Table of Contents

Introduction...............................................................................2
Control Circuits and Symbols.....................................................4
Line Diagrams.......................................................................... 14
Overload Protection................................................................. 19
Manual Control........................................................................22
Magnetic Contactors...............................................................27
Overload Relays.......................................................................31
NEMA Starters........................................................................41
IEC Starters.............................................................................54
Lighting and Heating Contactors.............................................68
Pilot Devices............................................................................70
Limit Switches.........................................................................79
Control Transformers................................................................80
Protection Devices and Terminal Blocks..................................81
Control Relays..........................................................................83
Solid-State Relays and Contactors...........................................87
Timing Relays and Function Modules......................................89
Monitoring Relays....................................................................93
Interface Converters................................................................94
LOGO! Programmable Relays..................................................95
SIRIUS Safety Integrated.........................................................97
Review Answers.................................................................... 105
Final Exam............................................................................. 108


Introduction

Welcome to another course in the STEP series, Siemens

Technical Education Program, designed to prepare our
distributors to sell Siemens Industry, Inc. products more
effectively. This course covers Basics of Control Components.

Upon completion of Basics of Control Components you will be

able to:

• State the purpose and general principles of control

components and circuits
• State the difference between manual and automatic
control operation
• Identify various symbols which represent control
components
• Read a basic line diagram
• Describe the construction and operating principles
of manual starters, electromagnetic contactors, and
electromagnetic motor starters
• Explain the need for motor overload protection
• Briefly describe the operation of thermal and electronic
overload relays
• Describe the advantages of reduced-voltage motor starting
• Describe the types and operating principles of lighting and
heating contactors
• Describe the operating principles of control relays
• Summarize the types of NEMA control products offered by
Siemens
• Summarize the types of IEC control products offered by
Siemens
• Briefly describe the uses for AS-Interface, ASIsafe, IO-Link,
and PROFIBUS DP
• Summarize the types of SIRIUS Safety Integrated products
offered by Siemens

This knowledge will help you better understand customer

applications. In addition, you will be better able to describe
products to customers and determine important differences
between products.


You should complete Basics of Electricity before attempting
Basics of Control Components. An understanding of many
of the concepts covered in Basics of Electricity is required for
this course.

After you have completed this course, if you wish to determine

how well you have retained the information covered, you can
complete a final exam online as described later in this course. If
you pass the exam, you will be given the opportunity to print a
certificate of completion.

Siemens is a trademark of Siemens AG. Product names

mentioned may be trademarks or registered trademarks of their
respective companies. Specifications subject to change without
notice.

NEMA® is a registered trademark and service mark of the

National Electrical Manufacturers Association, Rosslyn, VA
22209.

Underwriters Laboratories Inc.® and UL® are registered

trademarks of Underwriters Laboratories Inc., Northbrook, IL
60062-2096.

Other trademarks are the property of their respective owners.


 Control Circuits and Symbols

Control Control, as it relates to machines and processes, is a broad

term that means anything from a simple toggle switch to a
complex system.

Control is considered to be manually operated when

someone must initiate an action for the circuit to operate. For
example, someone might have to flip the switch of a manual
starter to start and stop a motor.

Although manual operation of machines is still common, many

machines are controlled automatically. Frequently there is a
combination of manual and automatic control. For example, a
machine that is started manually may stop automatically when
certain conditions are met.

Control Components While many control components are used in circuits that involve
motors, control components are also used with a variety of
other equipment. Various types of control components are
used for switching, starting, protecting, detecting, monitoring,
communicating, and other functions. The full range of these
capabilities is beyond the scope of this course, but examples
of devices that perform these types functions are discussed
throughout this course.


 In some cases, the interaction of these components is
dependent only on how they are wired to each other. This
is sometimes referred to as hard-wired logic. Increasingly,
however, these components are wired or networked to a
control system, such as a programmable logic controller or
variable frequency drive. In such cases, the interaction of
the circuit components is dependent both on wiring and the
software stored in the controller.

Before discussing specific control devices; however, it is

important to understand some basic symbols and diagrams. The
symbols and diagrams described in this course are commonly
used in North America. Other types of symbols and diagrams
are also used.

Contact Symbols Various devices incorporate contacts to control the flow of

current to other control components. When in operation, a
contact may be either open, a condition which blocks current
flow, or closed, a condition which allows current flow. Control
logic diagrams, however, cannot show the dynamic operation
of contacts. Instead, these diagrams show contacts as either
normally open (NO) or normally closed (NC).

The standard method of showing contacts is to indicate the

circuit condition produced when the actuating device is in
the de-energized (off) state. For example, in the following
illustration, the contacts are part of a relay. The contacts are
shown as normally open to indicate that, when there is no
power applied to the relay’s coil, the contacts are open. With
the contacts open, there is no current flow to the light.

Relay
De-energized

Battery


 Symbols on a control logic diagram are usually not shown in
their energized (on) state. However, in this course, contacts
and switches are sometimes shown in their energized state for
explanation purposes. In such cases, the symbol is highlighted.

Normally Open Contact For example, in the following illustration, the circuit is first
Example shown in the de-energized state, and the normally open
contacts are not highlighted. When the relay energizes, the
contacts close, completing the path for current and illuminating
the light. The contacts are then shown as highlighted to indicate
that they are not not their normal state. Note: This is not a
standard symbol.

Relay Relay
De-energized Energized

Battery Battery
Contacts are shown
opposite their normal
state

Normally Closed Contact In the following illustration, when the relay is de-energized, the
Example normally closed contacts are shown as closed and are not
highlighted. A complete path of current exists at this time, and
the light is on. When the relay is energized, the contacts open,
turning the light off.

Relay Relay
De-energized Energized

Battery Battery
Contacts are shown
opposite their normal
state


Switch Symbols Various types of switches are also used in control circuits. Like
the contacts just discussed, switches can also be normally
open or normally closed and require another device or action
to change their state. In the case of a manual switch, someone
must change the position of the switch. A switch is considered
to be in its normal state when it has not been acted upon.

Switch symbols, like the ones shown in the following

illustration, are also used to indicate an open or closed path of
current flow. Variations of these symbols are used to represent
a number of different switch types.

Normally Open Switch In the following illustration, a battery is connected to one side of
Example a normally open switch, and a light is connected to the other
side. When the switch is open, current cannot flow through the
light. When someone closes the switch, it completes the path
for current flow, and the light illuminates.

Switch is shown opposite

its normal state

Battery Battery

Normally Closed Switch In the following illustration, a battery is connected to one side of
Example a normally closed switch and a light is connected to the other
side. When the switch is closed, current flows through the light.
When someone opens the switch, current flow is interrupted,
and the light turns off.

Switch is shown opposite

its normal state

Battery Battery


Pushbutton Symbols There are two general types of pushbuttons, momentary and
maintained. The contacts of a momentary pushbutton change
state, open to closed or vice versa, when the pushbutton is
pressed. They return to their normal state as soon as the button
is released. In contrast, a maintained pushbutton latches in
place when pressed. It must be unlatched to allow it to return
to its normal state.

Normally Open In the following illustration, a battery is connected to one side of

Pushbutton Example a normally open pushbutton, and a light is connected to the
other side. When the pushbutton is pressed, current flows
through the pushbutton, and the light turns on.

Switch is shown
opposite its normal
state

Normally Closed In the following example, current flows to the light as long as
Pushbutton Example the pushbutton is not pressed. When the pushbutton is
pressed, current flow is interrupted, and the light turns off.

Switch is shown
opposite its normal
state


Coil Symbols Motor starters, contactors, and relays are examples of
devices that open and close contacts electromagnetically. The
electromagnet in these devices is called a coil.

A coil is commonly symbolized as a circle with one or more

letters and possibly a number inside. The letters often represent
the type of device, such as M for motor starter or CR for control
relay. A number is often added to the letter to differentiate one
device from another.

The contacts controlled by a coil are labeled with the same

letter (and number) as the coil so that it is easy to tell which
contacts are controlled by each coil. A coil often controls
multiple contacts and a combination of normally open and
normally closed contacts may be used.

Coil and Contact Example In the following example, the “M” contacts in series with the
motor are controlled by the “M” contactor coil. When someone
closes the switch, current flows through the switch and “M”
contactor coil. The “M” contactor coil closes the “M” contacts
and current flows to the motor.


Overload Relay Symbol Overload relays are used to protect motors from overheating.
When excessive current is drawn for a predetermined amount
of time, the overload relay’s contacts open, removing power
from the motor. The following symbol is for contacts associated
with a thermal overload relay. An overload relay used with a
three-phase motor has three such contacts, one for each phase.

Indicator Light Symbols An indicator light, often referred to as a pilot light, is a small
electric light used to indicate a specific condition of a circuit.
For example, a red light might be used to indicate that a motor
is running. A letter in the center of the indicator light symbol is
sometimes used to indicate the color of the light.

Other Symbols In addition to the symbols discussed here, there are many other
symbols used in control circuits. The following charts show
some of the commonly used symbols.

10
11
Static switching control uses
solid-state devices instead of
electromechanical devices. Many
of the symbols used with this
type of control are the same
as those shown on the previous
page, but enclosed in a square as
shown in the following examples.

Contact Limit Switch

Coil (NO) (NO)

12
Abbreviations Abbreviations are frequently used in control circuits. The
following list identifies commonly used abbreviations.

AC Alternating Current MTR Motor

ALM Alarm MN Manual
AM Ammeter NEG Negative
ARM Armature NEUT Neutral
AU Automatic NC Normally Closed
BAT Battery NO Normally Open
BR Brake Relay OHM Ohmmeter
CAP Capacitor OL Overload
CB Circuit Breaker PB Pushbutton
CKT Circuit PH Phase
CONT Control POS Positive
CR Control Relay PRI Primary
CT Current Transformer PS Pressure Switch
D Down R Reverse
DC Direct Current REC Rectifier
DISC Disconnect Switch RES Resistor
DP Double-Pole RH Rheostat
DPDT Double-Pole, Double-Throw S Switch
DPST Double-Pole, Single-Throw SEC Secondary
DT Double Throw SOL Solenoid
F Forward SP Single-Pole
FREQ Frequency SPDT Single-Pole, Double Throw
FTS Foot Switch SPST Single-Pole, Single Throw
FU Fuse SS Selector Switch
GEN Generator SSW Safety Switch
GRD Ground T Transformer
HOA Hand/Off/Auto Selector Switch TB Terminal Board
IC Integrated Circuit TD Time Delay
INTLK Interlock THS Thermostat Switch
IOL Instanstaneous Overload TR Time Delay Relay
JB Junction Box U Up
LS Limit Switch UV Under Voltage
LT Lamp VFD Variable Frequency Drive
M Motor Starter XFR Transformer
MSP Motor Starter Protector

Review 1
1. A control is ________ operated when someone must
initiate an action for the circuit to operate.

2. Identify each of the following symbols.

a. b. c.

3. Which of the following symbols represents a normally

open pushbutton?

a. b. c.

13
Line Diagrams

Control symbols are used in line diagrams, also referred to

as ladder diagrams. Line diagrams are made up of two types
of circuits, control circuits and power circuits. Within a line
diagram, control circuit wiring is represented by a light line, and
power circuit wiring is represented by a heavy line. A small dot
or node at the intersection of two or more wires indicates an
electrical connection.

Control Power Not Connected

Wiring Wiring Connected

Line diagrams show the functional relationship of components

in an electrical circuit, not the physical relationship. For example,
the following illustration shows the physical relationship of an
indicator light and a pushbutton.

Indicator
(Pilot) Light

Pushbutton

The functional relationship can be shown pictorially with the

following illustration.

L1 L2

Pushbutton Indicator (Pilot) Light

14
Reading a Line Diagram The following line diagram symbolically displays the functional
relationship of these same components. In order to properly
interpret this diagram, you must read it starting at L1 from
left to right to L2. With that in mind, note that pressing the
pushbutton allows current to flow from L1 to L2 through the
pushbutton and the pilot light. Releasing the pushbutton stops
current flow, turning the indicator light off.

Power and Control Circuits The following line diagram includes both power and control
circuits. The power circuit, drawn with a heavy line, is the
circuit that supplies power to the motor. The control circuit,
drawn with a light line, controls the distribution of power.

A typical control circuit includes a control load and one or more

components that determine when the control load will be
energized. Some control loads, such as relays and contactors,
activate other devices, but other control loads, such as
indicator lights, do not. For example, the following illustration
shows the connection of an indicator light and a pushbutton.
The power lines are drawn vertically and marked L1 and L2.
In this example, the voltage between L1 and L2 is 120 VAC.
This means that the indicator light must be rated for 120 VAC,
because, when the pushbutton is pressed, 120 VAC is applied
to the indicator light.

15
Connecting the Load to L2 Only one control load can be placed in any one circuit line
between L1 and L2. One side of the control load is either
directly or indirectly connected to L2.

In the following example, an indicator light is directly connected

to L2 on one circuit line. A contactor coil is indirectly connected
through a set of overload contacts (OL) to L2 on a second,
parallel circuit line. Pressing the pushbutton applies 120 VAC to
the indicator light and to the “M” contactor.

L1 120 VAC L2
Pilot light connected
directly to L2
Pushbutton
120 VAC
Pilot Light Contactor connected to L2
through a normally closed
M overload relay contact

120 VAC OL
Contactor

Control loads are generally not connected in series. The

following illustration shows why. In the circuit on the left, the
control loads are improperly connected in series. When the
pushbutton is pressed, the voltage across L1 and L2 is divided
across both loads with neither load receiving the full 120 VAC
necessary for proper operation.

