Guy PONCET celduc 20061 ISO 9001 N° 1993/1106b Solid State Relays okpac ® range European Meeting

Guy PONCET celduc 2006Guy PONCET celduc 2006 11

ISO 9001N° 1993/1106bSolid State Relays

okpac® range

European Meeting


Innovation 2004 ISO 9001N° 1993/1106b

Solid State Relays

okpac® range

SC range SV range

New range ?a) Manufacturing Cost

Reduction

b) Performances

c) IP 20 = protection cover (mainly for Europe)

d) New look

COMMERCIAL IMPACT

SC5 : 1980 SC8 : 1990

SV8 : 1995

SO range

New 2004


ISO 9001N° 1993/1106b

okpac® range

CARLO

GAVAZZI

CROUZET/

GORDOSCRYDOM OMRON

Competition

Some Asian manufacturers

NAIS, KYOTTO FOTEK WOONYOUNG……


ISO 9001N° 1993/1106b

okpac® range

Our main goals are :

a) Innovation with Performances & Reliability

- Electricals

- Mechanical : terminals, IP 20 or not

b) Look : New celduc design

c) Lower price


ISO 9001N° 1993/1106b

okpac® range

a) Construction :* New housing, new terminals, SMD LED,…

LOW profile

L= 58.5mm

l = 44.5mm

H = 29mm

* Less mould mass : tropicalisation

Environment friendly Weight = 20 to 25% less Higher life-time expectancy

* IP20 or not. We can touch without any risk

Easy screwing thanks to open flaps

* Input connector in option


ISO 9001N° 1993/1106b

okpac® range

a) Construction :

Power thyristors (TMS2) on the aluminium base plate, nickel plated

SMD components

Screws are mounted on an encapsulated metallic base, (not a plastic base)


ISO 9001N° 1993/1106b

okpac® range

Without flaps With IP20 flaps on terminals

Open flaps for easy screwing connector

Pluggable spring connector for input

b) Configurations :


ISO 9001N° 1993/1106b

okpac® range Terminals :

The same screwdriver for input and output ! ( We are alone) The best terminals of the market !

Power

conductors sizes

according to

permanent currents


ISO 9001N° 1993/1106b

okpac® range

Direct wiring or with ferrules 1 or 2 wires per terminal

Wiring with power tabs

Up to 50mm2

Up to 2 x10 mm2

Means up to 2 x 50 A

Means 150A

Power Terminals : The best terminals of the market !

Wiring with a copper bar.


ISO 9001N° 1993/1106b

okpac® range

Power Terminals : The best terminals of the market !

FASTON terminals

COPPER LUGS WITH

CONTAINED PALM

up to 50mm2

(AWG0) = 150A

Washer

Very good in term of vibrations : Avionic, trains…..


ISO 9001N° 1993/1106b

okpac® range

Control terminals

Spring terminals or diagnostic models :« Plug and Play »

Standard M4 terminals For direct wiringOr for flat tabs

Pluggable.


INS

UL

AT

ION

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input

Serial resistor + reverse protection

Rectifier + filter

Opto-isolation

Zero mains voltage switch ON

Random mains voltage switch ON

Triac

Alternistor

Back to back thyristors

CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input

Current regulator + voltage protection

Transils on the gates.

Turn ON the SSR in case of overvoltage

ISO 9001N° 1993/1106bokpac® range

1P

ower

2

3 Protection

5

Op

to

Inp

ut

4

Sw

itchin

g

Solid State Relay construction


ISO 9001N° 1993/1106b

okpac® range

1 Power thyristors

Technology Comparison

Life Time expectancy

Chip size & Performances

INS

UL

AT

ION

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input


Rectifier + filter

Opto-isolation



Triac

Alternistor


CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input




SSR construction


ISO 9001N° 1993/1106b

Chipset used by most competitors(CRYDOM, NAIS, OMRON…)

Lot of layers:Connections, Solders, Molybdenum,silicon, ……..


