3RW34-Variador de Velocidad

Siemens Energy & Automation, Inc.
SIKOSTART
TM
3RW34 Instruction Guide
3ZX1012-0RW34-1AN1
September, 2000
Siemens Energy & Automation, Inc. 2
Hazardous voltage.
Will cause death
or serious injury.
Always de-energize and ground the equip-
ment before maintenance. Read and
understand this manual before installing,
operating or maintaining the equipment.
Maintenance should be performed only
by qualified personnel. The use of unau-
thorized parts in the repair of the equip-
ment or tampering by unqualified person-
nel may result in dangerous conditions
which may cause death or serious injury,
or equipment or property damage. Follow
the pertinent standards and all safety
instructions contained herein.
QUALIFIED PERSON
For the purposes of this manual and product
labels, a qualified person is one who is familiar
with the installation, construction, operation or
maintenance of the equipment and the haz-
ards involved. In addition this person has the
following qualifications:
(a) is trained and authorized to energize,
de-energize. clear, ground and tag cir-
cuits and equipment in accordance with
established safety practices.
(b) is trained in the proper care and use of
protective equipment such as rubber
gloves, hard hat, safety glasses or
face shields, flash clothing, etc., in
accordance with established safety
practices.
(c) is trained in rendering first aid.
SIGNAL WORDS
The signal words Danger, Warning and
Caution used in this manual indicate the
degree of hazard that may be encountered by
the user. These words are defined as:
Danger - Indicates death or serious injury will
result if proper precautions are not taken.
Warning - Indicates death, serious injury or
property damage can result if proper precau-
tions are not taken.
Caution - Indicates some injury or property
damage may result if proper precautions are
not taken.
Table of Contents
1 Introduction
1.1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 SIKOSTART 3RW34 Features . . . . . . . . . . . . . . .5
1.3 Applications and Benefits . . . . . . . . . . . . . . . . . .5
2 Operating Principle
2.1 Function Overview . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Functional Description . . . . . . . . . . . . . . . . . . . .5
2.3 Three-phase Systems . . . . . . . . . . . . . . . . . . . . .6
2.4 AC Motor Starting and Stopping . . . . . . . . . . . . .8
3 Controller Selection . . . . . . . . . . . . . . . . . . . . .10
4 Installation
4.1 Incoming Inspection . . . . . . . . . . . . . . . . . . . . .13
4.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.3 Installation Precautions . . . . . . . . . . . . . . . . . . .13
4.4 General Wiring . . . . . . . . . . . . . . . . . . . . . . . . .14
4.5 Power and Motor Connections . . . . . . . . . . . . .19
4.6 Control Connections . . . . . . . . . . . . . . . . . . . . .20
4.7 Installation Check . . . . . . . . . . . . . . . . . . . . . . .20
5 Wiring Diagrams
5.1 Typical Applications . . . . . . . . . . . . . . . . . . . . . .21
5.2 Circuit Devices . . . . . . . . . . . . . . . . . . . . . . . . .21
6 Setup and Operation
6.1 Setup Controls . . . . . . . . . . . . . . . . . . . . . . . . .30
6.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . .31
6.3 Controller Setup . . . . . . . . . . . . . . . . . . . . . . . .31
6.4 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . .31
6.5 Initial Energization . . . . . . . . . . . . . . . . . . . . . . .31
6.6 Motor Starting Adjustments . . . . . . . . . . . . . . .32
7 Electrical Specifications . . . . . . . . . . . . . . . . .33
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9 Troubleshooting
9.1 Maintenance and Troubleshooting . . . . . . . . . . .37
9.2 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . .37
9.3 Inside Delta Wiring Problems . . . . . . . . . . . . . .40
9.4 Shorted SCR Checks . . . . . . . . . . . . . . . . . . . .41
9.5 SCR (Thyristor) Testing . . . . . . . . . . . . . . . . . . . .41
10 Spare and Optional Parts
10.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
10.2 Optional Parts . . . . . . . . . . . . . . . . . . . . . . . . . .45
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
1 SIKOSTART 3RW34 Block Diagram . . . . . . . . . . . . . . . 6
2 Basic Three-phase Waveforms . . . . . . . . . . . . . . . . . . . 6
3 Three-phase In Line-connected Arrangement . . . . . . . . 7
4 Three-phase Inside Delta-connected Arrangement . . . . 7
5 Wye and Delta Motor Connections . . . . . . . . . . . . . . . 8
6 Typical Torque/Speed Curves for
Motor at Reduced Voltages . . . . . . . . . . . . . . . . . . . . . 8
7 Voltage and Time Curves for
Soft Start with Coast to Stop. . . . . . . . . . . . . . . . . . . . 9
8 Voltage and Time Curves for
Soft Start with Soft Stop . . . . . . . . . . . . . . . . . . . . . . . 9
9 Typical Over Temperature Switch Wiring . . . . . . . . . . . 15
10 Inductive Load Suppression . . . . . . . . . . . . . . . . . . . . 16
11 SIKOSTART Controller
Power and Motor Connections . . . . . . . . . . . . . . . . . . 17
12 SIKOSTART Controller Control Connections . . . . . . . . 18
13 Power wiring for motors,
wired "In Line", in a vented enclosure (circuit breaker
or fusible disconnect) . . . . . . . . . . . . . . . . . . . . . . . . 22
14 Control wiring for motors,
wired "In Line", in a vented enclosure (circuit breaker
or fusible disconnect) . . . . . . . . . . . . . . . . . . . . . . . . 23
15 Power wiring for a motor,
wired "In Line" with bypass contactor . . . . . . . . . . . . 24
List of Figures
16 Control wiring for a motor,
wired "In Line" with bypass contactor . . . . . . . . . . . . 25
17 Power wiring for motors, wired "Inside Delta"
in a vented enclosure, with fusible disconnect and
isolation contactor, and shunt trip circuit breaker. . . . 26
18 Control wiring for motors, wired "Inside Delta"
in a vented enclosure, with fusible disconnect and
isolation contactor, and shunt trip circuit breaker. . . . 27
19 Power wiring for a motor, wired "Inside Delta",
with bypass and isolation contactors . . . . . . . . . . . . . 28
20 Control wiring for a motor, wired "Inside Delta",
with bypass and isolation contactors . . . . . . . . . . . . . 29
21 Setup Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
22 Potentiometer Settings . . . . . . . . . . . . . . . . . . . . . . . 32
23 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
24 Proper Inside Delta Wiring Connection. . . . . . . . . . . . 40
25 Typical Isolated Power Pole . . . . . . . . . . . . . . . . . . . . 41
26 Gate Triggering Test Diagram . . . . . . . . . . . . . . . . . . . 43
27 Latching/Holding Test Diagram. . . . . . . . . . . . . . . . . . 43
28 Typical 35 or 80 Amp SCR . . . . . . . . . . . . . . . . . . . . . 44
29 Typical 130 or 240 Amp SCR . . . . . . . . . . . . . . . . . . . 44
30 Typical 420 or 720 Amp SCR . . . . . . . . . . . . . . . . . . . 44
List of Tables
1 Motor Power Ratings (Kilowatts) TA = 40C . . . . . . . . 10
2 Motor Power Ratings (Horsepower) TA = 50C. . . . . . 11
3 Motor Power Rating (Kilowatts) TA = 60C . . . . . . . . . 12
4 Motor Power Ratings (Horsepower) TA = 60C . . . . . 12
5 Terminal Screw and Ground Stud Nut Torque . . . . . . . 19
6 3-Lead Connections for
Dual Voltage 9-Lead Wye Motor . . . . . . . . . . . . . . . . . 20
7 6-Lead Connections for Dual Voltage
12-Lead Delta Motor . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Potentiometer Setting Values . . . . . . . . . . . . . . . . . . . 30
9 Input (RUN) Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 Control Power Requirements . . . . . . . . . . . . . . . . . . . 35
11 LED Fault Indications. . . . . . . . . . . . . . . . . . . . . . . . . 37
12 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13 Inside Delta Wiring Problems. . . . . . . . . . . . . . . . . . . 40
14 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure Page Figure Page
Table Page Table Page
1 Introduction
1.1 Scope of Manual
This manual provides an overview for the installation, setup and
operation of the Siemens SIKOSTART 3RW34 controller.
Maintenance data consists of troubleshooting and spare parts
information. Note that the instructions in this manual do not
cover all details or variations in equipment, nor provide for every
possible contingency to be met in connection with installation,
operation, or maintenance.
1.2 3RW34 SIKOSTART Features
The SIKOSTART 3RW34 product line is the next generation of
Siemens solid state reduced voltage controllers. This controller com-
bines DSP microprocessor and SCR technologies to provide AC
induction motor starting and operation. The sturdy compact frame
affords rugged, industrial grade reliability.
The SIKOSTART 3RW34 controller is a single ramp style con-
troller using phase control for the operation of three-phase
induction motors. The controller can be set to operate either
wye (star) or delta type motors. Each unit includes soft start and
stop parameters plus fault detection. The controller can be used
with an electro-mechanical starter or, when combined with an
overload relay, the controller can be used as a solid-state starter.
The SIKOSTART 3RW34 controller is available as an open type
(compact frame, no enclosure) or in a NEMA 1, 3R, 4, or 12
enclosure. The unit can be ordered as a starter with overload
relays or as a combination starter with disconnecting means and
circuit overload protection devices. Additional options are also
available such as push buttons, pilot lights, and meters.
1.3 Applications and Benefits
Typical applications for the SIKOSTART 3RW34 controller are to
soft start and soft stop AC induction motor driven equipment
such as fans, pumps and compressors. Applications also
include controlling machines with gearbox, belt or chain drive
elements, such as: conveyors, sanders, planers, saws, packag-
ing machines and punch presses.
Using the SIKOSTART 3RW34 controller provides benefits to
the drive system in the following ways:
1 )the life of mechanical drive transmission elements is
extended, e.g., gearbox jerking is substantially reduced
resulting in less wear and tear;
2) reduced starting current relieves the supply network of cur-
rent peaks; and
3) smoother acceleration of loads eliminates process or product
damage.
2 Operating Principle
2.1 Function Overview
The SIKOSTART 3RW34 controller utilizes a voltage ramp design
to produce an output voltage to the motor that increases from a
customer selected initial voltage to full line supply voltage over
an adjustable starting time. This voltage ramp produces a
reduced current start (soft start) similar to a current limit start
without the load dependence of the current limit type start.
Similarly, stopping time can be adjusted to provide a soft stop
for many pumping applications.
The SIKOSTART controller employs a DSP (digital signal proces-
sor) to control the motor. This advanced type of microprocessor
allows the controller to contour the starting and stopping
ramps. This contour adjusts for the nonlinearities of an induction
motor to produce a smoother and more linear motor start and
stop.
2.2 Functional Description
Power Poles: As is shown in the block diagram of figure 1, the
incoming main power (L1, L2, L3) is connected to the con-
trollers three power poles which control the voltage to the
motor windings. Each power pole consists of two SCRs in a
back-to-back arrangement for each phase which allows alternat-
ing current to pass to the motor.
Snubber PCB: The snubber printed circuit board(s) contains the
trigger circuit for each SCR. The firing signal for each trigger cir-
cuit is generated at the logic printed circuit board. The snubber
board sensing circuits send data to the logic board for factoring
into firing signal generation. The snubber board also includes an
RC network for a degree of protection against false firing of the
SCRs due to dv/dt and MOVs for transient protection.
