal blocks (for devices of size S6 and S10/S12).
● Terminal covers (for devices of size S6 and S10/S12).
● Push-in lugs for screw mounting (for devices of size S00 to S3).
Table 3- 4 Accessories for the current measuring module
Order number Components supplied Image
3RB1900-0B Push-in lug for screw mounting (two per
module required)
Box terminal blocks
3RT1956-4G Box terminal blocks for ribbon cable
conductors to 120 mm2 (size S6)
3RT1966-4G Box terminal blocks for ribbon cable
conductors to 240 mm2 (size S10/S12)
Terminal covers
3RT1956-4EA1 Cover for cable lug and busbar connection,
length 100 mm (size S6)
3RT1966-4EA1 Cover for cable lug and busbar connection,
length 120 mm (size S10/12)
Product description
3.6 Accessories
3RB24 solid-state overload relay for IO-Link
28 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Order number Components supplied Image
3RT1956-4EA2 Cover for box terminals, length 25 mm
(size S6)
3RT1966-4EA2 Cover for box terminals, length 30 mm
(size S10/12)
3RT1956-4EA3 Cover for screw-type connection between
contactor and overload relay, without box
terminals (one required per combination)
(size S6)
3RT1966-4EA3 Cover for screw-type connection between
contactor and overload relay, without box
terminals (one required per combination)
(size S10/12)
Product description
3.6 Accessories
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 29
Operator panel
The 3RB24 solid-state overload relay for IO-Link is controlled in manual mode with the
operator panel. The device statuses are also scanned. The operator panel is connected to
the front interface of the solid-state overload relay via the 10-core to 10-core connecting
cable. If the voltage supply is present via IO-Link, an additional voltage supply is not
required.
You can find more information on using the operator panel in Chapter "Operation using the
operator panel (Page 94)".
Table 3- 5 Scope of supply of operator panel
Order number Scope of supply Image
3RA6935-0A 1 x operator panel
1 x enabling module
1 x interface cover
4 x mounting bracket
Table 3- 6 Accessories operator panel
Order number Scope of supply Image
3UF7933-0BA00-0 1 x connecting cable 10-core to
10-core, length 2.5 m (round) for
operator panel
3RA6936-0A 1 x enabling module
3RA6936-0B 5 x interface cover
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
30 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3.7 Technical data
3.7.1 3RB24 evaluation unit
General technical data
Order number 3RB2483-4AA1 3RB2483-4AC1
Product brand name SIRIUS
Product designation Solid-state overload relay for IO-Link
IP degree of protection front IP20
Insulation voltage at pollution degree 3,
rated value
300 V
Installation altitude above sea level Max. 2000 m
Ambient temperature
• During storage -40 °C to +80 °C
• During transport -40 °C to +80 °C
• During operation -25 °C to +60 °C
Relative humidity during operation
• Minimum 10 %
• Maximum 100 %
Immunity to electromagnetic
interference acc. to IEC 60947-1
Corresponds to degree of severity 3
Conducted interference, BURST to
IEC 61000-4-4
2 kV (relay contacts 95-96-98), 1 kV (IO-Link connections, thermistor, remote
reset, analog output) corresponds to degree of severity 3
Conducted interference, SURGE to
IEC 61000-4-5
• Line to ground 2 kV (line to ground) corresponds to degree of severity 3
• Line to line 1 kV (line to line) corresponds to degree of severity 3
Electrostatic discharge in accordance
with IEC 61000-4-2
6 kV contact discharge/8 kV air discharge
Field-related interference to
IEC 61000-4-3
10 V/m
Shock resistance 15 g / 11 ms
Vibration resistance 2 g
Impulse withstand voltage rated value 4000 V
Total power loss, typical 0.5 W
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 31
Order number 3RB2483-4AA1 3RB2483-4AC1
Equipment designation
• In accordance with DIN 40719,
expanded in accordance with
IEC 204-2 and IEC 750
F
• In accordance with DIN EN 61346-2 F
Size of the overload relay S00
Size of the contactor, combinable
company-specifically
S00 ... S12
Protection against ignition Increased safety EEX e
Maximum cable length remote reset On request
Minimum pulse length remote reset
(Y1-Y2)
150 ms
Main circuit
Table 3- 7 Main circuit
Order number 3RB2483-4AA1 3RB2483-4AC1
Tripping class acc. to IEC 60947-4-1 CLASS 5, 10, 20 and 30 adjustable
Number of poles for main circuit 3
Adjustable current response value of
the current-dependent overload release
0.3 A to 630 A
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
32 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Auxiliary circuit
Table 3- 8 Auxiliary circuit
Order number 3RB2483-4AA1 3RB2483-4AC1
Contact reliability of the auxiliary
contacts
Suitability for PLC control (17 V, 5 mA)
Number of NC contacts for auxiliary
contacts
0
Number of NO contacts for auxiliary
contacts1)
1
Number of changeover contacts for
auxiliary contacts1)
1
Operational current of the auxiliary
contacts at DC-13
• At 24 V 2 A
• At 60 V 0.55 A
• At 110 V —
• At 125 V 0.3 A
• At 220 V 0.2 A
Operational current of the auxiliary
contacts at AC-15
• At 24 V 6 A
• At 110 V —
• At 120 V —
• At 125 V 6 A
• At 230 V 3 A
• At 400 V —
1) NO contacts and changeover contacts are switched in series.
Short-circuit protection
Table 3- 9 Short-circuit protection auxiliary circuit
Order number 3RB2483-4AA1 3RB2483-4AC1
Version of the fuse link required for
short-circuit protection of the auxiliary
switch
Fuse gL/gG: 6 A
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 33
Mechanical design
Table 3- 10 Mechanical design
Order number 3RB2483-4AA1 3RB2483-4AC1
Mounting position Any
Installation altitude at maximum height
above sea level
2000 m
Type of mounting • Snap-on mounting:
- Standard mounting rail
- Current measuring module (to size S3)
• Screw-type mounting (accessories 3RP1903)
Width 45 mm
Height 111 mm 113 mm
Depth 95 mm
Distance to be maintained with side-by-
side mounting
• At the top 0 mm
• At the front 0 mm
• At the side 0 mm
• At the rear 0 mm
• At the bottom 0 mm
Distance to be maintained from
grounded parts
• At the top 0 mm
• At the front 0 mm
• At the side 6 mm
• At the rear 0 mm
• At the bottom 0 mm
Distance to be maintained from live
parts
• At the top 0 mm
• At the front 0 mm
• At the side 6 mm
• At the rear 0 mm
• At the bottom 0 mm
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
34 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Connections
Table 3- 11 Connections
Order number 3RB2483-4AA1 3RB2483-4AC1
Connection electrical version Screw-type connection Spring-loaded connection
Product function removable terminal for
auxiliary circuit and control circuit
Yes Yes
Type of connectable conductor cross-sections
Tool ∅ 5 ... 6 mm/PZ 2 3 mm flat-bladed screwdriver
(3.0 x 0.5 mm)
Tightening torque 0.8 to 1.2 Nm
(7 to 10.3 lb in)
—
Solid 1 x (0.5 … 4.0) mm2
2 x (0.5 … 2.5) mm2
2 x (0.25 … 1.5) mm2
Finely stranded without end sleeve — 2 x (0.25 … 1.5) mm2
Finely stranded with end sleeve 1 x (0.5 to 2.5) mm2
2 x (0.5 to 1.5) mm2
2 x (0.25 … 1.5) mm2
AWG cables 2 x (20 to 14) 2 x (24 to 16)
Approvals/certificates
Table 3- 12 Approvals/certificates
Order number 3RB2483-4AA1 3RB2483-4AC1
Certificate of suitability IEC / CSA / UL / CCC
Safety (3RB2483-4A.1 evaluation unit)
Table 3- 13 Safety
Standard Designation Value
IEC 61508 SIL 1
IEC 61508 PFDavg < 3.0 x 10-2
DIN EN 60079-17, Section 4.4 Repeat test —
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 35
IO-Link
Table 3- 14 IO-Link
Order number 3RB2483-4AA1 3RB2483-4AC1
IO-Link transfer rate COM2 (38.4 kbit/s)
IO-Link communication connection Yes
IO-Link protocol supported Yes
Status display for IO-Link
communication
Dual LED green/red
Status display for IO-Link device Dual LED green/red
Voltage supply from IO-Link master
sufficient
Yes
Point-to-point cycle time between the
master and the IO-Link device
2.3 ms1)
Data volume of the address area of the
outputs with cyclic transfer
1 bytes
Data volume of the address area of the
inputs with cyclic transfer
2 bytes
1) 4 cycles are required to exchange a complete message frame (PII and PIO) between the IO-Link master and 3RB24.
This results in a frame transfer time of approx. 10 ms (depending on the corresponding cycle time on the master).
Example:
3RB24 4SI IO-Link 4SI SIRIUS
Point-to-point cycle time between the master and the IO-Link
device
approx. 2.3 ms approx. 3 ms approx. 5 ms
3RB24 + 4SI IO-Link 3RB24 + 4SI SIRIUS
Frame transfer time Approx. 4 x 3 ms Approx. 4 x 5 ms
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
36 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3.7.2 3RB29 current measuring module
Main circuit
Table 3- 15 Main circuit - current measuring module 3RB29..
Type – overload relay current
measuring module
3RB2906 3RB2906 3RB2956 3RB2966
Size S00/S0 S2/S3 S6 S10/S12
Width 45 mm 55 mm 120 mm 145 mm
Rated insulation voltage Ui (pollution
degree 3)
1000 V
Rated impulse withstand
voltage Uimp
6 kV 8 kV
Rated operational voltage Ue 1000 V
Type of current
• Direct current No
• Alternating current Yes, 50/60 Hz ± 5%
Current setting 0.3 ... 3 A;
2.4 ... 25 A
10 to 100 A 20 to 200 A 63 to 630 A
Power loss per device (max.) 0.5 W
Short-circuit protection
• With fuse without contactor You can find more information in the "Reference Manual Protection Equipment -
Overload Relays 3RU1, 3RB2"
(http://support.automation.siemens.com/WW/view/en/35681830) .
• With fuse and contactor You can find more information in the "Configuration Manual SIRIUS Configuration"
(http://support.automation.siemens.com/WW/view/en/40625241).
Protective separation between main
and auxiliary current paths acc. to
IEC/EN 60947-1 (pollution degree 2)
690 V1)
1) For grounded networks, otherwise 600 V.
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 37
Connection of the main circuit
Table 3- 16 Connecting the main circuit - current measuring module 3RB29..
Type – overload relay current
measuring module
3RB2906 3RB2906 3RB2956 3RB2966
Size S00/S0 S2/S3 S6 S10/S12
Width 45 mm 55 mm 120 mm 145 mm
Type of connection Screw with box terminal
• Connection screw
(hexagon socket-head screw)
— 4 mm 5 mm
• Tightening torque — 10 … 12 Nm 20 … 22 Nm
• Conductor cross-sections
(min./max.), 1-wire or 2-wire
- Solid — — —
- Finely stranded
without end sleeve
— with box terminal
3RT1955-4G:
2 x (1 x max. 50,
1 x max. 70) mm2,
1 x (10 ... 70) mm2
with box terminal
3RT1956-4G:
2 x (1 x max. 95,
1 x max. 120) m2,
1 x (10 ... 120) mm2
2 x (50 to 185) mm2
front clamping point only: 1 x
(70 to 240) mm2
rear clamping point only: 1 x
(120 to 185) mm2
- Finely stranded
with end sleeve
— With box terminal
3RT1955-4G:
2 x (1 x max. 50,
1 x max. 70) mm2,
1 x (10 ... 70) mm2
with box terminal
3RT1956-4G:
2 x (1 x max. 95,
1 x max. 120) m2,
1 x (10 ... 120) mm2
2 x (50 to 185) mm2
front clamping point only:
1 x (70 to 240) mm2
rear clamping point only: 1 x
(120 to 185) mm2
- Stranded — With box terminal
3RT1955-4G:
2 x (max. 70) mm2,
1 x (16 ... 70) mm2
with box terminal
3RT1956-4G:
2 x (max. 120) mm2,
1 x (16 ... 120) mm2
2 x (70 to 240) mm2
front clamping point only: 1 x
(95 to 300) mm2
rear clamping point only: 1 x
(120 to 240) mm2
Product description
3.7 Technical data
3RB24 solid-state overload relay for IO-Link
38 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Type – overload relay current
measuring module
3RB2906 3RB2906 3RB2956 3RB2966
Size S00/S0 S2/S3 S6 S10/S12
Width 45 mm 55 mm 120 mm 145 mm
- AWG cables, solid
or stranded
— With box terminal
3RT1955-4G:
AWG 2 x (max. 1/0),
AWG 1 x (6 ... 2/0)
with box terminal
3RT1956-4G:
AWG 2 x (max. 3/0),
AWG 1 x (6 ... 250 kcmil)
2 x (2/0 ... 500 kcmil),
front clamping point only:
1 x (3/0 ... 600 kcmil),
rear clamping point only:
1 x (250 kcmil ... 500 kcmil)
- Ribbon cable
conductors
(number x width
x thickness)
— With box terminal
3RT1955-4G:
2 x (6 x 15.5 x 0.8) mm,
1 x (3 x 9 x 0.8 ... 6 x 15.5
x 0.8) mm
with box terminal
3RT1956-4G:
2 x (10 x 15.5 x 0.8) mm,
1 x (3 x 9 x 0.8 ... 10 x 15.
5 x 0.8) mm
2 x (20 x 24 x 0.5) mm,
1 x (6 x 9 x 0.8 ... 20 x 24 x 0.5)
mm
Type of connection Busbar connection
• Connection screw — M8 x 25 M10 x 30
• Tightening torque — 10 to 14 Nm 14 to 24 Nm
• Conductor cross-sections
(min./max.)