ISO 9001N° 1993/1106b

okpac® range

Innovation in the substrate :Thanks to a high temperature (approx. 1000°C) diffusion process, a thick layer of copper (usually 0.4 mm) is directly imbedded onto the alumina substrate.( No extra layers)

The jumpers are replaced by a multitude of bonding wires with several anchor points to withstand significant overload currents.

This technology brings the following assets :

* Well improved thermal resistance (Rthj/c)

* Thermal cycle stress divided by 2 or 3.

* Simplified mounting, with automation giving rise to total control of the production process

For I >32A


ISO 9001N° 1993/1106b

okpac® range

Chip size35A : 5.6 x 5.6mm

50A : 7 x 7 mm

75A : 8.9 x 8.9mm

95A : 10.3 x 10.3mm

125A : 12.4 x 12.4mm


ISO 9001N° 1993/1106b

okpac® range

Current range:

12A - 25A - 35A - 50A - 75A - 95A -125A

Voltage range :

600V - (800V) - 1200V - 1600V

The largest range of the market !


ISO 9001N° 1993/1106b

okpac® range

Variation of temperature (°C)

1 : standard product2 : first generation of TMS23 : TMS2 second generation

LIFE TIME EXPECTANCY

preheating regulation

Inrush current at starting

Temperature variation


ISO 9001N° 1993/1106b

okpac® rangeReliability / Thermal cycling results

CRYDOM tests : 500 cycles with a variation of temperature of 100°C

CARLO tests : 5400 cycles with a variation of temperature of 100°C

CROUZET : 5100 cycles with a variation of temperature of 100°C

OMRON : 4500 cycles with a variation of temperature of 100°C

celduc ® standard SC range: 5 400 cycles with a variation of temperature of 100°C

celduc ® new okpac ® range: 10 000 cycles with a variation of temperature of 100°C

Tests made on a

50A model

SCRB to B Thyristor


ISO 9001N° 1993/1106b

okpac® range

Big advantage to have high current SSR

Origin of overload current : Load Inrush current

Load currentRMS nominal load current Ie

Overload currents

Io RMS

ORIGINS :- Motor starting, - Accidental mechanical load

increase on the motor shaft, - Lamp load (IR lamps) at

turn ON (cold state), - Transformer turn ON.

Io 5 to 10xIe Duration : 0,5s to 10s}

Io 10 to 20xIe Duration : 20 to 100ms

Io 20 to 100xIe Duration : 20 to 50ms

}

}

Advantages to have high surge current SSRs


ISO 9001N° 1993/1106b

okpac® range

Advantages to have high I2t SSR :

The capability to sustain overloads and inrush current is directly proportional with the size of the dices

Origin of overload current short-circuit of the load Iq = prospective short-circuit

current (current without protection on line) : can be > 1000x Ie

Actual current limited by the short-circuit protection device correponding to the I2t applied to the SSR

ORIGINS :

- Ageing of heating resistors,

- Ageing of insulating materials in motors ...

- Accidental short-circuit made by the user.



ISO 9001N° 1993/1106b

okpac® range

Short-circuit of the load :protection solutionFast Fuses

I2t fuse < I2t SSR

Fast Circuit Breakers

SSR with I2t > 5000A

2s

Advantages to have high I2t SSR :

Easy to protect even with a fast MCB

Short circuit

Mains

I >

Short-circuit

protection

Or

SSR

or

Load




Advantages to have high voltage SSRs

World Electricity Supplies:

Europe: 230VRMS & 400VRMS 50hz ±10% (690VRMS on few applications)

USA: 120 VRMS & 240 VRMS 60hz 460 & 480VRMS (+6% max)

Canada: 600VRMS (+4% max)

Japan: 100VRMS 50 and 60Hz / 200VRMS 50 and 60hz

Australia: 415 VRMS

KOREA & China: 380VRMS & 220VRMS India: 220VRMS & 400VRMS 50hz (with lots of perturbations)

……….

