3RV1011-1AA10-ZW98 - Siemens - Datasheet.Directory

GerätehandbuchSystem Manual

Industrial Controls

SIRIUS Modular System

System Overview

Edition

Answers for industry.

09/2016

___________________

Industrial Controls

SIRIUS - system overview

System Manual

09/2016

A5E03656507020A/RS

-AB/003

Introduction

Safety instructions

Standards and approvals

Overview

System properties

Customer benefits

Components and

combinations

Mounting and disassembly

Connection

Siemens AG

Division Digital Factory

Postfach 48 48

90026 NÜRNBERG

GERMANY

3ZX1012-0RA01-5AC1

Ⓟ

09/2016 Subject to change

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

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will

be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to

property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by

personnel qualified

for the specific

task in accordance with the relevant documentation, in particular its warning notices and safety instructions.

Qualified personnel are those who, based on their training and experience, are capable of identifying risks and

avoiding potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

documentation. If products and components from other manufacturers are used, these must be recommended

or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and

maintenance are required to ensure that the products operate safely and without any problems. The permissible

ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication

may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software

described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the

information in this publication is reviewed regularly and any necessary corrections are included in subsequent

editions.

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 5

Table of contents

1 Introduction................................................................................................................................... 9

1.1 Preface ............................................................................................................................... 9

1.2 Siemens Industry Online Support ...................................................................................... 10

1.3 DataMatrix code ................................................................................................................ 12

1.4 Security information ........................................................................................................... 13

1.5 Recycling and disposal ...................................................................................................... 13

1.6 Technical Assistance ......................................................................................................... 13

2 Safety instructions ....................................................................................................................... 15

3 Standards and approvals .............................................................................................................. 17

3.1 Standards.......................................................................................................................... 17

3.2 IE3 / IE4 ready .................................................................................................................. 19

4 Overview .................................................................................................................................... 21

4.1 SIRIUS modular system .................................................................................................... 21

4.2 Manuals - SIRIUS Modular System.................................................................................... 26

5 System properties ....................................................................................................................... 29

5.1 System properties ............................................................................................................. 29

5.2 Modular system design ...................................................................................................... 30

5.3 Switching technology ......................................................................................................... 32

5.4 Uniform connection system................................................................................................ 35

5.5 Flexible assembly methods................................................................................................ 36

5.6 Performance capability ...................................................................................................... 37

5.7 Assembly and mounting .................................................................................................... 37

5.8 Load feeders ..................................................................................................................... 38

5.9 Application monitoring ....................................................................................................... 40

5.10 Industrial communication ................................................................................................... 41

5.10.1 Communication overview ................................................................................................... 41

5.10.2 IO-Link .............................................................................................................................. 44

5.10.2.1 Overview ........................................................................................................................... 44

5.10.2.2 System components .......................................................................................................... 46

5.10.2.3 Benefits ............................................................................................................................. 50

5.10.2.4 Applications ....................................................................................................................... 51

5.10.2.5 More information ............................................................................................................... 52

5.10.3 AS-Interface ...................................................................................................................... 53

5.10.3.1 Overview ........................................................................................................................... 53

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5.10.3.2 System components ...........................................................................................................54

5.10.3.3 Benefits ..............................................................................................................................55

5.10.3.4 Application .........................................................................................................................56

5.10.3.5 More information ................................................................................................................57

5.11 Safety applications .............................................................................................................58

5.12 Environmental protection ....................................................................................................58

5.13 Energy efficiency ................................................................................................................59

5.13.1 Energy efficiency ................................................................................................................59

5.13.2 Acquisition of measured energy values ...............................................................................59

5.13.3 Reduction in intrinsic power losses .....................................................................................60

5.13.4 Optimal drive solution .........................................................................................................62

5.13.5 Energy efficiency examples ................................................................................................63

6 Customer benefits ....................................................................................................................... 65

6.1 Customer benefits ..............................................................................................................65

7 Components and combinations ..................................................................................................... 69

7.1 Switching and starting ........................................................................................................69

7.1.1 SIRIUS 3RT contactors ......................................................................................................69

7.1.1.1 Overview of the contactor range .........................................................................................69

7.1.1.2 Device versions ..................................................................................................................73

7.1.1.3 Applications........................................................................................................................74

7.1.1.4 SIRIUS 3RT2 contactors ....................................................................................................76

7.1.1.5 SIRIUS 3RT1 contactors ....................................................................................................85

7.1.2 3RA27/3RA28 function modules .........................................................................................89

7.1.2.1 3RA27 function modules for connection to the higher-level control ......................................90

7.1.2.2 SIRIUS 3RA28 function modules for mounting on 3RT2 contactors ....................................94

7.1.3 3RF34 solid-state switching devices .................................................................................102

7.1.3.1 Device versions ................................................................................................................103

7.1.3.2 Applications......................................................................................................................105

7.1.4 SIRIUS 3RW30/40 soft starters ........................................................................................106

7.1.4.1 Applications and use ........................................................................................................107

7.1.4.2 Fields of application ..........................................................................................................108

7.2 Protecting .........................................................................................................................111

7.2.1 SIRIUS 3RV motor starter protectors ................................................................................111

7.2.1.1 Introduction ......................................................................................................................112

7.2.1.2 Versions ...........................................................................................................................113

7.2.1.3 Applications......................................................................................................................114

7.2.1.4 Performance features .......................................................................................................115

7.2.1.5 Accessories for SIRIUS 3RV motor starter protectors .......................................................116

7.2.1.6 SIRIUS 3RV2917 infeed system .......................................................................................120

7.2.2 SIRIUS 3RU thermal overload relays / SIRIUS 3RB electronic overload relays .................122

7.2.2.1 Introduction ......................................................................................................................124

7.2.2.2 Versions ...........................................................................................................................126

7.2.2.3 Applications......................................................................................................................128

7.2.3 3RB24 electronic overload relays for IO-Link ....................................................................131

7.2.3.1 Properties ........................................................................................................................132

7.2.3.2 System structure ..............................................................................................................133

7.2.3.3 Reference ........................................................................................................................134

7.3 Monitoring ........................................................................................................................135

Table of contents

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 7

7.3.1 3UG4 / 3RR2 monitoring relays ....................................................................................... 135

7.3.1.1 SIRIUS 3RR2 current monitoring relays ........................................................................... 135

7.3.1.2 Overview of the functions ................................................................................................ 139

7.3.1.3 Reference ....................................................................................................................... 141

7.3.2 3RS1 / 3RS2 temperature monitoring relays .................................................................... 142

7.3.2.1 Product description .......................................................................................................... 142

7.3.2.2 Overview of the functions (3RS10/ 11/ 20/ 21) ................................................................. 143

7.3.3 3UG48 / 3RR24 monitoring relays for IO-Link .................................................................. 144

7.3.3.1 Product description .......................................................................................................... 144

7.3.3.2 Overview of the functions ................................................................................................ 146

7.3.3.3 Reference ....................................................................................................................... 147

7.3.4 3RS14 / 3RS15 temperature monitoring relays for IO-Link ............................................... 148

7.3.4.1 Product description .......................................................................................................... 148

7.3.4.2 Overview of the functions ................................................................................................ 150

7.4 Feeders and tested switchgear assemblies...................................................................... 151

7.4.1 SIRIUS 3RA load feeders ................................................................................................ 151

7.4.1.1 Overview ......................................................................................................................... 151

7.4.1.2 Device versions ............................................................................................................... 151

7.4.1.3 SIRIUS 3RA21/22 load feeders ....................................................................................... 155

7.4.1.4 SIRIUS 3RA21/22 pre-assembled load feeders ............................................................... 156

7.4.1.5 Self-assembled load feeders ........................................................................................... 156

7.4.1.6 Applications ..................................................................................................................... 158

7.4.2 Device combinations ....................................................................................................... 159

7.4.3 SIRIUS 3RA6 compact starters........................................................................................ 161

7.4.3.1 System overview ............................................................................................................. 162

8 Mounting and disassembly ......................................................................................................... 169

8.1 Screw mounting .............................................................................................................. 169

8.2 Snap-on mounting ........................................................................................................... 170

9 Connection ............................................................................................................................... 173

9.1 Connection systems ........................................................................................................ 173

9.1.1 Screw connection ............................................................................................................ 173

9.1.2 Spring-loaded connection ................................................................................................ 174

9.1.3 Ring cable lug connection ................................................................................................ 180

9.2 Conductor cross-sections ................................................................................................ 181

9.2.1 Conductor cross-sections for screw-type connection systems .......................................... 181

9.2.2 Conductor cross-sections for spring-loaded connection systems ...................................... 192

9.2.3 Conductor cross-sections for ring cable lug connection system ........................................ 194

9.3 CAx data ......................................................................................................................... 198

Glossary ................................................................................................................................... 199

Index ....................................................................................................................................... 215

Table of contents

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Introduction

1.1

Preface

Purpose of this manual

The information in this manual provides you with an overview of the SIRIUS modular system.

The SIRIUS modular system consists of the following devices:

● 3RT contactors, 3RH contactor relays and 3RA contactor assemblies

● 3RF solid-state switching devices

● 3RW soft starters

● 3RV motor starter protectors

● 3RU thermal overload relays

● 3RB electronic overload relays

● 3RR current monitoring relays

● 3RA feeders and tested switchgear assemblies

The relevant manuals are needed for configuring and commissioning the devices.

Basic knowledge required

To understand these operating instructions you should have a general knowledge of

automation engineering and low-voltage controls.

Validity

The system manual is valid for the devices belonging to the SIRIUS modular system. It

contains a description of the devices in the SIRIUS modular system that are valid at the time

of publication.

Introduction

1.2 Siemens Industry Online Support

SIRIUS - system overview

10 System Manual, 09/2016, A5E03656507020A/RS-AB/003

1.2

Siemens Industry Online Support

Information and Service

In Siemens Industry Online Support, you can obtain up-to-date information from our global

support database quickly and simply. To accompany our products and systems, we offer a

wealth of information and services that provide support in every phase of the lifecycle of your

machine or plant – from planning and implementation, through commissioning, up to

maintenance and modernization:

● Product support

● Application examples

● Services

● Forum

● mySupport

Link:

Siemens Industry Online Support (https://support.industry.siemens.com/cs/ww/en)

Product support

You will find here all the information and comprehensive know-how covering all aspects of

your product:

●

FAQs

Our answers to frequently asked questions.

●

Manuals/operating instructions

Read online or download, available as PDF or individually configurable.

●

Certificates

Clearly sorted according to approving authority, type and country.

●

Characteristic curves

For support in planning and configuring your system.

●

Product announcements

The latest information and news concerning our products.

●

Downloads

You can find here updates, service packs, HSPs and much more for your product.

●

Application examples

Function blocks, background and system descriptions, performance statements,

demonstration systems, and application examples, clearly explained and represented.

●

Technical data

Technical product data for support in planning and implementing your project.

Link:

Product support (https://support.industry.siemens.com/cs/ww/en/ps)

Introduction

1.2 Siemens Industry Online Support

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 11

mySupport

With "mySupport", your personal workspace, you get the very best out of your Industry

Online Support. Everything to enable you to find the right information every time.

The following functions are now available:

●

Personal messages

Your personal mailbox for exchanging information and managing your contacts

●

Inquiries

Use our online form for specific solution suggestions, or send your technical inquiry

directly to a specialist in Technical Support

●

Notifications

Make sure you always have the latest information - individually tailored to your needs

●

Filters

Simple management and re-use of your filter settings from Product Support and the

Technical Forum

●

Favorites / Tags

Create your own knowledge database by assigning "Favorites" and "Tags" to documents

– simply and efficiently

●

Entries last viewed

Clear presentation of your last viewed entries

●

Documentation

Configure your individual documentation from different manuals – quickly and without

complications

●

Personal data

Change personal data and contact information here

●

CAx data

Simple access to thousands of items of CAx data such as 3D models, 2D dimension

drawings, EPLAN macros and much more

Introduction

1.3 DataMatrix code

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12 System Manual, 09/2016, A5E03656507020A/RS-AB/003

1.3 DataMatrix code

A Data Matrix code has been lasered onto the devices in the SIRIUS modular system.

The Data Matrix codes are standardized in ISO/IEC 16022. The Data Matrix codes on

Siemens devices use ECC200 coding for powerful error correction.

The following information is stored in the Data Matrix code:

1P Article

number

+ S Location / Date Serial

number

Data

identifier

User

content

Separator User content Separator User content User

content

Note

The information content is displayed without spaces.

This machine-readable information simplifies and accelerates handling of the respective

devices.

As well as fast access to the serial numbers of the respective devices for unique

identification, the Data Matrix codes simplify communication with Siemens Technical

Support.

Siemens Industry Online Support app

You can use the Siemens Industry Online Support app to access all the device-specific

information available on the Siemens Industry Online Support portal for a particular article

number, including operating instructions, manuals, datasheets, FAQs etc.

The Siemens Industry Online Support app is available for iOS, Android or Windows Phone

devices. You can download the app from the following links:

Link for Android Link for iOS Link for Windows Phone

Introduction

1.4 Security information

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 13

1.4

Security information

Siemens provides products and solutions with industrial security functions that support the

secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is

necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial

security concept. Siemens’ products and solutions only form one element of such a concept.

Customer is responsible to prevent unauthorized access to its plants, systems, machines

and networks. Systems, machines and components should only be connected to the

enterprise network or the internet if and to the extent necessary and with appropriate security

measures (e.g. use of firewalls and network segmentation) in place.

Additionally, Siemens’ guidance on appropriate security measures should be taken into

account. For more information about industrial security, please visit:

http://www.siemens.com/industrialsecurity

Siemens’ products and solutions undergo continuous development to make them more

secure. Siemens strongly recommends to apply product updates as soon as available and to

always use the latest product versions. Use of product versions that are no longer supported,

and failure to apply latest updates may increase customer’s exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS

Feed under:

http://www.siemens.com/industrialsecurity

1.5

Recycling and disposal

These devices can be recycled thanks to their low pollutant content. For environmentally-

friendly recycling and disposal of your electronic waste, please contact a company certified

for the disposal of electronic waste.

1.6

Technical Assistance

Up-to-the-minute information

You can obtain further assistance by calling the following numbers:

Technical Assistance:

Telephone: +49 (911) 895-5900 (8 a.m. to 5 p.m. CET)

Fax: +49 (911) 895-5907

or on the Internet at:

E-mail: (mailto:technical-assistance@siemens.com)

Internet: (http://www.siemens.com/sirius/technical-assistance)

Introduction

1.6 Technical Assistance

SIRIUS - system overview

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 15

Safety instructions

Five safety rules for work in or on electrical installations

A set of rules, which are summarized in DIN VDE 0105 as the "five safety rules", are defined

for work in or on electrical installations as a preventative measure against electrical

accidents:

1. Isolate

2. Secure against switching on again

3. Verify that the equipment is not live

4. Ground and short-circuit

5. Erect barriers around or cover adjacent live parts

These five safety rules must be applied in the above order prior to starting work on an

electrical system. After completing the work, proceed in the reverse order.

It is assumed that every electrician is familiar with these rules.

Explanations

1. The isolating distances between live and de-energized parts of the system must vary

according to the operating voltage that is applied.

In electrical installations, "isolate" refers to the disconnection of all poles of live parts.

Disconnection of all poles can be achieved by, for example:

– Switching off the miniature circuit breaker

– Switching off the motor starter protector

– Unscrewing fuses

– Removing LV HRC fuses

2. The feeder must be secured against inadvertent restarting to ensure that it remains

isolated for the duration of the work. This can be achieved, for instance, by securing the

motor starter protector and miniature circuit breaker with lockable blocking elements in

the disconnected state, either using a lock or by unscrewing the fuses.

3. The deenergized state of the equipment should be verified using suitable test equipment,

e.g. a two-pole voltmeter. Single-pole test pins are not suitable for this purpose. The

absence of power must be established for all poles, phase to phase, and phase to N/PE.

4. Grounding and short-circuiting are only mandatory if the system has a nominal voltage

greater than 1 kV. In this case, the system should always be grounded first and then

connected to the live parts to be short-circuited.

5. These parts should be covered, or barriers erected around them, to avoid accidental

contact during the work with adjacent parts that are still live.

Safety instructions

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Standards and approvals

3.1

Standards

The standards from Catalog IC 10 "SIRIUS Industrial Controls" in the appendix always apply.

Below are some of the most important standards which apply to the devices in the

SIRIUS modular system.

Standards / approvals

Table 3- 1 IEC standards

IEC

Title

IEC 60947-1

Low-voltage switchgear and controlgear - General rules

IEC 60947-2

Low-voltage switchgear and controlgear – Part 2: Circuit breakers

IEC 60947-4-1 Low-voltage switchgear and controlgear – Part 4-1: Electromechanical contactors and

motor-starters

IEC 60947-4-2 Low-voltage switchgear and controlgear – Part 4-2: Contactors and motor-starters - AC

semiconductor motor controllers and starters

IEC 60947-4-3

Low-voltage switchgear and controlgear – Part 4-3: Contactors and motor-starters - AC

semiconductor controllers and contactors for non-motor loads

IEC 60947-5-1 Low-voltage switchgear and controlgear – Part 5-1: Control circuit devices and switching

elements - Electromechanical control circuit devices

IEC 60947-6-2 Low-voltage switchgear and controlgear – Part 6-2: Multiple function equipment. Control

and protective switching devices (or equipment)

Standards and approvals

3.1 Standards

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18 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Table 3- 2 UL standards

Title

UL 60947-1

Low-Voltage Switchgear and Control gear - Part 1: General rules

UL 60947-4-1 Low-Voltage Switchgear and Control gear - Part 4-1: Contactors and motor-starters -

Electromechanical contactors and motor-starters

UL 489

Molded-Case Circuit Breakers, Molded-Case Switches and Circuit-Breaker Enclosures

Table 3- 3 CSA standards

CSA

Title

CSA-C22.2 No. 14-13

Industrial Control Equipment

CAN/CSA-C22.2 No 60947-1-13

Low-Voltage Switchgear and Control gear - Part 1: General rules

CAN/CSA-C22.2 No 60947-4-1-14 Low-Voltage Switchgear and Control gear - Part 4-1: Contactors and motor-

starters - Electromechanical contactors and motor-starters

Table 3- 4 CCC standard

CCC

Title

CCC

Certificate for China Compulsory Product Certification

Approvals, test certificates, characteristics

You can find an overview of the certifications available for low-voltage controls and

distribution products and other technical documentation, updated daily, on the Internet

(https://support.industry.siemens.com/cs/ww/en/ps/16027/cert).

Standards and approvals

3.2 IE3 / IE4 ready

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 19

3.2

IE3 / IE4 ready

Ambitious climate protection goals in Europe call for increasingly energy-efficient

components.

With this in mind, the energy efficiency class IE3 / IE4 has been mandatory since January

2015 (with exceptions) for three-phase asynchronous motors, and this will have an effect on

motors, low-voltage power distribution systems, and industrial controls.

This applies:

● Since January 1, 2015 for motors from 7.5 kW to 375 kW

● From January 1, 2017 for motors from 0.75 kW to 375 kW

You will be optimally equipped for the current motor generation with the SIRIUS modular

system components and 3VA molded case circuit breakers.

You will find information on IE3 / IE4 at:

Information IE3 (http://www.siemens.com/IE3ready)

Note

Using SIRIUS controls with IE3 / IE4 motors

For the use of SIRIUS

controls in conjunction with highly energy-efficient IE3 / IE4 motors,

please observe the information on dimensioning and configuring

in the "Application Manual -

SIRIUS Controls with IE3

/ IE4 Motors

(

https://support.industry.siemens.com/cs/ww/en/view/94770820)".

Standards and approvals

3.2 IE3 / IE4 ready

SIRIUS - system overview

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SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 21

Overview

4.1

SIRIUS modular system

The SIRIUS modular system comprises devices for use in switching, starting, protecting, and

monitoring, as well as combinations thereof.

Device

Performance range / adjustable current range

3RT contactors

3 ... 250 kW (P / AC-3 / 400 V)

3RH contactor relays

Switching in the control circuit

3RF solid-state switching

devices

2.2 ... 7.5 kW (P / Ue / 400 V)

3RW soft starters

1.5 ... 250 kW (P / U

/ 400 V)

3RV motor starter protectors

0.11 ... 100 A

3RU thermal overload relays

0.11 ... 100 A

3RB electronic overload relays

0.1 ... 630 A

3RR current monitoring relays

1.6 ... 80 A

The devices named above are supplemented for the main circuit by devices for the control

circuit: 3RA28 function modules for mounting on 3RT2 contactors and 3RA27 function

modules for connection to the higher-level control.

Overview

4.1 SIRIUS modular system

SIRIUS - system overview

22 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Switching and starting

Table 4- 1 Function - switching and starting - contactors

Size

S00

S10

S12

Table 4- 2 Function - switching and starting - solid-state switching devices

Size

S00

Table 4- 3 Function - switching and starting - soft starters

Size

S00

S10 / S12

Overview

4.1 SIRIUS modular system

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 23

Protecting

Table 4- 4 Function - protecting - motor starter protectors

Size

S00

S10

S12

— — —

Table 4- 5 Function - protecting - electronic overload relays

Size

S00

S10 / S12

Table 4- 6 Function - protecting - thermal overload relays

Size

S00

S10

S12

—

Overview

4.1 SIRIUS modular system

SIRIUS - system overview

24 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Monitoring

Table 4- 7 Function - monitoring - current monitoring relays

Size

S00

S10

S12

— — — —

Feeders

Table 4- 8 Function - Feeders - pre-assembled load feeders

Size

S00

S10

S12

— — — —

Table 4- 9 Function - feeders - compact starters

Size

S00

Overview

4.1 SIRIUS modular system

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 25

Table 4- 10 Function modules

Components

Size

S00

S10

S12

Function

modules for

mounting on

contactors

— — —

Function

modules for

connection

to the

automation

level

— — —

Overview

4.2 Manuals - SIRIUS Modular System

SIRIUS - system overview

26 System Manual, 09/2016, A5E03656507020A/RS-AB/003

4.2

Manuals - SIRIUS Modular System

This system manual focuses on the product descriptions of the SIRIUS components in

sizes S00 to S12 for motors in the performance range up to 250 kW (400 V). Products which

have separate, device-specific manuals, are only briefly mentioned in this system manual.

Comprehensive technical details for such devices can be found in the relevant device-

specific manuals. You can download the manuals from the Internet

(https://support.industry.siemens.com/cs/ww/en).

Information about ...

Is available in ...

• SIRIUS - system overview • "SIRIUS - System Overview"

(http://support.automation.siemens.com/WW/view/en/60311318)

manual

(Article number: 3ZX1012-0RA01-5AC1)

• 3RT, 3RH and 3RA

contactors and contactor

assemblies

• "SIRIUS - SIRIUS 3RT contactors and contactor assemblies"

(http://support.automation.siemens.com/WW/view/en/60306557)

manual

(Article number: 3ZX1012-0RT20-5AB1)

• 3RF34 solid-state

switching devices

• "SIRIUS - SIRIUS 3RF34 solid-state switching devices"

(http://support.automation.siemens.com/WW/view/en/60298187)

manual

(Article number: 3ZX1012-0RF34-5AC1)

• 3RW soft starters • "SIRIUS 3RW30/3RW40 soft starters"

(http://support.automation.siemens.com/WW/view/en/38752095)

manual

(Article number: 3ZX1012-0RW30-1AC1)

• "SIRIUS 3RW44 Soft Starter"

(http://support.automation.siemens.com/WW/view/en/21772518)

manual

(Article number: 3ZX1012-0RW30-1AC1)

• 3RV motor starter

protectors

• "SIRIUS - SIRIUS 3RV" motor starter protectors

(http://support.automation.siemens.com/WW/view/en/60279172)

manual

(Article number: 3ZX1012-0RV20-5AC1)

• 3RU, 3RB overload relays • "SIRIUS - SIRIUS 3RU thermal overload relays / SIRIUS 3RB

electronic overload relays"

(http://support.automation.siemens.com/WW/view/en/60298164)

(Article number: 3ZX1012-0RU20-5AC1)

• 3RB24 electronic overload

relays

• "3RB24 electronic overload relay for IO-Link"

(http://support.automation.siemens.com/WW/view/en/46165627)

manual

(Article number: 3ZX1012-0RB24-0AC0)

• 3UG4 monitoring relays /

3RR2 current monitoring

relays

• "3UG4/3RR2 monitoring relays" manual

(http://support.automation.siemens.com/WW/view/en/70210263)

(Article number: 3ZX1012-0UG40-0AC0)

Overview

4.2 Manuals - SIRIUS Modular System

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 27

Information about ...

Is available in ...

• 3RS1/3RS2 temperature

monitoring relays

• "3RS1/3RS2 temperature monitoring relays" manual

(http://support.automation.siemens.com/WW/view/en/54999309)

(Article number: 3ZX1012-0RS10-1AC1)

• 3UG48 monitoring relays /

3RR24 current monitoring

relays for IO-Link

• "3UG48/3RR24 monitoring relays for IO-Link"

(http://support.automation.siemens.com/WW/view/en/54375430)

manual

(Article number: 3ZX1012-0UG48-0AC1)

• 3RS14/3RS15

temperature monitoring

relays for IO-Link

• "3RS14/3RS15 temperature monitoring relays for IO-Link"

(http://support.automation.siemens.com/WW/view/en/54375463)

manual

(Article number: 3ZX1012-0RS14-0AC0)

• 3RA load feeders • "SIRIUS - SIRIUS 3RA load feeders" manual

(http://support.automation.siemens.com/WW/view/en/60284351)

(Article number: 3ZX1012-0RA21-5AC1)

• 3RA6 compact starters • "SIRIUS 3RA6 compact starter"

(http://support.automation.siemens.com/WW/view/en/27865747)

manual

(Article number: 3RA6992-0A)

• 3RA28 function modules

for mounting on

contactors

• "SIRIUS Innovations - SIRIUS 3RA28 function modules for

mounting on 3RT2 contactors" manual

(http://support.automation.siemens.com/WW/view/en/60279150)

(Article number: 3ZX1012-0RA28-5AC1)

• 3RA27 function modules

for connection to the

higher level control

• "SIRIUS - SIRIUS 3RA2712 function modules for AS-Interface"

manual

(http://support.automation.siemens.com/WW/view/en/39318922)

(Article number: 3ZX1012-0RA27-0AC0)

• "SIRIUS - SIRIUS 3RA2711 function modules for IO-Link" manual

(http://support.automation.siemens.com/WW/view/en/39319600)

(Article number: 3ZX1012-0RA27-1AC1)

• 4SI SIRIUS electronic

module

(3RK1005-0LB00-0AA0)"

• "4SI SIRIUS Electronic Module (3RK1005-0LB00-0AA0)"

(http://support.automation.siemens.com/WW/view/en/37856470)

manual

(Article number: 3ZX1012-0LB00-0AA1)

Overview

4.2 Manuals - SIRIUS Modular System

SIRIUS - system overview

28 System Manual, 09/2016, A5E03656507020A/RS-AB/003

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 29

System properties

5.1

System properties

The entire device spectrum in the SIRIUS modular system is subdivided into the following

sizes:

● Size S00: up to 7.5 kW at 400 V

● Size S0: up to 18.5 kW at 400 V

● Size S2: up to 37 kW at 400 V

● Size S3: up to 55 kW at 400 V

● Size S6: up to 90 kW at 400 V

● Size S10: up to 160 kW at 400 V

● Size S12: up to 250 kW at 400 V

The device portfolio has a uniform range of accessories.

System properties

5.2 Modular system design

SIRIUS - system overview

30 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.2

Modular system design

The individual SIRIUS components are modules from the complete SIRIUS modular system

(up to size S12, 250 kW at 400 V), which are matched to one another in terms of their size

and their technical data. This enables individual requirements to be met quickly and cost-

effectively. And it goes without saying that this applies to the uniform range of accessories as

well.

