SIEMENS-Basics of Control Components

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 relays 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
Example
For example, in the following illustration, the circuit is first

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
Energized
Relay
De-energized
Battery
Battery
Contacts are shown
opposite their normal
state
Normally Closed Contact

Example
In the following illustration, when the relay is de-energized, the

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
Energized
Relay
De-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

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

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
Normally Closed Switch

Example
Battery

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
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
Pushbutton Example
In the following example, current flows to the light as long as

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 relays 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.
Coil
Contact
(NO)
Limit Switch
(NO)
12
Abbreviations
Abbreviations are frequently used in control circuits. The

following list identifies commonly used abbreviations.
AC
ALM
AM
ARM
AU
BAT
BR
CAP
CB
CKT
CONT
CR
CT
D
DC
DISC
DP
DPDT
DPST
DT
F
FREQ
FTS
FU
GEN
GRD
HOA
IC
INTLK
IOL
JB
LS
LT
M
MSP
Alternating Current
Alarm
Ammeter
Armature
Automatic
Battery
Brake Relay
Capacitor
Circuit Breaker
Circuit
Control
Control Relay
Current Transformer
Down
Direct Current
Disconnect Switch
Double-Pole
Double-Pole, Double-Throw
Double-Pole, Single-Throw
Double Throw
Forward
Frequency
Foot Switch
Fuse
Generator
Ground
Hand/Off/Auto Selector Switch
Integrated Circuit
Interlock
Instanstaneous Overload
Junction Box
Limit Switch
Lamp
Motor Starter
Motor Starter Protector
MTR
MN
NEG
NEUT
NC
NO
OHM
OL
PB
PH
POS
PRI
PS
R
REC
RES
RH
S
SEC
SOL
SP
SPDT
SPST
SS
SSW
T
TB
TD
THS
TR
U
UV
VFD
XFR
Motor
Manual
Negative
Neutral
Normally Closed
Normally Open
Ohmmeter
Overload
Pushbutton
Phase
Positive
Primary
Pressure Switch
Reverse
Rectifier
Resistor
Rheostat
Switch
Secondary
Solenoid
Single-Pole
Single-Pole, Double Throw
Single-Pole, Single Throw
Selector Switch
Safety Switch
Transformer
Terminal Board
Time Delay
Thermostat Switch
Time Delay Relay
Up
Under Voltage
Variable Frequency Drive
Transformer
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.
13
c.
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
Wiring
Power
Wiring
Not
Connected
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
14
Indicator (Pilot) Light
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, 120VAC 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
overload relay contact
M
120 VAC
Contactor
OL
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 120VAC
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 120VAC
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
L1
120 VAC
120 VAC
Pilot Light
L2
120 VAC
Pilot Light
L1
Improper Parallel Connection

120 VAC
120 VAC
Pilot Light
120 VAC
Pilot Light
16
L2
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
c
d
Control Circuit
Control Device
Control Load
Node
Power Circuit
Power Load
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 Ohms 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
Ohms Law I =
E
R
I=
240 V
24
= 10 A
After Short Circuit

I=
240 V
= 10,000 A
0.024
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 designB motor typically has a starting current
that is about six times its full-load current. For some highefficiency 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 motors 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
22
Switch in ON Position
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).
T2
L2
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

and Switches
Siemens SMF fractional-horsepower starters provide

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
RESET
STOP
RESET
NEMA 7 & 9
Class I Group C &D
Class II Group E, F & G
25
NEMA 3 & 4, NEMA 7 & 9

Class I Group C &D
Class II Group E, F & G
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
UL508, making them appropriate for manual starting and
stopping applications where upstream short-circuit protection is
provided. 3RV102, 3RV103, and 3RV104 MSPs 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 Manufacturers 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.
Power Circuit
Armature
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

electromagnets coil de-energizes, the magnetic field collapses,
and the movable contacts open under spring pressure.
Line
Line
Load
Control Signal
Contactor De-energized
Load
Control Signal
Contactor Energized
The following line diagram shows a contactor that provides onoff 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 threephase 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.
OL
L1
T1
Power
Source
L2
Thermal Overload Relays
Motor
T2
M
Starter Contracts Open
L1
OL
T1
Power
Source
L2
Motor
T2
M
Starter Contacts Closed
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 relays trip mechanism is tripped. This causes the
overload relays contacts to open, removing power from the
motor.
Motor
To Power Circuit
To Power Circuit
Motor
Heater Element
Heater Element
Bimetalic Strip
To Control Circuit
Bimetalic Strip
To Control Circuit
Trip Mechanism
Trip Mechanism
Normal Current Flow
32
Overload Condition
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
Compensation
In some applications, a motor is installed in a location with a

