Protection devices 3RB24 solid-state overload relay for IO-Link Manual * 12/2011 Industrial Controls Answers for industry. 1 3RB24 solid-state overload relay for IO- ___________________ Introduction Link SIRIUS industrial controls Protection devices 3RB24 solid-state overload relay for IO-Link Manual 2 ___________________ Safety information 3 ___________________ Product description ___________________ 4 Use planning ___________________ 5 Configuring ___________________ 6 Parameters Process image of outputs ___________________ 7 (PIQ) and inputs (PII) ___________________ 8 Mounting/removal ___________________ 9 Connecting ___________________ 10 Operation ___________________ 11 Diagnostics ___________________ A Appendix 12/2011 GWA 4NEB 969 1656-02 DS 02 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 (R) 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 NURNBERG GERMANY Order number: 3ZX1012-0RB24-0AC0 12/2011 Technical data subject to change Copyright (c) Siemens AG 2011. All rights reserved Table of contents 1 Introduction...................................................................................................................................9 2 Safety information ....................................................................................................................... 11 3 Product description...................................................................................................................... 15 4 5 6 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 3.7.1 3.7.2 Technical data........................................................................................................................ 30 3RB24 evaluation unit ............................................................................................................ 30 3RB29 current measuring module .......................................................................................... 36 Use planning............................................................................................................................... 39 4.1 Applications............................................................................................................................ 39 4.2 Special application cases ....................................................................................................... 40 Configuring ................................................................................................................................. 43 5.1 5.1.1 5.1.2 5.1.3 Configuring in STEP 7............................................................................................................ 43 Requirements......................................................................................................................... 43 Configuration with STEP 7 and S7-PCT.................................................................................. 44 Configuration with STEP 7 and S7-PCT (GSD version)........................................................... 45 5.2 5.2.1 5.2.2 Configuring without STEP 7.................................................................................................... 46 Requirements......................................................................................................................... 46 Configuring without STEP 7.................................................................................................... 47 5.3 5.3.1 5.3.2 5.3.3 Module replacement ............................................................................................................... 48 Module replacement (replacement of an IO-Link device)......................................................... 48 Module replacement with PG/PC............................................................................................ 48 Module replacement without PG/PC ....................................................................................... 49 5.4 Integration into the SIMATIC environment (3RB24)................................................................. 50 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 5 Table of contents 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 6.9.1 6.9.2 Operation with operator panel .................................................................................................56 "Operator panel available" parameter ......................................................................................56 Parameter "Operation at Preset <> Actual Operation"..............................................................56 7 Process image of outputs (PIQ) and inputs (PII) ............................................................................. 59 8 Mounting/removal ....................................................................................................................... 63 9 10 11 A 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 Connecting................................................................................................................................. 69 9.1 Connection via terminals .........................................................................................................69 9.2 Connecting the solid-state overload relay for IO-Link ...............................................................75 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 10.5.1 10.5.2 Performing a reset...................................................................................................................89 Manual reset ...........................................................................................................................91 Automatic reset .......................................................................................................................92 10.6 Operation using the operator panel..........................................................................................94 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 Appendix ..................................................................................................................................109 A.1 A.1.1 A.1.1.1 A.1.1.2 A.1.1.3 Dimension drawings (dimensions in mm)...............................................................................109 Current measuring module ....................................................................................................111 Current measuring module 3RB2906-2BG1 and 3RB2906-2DG1 ..........................................111 