In power electronic and for a good reliability the rule is :

Device Peak voltage > about 2 times the mains voltage

In sine wave : Vpeak = VRMS x square root 2 = VRMS x 1.414

(Example 400VRMS + 10% 440 x 1.414 = 622Vpeak

Vpeak

VRMS


ISO 9001N° 1993/1106b

okpac® range

600Vpeak SSR Mains up to 275 / 280VRMS (Depends on the protection)

800Vpeak SSR Mains up to 440VRMS for mains without lots of perturbations !!!

1200Vpeak SSR Mains up to 510 / 600VRMS (Depends on the protection)

1600Vpeak SSR up to 690VRMS

We accept 10% more for the mains tolerance

Take Precautions for loads

with overvoltage at turn OFF

Advantages to have high voltage SSRs

Vpeak mains

VRMS mains

Vpeak SSR


ISO 9001N° 1993/1106b

okpac® range

2Optocouplers

Performances

INS

UL

AT

ION

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input


Rectifier + filter

Opto-isolation



Triac

Alternistor


CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input




SSR construction


ISO 9001N° 1993/1106b

okpac® range

OPTOISOLATOR

Typically Insulation Level : 5kV

Internal distances in compliance with VDE

Creepage & Clearance distances : 8mm In/Out

High level SO8 Standard SO9 Random SO7Zero Cross Level <12V <35V -

Turn ON time 10ms @ 50hz 10ms @ 50hz 0,050 ms

Coupler Immunity 10 000V/microsecond 500V/microsecond 10 000V/microsecond

2

Means low EMI in commutation

Means high Immunity

Means very fast answer

Means like competitors


ISO 9001N° 1993/1106b

okpac® range

3Input

INS

UL

AT

ION

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input


Rectifier + filter

Opto-isolation



Triac

Alternistor


CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input




SSR construction

DC control range

AC control range

Input current

LED


ISO 9001N° 1993/1106b

okpac® range

InputLEDs on Input with current regulator

Large input voltage

4-A2

3+A1

V1

DC input : 3-32 VDC with a limited current and

a voltage protection

3

AC input : 20-265VAC or DC with a limited current

1

2 4

6

filter


ISO 9001N° 1993/1106b

okpac® range

4 SwitchingIN

SU

LA

TIO

N

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input


Rectifier + filter

Opto-isolation



Triac

Alternistor


CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input




SSR construction

Zero Cross

How to choose ?

Type of loads ?

Random


ISO 9001N° 1993/1106b

okpac® range

4 Switching

Zero Cross SSR

AC-51

Heating loads

(Non Inductive or slightly inductive loads, resistance furnaces)

No Inrush current

No overvoltage

AC-55b

Lamps, Infrared lamps. Switching of incandescent lamps

Inrush current

( 8 to 10 times nominal current)

No overvoltage

SO9 SO8 (with In SSR = 8 x In load)


ISO 9001N° 1993/1106b

okpac® range

4 Switching

Zero Cross SSR

AC-55a

Discharges Lamps,

Switching of electric discharge lamp controls Inrush current

Inrush current


Overvoltages

One pole asynchronous motors with capacitor

(exemple compressor

= AC-58)

Inrush current


Overvoltages

SO8 (with In SSR = 8 x In load and U SSR = 2 x U mains)

SO8 (with In SSR = 8 x In load and U SSR = 2 x U mains)


ISO 9001N° 1993/1106b

okpac® range

4 Switching

Random SSR

AC-53 : Three pole asynchronous motors

Control of squirrel cage motors with two or three one pole SSRs

Inrush current

= 8 times nominal current


Few Overvoltages

AC-56a : Transformers

Inrush current

= up to 100 times nominal current

No overvoltage

High Inductive Loads

SO7 (with In SSR =8 x In load)

SO7 ! To choose consult celducSOP possible: (peak turn ON) but on request



4 SwitchingOther loads :

In any case consult celduc for these specific loads

Battery

rectifier

Inverter IGBT

mains

Output SSR

bypass SSRuser

K2

K1

SSRs for UPS Uninterrupted Power Supply

Random SSR (S07) high voltage

Capacitors for Power Factor Correctors

High voltage (1600V) Zero Cross SSR with some precautions : SO88xxx


ISO 9001N° 1993/1106b

okpac® range

5 Voltage Protection

Overvoltage originsEMC standards (*)Solutions

INS

UL

AT

ION

InputInput

adaptation circuit

Driving circuit

Power switching

device

Protection circuit

Output

DC voltage input


Rectifier + filter

Opto-isolation



Triac

Alternistor


CR

RC network

Varistor (VDR)

AC voltage input

DC voltage input




SSR construction

(*) : EMC = ElectroMagnetic Compatibility.