- Solid with cable lug — 16 ... 95 mm2 1) 50 ... 240 mm2 2)
- Stranded with cable
lug
— 25 ... 120 mm2 1) 70 ... 240 mm2 2)
- AWG cables, solid
or stranded with
cable lug
— 4 ... 250 kcmil 2/0 ... 500 kcmil
- With connecting
bars (max. width)
— 15 mm 25 mm
Type of connection Straight-through transformers
Opening diameter 7.5 14 25 mm —
1) When connecting cable lugs in accordance with DIN 46235 for conductor cross-sections from 95 mm2, use the
3RT1956-4EA1 terminal cover to ensure phase spacing.
2) When connecting cable lugs in accordance with DIN 46234 for conductor cross-sections from 240 mm2, as well as
DIN 46235 for cable cross-sections from 185 mm2, use the 3RT1956-4EA1 terminal cover to ensure phase spacing.
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 39
Use planning 4
4.1 Applications
Sectors
The 3RB24 solid-state overload relay for IO-Link is suitable for customers from all industries
who want to ensure optimal current-dependent and temperature-dependent protection of
their electrical loads (such as motors) under normal starting and heavy starting conditions
(CLASS 5 to CLASS 30), and also minimize project runtimes, inventories and energy
consumption, and optimize plant availability and maintenance management.
Application area
The 3RB24 solid-state overload relays for IO-Link have been designed to protect three-
phase asynchronous motors and single-phase AC motors.
In addition to the protective function, these devices can be used in conjunction with
contactors as direct starters or reversing starters (star-delta start also possible) controlled via
IO-Link. This makes it possible to control drives direct via IO-Link from a higher-level
controller, or on-site using the optional hand-held operator panel, and also, for example, to
return current values direct via IO-Link.
If single-phase AC motors are to be protected with the 3RB24 solid-state overload relay for
IO-Link, the main circuits of the current measuring modules must be switched in series.
You can find more information in Chapter "Connecting (Page 69)".
Ambient conditions
The 3RB24 solid-state overload relays for IO-Link are not sensitive to external influences
such as shocks, corrosive ambient conditions, ageing, and temperature fluctuations. The
3RB24 solid-state overload relays compensate temperature in the temperature range from
–25 °C to +60 °C according to IEC/EN 60947-4-1.
You can obtain configuring information for using the devices under -25 °C or over +60 °C on
request on the Internet (www.siemens.com/industrial-controls/technical-assistance).
Use planning
4.2 Special application cases
3RB24 solid-state overload relay for IO-Link
40 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
4.2 Special application cases
Overload relays in contactor assemblies for star-delta (wye-delta) start
When using the 3RB24 solid-state overload relay in conjunction with contactor assemblies
for star-delta (wye-delta) start, you need to bear in mind that only 0.58 times the motor
current flows through the line contactor. The solid-state overload relay mounted onto the line
contactor must be set to this level of 0.58 times the motor current.
Note
When using the 3RB24 solid-state overload relay in conjunction with contactor assemblies
for start-delta (wye-delta) start, internal ground fault detection must not be enabled on the
overload relay.
Overload protection of motors in hazardous environments
The 3RB24 solid-state overload relay for IO-Link with monostable relays is suitable for
overload protection of explosion-proof motors. The device must only be used outside the
hazardous area for protecting explosion-proof electric motors in accordance with
RL94/9/EG Group II of Category 2 and 3 (gas: Zone 1 and 2 or dust : Zone 21 and 22).
NOTICE
When using motors in hazardous environments, the information in the Safety and
commissioning instructions
(http://support.automation.siemens.com/WW/view/en/22712155) must be observed at all
times.
Operation with frequency converter
The 3RB24 solid-state overload relay is suitable for frequencies of 50/60 Hz and their
associated harmonics. This makes it possible to use the solid-state overload relay on the
input side of the frequency converter. If motor protection is required in the outgoing circuit of
the frequency converter, the 3RN thermistor motor protection devices or the 3RU thermal
overload relays are recommended.
Use planning
4.2 Special application cases
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 41
Operation with loads in excess of 630 A rated operational current
The 3RB24 solid-state overload relay for IO-Link can also be used for protecting loads up to
820 A by means of an external 3UF1868-3GA00 current transformer . The secondary cables
of the current transformer are looped through the three feed-through openings of the current
measuring module, and short-circuited. The secondary current of the external current
transformer is the primary current of the 3RB29 current measuring module of the
3RB24 solid-state overload relay. You can find a connection example in the Chapter "Circuit
diagrams (Page 116)".
Other current transformers can also be used for protecting loads with a rated operational
current greater than 630 A. The current transformers used must have the following
characteristics:
● Secondary current: 1 A
● Frequency: 50 Hz/60 Hz
● Recommended transformer rating: ≥ 2.5 VA (depending on the secondary current and
cable length)
● Overcurrent factor: 5P10 or 10P10
● Accuracy class: 1
NOTICE
If the main circuit is using rated current, the secondary current of the current transformer
must be within the setting range of the current measuring module used!
Example
● 3UF1868-3GA00 current transformer:
● Primary: 820 A with rated operational current
● Secondary current: 1 A
● 3RB24 solid-state overload relay with 3RB2906-2BG1 current measuring module with a
setting current of 0.3 A to 3.0 A.
The secondary current of the current transformer is 1 A at rated load and is, therefore, within
the 0.3 to 3.0 A setting range of the current measuring module used. The setting current Ie in
the 3RB24 solid-state overload relay is 1 A.
If the analog value transfer function is used, the transformation ratio must be taken into
account: The transferred value of 1 A corresponds to an actual current of 820 A when using
the external 3UF1868-3GA00 current transformer with a transformation ratio of 820 at rated
operational current.
Use planning
4.2 Special application cases
3RB24 solid-state overload relay for IO-Link
42 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Representation of the current values of the 3RB24 solid-state overload relay for IO-Link (the
actual image may deviate from this example).
Figure 4-1 SIMATIC WINCC flexible 2008 for the 3RB24 solid-state overload relay for IO-Link
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 43
Configuring 5
5.1 Configuring in STEP 7
5.1.1 Requirements
Procedure when configuring IO-Link master and IO-Link device
Configuration takes place in two steps with STEP 7, V5.4 SP5 or higher:
1. In
HW Config
, configure the IO-Link master (with GSD if necessary), e.g. the 4SI SIRIUS
electronics module or 4SI IO-Link (both require at least firmware version 1.0.1).
2. With the Port-Configurator-Tool
S7-PCT (V2.0 or higher)
you configure the connected
solid-state overload relay for IO-Link (IO-Link Device).
Requirements
● STEP 7 V5.4 SP5 or higher
● The Port-Configurator-Tool
S7-PCT
(V2.0 or higher)
is installed on the PG/PC.
You can either install
S7-PCT
together with STEP 7 V5.4 SP5 or higher, or you can
download it from the Internet
(http://support.automation.siemens.com/WW/view/en/33102519/133100).
● The associated IO-Link IODD file (IO Device Description) is installed in
S7-PCT
. You
can download the IODD files for the SIRIUS Devices from the Internet
(http://support.automation.siemens.com/WW/view/en/29801139/133100).
● Optional: The GSD files are installed in HW Config. You can download the GSD files for
the ET 200S from the Internet (http://www.siemens.com/comdec).
● Optional: Install the function block FB ""IOL_CALL" " for backing up/restoring IO-
Link master parameters and IO-Link device parameters.
You can obtain the function block on the Internet
(http://support.automation.siemens.com/WW/view/en/33102519/133100).
You can find further information on the function block in "Module replacement (Page 48)".
Configuring
5.1 Configuring in STEP 7
3RB24 solid-state overload relay for IO-Link
44 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
5.1.2 Configuration with STEP 7 and S7-PCT
Configuring the IO-Link master in
HW Config
1. Start the SIMATIC Manager and configure the project as described in the
STEP 7
online
help.
2. Select the IO-Link master in the hardware catalog of
HW Config
(in the ET 200S or
ET 200eco PN distributed I/O system, for example).
3. Drag-and-drop the IO-Link master from the hardware catalog to the configuration table.
4. Parameterize the IO-Link master.
Configuring the IO-Link device with the Port Configurator Tool
1. In the configuration table, select the IO-Link master (e.g. the 4SI SIRIUS electronics
module).
2. Right-click and select "Launch IO-Link Configurator" in the shortcut menu.
Result:
S7-PCT
is started.
3. Select the SIRIUS 3RB24 overload relay IO-Link in the hardware catalog of the S7-PCT.
4. Load the configuration into the IO-Link master before parameterizing the overload relay.
5. Start by parameterizing the SIRIUS overload relay IO-Link (IO-Link device).
Additional information is available in the
S7-PCT
online help.
Configuring
5.1 Configuring in STEP 7
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 45
5.1.3 Configuration with STEP 7 and S7-PCT (GSD version)
Configuring the IO-Link master in
HW Config
with GSD
1. Start the SIMATIC Manager and configure the project as described in the
STEP 7
online
help.
2. Select the IO-Link master in the hardware catalog of
HW Config
(e.g. in the ET 200S or
ET 200eco PN distributed I/O system).
3. Drag-and-drop the IO-Link master from the hardware catalog to the configuration table.
4. Parameterize the IO-Link master.
Configuring the IO-Link device with the Port Configurator Tool
1. In the configuration table, select the IO-Link master (e.g. the 4SI SIRIUS electronics
module).
2. Right-click and select "Start Device Tool" in the shortcut menu. Click on "S7-PCT" in the
submenu.
Result:
S7-PCT
will be started.
3. Select the SIRIUS 3RB24 overload relay IO-Link in the hardware catalog of the S7-PCT.
4. Load the configuration into the IO-Link master before parameterizing the overload relay.
5. Start by parameterizing the SIRIUS overload relay IO-Link (IO-Link device).
Additional information is available in the
S7-PCT
online help.
Configuring
5.2 Configuring without STEP 7
3RB24 solid-state overload relay for IO-Link
46 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
5.2 Configuring without STEP 7
5.2.1 Requirements
Basic procedure when configuring IO-Link master and IO-Link devices with S7-PCT stand-alone
1. You configure the connected solid-state overload relay (IO-Link device) with the Port
Configurator tool
S7-PCT (V2.0 or higher)
.
Requirements
● The Port Configurator tool
S7-PCT
(V2.0 or higher)
is installed on the PG/PC.
You can either install
S7-PCT
together with STEP 7 V5.4 SP5 or higher, or you can
download it from the Internet
(http://support.automation.siemens.com/WW/view/en/33102519/133100).
● The associated IO-Link IODD file (IO-Link Device Description) is installed in
S7-PCT
. You
can download the IODD files for the SIRIUS devices from the Internet
(http://support.automation.siemens.com/WW/view/en/29801139/133100).
Note
Configuring with S7-PCT Stand-Alone is not possible for the CPU versions of the ET 200.
Configuring
5.2 Configuring without STEP 7
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5.2.2 Configuring without STEP 7
Configuring the IO-Link device with the Port Configurator Tool
1. Start the S7-PCT Port Configurator Tool.
2. Create a new project or open an existing project as described in the online help.
3. Select an IO-Link master.
4. Select the SIRIUS overload relay IO-Link in the hardware catalog of the S7-PCT.
5. Load the configuration into the IO-Link master before parameterizing the overload relay.
6. Start by parameterizing the SIRIUS overload relay IO-Link (IO-Link device).
Additional information is available in the
S7-PCT
online help.
Note
To be able to access the IO-Link master or an IO-Link device online, communication
between the ET 200 and the higher-level controller must be active (BF-LED on ET 200
interface module is off).
Configuring
5.3 Module replacement
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5.3 Module replacement
5.3.1 Module replacement (replacement of an IO-Link device)
Parameter data and configuration data specially optimized for a specific application are
stored in an IO-Link Device. This data deviates in many cases from the default values stored
in the IO-Link Device.
In the event of replacement of an IO-Link Device (referred to below as "module"), the
optimized data must be transferred to the new module.
Data can be transferred via two channels:
● Module replacement with PG/PC
● Module replacement without PG/PC
5.3.2 Module replacement with PG/PC
Procedure
In the event of a replacement, a PG/PC is available with the SIMATIC project of the plant.
With the data stored in the SIMATIC project, and the S7-PCT, you transfer the parameters
belonging to the replaced Device to the new Device.
Configuring
5.3 Module replacement
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5.3.3 Module replacement without PG/PC
Procedure
On completion of commissioning, a PG/PC with the project is no longer available. For
backing up and restoring the parameter data and configuration data from or to a module, the
function block (FB) "IOL_Call" is available for the SIMATIC controllers of the S7-300 and S7-
400 families.
With this function block, you back up all relevant data records of a module after
commissioning, in a data block (DB), for example. In the event of a replacement, you write
the relevant data from the data block to the replaced module with the IOL_Call.
Refer to the Appendix "Data sets (Page 120)" for data records to be backed up in the case of
a module.
Note
An IO-Link Device is a module that communicates with the IO-Link master via its
communication connection. With the special cases "SIRIUS 3RA64/65 compact starter " and
"SIRIUS 3RA2711 function modules", where group formations of up to four starters are
possible, the above information refers to the replacement of the first load feeder.
Replacement of load feeders 2 to 4 of a group of four does not require any supplementary
measures.
Requirements
● Install the demo project "IOL-CALL".
You can download the "IOL-CALL" and the description from the Internet
(http://support.automation.siemens.com/WW/view/en/33102519/133100).
● Copy the IO-Link Call function block FB1 (including data block DB10) to a STEP 7
project.
● Use the IO-Link Call function block FB1 as described in the demo project.
Configuring
5.4 Integration into the SIMATIC environment (3RB24)
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5.4 Integration into the SIMATIC environment (3RB24)
Integration into the SIMATIC environment
Faceplates embedded in a demo project are offered for download for human machine
interfacing and diagnostics for Siemens IO-Link Devices in conjunction with a SIMATIC and
WinCC flexible 2008.
The faceplates can be transferred from the demo project to your own WinCC flexible 2008
project.