X1
X2
A1
A2
13
14
27
28
RUN_OUT
RUN_LOCAL
POWER
SUPPLY
ASi+
ASi-
RUN_IN
RUN_OUT
UP-TO-VOLTAGE
FAULT
RUN_NET
RUN_IN
CONTROLLER
OR
RUN_IN
RUN_OUT
UP-TO-VOLTAGE
FAULT
UP-TO-
VOLTAGE
AS-i MODULE
DSP
38
37
FAULT_OUT
LOGIC PCB
Control
F
I
R
E
S
E
N
S
E
SNUBBER
PCB
FIRE
LINE SENSE
LOAD SENSE
FAN(S)
SCRs
1 L1 3 L2 5 L3
6 T3 4 T2
2 T1
6
3
3
Figure 1 3RW34 SIKOSTART Block Diagram Logic PCB. A
power supply on the logic printed circuit board accepts control
power (X1, X2) and provides power to the central processing unit
(DSP), support circuitry, and cooling fan(s). The input coil termi-
nals (A1, A2) are for commanding the motor to RUN and STOP.
The three sets of numbered output terminals are for customer
control devices related to Motor Running (e.g., start / stop
devices), Motor Running at Full Voltage (e.g., to drive a bypass
contactor), and Fault (e.g., phase loss or shorted SCR).
Setup Controls. Setup controls are connected to the logic board
but are accessible from the controllers front cover. Three poten-
tiometers provide customer adjustments: T1 - the rate of the
voltage rise (accel ramp time); U - the initial motor start voltage;
and T2 - decel ramp time for a soft stop (pump stop).
A dip switch (SW1, figure 20) is used to set the controller soft-
ware to the proper application. The functions set are:
1. delay at stop: when bypass contactor is used.
2. delay at start: when isolation contactor is used.
3. circuit-type: In line or Inside Delta connection.
4. Fault output: opens or closes on fault.
2.3 Three-phase Systems
Since the controller can be used with In line or Inside Delta con-
nection a brief discussion of currents and voltages for three-
phase wye and delta arrangements with balanced loads is
included here as an aid to understanding controller setup pro-
cedures and to assure proper controller selection.
Figure 2 shows the voltage waveforms for a three-phase system
of three equal voltages separated by 120-degree phase angles.
The voltage in phase a, or Ua, leads the voltage in phase b, or
Ub, by 120. Likewise, Ub leads Uc by 120, and Uc leads Ua
by 120.
Figure 1 SIKOSTART 3RW34 Block Diagram
Figure 2 Basic Three-phase Waveforms
120 120 120
Figure 3 Three-phase In Line-connected Arrangement
Figure 4 Three-phase Inside Delta-connected Arrangement
Figure 3a
Figure 3b
Figure 4b
Figure 4a
I2
Eb
b
U1,2
U2,3
U3,1
2
1
3
I3
I1
Ec
Ea
a
c
Neutral
U1,2
U2,3
2
1
3
SIKOSTART
I_w3
Motor
w1
w2
w3
T2
T3
T1
L2
L3
L1
U3,1
I_scr3 I_L3
scr2
scr1
scr3
I_scr = I_winding = 100% * I_Iine
I_scr = I_winding = 1/SqRt(3) * I_Iine = 57% * I_line
or
I_line = SqRt(3) * I_scr = 1.73 * I_scr = 1.73 I_winding
U1,2
U2,3
SIKOSTART
Motor
w1
w2
w3
T2
T1
L2
L3
L1
U3,1
I_w2
I_L3
scr2
L2
T3
L3
scr3
L1
scr1
I_w3
2.3.1 Inline Connection
Figure 3a represents a three-phase inline-connected motor with
three sources connected to supply voltages, U1,2, U2,3, and U3,1.
The SIKOSTART controller is connected in line with the motor
windings.
As can be seen, the source current, the SIKOSTART current, and
the motor winding current are all equal.
2.3.2 Inside Delta Connection
Figure 4b represents a three-phase inside-delta-connected
motor. The three sources are connected to supply voltages,
U1,2, U2,3, and U3,1. The SIKOSTART controller is connected
inside of the delta in series with the motor winding.
As can be seen, the source or line current is split between two
motor windings. The winding current and SIKOSTART current is
therefore less than the source or line current. Note that the
magnitude of a line current is greater than the magnitude of a
winding and SIKOSTART current by a factor of the square-root-
of-three (1.73). This allows the SIKOSTART controller to operate
a motor of a higher current rating when connected inside of the
delta.
Figure 6 Typical Torque/Speed Curves for Motor at Reduced Voltages
Torque of the motor in the case of
a direct-on-line starting
@Um (0) = 100% Ue
b starting with 3RW34
@Um (0) = 75% Ue
c starting with 3RW34
@Um (0) = 50% Ue
Relationship of voltage and
speed with respect to time
in the case of soft - starting.
Showing the effect of the
potentiometers Um and tr
located on the front panel of
the devices.
Figure 5 Wye and Delta Motor Connections
2.3.3 Controller-to-Motor Connections
Wye Motor. The controller can be used for either a three- lead
or nine-lead wye motor. Connecting the controller to a wye
motor inserts the SCRs directly in the line wiring, referred to as
In Line wiring.
Delta Motor. The controller can be used for either 6 or 12 lead
delta motors. If the motor is hard wired as delta, the controller
must be connected and sized with In Line wiring as shown in
figure 5a.
Figure 5b shows the controller connected with the thyristors
inside the delta, referred to as Inside Delta wiring. For Inside
Delta wiring, the controller power rating may be increased (line
current = 1.73 phase current, figure 4) relative to the In Line
power rating.
2.4 AC Motor Starting and Stopping
Figure 6 shows three torque/speed curves (a, b, c) for a typical
induction motor.
a This curve shows the torque/speed relation when the motor
starting voltage, U, is 100% of line voltage (Ue).
b This curve shows the relation when the controller voltage
potentiometer, U (initial soft start voltage setting) is set for
75% of line voltage.
c This curve shows the relation when the controller voltage
potentiometer is set for 50% of line voltage.
The curve a motor (without soft starting) produces a very high
torque across most of the speed range, whereas, the curves b
and c motors (with soft starting) produce a much lower and
adjustable torque. This allows slower and smoother acceleration
of the motor and its load.
Figure 5a
Figure 5b
Volage U
t
2
= 0
t
1
Time t
U
m
3 or 9 Lead Wye Motors and 3 Lead Delta Motors
T1
T2
T3
T1
T2
T3
T1
L1
T2
L2
T3
L3
From Source Power
T1
T2
T3
T6
T5
T4
T1
L1
T2
L2
T3
L3
From Source Power
T6 T4 T5
6 or 12 Lead Delta Motors
Note Order of
T6 from L1
T2 from L2
T5 from L3
2.4.1 Soft Start with Coast to Rest
Figure 7 shows the relationship of voltage and speed with
respect to time when a soft start is used with coast to rest. The
controller potentiometers have been set as follows.
U
m
The initial voltage is set at approximately 30%.
t1 The start time setting is greater than 0.
t2 The stop time is set at 0 which allows the motor to coast
to a stop.
On the voltage/time graph, the voltage starts at Um when the
run coil is energized and increases to 100% within the T1 time
setting. The voltage immediately drops to zero when the run
coil is de-energized.
The speed/time graph shows the motor accelerating from 0,
when the run coil is energized, to operating speed. The time
required to accelerate may be more or less than the T1 setting
depending on the connected inertia. The motor speed coasts to
zero when the motor is de-energized.
2.4.2 Soft Start with Soft Stop
Figure 8, like figure 7, shows the voltage and speed curves for a
soft start but with controlled deceleration. The potentiometers
have been set as follows.
U
m
The initial voltage is set at approximately 30%.
t1 The start time setting is greater than 0.
t2 The stop time setting is greater than 0 which allows the
motor to soft stop.
The motor starting ramp is similar to the one shown in figure 7.
But, when the run coil is de-energized, a motor stopping ramp
is formed where the motor voltage starts at 100% and decreas-
es to 80% of Um (the initial start voltage) within the T2 time set-
ting. Then the voltage immediately drops to zero. The time
required to decelerate may be more or less than the T1 setting
depending on the connected inertia.
When the run coil is de-energized, the speed decreases
throughout the T2 time period and then coasts to zero.
Figure 7 Voltage and Time Curves for Soft Start
with Coast to Stop
Figure 8 Voltage and Time Curves for Soft Start with Soft Stop
Motor
Voltage
F
0
100%
t2 = 0
t1
U
0
F
t
Motor
Speed
F
0
100%
t2 = 0
t1
U
0
F
M Coil
Input
Energized
t
t
Motor
Voltage
F
0
100%
t2
t1
U
0
F
Motor
Speed
F
0
100%
t1
U
0
F
M Coil
Input
Energized
F
0
t2
F
0
t
t
t
3 Controller Selection
Each controller has two ratings: In Line and Inside Delta.
Inside Delta ratings are higher than In Line ratings.
Be sure to select equipment with the proper ratings for
the type of connections used.
For 24 VDC replace the ? in the catalog no. with 2.
For 120 VAC replace the ? in the catalog no. with 3.