3RV29 infeed systems and busbar adapters

3RV2 motor starter protectors

System properties

5.2 Modular system design

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 31

3RT2 contactors and contactor assemblies

3RF34 solid-state switching devices

3RW30/3RW40 soft starters

3RU2 thermal overload relays

3RB3 electronic overload relays

3RR2 current monitoring relays

Figure 5-1 Overview diagram

System properties

5.3 Switching technology

SIRIUS - system overview

32 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.3

Switching technology

The SIRIUS modular system has the right technology for every application:

Table 5- 1 Motor starting options

Switching principle

Switching function

SIRIUS products

Electromechanical

starting

• Direct-on-line start • 3RT contactors, 3RA load feeders, or

3RA6 compact starters

• Reversing start • 3RA reversing contactor assemblies or

3RA reversing starters

• 3RA6 compact starters

• Star-delta (wye-delta) start • 3RA contactor assemblies for star-delta

(wye-delta) start

Electronic starting • Direct-on-line start • 3RF solid-state switching devices

• Reversing start • 3RF solid-state switching devices

• Soft start • 3RW soft starters

Example: 3RT contactors

3RT contactors can be used for all standard applications up to 250 kW.

Figure 5-2 Direct switching through current feed of the contactor coil

Example: 3RF solid-state switching devices

3RF solid-state switching devices can be used for frequent switching of motors in parcel

distribution systems, for example.

Figure 5-3 Two-phase switching through antiparallel thyristor pairs

System properties

5.3 Switching technology

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 33

Example: 3RW soft starters

3RW soft starters are used for soft starting and ramp-down, for pumps and fans, for

example.

Figure 5-4 Phase angle control of the thyristor pairs

System properties

5.3 Switching technology

SIRIUS - system overview

34 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Technology selection depends on various factors. The table below provides an overview of

the most important aspects:

Table 5- 2 Technology selection

Technology

Electromechanical

Electronic

3RT contactors, 3RA

load feeders, or 3RA6

compact starters

3RF solid-state

switching devices

3RW soft starters

Number of starts per

hour

Average High Low

Switching service life

Average

Long

Average

Switching capacity

High

Low

High

Occurrence of current

peaks

High High Low

Occurrence of torque

peaks

High High Low

Reversing operation

Yes

Acoustic noise

generation

Average None Low

Galvanic isolation

Yes

Shock and vibration

resistance

Average High Average

Power loss

Low

High

Low

System properties

5.4 Uniform connection system

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 35

5.4

Uniform connection system

The devices are matched to one another in terms of their rated sizes and technical data.

● The same width guarantees quick mounting.

● Devices with the same rated current have the same terminals.

● Device combinations are matched to one another and offer screw-type, spring-loaded,

and ring cable lug connection systems. Larger devices are also available with through-

hole technology featuring straight-through transformers, bus connection and ring cable

lug connection system.

The SIRIUS modular system has the right connection system for every environment.

System properties

5.5 Flexible assembly methods

SIRIUS - system overview

36 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.5

Flexible assembly methods

The SIRIUS modular system offers maximum flexibility in terms of configuration. The system

components can be assembled as feeders or mounted separately.

Table 5- 3 Assembly (mounted separately or assembled as feeders)

Separately mounted

Mounted as complete feeders

The system components are assembled

separately (e.g. on separate DIN rails).

The system components are assembled as a unit

(e.g. with a link module).

The SIRIUS modular system offers the right solution for every type of assembly:

Table 5- 4 Assembly types

Assembly type

Benefit

Feeders assembled from individual SIRIUS

devices

More than 45000 tested combinations offer

solutions for almost every application.

SIRIUS 3RA2 load feeders More than 500 pre-assembled combinations

facilitate rapid and fault-free control cabinet

assembly.

SIRIUS 3RA6 compact starters Compact devices with high integrated functionality

for improved efficiency and reliability in the control

cabinet.

System properties

5.6 Performance capability

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 37

5.6

Performance capability

All components in the SIRIUS modular system can be mounted side by side and operated at

an ambient operating temperature of -25 °C to +60 °C. The SIRIUS modular system is

optimally suited for applications in demanding environments (in terms of dust exposure,

vibration and shock load, etc.). Extensive approvals and certification enable worldwide use.

The table below provides an overview of the individual sizes and performance ranges. A

short-circuit breaking capacity of up to 150 kA is available.

Size

SIRIUS products

Current

Power

S00 (45 mm)

3RV motor starter protectors

3RT contactors

3RB electronic overload relays

3RU thermal overload relays

3RR current monitoring relays

3RA load feeders

3RF solid-state relays

16 A

7.5 kW

S0 (45 mm) 40 A 18.5 kW

S2 (55 mm) 80 A 37 kW

S3 (70 mm)

3RV motor starter protectors

100 A

55 kW

3RT contactors

110 A

3RB electronic overload relays

115 A

3RU thermal overload relays

100 A

S6 (120 mm)

Tested assemblies (with 3VA

and 3VL molded case circuit

breakers)

3RT contactors

3RB overload relays

200 A

90 kW

S10 (145 mm)

300 A

160 kW

S12 (160 mm) 630 A 250 kW

5.7

Assembly and mounting

Accessories such as auxiliary switches and surge suppressors can be mounted quickly and

disassembled in just a few short steps. Standard tools are required to disassemble

components only very rarely. For the SIRIUS devices with spring-loaded connections,

Siemens offers a standardized operating tool (screwdriver 3RA2908-1A).

System properties

5.8 Load feeders

SIRIUS - system overview

38 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.8

Load feeders

Link modules based on screw-type and spring-loaded connection systems are available for

assembling device combinations and fuseless load feeders. The link modules establish the

mechanical and electrical connections for the devices. Motor starter protectors can be

combined with the following devices via link modules:

● Contactors

● Soft starters

● Solid-state switching devices

The SIRIUS devices with spring-loaded terminals, a "plug-in connection system" is available

for assembling load feeders. Contactors, solid-state switching devices, and soft starters can

be connected to the motor starter protector by simply plugging them in via a link module:

Link module

①

Slot for link modules

②

Slot for conductor connection

③

Screwdriver opening for assembly/disassembly without a link module

Figure 5-5 Link module

The link module is first attached to the device to be connected, then the resulting unit is

plugged on to the motor starter protector. This ensures that the requisite electrical and

mechanical connections are established in the main circuit.

System properties

5.8 Load feeders

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 39

Overload relays and current monitoring relays can easily be mounted on contactors in a

similar way, without the need for another link module:

Current monitoring relay

①

Slot for link modules

②

Slot for conductor connection

③

Screwdriver opening for assembly/disassembly without a link module

Figure 5-6 Plug-in connection system on the current monitoring relay

System properties

5.9 Application monitoring

SIRIUS - system overview

40 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.9

Application monitoring

The current monitoring relays, which enable intelligent protective functions to be easily

implemented within the application, are a central component of the components in the

SIRIUS modular system.

Increasing numbers of customers require application monitoring in addition to motor

protection. Overload protection (based on I²t measuring/calculation) provides information on

the motorized load, but it does not necessarily allow for conclusions to be drawn regarding

the correct execution of processes within the machine. 2- or 3-phase current monitoring with

SIRIUS 3RR2 current monitoring relays facilitates the direct monitoring and protection of the

application.

①

Application monitoring

②

Motor protection

Figure 5-7 Application monitoring

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 41

5.10

Industrial communication

5.10.1

Communication overview

Industrial communication with Siemens products and systems enhances efficiency.

Consistent, powerful data networks that will also do justice to future requirements can be

realized with components based on proven communication standards, for example IO-Link

and AS-Interface. Fast installation and simple connection of sensors and actuators by means

of standardized cabling produce time savings and minimize errors. Industrial communication

is necessary to record and transmit all measured values, diagnostics data, energy data and

product data to control, monitor and protect machinery and production lines.

Acquisition or connection of distributed I/Os and distributed load feeders.

A point-to-point connection is established via IO-Link if a number of signals are grouped together.

Classic wiring via digital I/Os is used if the number of signals is manageable.

Figure 5-8 Options for connection to the automation level

IO-Link closes the communication gap at the lowest field level with the sensors and

actuators. Moreover, the communication standard reduces the diversity of existing interfaces

(e.g. the serial RS-232 and RS-422 interfaces or the standard 4-20 mA signal, etc.) and is

based on a conventional point-to-point connection via a standard unshielded three-wire

cable. Furthermore, IO-Link is already integrated in the sensor /actuator.

System properties

5.10 Industrial communication

SIRIUS - system overview

42 System Manual, 09/2016, A5E03656507020A/RS-AB/003

The IO-Link communication standard underneath the control level enables central fault

diagnostics and fault locating down to the actuator/ sensor level. Thanks to dynamic

modification of parameter data directly from the application, the IO-Link communication

standard facilitates commissioning and maintenance. The increasing intelligence of field

devices and their integration into automation as a whole now allows data to be accessed

right down to the lowest field level. This results in greater plant availability and less

engineering work.

With the AS-Interface communication standard, connection of all sensors and actuators in

the field to the higher-level control system can be realized more simply, flexibly and

efficiently than any other. Via a simple two-wire cable, in an AS-Interface network up to 62

bus nodes can be connected to the AS-Interface master and simultaneously supplied with

power.

Connection to the automation level

SIRIUS switching devices can be connected to higher-level control systems using

conventional wiring, but also by means of a point-to-point connection (IO-Link) or via a

fieldbus (AS-Interface).

The SIRIUS 3RA2711 function modules for IO-Link and the SIRIUS 3RA2712 function

modules for AS-Interface enable the assembly of starters and contactor assemblies for

direct-on-line, reversing and star-delta (wye-delta) starting without any additional,

complicated wiring of the individual components. The devices include the key control

functions required for the particular feeder.

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 43

The SIRIUS switching devices for AS-Interface and IO-Link are connected to the control

system level without any additional wiring. These interfaces ensure that information about

the switch position and the readiness of the feeder for operation is transferred, and that

contactor control is implemented. In addition to these three items of information relating to

feeders, IO-Link also transfers diagnostics data.

Figure 5-9 Communication via AS-Interface or IO-Link

The SIRIUS 3RA27 function modules or the SIRIUS 3RA6 compact starters can

communicate with a higher-level control either via the AS-Interface fieldbus or via the IO-Link

point-to-point connection. Cyclic data transmission (DIs and DQs) is identical for both IO-Link

and AS-Interface.

Table 5- 5 Motor starter profile

Standard motor starter profile

Group diagnostics (only with IO-Link)

• 4 DIs, 2 DQs (per feeder)

• 2 LEDs for "Device" and "Group fault"

• Device fault

• No main voltage (motor starter protector

tripped)

• Auxiliary voltage 24 V DC (Uaux) missing

• Signaling limit position right/left

• Manual/local mode

DI 0.0

Ready

DI 0.1

Motor ON

DI 0.2

Group fault

DI 0.3

Group warning

DQ 0.0

Motor ON or Motor CW

DQ 0.1

Motor CCW

System properties

5.10 Industrial communication

SIRIUS - system overview

44 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.10.2

IO-Link

5.10.2.1

Overview

IO-Link is a communication standard for sensors and actuators – defined by the PROFIBUS

User Organization (PNO). IO-Link technology is based on the point-to-point connection of

sensors and actuators to the control system. Therefore, this technology is not a bus system,

but an enhanced version of a classical point-to-point connection. In addition to the cyclic

operating data, comprehensive parameters and diagnostics data are transferred for the

connected sensors and actuators. The same 3-wire connecting cable as currently used for

standard sensors is used.

The IO-link system offers important benefits when connecting complex (intelligent)

sensors/actuators:

● Open standard in accordance with IEC 61131-9 for transmission of device-specific data

● Simple, standardized and unshielded wiring (also for analog signals) and clearly reduced

diversity of interfaces at the sensors /actuators

● Consistent communication between sensor/actuator and the control system

● Consistent diagnostic information right down to the sensor/actuator level

● Alarms and indicators for preventive maintenance

● Dynamic modification of sensor/actuator parameters by the control system or the operator

on the HMI

● Reparameterization during ongoing operation

● Consistent device identification

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 45

Figure 5-10 IO-Link

System properties

5.10 Industrial communication

SIRIUS - system overview

46 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.10.2.2

System components

An IO-Link system essentially comprises the following components:

● IO-Link master

Gateway between the IO-Link device and the higher-level communication system, such

as Ethernet-based systems (PROFINET, Ethernet / IP, etc.), fieldbus (PROFIBUS), or a

device-specific backplane bus.

● IO-Link device

– Sensors

– Switching devices such as the 3RA2711 function module for IO-Link and 3RA64 /

3RA65 compact starters for IO-Link

– 3RB24 electronic overload relays for IO-Link

– Monitoring relays for precise monitoring and transmission of electrical and mechanical

quantities such as voltage, power factor, speed, fault current, 3UG48 line monitoring,

3RR24 current and 3RS14 / 3RS15 temperature

– Valve terminal

– RFID device

– Indicator light

– 3SU14 electronic module for IO-Link for connecting SIRIUS ACT 3SU1 pushbuttons

and indicator lights

– 3SU14 electronic module for ID key-operated switches (SIRIUS ACT) for selection of

authorization levels and as an access system for groups or individuals

– etc.

● 3-wire

Unshielded standard cable

● Engineering software and device description files

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 47

Figure 5-11 Example of a configuration with the system components

Compatibility of IO-Link

IO-Link guarantees compatibility between standard modules and those with IO-Link

capability as follows:

● IO-Link sensors/actuators can generally be operated on IO-Link modules (master) and on

standard I/O modules.

● Both IO-Link sensors/actuators and current standard sensors/actuators can be used on

IO-Link modules (master).

● If conventional components are used in the IO-Link system, naturally only the standard

functions are available in this case.

● A large number of IO-Link-capable Siemens components are available for a broad

spectrum of applications (e.g. 3RA27 function modules for IO-Link for sizes S00 to S3 for

easy fitting onto SIRIUS 3RT2 contactors). These devices also enable a clear reduction

of wiring and extensive individual diagnostics, and possess the essential control

functions.

System properties

5.10 Industrial communication

SIRIUS - system overview

48 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Expansion by means of IO-Link input modules (IO-Link module K20)

The compatibility of IO-Link means that you can connect standard (conventional)

sensors/actuators to it too. This is particularly effective with the IO-Link input modules, which

allow several sensors to be connected at one time via a cable to the controller.

Integration in STEP 7 (STEP 7 V5.5 or higher and STEP 7 TIA Portal V13 SP1 or higher)

Integration of the device configuration into the STEP 7 environment ensures:

● Simple and fast engineering.

● Consistent data storage.

● Fast location and clearance of faults.

A block library is designed to make it easier for users to connect the IO-Link devices, and to

demonstrate use of the library using actual examples. The library provides function blocks

and UDTs for all IO-Link devices from the Siemens portfolio. These blocks and UDTs

standardize and simplify communication with IO-Link devices. The function blocks have a

standardized interface for the individual IO-Link devices. For every read/write job, only the

data record specified at the input is read/written. You will find the block library and an

application example of how to read and write process data and parameterization data of

IO-Link devices on the Internet

(https://support.industry.siemens.com/cs/ww/en/view/90529409).

This raises productivity across all phases of the system lifecycle − configuration,

commissioning, and operation. With the Siemens IO-Link solution, even sensors and

actuators below the control system level are optimally integrated with their complete

performance capability in the Totally Integrated Automation (TIA) environment.

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 49

IO-Link master modules

The SIMATIC ET 200 distributed I/Os and the SIMATIC S7-1200 automation system

integrate fast and easy IO-Link communication with sensors and actuators to the established

PROFIBUS and PROFINET fieldbus systems and thus to Totally Integrated Automation

(TIA).

A broad spectrum of IO-Link master modules is available for the essential systems:

Automation system/distributed I/O system

IO Link master module

For the control cabinet

(IP20)

SIMATIC ET 200SP

CM 4xIO-Link communication module

SIMATIC ET 200S 4SI IO-Link electronic module

4SI SIRIUS electronic module

SIMATIC S7-1200

SM 1278 4xIO-Link signal module

For installation in the

field (IP67)

SIMATIC ET 200AL CM 4xIO-Link communication module

SIMATIC ET 200eco PN 4 IO-L + 8 DI + 4 DQ compact module

4 IO-L compact module

SIMATIC ET 200pro

EM 4 IO-Link HF electronic module

IO-Link devices

Besides the SIRIUS 3RA6 compact starter, which can be connected simply to the

IO-Link master via a standardized IO-Link connection, Siemens offers the SIRIUS 3RA27

function modules for IO-Link for connection to IO-Link. The SIRIUS 3RA27 function modules

for IO-Link are plugged directly onto a SIRIUS 3RT2 contactor. As a result, whole groups of

load feeders become immediately capable of communicating. Up to four load feeders (direct-

on-line starters, reversing starters and star-delta (wye-delta) starters) can be combined in a

group, occupying one port on the IO-Link master as one IO-Link device.

Moreover, a large number of monitoring relays and overload relays are available for

connecting to IO-Link, thus enabling transmission of various electrical and mechanical

quantities and temperature values to the higher-level control system.

K20 IO-Link input modules with versions for 4 or 8 digital inputs are available for connection

of binary sensors. The sensors are connected by M8 or M12 connection technology.

Connection to the IO-Link master is made using a standard M12 connecting cable.

SIRIUS ACT pushbuttons and indicator lights can also be connected to the higher-level

control system via IO-Link.

System properties

5.10 Industrial communication

SIRIUS - system overview

50 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.10.2.3

Benefits

The IO-link system offers important benefits when connecting complex (intelligent)

sensors/actuators:

● Dynamic modification of the sensor and actuator parameters directly via the PLC.

● Possibility of device replacement during operation without a programming device/PC, by

means of re-parameterization via the consistent storage of parameters.

● Fast commissioning due to central data storage.

● Integrated diagnostics information as far as the sensor and actuator levels.

● Uniform and significantly reduced wiring of different sensors and actuators.

● Fewer parameterization tools.

● Integrated communication: transmission of process data and service data between

sensors/actuators and the control.

● Uniform and transparent configuration and programming by means of a parameterization

tool (Port Configuration Tool S7-PCT) integrated into SIMATIC STEP 7.

● Transparent representation of all parameter and diagnostics data.

● Reduced costs during configuration and commissioning.

● Diagnostics and measured values for preventive maintenance and energy management.

System properties

5.10 Industrial communication

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 51

5.10.2.4

Applications

IO-Link can be used in the following applications:

● Simple connection of complex sensors/actuators with a large number of parameters to

the control.

● Optimum replacement of IO-Link modules for sensor/actuator boxes when connecting

binary sensors.

In both cases, all diagnostics data is transmitted to the higher-level control via IO-Link.

Parameter settings can be changed during operation. A sensor/actuator can be replaced

without a programming device/PC thanks to the central data storage feature.

Figure 5-12 Comparison of automation structures with and without IO-Link

System properties

5.10 Industrial communication

SIRIUS - system overview

52 System Manual, 09/2016, A5E03656507020A/RS-AB/003

5.10.2.5

More information

Always observe the conditions and constraints for use and the additional information

available for the modules referred to above.

IO-Link function manual

You will find further information on IO-Link in the IO-Link function manual

(https://support.industry.siemens.com/cs/ww/en/view/65949252).

Internet

You will find further information on IO-Link on the Internet

(https://support.industry.siemens.com/cs/ww/en/ps/15818).

You will find an overview of the most important documents and links on IO-Link here

(https://support.industry.siemens.com/cs/ww/en/view/109737170).

System properties

5.10 Industrial communication

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 53

5.10.3

AS-Interface

5.10.3.1

Overview

The AS-Interface is an open, international standard in accordance with EN 50295 and

IEC 62026-2 for process communication and field communication. Leading manufacturers of

actuators and sensors worldwide support AS-Interface.

AS-Interface is a single master system. For direct integration into automation systems from

Siemens, e.g. S7-300 or S7-1200, communications processors (CPs or CMs) are the

obvious choice. In addition, AS-i networks can also be connected via PROFINET or

PROFIBUS with the help of routers (links).

In both cases, the lower-level AS-i networks with connected actuators and sensors can be

parameterized and diagnosed direct from the controller.

Figure 5-13 AS-Interface

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5.10.3.2

System components

Numerous system components are offered to perform communication. The main

components of a system installation are:

● Master interface modules for central control units such as SIMATIC S7, ET 200

distributed I/O or network transitions from PROFIBUS/PROFINET to AS-Interface

● AS-Interface shaped cable

● Network components, e.g. repeater and extension plug

● Power supply unit for powering the slaves

● Modules for connecting standard sensors/actuators

● Sensors and actuators with integrated AS-i slave (e.g. motor starters, soft starters, load

feeders, pushbuttons, indicator lights, or position switches)

● Secure modules for transferring safety-related data over AS-Interface

● Addressing device for setting slave addresses during commissioning

Figure 5-14 Configuration of AS-Interface networks under a SIMATIC ET 200SP

ASIsafe

ASIsafe enables the integration of safety-related components, such as EMERGENCY-STOP

pushbuttons, protective door switches or safety light arrays, in an AS-Interface network. The

safety-related components are fully compatible with the familiar AS-Interface components

(masters, slaves, power supplies, repeaters, etc.) in accordance with IEC 62026-2 and are

operated in conjunction with them on the yellow AS-Interface cable. The transmission

method for safety-related signals is released for applications up to PL e according to

EN ISO 13849-1 and up to SIL 3 (IEC 61508/EN 62061).

System properties

5.10 Industrial communication

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 55

Integration in STEP 7

With the integration of AS-Interface into the TIA Portal, users benefit from a highly consistent

network view: All network nodes are presented in a clear graphical manner. Handling is

identical to that of PROFIBUS and PROFINET networks.

5.10.3.3

Benefits

An important characteristic of the AS-Interface technology is the use of a shared two-wire

cable for data transmission and distribution of auxiliary power to the sensors and actuators in

a high degree of protection IP65 / IP67. One AS-Interface power supply unit per AS-i

network is used to distribute the auxiliary power.

The AS-i network is installed with the help of a profiled (reverse-polarity-protected)

AS-Interface cable on which the AS-i slaves can be mounted as desired. The AS-i network is

electrically contacted by the piercing contacts of the AS-i slaves (insulation displacement

method). Any bus topology can therefore be chosen.

Complex control cable wiring in the control cabinet and terminal blocks can be replaced with

AS-Interface. Thanks to a specially developed cable and the insulation displacement

method, the AS-Interface cable can be connected anywhere. This concept is extremely

flexible and enables you to make huge savings.

AS-Interface has the following advantages:

● Open standard

● Flexible topologies

● Only one cable for data and energy

● Safety functions

● Time-saving mounting and installation

● Engineering in the TIA Portal

● Convenient addressing

● Device and network diagnostics

● Expandability

● Fast device replacement

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5.10.3.4

Application

The AS-Interface is used where individual actuators and sensors are distributed at different

locations on a machine (e.g. in a bottling plant or production line, etc.). AS-Interface replaces

complex cable harnesses and connects binary and analog actuators and sensors such as

proximity switches, valves, or indicator lights with a control, such as SIMATIC, or a PC.

In practice this means that the installation process is really simple, because both data and

power are transported via the same cable. No expert knowledge is required for installation

and commissioning. Furthermore, thanks to the simple cable laying procedure and the clear

cable structure, as well as the special design of the cable, you not only significantly reduce

the risk of errors, but also service and maintenance costs.

The AS-i master automatically transfers the inputs and outputs between the controller and

the digital and analog AS-Interface slaves. Slave diagnostics information is forwarded to the

control system when required. The latest AS-Interface masters according to the

AS-Interface Specification V3.0 support integrated analog value processing. This means that

data exchange with analog AS-Interface slaves is just as easy as with digital slaves.

Figure 5-15 Example of a system configuration

System properties

5.10 Industrial communication

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 57

5.10.3.5

More information

Always observe the conditions and constraints for use and the additional information

available for the modules referred to above.

AS-Interface System Manual

More information about the AS-Interface is available in the AS-Interface System Manual.

The system manual can be downloaded from the Internet

(http://support.automation.siemens.com/WW/view/en/26250840) free of charge:

Internet

You will find further information on AS-Interface on the Internet

(http://support.automation.siemens.com/WW/view/en/10805888/130000).

System properties

5.11 Safety applications

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5.11

Safety applications

SIRIUS switching devices are often used in parts of the system which have a bearing on

safety. The Safety Integrated concept enables uniform solutions to be created, from safety

relays through to fail-safe communication via AS-Interface or PROFIBUS DP.

Example

SIRIUS contactor in a safety application:

● Motor starter protectors in combination with undervoltage release and contactor:

PL d (ISO 13849-1) or SIL 2 (IEC 62061)

● Contactor assemblies for star-delta (wye-delta) start:

PL e (ISO 13849-1) or SIL 3 (IEC 62061)

5.12

Environmental protection

Siemens attaches great importance to the subject of eco-design. Our company-internal

standard SN 36350 on environmentally compatible product design has been permanently

integrated in our product development processes since 1993. Our production meets the

highest quality and environmental standards.

The CO2 balance is another important topic as regards the manufacturing processes used

for our products. All Siemens products are eco-labeled in accordance with

DIN EN ISO 14021 as a matter of course. This process of eco-labeling makes our

environmentally-compatible product design more transparent and ensures that a continual

improvement in the CO2 balance can be observed.

System properties

5.13 Energy efficiency

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 59

5.13

Energy efficiency

5.13.1

Energy efficiency

The

SIRIUS modular system

offers products that significantly reduce energy consumption in

the control cabinet thanks to their minimum intrinsic power losses. The modular system

includes devices that not only switch reliably, but also measure energy and thus supply

solutions for energy-optimized drive concepts.

Energy efficiency increases resulting from the use of SIRIUS devices can be divided into

three topic areas:

● Acquisition of measured energy values

● Reduction in intrinsic power losses

● Optimal drive solution

These three pillars form the basis of optimized energy management with the support of

products from the SIRIUS modular system.

5.13.2

Acquisition of measured energy values

Acquisition of measured energy values (identification of energy flows)

One of the essential starting points for increasing energy efficiency is the acquisition of

energy flows through detailed analysis of the machinery and systems used. You can do

without installing additional measuring instruments if you use switching devices with integral

current acquisition and communication interface at the planning phase, e.g. motor starters of

the SIMATIC ET 200S distributed I/O device. These switching devices can transfer the up-to-

date current value to the higher-level controller via PROFIBUS or PROFINET. With overload

relays for IO-Link, monitoring relays for IO-Link, the SIMOCODE motor protection and

control device, or the SIRIUS 3RW44 soft starter, further additional measured values such

as voltage and power values can be acquired and transferred. Like the ET 200S motor

starter and the High Feature motor starter, the M200D motor starter in degree of

protection IP65 offers current values in the standard format of the PROFIenergy profile. This

simplifies integration into energy management systems. The measured values of the

actuators – thus simultaneously serving as sensors – can be dragged and dropped to the

visualization system of the energy data.

Thanks to evaluation and analysis of the measured current values, energy management

systems are able to make an assessment of the current situation and thus shut down

individual load groups or consumers.

System properties

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5.13.3

Reduction in intrinsic power losses

Reduction in intrinsic power losses (calculation of potential savings)

Each device installed in a control cabinet produces a power loss. For example, devices with

integral power electronics (e.g. soft starters) are already burdened with higher power losses

than non-solid-state power contactors. Significantly higher power losses are sustained when

using frequency converters.

The power loss can be perceived in the form of heat that usually has to be minimized with

high energy consumption using, for example, fans or air conditioners requiring regular

maintenance. By using SIRIUS soft starters, the power semiconductors are bypassed after

the power-up phase with the help of bypass contacts. This reduces the resulting heat losses

to a minimum.

When using

SIRIUS contactors

, the potential savings in the main circuit are extremely low

since the electromechanical contacts generate very low intrinsic heat losses. The savings

potential is to be found in the control circuit where the pickup currents and holding currents

of conventional AC coils or DC coils are reduced by up to 92 % thanks to modern control

electronics.