Faceplates are available for the process data and the diagnostics data.
You can download the project from the Internet
(http://support.automation.siemens.com/WW/view/en/38006560) free of charge.
Example
Process image for the solid-state overload relay for IO-Link 3RB24 (the actual image may
deviate from this example).
Figure 5-1 SIMATIC WINCC flexible for the solid-state overload relay for IO-Link 3RB24
3RB24 solid-state overload relay for IO-Link
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Parameters 6
6.1 Parameters
Parameters
You can set the following parameters:
via IO-Link on the device
• Cold start
• Ground fault detection
• Operator panel available
• Operation at Preset <> Actual Configuration
• Rated operational current Ie
• Trip class [CLASS]
• Response to overload - thermal motor model
• Response to overload - thermistor
• Thermistor - monitoring
Notes on parameter assignment
Parameter assignment is carried out in two ways.
With the help of the local control elements, the following parameters can be set:
● Rated operational current Ie (rotary switch)
● Trip class [CLASS] (rotary switch)
● Response to overload - thermal motor model (slide switch for AUTO/MAN-RESET)
● Response to overload - thermistor (slide switch for AUTO/MAN-RESET)
● Thermistor - monitoring (TEST/RESET pushbutton)
Parameters
6.2 "Cold start" parameter
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The following parameters can be read out via IO-Link:
● Rated operational current Ie [A]
● Trip class [CLASS]
● Response to overload - thermal motor model
● Response to overload - thermistor
● Thermistor - monitoring
● Cold start
● Ground fault detection
● Operator panel available
● Operation at Preset <> Actual Configuration
This parameter can also be set without connected voltage and is described in detail in
Chapter "Operation (Page 79)".
The parameters accessible via IO-Link are shown below.
6.2 "Cold start" parameter
"Cold start" parameter
The "Cold start" parameter enables startup without connected motor or without main power.
If an ON command is received via the process image ("Motor direction of rotation 1" or
"Motor direction of rotation 2"), the contactor is activated. If the "Cold start" parameter is set
to "Enable", the contactor only remains activated if no current flow is measured.
If a current flow is detected during cold starting (no current flow on the activated contactor), a
fault message appears and the device trips immediately.
The table below shows the values for the "Cold start" parameter.
Table 6- 1 "Cold start" parameter
Value Description Default setting
0 Cold start:Disable Disable
1 Cold start: Enable —
The "Cold start" parameter can only be modified via IO-Link. It cannot be adjusted at the
device.
Parameters
6.3 "Ground fault detection" parameter
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6.3 "Ground fault detection" parameter
"Ground fault detection" parameter
The "Ground fault detection" parameter enables detection of a "ground fault". If the "Ground
fault detection" parameter is enabled, the relays trip instantaneously in the event of a ground
fault.
The table below shows the values for the "Ground fault detection" parameter.
Table 6- 2 "Ground fault detection" parameter
Value Description Default setting
0 Ground fault detection: Disable Disable
1 Ground fault detection: Enable —
The "Ground fault detection" parameter can only be modified via IO-Link if no ground fault
has been detected. It cannot be adjusted at the device.
Tripping characteristic
The following information refers to sinusoidal fault currents of 50/60 Hz. With a motor current
between 0.3 and 2 times the rated operational current Ie, the device trips at a ground fault
current that is 30% of the rated operational current. With a motor current between 2 times
and 8 times the rated operational current Ie, the device trips at a ground fault current that is
15% of the motor current.
The response delay is 0.5 to 1 s.
Imotor
10 x I
e
80,3 1 2 3 4 5 6 7 9
Itrip_GF
0,3
0,6
0,9
1,2
x I
e
Tripping area
IGF Ground fault current
Itrip_GF Tripping current at ground fault
Figure 6-1 Tripping Area (ground fault protection)
Parameters
6.4 "Rated operational current" parameter
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6.4 "Rated operational current" parameter
"Rated operational current Ie" parameter
The "Rated operational current Ie" parameter is set using two rotary switches on the device.
A detailed explanation of the control elements for setting the rated operational current can be
found in Chapter "Setting the current (rated operational current) and trip class (Page 79)".
Note
The absolute value of the rated operational current can be read out via IO-Link for
documentation purposes, for example. This value cannot be set or modified via IO-Link.
6.5 "Trip class [CLASS]" parameter
"Trip class [CLASS]" parameter
The "Trip class [CLASS]" parameter is set using a rotary switch on the device.
A detailed explanation of the control elements for setting the trip class can be found in
Chapter "Setting the current (rated operational current) and trip class (Page 79)".
Note
The set trip class can be read out via IO-Link for documentation purposes, for example. This
value cannot be set or modified via IO-Link.
Parameters
6.6 "Response to overload - thermal motor model" parameter
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6.6 "Response to overload - thermal motor model" parameter
"Response to overload - thermal motor model" parameter
The Response to overload - thermal motor model parameter can only be set using the slide
switch for AUTO/MAN-RESET on the overload relay.
A detailed explanation of the functional principle of automatic and manual resetting can be
found in Chapter "Performing a reset (Page 89)".
Note
The "Response to overload - thermal motor model" parameter can be read out via IO-Link for
documentation purposes, for example. This parameter cannot be set or modified via IO-Link.
6.7 "Response to overload - thermistor" parameter
"Response to overload - thermistor" parameter
The Response to overload - thermistor parameter can only be set using the slide switch for
AUTO/MAN-RESET on the overload relay.
A detailed explanation of the functional principle of automatic and manual resetting can be
found in Chapter "Performing a reset (Page 89)".
Note
The "Response to overload - thermistor" parameter can be read out via IO-Link for
documentation purposes, for example. This parameter cannot be set or modified via IO-Link.
6.8 "Thermistor - monitoring" parameter
"Thermistor - monitoring" parameter
The "Thermistor - monitoring" parameter indicates whether the thermistor protection function
is activated or deactivated.
A detailed explanation of thermistor protection can be found in Chapter
"Activating/deactivating thermistor protection (Page 84)".
Note
The "Thermistor - monitoring" parameter can be read out via IO-Link for documentation
purposes, for example. This parameter cannot be set or modified via IO-Link.
Parameters
6.9 Operation with operator panel
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6.9 Operation with operator panel
6.9.1 "Operator panel available" parameter
With the "Operator panel available" parameter, you determine whether or not an operator
panel is available for operating the solid-state overload relay.
In conjunction with the "Operation at Preset <> Actual Configuration" parameter, operation of
the solid-state overload relay with or without operator panel can be configured (see Chapter
"Parameter "Operation at Preset <> Actual Operation" (Page 56)").
Use of the operator panel is above all useful if manual intervention in an application is an
indispensable requirement for operating the plant, or to enable manual intervention in an
emergency.
The table below shows the values for the "Operator panel available" parameter.
Table 6- 3 "Operator panel available" parameter
Value Description Default setting
0 Operator panel available: No —
1 Operator panel available: Yes Yes
The "Operator panel available" parameter can only be modified via IO-Link. It cannot be
adjusted at the device.
6.9.2 Parameter "Operation at Preset <> Actual Operation"
The "Operation at Preset <> Actual Configuration" parameter sets the severity level of the
test for the "Operator panel available" parameter.
The table below shows the values for the "Operation at Preset <> Actual Configuration"
parameter.
Table 6- 4 "Operation at Preset <> Actual Configuration" parameter
Value Description Default setting
0 Operation at Preset <> Actual
Configuration: Disable
—
1 Operation at Preset <> Actual
Configuration: Enable
Enable
If the value of the "Operation at Preset <> Actual Configuration" parameter is set to "Enable",
the solid-state overload relay can be operated via IO-Link regardless of whether an operator
panel is connected or not.
Parameters
6.9 Operation with operator panel
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If the value of the "Operation at Preset <> Actual Configuration" parameter is set to
"Disable", the solid-state overload relay can only be operated if the setting of the "Operator
panel available" parameter is precisely fulfilled. If the setting of the "Operator panel
available" parameter is not fulfilled, the diagnostics message "Preset <> Actual
Configuration" is output by the controller.
The following table shows the effects of the sample parameter values set:
Table 6- 5 Parameter setting - example of operation with operator panel
Practical implementation
Set parameter values
Operator panel
available
Operator panel not
available
Operator panel is
disconnected during
operation
"Operator panel
available" = "yes" and
"Operation at Preset <>
Actual Configuration =
"Disable"
Operation of the solid-
state overload relay
possible.
Operation of the solid-
state overload relay not
possible.
→ Fault message
"Preset <> Actual
Configuration"
The solid-state
overload relay trips.
Further operation of the
device not possible.
→ Fault message
"Preset <> Actual
Configuration"
"Operator panel
available" = "no" and
"Operation at Preset <>
Actual Configuration =
"Disable"
The solid-state
overload relay trips.
Further operation of the
device not possible.
→ Fault message
"Preset <> Actual
Configuration"
Operation of the solid-
state overload relay
possible.
The group error (SF) is
reset automatically.
Operation of the solid-
state overload relay
possible.
"Operator panel
available" = "yes" and
"Operation at Preset <>
Actual Configuration =
"Enable"
Operation of the solid-
state overload relay
possible.
Operation of the solid-
state overload relay
possible.
Operation of the solid-
state overload relay
possible.
"Operator panel
available" = "no" and
"Operation at Preset <>
Actual Configuration =
"Enable"
Operation of the solid-
state overload relay
possible.
Operation of the solid-
state overload relay
possible.
Operation of the solid-
state overload relay
possible.
The "Operation at Preset <> Actual Configuration" parameter can only be modified via
IO-Link. It cannot be adjusted at the device.
Note
Parameter assignment for "Operation at Preset <> Actual Configuration" refers only to the
connectable operator panel.
By contrast, the diagnostics message "Preset <> Actual Configuration" can have different
causes:
• The condition of the "Operator panel available" parameter is not fulfilled.
• Communication with current measuring module faulty.
• An incorrect current measuring module is connected.
Parameters
6.9 Operation with operator panel
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Process image of outputs (PIQ) and inputs (PII) 7
Process image of output (PIQ)
The process image of outputs contains the control commands for the solid-state overload
relay for IO-Link.
Table 7- 1 PIQ - Control commands
DO (1 bytes) PIQ Explanation
DO0.0 1: Motor direction of rotation 1 The bit affects terminals 95 / 961)
DO0.1 1: Motor direction of rotation 2 The bit affects terminals 95 / 981)
DO0.2 Reserved —
DO0.3 1: Trip Reset Acknowledgment of resettable group error 2)
DO0.4 Reserved —
DO0.5 Reserved —
DO0.6 Reserved —
DO0.7 Reserved —
1) See also Chapter "Carrying out self-test (Page 86)".
2) For additional information on acknowledging and resetting group errors, please refer to
Chapter "Performing a reset (Page 89)".
Process image of outputs (PIQ) and inputs (PII)
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Process image of inputs (PII)
The process image of outputs contains the most important status information of the solid-
state overload relay for IO-Link.
Table 7- 2 PII - status information
DI (2 bytes) PII Explanation
DI0.0 1: Ready (automatic) Bit is set:
The solid-state overload relay can be
controlled via IO-Link.
DI0.1 1: Motor ON Bit is set if a current flow is measured.
DI0.2 1: Group error Bit is set if an error results in
disconnection of the device or if the
device cannot be switched on due to an
error.1)
DI0.3 1: General warning Bit is set if the device is close to a trip
(thermal motor model) (LED
OVERLOAD flashing) or if the device is
carrying out a self-test. 2)
DI0.4 Reserved —
DI0.5 Reserved —
DI0.6 Reserved —
DI0.7 Reserved —
DI1.0
DI1.1
DI1.2
DI1.3
DI1.4
DI1.5
Motor current [%] The returned 6-bit value DI1.0 - DI1.5
gives the motor current ratio of the
actual current to the set current in steps
of 3.125%:
I
act
(max) = 1.97 • I
rated
3) 4)
DI1.6 1: Manual mode Bit is set:
The solid-state overload relay can be
controlled via a connected operator
panel.
DI1.7 Reserved —
1) You can find detailed information on the group error via diagnostics set 92 in Chapter
"Diagnostics - data set (index) 92 (Page 123)"
2) You can find detailed information on the general warning via diagnostics set 92 in Chapter
"Diagnostics - data set (index) 92 (Page 123)"
3) Iact = actually flowing current [A]; Irated = rated operational current [A]
4) In the case of "non-acknowledgable" errors, the maximum current is displayed: 63
(= 111111B = 0x3F)
Process image of outputs (PIQ) and inputs (PII)
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6-bit value
6-bit value = (Iact • 100) / (Irated • 3.125)
Evaluation of the 6-bit value
Iact = (6-bit value • Irated • 3.125) / 100 = (6-bit value • Irated) / 32
Table 7- 3 Examples of evaluation of the 6-bit value
Irated 200 A 200 A 200 A 200 A
6-bit value 0 32 44 64
Iact 0 A 200 A 275 A 393.75 A
Iact / Irated 0 1 1.38 1.97
Process image of outputs (PIQ) and inputs (PII)
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Mounting/removal 8
8.1 Mounting options
Evaluation module
The following mounting options are available for the evaluation module:
● Snap-on mounting on 35 mm rail in accordance with EN 50022
● Snap-on mounting straight onto the current measuring module 3RB2906.. (only for the
sizes S00 / S0 and S2 / S3)
● Screw mounting on a flat surface with push-in lugs as accessories (3RP1903)
Current measuring module
The following mounting options are available for the current measuring module:
● Snap-on mounting on 35 mm rail in accordance with EN 50022
● Screw mounting on a flat surface with push-in lugs as accessories (3RB1900-0B)
The current measuring modules in size S00 / S0 and S2 / S3 are designed for stand-alone
installation. The current measuring modules in size S6 and S10 / S12 are suitable for stand-
alone installation and mounting onto contactors.