Current measuring module 3RB2906-2JG1 ...........................................................................112 Current measuring module 3RB2956-2TG2...........................................................................113 3RB24 solid-state overload relay for IO-Link 6 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Table of contents A.1.1.4 A.1.1.5 Current measuring module 3RB2956-2TH2 ...........................................................................114 Current measuring module 3RB2966-2WH2 ..........................................................................115 A.2 A.2.1 A.2.2 Circuit diagrams ....................................................................................................................116 Internal circuit diagram ..........................................................................................................116 Sample circuit diagrams ........................................................................................................117 A.3 A.3.1 A.3.2 A.3.3 A.3.4 A.3.5 A.3.6 A.3.7 Data sets...............................................................................................................................120 Structure of the data sets.......................................................................................................120 IO-Link communication parameters .......................................................................................121 Identification data ..................................................................................................................122 Diagnostics - data set (index) 92............................................................................................123 Measured value - data set (index) 94.....................................................................................125 Preset configuration - data set (index) 130.............................................................................126 Technology functions - data set (index) 131...........................................................................127 A.4 References............................................................................................................................129 A.5 Correction sheet....................................................................................................................130 Index ....................................................................................................................................... 131 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 7 Table of contents 3RB24 solid-state overload relay for IO-Link 8 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 9 Introduction 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 10 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 11 Safety information 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. 3RB24 solid-state overload relay for IO-Link 12 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Safety information 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 13 Safety information 3RB24 solid-state overload relay for IO-Link 14 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.1 3 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 stardelta (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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 15 Product description 3.2 System structure 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. 2 1 .. . 3 Evaluation module 3RB2483-4A .1 Current measuring module 3RB29.6-2... 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)". 3RB24 solid-state overload relay for IO-Link 16 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.3 Functions 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 17 Product description 3.3 Functions 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 in the case of a short-circuited thermistor. 3RB24 solid-state overload relay for IO-Link 18 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.3 Functions 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 19 Product description 3.3 Functions 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)". 3RB24 solid-state overload relay for IO-Link 20 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.4 Operator controls and display elements 3.4 Operator controls and display elements Equipment features of the evaluation module 96 95 98 T2 I(-) Y2 T1 I(+) Y1 SIRIUS DEVICE / IO-LINK 96 95 98 Q1 GND FAULT 5$$RQO\ Q2 THERMISTOR OVERLOAD 10 10 20 30 30 20 20 TEST/ RESET 5 5 10 10 5 30 20 1A 10 0 1 0A 20 10 5 A AUTO MAN 00 CLASS/I MAX A 30 RESET 30 15 40 50 60 10 100 70 90 80 %x I MAX 3RB2483-4AA1 G/JJMMTT *Exx* L+ C/Q L- Interface for operator panel: Enables connection of the 3RA6935-0A operator panel (optional accessory). 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. 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. Interface for current measuring module: Enables the connection of a current measuring module (device required for system setup). 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. Slide switch for AUTO/MAN-RESET: Enables selection between manual and automatic reset. Automatic reset is only possible after overload tripping and thermistor tripping. Red "OVERLOAD" LED: A continuous red light signals an active overload trip; a flickering red light signals an imminent trip (overload warning). Red "THERMISTOR" LED: A continuous red light signals an active thermistor trip. Red "GND FAULT" LED: A continuous red light signals an active ground fault trip. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 21 Product description 3.4 Operator controls and display elements 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 nonacknowledgeable 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)". 