In the circuit on the right, the loads are properly connected in

parallel, and, when the pushbutton is pressed, the full 120 VAC
is applied to both loads. In addition, if one load fails in this
configuration, the other load will continue to operate normally.
Improper Series Connection Improper Parallel Connection
L1 120 VAC L2 L1 120 VAC L2

120 VAC 120 VAC 120 VAC

Pilot Light Pilot Light Pilot Light

120 VAC
Pilot Light

16
Connecting Control Devices In the previous example, only one control device is used to
control the load. Usually more than one control device is
needed. These control devices may be connected in series,
parallel, or in a combination series-parallel circuit, depending
on the logic required to control the load. For example, in the
following illustration, the pushbuttons are connected in parallel.
Pressing either pushbutton, or both pushbuttons, allows current
to flow from L1, through the indicator light, to L2.

The next illustration shows two pushbuttons connected in

series. Both pushbuttons must be pressed at the same time to
allow current to flow from L1 through the load to L2.

Line Numbering Because line diagrams often have multiple lines, the lines are
often numbered to simplify describing the logic. For example, in
the following illustration, line 1 connects pushbutton 1 to pilot
light 1, line 2 connects pushbutton 2 to pilot light 1, and line 3
connects switch 1 to pilot light 2 and to the “M” contactor on
line 4.

17
Review 2
1. Line diagrams are read starting at L1 from ________ to
________ to L2.

2. Match the items on the line diagram with the

associated list.

a b Control Circuit
Control Device
Control Load
c Node
Power Circuit
Power Load
d

e
f

a. ________ b. ________ c. ________

d. ________ e. ________ f. ________

18
 Overload Protection

Some of the control components covered in this course

are designed to protect motors from overloads. In order to
understand these control components, you must have a clear
understanding of what an overload is and how it differs from a
short circuit, another type of overcurrent condition.

Current and Temperature To begin with, current flow always generates heat. The amount
of heat generated is proportional to both the amount of current
flow and the resistance of conductive path. Keep in mind that
conductors can be damaged by excess heat. For that reason,
each conductor has a continuous current rating, also called its
ampacity.

Excessive current is referred to as overcurrent. An overcurrent

may result from a short circuit, overload, or ground fault. The
first two types of overcurrent conditions are pertinent to this
discussion.

Normal Current Flow

Excessive Current Flow

19
Short Circuits Normally, the insulation used to separate conductors prevents
current from flowing between the conductors. When the
insulation is damaged; however, a short circuit can result. A
short circuit occurs when bare conductors touch and the
resistance between the conductors drops to almost zero. This
reduction in resistance causes current to rise rapidly, usually to
many times the normal circuit current.

To understand this better, consider the relationship between

current and resistance described by Ohm’s Law. For example,
if the voltage in a circuit is 240 volts and the resistance is 24
ohms, the current is 10 amps. When a short circuit occurs, the
resistance between conductors drops to a very low value, 0.024
ohms in this example. Note that this causes the current to rise
proportionally.

Before Short Circuit After Short Circuit

E 240 V 240 V
Ohm’s Law I = I= = 10 A I= = 10,000 A
R 24 Ω 0.024 Ω

The heat generated by this current will cause extensive damage

to connected equipment and conductors if not interrupted
immediately by a circuit breaker or fuse.

Overloads In contrast, an overload is a much lower current than a

short circuit. An overload occurs when too many devices are
connected to a circuit or when electrical equipment is made to
work beyond its rated capabilities. For example, if a conveyor
jams, its motor may draw two or more times its rated current.

20
 In the previous example, the overload resulted when a circuit
exceeded its rated capacity for an extended time. In such a
situation, an overcurrent protection device should shut down
the circuit.

A different response is required for a short-duration overload.

In such a situation, it may be undesirable to disable the circuit.
To understand this better, consider what happens when an
electric motor is started. When most motors start, they draw
current in excess of their full-load current rating. For example,
a NEMA design B motor typically has a starting current
that is about six times its full-load current. For some high-
efficiency motors, the starting current is even higher. Motors
are designed to tolerate a high starting current for a short time.
As a motor accelerates to operating speed, its current drops off
quickly. In the following example, the motor’s starting current is
600% of full load current, but after eight seconds, current has
dropped to the rated value.

Overload Protection Fuses and circuit breakers are designed to protect circuit
conductors in the event of a short circuit or overload. Under
such conditions, these devices open the path for current flow
before damage to conductors occurs. In a motor circuit, circuit
conductors and the fuse or circuit breaker designed to protect
them must be sized to allow for the high starting current of the
motor. Because of this, overload protection for the motor must
be provided by a separate device known as an overload relay.

21
 Manual Control

As the name implies, manual controls are devices operated

by hand. A simple knife switch, like the one shown in the
following illustration, was the first manual-control device used
to start and stop motors. The knife switch was eventually
replaced with improved control designs such as manual and
magnetic starters.

From Power Source

To Motor

In addition to turning a motor on and off, a motor control

device may also provide overload protection for the motor. To
accomplish these tasks, manual starters combine a manual
contactor or switch mechanism and an overload protection
device.

The following diagram illustrates a single-pole manual motor

starter. Each set of contacts is called a pole. A starter with two
sets of contacts would be called a two-pole starter.
To Motor To Motor

Overload Protection
Stationary Contacts
Moveable Contracts

Power Source Power Source

Operating Lever
Switch in “OFF” Position Switch in “ON” Position

22
 Starters are connected between the power source and the
load. In the following example, a two-pole or single-phase motor
starter is connected to a motor. When the switch is in the
“OFF” position, the contacts are open, preventing current flow
to the motor from the power source. When the switch is in the
“ON” position, the contacts are closed, and current flows from
the power source (L1), through the motor, then returning to the
power source (L2).

L2
T2

L1

T1

This is represented with a line drawing like the one shown in

the following illustration.

Some manual motor starters offer low-voltage protection

(LVP) as an option. LVP automatically removes power from the
motor when incoming power drops or is interrupted.

An LVP starter must be manually reset when power is restored.

This protects personnel from potential injury caused by
machinery that would otherwise automatically restart when
power is restored.

23
Siemens Manual Starters Siemens SMF fractional-horsepower starters provide
and Switches overload protection and manual “ON/OFF” control for small
motors. SMF starters are available in one-pole or two-pole
versions suitable for AC motors up to 1 HP and 277 VAC.
The two-pole version is suitable for DC motors up to 3/4 HP
and 230  VDC. A melting-alloy type overload relay is used for
overload protection. SMF manual starters are available in a
variety of enclosures. A two-speed version is also available.

Two-Pole Manual Starter

Siemens MMS and MRS switches are similar to SMF

starters but do not provide overload protection. MMS and
MRS switches only provide manual “ON/OFF” control of DC
and single-phase or three-phase AC motors where overload
protection is provided separately. These devices are suitable
for use with three-phase AC motors up to 10 HP and 600 VAC
and up to 1-1/2 HP and 230 VDC. The MMS and MRS manual
switches are available in various enclosures. Two-speed and
reversing versions are also available.

Three-Pole Manual Switch

24
Siemens Class 11 across-the-line manual starters and
switches provide control for machinery where remote start and
stop control is not required.

Class 11 - 3RV manual starters are used for single-phase and

three-phase motors up to 15 HP at 460 VAC and have bimetallic
heater elements that provide class 10 overload protection.
These starters have ambient temperature compensation. A
built-in differential trip bar reduces tripping time in the event of
a phase loss condition.

Class 11 - 3RV switches provide control where overload

protection is not required or is provided separately.

Class 11 - 3RV controllers are available with low voltage

protection which automatically opens the power poles when
the voltage drops or power is interrupted. They are available in
an open style (without enclosure), in NEMA 1 general purpose
enclosures, and in NEMA 7 & 9 or NEMA 3 & 4/NEMA 7 & 9
enclosures (for hazardous locations).

Open Type
Starter
NEMA 1 Enclosure

START START

STOP STOP
RESET RESET

NEMA 7 & 9 NEMA 3 & 4, NEMA 7 & 9

Class I Group C &D Class I Group C &D
Class II Group E, F & G Class II Group E, F & G

25
Motor Starter Protectors Motor starter protector (MSP) is a name used in the U.S. and
some other countries to identify a type of component that is
referred to in International Electrotechnical Commission (IEC)
standards as a circuit breaker. Siemens 3RV MSPs are part
of the SIRIUS modular system of control products described
throughout this course.

3RV1 Motor Starter Protectors feature a manual on/off switch,

a Class 10 adjustable thermal overload relay (Class 20 available
in the two largest frame sizes), and magnetic trip elements for
short circuit protection.

3RV1 MSPs are UL listed as manual motor controllers per

UL 508, making them appropriate for manual starting and
stopping applications where upstream short-circuit protection is
provided. 3RV102, 3RV103, and 3RV104 MSP’s can be used as
Type E self-protected manual combination starters per UL 508
(3RV102 and 3RV104 require additional terminal adapters) or
as components in group installation per NEC 430-53(C) to turn
motors on and off.

3RV2 MSPs are available in sizes S00 and S0 up to 40 A with

screw-type, spring-loaded, or ring cable lug connections. 3RV2
MSPs are part of the SIRIUS Innovations addition to the SIRIUS
modular system as discussed later in this course. Among other
advantages, 3RV2 motor starter protectors have 5 to 10 percent
lower power losses than previous models thanks to new
bimetal technology. This plays an important role in reducing the
temperature within the control cabinet.

Spring-loaded Terminals Screw-type Terminals

3RV2 Motor Starter Protectors

26
 Magnetic Contactors

NEMA and IEC Contactors Most motor applications require the use of remote control
devices to start and stop the motor. Magnetic contactors,
similar to the ones shown below, are commonly used to provide
this function. As discussed later in this course, some magnetic
contactors are used to control the distribution of power in
lighting and heating circuits.

NEMA Contactor IEC Contactor

Like many other control components, contactors are most

often manufactured to specifications provided either by the
National Electrical Manufacturer’s Association (NEMA) or
the International Electrotechnical Commission (IEC).

27
Basic Contactor Operation Magnetic contactors utilize basic electromagnetic principles. To
understand these principles, consider a simple electromagnet
fashioned by winding a wire around a soft iron core and
connecting the coil to a DC voltage source. Current flowing
through the wire temporarily magnetizes the iron core coil.
When the coil is disconnected from the DC voltage, the current
stops and the iron core coil returns to its nonmagnetic state.

Wound Coil
Soft Iron Core

DC Voltage Source
(Battery)

The following illustration shows the interior of a basic contactor.

There are two circuits involved in the operation of a contactor,
the control circuit and the power circuit. The control circuit is
connected to the coil of an electromagnet, and the power circuit
is connected to the stationary contacts.
Armature
Power Circuit
Spring
Movable Contacts
Coil

Electromagnet

Control Circuit

Stationary Contacts

Power Circuit

The operation of this electromagnet is similar to the operation

of the electromagnet made by wrapping wire around a soft iron
core. When power is supplied to the coil from the control circuit,
a magnetic field is produced, magnetizing the electromagnet.
The magnetic field attracts the armature to the magnet, which
in turn closes the contacts. With the contacts closed, current
flows through the power circuit from the line to the load.

28
When current no longer flows through the control circuit, the
electromagnet’s coil de-energizes, the magnetic field collapses,
and the movable contacts open under spring pressure.
Line Line

Load Load
Control Signal Control Signal
Contactor De-energized Contactor Energized

The following line diagram shows a contactor that provides on-

off control for a three-phase motor. Note that the power to the
electromagnetic coil of this contactor is controlled by SW1.

When SW1 closes, the electromagnetic coil energizes, closing

the “M” contacts and applying power to the motor. When SW1
opens, the coil de-energizes, opening the “M” contacts and
removing power from the motor.

29
Review 3
1. With an increase in current, heat ________.

2. Excessive current is referred to as ________.

3. An ________ occurs when too many devices are

connected to a circuit or when electrical equipment is
made to work beyond its rated capabilities.

4. Some manual motor starters offer ________ protection

which automatically removes power from the motor
when incoming power drops or is interrupted.

5. Siemens ________ fractional horsepower starters

provide overload protection and manual on/off control
for small motors.

6. Siemens ________ and ________ switehes provide

manual on/off control of DC and single-phase or three-
phase AC motors where overload protection is provided
separately.

7. _________ is a name given in the U.S. and some other

countries to a type of IEC circuit breaker that is used for
manual motor control.

8. ________ are used to remotely start and stop motors or

control the distribution of power in lighting and heating
applications.

30
Overload Relays

Overload relays are designed to meet the special protective

needs of motors. Overload relays do not disable the circuit
during a short-duration overload, but will trip and open a circuit
to protect a motor if current remains above the rated value long
enough. After an overload relay has tripped and the cause of
the overload has been cleared, the overload relay can be reset
to allow the motor to be restarted.

An overload relay has a trip class rating which identifies the

maximum time (in seconds) it takes for the overload relay
to trip at a specific current, typically six times its continuous
current rating. The most common trip classes are 5, 10, 20, and
30.

31
 The following illustration shows a circuit with a manual motor
starter (M) and an overload relay (OL). When the starter
contacts close, current flows through the overload relay and
motor. If the motor is overloaded, excess current will cause the
overload relay to trip, opening the circuit between the power
source and the motor. After the overload relay cools, it can be
reset. This allows the motor to be restarted, preferably after the
cause of the overload has been corrected.

M OL M
OL
L1 L1
T1 T1

Power Power
Motor Motor
Source Source

T2 T2
L2 L2
M M
Starter Contracts Open Starter Contacts Closed

Thermal Overload Relays Thermal overload relays, also called bimetal overload
relays, use a bimetallic strip to sense an overload condition.
A thermal overload relay incorporates a small heater element
wired in series with the motor and a bimetallic strip that
functions as a trip lever. The bimetallic strip is made of two
dissimilar metals bonded together. These metals have different
thermal expansion characteristics, causing the bimetallic strip to
bend when heated.