ISO 9001N° 1993/1106b

okpac® rangeVoltage Protection

High energy / medium frequency mains overvoltage

Mains voltageORIGIN : LIGHTNINGS

IEC/EN1000-4-5 (EMC standard)

IMMUNITY : (Overvoltages)

In case of overvoltage due to lightnings, the SSR can turn ON without control.

The high energy of this overvoltage can damage a SSR !

High Energy overvoltage


ISO 9001N° 1993/1106b


Immunity EMC: High Energy overvoltage solutions:

Mains

VDR

Load

VDR :

Overvoltage clamped by VDRMains

Load

Transils on the gate :

The SSR is turned ON.

In option for SO9

In standard for SO7, SO8, SOR.

In option for SO9

IEC/EN1000-4-5


ISO 9001N° 1993/1106b


Low energy / high frequency mains overvoltage

Mains voltage

ORIGIN :

dv/dt

Load current

Mains voltage

Time

dV/dt during commutations on inductive load

ORIGIN :

ON-->OFF

IEC/EN1000-4-4 (EMC standard)IMMUNITY : (dv/dt)

In case of overvoltage or dv/dt due to perturbations on the mains, the SSR can turn ON without control.

Generally, the low energy of this overvoltage doesn’t damage the SSR, but during few milliseconds, the load is ON without control (can be acceptable for an heating load, not for a lamp or a motor)

Fast Transient bursts


ISO 9001N° 1993/1106b


Immunity EMC : Fast Transient bursts solution

In option for SO9

In standard for SO7 (Inductive loads)

SO8 use high immunity components. So RC is not necessary (except for some inductive loads where random SO7 range with RC is adapted)

SSR with high immunity components

Mains

R

C

Load

Adding a RC snubber

IEC/EN1000-4-4


ISO 9001N° 1993/1106b


Other Type of overvoltages

SSR voltageNominal mains voltage

High energy / long duration overvoltages

ORIGINS :

µF

After turn OFF

Overvoltages due to the loads

Use SSRs with adapted voltages :

celduc :

up to 1600V


ISO 9001N° 1993/1106b

okpac® range

celduc Patented !

okpac with output status

yellow



okpac with status

Mains

Control

Load current

ON

No Mains or fuse open

Short-circuit SSR

Control LED

Status LED

OFF

Closed

Openton toff

to1to2

tc1 to1to2

to1to2

tc2 tc1

Status output

OPEN LOAD

Mains Failure Load Failure SSR Failure

celduc Patented !



okpac with status

Status output is normally closed without failure on the mains, the relay and/or the load . The yellow LED is switched ONIn case of failure on the mains (missed), the load (opened) or on the SSR (short-circuited), the status is opened . The yellow LED is switched OFF.

Advantages :• No power supply required• Outputs Status can be chained celduc Patented !

status

status


ISO 9001N° 1993/1106b

Complete

okpac® range


ISO 9001N° 1993/1106b

okpac®

o SO9 range for resistive loads

Output voltage

Output current

Vpeak (V)

Control Voltage Type Reference

SO941460SO942460SO945460SO963460SO965460SO967460

12-280VAC

12-280VAC

12-280VAC

24-600VAC

24-600VAC

24-600VAC

12A 600V 3-32VDC zero cross



35A 1200V 3.5-32VDC zero cross



With input

current regulator

SO942560SO963560SO965560SO967560

12-280VAC

12-280VAC

12-280VAC

24-600VAC





Input resistor

= Lower price

Market Entry

Flaps on request :

Minimum 1 flap for power .