3RB24 solid-state overload relay for IO-Link 22 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.5 System components 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 3RB2483-4AA1 Solid-state overload relay for IO-Link: 1 x evaluation module with screwtype terminals 3RB2483-4AC1 Solid-state overload relay for IO-Link: 1 x evaluation module with springloaded 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) Image 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 23 Product description 3.5 System components Order number Scope of supply 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) Image 3RB24 solid-state overload relay for IO-Link 24 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.5 System components Order number Scope of supply 3RB2987-2B 1 x connecting cable for linking the evaluation module and the current measuring module (length 0.1 m); Image 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 25 Product description 3.6 Accessories 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 3RP1903 Push-in lugs for screw mounting 3RB2984-2 Sealable cover Image 3RB24 solid-state overload relay for IO-Link 26 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.6 Accessories 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 3RB1900-0B Push-in lug for screw mounting (two per module required) Image 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) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 27 Product description 3.6 Accessories Order number Components supplied 3RT1956-4EA2 Cover for box terminals, length 25 mm (size S6) Image 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) 3RB24 solid-state overload relay for IO-Link 28 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.6 Accessories 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 3RA6935-0A 1 x operator panel 1 x enabling module 1 x interface cover 4 x mounting bracket Table 3- 6 Image Accessories operator panel Order number Scope of supply 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 Image 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 29 Product description 3.7 Technical data 3.7 Technical data 3.7.1 3RB24 evaluation unit General technical data Order number 3RB2483-4AA1 Product brand name SIRIUS Product designation Solid-state overload relay for IO-Link IP degree of protection front IP20 3RB2483-4AC1 Insulation voltage at pollution degree 3, 300 V rated value 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 2g Impulse withstand voltage rated value 4000 V Total power loss, typical 0.5 W 3RB24 solid-state overload relay for IO-Link 30 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.7 Technical data Order number 3RB2483-4AA1 3RB2483-4AC1 Equipment designation F * In accordance with DIN 40719, expanded in accordance with IEC 204-2 and IEC 750 * 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 Tripping class acc. to IEC 60947-4-1 CLASS 5, 10, 20 and 30 adjustable Number of poles for main circuit 3 3RB2483-4AC1 Adjustable current response value of 0.3 A to 630 A the current-dependent overload release 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 31 Product description 3.7 Technical data Auxiliary circuit Table 3- 8 Auxiliary circuit Order number 3RB2483-4AA1 Contact reliability of the auxiliary contacts Suitability for PLC control (17 V, 5 mA) 3RB2483-4AC1 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 2A * 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 6A * At 110 V -- * At 120 V -- * At 125 V 6A * At 230 V 3A * 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 Version of the fuse link required for short-circuit protection of the auxiliary switch Fuse gL/gG: 6 A 3RB2483-4AC1 3RB24 solid-state overload relay for IO-Link 32 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.7 Technical data Mechanical design Table 3- 10 Mechanical design Order number 3RB2483-4AA1 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 Depth 95 mm 3RB2483-4AC1 113 mm Distance to be maintained with side-byside 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 33 Product description 3.7 Technical data 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 Yes auxiliary circuit and control circuit 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) Order number 3RB2483-4AA1 3RB2483-4AC1 Certificate of suitability IEC / CSA / UL / CCC Approvals/certificates Table 3- 12 Approvals/certificates 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 -- 3RB24 solid-state overload relay for IO-Link 34 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.7 Technical data IO-Link Table 3- 14 IO-Link Order number 3RB2483-4AA1 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) 3RB2483-4AC1 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 35 Product description 3.7 Technical data 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 1000 V degree 3) Rated impulse withstand voltage Uimp 6 kV Rated operational voltage Ue 1000 V 8 kV Type of current * Direct current No * Alternating current Yes, 50/60 Hz 5% Current setting 0.3 ... 3 A; 2.4 ... 25 A Power loss per device (max.) 0.5 W 10 to 100 A 20 to 200 A 63 to 630 A 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 690 V1) and auxiliary current paths acc. to IEC/EN 60947-1 (pollution degree 2) 1) For grounded networks, otherwise 600 V. 3RB24 solid-state overload relay for IO-Link 36 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Product description 3.7 Technical data 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 37 Product description 3.7 Technical data Type - overload relay current measuring module 3RB2906 3RB2906 3RB2956 3RB2966 Size S00/S0 S2/S3 S6 S10/S12 45 mm 55 mm Width 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 38 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Use planning 4.1 4 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 threephase 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). 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 39 Use planning 4.2 Special application cases 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. 3RB24 solid-state overload relay for IO-Link 40 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Use planning 4.2 Special application cases 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 41 Use planning 4.2 Special application cases 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 42 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 5 Configuring 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 IOLink 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)". 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 43 Configuring 5.1 Configuring in STEP 7 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. 3RB24 solid-state overload relay for IO-Link 44 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Configuring 5.1 Configuring in STEP 7 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 45 Configuring 5.2 Configuring without STEP 7 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. 3RB24 solid-state overload relay for IO-Link 46 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Configuring 5.2 Configuring without STEP 7 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). 