8.2 Mounting position
Mounting position
Arbitrary mounting position of the solid-state overload relay for IO-Link.
Mounting/removal
8.3 Snapping onto/off DIN rail (snap-on mounting)
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8.3 Snapping onto/off DIN rail (snap-on mounting)
The illustration below shows how to snap the devices onto/off a DIN rail:
Step Instruction Image
1 Place the evaluation module on the upper
edge of the rail and press it down until it
snaps onto the lower edge of the rail.
To remove, push the evaluation module
against the pressure of the securing spring
and swing it out.
Mounting/removal
8.4 Screw mounting
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8.4 Screw mounting
The illustrations below show how to mount the evaluation module on a level surface.
Step Instruction Image
1 Insert the push-in lugs for screw
mounting 3RP1903 into the evaluation
module at the top and bottom. Use a
screwdriver to tighten the screws in the
drill holes provided on the evaluation
module.
You can find information on the drill hole dimensions in Appendix "Dimension drawings
(dimensions in mm) (Page 109)".
8.5 Mounting the sealing cover
The illustration below shows how to mount the sealing cover.
Step Instruction Image
1 Break off the clip on the sealing cover.
2 Insert the sealing cover into the openings
on the evaluation module.
3 Fold the sealing cover up.
4 Insert the clip into the opening until it
engages.
5 Seal the clip to secure it against
unauthorized removal.
Mounting/removal
8.6 Inserting the interface cover
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8.6 Inserting the interface cover
Use the interface covers to close unused interfaces. This prevents damage or contamination
to the interfaces.
The illustration below shows how to assemble the interface cover.
Step Instruction Image
1 / 2 /
3
Insert the interface cover into the slot from
the front until it engages in the locking
mechanism.
Mounting/removal
8.7 Installing an operator panel
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8.7 Installing an operator panel
The operator panel is designed for use in the front panels of motor control centers, for
example, or in control cabinet doors.
For information on connecting the operator panel, please refer to "Operation using the
operator panel (Page 94)".
Installing
Step Instruction Image
1 Make a cutout in the front panel, for
example, or in the control cabinet door.
90
+0.5
30
+0.5
2 Insert the operator panel in the cutout.
3 Snap the four securing brackets onto the
operator panel. Screw the securing
brackets with one screw each (maximum
tightening torque 4 x 0.15 + 0.05 Nm).
4 Lock the operator panel in position by
tightening the four screws on the securing
brackets.
4x
CAUTION
In order to guarantee the IP54 tightness and correct functionality of the operator panel,
ensure that the tightening torque of the screws selected is not excessive when tightening
the enclosed screws.
Mounting/removal
8.7 Installing an operator panel
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Mounting onto the solid-state overload relay for IO-Link
The illustration below shows how to mount the operator panel onto the solid-state overload
relay for IO-Link.
Step Instruction Image
1 / 2 Disengage the locking mechanism
and remove the interface cover on
the front of the solid-state overload
relay for IO-Link.
3 Insert the 10-core connecting cable
for the operator panel from the front
into the interface of the solid-state
overload relay for IO-Link.
Note
Use the interface covers to close unused interfaces. This prevents damage or contamination
to the interfaces.
3RB24 solid-state overload relay for IO-Link
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Connecting 9
9.1 Connection via terminals
Connection types
The solid-state overload relays for IO-Link are connected via removable terminals with the
following connection options:
● Free wiring on screw-type terminals
● Free wiring on spring-loaded terminals
Connection using screw-type terminals
DANGER
Hazardous voltage!
Will cause death or serious injury.
Turn off and lock out power before working on this equipment.
To tighten/release the screw-type terminals, you need a PZ 2 screwdriver. The tightening
torque must be between 0.8 and 1.2 Nm.
Please refer to the table for the conductor cross-sections and stripping lengths.
Table 9- 1 Conductor cross-sections for screw-type terminals
Type of connection Conductor cross-section
∅ 5 ... 6 mm/PZ 2
0.8 to 1.2 Nm
(7 to 10.3 lb in)
1 x (0.5 to 4) mm2
2 x (0.5 to 2.5) mm2
1 x (0.5 to 2.5) mm2
2 x (0.5 to 1.5) mm2
AWG 2 x (20 to 14)
Connecting
9.1 Connection via terminals
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Connection via spring-loaded terminals
DANGER
Hazardous voltage!
Will cause death or serious injury.
Turn off and lock out power before working on this equipment.
You need a 3-mm flat-bladed screwdriver (3.0 x 0.5 mm).
Step Instruction
1 To release the clamping springs,
insert the screwdriver as far as it
will go into the square opening of
the spring-loaded terminal. Position
the screwdriver at an angle of 10°
with respect to the oval opening.
2 Insert the cable as far as it will go
into the oval opening and hold it in
place.
3 Remove the screwdriver.
Pull on the cable to ensure it is
completely secure.
PP
PP
[>PP@
Connecting
9.1 Connection via terminals
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Please refer to the table for the conductor cross-sections and stripping lengths.
Table 9- 2 Conductor cross-sections for spring-loaded terminals
Type of connection Conductor cross-section
(3.0 x 0.5) mm
2 x (0.25 … 1.5) mm2
2 x (0.25 … 1.5) mm2
2 x (0.25 … 1.5) mm2
AWG 2 x (24 to 16)
Connecting
9.1 Connection via terminals
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Replacing the removable terminals
DANGER
Hazardous voltage!
Will cause death or serious injury.
Turn off and lock out power before working on this equipment.
The removable terminals of the solid-state overload relay for IO-Link facilitate module
replacement when necessary. The mechanical coding on the terminals prevents mix-ups.
Note
Terminals C and D can only be installed in the following order because of how they are
arranged on the solid-state overload relay for IO-Link:
1. Rear terminal (D)
2. Front terminal (C)
Step Instruction Image
1 Press the interlock.
2 Remove the terminal.
3 / 4 Attach the new terminal and press the
terminal into the device until the
interlock audibly engages.
$
&
'
Connecting
9.1 Connection via terminals
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Connection example for applications to 630 A
The motor current is calculated with the current measuring module 3RB29.6-2.... The
evaluation module is connected to the current measuring module by a ribbon cable
(3RB2987-2.).
Note
Connection of the main circuit is shown in the operating instructions of the current measuring
module. You can find more information in Chapter "References (Page 129)"
AU
F
)
IO-Link
Master
L1
L2
L3
N
PE
F3 F4 F5
531
642
-Q1E
H1
H2
H3
H4
3~
M
T1 T2 T3
L1 L2 L3
F1
U
V
W
96
F2
T1 T2
DEVICE/
GND
FAULT
THER-
MISTOR
OVER-
LOAD
RESET
TO
MAN
Ground
ault
CLASS
5, 10, 20, 30
Y1 Y2
REMOTE-
RESET
I(-
I(+)
4-20 mA
98 95
3RB29.6...
3RB24...
3RB2987-2...
Q2
Q1
IO-LINK
F6
6A
gG
L+ C/Q L-
L+ C/Q L-
Q1E
Figure 9-1 Connection example
Connecting
9.1 Connection via terminals
3RB24 solid-state overload relay for IO-Link
74 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Protection of single-phase motors
The graphic below shows the main current connection for single-phase operation.
Note
Protection of single-phase motors is not possible in conjunction with internal ground fault
detection!
M
1~
L1 L2 L3
T1 T2 T3
L
N
5%
0
a
Figure 9-2 3RB2906-2.G1, 3RB2956-2TG2
L1 L2 L3
T1 T2 T3
L
N
5%
M
1~
0
a
Figure 9-3 3RB2956-2TH2, 3RB2966-2WH2
Connecting
9.2 Connecting the solid-state overload relay for IO-Link
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 75
9.2 Connecting the solid-state overload relay for IO-Link
The 3RB24 solid-state overload relay for IO-Link is connected to the IO-Link master via
removable terminals and supplied with 24 V DC via this connection.
DANGER
Hazardous voltage!
If voltages are too high, the overload relay can be damaged and electric shock can result.
Use only power supplies that comply with the requirements of protective extra-low voltage
(PELV in accordance with IEC EN 50178).
DANGER
Hazardous voltage!
Will cause death or serious injury.
Turn off and lock out power before working on this equipment.
There are 2 methods of supplying the overload relay with voltage via the control circuit.
Option 1: Connection to IO-Link master
Connect the overload relay with the master via the three cables L+, C / Q and L-. The
overload relay (slave) is supplied with voltage via the three cables L+, C / Q and L-. The
overload relay communicates with the master via the cable C / Q.
OVERLOAD
RESET
MAN
AUTO
Y1 T1
CLASS/I
I(-)
T2
I(+)
L+
SIRIUS
DEVICE /
IO-LINK
GND FAULT
THERMISTOR
3RB2483-4AA1
G/JJMMTT *Exx*
10
20 30
40
50
60
70
80
90
100
15
x I
MAX
%
20
10
5
30
20
10 5 30 20
10
5
30
10
5
30
20
1
0
0
A
1
0
0
0
A
A
0
1
1
A
TEST/
RESET
Y2
MAX
C/Q L-
96 9895
96 95 98
Q1
Q2
5$$RQO\
,2/LQN
0DVWHU
Figure 9-4 Connection to IO-Link master
Connecting
9.2 Connecting the solid-state overload relay for IO-Link
3RB24 solid-state overload relay for IO-Link
76 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Option 2: Direct voltage supply with 24 V DC
If no master is available, you can operate the overload relay with a 24 V DC voltage source
in conjunction with the operator panel.
For this purpose, connect the overload relay with the voltage source via the two cables L+
and L-. Since the cable C / Q is not used in this case, communication via the IO-Link is not
possible. You cannot adjust the parameters "Cold start", "Ground fault detection", "Operator
panel available" and "Operation at Preset <> Actual Configuration".
OVERLOAD
RESET
MAN
AUTO
Y1 T1
CLASS/I
I(-)
T2
I(+)
L+
SIRIUS
DEVICE /
IO-LINK
GND FAULT
THERMISTOR
3RB2483-4AA1
G/JJMMTT *Exx*
10
20 30
40
50
60
70
80
90
100
15
x I
MAX
%
20
10
5
30
20
10 5 30 20
10
5
30
10
5
30
20
1
0
0
A
1
0
0
0
A
A
0
1
1
A
TEST/
RESET
Y2
MAX
C/Q L-
96 9895
96 95 98
Q1
Q2
5$$RQO\
'&9
Figure 9-5 Direct voltage supply with 24 V DC
Connecting
9.2 Connecting the solid-state overload relay for IO-Link
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 77
Pin assignment of the solid-state overload relay for IO-Link
The following pin assignments apply for the solid-state overload relay for IO-Link with screw-
type terminals or spring-loaded terminals.
Table 9- 3 Pin assignment of the solid-state overload relay for IO-Link
Marking Meaning Image
L+ Supply voltage IO-Link/24 V DC
C/Q Communication signal IO-Link
L- Chassis ground IO-Link/24 V DC
Connection for IO-Link
master/PELV 24 V DC
T2 Thermistor input
I(-) Analog output
Y2 Remote reset
T1 Thermistor input
I(+) Analog output
Y1 Remote reset
96 Changeover contact Q2 - NC contact
95 Switching contact Q1 - NO contact 1)
98 Changeover contact Q2 - NO contact
4
4
OVERLOAD
RESET
MAN
AUTO
Y1 T1
CLASS/I
MAX
I(-)
T2
I(+)
L+
SIRIUS
DEVICE /
IO-LINK
GND FAULT
THERMISTOR
3RB2483-4AA1
G/JJMMTT *Exx*
10
20 30
40
50
60
70
80
90
100
15
x I
MAX
%
20
10
5
30
20
10 5 30 20
10
5
30
10
5
30
20
1
0
0
A
1
0
0
0
A
A
0
1
1
A
TEST/
RESET
Y2
e
C/Q L-
96 9895
96 95 98
Q1
Q2
5$$RQO\
1) Q1 is responsible for the ON and OFF function of the changeover unit. Q2 is responsible for the actual changeover
function.
Note
Connection of the main circuit is shown in the operating instructions of the current measuring
module. You can find more information in Chapter "References (Page 129)"
Connecting
9.2 Connecting the solid-state overload relay for IO-Link
3RB24 solid-state overload relay for IO-Link
78 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 79
Operation 10
10.1 Setting the current (rated operational current) and trip class
The 3RB24 solid-state overload relay is set to the rated operational current Ie with two rotary
switches.
Upper rotary switch
The upper rotary switch (CLASS / I MAX) is divided into 4 ranges: 1 A, 10 A, 100 A and
1000 A. The relevant range must be selected depending on the rated operational current Ie of
the motor and the current measuring module to be used with this. Within the selected range,
the necessary trip class must be determined (CLASS 5, CLASS 10, CLASS 20 or
CLASS 30).
CLASS/I
20
10
5
30
20
10 5 30 20
10
5
30
10
5
30
20
1
0
0
A
1
0
0
0
A
A
0
1
1
A
MAX
Figure 10-1 Set CLASS and I MAX (e.g. CLASS 5 / 1 A)
Lower rotary switch
Using the lower rotary switch (% x I MAX) with percentage scale from 10 to 100%, the rated
operational voltage Ie of the motor is set as a percentage of the range selected via the upper
rotary switch (CLASS / I MAX).
10
20
30
40
50
60
70
80
90
100
15
x MAX
% I
Figure 10-2 Setting the rated operational current Ie of the motor (e.g. 90%)
Operation
10.1 Setting the current (rated operational current) and trip class
3RB24 solid-state overload relay for IO-Link
80 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Example:
CLASS / I MAX = 5/1 A
% x I MAX = 90%
⇒ Ie = 0.9 A
Note
The motor, cables and contactor must be designed for the corresponding
trip class (CLASS).
• Check the CLASS setting before initial commissioning.
• Select the relevant tripping characteristic with the rotary switch for the trip classes
(CLASS / I MAX).