The control electronics of these contactors with electronic operating mechanism (AC / DC

drive) offer the following benefits:

● Smaller power supply units in the control circuit thanks to significantly reduced pickup

currents and holding currents

● Control optionally with DC voltage or AC voltage

● Reduced stockkeeping thanks to wide voltage ranges

● Control by 0.5 A outputs of the controller

● Avoidance of overvoltage damage in the control electronics thanks to integral suppressor

circuit

In the sphere of influence of IEC standards,

fuseless

design of

load feeders

has become

established. The preferred method of protecting plants, cables and motors is to use circuit

breakers or motor starter protectors with conventional electromechanical design. The

protective function against overload is performed with the help of bimetal strips with low heat

losses. These losses are reduced by up to 20% on the SIRIUS devices (size S0) thanks to

the use of modern materials, so that it has been possible to increase the maximum settable

current from 25 A to 40 A.

The current setting ranges of the

SIRIUS motor starter protectors

overlap

(size S00: 11 ... 16 A and size S0: 14 ... 20 A). If the user requires, for example, a motor

starter protector for a 7.5 kW IE2 motor (IN = 14.7 A), the size S0 motor starter protector is

the obvious choice since the intrinsic power losses can be reduced by up to 40% thanks to

the low setting of the overload protection.

System properties

5.13 Energy efficiency

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 61

As well as the widespread use of fuseless load feeders, the following reasons speak in favor

of the design with

SIRIUS overload relays (thermal or electronic)

● Differentiation of the signals for overload and short-circuit

● Extremely high short-circuit breaking capacity in high rated operating voltage ranges in

combination with fuses

Further benefits result from the use of electronic overload relays instead of the widely used

thermal overload relays:

● Wide setting range of the rated operational current of up to 1:10

● Adjustable tripping classes (also suitable for heavy starting)

● Remote reset after overload tripping

Thanks to the use of the electronic overload relays and the fact that there is no need for the

motor starter protector, power losses are reduced by up to 98%. This reduction in intrinsic

heat buildup can significantly simplify air-conditioning in the control cabinet, particularly with

compact constructions.

The

SIRIUS compact starter

represents a new class of energy-efficient switching devices.

The combination of motor starter protector, contactor and electronic overload relay in one

enclosure, and the specified benefits of each individual device result in savings in intrinsic

power losses of up to 80% compared to conventional load feeders.

Consistent use of energy-efficient switching devices allow significant reductions in the

intrinsic losses of the devices and the associated measures for heat dissipation in the control

cabinet. This essential benefit affects not only power costs but also the availability of the

plant.

System properties

5.13 Energy efficiency

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5.13.4

Optimal drive solution

Optimal drive solution (specific measures for realizing potential energy savings)

Three-phase induction motors have a substantial responsibility for the power of a machine.

These motors can be operated in the most diverse ways. While the optimal area of

application of the frequency converters is in closed-loop speed control, soft starters

specialize in the regulation of current and torque during start-up and run-down. In

combination with the contactor-based motor starters and load feeders, soft starters have a

cost-optimized design for long operating periods at rated speed of the motors.

In such applications, the obvious choice is the combination with motors of Energy Efficiency

Class 2 (IE2) or high-efficiency motors of Energy Efficiency Class 3 (IE3). These motors

have especially low power losses in operation and thus improve the energy balance.

The power losses of the devices increase as the functionality increases. Choosing an

optimal drive solution requires economic dimensioning of the motor power to avoid

generating high losses with overdimensioned motors and later having to adapt an

overdimensioned application to low requirements using a frequency converter. Simple

closed-loop control methods, such as two-step controllers, usually represent an ecologically

better and economically more favorable alternative.

Further savings potential, e.g. with pumps, fans or compressors, the obvious choice is a

combination of a cascaded frequency converter and switching devices. In this case, the

switching devices cover the basic load requirements of the plant, and the frequency

converter covers the variable proportion of the application. This means the following benefits

of both drive systems can be optimally exploited:

● Very user-friendly closed-loop control

● Low intrinsic energy losses with simultaneously high efficiency

System properties

5.13 Energy efficiency

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5.13.5

Energy efficiency examples

The devices which make up the SIRIUS modular system are designed for minimum power

loss, and passively and actively support the realization of efficient systems and applications.

The devices have an average 10% lower intrinsic power loss so that, as well as saving on

energy costs, the heat generated in the control cabinet can also be reduced. This enables a

higher packing density in the control cabinet and reduces the cooling capacity.

The following examples show the reduction in intrinsic power loss compared to the

predecessor devices.

Product example soft starters

● Reduction of peak loads by up to 60%.

– The soft starter protects the connected products and systems both on the connection

and drive sides.

● Minimum intrinsic power loss thanks to integrated bypasses.

– The complete soft starter portfolio bridges the thyristors during operation by means of

bypasses and thus enables the intrinsic power loss to be reduced to contactor level.

– 1 W power loss requires 3 W cooling expenditure. Typical frequency converters

generate a power loss which is 30 times higher than that created by a comparable soft

starter (bypass operation) and thus require 90 times the cooling expenditure.

● The most space-saving starter ever.

– Volume reduction compared to typical contactor assemblies for star-delta (wye-delta)

start: 66 %.

– Volume reduction compared to typical frequency converters: up to 98%.

Product example contactors

● Minimized holding and closing power.

– The aspects of low power loss and further optimization of the holding and closing

power ratings played an important role in the development of SIRIUS contactors.

– SIRIUS contactors with electronically controlled coils support further reduction of the

holding power by up to 90%.

– All SIRIUS contactors can be used on the Chinese market, as they meet the Chinese

energy efficiency standard GB 21518-2008 for AC contactors in accordance with

"Grade 2". The contactors thus far exceed the minimum requirement ("Grade 3") and

are optimally equipped for the future.

Product example compact starters

● Only one switching point for minimized losses on the current path.

– Thanks to the combined functions of an electronic overload relay, a motor starter

protector, and a contactor in a single device, transfer resistances (switching points,

cable transitions, etc.) are reduced to a minimum.

System properties

5.13 Energy efficiency

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64 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Product example overload relays

● Electronics instead of bimetal for minimized intrinsic power loss.

– In addition to a wide setting range of up to 1:10, the application of electronic sensors

and actuators facilitates intrinsic power loss reductions of more than 98%.

● Optimized thermal release (bimetal).

– For devices with thermal overload relay, the power loss compared to predecessor

products is reduced by 5 to 10% thanks to the optimized bimetal release.

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 65

Customer benefits

6.1

Customer benefits

SIRIUS offers benefits in the following areas:

● Assembly and handling

● Planning and configuration

● Connecting to higher-level control systems

● Applications at a glance

Table 6- 1 Customer benefits

Area

Technical highlights

Customer benefits

Proven and optimized modularity and functional

diversity in the SIRIUS modular system

Maximum flexibility for application-

oriented solutions

Performance increase with unchanged size,

functions which are already integrated, and "all-

in-one" solution with compact starters

Space savings in the control cabinet

Reduced variance, e.g. thanks to size-

independent accessories and wide voltage and

wide setting ranges

Reduced storage costs as well as

planning and ordering expenditure

Customer benefits

6.1 Customer benefits

SIRIUS - system overview

66 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Area

Technical highlights

Customer benefits

Assembly and handling •

Load feeders

Easy to implement up to 250 kW / 400 V

from standard devices

•

Modular structure

Everything fits together and can be combined

•

Versions and sizes

Economical and flexible thanks to 7 compact

sizes

•

Accessories

Low variance with uniform accessories

•

Design

Fast startup, short setting-up times, and

simple wiring

•

Mounting

Permanently secure mounting, with screw

terminals or simply by plugging in

•

Spring-loaded connection system

Quick and secure connection, vibration-proof

and maintenance-free

•

Reduced wiring

Significant reductions in cable connections

thanks to plug-in design and IO-Link or

AS-Interface

• Assembly of

starters

with plug-in connection

system

• Corresponding infeed systems and

integrated functionalities

Reduced wiring expenditure and fault

avoidance in terms of assembly and

handling

Applications at a glance

System monitoring

•

Maintenance:

Extremely durable, low maintenance and

reliable

•

Application monitoring

integrated extremely flexibly into the feeder –

thanks to monitoring relays and function

modules for extremely simple application

monitoring

• IE3 / IE4ready: With the SIRIUS modular

system, we also offer you our familiar

reliability when converting to IE3 / IE4 motors

• Remaining lifetime detection for 3RA6

compact starter

• Comprehensive diagnostics messages

Increased operational reliability and

system availability

Customer benefits

6.1 Customer benefits

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 67

Area

Technical highlights

Customer benefits

Connecting to higher-level

control systems

•

Industrial communication

Standardized connection to AS-Interface,

IO-Link and PROFIBUS DP possible

Optimum integration in the automation

environment (TIA)

Planning and configuration •

Configuration

Easy and fast thanks to extensive CAx data

provision

•

Service

Short delivery times even for spare parts

thanks to global logistics network

•

Environment

Environmentally friendly production and

materials, recyclable

•

Design

Clear-cut, ergonomic design (winner of the

iF Product Design Award)

•

Configurator

For the simplest possible selection of

products including accessories

•

Can be used worldwide

: thanks to

comprehensive approvals

• Numerous combination tests for SIRIUS

• Simplified system planning and

documentation

• Global applicability

Customer benefits

6.1 Customer benefits

SIRIUS - system overview

68 System Manual, 09/2016, A5E03656507020A/RS-AB/003

SIRIUS offers the perfect solution throughout the entire product lifecycle:

Figure 6-1 Customer benefits by product lifecycle

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 69

Components and combinations

7.1

Switching and starting

7.1.1

SIRIUS 3RT contactors

7.1.1.1

Overview of the contactor range

The SIRIUS portfolio offers various switching devices for the safe and functional switching of

electrical loads. The table below provides an overview of the contactor versions and

contactor assemblies available in sizes S00 to S12 (table contains versions featuring screw-

type connection system).

Size

3RH2 contactor

relays

3RT2 power contactors

3RA23 reversing contactor

assembly

3RA24 contactor assembly for

star-delta (wye-delta) start

S00

S0 ---

Components and combinations

7.1 Switching and starting

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Size

3RH2 contactor

relays

3RT2 power contactors

3RA23 reversing contactor

assembly

3RA24 contactor assembly for

star-delta (wye-delta) start

S2 ---

S3 ---

Components and combinations

7.1 Switching and starting

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Size

3RT10 power contactors

S10 / S12

Size

3RT12 vacuum contactors

S10 / S12

Components and combinations

7.1 Switching and starting

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Size

Reversing contactor assembly (for self-assembly), size S6, as an example

S6 / S10 / S12

Size

Contactor assembly for star-delta (wye-delta) start (for self-assembly), size S6, as an example

S6 / S10 / S12

Components and combinations

7.1 Switching and starting

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7.1.1.2

Device versions

Various different switching devices are available for switching electrical loads. The contactor

is the ideal device for performing switching operations which are frequently repeated. it is the

most commonly used switching device in industry, mechanical engineering, and the

manufacture of switching stations. 3RT2 contactors are available in sizes S00 to S3.

3RT1 contactors are available in sizes S6 to S12.

The SIRIUS range of contactors encompasses:

● 3RT.0 power contactors and 3RT12 vacuum contactors for switching motorized loads

● 4-pole 3RT23 contactors for switching resistive loads

● 3-pole 3RT24 / 3RT14 contactors for switching resistive loads

● 4-pole 3RT25 contactors for changing the polarity of hoisting gear motors

● 3RH2 contactor relays for switching in the control circuit

● 3RT26 capacitor contactors for switching capacitive loads (AC-6b)

● 3RT1 / 3RT2 / 3RH2 contactors with extended operating range

– 3RT10 / 3RT20 / 3RH21 contactors for rail applications

– 3RT20 / 3RH21 coupling relays for system-compliant interaction with electronic

controllers

● Operation of a motor in two directions of rotation (reversing contactor assembly)

● Starting three-phase motors with reduced starting current peaks (contactor assemblies for

star-delta (wye-delta) start)

Sizes

With its seven sizes, the SIRIUS contactor series covers the entire range up to 250 kW.

Several standard motor ratings are available for each size.

Components and combinations

7.1 Switching and starting

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7.1.1.3

Applications

Use and application areas

Various different switching devices are available for switching electrical loads. When

frequent switching is necessary, the contactor is the ideal device.

Contactors are the most commonly used switching devices in industry, mechanical

engineering and switchgear construction. The progressive automation of production plants

has increased the significance of contactors, but this is also associated with higher and

sometimes different requirements.

An automatic production system is significantly more sensitive to operating faults than

manually operated systems. Every fault on an electrical device means a standstill,

production downtime, and often substantial costs for recommissioning.

For this reason, value was placed on high operational reliability in the development of the

SIRIUS contactor series. High service life, high contact reliability, and the option of using the

contactors in the control cabinet at higher ambient temperatures are among the factors

contributing to this. The contactors can be used at up to 60 °C and without derating even

with side-by-side mounting.

Due to the diverse range application options, the range of contactors also encompasses

versions for special applications such as switching resistive loads or switching capacitors, as

well as the main 3RT20 and 3RT10 series for switching motorized loads.

The different contactor series with their possible application areas are explained in the

following subsections.

Components and combinations

7.1 Switching and starting

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Utilization categories

According to DIN EN 60947-4-1, the application area of and the load applied to power

contactors can be identified by looking at the specified utilization category in conjunction with

the specified rated operational current or the motor power and the rated voltage. The table

below lists the most important utilization categories for contactors.

Utilization categories

Main circuit contacts: Utilization category for AC voltages

AC-1 Non-inductive or slightly inductive loads, resistance furnaces

AC-2

Slip-ring motors: starting, switching off

AC-3 Squirrel-cage motors: starting, switching-off motors during running

AC-4

Squirrel-cage motors: starting, plugging, inching

AC-5a

Switching of discharge lamp controls

AC-5b

Switching of incandescent lamps

AC-6a

Switching of transformers

AC-6b

Switching of capacitive loads

Main circuit contacts: Utilization category for DC voltages

DC-1

Non-inductive or slightly inductive loads, resistance furnaces

DC-3

Shunt-wound motors: Starting, plugging, reversing, inching, dynamic braking

DC-5

Series-wound motors: Starting, plugging, reversing, inching, dynamic braking

Auxiliary circuit contacts: Utilization category for AC voltages

AC-12 Control of resistive loads and solid-state loads with isolation by opto couplers

AC-14

Control of small electromagnetic loads (max. 72 VA)

AC-15 Control of electromagnetic loads (over 72 VA)

Auxiliary circuit contacts: Utilization category for DC voltages

DC-12

Control of resistive loads and solid-state loads with isolation by opto couplers

DC-13 Control of electromagnets

Components and combinations

7.1 Switching and starting

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7.1.1.4

SIRIUS 3RT2 contactors

3RT2 contactors up to 55 kW

SIRIUS 3RT2 contactors and contactor assemblies offer maximum flexibility in terms of

dimensioning, handling, and function:

Table 7- 1 3RT2 contactors and contactor assemblies

Area

Customer benefits

Functions • Power contactors (motors, resistive loads) and contactor relays

• Conventional (S00, S0 and S2) and electronic drive (S0 and S2 only;

reduced power consumption)

• Contactors for switching capacitive loads (S00, S0 and S2)

• Contactors with extended temperature range for railway applications

• Function modules for mounting on contactors and for connection to the

automation level (AS-i/IO-Link)

• Reversing contactor: space-saving mechanical interlock for S00 and S0

Dimensioning and

design

• Performance ranges:

– S00 (7.5 kW, 16 A)

– S0 (18.5 kW, 38 A)

– S2 (37 kW, 80 A)

– S3 (55 kW, 110 A)

• Width:

– S00 / S0 (45 mm)

– S2 (55 mm)

– S3 (70 mm)

• Integrated auxiliary contacts

• Identical auxiliary switch blocks for all sizes

• Screw-type connection system, spring-loaded connection system (with S2

and S3 only in the control circuit), ring cable lug connection system (S00

and S0 only), solder pin connection system (S00 only)

Components and combinations

7.1 Switching and starting

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Area

Customer benefits

Mounting

advantages

• Contactor assemblies (for star-delta (wye-delta) start, reversing contactor

assembly, 2 contactors in series)

• Contactor assembly for star-delta (wye-delta) start:

– Up to 90 kW

– Control circuit wiring integrated in function modules, incl. electrical and

mechanical interlock

– Mechanical interlock (optionally available with S2)

• Easy assembly of contactor assemblies and feeders by means of link

modules for screw-type and spring-loaded terminals

• Integrated cable duct for feeder-oriented assembly (with S0, S2 and S3)

Application

areas/customer

benefits

• Easy connection of feeders to the automation level via AS-Interface or

IO-Link

• Safety applications: Motor starter protectors in combination with

– Undervoltage release and contactor usable in PL d/SIL 2

– Star-delta (wye-delta) starter usable in PL e/SIL 3

• Switching of capacitive loads:

– Power capacitors in reactive-power compensation equipment

– Switching on converters

• For operation in installations that are subject both to considerable

variations in the control voltage and to high ambient temperatures, e. g.

railway applications under extreme climatic conditions

• Switching of highly efficient IE3 / IE4 motors

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

78 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Size-specific accessories for 3RT2 contactors (size S00)

Contactor size S00

Laterally mountable auxiliary switch block (right or left), 2-pole

Auxiliary switch block for snapping onto the front, 1-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 2-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 4-pole

3RA28 function modules

Function module for AS-Interface, direct-on-line start

Function module for IO-Link, direct-on-line start

Surge suppressor

3-phase infeed terminal

Star jumper, 3-pole, without connection terminal

Parallel switching connector, 3-pole or 4-pole, with connection terminal

Wiring modules on the top and bottom, for connecting the main and control current paths

Solder pin adapter

Terminal module (adapter) for contactors with screw connections

Safety main circuit connectors for 2 contactors

Figure 7-1 Size-specific accessories for 3RT2 contactors (size S00)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 79

Size-specific accessories for contactors (size S0)

Contactor size S0

Laterally mountable auxiliary switch block (right or left), 2-pole

Auxiliary switch block for snapping onto the front, 1-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 4-pole

Auxiliary switch block for snapping onto the front, 2-pole (cable entry from above or below)

Surge suppressor

Function module for AS-Interface, direct-on-line start

3RA28 function modules

Function module for IO-Link, direct-on-line start

Pneumatic delay block

Mechanical latch

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

80 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Parallel switching connector

Terminal module (adapter) for contactors with screw connections

Coil terminal module, top and bottom

Wiring modules, top and bottom, for connecting the control current paths

Wiring modules, top and bottom, for connecting the main current paths

Star jumper, 3-pole, without connection terminal

3-phase infeed terminal

Link module for two contactors in series (safety main circuit connectors for two contactors)

Link module for motor starter protector

LED display indicator module

Control kit for manual operation of contactor contacts

Figure 7-2 Size-specific accessories for 3RT2 contactors (size S0)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 81

Contactor accessories (size S2)

Contactor size S2

Mechanical interlock

Laterally mountable auxiliary switch block (right or left), 2-pole

Auxiliary switch block for snapping onto the front, 1-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 2-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 4-pole

Function module for AS-Interface, direct-on-line start

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

82 System Manual, 09/2016, A5E03656507020A/RS-AB/003

3RA28 function modules

Function module for IO-Link, direct-on-line start

LED display indicator module

Surge suppressor

Control kit for manual operation of contactor contacts

3-phase infeed terminal (type E)

Wiring modules, top and bottom, for connecting the main current paths

Wiring modules, top and bottom, for connecting the control current paths

Link module for motor starter protector

Star jumper, 3-pole, without connection terminal

Link module for two contactors in series (safety main circuit connectors for two contactors)

Coil terminal module, top and bottom

Parallel switching connector

Figure 7-3 Accessories for 3RT2 contactors (size S2)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 83

Accessories for contactors (size S3)

Contactor size S3

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

84 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Mechanical interlock

Laterally mountable auxiliary switch block (right or left), 2-pole

Auxiliary switch block for snapping onto the front, 1-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 2-pole (cable entry from above or below)

Auxiliary switch block for snapping onto the front, 4-pole

Function module for AS-Interface, direct-on-line start

3RA28 function modules

Function module for IO-Link, direct-on-line start

LED display indicator module

Surge suppressor without / with LED (varistor)

Control kit for manual operation of contactor contacts

Three 1-phase infeed terminals

Wiring modules, top and bottom, for connecting the main current paths

14.1 Wiring modules on the top for connecting the main current paths (contactor assembly for star-delta (wye-delta)

start)

14.2

Wiring modules on the top for connecting the main current paths (reversing contactor assembly)

14.3 Wiring modules on the bottom for connecting the main current paths (reversing contactor assembly and contactor

assembly for star-delta (wye-delta) start)

15 Wiring modules, top and bottom, for connecting the control current paths (reversing contactor assembly and

contactor assembly for star-delta (wye-delta) start)

Link module for motor starter protector

Star jumper, 3-pole, without connection terminal

Surge suppressor without LED (RC element)

Coil terminal module, top and bottom

Parallel switching connector

Figure 7-4 Accessories for 3RT2 contactors (size S3)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 85

7.1.1.5

SIRIUS 3RT1 contactors

3RT1 contactors up to 250 kW

SIRIUS 3RT1 contactors and contactor assemblies offer maximum flexibility in terms of

dimensioning, handling and function:

Table 7- 2 3RT1 contactors

Area

Customer benefits

Functions • Power contactors (motors, resistive loads)

• Vacuum contactors (electrical loads)

• Conventional operating mechanisms

• Solid-state operating mechanisms (for 24 V DC PLC output and for

24 V DC PLC output with remaining lifetime indicator)

Dimensioning and

design

• Performance ranges:

– S6 (90 kW, 185 A)

– S10 (160 kW, 185 A)

– S12 (250 kW, 500 A)

• Width:

– S6 (120 mm)

– S10 (145 mm)

– S12 (160 mm)

• Factory-assembled auxiliary contacts (2 NC contacts and 2 NO contacts)

• Identical auxiliary switch blocks for all sizes

• Screw-type connection system, spring-loaded connection system, bus

connection system, box terminal connection

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

86 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Area

Customer benefits

Mounting

advantages

• Assembly of reversing contactor assemblies up to 250 kW and contactor

assemblies for star-delta (wye-delta) start up to 500 kW with wiring kits for

customer assembly

• Wiring kit for reversing contactor assembly:

– Mechanical interlocks

– Mechanical connectors

– Wiring modules on the top and bottom for contactors with box terminal

block and bus connection

– Base plates

• Wiring kit for contactor assembly for star-delta (wye-delta) start:

– Mechanical connectors

– Neutral bridges

– Wiring modules on the bottom for contactors with box terminal block

and bus connection

– Base plates

• Easy assembly of contactor assemblies by means of link modules for

screw-type and spring-loaded terminals

Application

areas/customer

benefits

• For operation in installations that are subject both to considerable

variations in the control voltage and to high ambient temperatures, e. g.

railway applications under extreme climatic conditions

• Comprehensive approvals for global applicability

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 87

Size-specific accessories for 3RT1 contactors (sizes S6 to S12)

①

3RT10 and 3RT14 air-break contactor, sizes S6, S10 and S12

②

Auxiliary switch block, electronically delayed (ON-delay or OFF-delay or star-delta (wye-

delta) function)

③

4-pole auxiliary switch block (terminal designations according to EN 50 012 or EN 50 005)

④

2-pole auxiliary switch block, cable entry from above

⑤

2-pole auxiliary switch block, cable entry from below

⑥

1-pole auxiliary switch block (max. 4 can be snapped on) (terminal designations according

to EN 50 012 or EN 50 005)

⑦

2-pole auxiliary switch block, attachable on the right or left side (terminal designations

according to EN 50 012 or EN 50 005)

⑧

Surge suppressor (RC element), can be attached at the top on the withdrawable coil

⑨

Mechanical interlock, laterally mountable

⑩

Wiring modules top and bottom (reversing duty)

⑪

Parallel connector (neutral bridge), 3-pole with through hole, different for sizes S6 and

S10/S12

⑫

Connection cover for cable lug and bar connection, different for sizes S6 and S10/S12

⑬

Cover for box terminal, different for sizes S6 and S10/S12

⑭

Box terminal block, different for sizes S6 and S10/S12

② to ⑨

Same accessories for sizes S6 to S12

⑩ to ⑭

Different accessories depending on size

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

88 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Reference

More information ...

Is available in ...

about the 3RT, 3RH2 and 3RA23 / 3RA24

contactors and contactor assemblies

section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RT

Contactors/Contactor Assemblies" manual

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 89

7.1.2

3RA27/3RA28 function modules

Figure 7-5 Function modules

Function modules are used to perform various control jobs on automatic production lines and

for processing machines. They are suited to all time-delayed switching operations in control,

starting, protection, and regulation circuits, and ensure a high degree of repeat accuracy for

delay times, once they have been set.

Function modules are divided into those with a communication connection (AS-Interface or

IO-Link) and those without a communication connection.

Communication-capable 3RA27 function modules are available for the following contactors

and contactor assemblies:

● For direct-on-line start

● For reversing start

● For star-delta (wye-delta) start

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

90 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.1.2.1

3RA27 function modules for connection to the higher-level control

3RA27 function modules are integrated into the higher-level control system via an IO-Link

master or AS-Interface. They facilitate the simple exchange of data with the control.

Communication-capable function modules are mounted on contactors or contactor

assemblies with a communication connection from the SIRIUS device family.

Table 7- 3 3RA27 function modules for connection to the automation level

Area

Customer benefits

Functions • Connection of direct-on-line, reversing, and star-delta (wye-delta) starters

to the automation level

• Function modules with IO-Link or AS-i interface

• 2- or 3-wire communication to the control

• Integrated logic functions for starter types

• Replacement of laborious control circuit wiring

• Additional diagnostics via IO-Link.

Dimensioning and

design

• One module for sizes S00, S0, S2 and S3

• Standard motor starter profile for all starter types

• Starter-oriented configuration in the TIA environment

• IO-Link:

– Up to 4 feeders in one group per channel on the master

– Addressing not required

• AS-i

– One address per feeder

– Max. 62 addresses

Mounting

advantages

• Just a few cable connections to the control

• Considerably minimized wiring complexity within a starter

• Also available as pre-assembled contactor assemblies (e.g. star-delta

(wye-delta) starters)

• No control circuit wiring to the motor starter protector (voltage check)

• Available with screw-type and spring-loaded connection systems

Application

areas/customer

benefits

• Easy and fast connection of a load feeder to the control

• Reduced number of I/O channels on the control

• Easy and fast configuration

• Improved transparency through integrated diagnostics

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 91

Assembly

With the 3RA27 function modules, feeder functions are realized with contactors and a

connection is established with the control. This connection is realized via IO-Link or AS-i

(3RA2712) or via parallel wiring (3RA28).

Table 7- 4 Assembly of 3RA27 function modules

Type of starter

Assembly

Direct-on-line start

Reversing start

Star-delta (wye-delta) start

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

92 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Function modules for IO-Link

Function modules for IO-Link are integrated in the higher-level control system via an IO-Link

master. They are mounted on contactors with a communication link or contactor assemblies

with a communication link from the SIRIUS device family.

The function modules for IO-Link comply with the IO-Link communication specification V1.1.

The function modules for IO-Link are available for the following contactors and contactor

assemblies:

● For direct starting

● For reversing starting

● For star-delta starting

The function modules are divided into basic modules and coupling modules. Coupling

modules are connected with the basic module or another coupling module via module

connectors.

The process image of the function module outputs controls the starter. The process image of

the inputs represents the status of the starter.

Operator panel

The starters are controlled with the operator panel in manual mode. The states of the device

are also queried for up to 4 starters.