Table 1 - Motor Power Ratings (Kilowatts) TA = 40C
Catalog In Line Inside Delta
Number le in Amps kW Voltage Amps kW Voltage
3RW3454-0DC?4 57 15/30 230/400 110 30/55 230/400
3RW3455-0DC?4 70 18.5/37 230/400 135 37/75 230/400
3RW3457-0DC?4 110 30/55 230/400 205 55/110 230/400
3RW3458-0DC?4 135 37/75 230/400 235 75/132 230/400
3RW3465-0DC?4 162 45/90 230/400 285 90/160 230/400
3RW3466-0DC?4 195 55/110 230/400 352 110/200 230/400
3RW3467-0DC?4 235 75/132 230/400 450 132/250 230/400
3RW3472-0DC?4 352 110/200 230/400 608 200/355 230/400
3RW3483-0DC?4 500 160/250 230/400 865 250/500 230/400
3RW3484-0DC?4 700 220/400 230/400 1216 400/710 230/400
3RW3486-0DC?4 1050 375/630 230/400 1720 530/1000 230/400
3RW3454-0DC?5 57 30/37 400/500 110 55/75 400/500
3RW3455-0DC?5 70 37/45 400/500 135 75/90 400/500
3RW3457-0DC?5 110 55/75 400/500 205 110/132 400/500
3RW3458-0DC?5 135 75/90 400/500 235 132/160 400/500
3RW3465-0DC?5 162 90/110 400/500 285 160/200 400/500
3RW3466-0DC?5 195 110/132 400/500 352 200/220 400/500
3RW3467-0DC?5 235 132/160 400/500 450 250/335 400/500
3RW3472-0DC?5 352 200/220 400/500 608 355/400 400/500
3RW3483-0DC?5 500 250/355 400/500 865 500/630 400/500
3RW3484-0DC?5 700 400/500 400/500 1216 710/850 400/500
3RW3486-0DC?5 1050 630/710 400/500 1720 1000/1200 400/500
Number le in Amps Hp Voltage le in Amps Hp Voltage
3RW3454-0DC?4 42 20/22 230/400 81 30 200/230
3RW3455-0DC?4 57 25/30 230/400 110 40 200/230
3RW3457-0DC?4 81 30/45 230/400 162 50 200/230
3RW3458-0DC?4 110 40/55 230/400 205 75 200/230
3RW3465-0DC?4 135 50/75 230/400 235 75 200/230
3RW3466-0DC?4 162 75/90 230/400 285 125 200/230
3RW3467-0DC?4 195 100/110 230/400 352 175 200/230
3RW3472-0DC?4 285 150/160 230/400 500 250 200/230
3RW3483-0DC?4 450 200/250 230/400 700 300 200/230
3RW3484-0DC?4 608 300/355 230/400 1050 500 200/230
3RW3486-0DC?4 865 500/865 230/400 1416 600 200/230
3RW3454-0DC?5 42 30/40 460/575 81 60/75 460/575
3RW3455-0DC?5 57 40/60 460/575 110 75/125 460/575
3RW3457-0DC?5 81 60/110 460/575 162 125/150 460/575
3RW3458-0DC?5 110 75/125 460/575 205 150/175 460/575
3RW3465-0DC?5 135 100/150 460/575 235 175/200 460/575
3RW3466-0DC?5 162 150/200 460/575 285 300/350 460/575
3RW3467-0DC?5 195 200/200 460/575 352 350/400 460/575
3RW3472-0DC?5 285 300/350 460/575 500 500/600 460/575
3RW3483-0DC?5 450 400/500 460/575 700 600/700 460/575
3RW3484-0DC?5 608 600/400 460/575 1050 1000/1200 460/575
3RW3486-0DC?5 865 800/1000 460/575 1416 1300/1700 460/575
Table 2 - Motor Power Ratings (Horsepower) TA = 50C
Number le in Amps Hp Voltage le in Amps Hp Voltage
3RW3454-0DC?4 35 15 230 57 20 230
3RW3455-0DC?4 42 20 230 81 30 230
3RW3457-0DC?4 57 20 230 135 50 230
3RW3458-0DC?4 81 30 230 162 60 230
3RW3465-0DC?4 110 40 230 205 75 230
3RW3466-0DC?4 135 50 230 235 100 230
3RW3467-0DC?4 162 60 230 285 125 230
3RW3472-0DC?4 235 100 230 448 175 230
3RW3483-0DC?4 352 150 230 637 250 230
3RW3484-0DC?4 500 200 230 865 350 230
3RW3486-0DC?4 726 300 230 1216 500 230
3RW3454-0DC?5 35 25/30 460/575 57 40/50 460/575
3RW3455-0DC?5 42 30/40 460/575 81 60/75 460/575
3RW3457-0DC?5 57 40/50 460/575 135 100/125 460/575
3RW3458-0DC?5 81 60/75 460/575 162 125/150 460/575
3RW3465-0DC?5 110 75/100 460/575 205 150/200 460/575
3RW3466-0DC?5 135 100/125 460/575 235 200/250 460/575
3RW3467-0DC?5 162 125/150 460/575 285 250/300 460/575
3RW3472-0DC?5 235 200/250 460/575 448 350/450 460/575
3RW3483-0DC?5 352 300/350 460/575 637 500/600 460/575
3RW3484-0DC?5 500 400/500 460/575 865 700/800 460/575
3RW3486-0DC?5 726 600/750 460/575 1216 1000/1200 460/575
Table 4 - Motor Power Ratings (Horsepower) TA = 60C
Table 3 - Motor Power Ratings (Kilowatts) TA = 60C
Number le in Amps kW Voltage le in Amps kW Voltage
3RW3454-0DC?4 35 11/18.5 230/400 57 15/30 230/400
3RW3455-0DC?4 42 11/22 230/400 81 22/45 230/400
3RW3457-0DC?4 57 16/30 230/400 135 37/75 230/400
3RW3458-0DC?4 81 22/45 230/400 162 45/90 230/400
3RW3465-0DC?4 110 30/55 230/400 205 55/110 230/400
3RW3466-0DC?4 135 37/75 230/400 235 75/132 230/400
3RW3467-0DC?4 162 45/90 230/400 285 90/160 230/400
3RW3472-0DC?4 235 75/132 230/400 448 132/250 230/400
3RW3483-0DC?4 352 110/200 230/400 637 200/375 230/400
3RW3484-0DC?4 500 160/250 230/400 865 250/500 230/400
3RW3486-0DC?4 726 220/400 230/400 1216 400/710 230/400
3RW3454-0DC?5 35 22 500 57 37 500
3RW3455-0DC?5 42 30 500 81 55 500
3RW3457-0DC?5 57 37 500 135 90 500
3RW3458-0DC?5 81 55 500 162 110 500
3RW3465-0DC?5 110 75 500 205 132 500
3RW3466-0DC?5 135 90 500 235 160 500
3RW3467-0DC?5 162 110 500 285 200 500
3RW3472-0DC?5 235 160 500 448 335 500
3RW3483-0DC?5 352 220 500 637 450 500
3RW3484-0DC?5 500 355 500 865 630 500
3RW3486-0DC?5 726 530 500 1216 850 500
4 Installation
4.1 Incoming Inspection
1. Unpack the controller from the carton and inspect for ship-
ping damage. Check that the items on the packing list agree
with the order. File claims for loss or damage with the
freight carrier immediately.
2. If the controller will not be installed immediately, it should be
stored in a clean, dry area where the ambient temperature is
between 0C and 70C. Avoid storage environments with
corrosive atmospheres or high humidity.
Note: Installation must be performed by qualified personnel
as indicated on page 2 of this manual.
3. The carton and packing materials should be retained in case
there is a future need to return the controller to the factory
for service or repair. The carton and packing material are
especially fitted to protect the controller from shipping dam-
age.
If these materials are not used for shipping, claims for shipping
damage may be rejected by the freight carrier.
4.2 Mounting
1. Section 8 of the manual contains controller mounting dimen-
sions and data. Air flow through the unit is vertical, from bot-
tom to top.
2. Adequate cooling is essential for proper operation. Leave at
least 6 inches of clearance above and below the unit to allow
unimpeded convection or fan air flow. Wire bending
allowance may require more than this recommended mini-
mum clearance.
3. When mounting the controller in an enclosure, the enclosure
must be properly sized or ventilated to provide cooling for
the continuous power dissipation in the thyristors, approxi-
mately 3 watts per ampere of continuous rating. The fol-
lowing vent areas are required for each inlet and each outlet
on customer furnished enclosures, motor control
centers, etc.
Locate front ventilation air inlet vent at least 3 inches below the
bottom edge of the controller. Locate the outlet air vent area at
least 6 inches above the controller top edge. Air filters impede
air circulation and require a fan at inlet and/or outlet.
Some enclosures use bypass contactors or heat exchange
devices to maintain the integrity of the type of protection.
Establish a maintenance schedule for enclosures with heat
exchangers. Equipment cleaning frequency should be based on
the operating environment.
4.3 Installation Precautions
The following precautions are intended for use as guidelines for
proper installation of the controller. Because of the variety of
applications, all of these precautions may not pertain to your
system and they are not all-inclusive. In addition to the follow-
ing, refer to codes and standards applicable to your particular
system.
4.3.1 Motor Branch Circuit
The IEC standard and local regulations govern the installation of
the SIKOSTART controller and the motor it will control. Refer to
IEC and DIN standards for requirements and data regarding 1)
motor disconnecting means, 2) motor branch circuit short circuit
and ground fault protection, and 3) motor overload regulations.
Voltage or fire hazard.
Can cause death, serious injury, or
property damage.
To prevent electrical shock or burns, do not
leave foreign objects (wire clippings, metal
chips, etc.) either inside or on top of the con-
troller during installation procedures.
Heavy equipment.
May cause injury or property damage.
To avoid personal injury or controller damage,
do not use the controller cover as a handle
when moving and/or positioning the unit.
Fire hazard.
property damage.
To prevent a fire, the controller, especially a
non-fan-cooled unit, must be mounted with
its fins in a vertical direction only. Side ways
mounting and improper ventilating can result
in fire.
Hazardous voltage.
property damage.
To avoid electrical shock, this controller
MUST be wired with motor disconnect-
ing means and branch circuit protection
because the controller does not provide
electrical isolation to the motor when the
controller is OFF.
Cat. Number sq. in. mm
2
Continuous Amps
3RW3454 not reqd not reqd up to 57A
3RW3455-65 20 129 up to 131A
3RW3466-67 40 258 up to 248A
3RW3472-83 80 516 up to 480A
3RW3484-86 120 774 up to 960A
Figure 11 shows the components generally required to meet
the various regulations. The overload relay indicated in the fig-
ure is necessary but the standard SIKOSTART controller is not
furnished with an overload relay.
The SIKOSTART controller does not utilize electronic means to
protect itself from damage due to short circuits applied to the
motor terminals or from the motor terminals to ground. Suitable
branch circuit protection must be provided per IEC and DIN
standards.
4.3.2 Controller Protection
When planning your installation, be aware of potential hazards
to personnel and to the controller that can be caused by control
devices used in the system or by unique system features.
Motor Disconnect. When any motor disconnect device con-
nected to the controller output (motor) terminals is opened dur-
ing operation, the controller continues to source full voltage if
running. If the disconnect device is reclosed, the motor will be
restarted at full voltage. When the disconnect device is opened,
a hazardous voltage is present at the controller output terminals
due to thyristor and snubber leakage.
Motor Start/Stop. For normal operation, the controller is
designed to start and stop the motor by using signals that are
input to the controller's circuitry. Do not use the device that dis-
connects and reapplies line power to the controller for ordinary
starting and stopping of the motor.
Asymmetric Motor Windings. Some delta motors are wound
(or re-wound) asymmetrically. This can cause low available start-
ing torque and noisy starting operation.
Power-factor-correcting (PFC) Capacitors. Do not use PFC
capacitors at the controller output terminals. Connection to the
output terminals will damage the controller. If PFC capacitors
are used, they must be connected on the line side of the con-
troller.
When an isolation contactor is used with the controller, the PFC
capacitors must be disconnected from the controller when the
isolation contactor is open (see figure 11).
Hazardous Environment. Depending on the system environ-
ment, consideration must be given to unexpected hazards such
as an accidental spray of gas, liquid or solid particles or inadver-
tent contact with moving machinery. Since the controllers
start/stop control circuitry includes solid-state components, a
potentially hazardous environment may require the installation
of an additional hard wired emergency stop circuit that will
either disconnect AC input power to the SIKOSTART controller
or disconnect the motor from the controller.
Multiple Motors. When the controller is used for more than
one motor, be sure the combined full load current (sum of indi-
vidual motor FLAs ) does not exceed the controllers rated out-
put current. Each motor requires separate overload relay pro-
tection.
Bypassing the Controller. When the controller is mounted in
a sealed enclosure, a bypass contactor generally is used to pre-
vent heat from being generated by the thyristors during running.
If not bypassed during operation, supplemental cooling may be
required depending on operating current and enclosure size and
type.
4.3.3 Electrical Noise Suppression
Noise usually enters solid-state controls through power supply
lines, input lines and output lines. Sources of electrical noise
which can be suppressed within the power distribution system
include:
1) inductive loads, such as relays, solenoids, motors, and motor
starters operated by hard-contact devices, such as push but-
tons or selector switches,
2) AC feeders,
3) high level noise generators, such as arc furnaces, high-fre-
quency welders, large AC machinery, etc.; consider electro-
statically shielded power transformers for suppression.
The most reliable way of minimizing noise coupling is to isolate
the noise generating devices and associated wiring from sensi-
tive control wiring. Group components and wires according to
signal levels and connect noise suppressors close to the noise
generators. Noise suppressors are electric components which
are used to filter, or minimize, the effect of indirect (capacitive or
inductive) coupling.
Recommended suppression practices for the noise sources list-
ed above are:
1) For an inductive load, refer to paragraph 4.4.4.
2) On AC feeders, use RF line filters.
3) On high level noise generators, use electrostatically shield-
ed power transformers.
4.4 General Wiring
Many startup difficulties are due to incorrect wiring. Observe
the following general instructions as well as the specific instruc-
tions in later paragraphs and in system instructions.
Hazardous voltage.
Will cause death or serious injury.
To avoid electrical shock or burn, do not
touch controller output terminals when
voltage is applied to the controller. Output
terminals will have voltage present even
when controller is OFF.