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 47 Configuring 5.3 Module replacement 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. 3RB24 solid-state overload relay for IO-Link 48 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Configuring 5.3 Module replacement 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 S7400 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 49 Configuring 5.4 Integration into the SIMATIC environment (3RB24) 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 50 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 6 Parameters 6.1 Parameters Parameters You can set the following parameters: via IO-Link * Cold start on the device * Rated operational current Ie * Ground fault detection * Trip class [CLASS] * Operator panel available * Response to overload - thermal motor model * Operation at Preset <> Actual Configuration * 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) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 51 Parameters 6.2 "Cold start" parameter 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. 3RB24 solid-state overload relay for IO-Link 52 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Parameters 6.3 "Ground fault detection" parameter 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. Itrip_GF The response delay is 0.5 to 1 s. x Ie 1,2 Tripping area 0,9 0,6 0,3 0,3 1 2 3 4 5 6 7 IGF Ground fault current Itrip_GF Tripping current at ground fault Figure 6-1 8 9 10 x Ie Imotor Tripping Area (ground fault protection) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 53 Parameters 6.4 "Rated operational current" parameter 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. 3RB24 solid-state overload relay for IO-Link 54 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Parameters 6.6 "Response to overload - thermal motor model" parameter 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 55 Parameters 6.9 Operation with operator panel 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. 3RB24 solid-state overload relay for IO-Link 56 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Parameters 6.9 Operation with operator panel 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 Set parameter values Practical implementation Operator panel available Operation of the solidstate overload relay "Operation at Preset <> possible. Actual Configuration = "Disable" "Operator panel available" = "yes" and Operator panel not available Operator panel is disconnected during operation Operation of the solidstate 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" Operation of the solidThe solid-state state overload relay overload relay trips. "Operation at Preset <> Further operation of the possible. device not possible. Actual Configuration = Fault message "Disable" "Preset <> Actual Configuration" "Operator panel available" = "no" and The group error (SF) is reset automatically. Operation of the solidstate overload relay possible. "Operator panel available" = "yes" and Operation of the solidstate overload relay "Operation at Preset <> possible. Actual Configuration = "Enable" Operation of the solidstate overload relay possible. Operation of the solidstate overload relay possible. Operation of the solidstate overload relay "Operation at Preset <> possible. Actual Configuration = "Enable" Operation of the solidstate overload relay possible. Operation of the solidstate overload relay possible. "Operator panel available" = "no" and 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 57 Parameters 6.9 Operation with operator panel 3RB24 solid-state overload relay for IO-Link 58 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 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 DO0.4 Reserved -- DO0.5 Reserved -- DO0.6 Reserved -- DO0.7 Reserved -- 1) 2) See also Chapter "Carrying out self-test (Page 86)". For additional information on acknowledging and resetting group errors, please refer to Chapter "Performing a reset (Page 89)". 2) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 59 Process image of outputs (PIQ) and inputs (PII) Process image of inputs (PII) The process image of outputs contains the most important status information of the solidstate 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 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%: DI1.1 DI1.2 Iact (max) = 1.97 * Irated 3) 4) DI1.3 DI1.4 DI1.5 DI1.6 1: Manual mode Bit is set: The solid-state overload relay can be controlled via a connected operator panel. DI1.7 Reserved -- You can find detailed information on the group error via diagnostics set 92 in Chapter "Diagnostics - data set (index) 92 (Page 123)" 1) You can find detailed information on the general warning via diagnostics set 92 in Chapter "Diagnostics - data set (index) 92 (Page 123)" 2) 3) Iact = actually flowing current [A]; Irated = rated operational current [A] In the case of "non-acknowledgable" errors, the maximum current is displayed: 63 (= 111111B = 0x3F) 4) 3RB24 solid-state overload relay for IO-Link 60 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Process image of outputs (PIQ) and inputs (PII) 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 0A 200 A 275 A 393.75 A Iact / Irated 0 1 1.38 1.97 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 61 Process image of outputs (PIQ) and inputs (PII) 3RB24 solid-state overload relay for IO-Link 62 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Mounting/removal 8.1 8 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 standalone installation and mounting onto contactors. 8.2 Mounting position Mounting position Arbitrary mounting position of 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 63 Mounting/removal 8.3 Snapping onto/off DIN rail (snap-on mounting) 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 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. Image 3RB24 solid-state overload relay for IO-Link 64 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Mounting/removal 8.4 Screw mounting 8.4 Screw mounting The illustrations below show how to mount the evaluation module on a level surface. Step Instruction 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. Image 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 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. Image 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 65 Mounting/removal 8.6 Inserting the interface cover 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 1/2/ 3 Insert the interface cover into the slot from the front until it engages in the locking mechanism. Image 3RB24 solid-state overload relay for IO-Link 66 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Mounting/removal 8.7 Installing an operator panel 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 Instruction Make a cutout in the front panel, for example, or in the control cabinet door. 