The operator panel is connected to the last available interface of a starter group via the 10-

core connecting cable.

The voltage supply of the operator panel is provided with the 2 m long connecting cable.

Note

If communication between the IO

-Link master and IO-Link device is interrupted, the IO-Link

devices switch off connected loads for safety reasons.

Manual operation is still possible with the operator panel.

Reference

More information ...

Is available in ...

about the 3RA2711 function modules for IO-Link Section "Manuals - SIRIUS Modular System

(Page 26)" in the

"SIRIUS - SIRIUS 3RA2711 function modules for

IO-Link" manual.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 93

Function modules for AS-Interface

Function modules for AS-Interface are mounted on contactors or contactor combinations of

the SIRIUS device family, and they connect these with the AS-Interface.

The function modules for AS-Interface are available for the following contactors and

contactor combinations:

● For direct starting

● For reverse starting

● For star-delta starting

The function modules are divided into basic modules and coupling modules. Coupling

modules are connected with the basic module or another coupling module via module

connectors.

Basic modules are connected with the AS-Interface using a removable terminal. For this

purpose, the AS-Interface cable and the auxiliary voltage are connected to the basic

module's removable terminal.

The process image of the function modules controls the starter. The process image of the

inputs represents the status of the starter.

AS-i addressing unit

The AS-i addressing unit can be used to control the contactors and display the process

image independently of the AS-i bus.

Reference

More information ...

Is available in ...

about the 3RA2712 function modules for

AS-Interface

Section "Manuals - SIRIUS Modular System

(Page 26)" in the

"SIRIUS - SIRIUS 3RA2712 function modules for

AS-Interface" manual.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

94 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.1.2.2

SIRIUS 3RA28 function modules for mounting on 3RT2 contactors

SIRIUS 3RA28 function modules for mounting on SIRIUS 3RT2 contactors enable the

control circuit wiring to be reduced significantly. With star-delta (wye-delta) starters, for

example, they replace the control circuit wiring in its entirety.

Table 7- 5 3RA28 function modules for mounting on 3RT2 contactors

Area

Customer benefits

Functions • Direct-on-line, reversing, and star-delta (wye-delta) start

• Time-delayed switching of contactors (0.05 ... 100 s)

• ON-delay and OFF-delay versions

• Star-delta (wye-delta) function module without extra control circuit wiring

• Switch position indication for the contactor via a mechanical plunger

Dimensioning and

design

• Only one version for S00, S0, S2 and S3

• Suitable for control voltages of 24 to 240 V AC/DC

• Contactor coil controlled via semiconductor output

• Star-delta (wye-delta) switchover 0.5 to 60 s

• Star-delta (wye-delta) changeover delay ≥ 50 ms

Mounting

advantages

• Easy plug-on assembly of a starter, without tools

• Removable terminals

• Screw-type and spring-loaded terminals

Application

areas/customer

benefits

• Assembly of star-delta (wye-delta) starters, including timing function and

electrical interlock, without additional wiring

• Universal applicability thanks to wide voltage and time ranges

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 95

Assembly

With 3RA28 function modules, a starter can be easily assembled by combining individual

modules together or by using pre-assembled combinations.

Type of starter

Individual modules

Pre-assembled combinations

Direct-on-line start

Reversing start

Star-delta (wye-delta)

start

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

96 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Applications

Function modules are used to perform various control jobs on automatic production lines and

for processing machines. They are suited to all time-delayed switching operations in control,

starting, protection, and regulation circuits, and ensure a high degree of repeat accuracy for

delay times, once they have been set.

The function modules are subdivided into function modules with communication interfacing

and function modules without communication interfacing.

Function modules

3RA28 function modules Electronic timing relays with semiconductor

output

Solid-state time-delay auxiliary switches

Function module for star-delta (wye-delta) start

3RA27 function modules with communication

connection

Function modules for AS-Interface

Function modules for IO-Link

This chapter describes 3RA28 function modules without a communication connection. You

will find information about function modules with a communication connection in the

corresponding manuals.

Function

Function modules are used to delay switching functions.

System integration

The 3RA28 function modules have been matched to the contactors in the 3RT2 and 3RH2

series1) both electrically and mechanically, and can be integrated in the feeders by directly

mounting them on contactors. The function modules can be used for size S00, S0, S2 and

S3 contactors.

The 3RA27 function modules can only be used for communication-capable contactors.

1) The 3RA28 function modules must not be mounted on 3RH2 coupling relays.

Connection system

Users can choose either function modules with screw-type connection system or function

modules with spring-loaded connection system.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 97

Device versions

● Function modules for direct-on-line start

– Solid-state timing relays with semiconductor output

– Solid-state time-delay auxiliary switches

● Function modules for star-delta (wye-delta) start

Characteristics

The table below provides an overview of the versions of 3RA28 function modules for

mounting on 3RT2 and 3RH2 contactors1).

1) The 3RA28 function modules must not be mounted on 3RH2 coupling relays.

Character-

istic

Versions

Function modules for direct-on-line start

Function module for

star-delta (wye-delta) start

Electronic timing relay with

semiconductor output

Solid-state time-delay auxiliary

switches

Function ON-delay and OFF-delay with control

signal

ON and OFF-delay

with/without control signal

Star-delta (wye-delta) function

Article

numbers

3RA2811-.CW10/

3RA2812-.DW10

3RA2831-.D.10/

3RA2832-.D.10

3RA2813-..W10/

3RA2814-..W10/

3RA2815-..W10

3RA2816-0EW20 comprising:

1 basic module

2 coupling modules

Size For size S00, S0

contactors.

For size S2 and

S3 contactors.

One module for size S00, S0, S2 and S3 contactors.

Width

45 mm

135 mm (3 x 45 mm)

Connection

system

Screw-type, spring-loaded Without terminals (can be used for

contactor screw-type and spring-

loaded connection systems)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

98 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Function modules for direct-on-line start

Applications

The function modules for direct-on-line start are used for the time-delayed switching of

contactors. The following function modules are available:

● Electronic timing relay with semiconductor output

● Solid-state time-delay auxiliary switch with 1 CO contact or 1 NC contact/1 NO contact

Features of direct-on-line starters

The function module for direct-on-line start has the following features:

● All modules with wide control voltage range

● Integrated varistor (surge suppressor)

● Applicable for size S00, S0, S2 and S3 contactors.

The following table is an overview of which function modules you can use for which size

of contactors.

S00

3RA2811, 3RA2812

3RA2831, 3RA2832 - - X X

3RA2813, 3RA2814, 3RA2815

● Large wide voltage range (24 ... 240 V AC/DC), except for 3RA2831, 3RA2832

● Extended operating ranges (24 ... 90 V, 90 ... 240 V), for 3RA2831 and 3RA2832 only

● 3 selectable time ranges (1 s, 10 s, 100 s)

● Operating time adjustment from 5 ... 100% per time range

● Switch position indicator for the contactor below (plunger)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 99

Function modules for star-delta (wye-delta) start

Applications

The function module for star-delta (wye-delta) start is used to switch from star (wye) to delta

operation.

Features

The function module for star-delta (wye-delta) start has the following features:

● All modules with wide control voltage range

● Integrated varistor (surge suppressor)

● One module kit for contactor screw-type and spring-loaded connection systems

● One module kit for S00, S0, S2 and S3 size contactors

(options only with main circuit connecting comb)

● Large wide voltage range (24 to 240 V AC/DC) and

● 3 selectable time ranges (10 s, 30 s, 60 s)

● Operating time adjustment from 5 to 100% per time range (corresponds to 0.5 s to 60 s)

● Changeover delay set to a non-adjustable value of ≥ 50 ms

● Switch position indication for the contactor below in the form of a mechanical switch

position indicator (plunger)

● Control exclusively via A1/A2 on the line contactor below

● No further wiring required

The wide voltage and the wide time range ensure advanced use of the function modules.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

100 System Manual, 09/2016, A5E03656507020A/RS-AB/003

3RA2816-0EW20 function module for contactor assemblies for star-delta (wye-delta) start

The function module for plugging into contactor assemblies for star-delta (wye-delta) start for

sizes S00, S0, S2 and S3 comprises the following devices:

● 1 basic module with time setting

● 2 coupling modules with corresponding connecting cable to coupling or function module

Figure 7-6 Star-delta (wye-delta) starter, completely assembled

The function module replaces the entire control circuit wiring and combines the functions of

the following devices and tasks:

● Timing relay star-delta (wye-delta) function

● Auxiliary switches

● Auxiliary conductor wiring

● Electrical interlock

● Switch position indicator for the contactor below (plunger)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 101

Note

Fitting of auxiliary switches

When the 3RA2816

-0EW20 function module for star-delta (wye-delta) start is used, the

following applies:

No more than one 3RH29

lateral auxiliary switch block (product version

E03 and higher) may

be mounted onto the line contactor

(Q11) and onto the star (wye) contactor (Q12).

Reference

More information ...

Is available in ...

about the 3RA28 function modules for mounting

on 3RT2 contactors

Section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RA28

function modules for mounting on 3RT2

contactors" manual.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

102 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.1.3

3RF34 solid-state switching devices

Figure 7-7 Solid-state switching device

SIRIUS 3RF34 solid-state switching devices feature a heat sink integrated in the insulated

enclosure, so no grounding is required.

Table 7- 6 3RF34 solid-state switching devices

Area

Customer benefits

Functions • Instantaneous switching solid-state contactors for motor switching

• Direct-on-line and reversing contactor (integrated electric interlock).

Dimensioning and

design

• S0 (0.5 to 16 A)

• Width 45 mm (2.2 kW/5.4 A) or 90 mm (7.5 kW/16 A)

• 24 V DC and 110 to 230 V AC

• Rated voltage up to 600 V

• Insulated enclosure

• Optimized sizing and few power versions up to 7.5 kW

• Screw-type and spring-loaded terminals

Mounting

advantages

• Side-by-side assembly possible

• Easy connection to the motor starter protector by means of link module

• Connection option for electronic overload relay or current monitoring relay

• Removable terminals for auxiliary circuit wiring

Application

areas/customer

benefits

• Wear- and noise-free operation for frequent motor switching

• Long service life (over 100 million operating cycles)

• Comprehensive approvals for global applicability

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 103

7.1.3.1

Device versions

Solid-state switching devices are primarily used in single-phase applications, which have to

meet the following requirements:

● Very high switching frequencies (> 1000 switching operations per hour)

● Resistive loads

The SIRIUS modular system features single- and three-phase solid-state contactors and

solid-state relays for the frequent switching of resistive loads. Three-phase solid-state

contactors and solid-state reversing contactors are available for switching motorized loads.

Standardized function modules for various applications complete the range of SIRIUS solid-

state switching devices.

The solid-state contactor and solid-state reversing contactor versions listed in this manual

are intended specifically for operation on three-phase motors up to 7.5 kW.

Overview

These 2-phase controlled instantaneous switching solid-state switching devices are operated

in two mounting widths in an insulating enclosure:

● In 45 mm width

– Up to 5.2 A as solid-state contactor (motor contactor) or

– Up to 5.4 A as solid-state reversing contactor and

● In 90 mm width

– Up to 16 A as solid-state contactor or

– Up to 7.4 A as solid-state reversing contactor

This means that it is possible to operate motors up to 7.5 kW.

The solid-state contactors and solid-state reversing contactors for screw-type connection can

be connected directly to a motor starter protector with a 3RA2921-1BA00 link module. Direct

mounting of a 3RB30/3RB31 solid-state overload relay and, in some cases, a 3RR2 current

monitoring relay, is also possible. This provides a time-saving way of implementing rapid-

switching motor feeders with and without fuses.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

104 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Versions

The following table provides an overview of the versions of the 3RF34 instantaneous

switching solid-state contactors for switching motors.

Table 7- 7 Versions of solid-state switching devices

Characteristic

Versions

Version

Solid-state contactor

Solid-state reversing contactor

Description

Complete devices in insulated enclosures for

frequent switching on and switching off of

AC drives.

Compact design of the reversing circuit for

frequent switching on and switching off of AC

drives with continuous reversal of the

direction of rotation

Order numbers

3RF34..-.BB..

3RF34..-.BD..

Size

Width (motor power1)/max.

rated operational current)

• 45 mm (motors up to 2.2 kW, 5.2 A)

• 90 mm (motors up to 7.5 kW, 16 A)

• 45 mm (motors up to 2.2 kW, 5.4 A)

• 90 mm (motors up to 3.0 kW, 7.4 A)

Number of poles

Connection system

Screw-type and spring-loaded terminals

Screw-type

Rated operating voltage

Up to 600 V

Up to 480 V

Rated control supply

voltage

24 V DC and 110 to 230 V AC

Switching delay

ON-delay

OFF-delay

1 ms (24 V DC), 5 ms (110 to 230 V AC)

1 ms (24 V DC), 30 ms (110 to 230 V AC)

plus up to one half-wave

5 ms (24 V DC), 20 ms (110 to 230 V AC)

5 ms (24 V DC), 10 ms (110 to 230 V AC)

plus up to one half-wave

Interlock time

60 to 100 ms (24 V DC), 50 to 100 ms (110 to 230 V AC)

Enclosure

Insulated (no grounding required)

Control connections Screw-type connection system and spring-

loaded connection system, removable

terminal for auxiliary circuit wiring

(2 contacts)

Screw-type connection system, removable

terminal for auxiliary circuit wiring (3 contacts)

1) Rating data relates to 400 V line voltage

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 105

7.1.3.2

Applications

Solid-state switching devices for switching motors

The

solid-state contactors

for the wear-free and noiseless switching of motors are designed

for the frequent switching on and switching off of AC drives up to 7.5 kW as well as for

reversing up to 3.0 kW. The devices are fully insulated and can be mounted directly on motor

starter protectors and overload relays or SIRIUS current monitoring relays, which makes

them really easy to integrate into motor feeders.

These 3-phase solid-state contactors are equipped with a 2-phase control which is

particularly suitable for typical motor circuits without a connection to the neutral conductor.

The integration of four current paths to form a single reversing circuit, accommodated in one

enclosure, makes the

solid-state reversing contactor

a particularly compact solution. Unlike

conventional systems which require two contactors, width can be reduced by up to 50% with

the 3-phase solid-state reversing contactors. Devices with a width of 45 mm cover motors up

to 2.2 kW and those with a width of 90 mm cover motors up to 3 kW.

Integration in the SIRIUS modular system facilitates connection to a SIRIUS motor starter

protector via a link module or to a 3RB30/3RB31 solid-state overload relay or a 3RR2 current

monitoring relay without additional steps. As a result, fuseless or fused motor feeders can be

implemented quickly and easily.

Main features:

● Insulated enclosure with integrated heat sink

● Degree of protection IP20

● Integrated mounting foot for snapping on a DIN rail or mounting on a support plate

● Variety of connection systems

● Plug-in control connection

● LED to indicate control voltage

Reference

More information ...

Is available in ...

about the 3RF34 solid-state switching devices section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RF34 Solid-

State Switching Devices" manual.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

106 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.1.4

SIRIUS 3RW30/40 soft starters

3RW30/40 soft starters

Figure 7-8 S0 soft starter

SIRIUS 3RW30 soft starters for standard applications in 200 – 480 V systems

(3RW40: 200 – 600 V) offer basic functionality at cost-optimized prices:

Table 7- 8 3RW30/40 soft starters

Area

Customer benefits

Functions • Soft starting for simple startup conditions

• Integrated bypass contact system

• Integrated protection functions for motor starter and soft starter (3RW40)

• Two-phase "polarity balancing" control method (consistently up to 250 kW)

• Thermistor motor protection (optional with 3RW40)

• Settable current limiting (3RW40)

Dimensioning and

design

• Performance ranges:

– S00 up to (7.5 kW, 17.6 A)

– S0 up to (18.5 kW, 38 A)

– S2 up to (37 kW, 72 A)

– S3 up to (55 kW, 106 A)

• Width:

– S00 / S0: 45 mm

– S2: 55 mm

– S3: 70 mm

• Screw-type and spring-loaded terminals

Mounting

advantages

• Easy commissioning and maintenance

• Easy retrofitting with wiring already installed

• Parameterizable output (3RW40)

Application

areas/customer

benefits

• Considerable power savings through integrated bypass contact system

• Adjustable tripping classes (3RW40)

• Integrated diagnostics functions (3RW40)

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

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7.1.4.1

Applications and use

Applications and selection criteria

The SIRIUS 3RW30 and 3RW40 soft starters represent a good alternative to direct or wye-

delta starters.

The most important advantages are:

● Soft start

● Soft stop (3RW40 only)

● Uninterrupted switching without current peaks that place a heavy load on the system

● Simple installation and commissioning

● Compact, space-saving design

Applications

The typical applications include:

● Conveyor belts

● Roller conveyors

● Compressors

● Fans

● Pumps

● Hydraulic pumps

● Agitators

● Circular saws / band saws

Advantages

Conveyor belts and transport systems:

● Smooth starting

● Smooth stopping

Rotary pumps and piston pumps:

● No pressure surges

● Increased service life of the pipe system

Agitators and mixers:

● Reduced starting current

Fans:

● Protection for the gearbox and V belt

Components and combinations

7.1 Switching and starting

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7.1.4.2

Fields of application

Soft starters are used to start three-phase induction motors with reduced torque and reduced

starting current.

SIRIUS soft starter family

The SIEMENS SIRIUS soft starter family comprises three different versions with different

functionalities and prices.

3RW30 and 3RW40

Simple or standard applications are covered by the SIRIUS 3RW30 and 3RW40 soft starters

and are described in a separate manual.

3RW44

The SIRIUS 3RW44 soft starter is used if higher functionality is specified, e.g.

communication over PROFIBUS or the availability of measuring and monitoring values, as

well as for ultra-heavy-duty starting. The SIRIUS 3RW44 soft starter is described in a

separate system manual.

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 109

Accessories for 3RW30 soft starters

Link module to motor starter protector with screw-type terminals

Link module to motor starter protector with spring-loaded terminals (size S0)

Link module to motor starter protector with spring-loaded terminals (size S00)

Infeed terminal (sizes S00 and S0)

Figure 7-9 Accessories for 3RW30 soft starters

Accessories for 3RW40 soft starters

Link module to motor starter protector with screw-type terminals

Link module to motor starter protector with spring-loaded terminals

Infeed terminal

Sealing cover

Fan for increased switching frequency

Figure 7-10 Accessories for 3RW40 soft starters

Components and combinations

7.1 Switching and starting

SIRIUS - system overview

110 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Reference

More information ...

Is available in ...

about the 3RW soft starters the chapter "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS 3RW30/3RW40 Soft

Starters" manual and the "SIRIUS 3RW44 Soft

Starters" manual.

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 111

7.2

Protecting

7.2.1

SIRIUS 3RV motor starter protectors

3RV motor starter protectors

Figure 7-11 Motor starter protector S0

SIRIUS 3RV motor starter protectors can be combined with other SIRIUS devices easily and

flexibly, while also saving on space and wiring:

Table 7- 9 3RV motor starter protectors

Area

Customer benefits

Functions • Short-circuit protection, overload protection, switching (manual), isolation

• Enables fuseless design of load feeders

• Motor protection, starter protection, system protection, and transformer

protection

• Fuse monitoring

• Distance protection

Dimensioning and

design

• S00 and S0 (up to 40 A in a width of only 45 mm)

• S2 (up to 80 A in a width of only 55 mm)

• S3 (up to 100 A in a width of only 70 mm)

• Screw-type connection system (up to 100 A), spring-loaded connection

system (3RV2 only, in sizes S00 and S0 up to 32 A), ring cable lug

connection system (3RV2 only, in sizes S00 and S0 up to 32 A and S3)

Mounting

advantages

• Can be combined easily and quickly with any SIRIUS switching device

• Reduced main circuit wiring through combination with:

– SIRIUS infeed system

– 3-phase busbar system

– 8US busbar system

Application

areas/customer

benefits

• Minimized space requirements

• Reduced power consumption

• Global applicability thanks to comprehensive approvals

Components and combinations

7.2 Protecting

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112 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.1.1

Introduction

Applications

3RV motor starter protectors are compact current-limiting devices which have been

optimized for load feeders. They are used for protecting and switching three-phase motors

and other loads. The scalable setting ranges mean that a suitable motor starter protector can

provide protection for all standard motors at ambient temperatures of ≤ 60 °C.

3RV1.11 motor starter protectors have a toggle switch. 3RV2 motor starter protectors are

uniformly fitted with rotary operating mechanisms.

Functions

The motor starter protectors protect loads against overloads and short circuits. They also

feature a lockable rotary operating mechanism / toggle switch to facilitate manual switching

on and off (e.g. in the event of repair work).

System integration

In both electrical and mechanical terms the motor starter protectors are compatible with 3RT

contactors, 3RF solid-state contactors, and 3RW soft starters. They can be integrated in the

feeder by means of direct mounting. 3RV1 motor starter protectors are available in size S00.

3RV2 motor starter protectors are available in four sizes, S00, S0, S2 and S3.

Note

3RF

solid-state contactors are available in two sizes, S00 and S0.

Connection systems

The motor starter protectors are available with the following connection system options (in

the main circuit):

● Screw-type connection terminals (up to 100 A)

● Spring-loaded connection system (3RV2 only, in sizes S00 and S0 up to 32 A)

● Ring cable lug connection technology (3RV2 only, in sizes S00 and S0 up to 32 A, and

S3)

Accessories

The accessories have been tailored to the motor starter protectors and they are available

with a screw-type connection system, spring-loaded connection system or ring cable lug

connection system. Accessories can be fitted easily and without the need for tools.

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 113

7.2.1.2

Versions

Device versions

● Motor starter protector standard version (3RV1011, 3RV20)

Overload and short-circuit protection

● Motor starter protectors with relay function (3RV21)

Short-circuit protection and auto-RESET in the event of overload in one device

● MSP for starter combinations (3RV23)

Short-circuit protection only

Combined with solid-state overload relay, large setting ranges and auto-RESET

● MSP for transformer protection (3RV24)

Standard version for transformers

● Circuit breakers in accordance with UL489 (3RV27/3RV28)

Overload protection, short-circuit protection, and transformer protection

● Circuit breaker for fuse monitoring (3RV1611-0BD10)

● Voltage transformer circuit breakers for distance protection (3RV1611-1.G14)

Sizes

3RV1 motor starter protectors are available in size S00 (45 mm width) up to a maximum

rated current of 12 A. 3RV2 motor starter protectors are available in four sizes, S00, S0, S2

and S3.

The table below lists the sizes and the corresponding maximum rated current at a voltage of

400 V AC. The last column of the table indicates the maximum power of the three-phase

motor which is suitable for the relevant size.

Table 7- 10 Size of the 3RV2 motor starter protector

Size

Width

Max. rated current

Power of three-phase motor

S00

45 mm

16 A

7.5 kW

S0 45 mm1) 40 A2) 18.5 kW

55 mm

80 A

37 kW

S3 70 mm4) 100 A 45 kW / 55 kW

3RV211, 3RV212: 65 mm

3RV20 and 3RV23 only

3RV213: 75 mm

4) 3RV214: 90 mm

Number of poles

3RV motor starter protectors have 3 poles.

Components and combinations

7.2 Protecting

SIRIUS - system overview

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7.2.1.3

Applications

General

3RV motor starter protectors are used for protecting and switching the following loads:

● Three-phase motors up to 45 kW / 55 kW at 400 V AC

● Loads with rated currents up to 100 A

Special applications

The various 3RV motor starter protectors are suitable for:

● Short-circuit protection

● Motor protection (also with overload relay function)

● System protection

● Short-circuit protection for starter combinations

● Transformer protection

● As main and EMERGENCY OFF switches

● Use in IT systems

● Switching direct current (size S2 and S3 on request)

● Hazardous areas (ATEX)

● Use as Branch Circuit Protection Device (BCPD) according to UL (3RV27/28)

● Circuit breaker for fuse monitoring (3RV1611-0BD10)

● Use as voltage transformer circuit breakers for distance protection (3RV1611-1.G14)

Components and combinations

7.2 Protecting

SIRIUS - system overview

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7.2.1.4

Performance features

SIRIUS motor starter protectors boast the following technical advantages:

Technical highlights

Customer benefits

Up to 20 % less power consumption than previous solutions • Reduced temperature rise in the control cabinet

• Cost savings during operation

Uniform connection systems:

• Screw-type connection (sizes S00, S0, S2 and S3)

• Spring-loaded connection (size S007), S0, S21) and S31))

• Ring cable lug connection (size S007), S0, S23) and S34))

The right connection for every application (e.g. operational

reliability (vibration-resistant, non-temperature-

specific, etc.) and less wiring thanks to spring-loaded

connection system)

Link modules for any device combination from the

SIRIUS modular system

Fast, error-free installation for screw-type connection

system and spring-loaded connection system

• Motor starter protectors up to 40 A (18.5 kW) in 45 mm

width

• Motor starter protectors up to 80 A (37 kW) in 55 mm

width

• Motor starter protectors up to 100 A (55 kW) in 70 mm

width

Space and cost savings

Motor starter protector combined with undervoltage release

and contactor can be used as a Cat. 3 feeder in accordance

with EN 951-1, SIL 2 in accordance with IEC 62061 or

PL d 13849-1

Safety solution can be implemented with just one switching

device

Factory-fitted integrated auxiliary switches (optional)

Reduced installation complexity

Joint range of accessories for sizes S00, S0, S2 and S3

Easy to configure, reduced stockkeeping

Current values graded in accordance with all standard motors • The right motor starter protector for every standard

motor

• Integrated protection even for ambient temperatures

> 60 °C (with derating)

Bimetals with extreme long-term stability

Operational reliability over many years

Compatible for use in all infeed systems (3-phase busbars5),

3RA6

, 3RV29 infeed

, 8US)

Maximum flexibility in terms of power infeed

In the case of size S2 and S3 devices, only connection of the auxiliary circuit is possible using spring-type terminals.

Only for devices of size S00 and S0.

In the case of size S2 devices, only connection of the auxiliary circuit is possible using ring cable lug connection

technology.

On devices of size S3, the terminal blocks of the main current connectors can be removed and conductors with ring

cable lugs can be connected.

Only for devices of size S00, S0 and S2.

Not applicable to 3RV1 motor starter protectors.

7) Not applicable to 3RV1 motor starter protectors.

Components and combinations

7.2 Protecting

SIRIUS - system overview

116 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.1.5

Accessories for SIRIUS 3RV motor starter protectors

Accessories

For maximum flexibility, accessories can be added to the motor starter protector as required,

easily, and without the need for tools.

Mountable accessories

The mountable accessories for size S00 3RV1011 motor starter protectors are illustrated

below.

①

Transverse auxiliary switch

②

Lateral auxiliary switch with 2 contacts

③

Lateral auxiliary switch with 4 contacts

④

Shunt release

⑤

Undervoltage release

⑥

Undervoltage release with leading auxiliary contacts

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 117

The mountable accessories for size S00/S0 3RV2 motor starter protectors are illustrated

below.

①

Signaling switch

②

Lateral auxiliary switch with 2 contacts

③

Lateral auxiliary switch with 4 contacts

④

Disconnector module

⑤

Terminal block type E

⑥

Undervoltage release

⑦

Shunt release

⑧

Undervoltage release with leading auxiliary contacts

⑨

Transverse auxiliary switch

⑩

Phase barriers / accessories, type E

Figure 7-12 Motor starter protectors size S00 and S0 with mountable accessories

Components and combinations

7.2 Protecting

SIRIUS - system overview

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The mountable accessories for size S2 and S3 3RV2 motor starter protectors are illustrated

below.