Under normal operating conditions, the heat generated by the

heater element causes the bimetallic strip to bend only slightly,
not enough to trip the overload relay. If an overload condition
occurs and persists long enough, the bimetallic strip bends until
the overload relay’s trip mechanism is tripped. This causes the
overload relay’s contacts to open, removing power from the
motor.

To Power Circuit Motor To Power Circuit

Motor

Heater Element Heater Element

Bimetalic Strip Bimetalic Strip

To Control Circuit
To Control Circuit
Trip Mechanism Trip Mechanism

Normal Current Flow Overload Condition

32
 Some thermal overload relays are designed to reset
automatically after the bimetallic strip has cooled. Depending
on the circuit, the motor may then restart automatically. In
some applications, this is desirable. However, if the cause of
the overload still exists, the overload relay will trip and reset
repeatedly. Proper circuit design can prevent this condition,
which can damage the motor.

Ambient Temperature In some applications, a motor is installed in a location with a

Compensation relatively constant ambient temperature, and the motor control
components are installed in a location with a varying ambient
temperature. In such cases, a typical thermal overload relay may
trip too soon or too late because its bimetallic strip is bent both
by heat from motor current and the surrounding air.

Ambient compensated thermal overload relays are

designed to overcome this problem. These overload relays
use a compensated bimetallic strip along with a primary
bimetallic strip. As the ambient temperature changes, both
bimetallic strips bend equally and the overload relay does not
trip. However, because current flow through the motor and the
heater element affects only the primary bimetallic strip, the
primary bimetallic strip will bend sufficiently to trip the overload
relay if an overload occurs.

Motor To Power Circuit

Heater Element
The compensating bimetalic strip bends
Primary as ambient temperature increases. This
Bimetalic prevents a nuisance overload trip.
Strip

To Control
Circuit
Compensated Overload Relay

Siemens Class 48 ambient compensated thermal overload

relays are available in single-pole or three-pole designs and can
be set for manual or self-resetting operation. An adjustment
dial allows the full load ampere (FLA) trip setting to be adjusted
by ±15%. A manual test button is provided to test the operation
of the overload relay control contacts.

33
 The ambient compensated thermal overload relay heater
elements are available with either class 10 or 20 ratings. A
normally open or normally closed auxiliary contact is available as
an option.

Automatic/Manual
Reset Selection

+15% of FLA Adjustment

Test Button

Reset Button

Siemens SIRIUS 3RU thermal overload relays are available

in single-phase and three-phase designs. They feature a Class
10 trip, manual or automatic reset selection, adjustable current
settings, ambient temperature compensation, and a differential
trip bar that causes the unit to trip faster in the event of a phase
loss.

SIRIUS 3RU overload relays include a normally closed auxiliary

contact for de-energizing the contactor and a normally open
auxiliary contact for signaling an overload trip. Pressing the
STOP button momentarily opens the normally closed contact
without affecting the normally open contact. The switch-position
indicator incorporates a Test function which, when activated,
simulates a tripped overload relay by activating both auxiliary
contacts and displaying the switch position.

SIRIUS 3RU1 thermal overload relays are available with current

ratings up to 100 A. SIRIUS 3RU2 thermal overload relays are
part of the SIRIUS Innovations addition to the SIRIUS modular
system as discussed later in this course and are available with
current ratings up to 40 A.

Position Switch Indicator

and Test Function
STOP button Motor Current Selector

Manual/Automatic
Reset Selector

SIRIUS 3RU2 Thermal Overload Relay

34
Electronic Overload Relays Electronic overload relays are another option for motor
protection. The features of electronic overload relays vary,
but there are a few common advantages. One advantage of
electronic overload relays is that they do not require heaters.
This eliminates the need to stock multiple heaters to match
motor ratings. This heaterless design also allows electronic
relays to be insensitive to the ambient temperature, minimizing
nuisance tripping.

In addition, unlike some thermal overload relays, most

electronic overload relays can detect a power phase loss
and disconnect the motor from the power source. This is an
important advantage because, without phase lose protection,
loss of a power phase can quickly result in damaged motor
windings.

Like other electronic overload relays, ESP200 electronic

overload relays eliminate the need for heaters. Instead of
installing a heater, a dial on the overload relay is set to the
motor’s full-load ampere (FLA) rating.

Class 48 ESP200 electronic overload relays, like the one

shown below, have two dual in-line package (DIP) switches
accessible from the front that simplify the trip class selection of
any of four trip classes (5, 10, 20, and 30).

Additional DIP switches provide on or off settings for phase

unbalance, phase loss, or ground fault detection as well as
selection of manual or automatic reset. Also accessible from
the front are the RESET button, for use when manual reset
is selected, and the TEST button, that triggers a complete
electronic functions test. One normally open auxiliary contact
and one normally closed auxiliary contact are standard.

TRIP CLASS
5 20
10 30
OFF
ESP200 PHASE UNBAL ON
PHASE LOSS ON
OFF DIP Switches
AUTO
RESET MODE MAN.
OFF
GROUND FAULT ON

FULL LOAD AMPS TEST

RESET

Current Adjustment Dial Reset Button Test Button

35
In addition to Class 48 ESP200, two other types of ESP200
electronic overload relays are available. 958 ESP200 electronic
overload relays are specifically designed for sealed
compressors and artificially-cooled motors. 958L electronic
overload relays are specifically designed for the oil market and
pumping applications with a precise trip curve.

SIRIUS is Siemens modular system of control components

designed to IEC specification. SIRIUS 3RB20/21 electronic
overload relays are available with current ratings up to 630 A.
SIRUIS 3RB30/31 electronic overload relays are part of the
SIRIUS Innovations addition to the SIRIUS modular system and
are available with current ratings up to 40 A.

SIRIUS 3RB20 and 3RB30 electronic overload relays come

with a class 10 or 20 trip and feature manual or automatic
reset, adjustable current settings, and ambient temperature
compensation. A normally closed auxiliary contact for de-
energizing the contactor and a normally open auxiliary contact
for signaling an overload trip are included.

Pressing the STOP button momentarily, opens the normally

closed contact without affecting the normally open contact. The
switch-position indicator incorporates a TEST function which,
when activated, simulates a tripped overload relay by actuating
both auxiliary contacts and displaying the switch position.

SIRIUS 3RB21 and 3RB31 electronic overload relays have

similar features to SIRIUS 3RB20 and 3RB30 overload relays,
but allow the trip class to be set from 5 to 30 and have a
ground fault detection function that can be enabled.

Position Switch Indicator

and Test Function
Reset Button
Motor Current Selector Trip Class and
Ground Fault Detection
Manual or Automatic
Selector
Reset Selector

3RB31 Electronic Overload Relay

36
SIRIUS 3RB22/23 electronic overload relays are available
with current ratings up to 630 A (up 820 A with an optional
module). These overload relays provide trip class adjustments
from class 5 to 30 and ground fault, phase imbalance, and
phase loss protection. Motor current is continuously monitored
in each phase.

Two auxiliary contacts, one normally open and one normally

closed, are switched in the event of an overload, phase
imbalance, or phase loss. One additional set of auxiliary
contacts, one normally open and one normally closed, are
switched without time delay in the event of a ground fault.

In addition to sensing current, SIRIUS 3RB22/23 overload

relays directly sense motor winding temperature via a
thermistor sensor. With an additional AS-Interface analog
module, 3RB22/23 overload relays can communicate via the
AS-Interface bus, described later in this course, to share
operational data, diagnostics, and parameter settings with a
PLC or other control system.

SIRIUS 3RB24 electronic overload relay has similar features

to SIRIUS 3RB22/23 electronic overload relays, but has IO-Link
communication capability (described later in this course), which
is ideal for use in a limited area, such as a control cabinet.

Current Transformer

Manual or Automatic
Reset Selector
Test/Reset Button

Motor Current and Optional Operator Panel

Trip Class Setting

3RB24 Electronic Overload Relay

37
Current Monitoring Relays SIRIUS 3RR2 current monitoring relays are part of the
SIRIUS Innovations addition to the SIRIUS modular system and
are available with current ratings up to 40 A.

Although a SIRIUS 3RR2 current monitoring relay monitors

motor current and can be directly mounted to a SIRIUS 3RT2
contactor in place of an overload relay, it provides more than
motor protection. Because variations in motor current can
indicate a variety of machine or process problems, SIRIUS 3RR2
current monitoring relays provide a means for direct monitoring
and protection of the application and can be very helpful in
reducing system downtime and maintenance expense.

SIRIUS 3RR2 current monitoring relays are available in

two versions. 3RR21 is a two-phase basic version with
potentiomenters for setting parameters such as on-delay
time, tripping delay time, current overshoot or undershoot
threasholds. 3RR22 is a three-phase version with a display for
setting parameters and viewing actual values and diagnostic
information.

3RV2
Motor
Starter
Protector

3RT2
Contactor

3RR2
3RR22 3RR21
Current
Current Monitoring Relays Monitoring
Relay

38
SIMOCODE pro Motor SIMOCODE pro is an alternative approach to use of overload
Management System relays or current monitoring relays. SIMOCODE pro is a
flexible, modular motor management system that provides
multifunctional, solid-state protection for constant speed
motors. SIMOCODE pro implements all motor protection
and control functions; provides for tracking of operational,
diagnostic, and statistical data; and communicates with the
automation system via PROFIBUS DP.

SIMOCODE pro C is a compact, economical system for full-

voltage forward and reversing starters. Each SIMOCODE pro C
includes a basic unit connected by a single cable to a current
measuring module. An optional operator panel may also be
connected to the basic unit.

SIMOCODE pro V is a variable system with an even greater

range of functions. In addition to a basic unit, it can include
either a current measuring module or a combination current/
voltage measuring module, up to five expansion modules, and
an optional operator panel (with or without display). Expansion
modules are available for discrete input/output, analog input/
output, ground fault detection, and temperature sensing.

SIMOCODE pro C Motor Management System

SIMOCODE pro V Motor Management System

39
Review 4
1. A class ________ overload relay will trip and remove
power from an overloaded motor within 10 seconds at
six times full-load current.

2. A ________ overload relay, also called a ________

overload relay incorporates a small heater element
wired in series with the motor and a bimetallic strip that
functions as a trip lever.

3. If an overload relay trips, it can be ________ after the

overload has been removed.

4. Siemens Class 48 and SIRIUS ________ thermal

overload relays provide ambient temperature
compensation.

5. Electronic overload relays provide overload protection

without the use of ________ and can also provide
________ protection.

6. Siemens ________ electronic overload relays have DIP

switches on the front for setting trip class or selecting
manual or automatic reset and phase unbalance, phase
loss, and ground fault detection.

7. SIRIUS ________ and ________ electronic overload

relays have similar features to SIRIUS 3RB20 and
3RB30 overload relays, but allow the trip class to be set
from 5 to 30 and have a ground fault detection function
that can be enabled.

8. SIRIUS 3RB24 electronic overload relay has similar

features to SIRIUS 3RB22/23 electronic overload relays,
but has ________ communication capability.

9. Although a SIRIUS ________ current monitoring relay

monitors motor current and can be directly mounted to
a SIRIUS 3RT2 contactor in place of an overload relay, it
provides more than motor protection.

10. ________ is a flexible, modular motor management

system that provides multifunctional, solid-state
protection for constant speed motors.

40
 NEMA Starters

Motor Starter Contactors and overload relays are separate control devices.
When a contactor is combined with an overload relay, it is called
a motor starter.

COIL NO. 110 V

3
L1
L2
L3
Contactor
Series A
Max HP Max Amps
Voltes 3 Ph 600 VAC

a, GA U.S.A. T3
SE&A Inc. Alpharett T2
T1
2

TRIP CLASS
5 20
10 30
ON
PHASE UNBAL
ESP200 PHASE LOSS ON
RESET MODE MAN.
ON
GROUND FAULT

FULL LOAD
AMPS
TEST
Overload Relay
RESET

NEMA Starter

Motor starters manufactured to NEMA specifications are

referred to as NEMA starters. Starters manufactured to IEC
standards are discussed later in this course. Siemens offers
both types of starters and associated components.

When a starter’s contactor is set up to supply the full line

voltage to a motor it is called a full-voltage, across-the-line, or
direct motor starter.

As discussed later in this course, some starters are capable

of reversing motor direction, controlling the starting voltage,
or controlling two speed motors. However, the most common
type of motor starter is designed to turn a motor on and off and
provide overload protection. The overload relay used may be a
thermal overload relay or an electronic overload relay.

41
The following diagram shows the electrical relationship of a
contactor and an overload relay in a full-voltage motor starter
circuit. The contactor (highlighted with the darker grey) includes
an electromagnetic coil (M) and auxiliary contacts (Ma) in the
control circuit and three main contacts (M) in the power circuit.
The overload relay, highlighted by the lighter grey, includes three
heaters contacts (OL) in the power circuit and auxilliary contacts
(OL) in the control circuit.

In this circuit, when the Start pushbutton is pressed, power is

provided to the coil, and the M contacts close. This provides
power to the motor through the OL heater contacts. At
the same time, Ma contacts close so that, when the Start
pusbutton is released, power is still provided to the coil.

The motor continues to run until the Stop pushbutton is

pressed, unless an overload occurs. If an overload occurs, the
OL heater contacts open, removing power from the motor,
and OL auxiliary contacts open, removing power from the coil.
Removing power from the coil is necessary to prevent the
motor from automatically restarting after the overload relay
cools.

42
 The National Electrical Manufacturers Association (NEMA)
and the International Electrotechnical Commission (IEC)
are two organizations that provide ratings for contactors, motor
starters, and other types of control components. NEMA is
primarily associated with equipment used in North America.
IEC is associated with equipment sold in many countries
worldwide, including the United States. International trade
agreements, market globalization, and domestic and foreign
competition have made it important to be increasingly aware of
international standards.