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
Primary
Bimetalic
Strip
The compensating bimetalic strip bends

as ambient temperature increases. This
prevents a nuisance overload trip.
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
Motor Current Selector
STOP button
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
motors 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
20
5
30
10
ESP200
PHASE UNBAL ON
PHASE LOSS ON
RESET MODE MAN.
GROUND FAULT ON
OFF
OFF
AUTO
DIP Switches
OFF
TEST
FULL LOAD AMPS

RESET
Current Adjustment Dial
35
Reset Button
Test Button
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 630A.
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 deenergizing 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
Trip Class and
Ground Fault Detection
Selector
Motor Current Selector

Manual or Automatic
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
Trip Class Setting
Optional Operator Panel

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
3RR21
3RR22
Current Monitoring Relays
38
3RR2
Current
Monitoring
Relay
SIMOCODE pro Motor

Management System
SIMOCODE pro is an alternative approach to use of overload

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 fullvoltage 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.
Voltes 3 Ph
110 V
Contactor
Series A
Max Amps
600 VAC
a, GA U.S.A.
SE&A Inc. Alpharett
2
L3
L2
L1
Max HP
T3
T2
T1
TRIP CLASS
20
5
30
10
ESP200
ON
PHASE UNBAL
PHASE LOSS ON
RESET MODE MAN.

ON
GROUND FAULT
TEST
AMPS
FULL LOAD
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 starters 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
Size
Continuous
Amp Rating
HP
230 VAC
HP
460 VAC
00
18
27
10
45
15
25
90
30
50
135
50
100
270
100
200
540
200
400
810
300
600
1215
450
900
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.
Class 14 NEMA Starters
MM Size
Continuous
Amp Rating
HP
230 VAC
HP
460 VAC
40
10
15
60
20
30
115
40
75
Class 14 NEMA starters with ambient-compensated bimetal

overload relays are available up to 100 HP at 460VAC (NEMA
sizes 00 through 4). In addition to whole sizes, this range
includes 1, 2, and 3 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 Class14

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.
Voltes 3 Ph
110 V
Series A
Max Amps
600 VAC
, GA U.S.A.
SE&A Inc. Alpharetta
2
L3
L2
L1
Max HP
T3
T2
T1
TRIP CLASS
20
5
30
10
ESP200
Contactor
ON
PHASE UNBAL
PHASE LOSS ON
RESET MODE MAN.

ON
GROUND FAULT
ESP200 Solid-State
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

Starters
The synchronous speed of a three-phase induction motor is a

function of the supply frequency and the number of poles. This
speed is the rate in RPMs for the motors rotating magnetic
field.
Synchronous Speed in RPM =
120 x Fequency
Number or Poles
For example, a motor with four poles on a 60 hertz AC line has a

synchronous speed of 1800 RPM.
Synchronous Speed =
120 x 60 Hz.
4
= 1800 RPM
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
motors 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 ambientcompensated 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 noncombination 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 threephase 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, partwinding 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
Close
L3
Siemens offers autotransformer starters as Class 36 noncombination 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 noncombination starters and Class 37 combination starters
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.
L1
L2
L3
1
2
Motor
4
6
9
8
To Start: Close 1, 2, 3, 4, 5, 6
Open 7, 8, 9
To Run: Open 4, 5, 6
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 noncombination starters and Class 37 combination starters
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, shortcircuit 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

screw terminals
55

spring-loaded terminals

ring lug terminals
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
2
3a
3b
3-phase busbar with infeed

3-phase busbar for system expansion
Expansion plug
Extra-wide expansion plug
4
5
6
7
End cover
Plug-in connector
Contactor base
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

Control System
Additional approaches applicable for control panels include

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
for Screw Terminals
60 mm Busbar Adapter
for Spring-loaded Terminals

Size S00/S0
Screw Terminals

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

Motor Loads
The SIRIUS modular system includes a wide range of power

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
S3
S0
S6
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

Function Modules
Plug-in function modules are available for selected versions

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 springloaded terminals.
Function Module
Plug-in Connections
3RT201
Size S00
Contactor
AS-Interface
Two-wire Cable
Full-voltage,
Non-reversing
Function Module for AS-Interface
Full-Voltage,
Reversing
59
3RT202
Size S0
Contactor
Function Module for IO-Link
Wye-Delta
IO-Link
Three-wire Cable
Solid State Contactors for

Motor Loads
Some applications require rapid switching of small, 3-phase

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 90mm,
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

for Motor Loads
60
SIRIUS 3RF2 Solid State Reversing Contactor

for Motor Loads
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.
Full Voltage,
Non-Reversing
Starter
3RA6 Infeed System
Full Voltage,
Reversing
Starter
Equipped for IO-Link