Hazardous voltage.
May cause property damage.
To avoid damaging solid-state power
devices, do not connect power-factor-cor-
recting capacitors to the load side of the
controller.
15
4.4.1 Power and Motor Wiring
Power supply and motor wiring ampacity should be based on
the current ratings of the motor as specified on the nameplate
and in compliance with NEC and local codes. Power and motor
supply wiring should be routed in its own separate conduit or
wireway.
Each SIKOSTART controller is available in several power supply
voltage range models. Ensure that the supply voltage and fre-
quency are within the rated range of the controller.
When welding cable or other fine wire cables are used for
power wiring, use crimp type solderless terminals due to the
fine strand characteristic of this cable. Screw type compression
terminals are not recommended. The fine wires can jam the
threads of the terminal and prevent sufficient compression of
the wire strands. In addition, the fine wires can relax in the ter-
minal, which can lower the compression of the cable. If the con-
tact ends of the cable are not properly compressed, arcing can
occur with the risk of a fire.
4.4.2 Grounding
The controller enclosure and the motor frame must be properly
grounded in a manner that meets all applicable wiring codes. A
ground stud at the line and motor terminals on the controller
frame is provided for connecting the SIKOSTART controller to
system earth ground.
A complex system must have only one ground point to common
power supplies, signal returns, etc. to prevent ground loops. In
most cases a large grounded metal object, such as a control
cabinet, may be considered a single point. Using a short ground
wire to a cabinet is better than using a long ground wire to a ter-
minal barrier bussing point.
4.4.3 Control Wiring
SIKOSTART 3RW3486 soft start controls rated at 960 amperes
require an over temperature shut off switch. Following is a
description of the mounting and wiring of this switch.
Mounting the Over Temperature Switch
The over temperature switch and bracket are mounted at the
top end of the SIKOSTART control without any cooling fans. This
is the main lines and utility power end of the control
(L1 to L3). The bracket is mounted under one of the middle case
mounting bolts.
Fire hazard.
equipment damage.
Welding cable requires crimp type solderless
terminals to prevent arcing and possible fire,
CAUTION
Only use flexible connectors
to connect power wires to
controller busbar.
Wiring the Over Temperature Switch
The over temperature switch has a normally closed contact
that opens when an over temperature condition exists. The
contact has two (2) quick-connect terminals for connection to
the control circuit. The contact is wired in series with the
start/stop control circuit. The switch contact is rated for
220 VAC at 8 amps resistive maximum.
Hazardous voltage.
To avoid electrical shock or burn, do not touch
controller output terminals when voltage is applied
to the controller.
Output terminals will have voltage present even
when the controller is OFF.
DANGER
Bypass
F1
Start
Stop RUN FAULT
G1
S1
S2
G1
G1
K1
A1
A2
X1
X2
27
28
G1 G1
13
14
37
38
over tenp
RUN
U_Motor
=100%
L1/L+
N/L-
Figure 9 Typical Over Temperature Switch Wiring
Hazardous voltage.
Can cause death, serious injury, or property
damage.
To prevent electrical shock or burns, do not leave
foreign objects (wire clip-pings, metal chips, etc.)
either inside or on top of the controller during
installation procedures.
WARNING
Control Wiring. The control wiring is connected at the logic
board terminals shown in figure 12.
Control Voltage. Each SIKOSTART controller is available in sev-
eral control voltage models. Ensure that the control voltage and
frequency supplied match the controller model.
Wire Specifications. Each control terminal can accept a maxi-
mum of two 14-AWG (2,5 mm
2
) stranded wires. Be sure ring
tongue terminals are sized correctly for the wire.
Labeling. Each wire should be appropriately labeled using
tape, shrink-tubing, or other dependable method.
Routing. All control wiring must be kept separate from power
and motor wiring and run in its own separate conduit. Keep con-
trol wire bundles physically separated from power wiring by at
least 6 inches. Where control and power wiring must cross,
they should intersect at right angles.
4.4.4 Coil Suppression
Relay, electromechanical brake, or solenoid coils produce elec-
trical noise transients (especially when being de-energized)
which can be coupled into the controller circuitry and cause
erratic operation. For all such devices connected to or near the
controller or its wiring, see figure 10 and observe the following.
24V DC Coils. Connect a diode directly across each DC coil. A
standard diode (e.g. 1N4004) is acceptable for most 24V DC
applications up to 1.0A. A varistor or surge suppressor can also
be used in place of the diode.
120V/230V AC Coils. Use an R-C circuit (0,47 F, 600V capaci-
tor in series with a 1/4 watt 220 ohm resistor) across each
120V/230V AC coil. An appropriately rated varistor or surge sup-
pressor can be used in place of the R-C circuit, however, R-C
circuits are recommended because they limit the rate of rise of
noise and thus help eliminate high frequency components.
CAUTION
The control outputs are semiconductor (solid state) out-
puts. Applying improper control voltage and/or frequen-
cy can damage the control circuits.
Use control circuits only at the rated voltage and frequency. DC24V
models have solid state FET outputs and should not be used on AC
circuits. Alternately, AC120V & AC230V models have triac outputs
and should not be used on DC circuits.
AC Coil
120/230
VAC
220 ohm
1/4 Watt
0,47 F
600VDC/
220VAC
Switch
DC Coil
+
Switch
+
24V
DC
Figure 10 Inductive Load Suppression
Cat.-No.
3RW3486-....
End with
no fans
Over
temperature
switch
assembly
Figure 11 SIKOSTART Power and Motor Connections
L1
(1)
L2
(3)
L3
(5)
PE
PE
Motor
3~
T1
(2)
T2
(4)
T3
(6)
Optional
Fusible Disconnect
Switch or
Circuit Breaker
SIKOSTART
Optional
Overload Relay
Optional Power
Factor Correction
Capacitor Contactor
Optional Power
Factor Correction
Capacitor
L1
L2
L3
PE
Control Power
Supply
Control Power
Supply
Control Input to
the Run Coil
Run Output
Contact
Motor at 100%
Voltage Output
Fault Output
Contact ( see SW1-1
to set for OPEN or
CLOSE on Fault)
Run/Starting/Shorted SCR LED
Ready/Phase Loss/EEPROM LED
Ramp Up Time Pot
Initial Voltage Pot
Ramp Down Time Pot
X1
X2
A1
A2
13
14
27
28
Us
Um = 100%
37
38
IN
ON
t1
U
t2
F
0
0
F
Um
Ue
t1
t2
U
O.K.
Um =
100%Ue
EEPROM
Ue <
3
Um <
100%Ue
F
0
EEPROM +
@ Us
@ Us &
<= 1.0 A
/ +
/ -
Us = DC24V
Us = AC120V
Us = AC230V
=
=
Figure 12 SIKOSTART Control Connections
Fault Output
Contact (see SW1-4
to set for OPEN or
CLOSE on Fault)
Motor at 100%
Voltage Output
Run Output
Contact
Run Input
(see SW 1-2 for
delay the input signal)
Control Power
Supply
4.5 Power and Motor Connections
The controller input terminals L1, L2 and L3, are at the top of
the unit and the output terminals T1, T2 and T3 are at the bot-
tom of the unit (figure 11). Observe the following:
1. Torque the power and motor terminal set screws according
to the wire size as indicated in table 5.
2. Torque the ground stud nut according to controller opera-
tional current as indicated in table 5.
4.5.1 Power Connections
1. Connect the proper capacity 3-phase 50/60 Hz voltage
source to the controller input terminals L1, L2, and L3. These
terminals are not phase sensitive.
The voltage source must be correct because:
a. Connecting the controller to a line voltage higher than its
rating will open the protective resistor in the snubber
board and prevent controller operation; repair will be
required before the controller can be put into operation.
b. Connecting the controller to a line voltage lower than its
rating will: 1) cause erratic controller operation resulting
in damage to the motor, or 2) prevent controller opera-
tion due to the low control voltage lockout protective fea-
ture.
2. Connect the ground terminal (labeled with ground symbol)
to earth ground.
4.5.2 Motor Connections
1. The VDE/NEC motor overload protection requirement can be
met with an optional overload relay.
2. The controller can be used for wye or delta motors with con-
nections to the motor as either In Line wiring or Inside Delta
wiring (paragraph 2.3.3). Be sure the power ratings are cor-
rect for the type of connection required for the application;
refer to section 3.
3. For a dual voltage 9-lead wye motor the 3-lead controller-to-
motor terminal connections are listed in Table 6.
Threaded Item
Terminal Screw
Wire Size Torque
AWG or MCM* mm
2
lb-in. Nm
6 to 4 16-25 100 11
3 to 2 35 125 14
1 50 135 15
1/0 to 2/0 50-70 150 17
3/0 to 4/0 95-120 225 25
250 to 400 120-185 290 33
500 to 600 240-300 335 38
Nut on Ground Stud Controller Operational Current
<=240A 75 8
>=360A 110 12
* for 75C Aluminum or Copper Wire
Hazardous voltage.
To avoid electrical shock or burn, turn off main
and control voltages before performing instal-
lation or maintenance.
Wrong power rating may cause injury or
property damage.
Confirm that the correct HP rating for the controller
corresponds to the type of connections being used;
e.g. dont use Inside Delta rating for a controller
wired In Line.
Wrong motor connection will cause
property damage.
Confirm that the motor connections are according
to the wiring diagrams in chap.5.
Hazardous voltage.
Can cause death, serious injury or
property damage.
The controller case must be grounded
to earth for operators safety.
Table 5 Terminal Screw and Ground Stud Nut Torque
Table 6 3-Lead Connections for Dual Voltage 9-Lead Wye Motor
High Voltage Wiring Low Voltage Wiring
Controller Motor Controller Motor
Terminal Terminal Terminal Terminal
T1 T1 T1 T1 & T7
T2 T2 T2 T2 & T8
T3 T3 T3 T3 & T9
T4-T7* T4-T5-T6*
T5-T8*
T6-T9*
* Jumper * Jumper
4. 6-lead delta motor connection is shown in figures 17 and 18.
Connections from controller to motor are one on one, i.e. T1
to T1, T2 to T2, etc.
5. For a dual voltage 12-lead delta motor the 6-lead controller-
to-motor connections are listed in Table 7.
Table 7 6-Lead Connections for Dual Voltage 12-Lead Delta Motor
High Voltage Wiring Low Voltage Wiring
Controller Motor Controller Motor
Connection Terminal Connection Terminal
T1 T1 T1 T1 & T7
T2 T2 T2 T2 & T8
T3 T3 T3 T3 & T9
T6 T12 T6 T6 & T12
T4 T10 T4 T4 & T10
T5 T11 T5 T5 & T11
T4-T7*
T5-T8*
T6-T9*
* Jumper
6. For multispeed application, the SIKOSTART controller can be
used with an electromechanical starter to provide soft start.
The controller output must be connected to the line input of
the multispeed starter. Individual motor overload protection
should be supplied for each motor speed separately. During
speed transitions, control input (A1, A2) must be off for a
minimum of 200 milliseconds.
7. When using the controller with part winding motors, these
motors must be connected in their full voltage run winding
configuration, and the three motor leads connected to the
controller output terminals.
8. The motor frame should be connected to the earth ground
terminal.
4.6 Control Connections
1. Connect the control power supply (Us) specified on the con-
troller label to the X1 and X2 terminals; see figure 12.
2. Connect control circuit pilot devices in accordance with the
application. Section 5 provides examples of several typical
arrangements; section 6 describes the dip switch (SW-1)
settings.
3. Torque the control circuit terminal screws according to the
wire size as indicated below.
4.7 Installation Check
1. Check that all wiring and power connections are secure and
that mounting bolts are tight.