NEMA Ratings Contactors and motor starters are rated according to size and
the type of load they are designed to handle. NEMA ratings
are based on maximum horsepower ratings as specified in
the NEMA ICS2 standards. NEMA starters and contactors are
selected according to their NEMA size, from size 00 to size 9.

NEMA Continuous HP HP
Size Amp Rating 230 VAC 460 VAC
00 9 1 2
0 18 3 5
1 27 5 10
2 45 15 25
3 90 30 50
4 135 50 100
5 270 100 200
6 540 200 400
7 810 300 600
8 1215 450 900
9 2250 800 1600

NEMA motor control devices have generally become known

for their very rugged, heavy-duty construction. NEMA motor
starters and contactors can be used in virtually any application
at their stated rating, from simple on and off applications to
more demanding applications that include plugging and jogging.
To select a NEMA motor starter for a particular motor, you
only need to know the horsepower and voltage of the motor.
However, if there is considerable plugging and jogging duty
involved, even a NEMA-rated device will require some derating.

43
 Siemens also has what are called Motor Matched sizes
available on some Siemens motor starters. The ratings for these
devices fall in between the ratings of normal NEMA sizes,
allowing the user to more closely match the motor control
to the actual application. Motor Matched sizes are beneficial
because they cost less than larger NEMA size starters. The
following table shows the Motor Matched sizes available.

MM Size Continuous HP HP
Amp Rating 230 VAC 460 VAC
1¾ 40 10 15
2½ 60 20 30
3½ 115 40 75

Class 14 NEMA Starters Class 14 NEMA starters with ambient-compensated bimetal

overload relays are available up to 100 HP at 460 VAC (NEMA
sizes 00 through 4). In addition to whole sizes, this range
includes 1¾, 2½, and 3½ sizes. These starters are available with
class 10 or 20 ambient-compensated bimetal overload relays.

Contactor

Ambient Compensated
Bimetalic Overload Relay

Class 14 ESP200 starters use the same contactors as Class 14

NEMA starters equipped with bimetal overload relays (for
NEMA sizes 00 through 4), but are supplied with an ESP200
solid-state overload relay. In addition, these starters are available
with contactors up to and including NEMA size 8.

44
 The ESP200 overload relay provides users with the specific
level of protection they desire. For example, the trip class (5, 10,
20, or 30) is set using DIP switches on the front of the unit and
the full-load ampere (FLA) dial allows for a wide range (4:1) of
adjustment.

COIL NO. 110 V

Contactor
L3
L2
L1
3

Series A
Max HP Max Amps
Voltes 3 Ph 600 VAC

, GA U.S.A. T3
SE&A Inc. Alpharetta T2
T1
2

ESP200 Solid-State
TRIP CLASS
5 20
10 30
ON
PHASE UNBAL
ESP200 PHASE LOSS ON
RESET MODE MAN.
GROUND FAULT
ON
Overload Relay
TEST
AMPS
FULL LOAD

RESET

As previously mentioned, 958 and 958L ESP200 solid state

overload relays are also available for specialized applications.

Reversing Starters Many applications require a motor to run in either direction,

forward or reverse. The direction of motor rotation is changed
by changing the direction of current flow through the windings.
This is done for a three-phase motor by reversing any two of the
three motor leads. Most often, T1 and T3 are reversed.

The following illustration shows a three-phase motor reversing

circuit with one set of forward (F) contacts controlled by the
“F” contactor and one set of reverse (R) contacts controlled by
the “R” contactor.

45
When the “F” contacts close, current flows through the motor
causing it to turn in a clockwise direction.

When the “F” contacts open and the “R” contacts close,
current flows through the motor in the opposite direction,
causing it to rotate in a counterclockwise direction. Mechanical
interlocks prevent both forward and reverse circuits from being
energized at the same time.

Siemens offers Class 22 reversing starters in NEMA sizes 00

through 8 including Siemens half-sizes. Both ESP100 solid-state
and ambient-compensated bimetal overload relays are available.

Siemens offers Class 43 reversing contactors in NEMA sizes

00 through 8, including Siemens half-sizes.

Siemens also offers IEC reversing starters as described later in

this course.

46
Two-Speed Heavy Duty The synchronous speed of a three-phase induction motor is a
Starters function of the supply frequency and the number of poles. This
speed is the rate in RPMs for the motor’s rotating magnetic
field.

120 x Fequency
Synchronous Speed in RPM =
Number or Poles

For example, a motor with four poles on a 60 hertz AC line has a

synchronous speed of 1800 RPM.

120 x 60 Hz.
Synchronous Speed = = 1800 RPM
4

For a three-phase induction motor, actual rotor speed is

always less than synchronous speed due to slip. The design
of the motor and the amount of load applied determine the
percentage of slip. For example, a NEMA B motor with a
synchronous speed of 1800 RPM will typically have a full-load
speed of 1650 to 1750 RPM.

When motors are required to run at different speeds, the

motor’s characteristics vary with speed. Therefore, proper motor
selection and application is critical. There are three categories of
multi-speed applications: constant torque, variable torque, and
constant horsepower.

Constant Torque (CT) applications require constant torque at

all speeds. Horsepower varies directly with speed. For example,
many conveyor applications require constant torque.

Variable Torque (VT) applications often have load torques

proportional to the square of the speed. Fans, blowers, and
centrifugal pumps are examples of variable torque applications.

Constant Horsepower (CHP) applications maintain constant

horsepower at all speeds, with torque varying inversely with
speed. Many metal-working machines such as drills, lathes,
mills, bending machines, punch presses, and power wrenches
are examples of constant horsepower applications.

Two types of induction motors that provide for two-speed

control using magnetic starters are separate winding motors
and consequent pole motors. Consequent pole motors
with two speeds on a single winding require a starter which
reconnects the motor leads to half the number of effective
motor poles for high speed operation. For this type of motor,
the low speed is one half the high speed.

47
 Separate winding motors have a winding for each speed
and provide more varied speed combinations because the
low speed need not be one half the high speed. Starters for
separate winding motors consist of a starter unit for each
speed.

Siemens offers Class 30 two-speed heavy duty starters for

separate-winding and consequent-pole motors used in constant
torque, variable torque, and constant horsepower applications.
Starters are available in NEMA sizes 0 through 4, including
Siemens Motor Matched sizes. Overload protection is furnished
either with ESP200 electronic overload relays or ambient-
compensated thermal overload relays. Siemens also offers
Class 32 combination two speed heavy duty starters.

Two Speed Heavy Duty Starter

with ESP200 Electronic Overload Relays

Combination Starters Combination starters incorporate a motor starter, short circuit

protection, and a means to safely disconnect power. Siemens
offers a variety of enclosed combination starters and non-
combination starters with NEMA components in a full range of
enclosure types.

Fusible
Disconnect
Switch

Motor Starter
Class 17 Combination Starter
in Type 1 Enclosure
NEMA Enclosed Starters

48
 Duplex motor controllers consist of two motor starters in a
common enclosure. Siemens duplex motor controllers are
specifically designed for industrial and commercial applications
that require duplex controls such as duel pumps or blowers.
Siemens Class 83 is a non-combination duplex motor
controller. Siemens Class 84 is a combination duplex motor
controller with two separate disconnects or circuit breakers.

Full-Voltage Starting The motor starters discussed thus far have all been full-voltage
starters. This is the most common type of motor starter
because the initial component cost is low. A full-voltage starter
is also referred to an as across-the-line starter because it starts
the motor by applying the full line voltage.

When a motor is started with full voltage, starting current can

be as high as 600% of full-load current for a standard three-
phase induction motors and as high as 1200% of full-load
current for high efficiency motors. This high starting current
causes power fluctuations that affect other equipment. As a
result, many power companies require reduced-voltage starting
for large-horsepower motors.

49
 Another potential problem with full-voltage starting is the high
torque developed when power is first applied to the motor.
As shown in the speed-torque curve for a NEMA B motor, the
initial torque, also called locked rotor torque, is typically around
150 percent of full-load torque. Additionally, the torque can rise
as high as 175 to 200 percent of full-load torque as the motor
accelerates to rated speed.

Many applications require the starting torque to be applied

gradually. For example, a belt-type conveyor application often
requires the starting torque to be applied gradually to prevent
belt slipping and bunching. Also, in any application that
involves frequent starts, the higher initial starting torque, over
time, results in higher maintenance costs due to repeated
mechanical shock.

Reduced-Voltage Starting As the name implies, reduced-voltage starting involves

starting a motor at less than its full voltage rating and then
increasing the voltage as the motor comes up to speed.
Reduced-voltage starting is used when it is necessary to limit
the starting current and/or starting torque of a motor. Several
methods are available for reduced-voltage starting.

Siemens offers the following types of reduced-voltage starters

with NEMA components: autotransformer starters, part-
winding starters, and wye-delta starters. Siemens also offers
wye-delta starters and soft starters with IEC components as
described later in this course.

50
Autotransformer Starters One of the more basic types of reduce-voltage starters is the
autotransformer reduced voltage starter. Autotransformer
reduced-voltage starters provide a high starting torque per
ampere of line current and are typically used for applications
where starting current must be reduced while retaining good
starting torque.

Autotransformers have adjustable taps to set the reduced

starting voltage as a percentage of the full-line voltage.

Common applications for autotransformer reduced-voltage

starters include: crushers, fans, conveyors, compressors, and
mixers

L1

L2

Open
L3
Close

Siemens offers autotransformer starters as Class 36 non-

combination starters and Class 37 combination starters
with a fusible or non-fusible disconnect or circuit breaker.

Part-Winding Starters Part-winding reduced-voltage starters are used with motors

which have two separate parallel windings on the stator. One
magnetic starter engages the first set of windings when the
motor is started. These windings draw about 65 to 85% of the
rated locked rotor current. After a set time, a second magnetic
starter energizes and places the second set of windings in
parallel with the first.

51
 Part winding reduced-voltage starters are the least expensive
type of reduced-voltage starters and use a simplified control
circuit. However, they require a special motor design, are not
suitable for high-inertia loads, and do not have adjustments for
current or torque.

Siemens offers part winding starters as Class 36 non-

combination starters and Class 37 combination starters
with a fusible or non-fusible disconnect or circuit breaker.

Wye-Delta Starters Wye-delta reduced voltage starters are applicable only for
motors with stator windings not connected internally and all six
motor leads available for external connections.

Connected in a wye configuration, the motor starts with a

significantly lower inrush current than if the motor windings had
been connected in a delta configuration. After a set time, starter
contacts change state to connect the stator windings in a delta
configuration. This increases the voltage applied across each
stator winding.
1
L1 Motor

2 7 4
L2
5
3
L3
6

9
8

To Start: Close 1, 2, 3, 4, 5, 6 To Run: Open 4, 5, 6

Open 7, 8, 9 Close 7, 8, 9

This type of starter is a good choice for applications that require

frequent starts, low starting torque, or long accelerating times.

Siemens offers wye-delta starters as Class 36 non-

combination starters and Class 37 combination starters
with a fusible or non-fusible disconnect or circuit breaker.

Pump Control Panels Pump controllers monitor flow and/or level variables and control
a pump to maintain the desired values. Pump control can
involve simply turning a pump on and off or can include more
advanced controls for pump speed, output pressure, etc.

Siemens pump control panels are factory wired to simplify

installation, provide flexible control, and protect against short
circuits and overloads. Ample space is provided for field
modifications and installation of accessories. 

52
 Siemens offers pump control panels as Class 87 full voltage
and vacuum starters as well as Class 88 autotransformer
starters, part-winding starters, and wye-delta starters.

Review 5
1. When a contactor is combined with an overload relay, it
is called a ________.

2. ________ and ________ are two organizations that

provide ratings for control components.

3. A NEMA size ________ contactor is rated for 200 HP at

460 VAC.
1
4. A Siemens Motor Matched Size 2 /2 contactor is rated
for ________ HP at 230 VAC.

5. A reversing starter reverses motor direction by

switching ________ motor leads.

6. Siemens offers Class 30 two-speed heavy duty starters

for ________ and ________ motors.

7. ________ starters incorporate a motor starter, short-

circuit protection, and a means to safely disconnect
power.

8. ________ reduced voltage starters are applicable

only for motors with stator windings not connected
internally and all six leads available for external
connections.

53
 IEC Starters

SIRIUS Modular System The SIRIUS modular system includes a complete range of
industrial control components designed to IEC specifications
for use in switching, starting, protecting, and monitoring of
systems and motors. Examples of some of these components
are shown in the following graphic, which displays a structured
range of motor starters, MSPs, contactors, and overload relays
in seven compact frame sizes. These frame sizes are referred
to as S00, S0, S2, S3, S6, S10, and S12. SIRIUS Innovations
additions to the SIRIUS system, shown outlined in black in
the following graphic, further enhance the capabilities of this
system.

A feature of the SIRIUS system is the narrow mounting width.

Along with the ability of SIRIUS components to operate at
o o
ambient temperatures up to 140 F (60 C), this allows more
units to be packed into a panel without overheating the
components.

54
 Among the many additional advantages of the SIRIUS system
is the significant reduction in wiring cost made possible by
plug-in connections and the use of IO-Link or AS-Interface
communications.

SIRIUS Innovations The SIRIUS Innovations additions to the SIRIUS modular

system result from a complete redesign of size S00 and S0
components, which extends the continuous current range (up
to 40 A for S0) while maintaining a 45 mm footprint.

This redesign incorporated many features which reduce heat

generation, required panel space, and the time required to
configure, assemble, and test a control system. One example
of the many time saving system enhancements is the
increased use of spring-loaded terminals in both the power and
control circuits. In addition to reducing assembly time, these
spring-loaded terminals provide gas-tight connections resistant
to shock and vibration.

While spring-loaded terminals are desired by many customers,

some customers prefer screw terminals. In addition, customers
purchasing components for railway and oil and gas applications
often require ring lug terminals. As a result, many SIRIUS
Innovations components are available with any of these three
terminal types.