Note
With the help of the sealable cover 3RB2984-2, you can secure the rotary switches against
inadvertent operation. Assembly of the sealable cover is described in Chapter "Mounting the
sealing cover (Page 65)"
Note
The set rated operational current can be read out via IO-Link for documentation purposes,
for example.
Example
● Three-phase motor power = 45 kW (AC 50 Hz, 400 V)
● Rated operational current of the motor = 80 A
● Required trip class = CLASS 20
● Selected transformer: 10 to 100 A
Solution:
● Step 1: Select the area 100 A using the upper rotary switch (CLASS / I MAX)
● Step 2: Set the trip class CLASS 20 within the range 100 A
● Step 3: Set the lower rotary switch to 80% (= 0.8) in accordance with 100 A × 0.8 = 80 A.
Note
If the current set on the evaluation module does not match the current range of the
connected current transformer, a diagnostics message results.
You can find more information on the errors in Chapter "Fault codes (only in the case of non-
acknowledgeable faults) (Page 104)".
Operation
10.1 Setting the current (rated operational current) and trip class
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 81
Trip classes
The 3RB24 solid-state overload relay for IO-Link is suitable for normal starting conditions
and heavy starting conditions. Depending on the prevailing starting condition, the required
trip class CLASS 5, CLASS 10, CLASS 20 or CLASS 30 can be set using a rotary switch.
Note
The set trip class can be read out via IO-Link for documentation purposes, for example.
Tripping characteristics
The tripping characteristics map the relationship between tripping time and tripping current
as a multiple of the rated operational current Ie ; they are specified for symmetrical 3-pole
loading and 2-pole loading from cold.
Minimum tripping current
The lowest current at which tripping will occur is known as the minimum tripping current.
According to IEC 60947-4-1, the minimum tripping current must be within defined limits. In
the case of the 3RB24 solid-state overload relay, the limits for the minimum tripping current
with symmetrical 3-pole loading are between 105 and 120% of the rated operational current.
Tripping times
The minimum tripping current determines the progression of the tripping characteristic up to
higher tripping currents based on the characteristics of the trip classes. The trip classes
describe time intervals within which the solid-state overload relays for IO-Link have to trip in
the case of a symmetrical, 3-pole load from the cold state with 7.2 times the rated
operational current Ie.
The tripping times according to IEC/EN 60947-4-1, tolerance band E, are shown in the table
below.
Table 10- 1 Tripping times
Trip class Tripping time
CLASS 5 3 ... 5 s
CLASS 10 5 ... 10 s
CLASS 20 10 ... 20 s
CLASS 30 20 ... 30 s
Operation
10.1 Setting the current (rated operational current) and trip class
3RB24 solid-state overload relay for IO-Link
82 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Tripping characteristics for 3-pole load
The tripping characteristic for a solid-state overload relay loaded at 3 poles from cold applies
subject to the requirement that all three phases are loaded with the same current at the
same time.
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Figure 10-3 Tripping characteristic for 3-pole load
Phase failure detection
To minimize the temperature rise of the load in the case of a phase failure during single-
phase operation, the 3RB24 solid-state overload relay for IO-Link has a phase failure
detection feature.
Operation
10.1 Setting the current (rated operational current) and trip class
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 83
Tripping characteristics for 2-pole load
In the case of a phase failure or current unbalance > 40 % (in accordance with NEMA), the
3RB24 solid-state overload relay disconnects the contactor faster to minimize the
temperature rise of the load. This operation takes place in accordance with the tripping
characteristic for two-pole load from cold.
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Figure 10-4 Tripping characteristic for 2-pole load
The characteristic curves apply for cold restart. In the case of a start with preloading, the
tripping times tA are lower.
Tripping time in the case of loads at operating temperature
Compared with a cold load, a load at operating temperature obviously has a lower
temperature reserve. It is for this reason that the tripping time of the 3RB24 solid-state
overload relay is reduced to approximately 30% following prolonged loading with the rated
operational current Ie.
Operation
10.2 Activating/deactivating thermistor protection
3RB24 solid-state overload relay for IO-Link
84 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
10.2 Activating/deactivating thermistor protection
Activation
The thermistor protection function is disabled in the delivery state. If the device detects a
connected thermistor when switched on, the thermistor is automatically activated. If the
thermistor is removed, the thermistor function must also be deactivated by the user,
otherwise, a diagnostics message is generated. You can find more information on the faults
in Chapter "Fault codes (only in the case of non-acknowledgeable faults) (Page 104)".
Deactivation
If you press and hold down the TEST/RESET button while switching on the control voltage
(L+ / L-), the THERMISTOR LED lights up. If you now release the button within 3 s, the
thermistor function is deactivated. This is indicated by flashing of the THERMISTOR LED at
7 s intervals.
NOTICE
Danger of false short-circuit detection!
To guarantee sure functioning of the short-circuit detection in the thermistor circuit, the line
resistance must not exceed 10 Ω in the case of a short-circuited thermistor.
Note
The "Thermistor - monitoring" parameter can be read out via IO-Link for documentation
purposes, for example. This parameter cannot be set or modified via IO-Link.
Operation
10.3 Outputting an analog signal
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 85
10.3 Outputting an analog signal
Outputting the motor current with the help of an analog signal
The motor current measured by the microprocessor can be output in the form of an analog
signal DC 4 mA to 20 mA for activating three-phase permanent-magnet moving-coil
instruments or supplying analog inputs of programmable controllers. The output value
always indicates the maximum value of the three phases. Transfer of the current values via
IO-Link is represented in Chapter "Process image of outputs (PIQ) and inputs (PII)
(Page 59)". The analog values of the 3 phases can be read out in detail via data set
"Measured value - data set (index) 94 (Page 125)".
Example of recording the analog value
Output current range: 4 ... 20 mA
Increment: 1 % x Ie = 0.128 mA
0 mA
4 mA
8 mA
12 mA
16 mA
20 mA
24 mA
0%xIe20%xIe40%xIe100%xIe
60%xI
e
80%xI
e
16.8 mA
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Figure 10-5 Recording the analog value
Example:
Output analog value Iout = 10.40 mA; set motor current Ie = 6.0 A
Imotor = ((10.40 mA - 4 mA) x 6 A) / 12.8 mA = 3 A
Table 10- 2 Example
Feature Value
Maximum output current 20 mA
Terminals I(+) and I(-)
Maximum load 100 Ω
Accuracy + / - 5 %
Short-circuit-proof and open circuit-proof Yes
Operation
10.4 Carrying out self-test
3RB24 solid-state overload relay for IO-Link
86 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
10.4 Carrying out self-test
TEST function
The proper function of the ready overload relay can be checked by pressing the
TEST/RESET button.
The following functions are tested:
● LEDs
● Device hardware
● Device configuration (GND FAULT, THERMISTOR): The actively parameterized functions
are tested.
Test phases
The test phase runs while the TEST/RESET button remains pressed for 6 seconds. During
the test phase, direct current is output at the terminals of the analog output. After
24 seconds, the auxiliary contacts are closed and the feeder is thus disconnected. The self-
test has been completed.
The self-test can be aborted at any time by releasing the TEST/RESET button.
Resetting the relay after test triggering
Following a successful self-test, the relays are in the OFF state. To be able to switch the
relays again, you must acknowledge the end of the test. For this purpose, press the
TEST/RESET button again for longer than 1 s.
The relays respond differently depending on whether the overload relay is controlled at this
time via IO-Link or via the operator panel:
1. Control via IO-Link (automatic mode)
After acknowledging the test, the switching signals DO 0.0 and DO 0.1 pending from the
controller are valid. The relays therefore assume the states requested by the controller
immediately after acknowledgment of the test. The reset mode of the device (automatic
reset/manual reset) is irrelevant.
2. Control via operator panel (manual mode):
After acknowledgment of the test, you must switch the relays on again manually. The
reset mode of the device (automatic reset/manual reset), and the switching signals
pending from the controller (DO 0.0 and D0 0.1) are irrelevant.
Operation
10.4 Carrying out self-test
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 87
Carrying out self-test
The self-test is initiated by pressing the TEST/RESET button for t > 1 s. All protection
functions remain active during the self-test. A trip/warning results in abort of the self-test. The
self-test is also carried out if the TEST/RESET button is pressed for t > 1 s at the moment of
switching on the overload relay.
Note
Regular tests of the device are described in EN 60079-17.
The self-test of the 3RB24 solid-state overload relay for IO-Link encompasses a full function
test. All the test phases described in the table below must be executed. The individual test
phases are the display test (1), the configuration test (2), the internal test with current
measurement (3), the relay test (4) and the acknowledgment (5).
The measured current values and the correct opening and closing of the relay contacts (test
phase 4) must be checked by the user!
Table 10- 3 Test phases
Test phase Duratio
n
Description Comment
1 3 s Indicator test Check that all LEDs flash.
2 3 s Configuration test Active ground fault monitoring and/or thermistor
monitoring is/are indicated by flickering of the
relevant LED(s). Active automatic reset is signaled
by a flickering DEVICE/IO-Link LED.
3 18 s Internal tests The system carries out internal tests. During the test,
you can compare the highest motor current of the
3 phases with the current of the analog output.
4 — Relay test 1) System opens the outputs 95/96 and 05/06.
5 2 s Acknowledgment 2) Press the TEST/RESET button for 2 s.
1) The flickering of the three red LEDs for 2 seconds initiates shutdown of the relays. The user test
can be aborted without shutting down the relays at any time up to this point.
2) In automatic mode (control via IO-Link), the relay control commands DO 0.0 / DO 0.1 are accepted
again.
The graphic below represents the chronological sequence of the test phases:
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Figure 10-6 Chronological sequence of the test phases
Operation
10.4 Carrying out self-test
3RB24 solid-state overload relay for IO-Link
88 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Response of the relay contacts
The device can be in one of the following three states at the time of the self-test:
1. Everything off (factory setting)
2. Clockwise rotation
3. Counter-clockwise rotation
During the first three test phases, the switching state of the relay contacts remains the same.
A change in the contacts only takes effect when the relay test is concluded (test phase 4):
Table 10- 4 Response of the relay contacts in test phase 4 depending on the current switching state
Current switching state Response of the relay contacts
Everything off
96 95 98
Q1
Q2
Relay Q1 and Q2 remain in the drop-out state.
Clockwise rotation
96 95 98
Q1
Q2
Relay Q1 is in the pick-up state.
Counter-clockwise rotation
96 95 98
Q1
Q2
Relay Q1 and Q2 are in the pick-up state.
Operation
10.5 Performing a reset
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 89
10.5 Performing a reset
Possible reset settings
When you confirm a fault, you confirm that you have taken account of the fault message.
You acknowledge fault messages with the Reset function.
You determine the reset method with the slide switch for AUTO/MAN RESET. You can
choose between manual and automatic reset. The position of the slide switch for AUTO/MAN
RESET is continuously read in by the controller during operation.
● Automatic reset: Automatic reset only functions with thermistor tripping and overload
tripping (thermal motor model overload). In the case of automatic reset, the fault
acknowledges itself automatically as soon as the cause of the fault (e.g. overheating of
the motor) is no longer active.
● Manual reset: With manual reset, you as the user must actively acknowledge the fault
message via the TRIP/RESET button on the device, the SF/RESET button on the
operator panel, a remote reset, or the IO-Link. All fault messages can be acknowledged
manually.
"Non-acknowledgeable faults" are the exception. "Non-acknowledgeable faults" can only
be reset by removing the control supply voltage for at least 3 seconds. You can diagnose
"non-acknowledgeable faults" direct on the device by means of a flashing code sequence
of the three red LEDs. You can find the fault codes for "non-acknowledgeable faults" in
Chapter "Fault codes (only in the case of non-acknowledgeable faults) (Page 104)".
Note
Resetting switching states
When you acknowledge a fault, you confirm that you have taken account of a fault message.
The acknowledgment deletes the fault bits in the device but the switching states are not
restored.
The switching states only become active again when the cause of the fault has been
removed and the switching relays are activated again.
You can find information on how to remove the causes of faults in Chapter " IO-Link
diagnostics (Page 106)".
Operation
10.5 Performing a reset
3RB24 solid-state overload relay for IO-Link
90 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
The table below provides an overview of the possible reset methods depending on the
pending fault message:
Error message Manual reset Automatic reset
Thermistor tripping ✓ ✓
Overload tripping ✓ ✓
Ground fault tripping ✓ —
Switching element defective (current flowing
despite disconnection)
✓ —
Residual current tripping (switching relay
switched on but no current flow can be
measured)
✓ —
Current flow in operating mode "Cold start" ✓ —
Connection abort in manual mode of the
operator panel 1)
✓ ✓
Process image error (both relay switching
options are selected simultaneously via IO-Link)
2)
✓ ✓
Preset <> Actual Configuration ✓ ✓
"Non-acknowledgeable faults" — 3) —
3)
1) In manual mode only (control via operator panel).
2) In automatic mode only (control via IO-Link).
3) Fault acknowledgment and resetting of the relay switching states only by opening and reclosing
the 3RB24 overload relay.
Operation
10.5 Performing a reset
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 91
10.5.1 Manual reset
Manual reset
If the slide switch on the device is set to "MAN", you can acknowledge faults in the following
ways:
● Trip reset (process image of the outputs via IO-Link)
● TEST/RESET button on the 3RB24 overload relay
● SF/RESET button on the 3RA6935-0A operator panel
● Remote reset: Remote reset can be implemented electrically by jumpering terminals Y1
and Y2.
WARNING
Automatic restart!
Can result in death, serious injury, or property damage.
The motor switches on again when the following condition is met:
• the overload relay is in automatic mode, and following the reset, the pending control
commands DO 0.0 / DO 0.1 of the higher-level controller are executed again.
Manual reset must not be used in applications where there is a risk of serious injury to
persons or substantial damage to property if the motor starts up again unexpectedly.
Make sure that the machine danger zone is kept clear of people at the time of restarting.