①

Transverse auxiliary switch

②

Lateral auxiliary switch with 2 contacts

③

Lateral auxiliary switch with 4 contacts

④

Shunt releases

⑤

Undervoltage releases

⑥

Undervoltage release with leading auxiliary contacts

⑦

Signaling switch

⑧

Isolator module (for size S2 only)

Figure 7-13 Motor starter protector size S2 and S3 with mountable accessories

Further accessories

● Phase barriers / accessories, type E

● Door-coupling rotary operating mechanism

● Enclosures and mounting accessories

● Sealable cover

● Insulated 3-phase busbar system

● 8US busbar adapter

● 3RV2917 infeed system (3RV2 only, in sizes S00 and S0)

● Link modules for the installation of contactors, solid-state contactors or soft starters

● Motorized remote operating mechanism (for 3RV2 motor starter protector, size S3 only)

Components and combinations

7.2 Protecting

SIRIUS - system overview

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Infeed systems

The SIRIUS modular system has the right infeed for every requirement.

SIRIUS infeed system (3RV2917)

3-phase busbar system (3RV1915)

3 Combination of 3RA68 infeed system for compact starter and

3RV2917 infeed system for motor starter protector

Busbar system (8US)

Figure 7-14 Infeed systems

Components and combinations

7.2 Protecting

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7.2.1.6

SIRIUS 3RV2917 infeed system

3RV2917 infeed system (for sizes S00 and S0)

3-phase busbar with infeed (optionally on the left or right)

3-phase busbar for system expansion

Expansion plug

End cap

Connector

Contactor base

Outgoing terminal

Figure 7-15 3RV2917 infeed system

Components and combinations

7.2 Protecting

SIRIUS - system overview

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Reference

More information ...

Is available in ...

about the 3RV motor starter protectors section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RV motor

starter protectors" manual.

Components and combinations

7.2 Protecting

SIRIUS - system overview

122 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.2

SIRIUS 3RU thermal overload relays / SIRIUS 3RB electronic overload relays

3RU thermal overload relays / 3RB electronic overload relays

Figure 7-16 S0 overload relay

The thermal and electronic overload relays are available in the modular system with graded

functionality, which reflects their flexible applicability.

Table 7- 11 SIRIUS 3RU thermal overload relays / SIRIUS 3RB electronic overload relays

Area

Customer benefits

Functions 3RU21 thermal overload relays:

• Tripping in the event of overload

• Tripping due to phase unbalance

• Tripping due to phase failure

• Protection of single-phase loads

3RB30 / 3RB31 and 3RB20 / 3RB21 electronic overload relays:

• Tripping in the event of overload

• Tripping due to phase unbalance

• Tripping due to phase failure

• Tripping in the event of a ground fault (can be activated by internal ground-

fault detection)

Components and combinations

7.2 Protecting

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Area

Customer benefits

Dimensioning and

design

• 3RU21 performance ranges:

– S00 (16 A)

– S0 (38 A)

– S2 (80 A)

– S3 (100 A)

• 3RB30 / 3RB31 performance ranges:

– S00 (16 A)

– S0 (38 A)

– S2 (80 A)

– S3 (115 A)

• 3RB20 / 3RB21 performance ranges:

– S6 (200 A)

– S10 / S12 (630 A)

• Width:

– S00 / S0 (45 mm)

– S2 (55 mm)

– S3 (70 mm)

– S6 (120 mm)

– S10 / S12 (145 mm)

• Large wide setting range of 1:4 with 3RB3

• High long-term stability through special bimetals with 3RU2

• Matched and uniform accessories for thermal and electronic overload

relays

• Screw-type connection system, spring-loaded connection system (sizes S2

and S3 auxiliary circuit only), ring cable lug connection system (3RU21

only: main circuit and auxiliary circuit in sizes S00 and S0; main circuit in

size S3 only)

Mounting

advantages

• Optional direct mounting on contactor or stand-alone assembly

• Removable terminals for control circuit wiring (3RB3)

• Same stand-alone assembly support for 3RU2 and 3RB3, with screw-type

and spring-loaded connection systems

Application

areas/customer

benefits

• Optimum adjustability to the motor current: overlapping ranges up to 60°C,

above that up to 70°C without overlapping

• Comprehensive approvals for global applicability (e.g. ATEX)

Components and combinations

7.2 Protecting

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7.2.2.1

Introduction

3RU21 thermal overload relays

3RU21 thermal overload relays up to 100 A have been designed to provide current-

dependent protection for loads with normal starting against impermissibly high temperature

rises due to overload, phase asymmetry or phase failure.

An overload or phase failure results in an increase of the motor current beyond the set rated

motor current. Via heating elements, this current rise increasingly heats up the bimetal strips

located inside the device. The deflection of these bimetal strips eventually activates the

auxiliary contacts via a release mechanism. The contacts then disconnect the load via a

contactor. (The contactor function is not an integral component of the overload relay).

3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays

3RB20 / 3RB21 electronic overload relays up to 630 A and 3RB30 / 3RB31 electronic

overload relays up to 115 A with internal power supply 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.

An overload, phase asymmetry or a phase failure results in an increase of the motor current

beyond the set rated motor current.

This rise in current is detected by the current transformers integrated into the devices and

evaluated by corresponding electronic circuits which then output a pulse to the auxiliary

contacts. The contacts then disconnect the load via a contactor. (The contactor function is

not an integral component of the overload relay).

In addition to current-dependent protection for loads against impermissibly high temperature

rise caused by overload, phase asymmetry, and phase failure, 3RB21 and 3RB31 electronic

overload relays feature internal ground-fault detection (not possible in conjunction with

contactor assemblies for star-delta (wye-delta) start). This provides protection of loads

against high-impedance faults to ground caused by damaged insulation, moisture,

condensation, etc.

Components and combinations

7.2 Protecting

SIRIUS - system overview

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System integration

The overload relays have been matched to the contactors in the 3RT series both electrically

and mechanically and can be integrated in the feeder by means of direct mounting. 3RU2

thermal overload relays are available in sizes S00 to S3 up to 100 A. 3RB30 and 3RB31

electronic overload relays are available in sizes S00 to S3 up to 115 A. 3RB20 and 3RB21

electronic overload relays are available in sizes S6 to S10 / S12 up to 630 A.

Connection systems

The overload relays are available with the following connection system options:

● Screw-type connection system

● Spring-loaded connection system (sizes S2 and S3 auxiliary circuit only)

● Ring cable lug connection technology (3RU21 only: main circuit and auxiliary circuit in

sizes S00 and S0; main circuit in size S3 only)

3RB3 (sizes S2 and S3) and 3RB2 (size S6) electronic overload relays are also available in

through-hole technology with straight-through transformer. As an alternative, 3RB20 / 3RB21

electronic overload relays in sizes S6 to S10 / S12 can be connected to the main circuit via

busbars.

Components and combinations

7.2 Protecting

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126 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.2.2

Versions

Sizes, setting ranges, and device versions

The table below provides an overview of the various sizes in which 3RU21 thermal overload

relays and 3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays are available. The

maximum rated currents, the minimum and maximum setting ranges, and the available

tripping classes are listed for each individual size.

Table 7- 12 3RU21 thermal overload relays

Size

Width

Current range

Rated operating

voltage Ue

Rated frequency

Trip class

S00

45 mm

0.11 to 16 A

690 V AC 50/60 Hz CLASS 10

S0 45 mm 1.8 to 40 A

S2 55 mm 11 to 80 A CLASS 10 or

CLASS 10A

70 mm

28 ... 100 A

690 V AC

CLASS 10

Components and combinations

7.2 Protecting

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Table 7- 13 3RB20 / 3RB30 electronic overload relays

Size

Width

Current range

Rated operating

voltage Ue

Rated frequency

Trip class

S00

45 mm

0.1 to 16 A

690 V AC 50/60 Hz CLASS 10E or 20E

(fixed)

S0 45 mm 0.1 to 40 A

S2 55 mm 12.5 to 80 A 690 V AC

Through-hole

technology: 1000

V AC

S3 70 mm 12.5 ... 115 A 1000 V AC

120 mm

50 ... 200 A

690 V AC

S10 / S12 145 mm 55 ... 250 A to

160 ... 630 A

690 V AC

Table 7- 14 3RB21 / 3RB31 electronic overload relays

Size

Width

Current range

Rated operating

voltage Ue

Rated frequency

Trip class

S00

45 mm

0.1 to 16 A

690 V AC 50/60 Hz CLASS 5E, 10E, 20E,

30E (adjustable)

45 mm

0.1 to 40 A

S2 55 mm 12.5 to 80 A 690 V AC

Through-hole

technology: 1000

V AC

70 mm

12.5 ... 115 A

1000 V AC

S6 120 mm 50 ... 200 A 690 V AC

S10 / S12 145 mm 55 ... 250 A to

160 ... 630 A

690 V AC

3RB30 / 3RB31 electronic overload relays have approximately the same dimensions as

3RU21 thermal overload relays. As a result, the thermal overload relays can be replaced

easily with the electronic variant 3RB30/3RB31. This is necessary, for example, if increased

overload protection is required (wide setting ranges (1:4), for example, or even reduced

power loss and, as a result, minimized energy consumption).

Components and combinations

7.2 Protecting

SIRIUS - system overview

128 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.2.3

Applications

Table 7- 15 Overview of applications

Applications

3RU21

3RB20 / 3RB21

3RB30 / 3RB31

System protection

✓

Motor protection ✓ ✓

Alternating current, 3-phase

✓

Alternating current, 1-phase ✓ -

DC current

✓

In the main circuit, the devices provide overload protection for the assigned electrical loads (e.g.

motors), feeder cable, and other switching and protection devices in the respective load feeder.

The 3 phases have to be under symmetrical load.

3RU21 thermal overload relays

3RU21 thermal overload relays have been designed to protect three-phase loads, DC loads,

and single-phase AC loads.

Note

Protection of DC loads/single-phase AC loads

If a 3RU21

thermal overload relay is to be used to protect DC loads or single-phase AC

loads, all the bimetal strips have to be heated. Therefore, all of the relay's main current paths

have to be connected in series.

3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays

3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays are designed to protect

three-phase loads in sinusoidal 50/60 Hz voltage supplies.

Note

DC loads/Single-phase AC loads

The relay is not suitable for protecting DC loads or single

-phase AC loads. On single-pole

loads, the 3RU21

thermal overload relay or the 3RB22, 3RB23 and 3RB24 electronic

overload relays for higher applications (no protection for DC loads) must be used for IO

-Link.

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 129

The advantages of load feeders with overload relays

Installing load feeders with overload relays (fuses + contactor + overload relay or MSP for

starter combinations/circuit breaker (acc. to UL) + contactor + overload relay) has the

following advantages over configurations without overload relays (motor starter protector +

contactor):

● Overload release and short-circuit release are signaled separately. In the event of a short

circuit the fuses or the MSP for starter combinations/circuit breaker (acc. to UL) limit the

short-circuit current and in the event of an overload the overload relay disconnects the

contactor (and thus the load).

● The overload relays are especially suitable for use in fused switchgear assemblies. The

devices are also used in applications in line networks with operating voltages pf more

than 400 V. Compared with fuseless design, the fuses still have an extremely high short-

circuit breaking capacity in excess of 100 kA, even in these voltage ranges.

● Automatic RESET is easy to implement with the overload relays. Following an overload

trip, the load feeder need not be switched on again on-site.

● Attachable electrical or mechanical RESET modules compatible for use with all sizes

enable 3RU21 thermal overload relays to be RESET remotely. Mechanical RESET

modules that are compatible for use with all sizes can also be attached to 3RB20 / 3RB21

und 3RB30 / 3RB31 electronic overload relays. An electrical remote RESET is an integral

component of the 3RB21 / 3RB31.

● Applications with lengthy start times can be implemented thanks to the different trip

classes of the 3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays.

● 3RB20 / 3RB21 and 3RB30 / 3RB31 electronic overload relays reduce variation and

simplify configuring and inventory management thanks to their wide 1:4 setting range.

● MSP for starter combinations/circuit breaker (acc. to UL) + contactor + overload relay

combinations have the advantage that the load feeder can be isolated easily and all three

poles can be disconnected in the event of a short circuit.

Components and combinations

7.2 Protecting

SIRIUS - system overview

130 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Accessories for 3RU2 and 3RB30/31 overload relays

Overload relay size S0

Stand-alone assembly support

Electrical remote RESET (3RU2 only)

Sealing cover

Figure 7-17 Accessories for 3RU2 and 3RB30/31 overload relays

Reference

More information ...

Is available in ...

about the 3RU, 3RB overload relays

section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RU thermal

overload relays / SIRIUS 3RB electronic overload

relays" manual.

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 131

7.2.3

3RB24 electronic overload relays for IO-Link

Figure 7-18 Electronic overload relay

Table 7- 16 SIRIUS 3RB24 electronic overload relays for IO-Link

Area

Customer benefits

Functions 3RB24 electronic overload relays for IO-Link:

• Tripping in the event of overload

• Tripping due to phase unbalance

• Tripping due to phase failure

• Tripping in the event of overheating (integrated thermistor motor protection

function)

• Tripping in the event of a ground fault (can be activated by internal ground-

fault detection)

Dimensioning and

design

• 3RB24 for IO-Link performance ranges and current ranges of the 3RB29.6

current measuring module:

– S00 / S0 (25 A)

– S2 / S3 (100 A)

– S6 (200 A)

– S10 (630 A)

– S12 (630 A)

• Width of the evaluation module:

– 45 mm

• 3RB24 for IO-Link: Screw-type connection system, spring-loaded

connection system

• 3RB29:

– Up to size S6: Straight-through transformers

– Sizes S6 and S10 / S12: Bus connection

Mounting

advantages

• Modular device concept:

– Evaluation module (independent of motor current)

– Current measuring module (independent of motor current)

– Connecting cable

• Removable terminals

Application

areas/customer

benefits

• Protection of three-phase motors

• Protection of induction motors

• Protection of single-phase AC motors

Components and combinations

7.2 Protecting

SIRIUS - system overview

132 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.3.1

Properties

Solid-state overload relay for IO-Link

The solid-state overload relay, comprising the 3RB24 evaluation module and a

3RB29 current measuring module, protects electrical equipment (e.g. three-phase motors)

with two different protection mechanisms: overload protection and thermistor protection.

Ground fault detection can also be enabled via IO-Link.

In conjunction with the 3RT contactors, the solid-state overload relay for IO-Link can be used

as a direct-on-line starter, reversing starter or, with the help of an additional circuit, as a star-

delta (wye-delta) starter. It is possible to read out diagnostics data, such as the current, via

IO-Link and to further process this data in the higher-level controller.

Components and combinations

7.2 Protecting

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 133

7.2.3.2

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.

①

Evaluation module 3RB2483-4A .1

②

Current measuring module 3RB29.6-2...

③

Connecting cable 3RB2987-2.

Figure 7-19 System structure

Components and combinations

7.2 Protecting

SIRIUS - system overview

134 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.2.3.3

Reference

More information ...

Is available in ...

about 3RB24 solid-state overload relay for IO-

Link

the chapter "Manuals - SIRIUS Modular System

(Page 26)" in the "3RB24 Solid-State Overload

Relay for IO-Link" manual.

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 135

7.3

Monitoring

7.3.1

3UG4 / 3RR2 monitoring relays

7.3.1.1

SIRIUS 3RR2 current monitoring relays

Figure 7-20 S0 current monitoring relays

Components and combinations

7.3 Monitoring

SIRIUS - system overview

136 System Manual, 09/2016, A5E03656507020A/RS-AB/003

The SIRIUS 3RR2 current monitoring relays are ideally suited to a range of applications,

thanks to the flexible way in which they can be adjusted:

Table 7- 17 3RR2 current monitoring relays

Area

Customer benefits

Functions • Analog or digital setting

• Versions available for IO-Link

• Overcurrent and undercurrent monitoring

• Phase sequence, phase failure, and fault current monitoring

• Apparent or active current monitoring

• Freely parameterizable threshold values and delay times

• Manual and automatic reset

Dimensioning and

design

• S00, S0, S2 (1.6 up to 80 A with only two versions)

• 24 V AC/DC, 24 to 240 V AC/DC

• 160 to 690 V wide voltage range in the main circuit

• Width:

– 45 mm (up to 40 A)

– 55 mm (up to 80 A)

• 1 CO contact and 1 semiconductor output

• Clear status signals on the display

• Screw-type and spring-loaded terminals

Mounting

advantages

• Removable terminals for auxiliary circuit wiring

• Direct mounting on contactor

• Same stand-alone mounting support as with overload relays

Application

areas/customer

benefits

• One device for overload and underload monitoring

• Integrated assembly:

– Reduced wiring

– No separate transformers required

– 3-phase current monitoring with further monitoring options

• Current monitoring relay for feeder-integrated load monitoring

• Detection of fast and substantial, as well as slight and "subtle" changes

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 137

Product description

The tried and tested SIRIUS monitoring relays for electrical and mechanical quantities

enable constant monitoring of all important characteristic quantities that provide information

about the reliability performance of the plant. Sudden disturbances and gradual changes,

which may reveal a maintenance requirement, for example, are both indicated. By means of

relay outputs, the monitoring relays enable direct shutdown of the affected sections of the

plant as well as issuing an alarm (e.g. by switching on a warning lamp). To respond flexibly

to short-term disturbances such as voltage dips or load variation, the monitoring relays have

settable delay times. This avoids unnecessary alarming and shutdowns while enhancing

plant availability.

The individual 3UG4 monitoring relays offer the following functions in various combinations:

● Undershoot and/or overshoot of liquid levels

● Phase sequence

● Phase failure, neutral failure

● Phase asymmetry

● Undershoot and/or overshoot of voltage thresholds

● Undershoot and/or overshoot of current thresholds

● Undershoot and/or overshoot of power factor thresholds

● Monitoring of the active current or apparent current

● Monitoring of the fault current

● Monitoring the insulation resistance

● Undershoot and/or overshoot of speed thresholds

The 3RT2 contactors for mounting on 3RR2 current monitoring relays offer:

● Phase sequence

● Phase failure

● Undershoot and/or overshoot of current thresholds

● Monitoring of the active current or apparent current

● Monitoring of the fault current

Components and combinations

7.3 Monitoring

SIRIUS - system overview

138 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Accessories for 3RR2 current monitoring relays

3RR21 current monitoring relays

3RR22 / 3RR24 current monitoring relays

Stand-alone assembly support

Sealing cover

Figure 7-21 3RR2 current monitoring relays

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 139

7.3.1.2

Overview of the functions

3RR2 current monitoring relays

Table 7- 18 Functions of the 3RR21 / 3RR22 current monitoring relays for analog and digital setting

Function

Current monitoring relay

3RR21

3RR22

Current monitoring

Monitoring for undercurrent

Monitoring for overcurrent 2p 3p

Apparent current monitoring

✓

Active current monitoring — ✓

Range monitoring

Monitoring for phase failure, wire break

Monitoring for phase sequence

—

✓

Internal ground-fault detection (fault current

monitoring)

— ✓

Blocking current monitoring

—

✓

Supply voltage

Self-powered, without auxiliary voltage

—

Externally powered, with auxiliary voltage

✓

: Function available

2p: Monitoring is 2

-phase

3p: Monitoring is 3

-phase

— : Function not available

Components and combinations

7.3 Monitoring

SIRIUS - system overview

140 System Manual, 09/2016, A5E03656507020A/RS-AB/003

3UG45 / 3UG46 monitoring relays

Table 7- 19 Functions of the 3UG45/3UG46 monitoring relays for analog and digital setting

Function

Monitoring relays

3UG45

3UG46

Line monitoring and voltage monitoring

Monitoring for phase sequence — ✓ ✓ ✓ — ✓ ✓ ✓ ✓ ✓ — — — — — — — —

Monitoring for phase failure

—

○

✓

—

✓

—

Monitoring for asymmetry — — 10

— ✓ ○2) ○2) ✓ ✓ — — — — — — — —

Monitoring for undervoltage

—

Monitoring for overvoltage

—

Monitoring for neutral failure

—

✓

—

✓

—

Automatic direction of rotation

correction in the case of

incorrect phase sequence

— — — — — — — — ✓ ✓ — — — — — — — —

Power factor monitoring and current monitoring

Monitoring for undercurrent

—

Monitoring for overcurrent

—

Active current monitoring

—

✓

—

Apparent current monitoring

—

✓

—

Power factor monitoring

—

✓

—

Fault current monitoring/insulation monitoring

Monitoring for fault

current/ground fault

— — — — — — — — — — — — — — — — ✓ —

Insulation monitoring

—

✓

—

Filling level monitoring

Monitoring for filling level

overshoot/resistance overshoot

✓ — — — — — — — — — — — — — — — — —

Monitoring for filling level

undershoot/resistance

undershoot

✓ — — — — — — — — — — — — — — — — —

Speed monitoring

Monitoring for speed overshoot

—

✓

Monitoring for speed undershoot

—

✓

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 141

Function

Monitoring relays

3UG45

3UG46

Rated control supply voltage

Self-powered, without auxiliary

voltage

— ✓ ✓ ✓ — ✓ ✓ ✓ ✓ ✓ — — ✓ — — ✓ — —

Externally powered, with

auxiliary voltage

✓ — — — ✓ — — — — — ✓ ✓ — ✓ ✓ — ✓ ✓

✓

: Function available

1p: Monitoring is 1

-phase

3p: Monitoring is 3

-phase

—

: Function not available

○: Function available with limitations

Detection causes problems with regenerative power recovery.

2) By monitoring the voltage thresholds.

7.3.1.3

Reference

More information ...

Is available in ...

about the 3UG4/3RR2 monitoring relays the chapter "Manuals - SIRIUS Modular System

(Page 26)" of the "3UG4/3RR2 Monitoring

Relays" manual.

Components and combinations

7.3 Monitoring

SIRIUS - system overview

142 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.3.2

3RS1 / 3RS2 temperature monitoring relays

7.3.2.1

Product description

The temperature monitoring relays are used for measuring temperatures in solid, liquid, and

gaseous media. The temperature is sensed by the sensors in the medium and evaluated by

the device. It is monitored for overshoot, undershoot or, on digital device versions, remaining

within a working range (range function).

The family comprises the following devices:

● Devices for analog setting, with one or two limit values

● Digital devices for 1 sensor (e.g. alternative to temperature controllers for low-end

applications)

● Digital devices for up to 3 sensors (optimized for monitoring large motors)

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 143

7.3.2.2

Overview of the functions (3RS10/ 11/ 20/ 21)

Function

Table 7- 20 Functions of the 3RS1 / 3RS2 temperature monitoring relays

Function

Temperature monitoring relays

3RS10

3RS202)

3RS11

3RS212)

Settings

Connectable sensor type

Resistance

sensors

✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ -- -- -- -- -- -- --

Thermocouple -- -- -- -- -- -- -- -- -- ✓ ✓ ✓ ✓ ✓ ✓ ✓

Number of

sensors that can

be monitored

1 1 1 1 1 3 1 1 3 1 1 1 1 1 1 1

Temperature monitoring

Temperature

monitoring for

overshoot

✓ -- ✓ -- ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

Temperature

monitoring for

undershoot

-- ✓ -- ✓ ✓ ✓ ✓ ✓ ✓ -- -- -- -- ✓ ✓ ✓

Number of limit

values that can be

set1)

1 1 2 2 2 2 2 2 2 1 1 2 2 2 2 2

1) The device versions with two limit values can be switched between the open-circuit

principle NO and the closed-circuit principle NC.

2) Temperature scale of the sensors in degrees Fahrenheit [°F].

✓: Function available

--: Function not available

a : Analog setting

d: Digital setting

Reference

More information ...

Is available in ...

about the 3RS1/3RS2 temperature monitoring

relays

the chapter "Manuals - SIRIUS Modular System

(Page 26)" in the "3RS1/3RS2 Temperature

Monitoring Relays" manual.

Components and combinations

7.3 Monitoring

SIRIUS - system overview

144 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.3.3

3UG48 / 3RR24 monitoring relays for IO-Link

7.3.3.1

Product description

The tried and tested SIRIUS monitoring relays for electrical and mechanical quantities

enable constant monitoring of all important characteristic quantities that provide information

about the reliability performance of the plant. Sudden disturbances and gradual changes,

which may reveal a maintenance requirement, for example, are both indicated. Through

relay outputs, the monitoring relays enable direct shutdown of the affected sections of the

plant as well as alarming (e.g. by switching a warning lamp). To respond flexibly to short-

term disturbances such as voltage dips or load variation, the monitoring relays have settable

delay times. This avoids unnecessary alarming and shutdowns while enhancing plant

availability.

The individual monitoring relays provide the following functions in different combinations:

● Phase sequence

● Phase failure, neutral failure

● Phase asymmetry

● Voltage below and / or above thresholds

● Current below and / or above thresholds

● Power factor below and / or above thresholds

● Monitoring of the active current or apparent current

● Speed below and / or above thresholds

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 145

The SIRIUS 3UG48/3RR24 monitoring relays for IO-Link offer many other performance

features in addition to monitoring functions:

● Measured values (including resolution and unit) to the higher-level control.

Some device versions allow you to set which value is to be transferred cyclically.

● Transmission of alarm flags to the higher-level control.

● Comprehensive diagnostics capability by querying the precise cause of the error in the

diagnostic data record.

● Remote parameterization additionally possible (supplementing local parameterization or

instead of local parameterization).

● Fast parameterization of identical devices by duplicating the parameter assignment in the

higher-level control.

● Parameter transfer by means of Upload to the higher-level control via- IO-Link call or by

parameter server1) when using an IO-Link master in

IO-Link Communication Specification V1.1 or higher).

● Local parameter assignment can be disabled via IO-Link.

● To prevent automatic startup after a power failure and to avoid losing diagnostic data,

errors can be configured so that they are saved to non-volatile memory.

● Linking to a higher-level control makes it possible to assign parameters to the monitoring

relays via a display unit. The measured values can be displayed directly in a control room

or at the machine/control cabinet.

Up until now, using redundant sensors and/or analog signal converters to transfer measured

values to a higher-level control incurred significant additional expense and wiring effort.

Combining the autonomous monitoring relays with IO-Link communication reduces this

wiring outlay and cuts costs.

As the availability of up-to-date measured values means that the higher-level control can

take care of the control tasks within the plant, the continued availability of the output relays

on the monitoring relays increases the plant's operational reliability (e.g. by shutting down

the plant if thresholds that cannot be achieved under normal operating conditions are

overshot).

The monitoring relays continue to function autonomously in spite of the IO-Link connection.

Parameters can be assigned locally at the device, independently of a higher-level control. As

long as the 24 VDC supply voltage is available, the monitoring relays will function if the

controller fails or is not yet available. If the 3UG48/3RR24 monitoring relay is used for

IO-Link without a connection to a higher-level control, because of the integrated SIO-Mode,

the devices feature an additional semiconductor output that switches when settable warning

thresholds are exceeded.

1) The parameter server provides an assurance of consistent central data management in the

event of changes to parameters (made locally or via the control). The "Parameter server"

function supports the automatic backup of parameter data (automatic re-assignment of

parameter data if a device is replaced).

Components and combinations

7.3 Monitoring

SIRIUS - system overview

146 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.3.3.2

Overview of the functions

3RR24 current monitoring relays for IO-Link

Table 7- 21 Functions of the digitally adjustable 3RR24 current monitoring relays for IO-Link

Current monitoring relay

3RR24

Current monitoring

Monitoring for undercurrent

Monitoring for overcurrent 3p

Range monitoring

Apparent current monitoring ✓

Active current monitoring

✓

Monitoring for phase failure, wire break

Monitoring for phase sequence

✓

Monitoring for current asymmetry

✓

Internal ground-fault detection (fault current monitoring)

✓

Blocking current monitoring

✓

Supply voltage

External power supply

(via the IO-Link master or an external 24 V DC voltage source)

✓

Additional functions

Runtime meter

✓

Switching cycle counter

✓

Voltage measurement

Cos phi calculation ✓

Runtime meter

✓

Switching cycle counter ✓

Voltage measurement

Cos phi calculation

✓

Apparent power calculation

Active power calculation

✓

: Function available

1p: Measuring is single

-phase

3p: Monitoring/calculation is 3-phase

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 147

3UG48 monitoring relays for IO-Link

Table 7- 22 Functions of the 3UG48 monitoring relays for IO-Link

3UG48 monitoring relays

Line monitoring and voltage monitoring

Monitoring for phase sequence

✓

—

Monitoring for phase failure ✓ ✓ — — — —

Monitoring for asymmetry

✓

—

Monitoring for undervoltage

—

Monitoring for overvoltage

—

Monitoring for N-conductor failure

—

✓

—

Cos phi monitoring and current monitoring

Monitoring for undercurrent

—

Monitoring for overcurrent

—

Active current monitoring

—

Apparent current monitoring

—

Monitoring for cos phi

—

Speed monitoring

Monitoring for speed overshoot

—

✓

Monitoring for speed undershoot

—

✓

Power supply

External power supply (via the

IO-Link master or an external

24 V DC voltage source)

✓ ✓ ✓ ✓ ✓ ✓

✓

: Function available

1p: Monitoring is

single-phase

3p: Monitoring is 3

-phase

— : Function not available

7.3.3.3

Reference

More information ...