Equipped for
AS-Inteface
61
Enclosed Starters with

Communication
SIRIUS M200D is an enclosed (IP65 rated) motor starter with

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
Model
M200D AS-i Standard

Model
M200D PROFIBUS
Model
M200D PROFINET
Model
Lockable, Manual Disconnect
3-Position Keyswitch
(Automatic, Off/Reset, Manual)
Keypad for Manual Control
Power Infeed Connections
SIRIUS Soft Starters
Motor Connections
(Line, Brake, Thermistor)
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
Soft Starters
SIRIUS 3RW30 soft starters have an especially compact design

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
AS-Interface
Over time, a number of networks have been developed for use

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 ASInternational 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
SIMOCODE pro 3RW44
Basic Unit Soft Starter AC Drive
SIMATIC S7 PLC
PROFIBUS DP
DP/AS-i
Link
SIMATIC
HMI
SIMATIC S7
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
Typical Control Circuit for an

Electrically Held Lighting Contactor
68
A2
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
Mechanically Latched
Contactors
Magnetically held and mechanically latched contactors are

also designed for lighting and resistive heating loads. Siemens
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
ASInterface 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 nonilluminated, and are available in a variety of configurations and
actuator colors.
16 mm 3SB2
Pushbutton
22 mm SIGNUM
3SB3 Pushbutton
70
30 mm Class 52
Pushbutton
Normally Open
Pushbuttons
Pushbuttons are used in control circuits to perform various

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
Normally Closed
Pushbuttons
Control Circuit
Normally closed (NC) pushbuttons, such as the one shown

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
Control Circuit
The following line diagram shows an example of how a

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 contactors
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 lowvoltage 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
OL
T2
OL
L1
L2
L3
Motor
T3
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 fourposition 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
Selector Switch
Two-Position Selector
Switch
22 mm SIGNUM
3SB3 Selector Switch
30 mm Class 52
Selector Switch
In the following example, pilot light PL1 is on when the

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
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
Selector Switch Contacts
PL1
Position
1
Three-Position Selector
Switch
A B
X
PL2
A three-position selector switch is used to select any of three

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
M1
Selector Switch Contacts
Position
1
A B C
X
X
X
Liquid Level
Indicator Lights
Indicator lights, also referred to as pilot lights, provide a

visual indication of a circuits operating condition, for example,
on, off, or alarm.
16 mm 3SB2
Indicator Light
22 mm 3SB3
Indicator Light
30 mm Class 52
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
Using an Indicator Light

in a Control Circuit
Green Indicator Light is On

Motor is Stopped
In the following diagram, when the motor is stopped, the

normally closed Mb contact is closed, and the green (G) light is
on.
L1
L2
Stop
Start
OL
M
Ma
R
Mb
G
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
Stop
Start
OL
M
Ma
R
Mb
G
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
Stop
Start
OL
M
Ma
R
Mb
G
OL
A
Signaling Columns and

Lamps
Signaling columns allow operating personnel to monitor

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
50mm 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 orplunger
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

Supplementary Protectors
Siemens UL 1077 supplementary protectors are designed to

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 70mm.
Supplementary Protector (70 mm)
5SJ4 Miniature
Circuit Breakers
IEC style miniature circuit breakers (MCBs), according to

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 UL489,
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 relays 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 relays 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 relays 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
Single Throw
Single Break
Double Pole
Single Throw
Single Break
Single Pole
Single Throw
Double Break
Double Pole
Single Throw
Double Break
Single Pole
Double Throw
Single Break
Double Pole
Double Throw
Single Break
Single Pole
Double Throw
Double Break
Double Pole
Double Throw
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 threephase, solid state relays are 45 mm wide.
SIRIUS Solid-State
Contactors
SIRIUS 3RF23 single-phase, solid state contactors and

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
1-Phase
Solid State
Relay
(45 mm)
3RF21
1-Phase
Solid State
Relay
(22.5 mm)
3RF23
1-Phase
Solid State
Contactor
87
3RF22
3-Phase
Solid State
Relay
(45 mm)
3RF24
3-Phase
Solid State
Contactor
SIRIUS 3RF29 Function

Modules
Many solid state switching applications require extended

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 threephase 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 singlephase 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.
Converter
Heating Current
Monitoring Module
88
Load Current
Monitoring Module
Power Controller
Power Regulator
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
Arrow Points Up
Off Delay
Arrow Points Down
On-delay and off-delay timers can turn their connected loads on

or off, depending on how the timers 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
timers 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 timers contacts change state.
On-Delay, Timed Closed
Timer
The following illustration shows an example of an on-delay,