2. Remove all wire cuttings, installation particles, metal chips
and debris before energizing.
3. Shut enclosure doors to protect equipment from dust and
personnel from hazardous voltage.
Wire Size Torque
AWG mm
2
lb-in. Nm
24 to 12 0.25-4 8 0.9
5 Wiring Diagrams
5.1 Typical Applications
This section contains four wiring diagram sets for typical appli-
cations as follows.
Figure 13 & 14 - Two Motors, Wired In Line, in a Vented
Enclosure
Figure 15 & 16 - Motor, Wired In Line, with Bypass Contactor
Figure 17 & 18 - Two Motors, Wired Inside Delta, in a Vented
Enclosure, 1 with Isolation Contactor 1 with Shunt Trip
Figure 19 & 20 Single Motor, Wired Inside Delta, with Bypass
and Isolation Contactors
Each diagram set consists of two sheets: one showing the
power and motor connections and one showing the control
wiring. The SW1 chart at the bottom of the power and motor
diagram indicates the switch settings required for that particular
configuration (refer to paragraph 6.1).
5.2 Circuit Devices
Common Circuit Devices. Some circuit devices common to
each application shown include:
an overload relay (F1, F2) for motor protection;
either a circuit breaker (Q1) or a fused disconnect switch
(S1/F1) to connect and disconnect main power to the
application;
a Start/Stop control that is connected so when the start
switch is pushed, the RUN coil in the controller is energized,
and the controller RUN interlock contact closes and latches
in the RUN coil. When the stop switch is pushed or power
is lost, the circuit is broken and the controller drops out
which shuts off power to the motor. If a two wire Start/Stop
control connection is used, the motor may automatically
restart when power is restored to the controller.
Bypass Contactor. The applications shown in figures 15 and 19
include a bypass contactor (K2). The bypass contactor is rated
to handle the running current of the motor but not the starting
current. The bypass contactor remains open until the controller
has soft-started the motor. Once the motor is operating at line
voltage, the Up-to-Voltage contact closes and the bypass con-
tactor is energized causing motor current to flow through the
bypass contactor rather than the controller.
A bypass contactor is useful when the controller is mounted in
a IP 4x, or other airtight enclosure. When the motor current is
routed through the bypass contactor, no current is flowing
through the controller SCRs, and the controller generates no
heat.
For both applications, the switch section SW1-1 is set to the
turn off delay position so that the bypass contactor de-energizes
before the controller (refer to paragraph 6.1).
Isolation Contactor. The applications shown in figures 17 and
19 include an isolation contactor. The isolation contactor is ener-
gized when the controller is operating (RUN coil is On) and pro-
vides power to half of the windings of the 6-lead delta motor. If
a controller fault occurs, the fault contact opens which de-ener-
gizes the isolation contactor and the motor stops.
For both applications, switch section SW1-4 is set to open the
fault contact on fault detection and switch section SW1-2 is set
so that the isolation contactor energizes before the controller
(refer to paragraph 6.1).
Shunt Trip. A shunt trip circuit breaker is used on the second
motor in figure 17. The switch section SW1-4 is set to close the
fault contact on fault detection. With the circuit breaker (Q1)
closed and the controller operating (RUN coil is On), the shunt
trip coil is de-energized. If a controller fault occurs, the fault con-
tact closes to energize the shunt trip coil which trips open the
circuit breaker and disconnects power to the controller and
motor.
The figure 17 application shows two methods of using the con-
troller fault contact to stop the motor when a fault occurs: 1) the
fault contact opens to de-energize the isolation contactor for
the first motor (M1 and 2) the fault contact closes to operate
the shunt trip on the circuit breaker for the second motor (M2).
Figure 13
Power wiring for motors, wired "In Line", in a vented enclosure (circuit breaker or fusible disconnect)
S1
F1
G2
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F3
U V W
M
3~
M2
Q1
G1
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F2
U V W
M
3~
M1
L1
L2
L3
PE
I > I > I >
Switch Settings for M1 Switch Settings for M2
Figure 14
Control wiring for motors, wired "In Line", in a vented enclosure (circuit breaker or fusible disconnect)
X1
X2
A1
G1
A2
F2
13
14
G1
RUN
INPUT
RUN FAULT Um=100%
G1
Stop
Start
S3
37
38
G1
27
28
G1
S2
X1
X2
A1
G2
A2
F3
13
14
G2
RUN
INPUT
RUN FAULT Um=100%
G2
Stop
Start
S5
37
38
G2
27
28
G2
S4
N/L
L1/L+
Figure 15
Power wiring for a motor, wired "In Line" with bypass contactor
Q1
G1
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F1
U V W
M
3~
M1
L1
L2
L3
PE
I > I > I >
K1
Switch Settings for M1
Figure 16
Control wiring for a motor, wired "In Line" with bypass contactor
X1
X2
A1
G1
A2
F1
13
14
G1
RUN
INPUT
RUN FAULT
G1
Stop
Start
S2
37
38
G1
S1
27
28
G1
K1
Um=100%
Bypass
N/L
L1/L+
Figure 17
Power wiring for motors, wired "Inside Delta" in a vented enclosure, with fusible disconnect and isolation contactor, and shunt trip
circuit breaker
G2
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F3
U1
V2
W1
M
3~
M2
PE
U2
W2
V1
S1
F1
G1
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F2
U1
V2
W1
M
3~
M1
Q1
L1
L2
L3
PE
I > I > I >
K1
PE
U2
W2
V1
Note
order of
terminal
leads
T6 T4 T5
12 8 10
Shunt
trip
Note
order of
terminal
leads
Switch Settings for M1 Switch Settings for M2
Figure 18
Control wiring for motors, wired "Inside Delta" in a vented enclosure, with fusible disconnect and isolation contactor, and
shunt trip circuit breaker
X1
X2
A1
G1
A2
F2
13
14
G1
RUN
INPUT
RUN FAULT Um=
100%
G1
Stop
Start
S3
37
38
G1
27
28
G1
S2
K1
X1
X2
A1
G2
A2
F3
13
14
G2
RUN
INPUT
RUN FAULT Um=
100%
G2
Stop
Start
S5
37
38
G2
27
28
G2
S4
Q1
Shunt
trip
FAULT
N/L
L1/L+
Figure 19
Power wiring for a motor, wired "Inside Delta", with bypass and isolation contactors
S1
F1
G1
L1 L2 L3 PE
1 3 5
T1 T2 T3
2 4 6 PE
F2
U1
V2
W1
M
3~
M1
L1
L2
L3
PE
K1
PE
U2
W2
V1
T6 T4 T5
12 8 10
U1 V1 W1 W2 U2 V2
K2
Note
order of
terminal
leads
Switch Settings for M1
Figure 20
Control wiring for a motor, wired "Inside Delta", with bypass and isolation contactors
X1
X2
A1
G1
A2
F2
13
14
G1
RUN
INPUT
RUN
G1
Stop
Start
S3
S2
27
28
G1
K2
37
38
G1
K1
Um=100% FAULT
Bypass Fault
N/L
L1/L+
6 Setup and Operation
6.1 Setup Controls
The setup controls are at the right side of the controller and are
accessible without removing the cover. Figure 21 shows the
controls: three potentiometers, T1, U, and T2; and DIP switch
SW1. Values for the potentiometer settings are listed in Table 6.
Use a small screwdriver to change the potentiometer setting,
rotating clockwise to increase and counterclockwise to
decrease.
Note: The controls are set at the factory for a typical starter.
Please verify the application for proper settings. (For detailed
picture of the potentiometers see figure 22)
T1 - Start Time. This 16-position potentiometer sets the accel-
eration ramp time up to 60 seconds maximum. This setting
determines the time interval for the voltage to increase from the
initial setting (U) to line voltage.
U - Initial Voltage. This 16-position potentiometer sets the ini-
tial voltage at a percentage of line voltage: 30% to 80%. The
initial setting should be the level that causes the motor shaft to
turn as soon as the run signal is given. .
T2 - Stop Time. This 16-position potentiometer sets the decel-
eration ramp time up to 60 seconds maximum. This setting
determines the time interval for the voltage to decrease from
line voltage to 80% of the initial setting (U).
SW1 - DIP Switch. This switch has four sections which provide
setting the controller software to correspond to the application.
Each switch section is positioned by sliding it to the right or left
as viewed in figure 21 (up or down when the controller is
mounted vertically). On the wiring diagrams in section 5, the
position of each switch section is indicated by an arrow pointing
to either the right or left.
1. SW1-1: This switch provides a turn off delay signal setting
(left position). The off delay allows a bypass contactor to
de-energize 1,0 seconds before the controller RUN coil de-
energizes.
The right position of switch SW1-1 provides no delay. When
the stop device is actuated, the RUN coil de-energizes
immediately.
2. SW1-2: This switch provides a turn on delay signal setting
(left position). The on delay allows an isolation contactor to
energize first, at zero current, followed by the controller RUN
coil 1,0 seconds later. The delay maximizes contact life on
the isolation contactor. If no delay is set this can cause a
failure (missing phase). Also use this switch for isolation
contactors behind the soft starter (e.g. Dahlander circuits).
The right position of switch SW1-2 provides no delay. When
the start device is actuated, the RUN coil energizes
immediately.
3. SW1-3: This switch directs the controller software to oper-
ate the SCRs for either a Wye motor - In Line wiring (left
position) or a Star/Delta motor - Inside Delta wiring (right
position).
Hazardous voltage.
To avoid electrical shock or burn, turn off
main and control voltages before per-
forming installation or maintenance
Figure 21 Setup Controls
Table 8 Potentiometer Setting Values
Ramp Time
Dial Initial Voltage U T1, T2
Setting (% Full Voltage) (Seconds)
0 30 0,5
1 33 1,0
2 36 2,0
3 40 4,0
4 43 6,0
5 46 8,0
6 50 10
7 53 12
8 56 15
9 60 20
A 63 25
B 66 30
C 70 35
D 73 40
E 76 50
F 80 60
Factory Settings T1=8 (15 sec)
T2=0 (0,5 sec)
U=8 (56%)
T2
U
T1
When the switch is set to Standard Circuit, the motor
must also be operated in the standard circuit; and
when the switch is set to Star-delta the motor must
also be operated in star-delta!
If the switch is set to a type of circuit not connected, this
can cause very high currents to occur during operation.
These currents can destory or demage thyristors and other
components. Be sure to set the soft starter to the type of
circuit actually in use.
4. SW1-4: This switch sets the fault contact, which is a nor-
mally open contact,to respond to a fault by either closing
(arrow down position, switch to the left) or opening (arrow
up position, switch to the right).
With the open on fault position selected, contact status is as
follows.
Power off - contact is open
Power on - contact closes
Fault occurs or loss of power - contact opens
With the close on fault position selected, contact status is
as follows.
Power off - contact is open
Power on - contact is open
Fault occurs - contact closes
The contact remains open for a loss of power.
The factory settings for switch SW1 sections are:
SW1-4: close on fault (switch left)
SW1-3: In Line wiring (switch left)
SW1-2: no on delay (switch right)
SW1-1: no off delay (switch right)
6.2 LED Indicators
Two LED indicators are located above the potentiometers.
These LEDs indicate controller status and fault conditions as fol-
lows.
LED 1 (Top)
Constant Display Controller is ready for operation
Single Flashing FAULT: Main voltage phase loss*
Double Flashing FAULT: EEPROM parity error
LED 2 (Bottom)
Constant Display Output voltage equals line voltage,
i.e., motor is up to speed
Single Flashing Output voltage is less than line voltage,
i.e., motor is starting or stopping
Double Flashing FAULT: Shorted SCR
* no action to fault output
6.3 Controller Setup
Before the initial startup, set the controls as follows.