Is available in ...

about the 3UG48 monitoring relays for IO-Link the chapter "Manuals - SIRIUS Modular System

(Page 26)" of the "3UG48 Monitoring Relays"

manual.

Components and combinations

7.3 Monitoring

SIRIUS - system overview

148 System Manual, 09/2016, A5E03656507020A/RS-AB/003

7.3.4

3RS14 / 3RS15 temperature monitoring relays for IO-Link

7.3.4.1

Product description

The new SIRIUS 3RS14/3RS15 temperature monitoring relays for IO-Link are used to

measure temperatures in solid, liquid, and gaseous media. The temperature is sensed by the

sensors in the medium and evaluated by the device. Up to 2 limit values for overshoot,

undershoot, or staying within a working range (range function) are monitored. In addition to

providing warning and shutdown functions in the event of temperature deviations, the

devices can be used as temperature controllers (single-step control, two-step control, or

three-step control).

The devices differ in terms of the type and number of temperature sensors that can be

connected to them:

● 3RS14: Connection for 1 or up to 3 resistance sensors

● 3RS15: Connection for 1 thermocouple

Components and combinations

7.3 Monitoring

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 149

The 3RS14/3RS15 temperature monitoring relays for IO-Link offer many other performance

features in addition to monitoring functions:

● Transmission of measured values (including resolution and unit) to the higher-level

control.

Local display and transmission of the temperature unit (°C or °F) can be parameterized.

The temperature measured value transferred from temperature monitoring relays with

more than one resistance sensor can be adjusted. Some device versions allow you to set

which value is transferred cyclically.

● Transfer of alarm flags to the higher-level control.

● Comprehensive diagnostics capability by querying the precise cause of the error in the

diagnostic data record.

● Remote parameterization is also possible (instead of local parameter assignment).

● Fast parameterization of identical devices by duplicating the parameter assignment in the

higher-level control.

● Parameter transfer by means of Upload to the higher-level control via- IO-Link call or by

parameter server1) when using an IO-Link master in

IO-Link Communication Specification V1.1 or higher).

● Local parameter assignment can be disabled via IO-Link.

● To prevent automatic startup after a power failure and in order not to lose diagnostic data,

errors can be configured so that they are saved to non-volatile memory.

● Linking to a higher-level control makes it possible to assign parameters to the monitoring

relays via a display unit. The measured values can be displayed directly in a control room

or at the machine/control cabinet.

1) The parameter server provides an assurance of consistent central data management in the

event of changes to parameters (made locally or via the control). The "Parameter server"

function supports the automatic backup of parameter data (automatic re-assignment of

parameter data if a device is replaced).

Up until now, using redundant sensors and/or analog signal converters to transfer measured

values to a higher-level control incurred significant additional expense and wiring effort.

Combining the autonomous monitoring relays with IO-Link communication reduces this

wiring outlay and cuts costs.

As the availability of up-to-date measured values means that the higher-level control can

take care of the control tasks within the plant, the continued availability of the output relays

on the monitoring relays increases the plant's operational reliability (e.g. by shutting down

the plant if limit values that cannot be achieved under normal operating conditions are

overshot).

The monitoring relays continue to function autonomously in spite of the IO-Link connection.

Parameters can be assigned locally at the device, independently of a higher-level control. As

long as the 24 VDC power supply is available, the monitoring relays will function should the

controller fail or not yet be available.

Components and combinations

7.3 Monitoring

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7.3.4.2

Overview of the functions

Function

Table 7- 23 Functions of the temperature monitoring relays for IO-Link

Function

Temperature monitoring relays

3RS14

3RS15

Connectable sensor type

Resistance sensors

✓

Thermocouple

✓

Number of sensors that can be monitored 1 3 1

Temperature monitoring

Temperature monitoring for overshoot ✓ ✓ ✓

Temperature monitoring for undershoot

✓

Number of limit values that can be set

It is possible to switch between the open-circuit principle NO and the closed-circuit principle NC.

✓

: Function available

--: Function not available

Reference

More information ...

Is available in ...

3RS14/3RS15 temperature monitoring relays for

IO-Link

the chapter "Manuals - SIRIUS Modular System

(Page 26)" of the "3RS14/3RS15 Temperature

Monitoring Relays for IO-Link" manual.

Components and combinations

7.4 Feeders and tested switchgear assemblies

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7.4

Feeders and tested switchgear assemblies

7.4.1

SIRIUS 3RA load feeders

7.4.1.1

Overview

Fuseless load feeders

Fuseless load feeders are device combinations comprising a 3RV motor starter protector for

overload and short-circuit protection and a 3RT contactor for normal switching. The SIRIUS

portfolio features two different configuration options for fuseless load feeders.

● 3RA2 tested pre-assembled complete devices (sizes S00 to S2 only)

● Tested combinations of individual devices

7.4.1.2

Device versions

The modular standard components in the SIRIUS modular system are ideally matched and

support the simple configuration of fuseless load feeders. The load feeders are also

available as 3RA2 complete devices.

Both options are characterized by the following features.

● Type of coordination 1 or 2

● Rated control supply voltage

● Mounting on busbar or DIN rail

● Screw or spring-loaded connection

A detailed overview of the fuseless load feeders product range appears below.

Components and combinations

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Types of coordination

Fuseless load feeders up to 38 A (discrete configuration of individual devices with

connecting cables) and 32 A (pre-assembled complete devices or configuration with link

module) can be assembled in sizes S00 and S0.

An assembly up to 80 A (discrete configuration of individual devices with connecting cables)

and 65 A (as pre-assembled complete devices, or configuration with link module) is possible

in size S2.

An assembly up to 100 A (discrete configuration of individual devices with connecting

cables) is possible in size S3.

The table below lists the maximum power of the three-phase motor for pre-assembled

3RA2 complete devices based on the type of coordination at a voltage of 400 V AC.

Table 7- 24 Motor starter protector sizes

Size

Type of coordination

Power of three-phase motor

S00

0.06 to 7.5 kW

2 0.06 to 1.5 kW

7.5 to 15 kW

2 1.5 to 15 kW

15 kW … 30 / 37 kW (max. 65 A)

Components and combinations

7.4 Feeders and tested switchgear assemblies

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Types of coordination

Standard DIN EN 60947-4-1 (VDE 0660 Part 102) or IEC 60947-4-1 distinguishes between

two types of coordination (type of coordination), which are referred to as coordination type

"1" and coordination type "2". In the case of both types of coordination, the short-circuit is

reliably mastered. the only differences are in the extent of the damage sustained by the

device following a short circuit.

Type of coordination 1

The load feeder may be non-operational after a short circuit has been cleared. Damage to

the contactor and the overload release is also permissible.

Type of coordination 2

After short-circuit disconnection, there must be no damage to the overload release or to any

other part. The load feeder can resume operation without needing to be renewed. Welding of

the contactor contacts only is permitted if these can be separated easily without significant

deformation.

Components and combinations

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Auxiliary contacts

The following auxiliary contacts are integrated into fuseless load feeders dependent upon

size.

Table 7- 25 Integrated auxiliary contacts

Size

Direct feeder

Reversing feeder

S00 1 NO contact is integrated in the

contactor.

1 NC contact is integrated in the contactor.

S0 1 NO contact and 1 NC contact are

integrated in the contactor. The user

can decide how the NC contact is

assigned.

1 NO contact and 1 NC contact are

integrated in the contactor. The NC contact

is assigned to the interlock.

Assembly/Installation

The devices are prepared for DIN rail mounting, for mounting on a 60 mm busbar or for

mounting on a base plate.

Table 7- 26 Mounting options

Starter combination

Direct-on-line starter

Reversing starter

Size

S00

Mounting on a standard rail

Snap-on mounting

without adapter

✓1) ✓1) ✓2) — ✓1) — ✓2) —

With DIN rail adapter

✓

Mounting on 8US busbar

With 8US busbar

adapter

✓ ✓ ✓ — ✓ ✓ ✓ —

Mounting on base plate

Direct

✓

—

✓

—

With DIN rail adapter

✓

Mounting on 1 DIN rail

Mounting on 2 DIN rails

3) Mounting on 1 or 2 DIN rails

Components and combinations

7.4 Feeders and tested switchgear assemblies

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7.4.1.3

SIRIUS 3RA21/22 load feeders

Figure 7-22 S0 load feeder

The tested load feeders offer switching and protection functions. Thanks to their multiple

combination options, they can be easily configured for almost any requirement.

Table 7- 27 Load feeders

Area

Customer benefits

Functions • Switching and protection functions in one mechanical unit

• High short-circuit breaking capacity

• Tested combinations (fuseless and fused)

• Coordination types 1 and 2 (tested up to 150 kA)

• Tested for CLASS 10, 20, 30

• With motor starter protectors or MSPs for starter combinations

• With contactor, solid-state contactor, and soft starter

• Connection to the automation level via IO-Link and AS-i

Dimensioning and

design

• Tested for all common line voltages

• S00, S0, S2 (0.06 up to 37 kW)

• Pre-assembled SIRIUS 3RA2 feeders with 230 V AC and 24 V DC

Mounting

advantages

• Easy mounting of individual components into tested combinations

• Direct connection of switching devices

• Perfectly matched accessories

• Screw-type, spring-loaded, ring cable lug connection systems

Application

areas/customer

benefits

• Completely pre-assembled load feeders

• Comprehensive type tests for load feeders for self-assembly by the

customer (approx. 45000 combinations)

• Comprehensive approvals for global applicability

• Comprehensive dimensioning, planning, and construction support

Components and combinations

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7.4.1.4

SIRIUS 3RA21/22 pre-assembled load feeders

3RA21/22 pre-assembled load feeders

3RA21 / 3RA22 fuseless load feeders are pre-assembled complete devices; they are

delivered ready-wired and with all mechanical connections established. The devices are

available in sizes S00, S0 and S2 for direct-on-line start. Pre-assembled complete devices in

sizes S00 and S0 are available for reversing start.

Sizes S00 and S0 are both available with either screw-type or spring-loaded connection

systems. Size S2 is available with screw-type connection system.

The fuseless load feeders can be ordered with or without pre-assembled busbar adapters for

mounting on a DIN rail or busbar.

Accessories for load feeders

The main accessories for 3RV2 motor starter protectors, and those for 3RT2 contactors

(such as side-mounted and transverse auxiliary switches, current limiters, undervoltage

limiters, rotary operating mechanisms, busbar adapters, etc.) can be used for 3RA21/22 load

feeders and feeders for self-assembly.

7.4.1.5

Self-assembled load feeders

Assembly of load feeders from individual devices

Self-assembly load feeders comprising individual devices are available as an alternative to

the 3RA2 complete device. In the case of a discrete configuration of individual devices

without a link module, the values of the basic devices apply. The following components can

be combined via the intermediary of a link module.

Combination

S00

Motor starter protector

and contactor

7.5 kW (16 A) 15 kW (32 A) 30 / 37 kW (65 A) 55 kW (100 A) 1)

Motor starter protector

and soft starter

7.5 kW (16 A) 15 kW (32 A) 30 / 37 kW (65 A) 1) On request

Motor starter protector

and solid-state contactor

— 7.5 kW (16 A) — —

1) A DIN rail adapter shall be used for this combination

The modularity of the SIRIUS system means that the standard devices are perfectly matched

from both a mechanical and an electrical point of view. As a straightforward means of

assembling starter combinations, wiring kits are available for contactor assemblies for

reversing and star-delta (wye-delta) start for size S2 / S3 with screw terminals, and for

size S00 / S0 with various connection systems. Assembly kits are available for mounting

self-assembled load feeders on DIN rails or busbars.

Components and combinations

7.4 Feeders and tested switchgear assemblies

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Assembly of three-part combinations with link module between the motor starter protector and the

contactor

You are basically advised to refrain from setting up combinations of a motor starter protector,

a contactor and an overload relay or a monitoring relay as a completely assembled three-

part combination. If this should nevertheless be necessary, the following restrictions apply:

Motor starter protector + contactor + electronic overload relay / 3RR monitoring relay

(size S00 / S0)

Thermal restrictions

Mechanical restrictions

No restrictions

DIN rail adapter required

Motor starter protector + contactor + electronic overload relay / 3RR monitoring relay

(size S2)

Thermal restrictions

Mechanical restrictions

• At an ambient temperature of Ta = 40 °C

(no restrictions)

• At an ambient temperature of Ta = 60 °C

(clearance between the load feeders:

≥ 10 mm)

No restrictions

Motor starter protector + contactor + solid-state overload relay (size S3)

Thermal restrictions

Mechanical restrictions

On request

Motor starter protector + contactor + thermal overload relay (size S00 / S0)

Thermal restrictions:

Mechanical restrictions

Reduce permissible ambient temperature by 20 K DIN rail adapter required

No side-by-side mounting

(≥ 10 mm clearance for vertical installation,

> 20 mm for horizontal installation)

Current derating to 87 % of In

Motor starter protector + contactor + thermal overload relay (size S2 / S3)

Note

A three

-part combination consisting of a motor starter protector, a contactor and a thermal

overload relay is not permissible for sizes S2 and S3.

Components and combinations

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7.4.1.6

Applications

Fuseless load feeders can be used anywhere in industry where fuse, contactor, and

overload relay combinations were previously used. The increased functionality of the motor

starter protector (unlike a fuse combination, it can be used as an EMERGENCY OFF and as

a disconnector) means that a fuseless load feeder is capable of solving numerous

applications easily.

Reference

More information ...

Is available in ...

about 3RA load feeders section "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS - SIRIUS 3RA load

feeders" manual.

Components and combinations

7.4 Feeders and tested switchgear assemblies

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7.4.2

Device combinations

The flexible designs enable the individual devices to be combined in myriad different ways.

More than 45000 combinations have been tested, which offer solutions for almost every

application. Over 500 pre-assembled combinations are available, facilitating rapid and fault-

free control cabinet assembly.

Device combinations

The combination matrix below shows which devices can be combined for the main circuit:

Screw-type connection system

Spring-loaded connection system (size S00 / S0 only)

Ring cable lug connection system (size S00 / S0 only)

Mechanical connection with link module

Direct mechanical connection

Figure 7-23 Device combinations

Components and combinations

7.4 Feeders and tested switchgear assemblies

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Link modules

Link modules can be used to easily assemble feeders from individual devices. The table

below shows the different combination options for devices with screw-type and spring-loaded

connection systems:

Combination device

3RV2 motor starter

protectors

3RT2 contactors;

3RW30, 3RW40

soft starters;

3RF34 solid-state

contactors

Link modules

3RV2 motor starter

protectors with

screw-type

terminals

3RV2 motor starter

protectors with

spring-loaded

terminals

Size

Link modules for connection of switching devices to 3RV2 motor starter protectors

3RT2 contactors with AC or DC

coil

S00 S00 3RA1921-1DA00 3RA2911-2AA00

3RT2 contactors with AC coil

3RA2921-1AA00

3RA2921-2AA00

3RT2 contactors with DC coil

3RA2921-1BA00

3RA2921-2AA00

3RT2 contactors with AC coil or

AC / DC coil

S2 S2 3RA2931-1AA00 —

3RT2 contactors with AC coil or

AC / DC coil

S3 S3 3RA1941-1AA00 —

3RW30 soft starters

S00

3RA2921-1BA00

3RA2911-2GA00

3RW30/3RW40 soft starters

3RA2921-1BA00

3RA2921-2GA00

3RW30/3RW40 soft starters

3RA2931-1AA00

—

3RW30/3RW40 soft starters

3RA1941-1AA00

—

3RF34 solid-state switching

devices

S00 S00 3RA2921-1BA00 —

Hybrid link modules for connection of contactors with a spring-loaded connection system to 3RV2 motor starter protectors

with a screw-type connection system

3RT2 contactors with AC or DC

coil

S00 S00 3RA2911-2FA00 —

3RT2 contactors with AC or DC

coil

S0 S0 3RA2921-2FA00 —

The link modules and hybrid link modules cannot be used for 3RV2.21-4PA1. and 3RV2.21-4FA1. motor starter

protectors or 3RV27 and 3RV28 circuit breakers.

Components and combinations

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7.4.3

SIRIUS 3RA6 compact starters

3RA6 compact starters

Figure 7-24 Compact starter

The SIRIUS 3RA6 compact starter is a compact, highly integrated device which features

state-of-the-art controls, including practical diagnostics functions. The compact starter

ensures improved efficiency and reliability in the control cabinet.

Table 7- 28 3RA6 compact starters

Area

Customer benefits

Functions • Direct-on-line starter and reversing starter

• Short-circuit protection,

electronic overload protection, functional switching,

and line protection

• Mechanical and electrical interlock with reversing starter

• IO-Link and AS-i connection

• Manual and automatic reset (remote reset via control)

Dimensioning and

design

• S0 (0.1 up to 32 A/15 kW)

• Width of 45 mm (direct-on-line starter) or 90 mm (reversing starter)

• 5 setting ranges from 0.1 A to 32 A

• Weld-free contacts (remaining lifetime indication)

• Screw-type and spring-loaded connection systems with removable

terminals in the main and auxiliary circuits

Components and combinations

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Area

Customer benefits

Mounting

advantages

• SIRIUS 3RA68 infeed system for simpler, space-saving installation

• Connection of cables up to 70 mm²

• Coding and locking options in the 3RA6 compact starter

• Screw-type and spring-loaded terminals

• Removable terminals for easy and quick replacement if service is required

(permanent wiring)

• Optional control kit for testing the main current path

Application

areas/customer

benefits

• Integrated diagnostics functions

• Large wide voltage ranges and wide setting ranges

• Three different power infeed options

• Comprehensive approvals for global applicability

• Fast and standardized configuration thanks to full integration in STEP 7

7.4.3.1

System overview

Features

The SIRIUS compact starter is a universal, weld-free motor feeder in accordance with

IEC/EN 60947-6-2. It combines the functions of a circuit breaker, a solid-state overload relay

and a contactor within a single enclosure and can be used in any application involving the

direct starting of standard three-phase motors with a rating of up to 32 A

(approx. 15 kW/400 V).

The compact starter is available as either a direct or a reversing starter.

As an option, an AS-i mounting module can be mounted on the 3RA61/3RA62 compact

starter with a 24 V control supply voltage. The AS-i mounting module enables the compact

starter to communicate via an AS-Interface.

The 3RA64/3RA65 compact starter with IO-Link can communicate via IO-Link.

Table 7- 29 Compact starter communication options

Compact starter

Communication

3RA61/3RA62 compact starter without optional

AS-i mounting module

Communication via auxiliary contacts

and signaling contacts

3RA61/3RA62 compact starter (24 V) with optional

AS-i mounting module

Communication via AS-Interface

3RA64/3RA65 compact starter with IO-Link

Communication via IO-Link

Components and combinations

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Accessories

You can find more information in the chapter Manuals - SIRIUS Modular System (Page 26)

in the "SIRIUS 3RA6 Compact Starter" manual.

In addition to the 3RA61/3RA62 compact starter and the 3RA64/3RA65 compact starter with

IO-Link, this document also describes the following accessories:

Table 7- 30 Accessories for the compact starter

Accessories

Description

Auxiliary switch block for compact

starter

Optional auxiliary switch block in the following versions: 2 NO

contacts, 2 NC contacts or 1 NO contact + 1 NC contact.

AS-i mounting module The AS-i mounting module enables the 3RA61/3RA62

compact starter with 24 V control supply voltage to

communicate via an AS-Interface.

Control kit Tool for closing the main contacts manually by means of the

handle.

Adapter for screw fastening the

compact starter

The adapters for screw fastening enable you to install the

compact starter on a level surface (screw fastening).

Terminals for

"Combination Controller Type E"

The terminals conform to the clearances and creepage

distances stipulated by UL 508 (Type E).

Infeed system for 3RA6 The infeed system for 3RA6 is a modular infeed system with

an optional PE system. The permanent wiring means that

compact starters can be mounted quickly and easily.

3-phase busbar The 3-phase busbar enables several compact starters to be

fed using a single infeed terminal.

8US busbar adapter The 8US busbar adapter enables the compact starter to be

mechanically fastened and electrically connected to a busbar

system.

Door-coupling rotary operating

mechanism

Door-coupling rotary operating mechanisms enable compact

starters to be operated with the control cabinet doors closed.

Components and combinations

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Versions

The 3RA6 compact starter is available in the following versions:

Table 7- 31 3RA6 compact starter versions

Version

Image

Compact starter direct-on-line version

Compact starter reversing version

Compact starter direct-on-line, IO-Link version

Compact starter reversing, IO-Link version

Components and combinations

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Accessories for 3RA6 compact starters

3RA6 compact starter

External auxiliary switch block

AS-i add-on module

4 AS-i add-on module with:

• Two local inputs for safe disconnection

• Two additional digital inputs

• One additional digital input and one digital output

• Two additional digital outputs

• For on-site control

Adapter for screw mounting

Figure 7-25 Accessories for 3RA6 compact starters

Components and combinations

7.4 Feeders and tested switchgear assemblies

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Infeed system for 3RA6 compact starter

Infeed on left or right using spring-loaded connection system

Infeed on left using screw-type connection system

Expansion module

Expansion plug

Terminal block

Expansion plug for 3RV19

PE infeed

PE expansion plug

PE tap

45 mm adapter for infeed system for 3RA6

Figure 7-26 Infeed system for 3RA6 compact starter

Components and combinations

7.4 Feeders and tested switchgear assemblies

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Reference

More information ...

Is available in ...

about the 3RA6 compact starters the chapter "Manuals - SIRIUS Modular System

(Page 26)" in the "SIRIUS 3RA6 Compact

Starter" manual.

Components and combinations

7.4 Feeders and tested switchgear assemblies

SIRIUS - system overview

168 System Manual, 09/2016, A5E03656507020A/RS-AB/003

SIRIUS - system overview

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Mounting and disassembly

Within each device size, the mounting options are identical.

Table 8- 1 Mounting options

Size

Mounting

Disassembly

S00, S0, S2,

Screw mounting

Disassembly with a screwdriver

Snap-on mounting on 35 mm DIN

rail (according to DIN EN 60715) or

75 mm DIN rail (size S3)

• Disassembly without tools (size S00 / S0)

• Disassembly with a screwdriver (size S2 /

S3)

S6, S10, S12 Screw mounting (wall mounting or

base plate)

Disassembly with a screwdriver

8.1

Screw mounting

SIRIUS switching devices can be screwed onto a level surface.

Push-in lugs are required in order to fasten the 3RV2 motor starter protectors with screws.

Mounting and disassembly

8.2 Snap-on mounting

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8.2

Snap-on mounting

SIRIUS switching devices in sizes S00 to S3 are snapped onto 35 mm DIN rails according to

DIN EN 60 715, without tools.

The tables below describe how to snap a component onto a DIN rail, using a contactor (size

S00) as an example. The procedure is the same for all SIRIUS switching devices.

Mounting on a DIN rail

①

Position the device on the top edge of the DIN rail. Press down until it snaps onto the bottom

edge of the DIN rail.

Disassembling from a DIN rail

①

To disassemble the device, press it down, pushing against the mounting springs. Swivel the

device to remove it.

Mounting and disassembly

8.2 Snap-on mounting

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Snapping onto / off DIN rail (size S2)

①

②

③

Position the device on the top edge of the DIN rail and press down until it snaps onto

the bottom edge of the DIN rail.

To disassemble the device, push down the lock with a screwdriver. (①/②) Then push

the device down against the pull of the mounting springs, and swivel the device to

remove it.③

Mounting and disassembly

8.2 Snap-on mounting

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Snapping onto DIN rail (size S3)

①

Position the device on the top edge of the DIN rail and press down until it snaps onto the

bottom edge of the DIN rail.

Snapping off DIN rail (size S3)

①

②

③

To disassemble the device, push down the lock with a screwdriver. (

①

②

) Then push

the device down against the pull of the mounting springs, and swivel the device to

remove it.③

Refer to the product manuals or operating instructions for specific details of how to snap the

different devices onto DIN rails.

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Connection

9.1

Connection systems

9.1.1

Screw connection

Within each device size, the terminals are identical. Therefore, the same tool can be used

thanks to the same conductor cross-sections and tightening torques within one size. The

stripped lengths are identical too; this is important for pre-assembled cables.

Size S00, S0 and S2 devices feature screw-type terminals with captive screws and terminal

washers. The screw-type terminals also allow for the connection of 2 conductors with

different cross-sections.

DANGER

Hazardous voltage.

Will cause death or serious injury.

Turn off and lock out all power supplying this device before working on this device.

Use the following tool to establish the connection: The screws are designed for a size PZ 2

Pozidriv screwdriver at rated currents of up to 80 A.

Connection

9.1 Connection systems

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9.1.2

Spring-loaded connection

The devices in the SIRIUS modular system are available with spring-loaded connection

system. Spring-loaded connection makes wiring quick and maintenance-free, while also

meeting high demands in terms of vibration and shock resistance. In sizes S00 and S0,

spring-loaded connection is possible in both the main circuit and the auxiliary circuit. As from

size S2, spring-loaded connection is possible in the auxiliary circuit.

①

Solid

②

Finely stranded

③

Stranded

④

Finely stranded with end sleeve

Spring-loaded terminal

Busbar

Figure 9-1 Spring-loaded terminal

The spring-loaded terminal on the switching devices clamps copper conductors from 0.25

mm2 (removable terminal) to 10 mm2 (main circuit terminal, size S0). You can find more

detailed information in the SIRIUS modular system manuals (Page 26). The conductors can

be clamped directly or you can pre-treat them to add a form of splice protection. This could

involve attaching end sleeves or pin cable lugs to the ends of the conductors; the tidiest

solution is to use conductors whose ends have been sealed by means of ultrasound.

Connection

9.1 Connection systems

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The devices are equipped with a two-wire connection, i.e. two independent connections per

current path. Just one conductor is connected to each clamping point. The spring-loaded

terminal presses the conductor against the busbar, which curves around inside the terminal.

The high contact pressure per unit area achieved in this way is gas-tight. The spring-loaded

terminal presses flat against the conductor, but does not damage it. The spring force of the

spring-loaded terminal has been dimensioned such that the clamping force adjusts to the

conductor diameter automatically. This ensures that any conductor deformation caused by

settling, creepage, or yielding is compensated for. The clamping point cannot become loose

of its own accord. This connection is vibration- and shock-proof. Vibrations or shocks will not

damage the conductor, nor will they cause contact separation. These terminals are

particularly well suited for use with machines and systems which are subject to stresses

such as these, e.g. vibrators, rail vehicles, and elevators.

Catalog IC 10 "SIRIUS Industrial Controls" offers a standard screwdriver, which can be used

as the operating tool for opening the spring-loaded connections.

Connection

9.1 Connection systems

SIRIUS - system overview

176 System Manual, 09/2016, A5E03656507020A/RS-AB/003

The table below describes the procedure for creating a spring-loaded connection:

DANGER

Hazardous voltage.

Will cause death or serious injury.