SIRIUS contactor with SIRIUS contactor with

screw terminals SIRIUS contactor with ring lug terminals
spring-loaded terminals

55
Easy Assembly The SIRIUS modular system is a flexible system of electrically
and mechanically matched components that can be easily
assembled to create load feeders. In addition, pre-assembled
load feeders are also available.

For example, the following graphic shows SIRIUS components

being assembled using the 3RV29 infeed system. Both the
3RV29 infeed system and 3RA6 infeed system (shown later) are
available with either screw or spring-loaded terminals.

1 3-phase busbar with infeed 4 End cover

2 3-phase busbar for system expansion 5 Plug-in connector
3a Expansion plug 6 Contactor base
3b Extra-wide expansion plug 7 Terminal block

To further simplify assembly, Siemens also offers SIRIUS 3RA2

pre-assembled starters (with screw terminals only) and SIRIUS
3RA6 compact starters.

56
Fast Bus Multi-Motor Additional approaches applicable for control panels include
Control System busbar adapters for use with Siemens Fast Bus Multi-Motor
Control System.

Fast Bus is a three-phase, insulated busbar system that

reduces wire connections and hole drilling when building
control panels.

Fast Bus is not new to Siemens, but due to the narrow

dimensions of SIRIUS components, more starters can fit
on the same run of Fast Bus. Components are available for
busbar center-line spacings of 60 mm.

60 mm Busbar Adapter 60 mm Busbar Adapter

for Screw Terminals for Spring-loaded Terminals

Motor Starter Protector

Size S00/S0
Screw Terminals
Motor Starter Protector
Size S00/S0
Spring-loaded Terminals

Link Module

Link Module

Contactor
Size S00/S0
Screw Terminals
Contactor Size S00/S0
Spring-loaded Terminals

Fast Bus Multi-Motor Control System

In addition to assembly systems for use in control panels,

SIRIUS communication options make distributed control
easier to implement as well.

57
SIRIUS Contactors for The SIRIUS modular system includes a wide range of power
Motor Loads contactors in sizes S00 to S12 for switching motors. In addition
to 3-pole standard contactors, vacuum contactors, coupling
relays for optimal interfacing with the outputs of controllers,
various 4-pole power relays and miniature contactors are also
available.

3RT2 contactors are part of the SIRIUS Innovations addition

to the SIRIUS modular system and are available in sizes S00
and S0. In addition to being used in full-voltage, non-reversing
starters, they can be easily configured for use in reversing or
wye-delta starters.
S12
S10
S6
S3
S0 S2
S00

3RT Size S00 Contactor

3RT Size S0 Contactor

Auxiliary contacts can be side mounted on all contactors or

a front-mounted contact block can be used. Communication
function modules are also available for use with 3RT2 S0 and
S00 contactors.

In addition to AC and DC powered versions, an electronic

UC coil version of the 3RT2 S0 contactor is available. The
UC contactor version can be controlled using either AC or
DC voltage with much lower power consumption. 3RT2 S0
contactors also have a number of features that make wiring
simpler and neater. In addition to the optional communication
function modules, this includes front coil terminals, two
integrated auxiliary contacts (one normally open and one
normally closed), and a control wiring duct door for routing of
control wires or inserting surge protection accessories.

58
S00 and S0 Contactor Plug-in function modules are available for selected versions
Function Modules of 3RT2 contactors to reduce the control circuit wiring when
assembling full-voltage, non-reversing; full-voltage, reversing;
and wye-delta starters.

Function modules for full-voltage, non-reversing starters support

time-delayed opening/closing of the contactor. Mechanical
and electrical interlocking is integrated for a reversing starter
assembly. For a wye-delta assembly, use of function modules
instead of complex wiring results in a 70 percent reduction in
wiring in the control circuit and a smaller footprint because the
timing relay and the coil protection circuit are integrated.

These function modules with starter functions are also available

with connections for AS-Interface or IO-Link communication.
In addition to the reduction in wiring within the branches,
interfacing to PLCs is greatly simplified and fewer PLC I/O
modules are needed. This approach also facilitates plant-wide
diagnostics down to the contactor level.

These function modules can be used with either the S00 or

S0 size contactor and are available with screw-type or spring-
loaded terminals.

Function Module
3RT201 Plug-in Connections 3RT202
Size S00 Size S0
Contactor Contactor

AS-Interface IO-Link
Two-wire Cable Function Module for AS-Interface Function Module for IO-Link Three-wire Cable

Full-voltage, Full-Voltage,
Wye-Delta
Non-reversing Reversing

59
Solid State Contactors for Some applications require rapid switching of small, 3-phase
Motor Loads motors. For example, conveyor technology or palletizing
machines may require rapid motor switching to satisfy the
demands of high-speed material handling systems. In such
cases, electromechanical contactors may be either unable to
switch fast enough or unreliable for prolonged use.

SIRIUS 3RF2 solid state contactors and reversing

contactors for motor loads are designed to satisfy the
demands of these rapid switching applications. In addition, they
switch quietly and are therefore suitable for noise-sensitive
environments.

3RF2 solid state contactors and reversing contactors are

two-phase controlled with instantaneous switching. They are
embedded in an insulated housing with a width of 45 mm or 90
mm. For reversing starters, this provides a substantial reduction
in mounting width over comparable electromechanical
contactors.

3RF2 solid state contactors and reversing contactors are

available with screw type or spring loaded terminals. As part of
the SIRIUS modular system, they can be easily integrated into
motor feeders employing other SIRIUS components.

3RF2 solid state contactors for motor loads are rated up to 5.2
A in a width of 45 mm and up to 16 A in a width of 90 mm,
allowing motors up to 10 HP (7.5 kW) to be controlled. 3RF2
solid state reversing contactors with a width of 45 mm can
switch motors up to 3 HP (2.2 kW) and the 90 mm width
design can switch motors up to 4 HP (3 kW).

SIRIUS 3RF2 Solid State Contactor SIRIUS 3RF2 Solid State Reversing Contactor
for Motor Loads for Motor Loads

60
Compact Starters SIRIUS 3RA6 compact starters incorporate a motor starter
protector, contactor, electronic overload relay, and all the typical
accessories in one unit for reduced panel space, installation
cost, and a significant reduction in power dissipation.

Trip class 10 or 20 and automatic or manual reset are selectable

along with a wide range of motor current settings. Auxiliary
contacts for signaling an overload or short circuit are integrated
into the design. An end of service life indicator provides
advance warning of the need for starter replacement and
removable terminals allow for quick device changes.

Four mounting options are available: parallel wiring (DIN or

surface mounted), comb bus bar (DIN or surface mounted),
3RA6 infeed system (up to 100 A), and Fast Bus.

SIRIUS 3RA6 compact starters can be equipped for IO-Link or

AS-Interface communication.

3RA6 Infeed System Full Voltage, Full Voltage,

Non-Reversing Reversing
Starter Starter

Equipped for IO-Link

Equipped for
AS-Inteface

61
Enclosed Starters with SIRIUS M200D is an enclosed (IP65 rated) motor starter with
Communication communication capability that is ideally suited for distributed
motor control applications such as material handling or
packaging. Four models of M200D starters are available. Two
models (Basic and Standard) work with AS-Interface (AS-i). One
of the remaining models works with PROFIBUS DP and the
other works with PROFINET.

MD200D starters come in two current ranges (0.15 to 2 A

and 1.5 to 12 A) with a maximum of 7.5 HP. All models include
a lockable manual disconnect, short-circuit and overload
protection, and connections for a thermistor to sense motor
temperature.

Optional selections include mechanical or electronic switching,

full-voltage non-reversing or reversing operation, and with or
without local control. The electronic switching versions of all
models, except AS-Interface Basic, are available with soft starter
functionality.
M200D AS-i Basic M200D AS-i Standard M200D PROFIBUS M200D PROFINET
Model Model Model Model

Lockable, Manual Disconnect

3-Position Keyswitch
(Automatic, Off/Reset, Manual)

Keypad for Manual Control

Power Infeed Connections Motor Connections

(Line, Brake, Thermistor)

SIRIUS Soft Starters Solid state, reduced-voltage starters, often called soft
starters, limit motor starting current and torque by ramping up
the voltage applied to the motor during the selectable starting
time. Soft starters accomplish this by gradually increasing
the portion of the power supply cycle applied to the motor
windings, a process sometimes referred to as phase control.

Once the start up has completed, SIRIUS soft starters use

integrated bypass contacts to bypass power switching devices
(thyristors). This improves efficiency, minimizes heat, and
reduces stress on these switching devices.
62
 Some soft starters (such as SIRIUS 3RW40 and 3RW44)
also allow the phase control process to be applied in reverse
when the motor is being stopped. This controlled starting and
stopping significantly reduces stress on connected devices and
minimizes line voltage fluctuations.

The SIRIUS modular system includes SIRIUS 3RW30 and

3RW40 soft starters for standard applications and SIRIUS
3RW44 soft starters for high feature applications.

SIRIUS 3RW30 and 3RW40 SIRIUS 3RW30 soft starters have an especially compact design
Soft Starters that saves space and easily integrates with other SIRIUS
components. 3RW30 soft starters are available for supply
voltages up to 480 VAC and operating current up to 106 A at
o
40  C. Potentiometers on the front of the unit provide settings
for ramp-up time and starting voltage.

SIRIUS 3RW40 soft starters have all the advantages of 3RW30

soft starters, but have more features and are available for
o
operating current up to 432 A at 40 C. Features include:
selectable motor overload protection (Class 10, 15, 20), manual
or remote reset, and optional thermistor motor protection.
3RW40 soft starters are also equipped with integrated intrinsic
device protection to prevent thermal overloading of the power
switching devices (thyristors). Potentiometers on the front of
the unit provide settings for current limit, starting voltage, and
ramp-up and ramp-down times.

3RW30 Soft Starters

3RW40 Soft Starters

SIRIUS 3RW44 Soft Starters SIRIUS 3RW44 soft starters make soft starting and stopping
attractive for demanding applications and combine a high
degree of functionality and extensive diagnostics. 3RW44 soft
o
starters are available for operating current up to 1214 A at 40 C.
63
 A backlit display with 4-key operation simplifies the process
of changing parameters. An RS-232 serial interface is provided
to communicate with the Soft Starter ES software for easy
configuration or a display for external operation and monitoring.

Additional features include, but are not limited to:

• Motor overload and thermistor protection
• Selectable current limiting
• Multiple starting and stopping/braking modes
• Intrinsic device protection for thyristors
• Optional PROFIBUS DP communication

3RW44 Soft Starters

PROFIBUS DP and Over time, a number of networks have been developed for use
AS-Interface in industrial applications. Some of these networks, like
Industrial Ethernet or PROFINET, are intended for higher
level communication, and others are designed for control
applications. A network intended to interconnect distributed
control devices is often referred to as a field bus.

Field buses, like PROFIBUS DP and Actuator-Sensor

Interface (AS-Interface or AS-i), provide efficient
communication enabling the use of distributed intelligence.

PROFIBUS DP is an open network that has been adopted by

many equipment suppliers. With regard to Siemens products,
PROFIBUS DP is used internal to a tiastar Smart MCC and
is also used to link many products and systems such as
SIMOCODE pro C and V motor management systems, SIRIUS
3RW44 soft starters, and SIMATIC PLCs.

AS-Interface is an open, low-cost network endorsed by the AS-

International Association that simplifies the interconnection of
actuators and sensors with controllers. AS-Interface replaces
the complex wiring and proprietary interfaces often used for
this interconnection with only two wires which transfer both
data and power.
64
 Industrial Ethernet

SIRIUS SIMATIC S7 PLC

SIMOCODE pro 3RW44
Basic Unit Soft Starter AC Drive PROFIBUS DP

DP/AS-i
Link

SIMATIC SIMATIC S7
HMI PLC

AS-Interface
AC Motors

Starters

tiastar Smart MCC I/O

AC Motors

AS-Interface and IO-Link AS-Interface allows actuators and sensors distributed

throughout a system to communicate with an AS-i master, and
through the master to other devices or networks. Each section
of an AS-i bus includes the AS-i master, an AS-i power supply
and up to 62 slave devices over a 100 meter, two-wire cable.
The length of the cable can be extended to 200 meters with an
extension plug or repeater and up to a maximum of 600 meters
with two repeaters and an extension plug.

In contrast, IO-Link is a newer, open communication standard

developed by the IO-Link research group of the PROFIBUS
& PROFINET International organization in response to the
need for a simple, low-cost way to allow actuator and sensor
communication in a more concentrated area, such for a control
panel or individual machine.

65
 IO-Link is a point-to-point system, not a field bus. It uses
a three-wire cable, 24 VDC power supply, and an IO-Link
master. Up to 16 devices per master are allowed, depending
on the number of ports on the master. The maximum distance
between the master and an actuator or sensor is 20 meters. An
IO-Link master, such as the SIRIUS 4SI electronic module for
SIMATIC ET 200S, allows IO-Link devices to be incorporated
into a PLC control scheme with communication to higher level
networks.

Siemens extensive array of IO-Link compatible devices,

combined with the low cost and ease of application for IO-Link,
makes more extensive actuator-sensor communication practical
and drives down the life-cycle costs for machines and systems
implemented using IO-Link.

SIMATIC S7 PLC

PROFIBUS DP

DP/AS-I Link ET200S with

IO-Link Master
AS-Interface IO-Link Cables to
Actuators and Sensors

66
Review 6
1. SIRIUS motor starter components are available in sizes
S00, S0, S2, S3, S6, ________ and ________.

2. SIRIUS Innovations additions to the SIRIUS modular

system include a complete redesign of _______ and
________ components.

3. SIRIUS 3RT2 contactor function modules are

available with connections for ________ and ________
communication.

4. SIRIUS ________ incorporate a motor starter protector,

contactor, electronic overload relay in one unit.

