RCDs_Schweissanlagen

RCDs in welding systems

False tripping can be avoided by intelligent technology in welding systems

 Unplanned shutdowns of parts of the installation lead to production losses and equipment damage, endanger process reliability and the quality of the goods to be produced. It is therefore important to use suitable protective devices to interrupt the power supply only in the event of actually existing fault currents. Furthermore, incipient residual currents should be detected at an early stage. Only those who keep an eye on their electrical installation can react in time without the protective device switching off. The high currents and/or high voltages generated during resistance welding often mean that conventional RCDs/residual current devices (such as RCCB, RCBO, CBR) cannot be used.

The short, pulsed and extremely high load currents and the system-related high-frequency leakage currents lead to false tripping and thus to unnecessary interruptions. Furthermore, conventional RCD solutions cannot be optimally adjusted to the installation.

What does the standard say?

The use of a residual current device (RCD) is often prescribed by standards for different protection goals, e.g. as protection against indirect contact or as additional protection in earthed systems. In resistance welding according to DIN EN 62135-1 (VDE 0545-1) or IEC 62135-1, a residual current device (RCD) can be used for protection against electric shock in the event of a fault (indirect contact):

  • Generally, in TT systems “For each circuit or part of the electrical equipment different from the welding circuit (...) for automatic disconnection of the power supply before the time of contact with a touch voltage can become hazardous” (DIN EN 62135-1 section 6.4.1.).
  • “To provide protection in the case of a fault between input and the output circuits, in contact with the work-pieces” (DIN EN 62135-1 section 6.4.2.).

Is there an alternative to a conventional RCD solution?

We recommend the use of a modular residual current device (MRCD) according to DIN EN 60947-2 Annex M or IEC 60947-2 Annex M. Depending on your installation and your individual needs, we currently offer two product lines:

MRCDB300 series  → The integrated solution: Evaluation unit and current detection unit are combined in one device. The devices have a communication interface for parameter setting and transmission of the present status and the currently measured values.

MRCDB423 → The combined solution: Evaluation unit and current detection unit are separated from each other. The evaluation unit with display enables direct parameter setting and allows direct reading of the actual status on site.

Why is a modular residual current device the right choice for you?

You gain flexibility. Modular residual current devices (MRCD) from Bender can be fully adapted to your application. Not only can the size of the external measuring current transformer be selected according to the conductor cross sections and the load current, but also can response values, response times, relay behaviour, frequency response etc. be individually adjusted to your installation.

False tripping is avoided. Due to the very precise measurements and the resulting much smaller tolerance range during tripping, your resistance welding system remains available for longer. Conventional RCD solutions can already trip at 50 % of the response value, the Bender MRCD trips at 65 % at the earliest, normally only at about 85 %. 

False tripping caused by external influences such as high load currents from nearby cables are reduced by the optionally available magnetically shielded measuring current transformers. The MRCD from Bender also offers an adjustable filter function for frequency ranges and allows you to use existing circuit breakers.

What happens next? How do you find out whether an MRCD fits into your installation?

Feel free to contact us – we will be happy to advise you. We are convinced that by using an MRCD you will gain flexibility, reduce unnecessary interruptions and use a residual current device that can be optimally adapted to the special requirements of your welding applications.

We will gladly advise you individually

The advantages of modular residual current devices at a glance:

Downloads

CategoryNameSizeLanguageTimestampD-/B-Number
Software Database software UNIData300 V3.42 84.3 MB 2019/05/13 10:32:1213.05.2019 10:32:12
Software Unibackup (Version 1.1) 3.9 MB 2019/05/13 10:31:5913.05.2019 10:31:59
Software TMK-Set (V4.25) 5.8 MB 2019/05/13 10:32:0513.05.2019 10:32:05
Software TMK-History 2.6 MB 2019/05/13 10:32:0513.05.2019 10:32:05
Software TMK USB Driver V6.5 Windows XP/2003/Vista(32/64)/7(32/64) 3.3 MB 2019/05/13 10:31:5913.05.2019 10:31:59
Software PEM735 Webserver-Firmware V1.01.03 + Webserver v1.00.658 3.4 MB 2019/05/13 10:31:5913.05.2019 10:31:59D00084
Software Medi-Set Setup V1.17 4.6 MB DE2019/05/13 10:32:0413.05.2019 10:32:04
Software COM460IP update V3.06 10.0 MB 2019/05/13 10:32:0413.05.2019 10:32:04D00023
Software CP9xx, CP9…-I, CP700, COM465xx - SNMP MIB-Dateien 7.6 KB 2021/11/26 13:38:0526.11.2021 13:38:05D00005
Software DI-2USB Treiber WinXP 1.1 MB 2019/05/13 10:32:1213.05.2019 10:32:12D00103
Software EDS195P Readout 297.2 KB 2019/05/13 10:31:5913.05.2019 10:31:59
Software GSD File COM465DP 1.1 KB 2020/06/02 13:17:0902.06.2020 13:17:09D00216
Software GSD File FTC470XDP 1.8 KB 2019/05/13 10:31:5913.05.2019 10:31:59D00111
Software iso1685FR-Set V2.0 Parametriersoftware 727.3 KB DE2019/05/13 10:32:1213.05.2019 10:32:12D00128
Software Medi-History Updade englisch V1.17 196.5 KB EN2019/05/13 10:32:1313.05.2019 10:32:13
Software Medi-History_setup V1.17 16.4 MB EN2019/05/13 10:32:1413.05.2019 10:32:14
Software Medi-Set Setup V1.15 13.6 MB EN2019/05/13 10:32:0513.05.2019 10:32:05
Software Informationen zum Software Update von UNIMET 359.9 KB DE2019/05/13 10:32:0413.05.2019 10:32:04
Software COM465DP Update V4.0.2 37.4 MB 2020/03/26 13:45:5026.03.2020 13:45:50D00216
Software COM465IP Update V4.0.2 37.4 MB 2020/03/26 12:58:2226.03.2020 12:58:22D00217
Software UNIMET - Control Center, V4.3.3 15.2 MB DE2021/02/18 09:48:4318.02.2021 09:48:43
Software UNIMET - Control Center, V4.3.3 15.2 MB EN2021/02/18 09:47:2418.02.2021 09:47:24
Software Information on the software update for UNIMET 107.7 KB EN2019/05/13 10:32:1313.05.2019 10:32:13
Software BCOM Group Manager 72.1 KB 2019/05/13 10:32:1313.05.2019 10:32:13
Software CP700 Update V4.0.2 39.0 MB 2020/03/26 13:47:0826.03.2020 13:47:08D00005
Software Modbus RTU - Monitor isoxx425 V2.2.2 setup 7.1 MB 2019/05/13 10:31:5913.05.2019 10:31:59
Software iso1685 Set V2.1 48.1 KB 2019/05/13 10:31:5913.05.2019 10:31:59
Software DI-2USB Treiber Win10 3.4 MB 2019/05/14 09:00:4914.05.2019 09:00:49D00103
Software CP900 Update V4.0.2 35.1 MB 2020/03/26 13:47:5326.03.2020 13:47:53D00349, D00418
Software CP907 Update V4.0.2 35.1 MB 2020/03/26 13:48:2026.03.2020 13:48:20D00349, D00418
Software CP700 Update V4.3.8 50.4 MB 2022/08/05 08:09:1005.08.2022 08:09:10D00005
Software COM465ID Update V3.03 22.1 MB 2021/08/12 06:52:1512.08.2021 06:52:15D00368
Software iso685(W)-S/D-P Update V1.29 7.0 MB 2021/11/17 05:59:1317.11.2021 05:59:13
Software iso685(W)-S/D-B Update V1.29 6.3 MB 2021/11/17 05:59:0417.11.2021 05:59:04
Software PEM735 Webserver v1.00.687 669.4 KB 2021/10/21 07:44:3621.10.2021 07:44:36D00084
Software iso685(W)-S/D Update V1.29 6.2 MB 2021/11/17 05:58:5017.11.2021 05:58:50
Software isoHR685(W)-S/D Update V1.27 6.3 MB 2021/11/17 05:51:2817.11.2021 05:51:28D00261
Software GSDML V2.42 Bender COM465XX 6.7 KB 2022/06/07 08:34:3307.06.2022 08:34:33
Software GSDML V2.42 Bender CP9XX 6.2 KB 2022/06/07 08:34:3307.06.2022 08:34:33
Technical information Protection of persons, fire and plant protection, not an issue? 158.1 KB EN2020/11/24 15:18:4324.11.2020 15:18:43
Software Bender Connect Android 32 V1.6.0 33.4 MB 2022/06/29 12:56:4229.06.2022 12:56:42
Software Bender Connect Android 64 V1.6.0 36.2 MB 2022/06/29 12:56:4329.06.2022 12:56:43
Software COM463BC Update V4.6.2 28.9 MB 2022/07/29 09:14:2029.07.2022 09:14:20D00427
Software COM465DP Update V4.6.2 28.9 MB 2022/07/29 09:14:1929.07.2022 09:14:19D00216
Software COM465IP Update V4.6.2 28.9 MB 2022/07/29 09:14:2029.07.2022 09:14:20D00217
Software CP900 Update V4.6.2 27.4 MB 2022/07/29 09:14:1729.07.2022 09:14:17D00349, D00418
Software CP907 Update V4.6.2 27.4 MB 2022/07/29 09:14:1729.07.2022 09:14:17D00349, D00418

Products

Residual current monitoring

MRCDB300-Serie
LINETRAXX® MRCDB300 series

AC/DC sensitive residual current monitoring modules for MRCD applications

MRCDB423
LINETRAXX® MRCDB423

Modular residual current device type B for additional protection (protection against indirect contact) in earthed systems (TN and TT systems)

Residual current monitoring

MRCDB300-Serie
LINETRAXX® MRCDB300 series

AC/DC sensitive residual current monitoring modules for MRCD applications

Details
MRCDB423
LINETRAXX® MRCDB423

Modular residual current device type B for additional protection (protection against indirect contact) in earthed systems (TN and TT systems)

Details
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