Operation
10.5 Performing a reset
3RB24 solid-state overload relay for IO-Link
92 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
10.5.2 Automatic reset
Automatic reset
If the slide switch on the device is set to "AUTO", a tripping operation (current-dependent or
temperature-dependent protection) is acknowledged as soon as the recovery time has
elapsed or the temperature measured by the thermistor has dropped below the reclosing
value.
WARNING
Automatic restart!
Can result in death, serious injury, or property damage.
The motor switches on again when all the following conditions are met:
• Automatic reset is set
• The cause of the fault message is no longer active
• The overload relay is in automatic mode and an ON command is active
Automatic reset must not be used in applications where there is a risk of serious injury to
persons or substantial damage to property if the motor starts up again unexpectedly.
Make sure that the machine danger zone is kept clear of people at the time of restarting.
Recovery time
The time between tripping and resetting is determined by the recovery time.
The recovery time depends on the tripping method:
1. Recovery time after current-dependent tripping:
On the 3RB24 solid-state overload relay for IO-Link, the recovery time following current-
dependent tripping is approximately three minutes regardless of the reset mode set. The
recovery time gives the load a chance to cool down.
2. Recovery time following temperature-dependent tripping:
If temperature-dependent tripping takes place through a connected PTC thermistor
sensor circuit, the device can only be reset manually or automatically when the winding
temperature at the installation location of the cold conductor has cooled down to 5 Kelvin
below its response temperature.
3. Recovery time following other faults:
With all other faults, the overload relay is capable of reclosing as soon as the fault has
been removed.
Operation
10.5 Performing a reset
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 93
If the solid-state overload relay for IO-Link has tripped for one of the following reasons, you
reset the device by one of the actions listed in the table below after the appropriate time.
Table 10- 5 Resetting the solid-state overload relay for IO-Link
Reset action
Reason for
tripping Brief pressing of the
TEST/RESET button
Remote reset
(press button at
Y1-Y2)
Automatic
reset (switch2))
Reset via IO-Link
Process image
Operator panel
Self-test Immediately
Overload1) After 3 min. After 3 min.3)
Thermistor1) When 5 K below response temperature reached. When 5 K below response
temperature reached.3)
Ground fault Immediately Not functional Immediately
1) If the thermistor trip and the overload trip have responded simultaneously, the longer reset phase is valid.
2) In the "AUTO" switch position, the overload relay resets automatically.
3) The slide switch must be set to "MAN".
NOTICE
Continuous reclosing!
If you apply the reset selection continuously, e.g. by continuously pressing the
TEST/RESET button, or by continuously sending a reset signal via the controller, the
overload relay closes continuously and trips again immediately afterwards.
Remove the cause for the trip before carrying out a reset.
Apply the reset selection for no more than 2 s, e.g. by briefly pressing the TEST/RESET
button, or by setting and then resetting the reset signal via the controller.
RESET function with trip-free mechanism
The RESET function with trip-free mechanism prevents reclosing of the solid-state overload
relay while a fault is being diagnosed.
The protection functions are not hindered by the following actions:
● Holding the TEST/RESET button
● Short-circuit of the contacts (Y1, Y2) of the remote reset
● Continuous pressing of the SF/RESET button at the connected operator panel
● Continuously active trip reset command from the controller
Note
The cause of the fault must be removed before the RESET.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
94 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
10.6 Operation using the operator panel
Operation using the operator panel
The solid-state overload relay for IO-Link is controlled in manual mode with the operator
panel. The device statuses are also scanned.
Connecting
The operator panel is connected to the interface on the front of the solid-state overload relay
for IO-Link using the 10-core connecting cable for the operator panel.
Figure 10-7 Connecting the operator panel to the solid-state overload relay for IO-Link
CAUTION
To avoid faults in the overload relay and a defect on the operator panel, connect or
disconnect the operator panel only when the power to the evaluation unit is turned off.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 95
Operator controls and display elements of the operator panel
The representation below explains the operator controls and display elements of the
operator panel.
Note
Enable signals from the enabling module
The operator controls of the operator panel only function if the enabling module is plugged
in.
Table 10- 6 Operator controls and display elements of the operator panel
(1) Manual Mode button and
LED
You isolate the solid-state overload relay for manual mode using the MANUAL MODE
button. Switching between manual mode and automatic mode is confirmed by lighting
up of the "MANUAL MODE" LED.
Please note the following warning information!
(2) SF LED The SF LED shows a RED light if there is a group error of the solid-state overload
relay.
(3) RESET SF button You manually reset the overload relay using the RESET SF button.
(4) Button and LED You use the button to activate the solid-state overload relay in direction of
rotation 2 (counter-clockwise). The LED lights up to confirm this.
(5) Button and LED You use the button to activate the solid-state overload relay in direction of
rotation 1 (clockwise). The LED lights up to confirm this.
(6) SELECT button If you press the SELECT button for more than 5 seconds, you switch the solid-state
overload relay between jog mode and continuous mode. The change to the operating
mode is confirmed by flashing of the "MANUAL MODE" LED.
(7) Slot for enabling module Plug the enabling module into the slot to take control priority of the solid-state
overload relay.
(8) LED 1 LED 1 indicates whether the solid-state overload relay is selected:
- Yellow: Connection to the solid-state overload relay.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
96 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
(9) FAULT LED The FAULT LED indicates whether communication between the solid-state overload
relay and the operator panel is functioning properly and whether a system fault is
pending:
- Red: No communication between the solid-state overload relay and the operator
panel.
- Flashing red: There is a non-acknowledgeable fault.
- Off: Communication between the solid-state overload relay and the operator panel
is functioning properly.
(10) DEVICE LED The DEVICE LED indicates whether the operator panel is ready to run:
- Green: Operator panel is ready to run.
WARNING
Automatic restart!
Can result in death, serious injury, or property damage.
The motor switches on again when the following condition is met:
• the overload relay is switched from manual mode to automatic mode with the help of the
operator panel, and the pending control commands DO 0.0 / DO 0.1 of the higher-level
controller are executed again.
Manual switching from manual mode to automatic mode must not be used in applications
where there is a risk of serious injury to persons or substantial damage to property if the
motor starts up again unexpectedly.
Make sure that the machine danger zone is kept clear of people at the time of restarting.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 97
Monitoring mode
The operator panel is always in monitoring mode as standard. The user can read the
switching states of the solid-state overload relay for IO-Link and detect group errors.
Table 10- 7 Monitoring mode of the operator panel
Action Procedure
Reading off the selection 1. Read off the selection:
- LED shows yellow light: Direction of rotation 1 (clockwise)
on.
- LED shows yellow light: Direction of rotation 2 (counter-
clockwise) on.
- LED and LED are off: No selection.
Detecting group errors 1. Check whether a group error is present:
- SF LED shows red light: Group error present.
- SF LED is off: No group error.
Detecting non-acknowledgeable
errors 1. Check whether a group error is present:
- SF LED shows red light: Group error present.
- SF LED is off: No group error.
2. Check whether a non-acknowledgeable error is present:
- FAULT LED flashes: Non-acknowledgeable error present
- FAULT LED is off: No system error
Manual mode
You can take control priority over the solid-state overload relay for IO-Link in manual mode.
This enables the user to activate the device using the operator panel.
Note
Switching between automatic mode and manual mode
To switch between automatic and manual mode, you require an enabling module.
Please therefore ensure when changing from manual to automatic mode that you activate
automatic mode first before removing the enabling module.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
98 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
To use the operating panel and activate manual mode of the solid-state overload relay, you
require an enabling module.
WARNING
Automatic restart!
Can result in death, serious injury, or property damage.
The motor switches on again when the following condition is met:
• the overload relay is in automatic mode, and following a manual or automatic reset, the
pending control commands DO 0.0 / DO 0.1 of the higher-level controller are executed
again
Manual or automatic reset must not be used in applications where there is a risk of serious
injury to persons or substantial damage to property if the motor starts up again
unexpectedly.
Make sure that the machine danger zone is kept clear of people at the time of restarting.
Note
After applying the control supply voltage, the operator panel is in jog mode. If the voltage
fails and manual mode is active, the operator panel will be in jog mode following renewed
application of the control supply voltage.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 99
Table 10- 8 Manual mode of the operator panel
Action Procedure
Activating manual mode 1. Insert the enabling module into the slot in the operator panel.
2. Press the MANUAL MODE button to activate manual mode.
Successful activation is confirmed by lighting up of the
"MANUAL MODE" LED.
Activating the solid-state
overload relay in jog mode 1. Activate the starter by pressing
- The button for direction of rotation 1 (clockwise) and
- The button for direction of rotation 2 (counter-clockwise).
2. Hold the button pressed while activating. Activation stops as
soon as you release the button.
Changing from jog mode 1) to
continuous mode 2)
Change to continuous mode by pressing the SELECT button for
longer than 5 seconds. The changeover is confirmed by flashing
of the "MANUAL MODE" LED.
Activating the solid-state
overload relay in continuous
mode
1. Activate the solid-state overload relay by pressing
- The button for direction of rotation 1 (clockwise) and
- The button for direction of rotation 2 (counter-clockwise).
2. Press the or button again to stop activation.
Change from continuous mode 2)
to jog mode 1)
Change to jog mode by pressing the SELECT button for longer
than 5 seconds. The changeover is confirmed by flashing of the
"MANUAL MODE" LED.
Resetting to automatic mode 1. Make sure that the solid-state overload relay is not activated.
2. Press the MANUAL MODE button to activate automatic mode.
If activation is successful, the "MANUAL MODE" LED goes
out.
3. Remove the enabling module from the operator panel.
1) Jog mode: The solid-state overload relay is only activated while you press the or
button. Activation stops as soon as you release the button.
2) Continuous operation: If you press the or button, the solid-state overload relay is
activated until you press the button again.
WARNING
Machine start-up!
Can Cause Death, Serious Injury or Property Damage
If you reset the operator panel to automatic mode while an ON command is simultaneously
pending via the IO-Link, the solid-state overload relay switches back on immediately and
the machine starts up. People may be injured if they stay in the danger area of the
machine.
Make sure that the danger area of the machine is kept clear of people.
Operation
10.6 Operation using the operator panel
3RB24 solid-state overload relay for IO-Link
100 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 101
Diagnostics 11
11.1 Indication of the operating state
Indication of the operating state
The operating state of the solid-state overload relay is indicated via four LEDs.
Status Status display Auxiliary contacts
Device ready, no trip DEVICE / IO-LINK:
green continuous light1)
The set status of the relay
remains in force.
Communication via IO-Link DEVICE / IO-LINK:
green interrupted continuous
light (LED is interrupted for
200 ms every 3 s)
The set status of the relay
remains in force.
Simultaneous flashing of the
following LEDs:
• GND FAULT
• THERMISTOR
• OVERLOAD
(See Chapter "Fault codes (only
in the case of non-
acknowledgeable faults)
(Page 104)")
or device defective
DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
Ground fault tripping GND FAULT:
red continuous light
DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
Thermistor trip THERMISTOR:
red continuous light
DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
Thermistor deactivated THERMISTOR:
red flashing at 7 s intervals
The set status of the relay
remains in force.
Overload tripping OVERLOAD:
red continuous light
DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
Overload warning2) OVERLOAD:
red flickering light
The set status of the relay
remains in force.
User test See Chapter "Carrying out self-test (Page 86)"
Diagnostics
11.1 Indication of the operating state
3RB24 solid-state overload relay for IO-Link
102 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Status Status display Auxiliary contacts
Device not ready
a) IO-Link voltage failure DEVICE / IO-LINK:
dark
95/96 open
95/98 open
b) Functional test negative DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
c) Device fault DEVICE / IO-LINK:
red continuous light
95/96 open
95/98 open
1) With existing IO-LINK connection, green interrupted continuous light (LED is interrupted for 200 ms
every 3 s)
2) The OVERLOAD LED flickers when the minimum tripping current is reached and indicates the
imminent trip:
● In 3-pole operation with a maximum unbalance ≤ 40%: from 1.14 x Ie
● In 1-pole and 2-pole operation with a maximum unbalance > 40%: 0.85 x Ie
Diagnostics
11.2 Auxiliary contacts
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 103
11.2 Auxiliary contacts
Auxiliary contacts
The auxiliary contacts of the 3RB24 solid-state overload relay are an NO contact and a
changeover contact switched downstream of the NO contact.
Response of the auxiliary contacts
The 3RB24 solid-state overload relay for IO-Link has monostable auxiliary contacts. The
auxiliary contacts return to the initial state if voltage is not supplied.
Response to IO-Link voltage failure
If the supply voltage fails, both internal relays drop out (95/96 open, 95/98 open). Depending
on whether the overload relay is controlled at this time via IO-Link or via the operator panel,
the relays assume different states when the supply voltage is restored:
1. Control via IO-Link (automatic mode)
When the supply voltage is restored, the control commands pending from the controller
(IO-Link master) are transferred direct and the relays are switched immediately.
2. Control via the operator panel (manual mode):
Relays remain in the drop-out state and must be closed again manually. Press the
relevant button ( button or button) on the operator panel to activate the directions of
rotation. After applying the control supply voltage again, the operator panel is in jog
mode.
WARNING
Automatic restart
Can result in death, serious injury, or property damage.
Automatic mode must not be used in applications where there is a risk of serious injury
to persons or substantial damage to property from an unexpected restart.
Diagnostics
11.3 Fault codes (only in the case of non-acknowledgeable faults)
3RB24 solid-state overload relay for IO-Link
104 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
11.3 Fault codes (only in the case of non-acknowledgeable faults)
In the case of faults, the system outputs fault codes in the form of a flashing sequence of the
three red LEDs "GND FAULT", "THERMISTOR" and "OVERLOAD".
The example shows a fault with code number 6.
1 s
1423 65
1 s
1423 65
Figure 11-1 Fault codes - example
The table below describes the possible faults and the measures to be taken to remedy a
fault.
