From an organizational and security standpoint for industrial or electrical equipment, DIN rails contribute significantly toward reliability and efficiency. These standardized metal rails are suitable for mounting various devices, including circuit breakers, terminal blocks, and relays, making them ideal for modern electrical engineering and industrial automation. What are DIN rails, and what are the best practices for ensuring optimal mounting to achieve maximum performance? This guide will define DIN rails’ primary characteristics, classes, and use case recommendations to achieve optimal installation results. This article seeks to establish the relevance of DIN rail systems to operations in the industry in photographic detail to help the novice or intermediate-level reader understand their significance.
What is a DIN Rail?
A DIN Rail is a marker bar for mounting and anchoring industrial control equipment such as circuit breakers, terminal blocks, relays, etc. It is usually made from steel or aluminum and, thus, has the specified measurement set by the Deutchs Institut fur Normung (DIN), enabling it to be compatible with other electrical and automation functionalities. DIN rails and a busbar are more significant in component arrangement and installation within electrical enclosures for both commercial and industrial systems. The most ordinary type varies, one being the TH35 model, which is 35mm wide.
Definition of DIN Rail
A DIN rail is an international standard metal frame that places industrial control elements like circuit breakers and terminal blocks within an electric box. It is made to achieve a specific international standard for uniformity and compatibility of diverse components.
History and Origin: From 1928 to Now
The German Institute for Standardization (DIN) developed a DIN rail in the late 1920s in 1928 to simplify the installation of electrical components. In the last eighty years, its construction and usage have changed with industrial modernization while remaining within the bounds of global engineering regulations. It is an essential part of global electrical systems because of its multi-functionality and standardization influence on different manufacturers and industries, including the c40 and c50 rails.
Common Applications in Electrical Equipment
DIN rails are used with control panels, switchgear assemblies, and circuit breaker enclosures for mounting electrical parts. Parts and components like terminal blocks, relays, power supplies, and circuit breakers are mounted onto the DIN rails, improving efficiency. Components fitted onto the DIN rails can be interchanged easily, and compatibility across manufacturers is ensured. This makes DIN rails universal in Industrial automation building management and energy distribution systems.
What are the Different Types of DIN Rail?
Understanding Top-Hat Rail and 35mm DIN Rail
Tremendous popularity via INDUSTRY and ELECTRICAL USES comes from top hats, commonly called 35mm DIN rails. They typically feature a standardized diameter of 35mm, allowing them to fit a variety of modular parts. These rails comply with international requirements like IEC/EN 60715, which guarantees compatibility among various producers. The standardization of their dimensions and design aids in the proper assembly and maintenance of power systems, incorporating an integrated busbar for power supply distribution.
Exploring Steel DIN and Aluminum DIN Rail
Steel DIN rails are renowned for their durability and impressive load-bearing capacity, which makes them ideal for applications that require strength and robustness. When treated with appropriate finishes, such as galvanization, these rails become corrosion-resistant, enabling them to withstand harsh conditions.
Aluminum DIN rails are quite the opposite. They’re lightweight yet sturdy, offering a fantastic strength-to-weight ratio. These rails are also naturally corrosion-resistant, making them suitable for systems where weight reduction is a priority.
Both types of DIN rails are made of steel or aluminum and conform to standard dimensions, making them compatible with modular components—the decision to use which material depends on the chosen environmental conditions and the application’s mechanical requirements.
Choosing the Right DIN Rail for Your Needs
When selecting a DIN rail, consider environmental factors, load requirements, and component compatibility. Aluminum DIN rails are ideal for areas with moisture or corrosion concerns because they do not rust. Steel DIN rails are better for use when they need high mechanical strength. Always verify that the DIN rail has standard dimensions to provide perfect alignment when using modular components.
How is DIN Rail Mounting Performed?
Step-by-step Installation Guide
- Prepare the Mounting Surface: Check that the surface to which the components will be attached is flat, clean, and capable of supporting their weight.
- Measure and Mark Positions: Ensure that the drilling points correspond with the length of the DIN rail and the mounting holes for the fixture.
- Secure the DIN Rail: Use screws and washers to mount the rail on the surface to make sure that it is not able to move. Use the correct fasteners for the mounting surface material.
- Install the Components: Modular components like terminal blocks and relays can be mounted onto the DIN rail by pressing downwards until a click is heard, indicating that it has been locked in.
- Check the Alignment: Ensure all components are positioned correctly to prevent them from becoming too loose or unstable during operation.
- Inspect and Test: Make a final check to confirm the installation meets safety benchmarks. Confirm that every component functions correctly and as intended, including any parts of the design that require snapping on.
Tools Required for DIN Rail Mounting
- Screwdriver: Used to fasten the DIN rail and its fasteners. Ensure its size matches the screw head for adequate torque.
- Drill (as needed): Establish mounting cavities on a surface without precut holes.
- Level: Ensures the tape components are straight concerning all other elements after the DIN rail has been affixed to the surface.
- Measuring Tape: Used during mounting space measurement to verify the proper placement of elements.
- Wire Cutters/Strippers: These are used to form the electrical wires for the installed parts.
- Safety Equipment: Includes protective gloves and goggles to avoid any unwanted injuries.
Ensuring Mechanical Support for Heavier Components
To support more significant parts mounted on a DIN rail, use a rail of greater strength or reinforced design, especially when mounting larger devices. When securing the rail, mount screws at several anchor locations throughout its length to avoid most of the weight being centered at one location, primarily for snap-on components. For very large components, consider using supplemental brackets or supports fastened under the rail to avoid droop or divorce. Always check with the manufacturer’s indicated loads for the DIN rail and ensure the total weight is below the specified limits for normal working conditions.
How are Switchgear and Terminals Used with DIN Rails?