1. Set switch SW1 sections in accordance with the application.
2. Set Start Time T1. This setting is application dependent,
affected by load torque, motor voltage, and total inertia. The
factory setting is 8, or 15 seconds.
3. Set Initial Voltage U. The factory setting is 8, or 56% of
the line voltage.
4. Set Stop Time T2. The 0 setting allows the load to coast to
rest. If the soft stop feature is required for the application,
set T2 to the 8 position. The factory setting is 0.
6.4 Preliminary Checks
With main power disconnect device open and control power off,
check the following.
1. Power and Motor Connections. Check that the controller
has been properly connected to the power source and
motor per figure 11.
2. Control Connections. Check that control power, the
start/stop control, and applicable devices have been proper-
ly connected to the control terminal board (figure 12).
3. AC Line Power Verification. Verify that each phase of the AC
line power at the disconnect device is within the rated value
of the controller as indicated on the controller nameplate.
4. Ground Check. Use an ohmmeter set to its highest scale
and observe the following.
a. Check for a ground between each controller output ter-
minal (T1, T2, T3) and chassis ground. Each terminal to
ground reading should be over 500K ohms.
b. The measurement between each input terminal (L1, L2,
L3) and ground should be over 500K ohms.
6.5 Initial Energization
1. Temporarily remove run signal connections by opening the
circuit at control terminals A1 and A2.
2. Turn on main AC power and control power to the controller;
LED 1 comes on.
3. Measure input AC voltages L1 to L2, L2 to L3, and L3 to L1.
Voltages should be within the controllers rated range and
balanced for proper motor operation.
When the line voltages are not equal, unbalanced currents in
the stator windings occur. A small percentage voltage
unbalance results in a much larger percentage current unbal-
ance. Consequently, the temperature rise of the motor
operating at a particular load and percentage voltage unbal-
ance is greater than for the motor operating under the same
conditions with balanced voltages.
Hazardous voltage.
To avoid electrical shock or burn, turn off
main and control voltages prior to performing
preliminary checks.
Hazardous Voltage.
property damage.
To avoid electrical shock or burn, do not
operate controller with either the cover or
the control terminal finger guard removed.
Figure 22 Potentiometer Settings
Record the final potentiometer settings in the blank spaces above.
Initial Voltage _______________
(0 is minimum, F is maximum)
Stop Time _________________
Start Time ________________
4. Measure individual input AC voltages L1, L2 and L3 to
ground. On most systems, voltage will be about 58% of line
voltage and nearly equal. Any unbalanced voltage may indi-
cate an undesired ground in the motor or the SIKOSTART
controller.
5. Measure the control voltage. It should be within -15% to
+10% of the nominal controller rating.
6. Measure voltage across each pole of the SIKOSTART
controller, i.e., L1 to T1, L2 to T2, and L3 to T3.
These voltages should be nearly equal and have values as
follows:
a. For a wye motor, voltage across each pole should be
approximately 58% of input line to line voltage.
b. For a delta motor, voltage across each pole should be
approximately 100% of input line to line voltage.
Low voltage, zero voltage, or unequal voltages indicate 1)
the load circuit to the motor is open or improperly grounded,
or 2) an SCR is shorted or bad (usually indicated by a double
flashing LED 2; refer to the troubleshooting section).
To check the load circuit, disconnect power to the controller,
check and correct connections and close any load circuit
switching device(s). Energize the controller and recheck
voltage across each pole.
7. De-energize main AC power and control power. Unit is now
ready. Reconnect actuating signal wires to terminals A1 and
A2.
8. Energize main AC power and control power. Initiate start by
actuating pilot device(s). Check for proper operation and
desired starting performance. Verify proper motor rotation;
if required, reverse rotation by interchanging motor leads.
Adjust potentiometers per paragraph 6.6.
6.6 Motor Starting Adjustments
Observe the motor during the first trial starts. With the setup
controls adjusted as described in paragraph 6.3 and controller
LED 1 on, start the motor.
Initial Voltage U. Ideally, the motor begins to rotate almost
immediately after starting voltage is applied to it and the load
begins to move. If the motor fails to start rotating when the
starting voltage is applied, increase the U potentiometer setting.
If the motor accelerates too quickly, decrease the U setting.
Repeat trial starts until the load just begins to move when
power is first applied.
Additional initial voltage may be needed if motor is subject to
starting load variance such as stiff belts, cold grease or process
loading.
Start Time T1. During setup procedures, T1 was set to a mid
range acceleration ramp time. If the controller ramp ends
before the motor reaches full speed, turn run signal off and
increase the T1 setting. Repeat trial starts to achieve a smooth
acceleration to full speed (LED 2 changes from single blinking
mode to continuously on) before the T1 time elapses.
Stop Time T2. For most applications, the motor load will coast
to rest; T2 setting equals 0.
A soft stop is required for some applications, e.g. to reduce
water hammer in a pumping system. For a soft stop, most appli-
cations require the stop time T2 to be equal to or longer than the
start time T1. Turn run signal off before changing the T2 setting.
Hazardous voltage.
Can cause death, serious injury or
property damage.
To avoid electrical shock or burn, turn
off main and control voltages between
starts when making adjustments.
Frequency of starting:
Keep cooling time in mind!
Order number 3RW34..0DC2. ..0DC3. ..0DC4.
Coil Voltage 24VDC 120VAC 230VAC
Isolation Voltage, VAC 1500 1500 1500
Input Current, mA 10@24VDC 10@120VAC 10@230VAC
On Voltage, volts min. 17 VDC 85 VAC 170 VAC
On Current, mA min. 6 6 6
Off Voltage, volts max. 8VDC 40VAC 80VAC
Off Current, mA max. 3 3 3
Input Impedance,
ohms (typical) 13k 13k 13k
7 Electrical Specifications
Main Voltage Required In Line Application: 200/460V AC or 400/600V AC each
15% (specified by catalog no.)
Inside Delta Application: 200/400V AC or
400/600V AC each 15% (specified by catalog no.)
Control Voltage Required 24V DC, 120V AC, or 230V AC, +10%, -15%
(specified by catalog no.)
Control power requirements are listed below (table 9).
AC Frequency & Phase 50/60 Hz, working 45 to 65 Hz; 3 phase
Temperature Range 0 to 60C, inside enclosure in which unit is mounted.
Derating for 60C see table 3
Permissible Altitude 1000m at rated output
2000m at 0.87*le
3000m at 0.77*le
Overcurrent Protection The standard SIKOSTART controller is not
equipped with overload protection. The user should
provide overload protection.
Ratings for Frequent Starts and Occasional - 20 times in any 60 minute period:
Stops, Plugging or Jogging Applications Controller rating to be 133% of motor rating.
Severe - 5 times in any 60 second period:
Controller rating to be 200% of motor rating.
Very Severe - 10 times in any 60 second period:
Controller rating to be 300% of motor rating.
Controller Current Ratings
During Start and Run: Current Cold Start Time @ 50C
115% Continuous
200% 480 sec.
300% 120 sec.
450% 30 sec.
500% 20 sec.
600% 10 sec.
Adjustment Ranges -
16 settings each:
Start Time (Accel Ramp) 0.5 to 60 seconds*
Stop Time (Decel Ramp) 0.5 to 60 seconds
Initial Voltage 30% to 80% of nominal voltage (approximately
10% to 64% on normal starting torque)
*Acceleration time of the motor will probably be
less than the Start Time setting and will vary
depending on the load friction and inertia
characteristics of the system.
Table 9 - Input (RUN) Coil Input (RUN) Coil
User Outputs Rating N.O. outputs are rated 0.5 Amp maximum at
Three solid state outputs are 24V DC, and 1.0 Amp at 120V AC and 230V AC.
available for the user to apply
Solid State Outputs M (RUN) When controller is operating,
the RUN contact is closed.
Um = 100% When motor is running at 100% of line
voltage (after starting is complete), the Um
contact is closed.
FAULT The FAULT contact closes for: an EEPROM
error or a shorted thyristor.
Refer to paragraph 6.1 re SW1-4 settings.
Reset of fault simply by giving a new start signal.
Recommended Fuse Style * Two levels of short circuit protection can be provided by the user:
1. Type 1 protection is available where the short circuit protective
device protects the wiring and the integrity enclosure. The controller
will probably damage and require replacement or repair befoe being
re-energized. Cirucit breakers and motor circuit protectors provide
this type of protection.
2. Type 2 protection is available where the short circuit protective
device protects both the wiring and the controller. The controller
should not require repair before re-energizing after the short circuit
has been cleared. Fuses of an KR-1 type or HRC-1 type sized in
accordance with the NEC/CEC code or semiconductor type fuses
provide this kind of protection.
Type RK-1 Dual Element
Partial List of Manufacturers
Bussman LPN-RK (250V or less)
LPS-RK (600V or less)
Gould A2D( )R (250V or less)
A2D( )R (600V or less)
Littelfuse LLN-RK (250V or less)
LLS-RK (600V or less)
User Output for ISOL Logic to Power 1500 V AC
120V AC and 230V AC Rating 10 Amp Make
version 1 Amp Break
1 Amp Continuous @ 120V AC / 230V AC
On Voltage Drop 1.2 V AC (typ)
On Current 25 mA (minimum)
Off Leakage Current 2 mA (typ)
User Output for ISOL Logic to Power 1500 V AC
24V DC version Rating 1.5 Amp Make
0.5 Amp Break
0.5 Amp Continuous @ 24V
On Voltage Drop 1.6 V DC (typ)
Off Leakage Current 2 mA (typ)
* For a complete listing of Siemens SITOR fuses, see Appendix A.
Current Required terminals X1, X2
Catalog 24V DC Control Voltage Number 120V AC Control Voltage Number 230V AC Control Voltage Number
Number Control Fans of fans Control Fans of fans Control Fans of fans
3RW3454 100 mA - 100 mA - 100 mA -
3RW3455 - 58 100 mA 450 mA 1 100 mA 200 mA 1 100 mA 100 mA 1
3RW3465 - 67 100 mA 300 mA 1 100 mA 150 mA 1 100 mA 75 mA 1
3RW3472 100 mA 600 mA 2 100 mA 300 mA 2 100 mA 150 mA 2
3RW3483 - 86 100 mA 900 mA 3 100 mA 450 mA 3 100 mA 225 mA 3
Operational Current Power Dissipation Surge Capacity I
2
t, (1/2 cycle)
Catalog Rating @ Rated Current (1 cycle) Controller
Number (Amperes) (Watts) (Amps) (A
2
-sec)
3RW3454... 57 154 1,900 18,000
3RW3455... 69 166 3,200 80,000
3RW3457... 80 192 4,400 97,000
3RW3458... 105 252 4,400 97,000
3RW3465... 131 315 8,000 306,000
3RW3466... 195 468 8,000 320,000
3RW3467... 248 595 14,500 1,051,000
3RW3472... 361 866 6,000 460,000
3RW3483... 480 1152 14,920 1,540,000
3RW3484... 720 1728 20,000 2,650,000
3RW3486... 960 2304 36,000 7,350,000
Electrical Data
Table 10 - Control Power Requirements
8 Dimensions
Catalog le, Wye Width Height Depth Mount Width Mount Height Mount
Number (Amps) (W) (H) (D) Width Offset Height Offset Hole
(MW) (Q) (MH) (P) (BH)
3RW345*... 35-105 216 356 187 127/ 61 327 16 6 (4)
94
3RW346*... 131-248 292 381 189 248 22 332 27 6 (4)
3RW3472... 361 344 417 224 286 29 336 45 6 (4)
3RW3483.../84... 480, 720 442 517 231 133 (3) 18 450 32 6 (8)
3RW3486... 960 448 719 220 101/ 23 653 29 6 (8)
138/
138
8.1 Dimensions (mm)
Figure 23 Dimension Drawings
94
127
23
39
101 138
133 133
138
18
133
Table 11 LED Fault Indications
Indication Cause Check/Remedy
LED 1 single flashing Phase loss Verify that proper three-phase incoming power is present per
paragraph 6.5, steps 3 and 4.