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. Image 90+0.5 30+0.5 Step 1 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 67 Mounting/removal 8.7 Installing an operator panel 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 1/2 Disengage the locking mechanism and remove the interface cover on the front of the solid-state overload relay for IO-Link. Image 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 68 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 9 Connecting 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) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 69 Connecting 9.1 Connection via terminals 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 3RB24 solid-state overload relay for IO-Link 70 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Connecting 9.1 Connection via terminals 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 AWG 2 x (0.25 ... 1.5) mm2 2 x (0.25 ... 1.5) mm2 2 x (0.25 ... 1.5) mm2 2 x (24 to 16) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 71 Connecting 9.1 Connection via terminals 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 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. Image ' & $ 3RB24 solid-state overload relay for IO-Link 72 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Connecting 9.1 Connection via terminals 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)" L1 L2 L3 N PE F3 F4 F5 F6 IO-Link Master -Q1E 1 3 5 2 4 6 L+ C/Q L+ F1 F2 L1 L2 L3 L- C/Q 6A gG Q1E L- 96 98 95 3RB24... 3RB29.6... 3RB2987-2... DEVICE/ IO-LINK GND FAULT THERMISTOR H1 RESET CLASS 5, 10, 20, 30 H2 H3 AUTO MAN Ground Fault H4 OVERLOAD Q2 Q1 T1 T2 T3 T1 T2 REMOTERESET U V W M 3~ Figure 9-1 Y1 Y2 I(- ) I(+) 4-20 mA Connection example 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 73 Connecting 9.1 Connection via terminals 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! L N L1 L2 L3 T2 T3 5% T1 0 a M 1~ Figure 9-2 3RB2906-2.G1, 3RB2956-2TG2 L N L1 L2 L3 T2 T3 5% T1 0 a M 1~ Figure 9-3 3RB2956-2TH2, 3RB2966-2WH2 3RB24 solid-state overload relay for IO-Link 74 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Connecting 9.2 Connecting the solid-state overload relay for IO-Link 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. 96 95 98 T2 I(-) Y2 T1 I(+) Y1 DEVICE / IO-LINK 96 95 5$$RQO\ SIRIUS 98 Q1 GND FAULT Q2 THERMISTOR OVERLOAD 10 10 20 30 1 0A 30 20 20 TEST/ RESET 5 5 10 10 5 30 20 1A 10 0 20 10 5 A AUTO MAN 00 CLASS/I MAX A 30 RESET 30 15 40 50 60 10 100 C/Q %x I MAX 3RB2483-4AA1 G/JJMMTT *Exx* L+ 70 90 80 L- ,2/LQN 0DVWHU Figure 9-4 Connection to IO-Link master 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 75 Connecting 9.2 Connecting the solid-state overload relay for IO-Link 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". 96 95 98 T2 I(-) Y2 T1 I(+) Y1 DEVICE / IO-LINK 96 95 5$$RQO\ SIRIUS 98 Q1 GND FAULT Q2 THERMISTOR OVERLOAD 10 10 20 30 1 0A 5 10 10 5 30 20 1A 10 0 5 30 20 20 TEST/ RESET 20 10 5 A AUTO MAN 00 CLASS/I MAX A 30 RESET 30 15 40 50 60 10 100 C/Q %x I MAX 3RB2483-4AA1 G/JJMMTT *Exx* L+ 70 90 80 L- '&9 Figure 9-5 Direct voltage supply with 24 V DC 3RB24 solid-state overload relay for IO-Link 76 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Connecting 9.2 Connecting the solid-state overload relay for IO-Link Pin assignment of the solid-state overload relay for IO-Link The following pin assignments apply for the solid-state overload relay for IO-Link with screwtype terminals or spring-loaded terminals. Meaning Supply voltage IO-Link/24 V DC C/Q Communication signal IO-Link L- Chassis ground IO-Link/24 V DC T2 Thermistor input I(-) Analog output Y2 Remote reset T1 Thermistor input Analog output Y1 Remote reset 96 95 98 I(-) Y2 T1 I(+) Y1 SIRIUS DEVICE / IO-LINK 96 95 98 Q1 GND FAULT Q2 THERMISTOR OVERLOAD CLASS/I e A RESET 95 Switching contact Q1 - NO contact 98 Changeover contact Q2 - NO contact 1) 4 MAX 10 20 30 5 10 20 30 30 20 20 TEST/ RESET 10 5 5 10 10 5 30 20 A Changeover contact Q2 - NC contact AUTO MAN 1 0A 96 30 15 40 50 60 10 4 100 L+ C/Q 70 90 80 %x I MAX 3RB2483-4AA1 G/JJMMTT *Exx* 1) T2 00 I(+) Connection for IO-Link master/PELV 24 V DC 5$$RQO\ L+ Image 1A Marking Pin assignment of the solid-state overload relay for IO-Link 10 0 Table 9- 3 L- 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)" 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 77 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 10 Operation 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 MAX A 10 20 30 30 20 5 10 A 1 0A 10 5 10 5 30 20 Figure 10-1 1A 10 0 00 20 30 5 10 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). 20 30 15 40 50 60 10 100 90 80 70 Figure 10-2 % x IMAX Setting the rated operational current Ie of the motor (e.g. 90%) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 79 Operation 10.1 Setting the current (rated operational current) and trip class 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 x 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 nonacknowledgeable faults) (Page 104)". 3RB24 solid-state overload relay for IO-Link 80 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.1 Setting the current (rated operational current) and trip class 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 81 Operation 10.1 Setting the current (rated operational current) and trip class 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. PLQ W$ &/$66 V 10 &/$66 Figure 10-3 [,H Tripping characteristic for 3-pole load Phase failure detection To minimize the temperature rise of the load in the case of a phase failure during singlephase operation, the 3RB24 solid-state overload relay for IO-Link has a phase failure detection feature. 3RB24 solid-state overload relay for IO-Link 82 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.1 Setting the current (rated operational current) and trip class Tripping characteristics for 2-pole load In the case of a phase failure or current unbalance > 40 % (in accordance with NEMA), the 3RB24 solid-state overload relay disconnects the contactor faster to minimize the temperature rise of the load. This operation takes place in accordance with the tripping characteristic for two-pole load from cold. PLQ W$ &/$66 V &/$66 Figure 10-4 [,H 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 83 Operation 10.2 Activating/deactivating thermistor protection 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 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. 