5. SIRIUS ________ is an enclosed motor starter with

communication capability.

6. The SIRIUS modular system includes ________ and

________ soft starters for standard applications and
________ soft starters for high feature applications.

7. Field buses like ________ and _________ provide

efficient communication enabling the use of distributed
intelligence.

8. ________ is a point-to-point system that provides a

simple, low-cost way to allow actuator and sensor
communication for a machine or control panel.

67
 Lighting and Heating Contactors

Electrically Held Contactors Most commercial lighting and heating applications require the
use of a contactor to control the loads. One type of contactor
used in these applications is an electrically held contactor,
which is similar to the contactor used with a magnetic motor
starter. Unlike a starter contactor, however, the lighting and
heating contactor is designed for lighting and resistive heating
loads rather than motor loads.

Siemens Class LE lighting and heating contactors are

available with 2 to 12 poles and current ratings from 20 to 400
amps. They can be used with 480 VAC tungsten and 600 VAC
ballast-type lighting loads as well as 600 VAC resistive loads.
Combination and non-combination enclosures are also available.

Electrically held lighting and heating contactors have the same

operating principles as the magnetic contactors covered earlier
in this course. Therefore, the control circuit for an electrically
held lighting and heating contactor is similar to the start-stop
circuit for a motor starter. Because the contacts of this type
of contactor are electrically held, these contacts open when
control power is lost.

L1 ON L2
OFF
(2) (3)
M
A1 A2
M

Typical Control Circuit for an

Electrically Held Lighting Contactor
68
 Electrically held contactors are typically used in applications
where noise is not an issue. These contactors have an inherent
hum when current is supplied to the coil to hold the contacts
closed. As a result, this type of contactor is not recommended
where the humming can be heard and will disturb building
occupants such as in libraries, hospitals, and some commercial
buildings.

Magnetically Held and Magnetically held and mechanically latched contactors are
Mechanically Latched also designed for lighting and resistive heating loads. Siemens
Contactors Class CLM lighting and heating contactors are available with 2
to 12 poles and current ratings from 20 to 400 amps. They can
be used on 480 VAC tungsten, 600 VAC ballast, and general
type lighting and resistive heating loads.

A magnetically held contactor contains a permanent magnet.

When the contactor is energized, current through a coil creates
a magnetic field that reinforces the permanent magnet and
closes the contacts. Current through the coil is then interrupted
and the contacts are held closed by the permanent magnet
even if control power is lost. Contacts are opened magnetically
when an OFF coil is energized.

A mechanically latched contactor has contacts that are

mechanically latched closed when the contactor is energized
and remain latched until a trip solenoid receives a signal to
release the mechanical latch.

Magnetically held and mechanically latched contactors are

typically used where noise is a concern or where it is desired to
maintain closed contacts when power is lost so that current will
be immediately provided when power resumes.

69
 Pilot Devices

A pilot device directs the operation of another device or

indicates the status of an operating machine or system.
Siemens pilot devices are available with a variety of features
and mounting dimensions and include product selections
appropriate for a broad range of applications. The following
product families are available. The mounting diameter refers to
the size of the knockout hole (in millimeters) required to mount
the devices.

• 3SB2 devices with 16 mm mounting diameters

• 3SB3 devices with 22 mm mounting diameters
• 3SF5 stations for the integration of 3SB3 devices in
AS‑Interface enclosures
• Class 52 devices with 30 mm mounting diameters are
heavy duty products that are oil tight and designed for
harsh, industrial environments
• Class 52 heavy duty pushbutton enclosures for use
with Class 52 devices
• Class 51 devices for use where the presence of
flammable gases, vapors, or finely pulverized dust create
the threat of explosion or fire
• Class 50 standard duty pushbutton stations for use
with magnetic controllers to start, stop, reverse, or adjust
the speed of applicable motors

The following paragraphs provide basic application information

for some of the types of devices listed above.

Pushbuttons A pushbutton is a control device used to manually open and

close a set of contacts. Pushbuttons may be illuminated or non-
illuminated, and are available in a variety of configurations and
actuator colors.

16 mm 3SB2 22 mm SIGNUM 30 mm Class 52

Pushbutton 3SB3 Pushbutton Pushbutton

70
Normally Open Pushbuttons are used in control circuits to perform various
Pushbuttons functions, for example, starting and stopping a motor. A typical
pushbutton uses an operating plunger, a return spring, and one
set of contacts.

The following drawing illustrates a normally open (NO)

pushbutton, so called because the contacts are open unless
the button is pressed. Pressing the button causes the contacts
to close. When the button is released, the spring returns the
plunger to the open position.

Plunger
Contacts
Spring

Control Circuit Control Circuit

Normally Closed Normally closed (NC) pushbuttons, such as the one shown
Pushbuttons in the following illustration, are also used to open and close
a circuit. In the normal position, the contacts are closed and
current can flow through them. Pressing the button opens the
contacts, preventing current flow through the circuit.

Plunger
Contacts

Spring

Control Circuit Control Circuit

The pushbuttons just described are momentary contact

pushbuttons because their contacts remain in their activated
state only as long as the button is pressed. Pushbuttons with
contacts that remain in their activated state after the button is
released are called maintained contact pushbuttons.

71
 Pushbuttons are available with various contact configurations.
For example, a pushbutton may have one set of normally
open and one set of normally closed contacts so that, when
the button is pressed, one set of contacts open and the
other set is closes. In this example, the pushbutton can be
wired to function as either a normally open or normally closed
pushbutton.

Using Pushbuttons in a The following line diagram shows an example of how a

Control Circuit normally open and a normally closed pushbutton might be used
in a control circuit.

Momentarily pressing the Start pushbutton completes

the path of current flow and energizes the M contactor’s
electromagnetic coil.

Three-Wire Control Pressing the Start pushbutton closes the M and Ma contacts.
When the Start pushbutton is released, auxiliary contacts
Ma function as a holding circuit supplying power to the M
electromagnetic coil. The motor will run until the normally
closed Stop pushbutton is pressed, breaking the path of current
flow to the M electromagnetic coil and opening the M and Ma
contacts.

72
 This is referred to as three-wire control because three wires
are required to connect the Start and Stop pushbuttons and the
holding circuit (Ma). An advantage of three-wire control that the
motor will not automatically restart after an overload. When an
overload causes the OL contacts in the control circuit to open,
the M coil de-energizes and the motor shuts down. When the
overload is cleared, an operator must depress the Start button
to restart the motor.

This circuit also has low voltage protection because if

control power is lost, it will shut down the motor and will not
automatically restart the motor when control power is regained.

Two-Wire Control Contrast this operation with that of a two-wire control circuit,
so called because the Start/Stop switch requires only two
wires to connect it into the circuit. This circuit provides low-
voltage release, but not low-voltage protection. Low-voltage
release means that in the event of a loss of control power, the
contactor de-energizes, stopping the motor. However, when
control power is restored, the motor will restart immediately if
the control device is still closed.
M OL T1
L1
M OL T2
L2 Motor
M OL T3
L3

OL
Start/Stop
M

This type of control scheme is used for remote or inaccessible

installations where it is often desirable to have an immediate
return to service when power is restored.

73
Selector Switches Selector switches are also used to manually open and close
contacts. Selector switches can be maintained, spring return,
or key operated and are available in two, three, and four-
position types.

The basic difference between a pushbutton and a selector

switch is the operator mechanism. With a selector switch, the
operator is rotated to open and close contacts. Contact blocks
used on pushbuttons are often interchangeable with those used
on selector switches of the same type.

Selector switches are used to select one of two or more circuit

possibilities, for example, stop and run or stop, low speed, and
high speed.

16 mm 3SB2 22 mm SIGNUM 30 mm Class 52

Selector Switch 3SB3 Selector Switch Selector Switch

Two-Position Selector In the following example, pilot light PL1 is on when the
Switch switch is in position 1, and pilot light PL2 is on when the switch
is in position 2. This is only part of a control circuit for a machine
and the status of the pilot lights could be used to indicate either
of two machine conditions, for example, stop and run.
L1 L2
1 2

PL1

PL2

Contact Truth Tables There are two accepted methods for indicating contact
positions of a selector switch. The first method, shown in the
previous example, uses solid and dashed lines to show contact
positions.

The second method uses a truth table, also known as a target

table, which uses a letter to represent each contact position.
An X in the truth table indicates which contacts are closed for a
given switch position.

74
 In the example below, the switch is in position 1, contact A is
closed and pilot light PL1 is on. When the switch is in position
2, contact B is closed and pilot light PL2 is on.

L1 L2
1 2
Selector Switch Contacts
A PL1
Position A B
1 X
B PL2 2 X

Three-Position Selector A three-position selector switch is used to select any of three

Switch contact positions. For example, the following diagram shows a
Hand/Off/Auto control circuit for a pump motor.

In the Hand (manual) position, the pump starts when the Start
pushbutton is pressed. The pump is stopped by switching to
the Off position. The liquid level switch has no effect until the
selector switch is set to Auto. Then, the pump is controlled by
the liquid-level switch. The liquid level switch closes when the
fluid rises to a preset level, starting the pump. When the fluid
drops to a lower preset level, the liquid level switch opens,
stopping the pump.
L1 L2
Off
Hand Auto Start
OL
Selector Switch Contacts
A
M1 Position A B C
1 X
B
2 X
C 3 X

Liquid Level

Indicator Lights Indicator lights, also referred to as pilot lights, provide a

visual indication of a circuit’s operating condition, for example,
on, off, or alarm.

16 mm 3SB2 22 mm 3SB3 30 mm Class 52

Indicator Light Indicator Light Indicator Light

Indicator lights are available with a variety of lens colors to

allow for a quick visual indication of machine or process status.
Siemens indicator lights are available with a red, green, amber,
blue, white, or clear lens.

75
 As shown in the following illustration, a red indicator light often
indicates that a system is running and a green indicator light
often indicates that a system is off.

Red Indicator Light is On

Motor is Running
Green Indicator Light is On
Motor is Stopped

Using an Indicator Light In the following diagram, when the motor is stopped, the
in a Control Circuit normally closed Mb contact is closed, and the green (G) light is
on.

L1 L2
Start
Stop OL

M
Ma

R
Mb

OL
A

When the coil is energized, the red (R) light is on to indicate that
the motor is running. In addition, the Mb contact is now open,
and the green light is off. Note that the indicator light is wired
in parallel with the coil so that the motor will turn on even if the
indicator light burns out.

L1 L2
Start
Stop OL

M
Ma

R
Mb

OL
A

76
 If an overload occurs, the normally closed OL contact opens,
stopping the motor and turning off the red light, the Mb contact
closes, turning on the green light, and the normally open OL
contact closes, turning on the amber (A) light.

L1 L2
Start
Stop OL

M
Ma

R
Mb

OL
A

Signaling Columns and Signaling columns allow operating personnel to monitor

Lamps machine or process operation from a distance. Columns are
easily assembled by stacking elements to achieve the desired
configuration. Various visual elements are available to provide
steady, flashing, and rotating beacon indications in five colors:
red, yellow, green, white, and blue. Buzzer or siren elements
can be added to provide audible indications of machine or
process conditions.

SIRIUS 8WD4 signaling columns are available with either a

50 mm or 70 mm mounting diameter and can be networked to
other devices through an optional AS-Interface adapter.

SIRIUS 8WD5 integrated signal lamps have a 70 mm

mounting diameter and can be directly attached to a machine.
They are available with red, yellow, green, blue or clear lenses
and with incandescent filaments or LEDs.

8WD5
Integrated Signal Lamps
8WD4
Signaling Column

77
Review 7
1. ________ lighting and heating contactors are best used
in applications where noise is not an issue.

2. Once their contacts are closed, ________ and ________

lighting and heating contactors keep their contacts
closed even if control power is lost.

3. A ________ device directs the operation of another

device or indicates the status of an operating system.

4. Siemens 3SB3 pushbuttons, selector switches, and

indicator lights have a ________ mm mounting diameter.

5. Siemens indicator lights are available with the following

lenses: red, green, amber, ________, ________, and
________.

6. SIRIUS 8WD4 signaling columns are available with

either a ________ or ________ mounting diameter and
can be networked to other devices through an optional
________ adapter.

7. SIRIUS 8WD5 ________ have a 70 mm mounting

diameter and can be directly attached to a machine.

78
Limit Switches

Limit switches are part of an assortment of position switches

used to mechanically detect the position of an object. Each
limit switch has an operating head with a lever arm or plunger
mechanism and a switch body that includes contacts.

When an object moves the lever arm or depresses the plunger,

contacts in the limit switch change state (open to closed or
vice versa). This contact state change is typically used to signal
another device or system to respond.

Siemens offers a variety of limit switches and accessories

including 3SE03 North American limit switches, designed to
NEMA specifications, and SIRIUS 3SE2, 3SE3, and 3SE5 limit
switches, designed to IEC specifications. SIRIUS 3SE5 limit
switches are part of the SIRIUS system of Safety Integrated
products discussed later in this course.

SIRIUS 3SE5 Limit Switches

79
Control Transformers

The voltage applied to the main terminals of an industrial motor

is frequently higher than the voltage needed by a control circuit.
In such cases, a control power transformer (CPT) is used to
step down the voltage. Siemens Class MT and Class MTG
control power transformers are available for a variety of
primary and secondary voltages with apparent power ratings
from 25 VA to 5 kVA.

In the following example, the voltage on the primary of the

CPT is 460 VAC. This voltage is stepped down to 24 VAC for
use in the control circuit. Fuses connected to the CPT primary
and secondary windings provide overcurrent protection for the
transformer.

80
 Protection Devices and Terminal Blocks

5SX, 5SY, and 5SP Siemens UL 1077 supplementary protectors are designed to
Supplementary Protectors trip faster than standard UL 489 circuit breakers providing
additional protection for more sensitive devices. In addition
to providing supplementary branch circuit protection,
supplementary protectors may also be used as a local
disconnect means inside a panel when a branch circuit
protection device is already present.