Turn off and lock out all power supplying this device before working on this device.

NOTICE

Damage to the spring-loaded terminal!

If you insert the screwdriver into the central opening on the spring-loaded terminal, this

could damage the terminal.

Do not insert the screwdriver into the central opening on the spring-loaded terminal.

Table 9- 1 Connecting the spring-loaded terminal

Step

Operating instruction

Image

1 Insert the screwdriver into the bottommost

(A) or topmost (B) operating slot on the right-

hand side.

2 Press the screwdriver down (A) or up (B),

then push it into the operating slot as far as it

will go.

The screwdriver blade keeps the spring-

loaded terminal open automatically.

3 Insert the conductor into the oval connection

slot.

Remove the screwdriver. The terminal closes

and the conductor is now securely clamped.

Connection

9.1 Connection systems

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 177

Link modules

Link modules enable load feeders to be assembled without tools, simply by plugging the

relevant devices in.

Link module

①

Slot for link modules

②

Slot for conductor connection

③

Screwdriver opening for mounting/disassembly without a link module

Figure 9-2 Link module

NOTICE

Damage to the spring-loaded terminal of the link module

If a conductor is plugged into the socket for conductor connection when a link module is

used, it can be damaged.

If a link module is used, do not plug a conductor into the slot for conductor connection.

Connection

9.1 Connection systems

SIRIUS - system overview

178 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Insulating stop

With conductor cross-sections which are ≤ 1 mm2, you should use an insulating stop to

prevent the conductor insulation from being clamped. The insulating stop can be used with

the following devices:

Table 9- 2 Overview table - Use of insulating stop for conductor cross-sections ≤ 1 mm2 (size S00 / S0)

Size S00

Size S0

Main circuit

Control circuit

Main circuit

Control circuit

3RT2/3RH2 contactors (basic devices) 2 2 — 1

Accessories for 3RT2 contactors

(e.g. auxiliary switches)

— 1 — 1

3RF34 solid-state switching devices — — 2 —

3RW30 / 40 soft starters

—

3RV2 motor starter protectors (basic

devices)

—

Accessories for 3RV2 motor starter

protectors (e.g. auxiliary switches)

— 1 — 1

3RU2 thermal overload relays

—

3RB3 electronic overload relays

—

3RA6 compact starters

—

3RA27/3RA28 function modules

—

3RR2 current monitoring relays

—

0: No insulating stop required

1: 3RT1916

-4JA02 insulating stop

2: 3RT2916

-4JA02 insulating stop

—: Not relevant (e.g. conductor cross-section ≤ 1 mm

) or not available

Connection

9.1 Connection systems

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 179

Table 9- 3 Overview table - Use of insulating stop for conductor cross-sections ≤ 1 mm2 (size 2)

Sizes S2 and S3

Main circuit

Control circuit

3RT2/3RH2 contactors (basic devices) — 1

Accessories for 3RT2 contactors (e.g.

auxiliary switches)

— 1

3RW30 / 40 soft starters — 0

3RV2 motor starter protectors (basic

devices)

— 1

Accessories for 3RV2 motor starter

protectors (e.g. auxiliary switches)

— 1

3RU2 thermal overload relays

—

3RB3 electronic overload relays

—

3RA27/3RA28 function modules

—

3RR2 current monitoring relays

—

0: No insulating stop required

1: 3RT1916

-4JA02 insulating stop

—: Not relevant (e.g. conductor cross-section ≤ 1 mm

) or not available

The graphic below shows how the insulating stop is used:

Figure 9-3 Insulating stop on spring-loaded connection system

Connection

9.1 Connection systems

SIRIUS - system overview

180 System Manual, 09/2016, A5E03656507020A/RS-AB/003

9.1.3

Ring cable lug connection

Ring cable lug connection (sizes S00 and S0)

The ring cable lug connection is equipped with an M3 or M4 combination screw. A special

cover ensures finger-safety.

DANGER

Hazardous voltage.

Will cause death or serious injury.

Turn off and lock out all power supplying this device before working on this device.

Figure 9-4 Ring cable lug connection system

Connection

9.2 Conductor cross-sections

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 181

9.2

Conductor cross-sections

Due to SIRIUS being a modular system, the conductor cross-sections of all the devices of

one size are identical.

9.2.1

Conductor cross-sections for screw-type connection systems

The tables below define the permissible conductor cross-sections for main terminals and

auxiliary conductor connections in sizes S00, S0 and S2 for screw-type connection systems.

Table 9- 4 Main conductors of size S00 with M3 combination screws

Motor starter protectors

Contactors

Overload relays 1),

current monitoring relays 1)

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightening torque 0.8 to 1.2 Nm

Solid and stranded

2 x (0.5 ... 1.5) mm²

2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm²

Max. 2 x 4 mm²

Finely stranded with

end sleeve

2 x (0.5 ... 1.5) mm²

2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm²

AWG

2 x (20 to 16)

2 x (18 to 14)

2 x 12

1) Only 1 conductor can be clamped on the stand-alone assembly support.

Connection

9.2 Conductor cross-sections

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182 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Table 9- 5 Main conductors of size S0 with M4 combination screws

Motor starter protector

Contactors

Overload relay 1),

current monitoring relay1)

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightening torque 2.0 to 2.5 Nm

Solid and stranded

2 x (1.0 to 2.5) mm²

2 x (2.5 to 10) mm² 2 x (2.5 to 10) mm² 2 x (2.5 to 10) mm²

Finely stranded with

end sleeve

2 x (1 to 2.5) mm²

2 x (2.5 to 6) mm²

Max. 1 x 10 mm²

AWG

2 x (16 to 12)

2 x (14 to 8) 2 x (14 to 8) 2 x (14 to 8)

1) Only 1 conductor can be clamped on the stand-alone assembly support.

Table 9- 6 Main conductors of size S2 with box terminal

Motor starter protectors

Contactors

Overload relays 1),

current monitoring

relays 1)

3RV2.31-

4S/T/B/D/E/P/U/V.1

3RV2.31-

4W/X/J/K/R.1.

3RV2431-4VA1.

3RV2.32-...

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightenin

g torque

3.0 ... 4.5 Nm

Solid and

stranded

2 x (1.0 ... 25) mm²

2 x (1.0 ... 35) mm²

1 x (1.0 ... 35) mm² 1 x (1.0 ... 50) mm² 2 x (1.0 ... 50) mm² 1 x (1.0 ... 50) mm²

Finely

stranded

with end

sleeve

2 x (1.0 ... 16) mm²

2 x (1.0 ... 25) mm²

1 x (1.0 ... 25) mm² 1 x (1.0 ... 35) mm² 1 x (1.0 ... 35) mm² 1 x (1.0 ... 35) mm²

AWG

2 x (18 to 3)

2 x (18 to 2)

1 x (18 to 2)

1 x (18 to 1)

1) Only 1 conductor can be clamped on the stand-alone assembly support.

Connection

9.2 Conductor cross-sections

SIRIUS - system overview

System Manual, 09/2016, A5E03656507020A/RS-AB/003 183

Table 9- 7 Main conductors of size S3 with box terminal block

Contactors,

overload relays,

motor starter protectors

Tool

4 mm Allen key

Tightening torque 4.5 ... 6.0 Nm

Solid

2 x (2.5 ... 16) mm²

Stranded

2 x (6 ... 16) mm²

2 x (10 ... 50) mm²

1 x (10 ... 70) mm²

Finely stranded without end

sleeve

–

Finely stranded with end

sleeve

2 x (2.5 ... 35) mm²

1 x (2.5 ... 50) mm²

Ribbon cables

2 x (6 x 9 x 0.8)

AWG

2 x (10 to 1/0)

1 x (10 to 2/0)

Connection

9.2 Conductor cross-sections

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184 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Table 9- 8 Main conductors of size S6 with box terminal block

Contactor with 3RT1955-4G box terminal block

Tool

4 mm Allen key

Tightening torque 10.0 ... 12.0 Nm

Solid

1 x (16 ... 70) mm² 1 x (16 ... 70) mm² max. 50 + 70 mm²

Finely stranded with

end sleeve

1 x (16 ... 70) mm² 1 x (16 ... 70) mm² max. 50 + 70 mm²

Ribbon cables

min. 3 x 9 x 0.8

max. 6 x 15.5 x 0.8

AWG

1 x (AWG 6 to 2/0)

max. AWG 1/0 + 1/0

Table 9- 9 Main conductors of size S6 with box terminal block

Contactor with 3RT1956-4G box terminal block

Tool

4 mm Allen key

Tightening torque

10.0 ... 12.0 Nm

Solid

1 x (16 ... 120) mm² 1 x (16 ... 120) mm² max. 95 + 120 mm²

Finely stranded with

end sleeve

1 x (16 ... 120) mm² 1 x (16 ... 120) mm² max. 95 + 120 mm²

Ribbon cables

min. 3 x 9 x 0.8

max. 10 x 15.5 x 0.8

AWG 1 x (AWG 6 to 250 kcmil) 1 x (AWG 6 to 250 kcmil) max. AWG 3/0 + 3/0

Connection

9.2 Conductor cross-sections

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 185

Table 9- 10 Main conductors of size S6 with box terminal block

Electronic overload relay with box

terminal block 3RT1955-4G

Electronic overload relay with box

terminal block 3RT1956-4G

Tool

4 mm Allen key

Tightening torque 10.0 ... 12.0 Nm

Solid

–

Stranded

2 x (max. 70) mm² 2 x (max. 120) mm²

1 x (16 ... 70) mm² 1 x (16 ... 120) mm²

Finely stranded without

end sleeve

2 x (1 x max. 50, 1 x max. 70) mm² 2 x (1 x max. 95,

1 x max. 120) mm²

1 x (1 ... 70) mm² 1 x (10 ... 120) mm²

Finely stranded with end

sleeve

2 x (1 x max. 50, 1 x max. 70) mm² 2 x (1 x max. 95,

1 x max. 120) mm²

1 x (1 ... 70) mm²

1 x (10 ... 120) mm²

Ribbon cables

2 x (6 x 15.5 x 0.8)

2 x (10 x 15.5 x 0.8)

1 x (3 x 9 x 0.8 ... 6 x 15.5 x 0.8) 1 x (3 x 9 x 0.8 ... 10 x 15.5 x 0.8)

AWG

2 x (max. 1/0)

2 x (max. 3/0)

1 x (6 ... 2/0)

1 x (6 ... 250 kcmil)

Connection

9.2 Conductor cross-sections

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186 System Manual, 09/2016, A5E03656507020A/RS-AB/003

Table 9- 11 Main conductors of size S10 / S12 with box terminal block

Contactor with 3RT1966-4G box terminal block

Tool

5 mm Allen key

Tightening torque 20.0 ... 22.0 Nm

Solid

1 x (95 ... 300) mm² 1 x (120 ... 240) mm² min. 70 + 70 mm²

max. 240 + 240 mm²

Finely stranded with

end sleeve

1 x (70 ... 240) mm² 1 x (120 ... 185) mm² min. 50 + 50 mm²

max. 185 + 185 mm²

Ribbon cables

min. 6 x 9 x 0.8

max. 20 x 24 x 0.5

11 x 21 x 1

AWG 1 x (AWG 3/0 to 600 kcmil) 1 x (AWG 250 to 500 kcmil) max. AWG 2/0 + 2/0

max AWG 500 + 500

Connection

9.2 Conductor cross-sections

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Table 9- 12 Main conductors of size S10 / S12 with box terminal block

Electronic overload relay with 3RT1966-4G box

terminal block

Tool

5 mm Allen key

Tightening torque

20.0 ... 22.0 Nm

Solid

–

Stranded

2 x (70 ... 240) mm²

Front clamping point only:

1 x (95 ... 300) mm²

Rear clamping point only:

1 x (120 ... 240) mm²

Finely stranded without end sleeve

2 x (50 ... 185) mm²

Front clamping point only:

1 x (70 ... 240) mm²

Rear clamping point only:

1 x (120 ... 185) mm²

Finely stranded with end sleeve

2 x (50 ... 185) mm²

Front clamping point only:

1 x (70 ... 240) mm²

Rear clamping point only:

1 x (120 ... 185) mm²

Ribbon cables

2 x (20 x 24 x 0.5)

1 x (6 x 9 x 0.8 ... 20 x 24 x 0.5)

AWG

2 x (2/0 ... 500 kcmil)

Front clamping point only:

1 x (3/0 ... 600 kcmil)

Rear clamping point only:

1 x (250 ... 500 kcmil)

Connection

9.2 Conductor cross-sections

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Table 9- 13 Auxiliary conductors of sizes S00 / S0 / S2 / S3 with M3 combination screws

Accessories for motor

starter protectors,

accessories for

contactors,

overload relays

Contactors,

size S00

Contactors,

thermal overload relay,

sizes S0, S2 and S3

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightening

torque

0.8 ... 1.2 Nm 0.8 ... 1.2 Nm

Solid and

stranded

2 x (0.5 ... 1.5) mm²

2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm²

Max. 2 x 4 mm²

Finely

stranded

with end

sleeve

2 x (0.5 ... 1.5) mm² 2 x (0.5 ... 1.5) mm² 2 x (0.5 ... 1.5) mm²

2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm²

AWG

2 x (20 to 16)

2 x (18 to 14)

2 x 12

Table 9- 14 Removable terminal for auxiliary conductor on the electronic overload relay

Removable terminal for auxiliary conductor on the electronic overload relay

Tool

Pozidriv size PZ 2, Ø 6 mm

Tightening torque

0.8 ... 1.2 Nm

Solid and stranded

1 x (0.5 to 4) mm²

2 x (0.5 to 2.5) mm²

Finely stranded with

end sleeve

1 x (0.5 to 2.5) mm²

2 x (0.5 ... 1.5) mm²

AWG

2 x (20 to 14)

Connection

9.2 Conductor cross-sections

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System Manual, 09/2016, A5E03656507020A/RS-AB/003 189

Table 9- 15 S00 and S0 capacitor contactors

Contactors,

size S00

Contactors,

size S0

A1/A2, NO/NC

L1, L2, L3

3RT261.-1

L1, L2, L3

3RT262.-1

3RV2925-5AB

Tool

Pozidriv size PZ 2,

Ø 5 … 6 mm

Pozidriv size PZ 2,

Ø 5 … 6 mm

Pozidriv size PZ 2,

Ø 5 … 6 mm

Pozidriv size PZ 2,

Ø 5 … 6 mm

Tightening

torque

0.8 ... 1.2 Nm

(7 to 10.3 lb·in)

0.8 ... 1.2 Nm

(7 to 10.3 lb·in)

2 … 2.5 Nm

(18 to 22 lb·in)

3 ... 4 Nm

(27 to 35.2 lb in)

Solid and

stranded

2 x (0.5 ... 1.5) mm² 2 x (0.5 ... 1.5) mm² 2 x (1 ... 2.5) mm² 1 x (2.5 ... 25) mm²

2 x (0.75 ... 2.5) mm²

2 x (2.5 ... 10) mm²

2 x 4 mm²

Finely

stranded with

end sleeve

2 x (0.5 ... 1.5) mm²

2 x (1 ... 2.5) mm²

1 x (2.5 ... 16) mm²

2 x (0.75 ... 2.5) mm² 2 x (0.75 ... 2.5) mm²

2 x (2.5 ... 6) mm²

1 x 10 mm²

AWG

2 x (20 … 16)

2 x (14 to 8) 1 x (10 to 4)

2 x (18 … 14)

2 x 12

Table 9- 16 Capacitor contactors main conductors of size S2 (3RT263.-1)

L1, L2, L3

3RT263.-1

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightening torque 3.0 ... 4.5 Nm

(27 to 40 lb in)

Solid and stranded

2 x (1 to 35) mm

1 x (1 to 50) mm2

Finely stranded with end

sleeve

2 x (1 to 25) mm

1 x (1 to 35) mm2

AWG

2 x (18 to 2)

1 x (18 to 0)

Connection

9.2 Conductor cross-sections

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Table 9- 17 Capacitor contactors auxiliary conductors of size S2 (3RT263.-1)

A1/A2, NO/NC

3RT263.-1

3RH29.1-1

Tool

Pozidriv size PZ 2, Ø 5 … 6 mm

Tightening torque M3: 0.8 ... 1.2 Nm

(7 to 10.3 lb in)

Solid and stranded

2 x (0.5 ... 1.5)

2 x (0.75 ... 2.5)

2 x 4

Finely stranded with end

sleeve

2 x (0.5 ... 1.5)

2 x (0.75 ... 2.5)

AWG

2 x (20 to 16)

2 x (18 to 14)

2 x 12

Table 9- 18 Capacitor contactors S2 (3RT263.-1 + 3RV2935-5A)

3RT263.-1

3RV2935-5A

Tightening torque 4 ... 6 Nm

(35 to 53 lb in)

Solid and stranded

2 x (2.5 to 50) mm

1 x (2.5 to 70) mm2

Finely stranded with end

sleeve

2 x (2.5 to 35) mm

1 x (2.5 to 50) mm2

AWG

2 x (10 to 1 / 0)

1 x (10 to 2 / 0)

Table 9- 19 Capacitor contactors S2 (3RT2637)

L1, L2, L3

3RT2637

rms

≤ 133 A

> 133 A

Finely stranded

1 x 50 mm2 2 x 35 mm2

AWG

1 x 0

2 x 2

Rated fuse current Max. 200 A Max. 160 A

Connection

9.2 Conductor cross-sections

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Table 9- 20 Main conductor connection of size S2 with through-hole technology

Electronic overload relay

The maximum diameter of the opening

is 12.8 mm.

Table 9- 21 Main conductor connection of size S3 with through-hole technology

Electronic overload relay

The maximum diameter of the opening

is 18 mm.

Table 9- 22 Main conductor connection of size S6 with through-hole technology

Electronic overload relay

The maximum diameter of the opening

is 24.5 mm.

Connection

9.2 Conductor cross-sections

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9.2.2

Conductor cross-sections for spring-loaded connection systems

The tables below define the permissible conductor cross-sections for main terminals

(sizes S00 and S0) and auxiliary conductor connections (sizes S00, S0, S2 and S3) for

spring-loaded connection systems.

Table 9- 23 Main conductors of size S00

Motor starter protectors,

contactors

Overload relays,

current monitoring relays

Tool Ø 3.0 x 0.5 (3RA2808-1A)

Solid and stranded

2 x (0.5 to 4.0) mm² 0.5 to 4.0 mm²

Finely stranded without end

sleeve

2 x (0.5 to 2.5) mm² 0.5 to 2.5 mm²

Finely stranded with end

sleeve (DIN 46 228 Part 1)

2 x (0.5 to 2.5) mm² 0.5 to 2.5 mm²

AWG

2 x (20 to 12)

Table 9- 24 Main conductors of size S0

Motor starter protectors,

contactors

Overload relays,

current monitoring relays

Tool Ø 3.0 x 0.5 (3RA2808-1A)

Solid and stranded

2 x (1.0 to 10) mm² 1.0 to 10 mm²

Finely stranded without end

sleeve

2 x (1.0 to 6.0) mm²

1.0 to 6.0 mm²

Finely stranded with end

sleeve (DIN 46 228 Part 1)

2 x (1.0 to 6.0) mm² 1.0 to 6.0 mm²

AWG 2 x (18 to 8) 2 x (18 to 8)

Connection

9.2 Conductor cross-sections

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Table 9- 25 Auxiliary conductors of sizes S00 / S0 / S2 / S3

Contactors, size S00,

basic devices

Contactors, sizes S0, S2 and S3,

integrated auxiliary switches,

overload relays,

accessories for contactors,

accessories for motor starter

protectors

Tool Ø 3.0 x 0.5 (3RA2808-1A)

Solid and stranded

2 x (0.5 to 4) mm² 2 x (0.5 to 2.5) mm²

Finely stranded without end

sleeve

2 x (0.5 to 2.5) mm² 2 x (0.5 to 2.5) mm²

Finely stranded with end

sleeve (DIN 46 228 Part 1)

2 x (0.5 to 2.5) mm² 2 x (0.5 ... 1.5) mm²

AWG

2 x (20 to 12)

2 x (20 to 14)

Table 9- 26 Removable terminal for auxiliary conductor on the 3RB3 electronic overload relay

Removable terminal

Tool Ø 3.0 x 0.5 (3RA2808-1A)

Solid and stranded

2 x (0.25 to 1.5) mm²

Finely stranded without end

sleeve

2 x (0.25 to 1.5) mm²

Finely stranded with end

sleeve

2 x (0.25 to 1.5) mm²

AWG 2 x (24 to 16)

Connection

9.2 Conductor cross-sections

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9.2.3

Conductor cross-sections for ring cable lug connection system

The tables below define the permissible conductor cross-sections for main terminals and

auxiliary conductor connections for ring cable lug connection systems.

Table 9- 27 Main conductors and auxiliary conductors of size S00 with M3 combination screws

SIRIUS devices

Tool Pozidriv size 2,

Ø 5 to 6 mm

Tightening torque 0.8 to 1.2 Nm

Ring cable lug 1)

= min. 3.2 mm

d3 = max. 7.5 mm

Table 9- 28 Main conductors and auxiliary conductors of size S0 with M4 combination screws

SIRIUS devices

Tool Pozidriv size 2,

Ø 5 to 6 mm

Tightening torque

2.0 to 2.5 Nm

Ring cable lug 1)

d2 = min. 4.3 mm

d3 = max. 12.2 mm

Connection

9.2 Conductor cross-sections

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Table 9- 29 Main conductors of size S3 with M6 screws

SIRIUS devices

Tool

4 mm Allen key

Tightening torque

4.5 ... 6.0 Nm

Busbars (M6 x 25) 2 x 12 x 4

Ring cable lug1)

d2 = min. 6.3 mm

d3 = max. 19.0 mm

Ring cable lug cover

3RT1946-4EA1

1) The following ring cable lugs are approved for achieving the required clearances and

creepage distances:

● For applications according to IEC 60947-1:

– DIN 46237 (with insulating sleeve)

– JIS CS805 type RAV (with insulating sleeve)

– JIS CS805 type RAP (with insulating sleeve)

● For applications according to UL 508:

– DIN 46 234 (without insulating sleeve)

– DIN 46225 (without insulating sleeve)

– JIS CS805 (without insulating sleeve)

A shrink-on sleeve must be used to insulate ring cable lugs without an insulating sleeve. The

following conditions must be met:

● Operating temperature: -55 °C to +155 °C

● UL 224 approved

● Flame-protected

DANGER

Hazardous voltage.

Will cause death or serious injury.

Only use approved ring cable lugs to meet the required clearances and creepage

distances.

Connection

9.2 Conductor cross-sections

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Table 9- 30 Main conductors of size S6 with M8 screws

Contactor with bus connection

Connecting bars (M8 x 25) 2 x 15 x 4 mm

M8 x 25

Tightening torque

10.0 ... 14.0 Nm

Finely stranded with cable lug 2 x (25 ... 120) mm²1)

2 x (AWG 4 to 250 kcmil)

Stranded with cable lug

2 x (16 ... 95) mm²1)

2 x AWG 6 to 3/0

AWG

4 ... 250 kcmil

When connecting cable lugs according to DIN 46235 with conductor cross-sections of 95 mm2 and more, the

3RT1956-4EA1 terminal cover must be used to ensure phase clearance.

Table 9- 31 Main conductors of size S10 / S12 with M10 screws

Contactor with bus connection

Connecting bars (M10 x 30) 2 x 25 x (..) mm

M10 x 30

Tightening torque

14.0 ... 24.0 Nm

Finely stranded with cable lug 2 x (70 ... 240) mm²1)

2 x (AWG 2/0 to 500 kcmil)

Stranded with cable lug

22 x (50 ... 240) mm²1)

2 x AWG 1/0 to 500 kcmil

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

, use the 3RT1966-4EA1 terminal cover to ensure phase clearance.

Connection

9.2 Conductor cross-sections

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Table 9- 32 Main conductors of size S6 with M8 screws

Electronic overload relay with busbar connection

Connecting bars

(M8 x 25)

2 x 15 x 4

Tightening torque

10.0 ... 14.0 Nm

Finely stranded with

cable lug

16 ... 95 mm²1)

Stranded with cable lug 25 ... 120 mm²1)

AWG

4 ... 250 kcmil

When connecting cable lugs according to DIN 46235 with conductor cross-sections of 95 mm2 and more, the

3RT1956-4EA1 terminal cover must be used to ensure phase clearance.

Table 9- 33 Main conductors of size S10 / S12 with M10 screws

Electronic overload relay with busbar connection

Connecting bars (M10 x 30) 2 x 25 x 6

Tightening torque

14.0 ... 24.0 Nm

Finely stranded with cable lug 50 ... 240 mm²1)

Stranded with cable lug 70 ... 240 mm²1)

AWG

2/0 ... 500 kcmil

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

, use the 3RT1966-4EA1 terminal cover to ensure phase clearance.

Connection

9.3 CAx data

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9.3

CAx data

You can find the CAx data in the Siemens Industry Online Support

(https://support.industry.siemens.com/cs/ww/en/ps/16027/td).

1. Enter the full article number of the desired device in the "Product" field, and confirm with

the Enter key.

2. Click the "CAx data link.

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Glossary

3-phase busbar

The 3-phase busbar enables several motor starter protectors or compact starters to be fed

using a single infeed terminal.

8US busbar adapter

The 8US busbar adapter enables motor starter protectors, load feeders, or compact starters

to be mechanically fastened and electrically connected to a busbar system.

a release

Short designation for "inverse-time delayed overload release".

Adapter for screw mounting

The adapters for screw mounting enable you to mount the compact starter on a level

surface.

Approvals

Approval of switching devices and switchgear in accordance with national standards, some

of which must be met on a mandatory basis, which exist in addition to "IEC", "CENELEC",

and "CEE" guidelines, for example. So, the North American market (the USA and Canada)

requires UL or CSA approvals, for instance. There is also an obligation to label the

equipment accordingly, i.e. the approval mark must be inscribed on the device itself.

AS-Interface

The AS-Interface is an open, international standard in accordance with EN 50295 and

IEC 62026-2 for process communication and field communication. Leading manufacturers of

actuators and sensors worldwide support AS-Interface. The electrical and mechanical

specifications of the AS-Interface Association are disclosed to interested companies.

Assembly method

SIRIUS offers maximum flexibility in terms of configuration. The system components can be

assembled as feeders or mounted separately.

Auxiliary switch block for compact starter

Optional auxiliary switch block in the following versions: 2 NO contacts, 2 NC contacts or

1 NO contact plus 1 NC contact.

Glossary

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AWG (American Wire Gauge)

A standard measure for conductors used in the USA, which is assigned to a specific cross-

sectional area of a conductor or wire. Each AWG number represents a jump of 26% in the

cross-sectional area. The thicker the wire, the smaller the AWG number.

Basic module

Function modules consist of at least one basic module, which can be expanded by adding

coupling modules as required. The basic module contains the control logic and, for star-delta

(wye-delta) modules, the time setting for starting in star operation and a 10-pin connector

into which the plug connectors on the coupling modules are inserted.

Bypass operation

Once the motor has been started up correctly, the thyristors in the SIRIUS soft starters are

subject to fully advanced control, meaning that the whole line voltage is applied to the motor

terminals. As the motor voltage does not have to be controlled during operation, the

thyristors are bridged by integral bypass contacts that are rated for AC1 current. This

minimizes the waste heat generated during continuous operation (which is caused by the

thyristors' power loss), and prevents the switching device's environment from heating up.

CLASS (time)

See "Tripping class".

Closing power

The power input of the magnet coils of a contactor, which is required to set the magnet

system in motion. In AC operation, this power input is usually higher than the holding power.

When running SIRIUS contactors in DC operation, the closing power is equal to the holding

power.

Connection system

SIRIUS has the right connection system for every environment: screw terminals, spring-

loaded terminals, or ring cable lug connection.