3RB24 solid-state overload relay for IO-Link 84 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.3 Outputting an analog signal 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 24 mA 20 mA 16.8 mA 16 mA 12 mA 8 mA ,,H>@ ,PRWRU>$@ ,RXW>P$@ 4 mA 0 mA 0%xIe 20%xIe Figure 10-5 40%xIe 60%xIe 80%xIe ,RXWP$ P$ , RXWP$ [,H P$ ,PRWRU[P$,HP$ 100%xIe 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 Accuracy +/-5% Short-circuit-proof and open circuit-proof Yes 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 85 Operation 10.4 Carrying out self-test 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 selftest 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. 3RB24 solid-state overload relay for IO-Link 86 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.4 Carrying out self-test 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 phase Test phases Duratio Description n Comment 1 3s Indicator test Check that all LEDs flash. 2 3s 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) 5 2s Acknowledgment System opens the outputs 95/96 and 05/06. 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: 7(67 5(6(7 ,QGLFDWRUWHVW &RQILJXUDWLRQWHVW ,QWHUQDOWHVWV 5HOD\WHVW 7HVWSKDVH Figure 10-6 W>V@ Chronological sequence of the test phases 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 87 Operation 10.4 Carrying out self-test 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 Relay Q1 and Q2 remain in the drop-out state. 96 95 98 Q1 Q2 Clockwise rotation 96 95 Relay Q1 is in the pick-up state. 98 Q1 Q2 Counter-clockwise rotation 96 95 Relay Q1 and Q2 are in the pick-up state. 98 Q1 Q2 3RB24 solid-state overload relay for IO-Link 88 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.5 Performing a reset 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)". 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 89 Operation 10.5 Performing a reset 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) Preset <> Actual Configuration 2) "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. 3RB24 solid-state overload relay for IO-Link 90 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.5 Performing a reset 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 91 Operation 10.5 Performing a reset 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 currentdependent 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. 3RB24 solid-state overload relay for IO-Link 92 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.5 Performing a reset 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 Reason for tripping Resetting the solid-state overload relay for IO-Link Reset action Brief pressing of the TEST/RESET button Remote reset (press button at Y1-Y2) Reset via IO-Link Automatic reset (switch2)) 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 Immediately Not functional 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 93 Operation 10.6 Operation using the operator panel 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. 3RB24 solid-state overload relay for IO-Link 94 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.6 Operation using the operator panel 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 95 Operation 10.6 Operation using the operator panel (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. 3RB24 solid-state overload relay for IO-Link 96 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.6 Operation using the operator panel 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 (counterclockwise) 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 1. Check whether a group error is present: errors - 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 97 Operation 10.6 Operation using the operator panel 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. 3RB24 solid-state overload relay for IO-Link 98 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Operation 10.6 Operation using the operator panel 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 Change from continuous mode to jog mode 1) Resetting to automatic mode 2) or button again to stop activation. 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. 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 button. Activation stops as soon as you release the button. 2) Continuous operation: If you press the or activated until you press the button again. or button, the solid-state overload relay is 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 99 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 11 Diagnostics 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: DEVICE / IO-LINK: red continuous light 95/96 open 95/98 open GND FAULT: red continuous light 95/96 open 95/98 open * GND FAULT * THERMISTOR * OVERLOAD (See Chapter "Fault codes (only in the case of nonacknowledgeable faults) (Page 104)") or device defective Ground fault tripping DEVICE / IO-LINK: red continuous light Thermistor trip THERMISTOR: red continuous light 95/96 open 95/98 open DEVICE / IO-LINK: red continuous light Thermistor deactivated THERMISTOR: red flashing at 7 s intervals The set status of the relay remains in force. Overload tripping OVERLOAD: red continuous light 95/96 open 95/98 open DEVICE / IO-LINK: red continuous light 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)" 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 101 Diagnostics 11.1 Indication of the operating state Status Status display Auxiliary contacts 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 Device not ready 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 3RB24 solid-state overload relay for IO-Link 102 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Diagnostics 11.2 Auxiliary contacts 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 103 Diagnostics 11.3 Fault codes (only in the case of non-acknowledgeable faults) 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 2 1s Figure 11-1 3 4 5 6 1 2 3 4 5 6 1s 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. 