Note
When remedying a fault, the following sequential order must always be followed:
1. Removing the control supply voltage at the 3RB24 solid-state overload relay.
2. Remove the cause of the fault.
3. Applying the control supply voltage at the 3RB24 solid-state overload relay.
Diagnostics
11.3 Fault codes (only in the case of non-acknowledgeable faults)
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 105
Table 11- 1 Error codes
Code Description Remedy1)
1 Thermistor fault on starting.
The thermistor is activated but not detectable or no longer
detectable. There is possibly a wire break.
Check the thermistor.
Deactivate the thermistor
or connect the thermistor.
2 Thermistor fault: Short-circuit.
The thermistor has short-circuited.
Remove the short-circuit.
3 Thermistor fault: Wire break.
The connection is interrupted.
Remove the interruption
and connect the
thermistor.
4 — —
5 There is a fault in communication with the current measuring
module during starting.
Check that the current
measuring module is
connected.
6 The assignment of the rated operational current Ie to the current
measuring module is incorrect:
The set rated operational current Ie is outside the permissible
current range of the current measuring module, or the rotary
switch is outside 10 ... 100%.
(See Chapter "Setting the current (rated operational current)
and trip class (Page 79)")
Check the set rated
operational current Ie on
the solid-state overload
relay. Correct the setting
error with the help of the
two rotary switches on the
device.
7 An invalid current measuring module has been detected. Connect the 3RB29..
current measuring module.
You can find the suitable
current measuring
modules in Chapter
"System components
(Page 23)".
8 Undervoltage detected:
The permissible lower limit for operating voltage has been
violated.
Correct the operating
voltage setting to a
permissible value.
9 — —
10 Internal fault:
An internal fault has been detected.
Return the device to the
manufacturer.
1) Reset possible by switching off the control voltage supply and disconnecting the IO-Link supply
voltage.
Diagnostics
11.4 IO-Link diagnostics
3RB24 solid-state overload relay for IO-Link
106 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
11.4 IO-Link diagnostics
IO-Link diagnostics
The manufacturer-specific diagnostics listed in the table are reported via the diagnostic
mechanism of IO-Link. The table below provides information on possible causes and
remedial measures:
Table 11- 2 Possible causes and remedial measures
Diagnostics and messages Possible causes Possible remedial measures
Preset <> actual configuration • Fault in communication with current
measuring module.
• Wrong current measuring module.
• Operator panel available/not
available.
• Check the connection to the current
measuring module and replace the
current measuring module if
necessary.
• Connect a suitable current
measuring module.
• Correct the parameter "Operator
panel available".
• Change the parameter "Operation
at Preset <> Actual Operation" to
"enable":
Switching element defective • Contactor welded.
• Defective relay contacts in the 3RB24
overload relay.
• Replace the contactor.
• Replace the overload relay.
Process image error Error in the process image of the
directions of rotation:
Direction of rotation 1 and direction of
rotation 2 are active simultaneously.
• Delete the selection of the two
directions of rotation in the process
image.
• Correct the selection via the
process image.
Manual mode connection abort
(operator panel)
Operator panel removed in "manual
mode"
Remount operator panel and perform
"reset to automatic mode". (see
"Manual mode" in the Chapter
"Operation using the operator panel
(Page 94)")1)
The overload relay is in manual mode
and cannot be controlled using the
operator panel.
• There is a group error.
• The enabling module has been
removed from the operator panel.
• Remove the cause of the fault and
reset the group error.
• Insert the enabling module into the
slot on the operator panel.
Thermistor overload Overheating of the motor. • Allow the motor to cool down.
Overload tripping Overheating of the motor. • Allow the motor to cool down.
Ground fault tripping The overload relay has detected a
ground fault.
Eliminate the ground fault.
Diagnostics
11.4 IO-Link diagnostics
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 107
Diagnostics and messages Possible causes Possible remedial measures
Residual current tripping
(Switching relay is switched on but
there is no current flow.)
• Defective contactor.
• Defective fuse in the main circuit.
• Defective relay in the overload relay.
• Replace the contactor.
• Replace the fuse in the main circuit.
• Replace the overload relay.
Thermistor wire break • Connection to the thermistor
disrupted.
• Thermistor is defective.
• Renew the connection to the
thermistor.
• Renew the thermistor.
Thermistor short-circuit • Connection to the thermistor is
defective/flattened.
• Thermistor is defective.
• Renew the connection to the
thermistor.
• Renew the thermistor.
Electronics supply voltage too low Supply voltage too low or incorrect • Ensure a supply voltage with
24 V DC.
Self-test error Fault in internal test Return the device to the manufacturer.
Impermissible Ie/CLASS setting The set rated operational current Ie is
outside the permissible current range of
the current measuring device or the
rotary switch.
• Correct the setting of the rated
operational current Ie.
• Select a current measuring module
that is suited to the set rated
operational current Ie .
Cold start tripping A current flow has been detected in the
main circuit during cold starting (current >
12%).
Switch off the main circuit.
Thermal motor model overload Overheating of the motor. Allow the motor to cool down.
1) Please note the following warning information:
CAUTION
To avoid faults in the overload relay and a defect on the operator panel, connect or
disconnect the operator panel only when the power to the evaluation unit is turned off.
Diagnostics
11.4 IO-Link diagnostics
3RB24 solid-state overload relay for IO-Link
108 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
The table below indicates how the manufacturer-specific diagnostics are reported:
Table 11- 3 Diagnostics and messages
PII 2) LED Diagnostics and messages IO-Link for event
code 1) SF3) GW
4)
Data set 92
DEVICE/
IO-LINK
Switching element defective 0x8CA9 x — x red
Thermistor wire break 0x8CA6 x — x red
Thermistor short-circuit 0x8CA1 x — x red
Overload tripping 0x8CB8 x — x red
Residual current detected 0x8CB8 x — x red
Ground fault tripping 0x8CB8 x — x red
Manual mode connection abort
(operator panel)
0x8CA9 x — x red
Process image error 0x8CBA x — x red
Self-test error 0x8CA9 x — x red
Preset <> actual configuration 0x8CB0 x — x red
Cold start tripping 0x8CB8 x — x red
Impermissible Ie/CLASS setting 0x8CB0 x — x red
Operating voltage too low 0x8CA9 x — x red
1) The manufacturer-specific diagnostic events listed in the table are reported to the IO-Link
master via the diagnostic mechanism of IO-Link.
2) With the "process input image" (see "Process image of outputs (PIQ) and inputs (PII)
(Page 59)"), you can determine via the group error (GE) bit or general warning (GW) bit in
the user program whether detailed information on diagnostics or messages in diagnostic
data set 92 are present. If bit ( = 1 ) is set, you can obtain detailed information on what
caused a "group error" or "general warning" by reading data set 92. The table above
provides information on the possible cause and remedial measures.
3) GE = Group error: You can obtain detailed information via diagnostics data set 92 (see
"Diagnostics - data set (index) 92 (Page 123)").
4) GE = Group error: You can obtain detailed information via diagnostics data set 92 (see
"Diagnostics - data set (index) 92 (Page 123)").
x: Bit set
—: Bit not set
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 109
Appendix A
A.1 Dimension drawings (dimensions in mm)
The dimension drawings below show the evaluation module with the different connection
methods: screw-type and spring-loaded.
F
G
D
E
3RB2483-4AA1
a 65
b 36
c 95
d 106
Figure A-1 Evaluation module 3RB2483-4AA1 (screw-type connection)
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
110 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
F
G
D
E
3RB2483-4AC1
a —
b —
c 99
d 110
Figure A-2 Evaluation module 3RB2483-4AC1 (spring-loaded connection)
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 111
A.1.1 Current measuring module
A.1.1.1 Current measuring module 3RB2906-2BG1 and 3RB2906-2DG1
The following dimension drawings show the different versions of the current measuring
modules.
Current measuring module 3RB2906-2BG1 and 3RB2906-2DG1
T1T3
T2
7.5
45 40
5
84
38
Figure A-3 Current measuring module 3RB2906-2BG1, 3RB2906-2DG1
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
112 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.1.1.2 Current measuring module 3RB2906-2JG1
Current measuring module 3RB2906-2JG1
T1
T2
T3
55 67
94
65
14
5
Figure A-4 Current measuring module 3RB2906-2JG1
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 113
A.1.1.3 Current measuring module 3RB2956-2TG2
Current measuring module 3RB2956-2TG2
120
95
79
95
5140
78
25
7
Figure A-5 Current measuring module 3RB2956-2TG2
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
114 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.1.1.4 Current measuring module 3RB2956-2TH2
Current measuring module 3RB2956-2TH2
120
95
37 17
9
79
95
119
747
140
5
84
Figure A-6 Current measuring module 3RB2956-2TH2
Appendix
A.1 Dimension drawings (dimensions in mm)
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 115
A.1.1.5 Current measuring module 3RB2966-2WH2
Current measuring module 3RB2966-2WH2
145
57
25
50
11
9
85
122
147
125
6
148
6
60.5
60.5
Figure A-7 Current measuring module 3RB2966-2WH2
Appendix
A.2 Circuit diagrams
3RB24 solid-state overload relay for IO-Link
116 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.2 Circuit diagrams
A.2.1 Internal circuit diagram
Internal circuit diagram for 3RB24 for IO-Link
+
+
+
+
4
4
/ &4 /
7 7 < < , ,
Figure A-8 Internal circuit diagram for 3RB24 for IO-Link
Appendix
A.2 Circuit diagrams
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 117
A.2.2 Sample circuit diagrams
The solid-state overload relay for IO-Link is connected to the current measuring module by a
ribbon cable (3RB2987-.).
Direct-on-line start/star-delta (wye-delta) start
Note
Star-delta (wye-delta) starters must be activated by the solid-state overload relay for IO-Link
as direct-on-line starters.
AU
F
)
IO-Link
Master
L1
L2
L3
N
PE
F3 F4 F5
531
642
-Q1E
H1
H2
H3
H4
3~
M
T1 T2 T3
L1 L2 L3
F1
U
V
W
96
F2
T1 T2
DEVICE/
GND
FAULT
THER-
MISTOR
OVER-
LOAD
RESET
TO
MAN
Ground
ault
CLASS
5, 10, 20, 30
Y1 Y2
REMOTE-
RESET
I(-
I(+)
4-20 mA
98 95
3RB29.6...
3RB24...
3RB2987-2...
Q2
Q1
IO-LINK
F6
6A
gG
L+ C/Q L-
L+ C/Q L-
Q1E
Figure A-9 Sample circuit diagram direct-on-line start/star-delta (wye-delta) start
Appendix
A.2 Circuit diagrams
3RB24 solid-state overload relay for IO-Link
118 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Current measuring with an external current transformer
AU
F
)
ϑ
ϑ
IO-Link
Master
L1
L2
L3
N
PE
F3 F4 F5
531
642
-Q1E
H1
H2
H3
H4
3~
M
T1 T2 T3
L1 L2 L3
F1
U
V
W
96
F2
T1 T2
DEVICE/
GND
FAULT
THER-
MISTOR
OVER-
LOAD
RESET
TO
MAN
Ground
ault
CLASS
5, 10, 20, 30
Y1 Y2
REMOTE-
RESET
I(-
I(+)
4-20 mA
98 95
3RB29.6...
3RB24...
3RB2987-2...
Q2
Q1
IO-LINK
F6
6A
gG
L+ C/Q L-
L+ C/Q L-
Q1E
T1 T2 T3
L1 L2 L3
3UF1868
K1
K2
K3
L
Figure A-10 Example circuit: current measuring with an external 3UF1868 current transformer
Appendix
A.2 Circuit diagrams
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 119
Reversing start
AU
F
)
IO-Link
Master
L1
L2
L3
N
PE
F3 F4 F5
531
642
-Q1E
H1
H2
H3
H4
3~
M
T1 T2 T3
L1 L2 L3
F1
U
V
W
96
F2
T1 T2
DEVICE/
GND
FAULT
THER-
MISTOR
OVER-
LOAD
RESET
TO
MAN
Ground
ault
CLASS
5, 10, 20, 30
Y1 Y2
REMOTE-
RESET
I(-
I(+)
4-20 mA
98 95
3RB29.6...
3RB24...
3RB2987-2...
Q2
Q1
531
642
-Q2E
IO-LINK
F6
6A
gG
L+ C/Q L-
L+ C/Q L-
Q1E Q2E
Figure A-11 Sample circuit diagram reversing start
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
120 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.3 Data sets
A.3.1 Structure of the data sets
Overview of the data sets
Table A- 1 Data sets - overview
Data set
Address
(dec)
Subindex
supported
Name Access Value Length
(bytes)
0x00 (0) Yes Parameter Page 0 r — 16
0x10 (16) No Manufacturer's name r Siemens AG 10
0x11 (17) No Manufacturer's text r Internet
(http://support.automation.siemens.com/WW/
view/en/37432258/133200)
64
0x12 (18) No Product name r SIRIUS Overload Relays IO-Link 30
0x13 (19) No Product ID r 3RB2483-4A*1 12
0x14 (20) No Product text r — 2
0x15 (21) No Serial number r
Serial number
1) 8
0x16 (22) No Hardware revision r
Hardware version
1) 4
0x17 (23) No Firmware revision r
Firmware version
1) 4
0x18 (24) No Application-specific name r/w — 64
0x28 (40) No Process Data Input r — 2
0x29 (41) No Process Data Output r — 1
1) Value varies for each overload relay.