Contactor

Switching device with just one neutral position, usually without a mechanical lock, which is

not activated manually and which, under normal circuit conditions, including an operating

overload, can switch on, conduct and switch off currents. Contactors are primarily used

where high switching frequencies are involved. A distinction is made between: contactors for

switching motors (motor switches) and contactor relays for control purposes.

Glossary

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Contactor assembly for star-delta (wye-delta) start

Contactor assembly which switches the motor to the star circuit during startup (1/3 of the

starting current compared to delta startup) and back to the delta circuit after a certain period

of time. Contactor assemblies for star-delta (wye-delta) start are used in situations where a

high starting current has to be avoided in order to reduce the effects on the mechanical

components or the line.

Control kit

Tool for closing the main contacts manually by means of the handle.

Coupling module

Function modules consist of at least one basic module, which can be expanded by adding

coupling modules as required. The coupling module includes one NO contact and one 10-

pole connecting cable with a plug connector for insertion into the coupling module and basic

module; it is used for the mutual interlocking of star and delta operation. The communication-

capable version transfers signals to the other contactors and implements the electrical

interlock (reversing/star-delta (wye-delta) start) - in this case, there is no integrated

connecting cable.

Current limiting for soft starters

The SIRIUS 3RW40 soft starter measures the phase current (motor current) continuously

with the help of integrated current transformers. The motor current that flows during the

startup process can be actively limited by means of the soft starter. The current limiting

function takes priority over the voltage ramp function. As soon as a parameterizable current

limit is reached, in other words, the voltage ramp is interrupted and the motor is started with

the current limiting value until it has started up successfully.

The current limiting function is always active with SIRIUS 3RW40 soft starters. If the current

limiting potentiometer is set to the right endstop (maximum), the starting current is limited to

five times the set rated motor current.

The current limiting value is set to the current required during startup as a factor of the rated

motor current. Since the starting current is asymmetrical, the set current corresponds to the

arithmetic mean value for the three phases.

Current monitoring relays

Current monitoring relays are used to monitor motors or other loads for underload and

overload. The level of current permits extensive conclusions to be drawn about the powered

process or plant, e.g. a torn belt, pump no-load operation, tool wear, hoist overload or

blockage. With multi-phase monitoring, the phase sequence, phase failure, or fault current

can be monitored too. If the current measured values are outside the defined range, an alert

will be issued or a disconnection initiated either immediately or with a time delay.

Current setting range (of an overcurrent release)

The range between the lowest and highest current value to which the release can be set.

Glossary

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Door-coupling rotary operating mechanism

Door-coupling rotary operating mechanisms enable motor starter protectors/circuit breakers

and compact starters to be operated with the control cabinet doors closed.

Electrical interlock

Electrical dependency between switching devices, implemented by means of circuitry.

Auxiliary contacts or auxiliary switches are usually used to realize an electrical interlock.

Explosion protection

Prerequisite for using electrical equipment in hazardous areas conforming to DIN EN 50014

(VDE 0170/0171). In terms of explosion protection, you must ensure that equipment which

may generate explosive arcs (plasma) during operation is enclosed in a flameproof casing.

This means that, although the potentially explosive mixture could penetrate the enclosure, if

an explosion were to occur inside it then no explosive flame could escape.

Function module

Different function modules are used for:

● Direct-on-line start

● Reversing start

● Star-delta (wye-delta) start

Function modules are also available in communication-capable versions with AS-i or IO-Link,

in order to establish a connection to a higher-level control system.

Function module for direct-on-line start

This function module is used for the time-delayed switching of contactors.

Function module for reversing start

The function module for reversing start is used to control a reversing starter. The version

without a fieldbus interface consists of bridge modules, while the version for AS-Interface or

IO-Link comprises basic and coupling modules. In all three cases, the electrical interlocks for

protection in both directions are already in place.

Function module for star-delta (wye-delta) start

The function module for star-delta (wye-delta) start is used for toggling between star (wye)

and delta operation. It consists of one basic module and two coupling modules. The

electrical interlocks are already in place in the modules.

Glossary

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Generalized phase control for soft starters

With SIRIUS soft starters, the rms value of the motor voltage is increased (from a settable

starting voltage) to the rated motor voltage within a definable start time by means of the

phase control of two anti-parallel thyristor pairs.

The motor current changes in proportion to the voltage applied to the motor. As a result, the

starting current is reduced by the factor of this voltage.

There is a quadratic relationship between the torque and the voltage applied to the motor. As

a result, the starting torque is reduced quadratically in relation to this voltage.

Heavy-duty starting

Heavy starting exists if a motor requires more than 10 to 15 seconds from being switched on

to reaching its rated speed on account of its special load conditions. When heavy starting

exists, the load torque of the machine to be driven is greater during startup than in rated

operation. It takes a long time for the rated speed to be reached because large centrifugal

masses need to be accelerated (e.g. on rolling mills, centrifuges). Special overload relays

(heavy-duty starting relays, solid-state overload relays) or thermistor motor protection

devices must be used to protect heavy-starting motors.

Heavy-duty starting for soft starters

Assuming that certain conditions and constraints apply, the SIRIUS soft starter size must be

at least one performance class higher than the motor rating for heavy-duty starting

(CLASS 20 startup). The tables in the relevant product manual provide sample set values

and device dimensions.

Holding power

The power input of the magnet coils of a contactor, which depends on the continuously

consumed current, and which is required to hold the magnet system in the ON state.

Infeed system for 3RA6

The infeed system for 3RA6 enables several compact starters to be fed using an infeed

system designed to modular principles with retained wiring.

Instantaneous short-circuit release

Release for a motor starter protector/circuit breaker, which provides short-circuit protection

for the downstream load or the cable. The instantaneous short-circuit release must disable

all poles of the motor starter protector/circuit breaker (acc. to UL) instantaneously or with a

short-time delay in the event of a short circuit.

Glossary

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Intrinsic device protection for soft starters

The SIRIUS 3RW40 soft starter features integrated intrinsic device protection, which protects

the thyristors from thermal overload. This is achieved by measuring the current via

transformers in the three phases on the one hand, and also by measuring the temperature

via thermal sensors on the thyristor heat sink. If the internal, permanently set trip value is

exceeded, the soft starter will switch off automatically.

Inverse-time delayed overload release (a release)

A thermal overload release which works with a time delay that decreases as the current

rises.

IO-Link

IO-Link is a new communication standard for sensors and actuators - defined by the

PROFIBUS User Organization (PNO). The IO-Link technology is based on a point-to-point

connection of the sensors and actuators to the control. Therefore, this technology is not a

bus system, but an enhanced version of a classic point-to-point connection. In addition to the

cyclic operating data, comprehensive parameters and diagnostics data are transferred for

the connected sensors and actuators. The connection system consists of a three-pole

standard cable or three single wires.

Leakage current

If semiconductors are used to control the current flow, no galvanic isolation can take place

within the device. This means that, even when the supply is disconnected, if a connected

load is present then a small residual current, known as the leakage current, will still flow.

Low-voltage switchgear and controlgear combination

A switchgear and controlgear combination is a grouping of one or more low-voltage

switching devices with associated equipment for controlling, measuring, and indicating,

together with the associated protective devices and control devices. The manufacturer is

responsible for all assembly work, including all internal electrical and mechanical

connections and structural parts.

Glossary

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Main switch

Every industrial machine which falls under the scope of DIN EN 60204 Part 1 (VDE 0113,

Part 1) must be equipped with a main switch which disconnects all electrical equipment from

the network while cleaning, maintenance, and repair work is being carried out, as well as

during long periods of downtime. Usually a switch which can be operated by hand is

stipulated in order to prevent electrical or mechanical hazards. The main switch can also

function as an EMERGENCY-STOP device.

It must meet the following requirements:

1. Externally accessible handle

2. Only one "Off" position and one "On" position with allocated stops

3. Two positions labeled "0" and "I"

4. Lockable "Off" position

5. Cover for the power supply terminals to protect against accidental contact

6. The switching capacity must correspond to AC-23 for motor switches and AC-22 for load-

break switches (utilization category).

7. Switch position displayed automatically

Mirror contacts of power contactors

A mirror contact is an NC contact, which cannot be closed at the same time as an NO main

contact (according to EN 60947-5-1, Annex F).

Modular system

The SIRIUS modular system offers all the functions and devices needed for switching,

starting, protecting, and monitoring motors and systems. In other words, it provides a

modular range of standard components, which are perfectly matched to one another, can be

combined really easily, and use the same accessories.

Motor protection

Protection for three-phase motors against overload and short circuit, i.e. protection for the

winding insulation against impermissible heating.

Motor starter protectors

Generally a latch-operated switch, which can switch on, conduct, and switch off currents in

the circuit under normal operating conditions; it can also switch on the current up to the point

of a short circuit under specified operating conditions that are not normal, conduct current for

a defined period, and interrupt it too.

n release

Short designation for "instantaneous electromagnetic overcurrent release".

Glossary

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OFF-delay

The time interval effected by a timing relay or timer (on contactors, for example) between a

switch-off command being issued and the contacts of the timing relay or timer reaching their

initial position.

ON time in %

The duty ratio ON time in % is the ratio between the load duration and the cycle duration for

loads that are frequently switched on and off.

Operating range

Range within which the operating voltage of a switching device (e.g. a contactor) may

deviate from the rated operating voltage without impairing the operational reliability of the

switching device (e.g. contactor drop-out).

Overload relays

Inverse-time delayed relay which responds to an overload in accordance with a time-current

characteristic, thus protecting the switching device and load from overloads.

Overload release

Overcurrent release that provides protection against overload.

Phase loss sensitivity

A product feature which enables the protective device to respond even when a three-phase

induction motor is running in single-phase operation, before the motor sustains thermal

damage (DIN VDE 0660 Part 102).

Polarity balancing for soft starters

In two-phase controlled SIRIUS 3RW30 and 3RW40 soft starters, the current that results

from the superimposition of the two controlled phases flows in the uncontrolled phase. The

main advantages of two-phase control include the more compact size compared to a three-

phase version and the lower hardware costs.

The occurrence of DC components, caused by the phase control and the overlapping of

phase currents, is a negative physical effect of two-phase control during the startup process

that can mean a louder noise is produced by the motor. The "Polarity Balancing" control

principle was developed and patented by SIEMENS to prevent these DC components during

starting.

""Polarity Balancing" effectively eliminates these DC components during the startup phase. It

allows the motor to be started up with a constant speed, torque, and current rise. The

acoustic quality of the startup process comes very close to that of a three-phase controlled

startup. This is made possible by the continuous dynamic alignment and balancing of current

half-waves with different polarities during motor startup.

Glossary

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Positively driven contacts for contactor relays

Positively driven contact elements are a combination of "n" NO contacts and "m" NC

contacts, which are designed such that they cannot be closed simultaneously

(EN 60947-5- 1, Annex L).

Preferred wiring for star-delta (wye-delta) starters

According to the preferred wiring, the motor terminals of a motor running in the clockwise

direction are connected correctly if phase L1 is connected to motor terminals U1 and V2, L2

to V1 and W2, and L3 to W1 and U2. This order should be observed during installation in

order to keep the switchover current peaks in a motor running in the clockwise direction as

low as possible during switchover from star to delta operation.

Protective technology

A basic distinction can be made between two current-based protective technologies: thermal

and electronic protection. Motor starter protectors and thermal overload relays provide

protection by means of bimetal releases, while solid-state overload relays, 3RW40 soft

starters, and 3RA6 compact starters offer protection via electronic means. Electronic

protective devices not only offer a significantly lower level of power loss, they also provide a

wide setting range of 1:4 and, as a result, much less variance than thermal releases. The

SIRIUS modular system offers the right solution for every type of switching technology.

Ramp time

With SIRIUS soft starters, the length of the set ramp time determines the time taken to

increase the motor voltage from the parameterized starting voltage to the line voltage. This

influences the motor's acceleration torque, which drives the load during the startup process.

A longer ramp time results in a lower acceleration torque as the motor is started up. The

startup is slower and smoother as a result. The ramp time should be long enough for the

motor to reach its nominal speed. If the time selected is too short, in other words if the ramp

time ends before the motor has started up successfully, a very high starting current that can

even equal the direct starting current at the same speed occurs at this instant.

Ramp-down time

The "Ramp-down time" potentiometer on the SIRIUS 3RW40 soft starter allows you to

specify how long power should still be supplied to the motor after the ON command has

been removed. The torque generated in the motor is reduced by means of a voltage ramp

function within this ramp-down time and the application stops smoothly.

Ramp-up detection for soft starters

The SIRIUS 3RW40 soft starter is equipped with an integrated ramp-up detection function. If

it detects a motor startup, the motor voltage is immediately increased to 100% of the line

voltage. The internal bypass contacts close and the thyristors are bridged.

Glossary

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Rated conditional short-circuit current Iq

The guaranteed short-circuit breaking capacity of switchgear assemblies and load feeders,

also called "rated conditional short-circuit current".

Rated data for the control circuit

The most important rated data for the control circuit in terms of selecting a switching device

(e.g. a contactor) are the rated control supply voltage Us (voltage of the coil terminal) with the

associated frequency (e.g. 50 Hz), as well as the power input of the coil (closing power and

holding power) in the case of contactors, for example.

Rated data for the main circuit

The most important rated data for the main circuit in terms of selecting a switching device

(e.g. a contactor) are the rated operational current Ie (current specified by the conditions of

use) or the rated power (motor power), as well as the corresponding rated voltage Ue.

Rated impulse withstand voltage (Uimp)

Peak value of a surge voltage with a defined waveform and polarity, which can be applied to

the device under specified test conditions without the device failing and to which the

clearances refer. The rated impulse withstand voltage of a device must be equal to or

greater than the transient overvoltages which occur in the network on which the device is

being used.

Rated insulation voltage Ui

Voltage value which specifies the insulation strength of the switching device or accessory

and to which the insulation tests and the creepages and clearances refer. The maximum

rated operational voltage must not be greater than the rated insulation voltage under any

circumstances.

Rated service short-circuit breaking capacity Ics

Compared to the rated ultimate short-circuit breaking capacity Icu, the test conditions here

are stricter and the short-circuit current is usually lower. Determined using test sequence II,

operating sequence O-t-CO-t-CO (O = open, t = time, CO = close-open). The function of the

motor starter protector/circuit breaker must remain unrestricted following this test.

Glossary

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Rated short-circuit breaking capacity Icn

According to IEC 60947-2 and DIN EN 60947-2, the rated short-circuit breaking capacity of a

motor starter protector/circuit breaker is the value of the short-circuit current, which it can

switch off at the rated operational voltage, rated frequency, and specified power factor (or

specified time constant). The value of the prospective current (for alternating current, the rms

value of the AC component) specified by the manufacturer applies. For AC motor starter

protectors/circuit breakers, the rated short-circuit breaking capacity must be independent of

the magnitude of the DC (direct-current) component. The rated short-circuit breaking

capacity also ensures that the motor starter protector/circuit breaker can switch off every

current up to the rated short-circuit breaking capacity in the event of a line-frequency

recovery voltage with 110% of the rated operational voltage.

This applies

● For alternating current, at every value of the power factor, but not lower than the value

defined in the relevant test specification

● For direct current, if no other specifications have been made to the contrary by the

manufacturer, with every time constant, but not greater than the value defined in the

relevant test specification.

The short-circuit breaking capacity does not apply in the event of a line-frequency recovery

voltage above 110% of the rated operational voltage.

Rated ultimate short-circuit breaking capacity Icu

Maximum short-circuit current Ik (limit value of the rated short-circuit breaking capacity),

which can switch the motor starter protector/circuit breaker off under specific conditions.

Determined using test sequence III, operating sequence O-t-CO (O = open, t = time,

CO = close-open). The function of the motor starter protector/circuit breaker may be

restricted following this test.

Recovery time

When a protection function in a switching device has been tripped (e.g. motor starter

protector, soft starter, overload relay, or current monitoring relay), the motor cannot be

restarted until a recovery time has elapsed. The length of the recovery time will vary,

depending on the cause of the error. For more information, refer to the corresponding

product documentation.

Response delay

The response delay is the time from when you start to enter a command until the first contact

connection is made, at the contactor, for example.

RoHS

EC Directive 2002/95/EC concerning the restriction of the use of certain hazardous

substances in electrical and electronic equipment regulates the use of hazardous

substances in devices and components. The English abbreviation RoHS is used to refer to

this directive: (Restriction of the use of certain hazardous substances), as well as all related

measures for implementing it into national legislation.

Glossary

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Service life

Period of time for which the switching device will work properly under normal operating

conditions. This is specified as the number of operating cycles, the electrical durability (e.g.

contact erosion), and the mechanical durability (e.g. operating cycles without load).

Short-circuit strength

This is the resistivity of a switching device in the closed state, along with its components

(e.g. releases), or a complete switchgear, to the electrodynamic (dynamic strength) and

thermal (thermal strength) stresses which arise in the event of a short circuit. The

characteristic for the dynamic stress is the rated peak withstand current, which is the

maximum instantaneous value of the short-circuit current. The characteristic for the thermal

stress of the short-circuit current is the root-mean-square value of the short-circuit current

throughout its duration.

SIL (Safety Integrity Level)

Discrete level (one of three possibilities) for defining safety integrity specifications of safety-

related control functions. Safety integrity level 3 is the highest possible level, level 1 the

lowest.

Soft ramp-down

The same principle as that used for soft starting is applied during the ramp-down process.

This ensures that the torque generated in the motor is reduced gradually, so that the

application can ramp down smoothly.

In "soft ramp-down" mode, the natural stop process of the load is decelerated. The function

is used when the load must be prevented from stopping abruptly. This is typically the case in

applications with a low mass inertia or a high counter-torque.

Soft start

Since the motor voltage is controlled (phase control) by an electronic soft starter during the

startup process, the consumed starting current and the starting torque generated in the

motor are also controlled.

Soft starter

This is a motor starter which reduces the starting torque (starting torque, break loose torque)

and the starting current of the motor in order to decrease the vibrations experienced by the

driven machine and to prevent current peaks in the network. The starting torque is reduced

because the supply voltage is initially set to a value lower than the rated voltage of the motor

(the starting torque is proportional to the square of the voltage applied). The terminal voltage

can be increased as soon as the motor starts to run. Classic ways of reducing the terminal

voltage are star-delta (wye-delta) start, startup via resistors in the stator, and startup with an

auto-transformer, for example. The use of solid-state motor controllers with switched thyristor

circuits is becoming more and more prevalent as a way of controlling the terminal voltage on

squirrel-cage motors. See also "Soft starting" and "Soft ramp-down".

Glossary

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Space above the arc chute

When a switching device is being operated, particularly when highly inductive load currents

or short-circuit currents are being switched off, the ionized gases generated by the arc are

pressed out of the openings in the arc chute. In order to ensure that the concentration of

these ionized gases does not reach a hazardous level, a specific clearance must be

provided above or in front of the device. This space above the arc chute is defined by the

manufacturer (usually on the dimension drawings) and depends on whether exposed live

conductors (e.g. busbars), conductive structural components, and insulating partitions can

be found on the switching device. Arc chute attachments can be mounted to larger motor

starter protectors in order to reduce the required clearance and therefore the space required

in the control cabinet. No space is required above the arc chute for vacuum circuit breakers

and vacuum contactors, since the arc will not escape from the vacuum chute and no ionized

gases will be released.

Star-delta (wye-delta) starter

See "Contactor assembly for star-delta (wye-delta) start".

Starting current

Three-phase induction motors have a high direct starting current Istarting. Depending on the

motor type, this current can be between three and fifteen times as high as the rated

operational current. Seven or eight times the rated motor current can be assumed as a

typical value.

Starting torque

The starting torque and the breakdown torque can usually be assumed to be between two

and four times the rated torque. From the point of view of the load machine, this means that

the starting and acceleration forces exert a higher mechanical load on the machine and the

product being conveyed compared to nominal operation.

Starting voltage

The starting voltage determines the starting torque of the motor for SIRIUS soft starters. A

lower starting voltage results in a lower starting torque and a lower starting current. The

starting voltage selected must be sufficiently high to ensure that motor starts up smoothly as

soon as the start command is received by the soft starter.

Switching frequency

Number of operating cycles per time unit (e.g. 15 operations per hour).

The maximum permissible switching frequency must not be exceeded because the SIRIUS

soft starters could be damaged due to thermal overloading. The switching frequency of

SIRIUS soft starters size S0 to S3 can be increased by installing an optional additional fan.

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Switching technology

A basic distinction can be made between two types of switching technology: On the

electromechanical side, there are contactors, contactor assemblies, and compact starters

which can be used to implement solutions for direct-on-line start, reversing start, and star-

delta (wye-delta) start. Frequent switching or reversing, soft starting, and soft ramp-down, on

the other hand, are initiated using electronic switching devices: solid-state switching devices

and soft starters. The SIRIUS modular system offers the right solution for every type of

switching technology.

Temperature compensation

With inverse-time delayed (thermal) overload releases and relays, not only the current, but

also the ambient temperature has an effect on the tripping time. An additional bimetal strip,

which is not heated up by the current, can be used to compensate for the influence of the

ambient temperature. If solid-state overload relays are used, electronic compensation is

possible.

Terminals for "Self Protected Combination Motor Controller Type E"

The terminals conform to the clearances and creepage distances stipulated by UL 508

(Type E).

Thermistor motor protection

Motor protection provided by temperature sensors (PTC sensors) integrated in the windings.

These sensors monitor the winding temperature directly.

Time-delayed auxiliary switch

Module which can be integrated into various combinations of auxiliary switches and can

usually be retrofitted to a switching device too.

Timing relay

Switching device with electronic time delay, which opens or closes contacts after a specified

period of time has elapsed.

Tripping characteristic curve

The tripping characteristic (curve) is the graphical representation of the relationship between

the tripping time and the controlling variable. The time-current diagram can be used to find

out, for example, how long it will take for the release or the tripping relay to respond at a

particular current.

Glossary

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Tripping class (CLASS)

The tripping class of a current-dependent overload relay (including thermal and solid-state

overload relays and releases) specifies the maximum tripping time from cold at a particular

load. The tripping class number (e.g. CLASS 10, 20, 30) represents the maximum

permissible tripping time in seconds when the relay is subjected to a symmetrical 3-pole load

from cold with 7.2 times the current setting (IEC 947-4-1; DIN VDE 0660 Part 107). Tripping

classes 20 and 30 are used for protecting the motor under heavy-duty starting conditions, for

example.

Tripping current (of an overload release)

The current value at which a release trips within a certain time.

Two-phase control

With solid-state switching devices like soft starters or solid-state contactors, two out of three

active phases are controlled by means of semiconductors. For example, SIRIUS 3RW30 and

3RW40 soft starters feature two anti-parallel thyristors in each of phases L1 and L3. Phase

L2 is an uncontrolled phase, which is routed through the starter via a copper link and

connected directly to the corresponding output terminal.

Types of coordination

The standard DIN EN 60947-4-1 (VDE 0660 Part 102) or IEC 0947-4-1 distinguishes

between two types of coordination, which are referred to as coordination type "1" and

coordination type "2". Any short circuits that occur are cleared safely in both types of

coordination. the only differences are in the extent of the damage sustained by the device

following a short circuit.

Utilization category

According to DIN EN 60947-4-1, the application area of and the load applied to power

contactors can be identified by looking at the specified utilization category in conjunction with

the specified rated operational current or the motor power and the rated voltage. An example

is utilization category AC-3 for starting and switching off squirrel-cage motors.

Voltage ramp

The SIRIUS 3RW30 and 3RW40 soft starters achieve soft starting by means of a voltage

ramp. The motor terminal voltage is increased from a parameterizable starting voltage up to

the line voltage within a definable start time.

Glossary

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Index

3D model, 11

3RA21 / 3RA22 load feeders, 155

3RA6 compact starters, 161

3RB24 electronic overload relays for IO-Link, 131

3RR2 current monitoring relays, 136

3RW44 soft starter, 108

Accessories

Motor starter protector, 116

Advantages

Motor starter protector, 115

Overload relay, 129

App

Siemens Industry Online Support, 12

Applications, 107

Contactors, 75

Function modules for mounting on contactors, 98

Load feeders, 158

Motor starter protector, 114

Overload relay, 128

Solid-state switching devices, 105

Approvals, 18

AS-Interface, 42, 53

Assembly, 36, 65

Auxiliary switches

Load feeders, 154

Auxiliary switches (function modules for mounting on

contactors)

Solid-state time-delay, 97

Basic knowledge, 9

Basic module

Function modules for mounting on contactors, 100

Bus connection system, 35

CAx data, 11, 198

Certifications, 18

Characteristics, 18

Combinations, 38, 95, 159

Compact starters, 36

Conductor cross-sections, 181

Connection, 39

Connection methods

Solid-state switching devices, 104

Connection systems, 35

Function modules for mounting on contactors, 97

Motor starter protector, 112

Overload relay, 125

Contactor assemblies for star-delta (wye-delta)

start, 69

Load feeders, 156

Contactor relays, 69

Contactors, 32, 39, 76, 85

Coupling module

Function modules for mounting on contactors, 100

Current monitoring relay, 40

Current monitoring relays, 39

Customer benefits, 65

Device concept, 133

Device versions

Contactors, 73

Function modules for mounting on contactors, 97

Load feeders, 151

Motor starter protector, 113

Overload relay, 126

Solid-state switching devices, 103

Diagnostics data, 43, 44

Dimension drawings, 11

Direct-on-line start, 32, 91, 95

Function modules for mounting on

contactors, 97, 98

Disposal, 13

Energy efficiency, 59, 59, 60, 62, 63

Environment, 58

EPLAN macros, 11

Index

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Features

Compact starter, 162

Function module for IO-Link, 92

Function module for star-delta (wye-delta) start

Control circuit wiring, 100

Pre-assembled, 100

Function modules, 21, 43, 89, 90

Function overview, 150

Functional overview, 147

Identification of energy flows, 59

Infeed systems, 119, 120, 166

Insulating stop, 178

Interlock

Electrical, 100

IO-Link, 42, 44

Link module, 38, 160, 177

Load feeders, 36, 38

Combination of individual devices, 156

Modular system, 21, 26, 30, 32, 37, 59, 59, 60, 62, 63

Monitoring, 21

Motor starter protector, 38, 111

Overload protection, 40

Overload relays, 39

Power contactor, 69, 71

Power loss, 59, 59, 60, 62, 63

Product data sheet, 198

PROFIBUS, 108

Properties

Solid-state overload relay for IO-Link, 132

Protective functions, 40

Recycling, 13

Reversing contactor assemblies, 69

Load feeders, 156

Reversing start, 32, 91, 95

Ring cable lug connection system, 35, 35, 180, 194

Safety applications, 58

Safety rules, 15

Screw mounting, 169

Screwdriver, 37

Screw-type connection system, 35, 173, 181

Selection criteria, 107

SIRIUS 3RU thermal overload relays / SIRIUS 3RB

electronic overload relays, 122

Snap-on mounting, 170

Soft start, 32

Soft starter, 33, 106

Solid-state contactors, 103, 104, 105

Solid-state reversing contactors, 103, 104, 105

Solid-state switching devices, 32, 39, 102

Instantaneous switching, 103, 104

Spring-loaded connection system, 35, 174, 192

Standards, 17

Star-delta (wye-delta) start, 32, 91, 95

Function modules for mounting on

contactors, 97, 99

Switch position, 43

Switching

Motorized load, 103, 105

Resistive load, 103

System components, 36, 133

System monitoring, 65, 66

Technical Assistance, 13

Technology, 34

Test certificates, 18

Three-phase induction motor, 108

Through-hole technology, 35, 191, 191, 191

Thyristor pair, 32, 33

Timing relays, 97

Function modules for mounting on contactors, 100

Tool, 37

Types of coordination, 153

Load feeders, 152

Index

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Ultra-heavy-duty starting, 108

Utilization categories

Contactors, 75

Vacuum contactor, 71

Validity, 9

Index

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