3RB24 solid-state overload relay for IO-Link 104 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Diagnostics 11.3 Fault codes (only in the case of non-acknowledgeable faults) 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 105 Diagnostics 11.4 IO-Link diagnostics 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 Preset <> actual configuration * Fault in communication with current measuring module. * Wrong current measuring module. * Operator panel available/not available. Switching element defective Process image error Manual mode connection abort (operator panel) Possible remedial measures * 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": * Contactor welded. * Defective relay contacts in the 3RB24 * overload relay. Error in the process image of the directions of rotation: Direction of rotation 1 and direction of rotation 2 are active simultaneously. Operator panel removed in "manual mode" The overload relay is in manual mode * and cannot be controlled using the * operator panel. * Replace the contactor. Replace the overload relay. * Delete the selection of the two directions of rotation in the process image. * Correct the selection via the process image. Remount operator panel and perform "reset to automatic mode". (see "Manual mode" in the Chapter "Operation using the operator panel (Page 94)")1) 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. 3RB24 solid-state overload relay for IO-Link 106 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Diagnostics 11.4 IO-Link diagnostics Diagnostics and messages Residual current tripping (Switching relay is switched on but there is no current flow.) Thermistor wire break Thermistor short-circuit Possible causes Possible remedial measures * Defective contactor. * Replace the contactor. * Defective fuse in the main circuit. * Replace the fuse in the main circuit. * Defective relay in the overload relay. * Replace the overload relay. * Connection to the thermistor disrupted. * Renew the connection to the thermistor. * Thermistor is defective. * Renew the thermistor. * Connection to the thermistor is defective/flattened. * Renew the connection to the thermistor. * Thermistor is defective. * Renew the thermistor. Ensure a supply voltage with 24 V DC. Electronics supply voltage too low Supply voltage too low or incorrect * 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 Switch off the main circuit. A current flow has been detected in the main circuit during cold starting (current > 12%). Thermal motor model overload Overheating of the motor. 1) Allow the motor to cool down. 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. 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 107 Diagnostics 11.4 IO-Link diagnostics The table below indicates how the manufacturer-specific diagnostics are reported: Table 11- 3 Diagnostics and messages Data set 92 IO-Link for event code 1) PII 2) SF3) GW 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 Diagnostics and messages LED DEVICE/ IO-LINK 4) 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. 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. 2) GE = Group error: You can obtain detailed information via diagnostics data set 92 (see "Diagnostics - data set (index) 92 (Page 123)"). 3) GE = Group error: You can obtain detailed information via diagnostics data set 92 (see "Diagnostics - data set (index) 92 (Page 123)"). 4) x: Bit set --: Bit not set 3RB24 solid-state overload relay for IO-Link 108 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 A Appendix 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. D E G F 3RB2483-4AA1 a 65 b 36 c 95 d 106 Figure A-1 Evaluation module 3RB2483-4AA1 (screw-type connection) 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 109 Appendix A.1 Dimension drawings (dimensions in mm) D E G F 3RB2483-4AC1 a -- b -- c 99 d 110 Figure A-2 Evaluation module 3RB2483-4AC1 (spring-loaded connection) 3RB24 solid-state overload relay for IO-Link 110 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.1 Dimension drawings (dimensions in mm) 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. 84 Current measuring module 3RB2906-2BG1 and 3RB2906-2DG1 5 45 40 7.5 T1 T2 Figure A-3 38 T3 Current measuring module 3RB2906-2BG1, 3RB2906-2DG1 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 111 Appendix A.1 Dimension drawings (dimensions in mm) A.1.1.2 Current measuring module 3RB2906-2JG1 94 Current measuring module 3RB2906-2JG1 5 55 67 14 T2 Figure A-4 65 T1 T3 Current measuring module 3RB2906-2JG1 3RB24 solid-state overload relay for IO-Link 112 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.1 Dimension drawings (dimensions in mm) A.1.1.3 Current measuring module 3RB2956-2TG2 Current measuring module 3RB2956-2TG2 120 79 95 95 5 140 78 7 25 Figure A-5 Current measuring module 3RB2956-2TG2 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 113 Appendix A.1 Dimension drawings (dimensions in mm) A.1.1.4 Current measuring module 3RB2956-2TH2 Current measuring module 3RB2956-2TH2 120 95 17 37 79 95 119 9 7 5 47 84 140 Figure A-6 Current measuring module 3RB2956-2TH2 3RB24 solid-state overload relay for IO-Link 114 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.1 Dimension drawings (dimensions in mm) A.1.1.5 Current measuring module 3RB2966-2WH2 Current measuring module 3RB2966-2WH2 145 25 50 85 122 147 57 11 125 9 6 148 6 60.5 60.5 Figure A-7 Current measuring module 3RB2966-2WH2 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 115 Appendix A.2 Circuit diagrams A.2 Circuit diagrams A.2.1 Internal circuit diagram Internal circuit diagram for 3RB24 for IO-Link / &4 / 4 + + + + 7 7 Figure A-8 4 < < , , Internal circuit diagram for 3RB24 for IO-Link 3RB24 solid-state overload relay for IO-Link 116 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.2 Circuit diagrams 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. L1 L2 L3 N PE F3 F4 F5 F6 IO-Link Master -Q1E 1 3 5 2 4 6 L+ C/Q L+ F1 F2 L1 L2 L3 L- C/Q 6A gG Q1E L- 96 98 95 3RB24... 3RB29.6... 3RB2987-2... DEVICE/ IO-LINK GND FAULT THERMISTOR H1 RESET CLASS 5, 10, 20, 30 H2 H3 AUTO MAN Ground Fault H4 OVERLOAD Q2 Q1 T1 T2 T3 T1 T2 REMOTERESET U V W M 3~ Y1 Y2 I(- ) I(+) 4-20 mA Figure A-9 Sample circuit diagram direct-on-line start/star-delta (wye-delta) start 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 117 Appendix A.2 Circuit diagrams Current measuring with an external current transformer L1 L2 L3 N PE F3 F4 F5 F6 IO-Link Master -Q1E 1 3 5 2 4 6 L+ 3UF1868 C/Q L+ L1 L2 L3 F1 F2 L1 L2 L3 K1 3RB29.6... K3 DEVICE/ IO-LINK GND FAULT THERMISTOR L OVERLOAD 3RB2987-2... U V W M 3~ C/Q Q1E L- 96 98 95 3RB24... K2 T1 T2 T3 L- 6A gG H1 RESET CLASS 5, 10, 20, 30 H2 H3 AUTO MAN Ground Fault H4 Q2 Q1 T1 T2 T3 T1 T2 Y1 REMOTERESET Y2 I(- ) I(+) 4-20 mA Figure A-10 Example circuit: current measuring with an external 3UF1868 current transformer 3RB24 solid-state overload relay for IO-Link 118 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.2 Circuit diagrams Reversing start L1 L2 L3 N PE F3 F4 F5 F6 IO-Link Master -Q1E 1 3 5 2 4 6 -Q2E 1 3 5 2 4 6 L+ C/Q L+ F1 F2 L1 L2 L3 L- C/Q Q2E Q1E L- 6A gG 96 98 95 3RB24... 