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

Timer
The following illustration shows an example of an on-delay,

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
Timing Relay
(22.5 mm)
3RP20
Timing Relay
(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
Current Monitoring
Relays
3UG4
Voltage
Monitoring
Relay
93
3RN1
Thermistor
Motor Protection
Relay
3RS1
Temperature
Monitoring
Relays
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.
Analog
Sensor
3RS17
Converter
Control System
Input
Output
3RS17
Converter
Analog
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,
24VDC, 24 VAC/DC, or 115/240VAC/DC. All units can accept
eight discrete inputs. For 12/24 VDC or 24 VDC units, four of
these inputs are usable as 0to 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, 8analog inputs, 16 digital outputs, and 2 analog outputs.
Expansion Module
LOGO! DM 8 12/24R
LOGO! DM 8 24
LOGO! DM 8 24R
LOGO! DM 8 230R
LOGO! DM 16 24
LOGO! DM 16 24R
LOGO! DM 16 230R
Power Supply
12/24 VDC
24 VDC
24 VAC/DC
115-240 VAC/DC
24 VDC
24 VDC
115-240 VAC/DC
LOGO! AM 2
12/24 VDC
LOGO! AM 2 PT100
12/24 VDC
LOGO! AM 2 RTD
12/24 VDC
LOGO! AM 2 AQ
24 VDC
Inputs
Outputs
4 discrete
4 relays (5A)
4 discrete
4 solid-state (24V/0.3A)
4 discrete
4 relays (5A)
4 discrete
4 relays (5A)
8 discrete
8 solid-state (24V/0.3A)
8 discrete
8 relays (5A)
8 discrete
8 relays (5A)
2 analog
none
0-10 V or
0-20 mA
2 PT100
none
-50oC to +200oC
2 PT100 or 2PT1000
or 1 each
none
o
o
-50 C to +200 C
2 analog
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
96
F2
F3
F4
ESC
OK
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.
3SE5 Position Switches
98
3SE6
Magnetically-Operated
Switches
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.
Cable-Operated Switches
3SB3 Pushbutton and

Indicator Lights
8WD5
Integrated Signal Lamps
3SE2 Foot Switch
99
8WD4 Signaling Column
3SB3 Two-Hand Operation Console
Monitoring with Safety

Relays
SIRIUS 3TK28 safety relays carry out the following safety

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 higherlevel 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
signal from the safety monitor can be
used via ASIsafe for the safety-oriented
disconnection of distributed safe AS-i
outputs.
Safe input slave: Safe signals
are made available through the
safe slaves and to the safety
monitor for evaluation.
Safe AS-I
Outputs
Safety monitor: The safety monitor

evaluates all safe inputs on the AS-i bus
and ensures safe disconnection.
Standard PLC and standard AS-i master:

Central installation at the PLC and distributed
installation using DP-AS-i Links is possible.
Safety
Monitor
PLC with AS-I Master
Safe Input
Slave
AS-I
Power Supply
Standard
Slave
Standard
Slave
Standard
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 failsafe 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 relays ________ number is the number of
isolated circuits that can pass through the relay.
4. A control relays ________ 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.
105
106
107
Final Exam
Before taking the final exam, it is recommended that you delete

the temporary internet files from your computers 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.
108

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Table of Contents

Welcome to another course in the STEP series, Siemens

State the purpose and general principles of control

This knowledge will help you better understand customer

You should complete Basics of Electricity before attempting

Control Circuits and Symbols

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

Although manual operation of machines is still common, many

While many control components are used in circuits that involve

In some cases, the interaction of these components is

Various devices incorporate contacts to control the flow of

The standard method of showing contacts is to indicate the

Symbols on a control logic diagram are usually not shown in

For example, in the following illustration, the circuit is first

Normally Closed Contact

In the following illustration, when the relay is de-energized, the

Various types of switches are also used in control circuits. Like

Normally Open Switch

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

Switch is shown opposite

Normally Closed Switch

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

Switch is shown opposite

There are two general types of pushbuttons, momentary and

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

In the following example, current flows to the light as long as

Motor starters, contactors, and relays are examples of

Coil and Contact Example

In the following example, the M contacts in series with the

Overload Relay Symbol

Overload relays are used to protect motors from overheating.

Indicator Light Symbols

An indicator light, often referred to as a pilot light, is a small

In addition to the symbols discussed here, there are many other

Static switching control uses

Abbreviations are frequently used in control circuits. The

A control is ________ operated when someone must

2. Identify each of the following symbols.

3. Which of the following symbols represents a normally

Control symbols are used in line diagrams, also referred to

Line diagrams show the functional relationship of components

The functional relationship can be shown pictorially with the

Indicator (Pilot) Light

Reading a Line Diagram

The following line diagram symbolically displays the functional

Power and Control Circuits

The following line diagram includes both power and control

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

Connecting the Load to L2

Pilot light connected

Control loads are generally not connected in series. The

Improper Parallel Connection

The next illustration shows two pushbuttons connected in

Line diagrams are read starting at L1 from ________ to

2. Match the items on the line diagram with the

Some of the control components covered in this course

To begin with, current flow always generates heat. The amount

Normal Current Flow

Excessive Current Flow

Normally, the insulation used to separate conductors prevents