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 121
A.3.2 IO-Link communication parameters
Parameter Page 0 - IO-Link communication parameters
Table A- 2 Parameter Page 0
Address
(dec)
Parameter name Access Description
0x00 (0) Master Command r/w —
0x01 (1) Master Cycle Time r/w —
0x02 (2) Min. Cycle Time r 0x17
0x03 (3) Frame Capability r 0x03
0x04 (4) IO-Link Revision ID r 0x10
0x05 (5) Process data IN r 0x10
0x06 (6) Process data OUT r 0x08
0x07 (7) Vendor ID 1 r 0x00
0x08 (8) Vendor ID 2 r 0x2A
0x09 (9) Device ID 1 r 0x09
0x0A (10) Device ID 2 r 0x06
0x0B (11) Device ID 3 r 0x01
0x0C (12) Function ID 1 r 0x00
0x0D (13) Function ID 2 — 0x00
0x0E (14) Reserved — —
0x0F (15) Reserved — —
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
122 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.3.3 Identification data
Identification data
Identification data refers to data stored in a module that supports users in the following
areas:
● When checking the system configuration
● When locating modified system hardware
● When troubleshooting a system.
Modules can be uniquely identified with the identification data.
Identification data
DPP 1) Data set
Index (dec) Index (dec)
Access Parameter Length
(bytes)
Default setting
0x07 (7) — r 0x00
0x08 (8) — r
Vendor ID 2
0x2A
0x09 (9) — r 0x09
0x0A (10) — r 0x06
0x0B (11) — r
Device ID 3
0x01
— 0x10 (16) r Manufacturer's name 10 Siemens AG
— 0x11 (17) r Manufacturer's text 64 Internet
(http://support.automation.siemens.com/WW/
view/en/37432258/133200)
— 0x12 (18) r Product name 30 SIRIUS Overload Relays IO-Link
— 0x13 (19) r Product ID 12 3RB2483-4A*1
— 0x14 (20) r Product text 2 —
— 0x15 (21) r Serial number 8
Serial number
2)
— 0x16 (22) r Hardware revision 4
Hardware version
2)
— 0x17 (23) r Firmware revision 4
Firmware version
2)
— 0x18 (24) r/rw Application-specific name 64 —
— 0x28 (40) r Process Data Input 2 —
— 0x29 (41) r Process Data Output 1 —
1) Direct Parameter Page
2) Value varies for each overload relay.
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 123
A.3.4 Diagnostics - data set (index) 92
Data set (index) 92 - diagnostics
Note
Bits that are not described in the tables below are reserved and should be ignored.
Note
Sub-indices are not supported.
Table A- 3 Data set (index) 92 (diagnostics) - solid-state overload relay for IO-Link
Byte.Bit Description SF1) GW
2)
Specific module diagnostics - solid-state overload relay for IO-Link
0.0 Ready
0.1 Motor direction of rotation 1 (clockwise)
0.2 Motor direction of rotation 2 (counter-clockwise)
0.0 ... 0.3
Reserved
0.4 Switching element defective x
0.5
Reserved
0.6 Group error
0.7 General warning
1
Reserved
2.0 Thermistor overload x
2.1 Thermistor wire break x
2.2 Thermistor short-circuit x
2.3 Thermal motor model overload x
2.4 Overload tripping x
2.5 ... 2.7
Reserved
3
Reserved
4.0 ... 4.4
Reserved
4.5 Residual current detected
4.6 Residual current tripping x
4.7 ... 5.7
Reserved
6.0 Ground fault detected
6.1 Ground fault tripping x
6.2 ... 6.6
Reserved
6.7 Electronics supply voltage too low x
7.0 ... 7.1
Reserved
7.2 ... 7.3 Automatic mode
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
124 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Byte.Bit Description SF1) GW
2)
7.4 ... 7.5 Manual mode (operator panel)
7.6 Manual mode connection abort (operator panel) x
7.7 Process image error x
8
Reserved
9.0 ... 9.1 Self-test active x
9.2 Self-test error x
9.3 ... 9.7
Reserved
10 ... 11
Reserved
12.0 ... 12.1
Reserved
12.2 Impermissible Ie/CLASS setting x
12.3 Preset <> actual configuration x
12.4 Thermistor protection deactivated
12.5 ... 12.7
Reserved
13
Reserved
14.0 Cold start active
14.1 Cold start tripping x
14.2 ... 14.7
Reserved
15 ... 23
Reserved
24.0 ... 24.2
Reserved
24.3 Prewarning limit: Motor heating exceeded x
24.4 ... 24.7
Reserved
1) GE = Group error
2) GW = General warning
For additional information, please refer to " Process image of outputs (PIQ) and inputs (PII)
(Page 59) " chapter.
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 125
A.3.5 Measured value - data set (index) 94
Data set (index) 94 - measured values
Note
Bits that are not described in the tables below are reserved and should be ignored.
Note
Sub-indices are not supported.
Table A- 4 Data set (index) 94 (measured values) - solid-state overload relay for IO-Link
Byte.Bit Description
0.0 ... 0.7 Phase current I (L1 rms in 3.125% steps)
1.0 ... 1.7 Phase current I (L2 rms in 3.125% steps)
2.0 ... 2.7 Phase current I (L3 rms in 3.125% steps)
3.0 ... 27.7
Reserved
28.0 ... 31.7 Phase current I (L1 rms in 0.01-A steps)
32.0 ... 35.7 Phase current I (L2 rms in 0.01-A steps)
36.0 ... 39.7 Phase current I (L3 rms in 0.01-A steps)
Example of relative value in [%] phase current I (L1 rms), Byte 0:
0x1E = 30 dec. → 30 • 3.125 = 93.75%
Example of absolute value in [A] phase current I (L1 rms), Byte 28 - 31:
00x00007A34 = 31284 dec. → 31284 • 0.01 A = 312.84 A
Note
In the case of non-acknowledgeable faults (see Chapter "Fault codes (only in the case of
non-acknowledgeable faults) (Page 104)"), the current value registers in data set 94 always
show maximum values:
• Phase current I (L1 rms in 3.125% steps) = 0xFF
• Phase current I (L2 rms in 3.125% steps) = 0xFF
• Phase current I (L3 rms in 3.125% steps) = 0xFF
• Phase current I (L1 rms in 0.01-A steps) = 0x7FFFFFFF
• Phase current I (L2 rms in 0.01-A steps) = 0x7FFFFFFF
• Phase current I (L3 rms in 0.01-A steps) = 0x7FFFFFFF
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
126 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.3.6 Preset configuration - data set (index) 130
Data set (index) 130 - preset configuration - operator panel
WARNING
Danger of uncontrolled motor start-up
Can Cause Death, Serious Injury, or Property Damage.
Make sure that the correct preset configuration is set in the new device after the solid-state
overload relay for IO-Link has been replaced.
For additional information on the procedure, please refer to "Parameters (Page 51)".
Note
Bits that are not described in the tables below are reserved and should be ignored.
Note
Sub-indices are not supported.
Table A- 5 Data set (index) 130 (target configuration) - operator panel
Byte.Bit Description
0 ... 17
Reserved
18.0 ... 18.5
Reserved
18.6 Operation at Preset <> Actual Configuration1)
18.7 Operator panel available2)
19 ... 21
Reserved
1) You can find more information on the "Operation at Preset <> Actual Configuration"
parameter for operation with the operator panel in Chapter "Parameter "Operation at Preset
<> Actual Operation" (Page 56)".
2) You can find more information on the "Operation at Preset <> Actual Configuration"
parameter for operation with the operator panel in Chapter ""Operator panel available"
parameter (Page 56)".
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 127
A.3.7 Technology functions - data set (index) 131
Data set (index) 131 - technology functions
Note
Bits that are not described in the tables below are reserved and should be ignored.
Note
Sub-indices are not supported.
Table A- 6 Data set (index) 131 (technology functions) - solid-state overload relay for IO-Link
Byte.Bit Bit length Access Description
0 ... 7
64
—
Reserved
8.5 1 r/w Ground fault detection2)
0 = Disable; 1 = Enable
9 ... 10
16
—
Reserved
11.3 1 r/w Cold start1)
0 = Disable; 1 = Enable
12 ... 15 32 r Rated operational current3) (in 0.01 A steps)
16 ... 17
16
—
Reserved
18.0 ... 18.1 2 r Response to overload - thermal motor model4)
0 = Tripping without restart (MAN);
1 = Tripping with restart (AUTO)
18.2 ... 18.7
6
—
Reserved
19.0 ... 19.3 4 r Trip class [CLASS]
CLASS 5 = 0x03
CLASS 10 = 0x00
CLASS 20 = 0x01
CLASS 30 = 0x02
Appendix
A.3 Data sets
3RB24 solid-state overload relay for IO-Link
128 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Byte.Bit Bit length Access Description
19.4 ... 19.7
4
—
Reserved
20 ... 23
32
—
Reserved
24.0 2 r Response to overload - thermistor5)
0 = Tripping without restart (MAN);
1 = Tripping with restart (AUTO)
24.2 ... 24.6
5
—
Reserved
24.7 1 r Thermistor - monitoring
0 = No; 1 = Yes
1) You can find more information on the "Cold start" parameter in Chapter ""Cold start"
parameter (Page 52)".
2) You can find more information on the "Ground fault detection" parameter in Chapter
""Ground fault detection" parameter (Page 53)".
3) You can find more information on the "Rated operational current" parameter in Chapter
""Rated operational current" parameter (Page 54)".
4) You can find more information on the "Response to overload - thermal motor model"
parameter in Chapter ""Response to overload - thermal motor model" parameter (Page 55)".
5) You can find more information on the "Response to overload - thermistor" parameter in
Chapter ""Response to overload - thermistor" parameter (Page 55)".
Appendix
A.4 References
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 129
A.4 References
Further references
In addition to this manual, please refer to the operating instructions and manuals for any
accessories. You can download the relevant documentation from the Internet
(www.siemens.com/automation/csi/manual). Simply enter the order number of the relevant
item into the search field.
Operating instructions
Title Order number
Solid-state overload relay for IO-Link
Solid-state overload relay for IO-Link (evaluation module) 3ZX1012-0RB24-1AA1
Current measuring module 3ZX1012-0RB00-1AA1
Contactors
Contactor S00 3ZX1012-0RH21-1AA1
Contactor S0 3ZX1012-0RT22-1AA1
Contactor combinations
Reversing combination S00 3ZX1012-0RA23-8AA1
Reversing combination S0 3ZX1012-0RA23-8BA1
Kit for reversing combination S00 3ZX1012-0RA20-4AA1
Kit for reversing combination S0 3ZX1012-0RA20-3AA1
Kit for star-delta contactor combination S00 3ZX1012-0RA20-4BA1
Kit for star-delta contactor combination S0 3ZX1012-0RA20-3BA1
Appendix
A.5 Correction sheet
3RB24 solid-state overload relay for IO-Link
130 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
A.5 Correction sheet
Correction sheet
Have you noticed any errors while reading this manual? If so, please use this form to tell us
about them. We welcome comments and suggestions for improvement.
Fax response
From (please complete):
To
SIEMENS AG
I IA CE MK&ST 3
92220 Amberg / Germany
Name
Company/Department
Address
_________________________________________________________________________________
Fax: +49 (0)9621-80-3337
Manual title:
Table A- 7 Errors, comments, and suggestions for improvements
3RB24 solid-state overload relay for IO-Link
Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 131
Index
A
Accessories - current measuring modules, 27
Accessories - evaluation module, 26, 29
Ambient conditions, 39
C
Commissioning
with no main power, 52
without connected motor, 52
Continuous operation, 98
Control commands, 59
Correction sheet, 130
D
Data set 130 - preset configuration, 126
Data set 131 - technology functions, 127
Data set 92 - Diagnostics, 123
Data set 94 - measured values, 125
Data sets
Overview, 120
Device concept, 16
Display elements
Operator panel, 95
Solid-state overload relay for IO-Link, 21
Disposal, 9
E
Enabling module, 98
F
Frequency converter, 40
G
Ground fault current, 53
Ground fault detection, 19, 40
Ground fault protection, 19, 53
H
Heavy starting, 39
I
Identification data, 122
IO-Link communication parameters, 121
IO-Link device
Configuring, 43, 44, 45, 46, 47
IO-Link diagnostics, 17, 106
IO-Link master
Configuring, 43, 44, 45, 46
J
Jog mode, 98
L
Loads in excess of 630 A rated operational current, 41
M
Manual mode, 97
MANUAL MODE, 97
Monitoring mode, 97
Motor current, 40, 53
Output using analog signal, 85
N
Normal starting, 39
O
Operating instructions, 129
Operator controls
Operator panel, 95
Solid-state overload relay for IO-Link, 21
Operator panel, 29
Connecting, 94
installing, 67
Operating, 95
Index
3RB24 solid-state overload relay for IO-Link
132 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02
Operator controls and display elements, 95
Order numbers
Accessories - current measuring modules, 27
Accessories - evaluation module, 26, 29
Overload protection, 18, 40
P
Parameter
Cold start (IO-Link), 52
Ground fault detection (IO-Link), 53
Operation at Preset <> Actual Configuration (IO-
Link), 56
Operator panel available (IO-Link), 56
Rated operational current, 54
Response to overload - thermal motor model
(RESET), 55
Response to overload - thermistor (RESET), 55
Thermistor protection, 55
Trip class, 54
Parameter assignment
Notes, 51
Parameter Page 0, 121
Phase asymmetry, 17, 18
Phase failure, 18
Phase failure detection, 17
PII
Solid-state overload relay for IO-Link, 60
PIQ
Solid-state overload relay for IO-Link, 59
Port Configurator Tool (S7-PCT), 43, 44, 45, 46, 47
Process data
read, 60
write, 59
Properties
Solid-state overload relay for IO-Link, 15
R
Recycling, 9
References, 129
Removable terminals, 72
Replacing
Terminals, 72
Required basic knowledge, 9
S
Scope
Manual, 9
Screw terminals, 69
Short-circuit protection, 17
Single-phase AC motor, 39
Solid-state overload relay for IO-Link
Contactor assembly for star-delta (wye-delta)
start, 40
Spring-loaded terminals, 70
Status information, 60
System components, 16, 23
T
Technical Assistance, 10
Terminal assignment
Solid-state overload relay for IO-Link, 77
Thermistor protection, 18
Three-phase induction motor, 39
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Order No.: 3ZX1012-0RB24-0AC0
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