Inside Delta wiring problem
See problem 2 in Table 13.
LED 1 double flashing EEPROM error Replace the logic board. Replacement instructions are included
with the new logic board. Return the faulty logic board to the fac-
tory.
LED 2 double flashing Shorted SCR Check SCRs as described in paragraph 9.4.
9 Troubleshooting
9.1 Maintenance and Troubleshooting
Step 1. Regularly check (the frequency depends upon the
amount of airborne particulate matter) the fans and heatsink fins
for unimpeded air flow and check that the fans are moving
freely.
Step 2. In case of installation according to NEMA standards the
following NEMA standards should be used as the basis of a
preventive maintenance program:
ICS 1.1-1984 (R1988) "Safety Guidelines for the Application,
Installation, and Maintenance of Solid State Control"
ICS 1.3-1986 (R1991) "Preventive Maintenance of Industrial
Control and Systems Equipment."
Step 3. If the torque requirements for wiring connections are
not legible, refer to UL 486E "Equipment Wiring Terminals for
use with Aluminum and/or Copper Conductors. for nominal
torque values.
Step 4. In the circumstance of a fault condition as indicated by
the opening of a short circuit protective device, refer to Annex A
("Maintenance of Motor Controllers After a Fault Condition") of
NEMA standard ICS 2-1993 "Industrial Control and Systems,
Controllers, Contactors, and Overload Relays Rated Not More
Than 2000 Volts AC or 750 Volts DC."
This checklist does not represent an exhaustive survey of main-
tenance steps necessary to ensure safe operation of the equip-
ment. Particular applications may require further procedures.
Should further information be desired or should particular prob-
lems arise which are not covered sufficiently for the purchaser's
purposes, the matter should be referred to the local Siemens
sales office.
Dangerous voltages are present in the equipment which can
cause death, serious injury, or property damage. Always deen-
ergize and ground the equipment before maintenance.
Maintenance should be performed only by qualified personnel.
The use of unauthorized parts in the repair of the equipment or
tampering by unqualified personnel will result in dangerous con-
ditions which can cause death, serious injury, or equipment
damage. Follow all safety instructions contained herein.
9.2 Troubleshooting Tables
Two LED indicators on the SIKOSTART controller provide fault
indications as listed in Table 11 which includes recommended
checks and remedies.
Table 12 is a general troubleshooting table listing troubles, their
possible causes, and recommended checks and remedies.
Inside Delta wiring problems are described in Table 13.
Hazardous voltage/fire hazard.
Failure to properly maintain this equipment
can result in death, serious injury, property
damage or product failure. The instructions
referred to below should be carefully
reviewed, understood and followed regularly.
Trouble Cause Check/Remedy
Motor does not start Check input side of terminals L1, L2 and L3 for open dis
and LED 1 is not on. No main power connect switch, breaker trip, or insecure terminal
connections. Verify that proper three-phase incoming
power is present per paragraph 6.5, steps 3, 4 and 6.
No control power Check input side of control terminals X1 and X2 for blown
fuse, any open circuit condition or insecure terminal
connections.
Verify that proper control voltage is present (within
+10%,-15% of nominal controller rating). If the control
circuit includes a control power transformer (CPT), verify
that the CPT primary voltage is present and proper for the
CPT primary tap.
Motor does not start Motor not connected Check that any series disconnect switch or
and LED 1 is to controller isolating contact is closed.
glowing steadily
Check for tripped overload relay. Determine and remedy
cause of trip per Motor overload relay trips...
trouble below.
Verify that the motor is connected to the controller. With
proper incoming power and the motor connected but
Stopped, voltmeter readings across terminals T1 and T2,
T2 and T3, and T3 and T1 should be zero. A reading of line
voltage indicates that the motor is not connected
properly.
Discontinuity in the Check that control power is present at terminals A1 and
control input circuit A2. If power is not present, check for insecure wiring
to the Run coil connections at terminals A1 and A2, at applicable control
terminals (13, 14, etc.), and at the control devices (e.g., start-
stop device, isolation contact) used in the input
circuit to the Run coil.
Bad cable connection Remove control power and check that Logic PCB
or defective printed -to-Snubber PCB cable is secure. If secure, remove main
circuit board (PCB) power and replace Logic PCB and/or snubber
component PCB or consult the factory for assistance.
Faulty motor Troubleshoot motor according to the
manufacturers instructions.
Motor does not start
and both LEDs come
on at Run command Inside Delta wiring problem See problem 3 in table 13.
Motor starts but does Controller not finished Check that LED 2 is on, which indicates output
not come up to speed ramping to line voltage voltage equals line voltage. If motor is coming
up to speed too slowly, decrease Start Time T1
and/or increase Initial Voltage U; refer to
paragraph 6.6.
Motor growls or hums Initial Voltage U is set Raise setting of Initial Voltage U until motor just
at start but comes too low starts to rotate when power is first applied;
up to speed refer to paragraph 6.6.
Table 12 Troubleshooting
Motor growls at start Motor unable to start load Check load for mechanical blockage
and does not come (rocks, logs, seized bearings, etc.)
up to speed Increase motor size; for proper controller
selection, refer to section 3.
Controller not finished Check that LED 2 is on, which indicates output
ramping to line voltage voltage equals line voltage. If motor is coming
up to speed too slowly, decrease Start Time T1
and/or increase Initial Voltage U; refer to
paragraph 6.6.
Shorted SCR (LED 2
double flashing) Check SCRs as described in paragraph 9.4.
Motor comes up to Improper settings Adjust Start Time T1 and Initial Voltage
speed too quickly or too U settings per paragraph 6.6.
slowly
Load is too light Adjust load or consider decreasing or increasing
or too heavy motor size; for proper controller selection, refer
to section 3.
Motor runs noisily with
very high current Inside Delta wiring problem See problem 1 in table 13.
Motor starts hard,
not softly Improper setup Refer to paragraph 6.6 for motor starting
adjustments.
Shorted SCR (LED 2
double flashing) Check SCRs as described in paragraph 9.3.
Inside Delta wiring problem See problem 4 in table 13.
Unsuitable delta motor A certain delta motor design (wired Inside Delta) will not
for Inside Delta wiring start softly with a high friction load (e.g., conveyor), only
with a low friction load (e.g., water pump). The soft start
produces balanced three-phase power to the motor, but it
becomes stuck at a low rpm until the end of the start
ramp at high current. It then jumps quickly to full speed
due to the high voltage and current. Consult the factory
for assistance.
Controller is off but Shorted SCRs Check voltage from terminal A1 to A2 to
motor is running (LED 2 double flashing) verify that Run coil is not energized. Check SCRs as
described in paragraph 9.4.
Motor overload relay Motor is overloaded
trips during starting while running Check for a mechanical cause of overload and clear.
Motor not able to Check that motor comes up to speed when
accelerate load started by applying across-the-line full voltage directly to
the motor. An alternative is to use the controller with T1
set at 0 (0.5 seconds) and U at F (80% full voltage).
a. If motor cant accelerate the load, increase
motor size; for proper controller selection,
refer to section 3.
b. If motor accelerates the load, continue
checking the following causes.
Improper overload
relay Check overload relay to determine correct settings.
Overload relay current
transformers incorrectly
wired Verify current transformer wiring per applicable diagram(s).
Table 12 Troubleshooting - Continued
Motor branch circuit Branch circuit protective Size the device in accordance with all applicable
protection trips during device incorrectly sized standards.
starting or running
Check circuit breaker trip settings.
Incorrect power wiring Check all power wiring connections to determine
causing a short on Iif a phase-to-phase or phase-to-ground short is present.
input or load side of
controller
9.3 Inside Delta Wiring Problems
Figure 24 shows a correct inside delta connection. With the cor-
rect connection, the motor runs properly with current limit dur-
ing starting and the line and leg currents are balanced.
Table 13 lists four improper connection problems and the unsuc-
cessful response for each. The Example column illustrates
only one of many combinations that may be responsible for the
problem.
Table 13 Inside Delta Wiring Problems
Problem Response/Example
1. Reversed Winding The motor runs but makes
non-normal sounds and
the running current is very high.
2. Dead Ended Winding The controller trips out on
a single phase fault.
The line with the Dead End
Winding will have no current flow.
The other two lines will have very
large currents flowing.
Note: Repeated attempts
at starting with this connection
can damage the controller.
3. Dead Ended on
All Windings The motor does not start. There
is no current flow on any of the
lines. The controller indicators
LED 1 and LED 2 come on at the
same time when a run command
is given.
4. Starter to Fault Contactor
Lead Swaps The motor runs but there is no
current limiting during starting.
The line and leg currents are
balanced. Due to the phase
shift in the leg currents compared
to the controllers internal timing
for starting control, there is no
current limiting during
starting.
5. Switch position SW1-3 Incorrect firing pulses cause very
does not correspond high currents to flow in the motor.
to the type of circuit These currents can destory the
in use soft starter. Figure 24 Proper Inside Delta Wiring Connection
L1
L2
L3
w1
w2
w3
scr1
scr2
scr3
T1
L1
L2
L3
T3
Motor
SIKOSTART
T4
T2 T5
T6
L1
L3
L2
L1
T1
T4
T6
T3
L3
T5
T2
T2
L2
L1
L3
L2
L1
T1
T1
T4
T4
T6
T3
L3
T5
T5
T2
T2
L2
L1
L3
L2
L1
T1
T1
T4
T4
T6
T6
T3
T3
L3
T5
T5
T2
T2
L2
L1
L3
L2
L1
T1
T1
T4
T4
T6
T6
T3 T3
L3
T5
T5 T2
T2
L2
Table 13 - Inside Delta Wiring Problems
Problem 1 Problem 2 Problem 3 Problem 4
When the switch is set to Standard Circuit, the motor
must also be operated in the standard circuit; and
when the switch is set to star-delta the motor must
also be operated in star-delta!
If the switch is set to a type of circuit not connected, this
can cause very high currents to occur during operation.
These currents can destory or demage thyristors and other
components. Be sure to set the soft starter to the type of
circuit actually in use.
9.4 Shorted SCR Checks
Perform one of the following checks to identify any shorted
SCRs. These checks require no disassembly of the unit.
Extensive SCR tests are detailed in later paragraphs.
9.4.1 Resistance Check
Use an ohmmeter to check for shorted SCR(s) as follows.
1. Disconnect and lock out all power to unit.
2. Measure the resistance from the line to load terminals (L1
to T1, etc.), across each phase of the controller.
3. Any reading of less than 3,000 ohms indicates a shorted
SCR that must be replaced. Note that the reading can be as
high as 3,000,000 ohms.
9.4.2 Voltage and Load Check
Main and control power are connected to the unit for this check.
To prevent motor operation during testing, disconnect the run
signal at terminals A1 and A2.
1. Measure AC voltage across each pole and check the load cir-
cuit as described in paragraph 6.5, step 5.
2. If voltage measurements indicate a shorted SCR, replace
the SCR.
9.5 SCR (Thyristor) Functional Testing
The following basic and advanced tests may be used to verify
SCR module functionality.
9.5.1 SCR Description
SCR descriptions and illustrations are included here to help
identify the terminals for the functional tests.