3RB29.6... 3RB2987-2... DEVICE/ IO-LINK GND FAULT THERMISTOR H1 RESET CLASS 5, 10, 20, 30 H2 H3 AUTO MAN Ground Fault H4 OVERLOAD Q2 Q1 T1 T2 T3 T1 T2 REMOTERESET U V W M 3~ Y1 Y2 I(- ) I(+) 4-20 mA Figure A-11 Sample circuit diagram reversing start 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 119 Appendix A.3 Data sets 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 Name Access Value Length (bytes) Address (dec) Subindex supported 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 0x16 (22) No Hardware revision r 4 0x17 (23) No Firmware revision r Hardware version 1) Firmware version 1) 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) 1) 8 4 Value varies for each overload relay. 3RB24 solid-state overload relay for IO-Link 120 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.3 Data sets 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 -- -- 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 121 Appendix A.3 Data sets 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) 0x07 (7) -- r 0x08 (8) -- r 0x09 (9) -- r Access Parameter Length Default setting (bytes) Vendor ID 2 0x00 Device ID 3 0x09 0x2A 0x0A (10) -- r 0x06 0x0B (11) -- r 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 -- 0x16 (22) r Hardware revision 4 -- 0x17 (23) r Firmware revision 4 Serial number 2) Hardware version 2) 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. 3RB24 solid-state overload relay for IO-Link 122 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.3 Data sets 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 Byte.Bit Data set (index) 92 (diagnostics) - solid-state overload relay for IO-Link 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 0.5 Reserved 0.6 Group error 0.7 General warning 1 Reserved x 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 3 4.0 ... 4.4 Reserved Reserved Reserved 4.5 Residual current detected 4.6 Residual current tripping 4.7 ... 5.7 Reserved 6.0 Ground fault detected 6.1 Ground fault tripping 6.2 ... 6.6 Reserved 6.7 Electronics supply voltage too low 7.0 ... 7.1 Reserved 7.2 ... 7.3 Automatic mode x x x 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 123 Appendix A.3 Data sets Byte.Bit Description 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 9.2 Self-test error 9.3 ... 9.7 10 ... 11 12.0 ... 12.1 Reserved Reserved Reserved SF1) GW 2) x x 12.2 Impermissible Ie/CLASS setting x 12.3 Preset <> actual configuration x 12.4 Thermistor protection deactivated 12.5 ... 12.7 13 Reserved Reserved 14.0 Cold start active 14.1 Cold start tripping 14.2 ... 14.7 15 ... 23 Reserved Reserved 24.0 ... 24.2 Reserved 24.3 Prewarning limit: Motor heating exceeded 24.4 ... 24.7 Reserved 1) GE = Group error 2) GW = General warning x x For additional information, please refer to " Process image of outputs (PIQ) and inputs (PII) (Page 59) " chapter. 3RB24 solid-state overload relay for IO-Link 124 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.3 Data sets 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 125 Appendix A.3 Data sets 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 18.0 ... 18.5 Reserved Reserved 18.6 Operation at Preset <> Actual Configuration1) 18.7 Operator panel available2) 19 ... 21 Reserved 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)". 1) 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)". 2) 3RB24 solid-state overload relay for IO-Link 126 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.3 Data sets 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 127 Appendix A.3 Data sets Byte.Bit Bit length Access Description 19.4 ... 19.7 20 ... 23 4 32 -- -- Reserved 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 You can find more information on the "Cold start" parameter in Chapter ""Cold start" parameter (Page 52)". 1) 2) You can find more information on the "Ground fault detection" parameter in Chapter ""Ground fault detection" parameter (Page 53)". You can find more information on the "Rated operational current" parameter in Chapter ""Rated operational current" parameter (Page 54)". 3) 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)". 4) You can find more information on the "Response to overload - thermistor" parameter in Chapter ""Response to overload - thermistor" parameter (Page 55)". 5) 3RB24 solid-state overload relay for IO-Link 128 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Appendix A.4 References 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 129 Appendix A.5 Correction sheet 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 To From (please complete): Name SIEMENS AG I IA CE MK&ST 3 Company/Department 92220 Amberg / Germany 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 130 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 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 3RB24 solid-state overload relay for IO-Link Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 131 Index 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 (IOLink), 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 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 R Recycling, 9 References, 129 Removable terminals, 72 Replacing Terminals, 72 Required basic knowledge, 9 S Scope Manual, 9 Screw terminals, 69 3RB24 solid-state overload relay for IO-Link 132 Manual, 12/2011, GWA 4NEB 969 1656-02 DS 02 Service & Support Download catalogs and information material: www.siemens.com/industrial-controls/catalogs Newsletter - always up to date: www.siemens.com/industrial-controls/newsletter E-business in the Industry Mall: www.siemens.com/industrial-controls/mall Online-Support: www.siemens.com/industrial-controls/support Contact for all technical information: Technical Assistance Tel.: +49 (911) 895-5900 E-Mail: technical-assistance@siemens.com www.siemens.com/industrial-controls/technical-assistance Siemens AG Industry Sector Postfach 23 55 90713 FUERTH GERMANY www.siemens.com/automation Subject to change without prior notice Order No.: 3ZX1012-0RB24-0AC0 (c) Siemens AG 2010