Siemens supplementary protectors are equipped with a thermal

bimetallic trip mechanism for low-current overloads and an
instantaneous electromagnetic trip for high-current overloads
and short circuits. Single-pole and multiple-pole varieties are
available with mounting depths of 55 or 70 mm.

Supplementary Protector (70 mm)

5SJ4 Miniature IEC style miniature circuit breakers (MCBs), according to

Circuit Breakers EN/IEC 60 898, are not always permitted in North America.
For this reason, MCBs were developed that are based on the
miniature circuit breakers of the 5SY series, but designed to
meet the special requirements of UL 489.

For areas influenced by NEMA (National Electrical

Manufacturers Association) and ANSI (American National
Standards Institute), MCBs are certified as a solution for
protective applications and can be used for branch circuit
protection in the branches of control panels and systems.

81
 MCB connection terminals are designed for the class: “Field
wiring”. This means that, as well as being installed in a factory,
these MCBs can be installed locally at customer sites. In
addition to the permissible tripping ranges according to UL 489,
device tripping characteristics C and D of EN/IEC 60 898 also
apply. Therefore, these MCBs comply with both standards.

5SJ4 Miniature Circuit Breaker

Terminal Blocks Siemens terminal blocks simplify the wiring of machines

and system controls and incorporate screw, spring loaded,
or insulation displacement connections that meet or exceed
the requirements of CSA, IEC, NEMA, UL, VDE and other
international standards. Meeting these requirements, combined
with worldwide acceptability and availability, enables Siemens
terminal blocks to be used domestically and incorporated into
equipment intended for export.

Virtually all terminal block bodies are insulated on both sides,

eliminating the need for barriers and end plates. The materials
used are free of cadmium, halogens, or silicone. Except for bare
terminals and solder connections, the terminals are finger-touch
safe to IEC 60529 and EN 50274. Siemens terminal block lines
include the following five connection types.

• 8WA1 terminals with screw connection

• 8WH2 terminals with spring loaded connection
• 8WH3 terminals with IDC connection
• 8WH4 terminals with push-in connection
• 8WH5 terminals with combi-plug connection

82
 Control Relays

Control relays are widely used for switching multiple control

circuits and to control light loads such as starting coils, indicator
lights, and audible alarms.

Relay Operation The operation of a control relay is similar to a contactor. In

the following illustration, a relay with a set of normally open
(NO) contacts is shown. When power is applied to the control
circuit, the relay’s coil (electromagnet) energizes, which then
magnetically pulls the armature and movable contacts to the
closed position. When power is removed the magnetic field
is lost and spring tension pushes the armature and movable
contacts to the open position.

Contact Arrangement A control relay usually has multiple normally open or normally
closed contacts or both. The main difference between a control
relay and a power relay or contactor is the size and number
of contacts. The contacts in a control relay are relatively small
because they need to handle only the small currents used in
control circuits. The small size of control relay contacts allows a
control relay to contain multiple isolated contacts.

The use of contacts in relays can be complex. There are three

key terms that describe the operation of these contacts, pole,
throw, and make.

83
Pole A control relay’s pole number is the number of isolated circuits
that can pass through the relay. This is the total number of
circuits that can be controlled by the relay. Control relays often
have multiple poles, but they need not all be used.
Circuit 1 Circuit 1

Single Pole Double Pole

Circuit 2

Throw A control relay’s throw number is the number of closed-contact

positions per pole.
Circuit 1

Circuit 1 Circuit 2
Single Throw Double Throw

The following abbreviations are frequently used to indicate

contact configurations: SPST (single pole, single throw),
SPDT (single pole, double throw), DPST (double pole, single
throw), and DPDT (double pole, double throw).

Break A control relay contact break number is the number of separate

contacts that open or close a circuit.

Single Break Double Break

The following diagram illustrates various contact arrangements.

Single Pole Double Pole Single Pole Double Pole

Single Throw Single Throw Single Throw Single Throw
Single Break Single Break Double Break Double Break

Single Pole Double Pole Single Pole Double Pole

Double Throw Double Throw Double Throw Double Throw
Single Break Single Break Double Break Double Break

84
Interposing a Relay The following line diagram illustrates one way that a control
relay can be used in a 24 VAC control circuit. In this example,
the 24 VAC coil is not strong enough to operate a large starter
(M) that is rated for 460 VAC. This type of arrangement is called
interposing a relay.

When the Start pushbutton is momentarily pressed, power is

supplied to the control relay (CR), and the CR contacts in lines
1 and 2 close. The M motor starter energizes and closes the M
contacts in the power circuit, starting the motor. Pressing the
Stop pushbutton de-energizes the CR relay and M motor starter.

85
SIRIUS 3RH Control Relays The SIRIUS modular system includes a complete line of control
relays. For example, SIRIUS 3RH control relays and latching
control relays are available with screw or spring-loaded
terminals.

Four contacts are available in the basic device. A contact block

with up to four additional contacts can be added to increase the
number of contacts.

Units are available for control supply voltages from 12 to 230

VDC and from 24 to 600 VAC.

3RH latching control relays have two coils, a relay coil and a
release coil, that are rated for continuous duty operation.

Control Relay

Contact Block

SIRIUS 3RH2 Control Relay

86
 Solid-State Relays and Contactors

Conventional electromechanical switching devices are

unsuitable for applications requiring high switching frequencies
due to the wear on mechanical components. In addition,
electromechanical switching devices are inherently noisy and,
as a result, unsuitable for use in noise-sensitive areas.

In addition to the SIRIUS 3RF2 contactors for motor loads

discussed earlier in this course, Siemens also developed SIRIUS
3RF2 solid state relays and contactors for use with other types
of loads. Versions are available for resistive loads, such as
injection molding heater elements, or inductive loads, such as
control valves. In addition to industrial applications, the quiet
switching characteristics of these devices makes them suitable
for use in commercial facilities.

SIRIUS Solid-State Relays SIRIUS 3RF2 solid state relays can be mounted on existing
cooling surfaces. 3RF21 single-phase, solid state relays are
22.5 mm wide and 3RF20 single-phase and 3RF22 three-
phase, solid state relays are 45 mm wide.

SIRIUS Solid-State SIRIUS 3RF23 single-phase, solid state contactors and

Contactors 3RF24 three-phase, solid state contactors incorporate a solid
state relay in an optimized heat sink to form a ready-to-use
device with defined current ratings.

3RF20 3RF21 3RF23 3RF22 3RF24

1-Phase 1-Phase 1-Phase 3-Phase 3-Phase
Solid State Solid State Solid State Solid State Solid State
Relay Relay Contactor Relay Contactor
(45 mm) (22.5 mm) (45 mm)

87
SIRIUS 3RF29 Function Many solid state switching applications require extended
Modules functionality that can be accommodated by using the following
SIRIUS 3RF29 function modules together with SIRIUS 3RF2
relays or contactors.

Converter – The module is used with single-phase and three-

phase 3RF2 relays and contactors. This module converts an
analog control signal to a pulse-width modulated digital signal.
This allows a SIRIUS 3RF2 solid state relay or contactor to
adjust power to a load based on an analog signal from a device
such as a temperature controller.

Heating current monitoring module – This module is for use

with single-phase 3RF2 relays and contactors used in heating
applications. This module detects a variety of faults, including
failure of load elements, and provides a fault indication by LEDs
and a normally-closed relay contact.

Load monitoring module – This module is for use with single-

phase 3RF2 relays and contactors. This module detects a
variety of faults, including failure of load elements, and provides
an LED fault indication and a PLC-compatible fault signal.

Power controller – This module is for use with single-phase

3RF2 relays and contactors for power control of complex
heating systems and for operating inductive loads. This
module combines load circuit monitoring capability and inrush
current limitation with proportional control of the power to the
connected loads.

Power regulator – This module is for use with single-phase

3RF2 relays and contactors for power control of complex
heating systems and inductive loads. It combines load circuit
monitoring and inrush current limitation with the ability to adjust
power to the connected loads.

Heating Current Load Current

Converter Power Controller Power Regulator
Monitoring Module Monitoring Module

88
 Timing Relays and Function Modules

A timing relay is a device that does either on-delay timing

or off-delay timing to delay some control response by a
predetermined time.

Time Delay Time delay contacts have an arrow pointing up to indicates an

on-delay timing action or an arrow pointing down to indicate
an off-delay timing action.

On Delay Off Delay

Arrow Points Up Arrow Points Down

On-delay and off-delay timers can turn their connected loads on

or off, depending on how the timer’s output is wired into the
circuit. The term “on delay” indicates that a preset time must
pass after the timer receives a signal to turn on before the
timer’s contacts change state. The term “off delay” indicates
that a preset time must pass after the timer receives a signal to
turn off before the timer’s contacts change state.

On-Delay, Timed Closed The following illustration shows an example of an on-delay,

Timer timed closed timer, also called a normally open, timed
closed (NOTC) timer. In this example, The timing relay (TR1)
has been set for an on delay of 5 seconds.

89
 When S1 closes, timer TR1 begins timing. After 5 seconds, TR1
contacts close, and pilot light PL1 turns on. When S1 opens,
timer TR1 de-energizes, and TR1 contacts open immediately,
turning off pilot light PL1.

On-Delay, Timed Open The following illustration shows an example of an on-delay,

Timer timed open timer, also called a normally closed, timed open
(NCTO) timer. The timing relay (TR1) has been set for an on
delay of 5 seconds.

When S1 closes, timer TR1 energizes. After 5 seconds, TR1

contacts open, and pilot light PL1 turns off. When S1 opens,
timer TR1 de-energizes, and TR1, contacts close immediately,
turning on pilot light PL1.

Off-Delay, Timed Open The following illustrations show an example of an off-delay,

timed open timer, also called a normally open, timed open
(NOTO) timer. The timing relay (TR1) has been set for an off
delay of 5 seconds.

90
 When S1 closes, TR1 contacts close immediately, and pilot light
PL1 turns on.

When S1 opens, timer TR1 begins timing. After 5 seconds, TR1

TR1 contacts open, and pilot light PL1 turns off.

Off-Delay, Timed Closed The following illustration shows an example of an off-delay,

timed closed timer, also called a normally closed, timed
closed (NCTC) timer. The timing relay (TR1) has been set for 5
seconds. When S1 closes, TR1 contacts open immediately, and
pilot light PL1 turns off.

When S1 opens, timer TR1 begins timing. After 5 seconds,

timer TR1 contacts close, and pilot light PL1 turns on.

91
Instantaneous Contacts Timing relays can also have normally open or normally
closed instantaneous contacts. In the following example,
when switch S1 closes, TR1 instantaneous contacts close
immediately, and pilot light PL1 turns on. After a preset time
delay, TR1 timing contacts close, and pilot light PL2 turns on.

The SIRIUS modular system includes timing relays as well as

timing relay function modules for use with SIRIUS contactors.

SIRIUS 3RP electronic timing relays have a compact design that

makes them well suited for use in industrial control cabinets.
They are optionally available with removable screw-type or
spring-loaded terminals.

SIRIUS function modules can be easily plugged onto SIRIUS

3RT contactors. Single-contactor function modules make it easy
to implement on-delay or off-delay timing. Wye-delta function
modules include all the necessary timing and interlocking
capabilities for wye-delta starters.

Timing Relay Function Module

(For use with 3RT2 S00 or S0 Contactors)

3RP15 3RP20
Timing Relay Timing Relay
(22.5 mm) (45 mm)

Function Module for Wye-Delta Starter

(for use with 3RT2 S00 or S0 contactors)

92
 Monitoring Relays

Monitoring relays reduce machine and plant downtime

by monitoring electrical and mechanical quantities and fault
conditions and providing appropriate diagnostic indications.

The SIRIUS modular system includes a variety of monitoring

relays in addition to the 3RR current monitoring relays
discussed earlier in this course. Examples of additional
functions performed by various monitoring relays include:

• Filling level monitoring

• Insulation resistance monitoring
• Line monitoring for phase sequence, phase failure,
phase asymmetry, undervoltage, and overvoltage
• Motor speed monitoring
• Power factor monitoring
• Residual current (ground fault) monitoring
• Single-phase current monitoring
• Single-phase voltage monitoring
• Temperature monitoring
• Thermistor motor protection

The following illustration shows a few of the various types of

monitoring relays available.

3RR 3UG4 3RN1 3RS1

Current Monitoring Voltage Thermistor Temperature
Relays Monitoring Motor Protection Monitoring
Relay Relay Relays

93
Interface Converters

Analog sensors and actuators may have different voltage or

current ranges than the control system inputs or outputs they
interface with. In addition, it is often necessary for signals
to travel long distances through electrically noisy industrial
environments. As a result, interface converters are frequently
needed to electrically isolate and convert analog signals. These
converters can also provide short circuit protection for a control
system output.

Control System
Analog 3RS17 3RS17 Analog
Input Output
Sensor Converter Converter Actuator

SIRIUS 3RS17 interface converters are available in both

active and passive types and for single or multiple signal lines.
Active converters support complete voltage isolation as well
as conversion of one signal type to another. Passive converters
do not require an electrical supply voltage and are used with
analog currents that do not require conversion.

SIRIUS 3RS17 Interface Converters

94
LOGO! Programmable Relays

Siemens LOGO! is a modular programmable relay system

used to perform basic control tasks that are otherwise often
handled using hard-wired control relays and other devices.

A LOGO! system can be assembled using a LOGO! Basic

module (shown below) with a built-in text display or a
LOGO! Pure module without a built-in display. Either module
offers an instruction set that includes eight basic functions and
31 special functions. LOGO! Soft Comfort software simplifies
development of logic which can include ladder logic and
function blocks.