Integrating Circuit Breaker and Relay with DIN Rails
Relay and circuit breakers are usually installed on a DIN rail, simplifying their installation and integration into the system. For them to be used effectively, devices engineered for DIN rail mounting should be selected first. To install, position the mounting clip of the component on the rail and press it downwards forcefully. DElectric faults and risks and safety will be enhanced if the rails and devices are properly grounded. The wiring terminals should be connected according to the circuit design, but all connections should be verified against the manufacturer’s wiring diagrams and specifications. Inspecting the assembly and all other components to ensure they are intact and functional should be done frequently.
Using Programmable Logic Controllers and Motor Controllers
Motor controllers and Programmable Logic Controllers (PLCs) can be readily and conveniently installed on standard DIN rails using the c40 and c50 rail types for greater functionality and cost efficiency. For PLCs, these units are mounted onto the rail via the mounting brackets that click and are locked in position by simply pressing the unit slightly downwards. The wiring supplied must be followed as directed in the manufacturer’s wiring diagram, including the power supply, input/output terminals, and communication ports.
Similarly, motor controllers are mounted by securing their clips on the motor to the DIN rail, preventing vibrations from dismounting the devices. The guide configuration must be followed when connecting the motor, power supply, and control wiring to minimize the chance of making mistakes. As a best practice, a space around both the PLCs and motor controllers should be left open for unobstructed airflow and heat transfer, mainly when more significant c50 parts are used. The system should be tested regularly for functional accuracy and reliability.
What Are the Standards for DIN Rails?
Understanding EN 50022 and EN 60715
The standards EN 50022 and EN 60715 encompass specifications for DIN rails utilized in electrical and automation systems, which are internationally accepted. About the more familiar 35 mm DIN rail, most in use, EN 50022 establishes its dimensions so that it can fit with virtually all devices. In addition, EN 60715 incorporates internationally accepted basic outlines of mechanical dimensions and tolerances, which aids in manufacturing and ensures dependable mounting. Components like PLCs, motor controllers, and terminal blocks can provide uniformity and safety to a system since they are guaranteed to be mounted securely and are interchangeable. Because of these parameters, such components marked as compliant with EN 50022 or EN 60715 can be used within industrial or commercial systems without hesitance.
Overview of IEC and German Standards
The International Electrotechnical Commission (IEC) and German companies’ standards advise on the design and execution of electrical parts and systems. German standards, specifically those of DIN (Deutsches Institut für Normung), are similar to IEC norms, but they also have some local additions to meet the region’s specific industrial requirements. Like German standards, these comprise policies that deal with safety, compatibility, and performance issues for different systems, components, and applications.
Frequently Asked Questions (FAQs)
Q: What are DIN rails, and how are they used for mounting?
A: Terminus and diverse power supply devices utilized in industrial control systems are mounted on a standardized DIN rail constructed of steel metal. The rail provides support and is conveniently organized within an enclosure or junction box.
Q: What is the “top hat” design in DIN rails?
A: The “top hat” design describes the standardized shape of the most frequently utilized style of the DIN rail profile, measuring 35 mm wide with seven-and-a-half to 15 mm vertical height. Due to the shape’s resemblance to a hat, it is commonly called a “top hat.”
Q: Why is zinc-plated steel often used for DIN rails?
A: Zinc-plated steel is utilized for the DIN rails to provide a corrosion-resistant environment and ensure the rail is long-lasting and dependable, particularly in industrial settings where moisture and other corrosive elements tend to be present.
Q: Define symmetrical and asymmetrical DIN rail profiles.
A: Symmetrical DIN rail profiles, including the top hat, have exact measurements on all sides of their cross-section, allowing them to mount various devices. Asymmetrical profiles, such as C-section rails C20 and C30, allow for multiple mounting options but are less common.
Q: What is the role of the mounting structure in commanding electrical grounding on a DIN rail?
A: DIN rails can be used as a grounding point for electrically active equipment, helping to protect the equipment by redirecting unwanted electricity. They may also be implemented in the electrical installation as part of a grounding system.
Q: What is the role of Deutsches Institut fur Normung concerning the DIN rail?
A: The Deutsches Institut Für Normung (DIN) is the German Institute for Standardization, which is responsible for defining the primary parameters of the DIN rails to ensure standardization and interoperability among a wide range of electrical devices and systems.
Q: What are the substitute components for the supports of the DIN rails?
A: Substitute supports for DIN rails may include accessory components such as end clamps and brackets. These fix the rails in an enclosure to ensure that the rails and the mounted equipment do not shift in position relative to each other during operation.
Q: How do vertical height and depth relate to selecting a DIN rail?
A: A DIN rail of a specific vertical height and depth, for example, 7.5 mm or 15 mm in height, has particular metrics for the load it can support and the devices it can be matched with. These parameters set the selection boundaries dependent on the particular mounting application needs.
Q: Name the most popular uses of DIN rails in electrical systems.
A: It is standard practice to use DIN rails for wiring terminal blocks, relays, circuit breakers, and other electrical devices. They offer a practical and tidy way of organizing wires and other components in electrical enclosures and junction boxes.
Reference Sources
1. Mounting rails and supporting structures with two Hutschienenträgern can accommodate various types of rail configurations.
- Authors: M. Berger, B. Grandjean
- Publication Date: 2006-09-13
- Citation Token: (Berger & Grandjean, 2006)
- Summary:
- This document puts forth a particular construction for installation rails employing two Hutschienenträgern, which are elements that enable the mounting rails to be attached to a grid framework.
- Methodology: The authors explain the construction process, which consists of bending portions of the mounting rail for attachment to a cross beam, with a particular focus on its simplicity and the strength of the resulting structure.
2. DIN rail
3. Metal
