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Installation Guide
for ESP100

14-HES

May, 2006
Supersedes Issue of September, 2004

THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES. DEATH, SERIOUS PERSONAL INJURY, OR PROPERTY DAMAGE CAN RESULT IF SAFETY INSTRUCTIONS ARE NOT FOLLOWED. ONLY QUALIFIED PERSONNEL SHOULD WORK ON OR AROUND THIS EQUIPMENT AFTER BECOMING THOROUGHLY FAMILIAR WITH ALL WARNINGS, SAFETY NOTICES, AND MAINTENANCE PROCEDURES CONTAINED HEREIN. THE SUCCESSFUL AND SAFE OPERATION OF THIS EQUIPMENT IS DEPENDENT UPON PROPER HANDLING, INSTALLATION, OPERATION AND MAINTENANCE.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT, NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE PURCHASERS PURPOSES, THE MATTER SHOULD BE REFERRED TO THE LOCAL SIEMENS SALES OFFICE. THE CONTENTS OF THIS INSTRUCTION MANUAL SHALL NOT BECOME PART OF OR MODIFY ANY PRIOR OR EXISTING AGREEMENT, COMMITMENT OR RELATIONSHIP THE SALES CONTRACT CONTAINS THE ENTIRE . OBLIGATION OF SIEMENS. THE WARRANTY CONTAINED IN THE CONTRACT BETWEEN THE PARTIES IS THE SOLE WARRANTY OF SIEMENS. ANY STATEMENTS CONTINUED HEREIN DO NOT CREATE NEW WARRANTIES OR MODIFY THE EXISTING WARRANTY.

IMPORTANT

QUALIFIED PERSON FOR THE PURPOSE OF THIS MANUAL AND PRODUCT LABELS, A QUALIFIED PERSON IS ONE WHO IS FAMILIAR WITH THE INSTALLATION, CONSTRUCTION AND OPERATION OF THE EQUIPMENT, AND THE HAZARD INVOLVED. IN ADDITION, HE OR SHE HAS THE FOLLOWING QUALIFICATIONS: a) Is trained and authorized to energize, de-energize, clear, ground and tag circuits 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.

1 Mounting
No Drilling required for retrofitting.
The Siemens ESP100 starter (full voltage, non-reversing NEMA sizes 0 & 1) has a universal baseplate which can directly replace other starters, such as: Eaton/Cutler Hammer Citation Series Freedom Series GE 300-Line Square D Type S

An additional adapter plate is available to retrofit the following: Allen Bradley Bulletin 509 Bulletin 709 Westinghouse Series A200

Fig. 1

The ESP100 with its existing baseplate mounts onto the adapter plate with three screws.

2 Wiring
Wire contactor per enclosed wiring diagram.
(If ESP100 has windows) Push one motor lead through each pass-through window in the overload relay, and connect to the contactor terminals (T1, T2, T3). (Use only with 3-phase motors at 50/60 Hz). (If ESP has terminals) Connect each motor lead to the overload relay terminals (T1, T2, T3) (Use only with motors at 50/60 Hz). T3

Wiring Diagram

Hazardous voltage. Will cause death or serious injury.

To avoid electrical shock or burn, turn off main and control voltages before performing installation or maintenance.

T1 (with windows)

T2

Fig. 2

T3 T1 (with terminals) T2

3 FLA Adjustment
Set the adjustment dial on the overload to the Full Load Amps on the motor nameplate.*
In addition to the markings on the dial there are audible clicks which allow for extremely fine tuning. Note that while thermal overload relays require a heater selection based on a relatively wide ampere range, the ESP100 overload relay has many clicks covering the same ampere range. See Fig 3. After the correct Full Load Amps have been selected with the dial, the dial can be covered or modified to resist unwanted tampering with the setting. If ESP100 has windows; snap a cover (49ASTC) over the dial: you may also add an optional wire seal (not included). If ESP100 has terminals: pull the tab on the dials gray cap with a pliers to remove the cap. To change the setting, first reinstall the cap by aligning its arrow with the line on the red disk, and push into place.

*For service factor of 1.0, multiply FLA by 0.9

Fig. 3
(For Engineering Reference Only - Rev. G)

Siemens Energy & Automation, Inc. 3333 Old Milton Parkway Alpharetta, GA 30005

Troubleshooting
Hot Terminals Possible cause: Loose wire connections Action: Clean connections and tighten to recommended torque Failure To Trip Out Possible cause: Incorrect dial setting Action: Readjust dial setting to the FLA on the motor nameplate Overload Trips Possible cause: Motor is overloaded Action: Remove cause of overload and reset overload relay Possible cause: Loss of phase Action: Replace burned-out fuse, or reconnect wire in missing phase Possible cause: Dial setting is too low Action: Readjust dial setting to the FLA on the motor nameplate

Looping Option
for ESP100 with windows
In applications involving the use of 12 or 14 AWG wire, usually motors of 5 HP or less, the wires may be looped and passed through the windows repeatedly before connecting to the contactor. By looping the motor leads through the windows in the overload a second time, the overload will read twice the current actually going to the motor. Hence the overload can protect a motor needing half the FLA capability of the overload. An overload with a current of 9 to 18 amperes can be used for a motor FLA between 4.5 to 9 amperes. Similarly, motors that require only one-third, one-fourth, or one-fifth the overloads FLA capability can use the same size ESP100 starter by looping three, four, or five times.

Fig. 4

Accessories
Safety Cover: Custom transparent cover may be sealed with wire seal to prevent unauthorized tampering with FLA adjustment dial. 49ASTC (Pkg. of 10)

The following table demonstrates how the looping process reduces the current setting of the overload by the number of times the wires pass through the windows of the overload. All current values are expressed in amperes. Overload Current Range Shown on label Option A Option B Option C Option D Option E 9-18 4.5 - 9.0 3.0 - 6.0 2.25 - 4.5 1.8 - 3.6 1.5 - 3.0 Number of Loops 0 1 2 3 4 5 Number of Times Wire Passes Thru Window 1 2 3 4 5 6

Auxiliary Contact Block: NO or NC block for ESP100 overload relays to signal remote alarms or other devices. 49ASNO 49ASNC

Reset Button Extender: Permits use with Siemens MCCs and extra deep enclosures. 49ASRE

Fire Hazard. May cause property damage. To prevent fire, the starter must be wired with polarity as shown. Polarity is indicated by .

Dust Seal: For use in extremely dusty environments. Not to be used in conjunction with auxiliary contact blocks. 49ASDS

120V/240V L1 L2

How to wire for

L1 L2 L3 Contactor T1 T2 T3

Single Phase Motor

The ESP100 with terminals has versions available for either 3-phase or single-phase applications. The ESP100 with windows is designed for use with 3-phase motors only: however, it is possible to use special wiring (see Fig 5) to convert 3-phase to single-phase motors. For an approximate single-phase setting of the ESP100 with windows, multiply the motor nameplate FLA by 0.75, and set the ESP100 dial to the resulting value.

ESP100 Overload Relay (w/ windows)

Motor

Fig. 5 2
Siemens Energy & Automation, Inc. 3333 Old Milton Parkway Alpharetta, GA 30005