Power Supply Terminals

Input Terminals

AC/DC 115...240V Input 8xAC/DC

Module Slot with Cap

Display

Operator Controls

6ED1 052-1FB00-0BA3

Output 4xRelay/10A

Output Terminals

LOGO! Basic and LOGO! Pure versions are available for use
with the following supply and input voltages: 12/24 VDC,
24 VDC, 24 VAC/DC, or 115/240 VAC/DC. All units can accept
eight discrete inputs. For 12/24 VDC or 24 VDC units, four of
these inputs are usable as 0 to 10 VDC analog inputs. All units
also have four relay-type outputs except the 24 VDC units which
have four solid-state discrete outputs.

95
 As shown in the following chart, a variety of expansion
modules are available to increase the number and types of
inputs and outputs. Including the inputs and outputs on the
controller module, LOGO! supports a maximum of 24 digital
inputs, 8 analog inputs, 16 digital outputs, and 2 analog outputs.

Expansion Module Power Supply Inputs Outputs

LOGO! DM 8 12/24R 12/24 VDC 4 discrete 4 relays (5A)
LOGO! DM 8 24 24 VDC 4 discrete 4 solid-state (24V/0.3A)
LOGO! DM 8 24R 24 VAC/DC 4 discrete 4 relays (5A)
LOGO! DM 8 230R 115-240 VAC/DC 4 discrete 4 relays (5A)
LOGO! DM 16 24 24 VDC 8 discrete 8 solid-state (24V/0.3A)
LOGO! DM 16 24R 24 VDC 8 discrete 8 relays (5A)
LOGO! DM 16 230R 115-240 VAC/DC 8 discrete 8 relays (5A)
2 analog
LOGO! AM 2 12/24 VDC 0-10 V or none
0-20 mA
2 PT100
LOGO! AM 2 PT100 12/24 VDC none
-50oC to +200oC
2 PT100 or 2PT1000
LOGO! AM 2 RTD 12/24 VDC or 1 each none
o o
-50 C to +200 C
2 analog
LOGO! AM 2 AQ 24 VDC none 0-10 V or
0/4-20 mA

Two communication modules are available. One module is for

connection to the AS-Interface, and the other module is for a
KNX/EIB connection.

LOGO! TD is a backlit, four-line LCD supporting text or numeric

displays up to 24 characters per line. The unit also supports a
built-in horizontal and vertical bar graph display feature that can
be configured to represent any numeric value in the LOGO!
controller. LOGO! TD screens are developed using the LOGO!
Soft Comfort software.

AC/DC 115...240V Input 8xAC/DC

6ED1 052-1FB00-0BA3

Output 4xRelay/10A
LOGO! TD

F1 F2 F3 F4 ESC OK

96
SIRIUS Safety Integrated

In recent years, safety has taken on an even greater importance

both as a result of changing regulations and standards and
the emergence of new technologies. As a result, Siemens
developed the Safety Integrated system which includes
products which offer comprehensive and consistent safety
solutions for factory automation and process automation.

Because Safety Integrated has been developed consistent

with Siemens Totally Integrated Automation (TIA) strategy, both
standard and safety-related components are combined in one
uniform system. This results in considerable cost savings for our
customers.

SIRIUS Safety Integrated products are part of the Siemens

Safety Integrated system of devices or systems associated with
safety-oriented industrial applications.

While it is beyond the scope of this course to cover the full

range of Siemens Safety Integrated products, the following
pages provide examples of SIRIUS Safety Integrated products
in the following categories:

• Detecting devices
• Commanding and signaling devices
• Monitoring and controlling devices and systems

97
Detecting Devices SIRIUS detecting devices perform precise detection of position
for machines and equipment in almost any application.

Included in this category of SIRIUS safety devices are 3SE2,

3SE3, 3SE5, 3SF1, and 3SF3 position switches and 3SE6
magnetically operated switches.

SIRIUS 3SE2, 3SE3, 3SE5, 3SF1, and 3SF3 position switches

include:

• Limit switches for mechanical detection of position, as

described earlier in this course
• Position switches with a separate actuator for use where
the switching element is attached to a door frame and the
actuator is attached to the door
• Position switches with tumbler for use when a locking
mechanism is required for a protective door
• Hinge switches for detecting the position of a protective
door or flap.
• 3SF1 and 3SF3 versions of the devices listed above with
an integrated AS-Interface connection.

SIRIUS 3SE6 magnetically-operated switches operate without

contact and are used to monitor protective doors. The reed
contacts in the switching element are actuated by means of a
coded switching magnet and are therefore tamper-proof.

3SE6
3SE5 Position Switches Magnetically-Operated
Switches

98
Commanding and Signaling SIRIUS commanding and signaling devices perform essential
Devices human-machine interaction tasks critical to the safe operation of
equipment.

The following device types are included in this category:

• SIRIUS 3SB2, 3SB3, and 3SB5 pushbuttons and
indicator lights
• SIRIUS 3SB3 two-hand operation consoles
• SIRIUS 3SE7 and 3SF2 cable-operated switches
• SIRIUS 3SE2 and 3SE3 foot switches
• SIRIUS 8WD4 signaling columns
• SIRIUS 8WD5 integrated signal lamps

Device types beginning with 3SF and selected other devices

have an integrated AS-Interface connection.

8WD5
Cable-Operated Switches Integrated Signal Lamps 8WD4 Signaling Column

3SB3 Pushbutton and

Indicator Lights 3SE2 Foot Switch 3SB3 Two-Hand Operation Console

99
Monitoring with Safety SIRIUS 3TK28 safety relays carry out the following safety
Relays tasks: emergency-stop (E-stop) switch off, protective door
monitoring, and motor standstill and speed monitoring. They are
available in the types described in the following paragraphs.

Sensing (Sensors) Evaluating (Safety Relay) Shutdown (Actuators)

SIRIUS safety relays with relay enable circuits featuring

positively-driven NO and NC contacts in pairs. If one of the
contacts welds, then the other contact is used to shut down
the circuit. A positively-driven feedback signal contact (NC
contact) detects the fault of the defective NO contact.

SIRIUS safety relays with electronic enabling circuits

have a compact design and can operate at considerably higher
switching frequencies and with longer service life than similar
devices with electromechanical contacts.

SIRIUS safety relay with contactor relay enable circuits

combine electronic safety functionality with two redundant
SIRIUS contactor relays assembled, wired, tested, and certified
as a unit.

SIRIUS safe standstill monitor detects when a motor has

stopped after shutdown and then permits access to restricted
areas.

SIRIUS reliable speed monitor functions as both a motor

continuous standstill monitor and a motor speed monitor.

SIRIUS 3TK28 Safety Relays

100
Modular Safety System SIRIUS 3RK3 modular safety system (MSS) combines the
functionality of safety relays with a fail-safe programmable logic
controller (PLC).

The 3RK MSS has a modular design that includes a central unit
with eight safety-related inputs, one safety-related relay output,
and one safety-related solid state output.

The input-output capability can be increased by adding up to

seven expansion modules of various types. Four module types
are available: eight safety-related inputs, four safety-related
inputs and two relay outputs, four safety-related inputs and two
solid state outputs, and eight standard outputs.

The DP interface module enables communication with higher-

level controllers via PROFIBUS DP.

The SIRIUS 3RK36 diagnostics display option can be added to

facilitate fast detection of the cause of system standstill in the
event of a fault or when a safety sensor is tripped.

Modular Safety System ES (MSS ES) parameterization software

simplifies system setup and commissioning tasks.

ASIsafe Communication As previously discussed, the Actuator-Sensor Interface is a

simple and effective networking system for the field level. It is
extremely rugged, even under the toughest of conditions. The
safety-related design of AS-Interface was standardized for all
manufacturers in the Safety at Work consortium (a sub-group
of the AS-i International Association). It is marketed by Siemens
under the copyrighted name ASIsafe.

101
 ASIsafe allows both standard and safe data to be used in one
bus system. Emergency STOP pushbuttons and a variety of
other field devices can be easily and safely connected directly
to the yellow AS-Interface cable . These devices are fully
compatible with standard AS-Interface components.

The signals from safety sensors are evaluated by a safety

monitor, which not only monitors the switching signals from
the safety sensors, but also continuously ensures that data is
transferred properly. The safety monitor is equipped with one
or two enabling circuits, which are configured with one or two
channels and are used to switch the machine or plant to safe
mode. Sensors and monitors can be connected anywhere
within the AS-Interface network. More than one monitor can
also be used in a network.

The ASIsafe system is can be used to meet a range of

communication requirements from a small, local ASIsafe
solution and to a plant-wide ASIsafe network using the DP/AS-i
F link as the transition from ASIsafe to a PROFIsafe network.

Safe AS-i outputs: The disconnection

Safety monitor: The safety monitor signal from the safety monitor can be
evaluates all safe inputs on the AS-i bus used via ASIsafe for the safety-oriented
and ensures safe disconnection. disconnection of distributed safe AS-i
Standard PLC and standard AS-i master: outputs.
Central installation at the PLC and distributed Safe input slave: Safe signals
installation using DP-AS-i Links is possible. are made available through the
safe slaves and to the safety
Safety monitor for evaluation. Safe AS-I
PLC with AS-I Master Monitor Outputs

Safe Input
Slave

AS-I
Power Supply

Standard Standard Standard

Slave Slave Slave

Basic ASIsafe Example

Signal evaluation of safe input slave/ safety monitor/
or safe disconnect signal to the safe AS-i output
AS-Interface cable
Extended ASIsafe diagnostics (through regular I/O transfer)

102
All This and More In addition to the SIRIUS Safety Integrated products
summarized in the previous pages, Siemens Safety Integrated
products include a broad range of devices and systems for
factory automation or process automation.

Multiple safety components can be interconnected using

ASIsafe or networked with PROFIsafe. PROFIsafe enables fail-
safe communication between sensors, safety control systems,
and actuators via PROFIBUS and PROFINET. Data transparency
at all levels ensures simplified commissioning, diagnostics and
maintenance. Additionally, wireless fail-safe communication via
PROFINET and IWLAN is ideal for mobile users.

103
Review 8
1. Siemens UL 1077 ________ are designed to trip
faster than standard UL489 circuit breakers, providing
additional protection for more sensitive devices.

2. Siemens terminal blocks are available with either ______

connections or ________ terminals.

3. A control relay’s ________ number is the number of

isolated circuits that can pass through the relay.

4. A control relay’s ________ number is the number of

closed contact positions per pole.

5. SIRIUS ________ solid-state relays, contactors, and

function modules operate quietly and perform reliably at
high switching frequencies.

6. A timing relay that receives a signal to turn on and then

begins timing is referred to as an ________ timer.

7. SIRIUS ________ reduce machine and plant downtime

by monitoring electrical and mechanical quantities and
fault conditions and providing appropriate diagnostic
indications.

8. ________ is a modular programmable relay system

used to perform basic control tasks that are otherwise
often handled using hard-wired control relays and other
devices.

9. SIRIUS Safety Integrated system incudes ________

devices, ________ devices, and ________ devices and
systems.

10. The safety-related design of AS-Interface was

standardized for all manufacturers in the Safety at Work
consortium and is marketed by Siemens under the
copyrighted name ________.

104
 Review Answers

Review 1 1) manually; 2) a. normally open contact, b. normally closed

contact, c. coil; 3) a.

Review 2 1) left, right; 2) a. Node, b. Power Circuit, c. Power Load,

d. Control Circuit, e. Control Device, f. Control Load.

Review 3 1) increases; 2) overcurrent; 3) overload; 4) low voltage;

5) SMF; 6) MMS and MRS; 7) motor starter protector;
8) contactors

Review 4 1) 10; 2) thermal, bimetal; 3) reset; 4) 3RU;

5) heaters, phase loss; 6) ESP200; 7) 3RB21, 3RB31;
8) IO-Link; 9) 3RR2; 10) SIMOCODE pro.

Review 5 1) motor starter; 2) NEMA, IEC; 3) 5; 4) 20; 5) 2;

6) separate winding and consequent pole; 7) Combination;
8) Wye-delta.

Review 6 1) S10, S12; 2) S00, S0; 3) AS-Interface, IO-Link;

4) 3RA6 compact starters; 5) M200D;
6) 3RW30, 3RW40, 3RW44; 7) PROFIBUS DP, AS-Interface
8) IO-Link

Review 7 1) Electrically held; 2) magnetically held, mechanically latched;

3) pilot; 4) 22; 5) blue, white, clear; 7) 50 mm, 70 mm;
8) integrated signal lamps.

Review 8 1) supplementary protectors; 2) screw, spring-loaded; 3) pole;

4) throw; 5) 3RF2; 6) on-delay; 7) monitoring relays;
8) LOGO!; 9) detecting, commanding and signaling, monitoring
and controling; 10) ASIsafe.

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Final Exam

Before taking the final exam, it is recommended that you delete

the temporary internet files from your computer’s web browser.
For most versions of Internet Explorer, you can do this by
selecting Internet Options from the Tools menu and then
clicking on the Delete Files button. If you do not perform this
step, you may see a score of 0% after you submit your exam for
grading.

The final exam for this is course is available online at

http://www.usa.siemens.com/step. This web page provides
links to all our quickSTEP online courses. To complete the
final exam for this course, click on the Basics of Control
Components link.

Next, move your mouse over to the left so that the navigation
bar pops out and select the Final Exam link. The final exam
page will appear.

Courses
Introduction

Starter Basics
Motor Starters
Other Devices
Final Exam

Glossary
Downloads

After you complete the final exam, click on the Grade the
Exam button at the bottom of the page. Your score on the exam
will be displayed along with the questions that you missed.

If you score 70% or better on the exam, you will be given two
options for displaying and printing a certificate of completion.
The Print Certificate option allows you to display and print
the certificate without saving your score in our database and
the Save Score option allows you to save your score and
display and print your certificate. The Save Score option is
primarily intended for use by our distributors and Siemens
employees.

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