The power switching device is furnished as an insulated dual
SCR module. The two SCRs in each module are connected in
inverse parallel (back-to-back). One module, or power pole, in
each line gives bidirectional control of the AC voltage. Typical
connections are shown in figure 25. Each SCR has two inter-
nally connected cathode terminations, a large power cathode
terminal, and a smaller auxiliary cathode terminal or wire for the
control connection.
A forward biased SCR (anode positive, cathode negative) will
turn on and conduct current if positive control voltage is applied
to the gate terminal and gate current flows inside the SCR junc-
tion to the cathode. The SCR turns on and stays on at anode
currents above the latching value. It remains on until anode cur-
rent falls below the holding value.
The module and SCR characteristics listed below are represen-
tative of all modules and SCRs. The value for each characteris-
tic is a typical value.
Illustrations identifying terminals and connections for thyristors
of various current ratings are included at the end of this section.
Hazardous voltage.
High voltage is present on all controller com-
ponents except heat sinks, current transform-
ers, and the basic control board. All bus bars,
terminals, snubber boards and the SCRs are
energized at rated voltage.
Figure 25
K2
L T
AK
A2
K1
G2
G1 K1
SCR2
SCR1
Typical Isolated Power Module
K = cathode
G = gate
A = anode
L T
SCR2
SCR1
K1
G1
G2
K2
A2
A1
Typical Isolated Power Pole
9.5.2 Test Equipment
The following equipment is used for the functional tests.
1. Portable DC multimeter - volts, ohms, and amperes (analog
type preferred).
2. Insulation tester - 1,000 volt DC megohmmeter (megger)
battery operated amp probe AMB-4D or similar.
3. 9-volt battery NEDA 1604.
4. 100-ohm resistor, 1 watt minimum.
5. 20-ohm resistor, 5 watts minimum.
6. Battery clip and clip leads.
Ground or case internal insulation . . . . . . . . . .2500V AC rating
SCR reverse blocking voltage . . . . . . . . . . . .rating 1300V peak
SCR forward off state voltage . . . . . . . . . . .rating 1300V peak
Reverse leakage current and
forward off state leakage
current at room temperature
and operating voltage levels . . . . . .less than one milliamp
Gate junction typical resistance
range as measured with
typical multimeter ohms scales . . . .10 ohms to 50 ohms
Gate trigger voltage to switch on . . . . . . . . . . . . . . . . . .2V DC
Gate trigger current to switch on . . . . . . . . .100 milliamps DC
Anode circuit holding and
latching currents . . . . . . . . . . . . .300 milliamps to 1 amp
9.5.3 Basic SCR Tests
Make sure all power sources are disconnected from controller
and locked out before performing the following test. See figures
28 through 30.
Test 1 - Verify Gate Integrity
1. Disconnect gate circuit wires only from each gate terminal.
2. Use a multimeter to measure each SCR gate junction resis-
tance.
3. Connect one meter lead to gate terminal TG.
4. Check gate resistance both to power cathode terminal T
and to the auxiliary cathode terminal TK. Typical readings
are 10 to 50 ohms. Open or short readings indicate a dam-
aged or defective SCR.
5. Repeat the measurements from LG to L and from LG to
LK. All SCRs in a controller should have similar values.
Test 2 - Verify Module Ground Insulation
1. Disconnect line L and motor load T power connections
from power terminals or thyristor module.
2. Use the megger 1,000V DC range to test between case
base or heat sink and each power terminal L and T. A high
megohm reading at 1,000V indicates 2,500V case insulation
is OK.
Test 3 - Verify Off State Blocking and Reverse Blocking Voltage
1. Disconnect the module anode to cathode power terminal
jumper (figures 28 - 30) to test individual SCRs for reverse
blocking and forward off state voltage.
2. Connect the megger across anode A and cathode K termi-
nals of one SCR; set megger to 1,000V setting. A typical
reading of greater than one megohm indicates an accept-
able SCR and leakage current of less than one milliamp at
1,000V DC.
3. Reverse the meter polarity and repeat the step 2 measure-
ment.
4. Proceed to the other SCR in the module. Make the anode
and cathode meter connections and measure for both polar-
ities.
5. A short circuit or a measurement below one megohm prob-
ably indicates a defective SCR.
Hazardous voltage.
To avoid electrical shock or burn, disconnect
and lock out all power sources from controller
before testing.
9.5.4 Advanced SCR Tests
Note: Steps using the battery should be performed quickly to
avoid draining the battery.
Test 1 - Check Gate Triggering
Gate triggering on can be demonstrated by using the 9V bat-
tery as a gate source and the megohmmeter as a high voltage
low current DC power source as indicated in figure 26. Use the
multimeter DC voltage range to determine the DC output volt-
age polarity of the megohmmeter if the megger is not marked.
Note: Gate and one cathode wire must be disconnected.
1. Connect megohmmeter positive lead to SCR anode A and
connect meter negative to the SCR cathode K.
2. Connect 9V battery negative to the SCR cathode K.
Connect the 100-ohm resistor to battery positive.
3. Energize the megohmmeter and note reading.
4. Touch the open end of the 100-ohm resistor to the appropri-
ate SCR gate TG or LG. Megger reading should go to
short.
5. Open the resistor connection to the gate. The megger read-
ing should rise to the reading noted in step 3.
6. Repeat connections and test sequence on the other SCR in
the module to verify its gating.
This test is for gating only since the megger cannot provide
enough anode current to latch or hold the SCR on. The SCR
turns off when gate current is removed.
Test 2 - SCR Latching and Holding
If latching or holding current SCR characteristics must be vali-
dated, perform the following low voltage test using resistors,
battery (see note), and multimeter; see figure 27.
Note: For the largest sizes of SCRs, paralleled batteries and/or
heavy duty batteries may be needed to deliver sufficient current
to latch and hold.
1. Connect battery minus to SCR cathode K.
2. Connect battery positive to the 100-ohm resistor; leave
other resistor end open.
3. Also, connect battery positive to the 20-ohm resistor and the
other resistor end to the SCR anode A.
4. Select DC voltage scale on the multimeter.
5. Connect the meter positive to the SCR anode A and meter
negative to the cathode K. Meter reading should be approx-
imately 9V DC.
6. Touch the open 100-ohm resistor end to the appropriate
SCR gate TG or LG. Meter reading should drop to approx-
imately 1V DC. Open the resistor connection to the gate;
meter should remain at 1V. (See note above re batteries.)
7. Disconnect all wires and meter.
8. Repeat above sequence on the second SCR in the module.
Meg
Ohm
100
9 Volt
A K
G K
Figure 26 Gate Triggering Test Diagram
V
100
9 Volt
A
K
G K
20
Volt Meter
Figure 27 Latching/Holding Test Diagram
Figure 28 for 3RW345*-..
Figure 29 for 3RW346*-..
Figure 30 Typical configurations for
3RW347*-.. to 3RW348*-..
10.2 Optional Parts
10.2.1 AS-i Module Catalog No. 3RW3400-0DC88
This AS-i Communications Interface Module, shown in diagram
form in figure 1, can be used with any SIKOSTART 3RW34 con-
troller. The AS-i unit allows the controller to be a slave to an AS-
i master. An instruction guide furnished with the module
describes installation, wiring and operation.
10.2.2 Overload Relays
The standard SIKOSTART Controller does not include overload
protection. Please refer to NSK-catalogue for overload selection
or contact Technical Support at the number printed on the back
cover of this manual.
Table 14 Spare Parts
Logic Board and Cooling Fan Catalog Numbers
Catalogue Numbers Uc = 24V DC Numbers Uc = 120V AC Numbers Uc = 230V AC
number of items Ue = All of items Ue = All of items Ue = All
Logic Board
3RW34... 3RW3950-6DC28 3RW3950-6DC38 3RW3950-6DC48
Cooling Fan
3RW3455-58 1 3RW3950-8DC28 1 3RW3950-8DC38 1 3RW3950-8DC48
3RW346. 1 3RW3960-8DC28 1 3RW3960-8DC38 1 3RW3960-8DC48
3RW347. 2 3RW3970-8DC28 2 3RW3960-8DC38 2 3RW3960-8DC48
3RW3483/84 3 3RW3972-8DC28 3 3RW3960-8DC38 3 3RW3960-8DC48
3RW3486 3 3RW3973-8DC28 3 3RW3960-8DC38 3 3RW3960-8DC48
10 Spare and Optional Parts
10.1 Spare Parts
Table 14 lists the catalog numbers for the logic board and
cooling fan(s) plus the quantity required for each controller.
10.1.1 Controller Amps, Uc and Ue
Three ratings identify each controller: current (Amps - In Line or
Inside Delta), control supply voltage Uc (24V DC, 120V AC, 230V
AC) and main supply voltage Ue (200-400V AC, 230-575V AC).
Each spare part relates to one or more of the ratings, e.g., each
cooling fan corresponds to the Amps and Uc ratings regardless
of the Ue ratings (Ue = All, where All means either main voltage
selection).
10.1.2 Fan Orientation
From one to three cooling fans are used per controller depend-
ing on the ratings. When one fan is used, it is mounted central-
ly along the width of the unit. When two fans are used, one is
mounted to the left (L) and the other to the right (R). Left and
right are defined by facing the cover of the unit, consequently,
the fan on the left is the furthest from the control terminals.
Similarly, when three fans are used, mounting locations are left
(L), center (Ctr), and right (R).
Order Number Order Number Nominal Size of the
Softstarter Fuse Current of Fuse Fuse
MLFB MLFB A
3RW3454-0DC?4 3NE1021-0 100 00
3RW3455-0DC?4 3NE1225-0 200 1
3RW3457-0DC?4 3NE1230-0 315 1
3RW3458-0DC?4 3NE1331-0 350 2
3RW3465-0DC?4 3NE1331-0 350 2
3RW3466-0DC?4 3NE1331-0 350 2
3RW3467-0DC?4 3NE1333-0 450 2
3RW3472-0DC?4 3NE1435-0 560 3
3RW3483-0DC?4 3NE1438-1 800 3
3RW3484-0DC?4 3NE1438-1 800 3
3RW3486-0DC?4 2 x 3NE1438-1 2 x 800 3
Appendix A
Nominal Voltage 400 V
Nominal Voltage 575 V
Fuse design (type of assignment 2) for 3RW34 with SITOR Fuses 3NE1..-0 (short-circuit and wire protection) Biggest-possible
design free of aging with reduced use of the Softstarter (e.g. 3 x Is for 5 sec)
Order Number Order Number Nominal Size of the
Softstarter Fuse Current of Fuse Fuse
MLFB MLFB A
3RW3454-0DC?5 2 x 3NE1817-0 2 x 50 000
3RW3455-0DC?5 3NE1225-0 200 1
3RW3457-0DC?5 3NE1230-0 315 1
3RW3458-0DC?5 3NE1230-0 315 1
3RW3465-0DC?5 3NE1230-0 315 1
3RW3466-0DC?5 3NE1230-0 315 1
3RW3467-0DC?5 3NE1332-0 400 2
3RW3472-0DC?5 3NE1334-0 500 2
3RW3483-0DC?5 3NE1436-0 630 3
3RW3484-0DC?5 2 x 3NE1334-0 2 x 500 2
3RW3486-0DC?5 2 x 3NE1436-0 2 x 630 3
Control supply voltage
2000 Siemens Energy & Automation, Inc.
Order No.: 3ZX1012-0RW34-1AN1
Subject to change without prior notice
Printed in the U.S.A.
1000 McKee Street, Batavia, IL 60510
phone:
++49(0)9131-7-43833 (8
00
-17
00
MEZ)
http://www.ad.siemens.de/cd
Technical Support:
Email: NST.Technical-Support@ERL7.siemens.de
SIKOSTART is a trademark of Siemens.

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