Normally not necessary for DC controlOutput VDR on request



o

Output voltage

Output current

Vpeak (V)


12-275VAC 25A 600V 3-32VDC zero cross SO84207412-275VAC 25A 600V 20-265VAC/DC zero cross SO84297412-275VAC 35A 600V 3-32VDC zero cross SO84307012-275VAC 35A 600V 20-265VAC/DC zero cross SO84397012-275VAC 50A 600V 3-32VDC zero cross SO84507012-275VAC 75A 600V 3-32VDC zero cross SO84707012-275VAC 95A 600V 3-32VDC zero cross SO84807012-275VAC 125A 600V 3-32VDC zero cross SO84907024-510VAC 35A 1200V 3.5-32VDC zero cross SO86307024-510VAC 35A 1200V 20-265VAC/DC zero cross SO86397024-510VAC 50A 1200V 3.5-32VDC zero cross SO86507024-510VAC 50A 1200V 20-265VAC/DC zero cross SO86597024-510VAC 75A 1200V 3.5-32VDC zero cross SO86707024-510VAC 75A 1200V 20-265VAC/DC zero cross SO86797024-510VAC 95A 1200V 3.5-32VDC zero cross SO86807024-510VAC 95A 1200V 20-265VAC/DC zero cross SO86897024-510VAC 125A 1200V 3.5-32VDC zero cross SO86907024-510VAC 125A 1200V 20-265VAC/DC zero cross SO869970

SO8 range

for most of loads

Universal



o

Output voltage

Output current

Vpeak (V)


24-690VAC 50A 1600V 3.5-32VDC zero cross SO88506024-690VAC 75A 1600V 3.5-32VDC zero cross SO88706024-690VAC 95A 1600V 3.5-32VDC zero cross SO88806024-690VAC 125A 1600V 3.5-32VDC zero cross SO889060

SO8 range

High voltage range

1600 Volts



o

Output voltage

Output current

Vpeak (V)


12-275VAC 50A 600V 3-32VDC Random SO74509012-275VAC 75A 600V 3-32VDC Random SO74709024-510VAC 35A 1200V 3.5-32VDC Random SO76309024-510VAC 50A 1200V 3.5-32VDC Random SO76509024-510VAC 75A 1200V 3.5-32VDC Random SO76709024-510VAC 95A 1200V 3.5-32VDC Random SO76809024-510VAC 125A 1200V 3.5-32VDC Random SO769090

SO7 range

Random range

Random



o

Output voltage

Output current

Vpeak (V)


70-275VAC 35A 600V 7-30 VDC zero cross SOD84318070-275VAC 50A 600V 7-30 VDC zero cross SOD845180150-510VAC 50A 1200V 7-30 VDC zero cross SOD865180150-510VAC 75A 1200V 7-30 VDC zero cross SOD867180

SOD range

Range with Diagnostic

Diagnostic



o

Output voltage

Output current

Vpeak (V)


12-275VAC 25A 600V 3-32 VDC zero cross SOR84207424-510VAC 35A 1200V 3.5-32 VDC zero cross SOR86307024-510VAC 50A 1200V 3,5-32 VDC zero cross SOR86507024-510VAC 75A 1200V 3,5-32 VDC zero cross SOR867070

SOR range

Range with Input connector

Input connector


ISO 9001N° 1993/1106b

okpac® range

ACCESSORIES

Heatsinks : New versions

WF151200 WF108100

Thermal pads

Standard model : 5TH21000 or

With adhesive on the SSRs base

Flaps

for SO9 Power

terminals


ISO 9001N° 1993/1106b

okpac® range

NEW THERMAL PADs

5THxxxx thermal PAD is a thermally conductive phase change material coated on both sides of aluminium foil. At temperatures greater than 52°C, 5THxxxx changes into a molten state and, under low closure force, wets the heat sink and component surfaces to create a very thin, low thermal resistance interface. 5THxxxx has great heat spreading characteristics and won’t flow from the interface. 5THxxxx has superior thermal performance comparable to the highest performing grease and phase change products available

Documents

Guy PONCET celduc 20061 ISO 9001 N° 1993/1106b Solid State Relays okpac ® range European Meeting