s SFIS-4511A-0499

April, 1999

SIKOSTARTTM 3RW34 Instruction Guide

Siemens Energy & Automation, Inc.

 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
all safety instructions contained herein.

SIGNAL WORDS QUALIFIED PERSON

The signal words “Danger” , “Warning” and For the purposes of this manual and product
“Caution” used in this manual indicate the labels, a qualified person is one who is familiar
degree of hazard that may be encountered by with the installation, construction, operation or
the user. These words are defined as: maintenance of the equipment and the haz-
ards involved. In addition this person has the
Danger - Indicates death or serious injury will following qualifications:
result if proper precautions are not taken.
(a) is trained and authorized to energize,
Warning - Indicates death, serious injury or de-energize. clear, ground and tag cir-
property damage can result if proper precau- cuits and equipment in accordance with
tions are not taken. established safety practices.
(b) is trained in the proper care and use of
Caution - Indicates some injury or property protective equipment such as rubber
damage may result if proper precautions are gloves, hard hat, safety glasses or
not taken. face shields, flash clothing, etc., in
accordance with established safety
practices.
(c) is trained in rendering first aid.

2 Siemens Energy & Automation, Inc.

 Table of Contents

1 Introduction 6 Controller Setup

1.1 Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . .5 6.1 Setup Controls . . . . . . . . . . . . . . . . . . . . . . . . .27
1.2 SIKOSTART 3RW34 Features . . . . . . . . . . . . . . .5 6.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . .28
1.3 Applications and Benefits . . . . . . . . . . . . . . . . . .5 6.3 Controller Setup . . . . . . . . . . . . . . . . . . . . . . . .28
6.4 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . .28
2 Operating Principle 6.5 Initial Energization . . . . . . . . . . . . . . . . . . . . . . .28
2.1 Function Overview . . .. . . . . . . . . . . . . . . . . . . .5 6.6 Motor Starting Adjustments . . . . . . . . . . . . . . .29
2.2 Functional Description . . . . . . . . . . . . . . . . . . . .5
2.3 Three-phase Systems .. . . . . . . . . . . . . . . . . . . .6 7 Electrical Specifications . . . . . . . . . . . . . . . . .30
2.4 AC Motor Starting . . . .. . . . . . . . . . . . . . . . . . . .8
8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3 Controller Selection . . . . . . . . . . . . . . . . . . . . .10
9 Troubleshooting
4 Installation 9.1 Maintenance and Troubleshooting . . . . . . . . . . .33
4.1 Incoming Inspection . . . . . . . . . . . . . . . . . . . . .10 9.2 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . .33
4.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 9.3 Inside Delta Wiring Problems . . . . . . . . . . . . . .36
4.3 Installation Precautions . . . . . . . . . . . . . . . . . . .11 9.4 Shorted SCR Checks . . . . . . . . . . . . . . . . . . . .37
4.4 General Wiring . . . . . . . . . . . . . . . . . . . . . . . . .13 9.5 SCR (Thyristor) Testing . . . . . . . . . . . . . . . . . . . .37
4.5 Power and Motor Connections . . . . . . . . . . . . .15
4.6 Control Connections . . . . . . . . . . . . . . . . . . . . .17 10 Spare and Optional Parts
4.7 Installation Check . . . . . . . . . . . . . . . . . . . . . . .17 10.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
10.2 Optional Parts . . . . . . . . . . . . . . . . . . . . . . . . . .43
5 Wiring Diagrams
5.1 Typical Applications . . . . . . . . . . . . . . . . . . . . . .18
5.2 Circuit Devices . . . . . . . . . . . . . . . . . . . . . . . . .18

Siemens Energy & Automation, Inc. 3

 List of Figures

Figure Page Figure Page

1 SIKOSTART 3RW34 Block Diagram . . . . . . . . . . . . . . . 6 16 Power wiring for single speed, non-reversing motor,
2 Basic Three-phase Waveforms . . . . . . . . . . . . . . . . . . . 6 wired "Inside Delta" in a vented enclosure, with fusible
3 Three-phase Wye-connected Arrangement. . . . . . . . . . 7 disconnect and isolation contactor, and short trip
4 Three-phase Delta-connected Arrangement . . . . . . . . . 7 circuit breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Wye and Delta Motor Connections . . . . . . . . . . . . . . . 8 17 Control wiring for single speed, non-reversing motor,
6 Typical torque/Speed Curves for wired "Inside Delta" in a vented enclosure, with fusible
Motor at Reduced Voltages . . . . . . . . . . . . . . . . . . . . . 8 disconnect and isolation contactor, and short trip
7 Voltage and Time Curves for circuit breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Soft Start with Coast to Stop. . . . . . . . . . . . . . . . . . . . 9 18 Power wiring for a single speed, non-reversing motor,
8 Voltage and Time Curves for wired "Inside Delta", with bypass and isolation
Soft Start with Soft Stop . . . . . . . . . . . . . . . . . . . . . . . 9 contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Inductive Load Suppression . . . . . . . . . . . . . . . . . . . . 13 19 Control wiring for a single speed, non-reversing motor,
10 SIKOSTART Controller wired "Inside Delta", with bypass and isolation
Power and Motor Connections . . . . . . . . . . . . . . . . . . 14 contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11 SIKOSTART Controller Control Connections . . . . . . . . 15 20 Setup Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12 Power wiring for single speed, non-reversing motors, 21 Potentiometer Settings . . . . . . . . . . . . . . . . . . . . . . . 29
wired. "In Line", in a vented enclosure (circuit breaker 22 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
or fusible disconnect). . . . . . . . . . . . . . . . . . . . . . . . . 19 23 Proper Inside Delta Wiring Connections . . . . . . . . . . . 36
13 Control wiring for single speed, non-reversing motors, 24 Typical 720A Power Module. . . . . . . . . . . . . . . . . . . . 37
wired "In Line", in a vented enclosure (circuit breaker 25 Gate Triggering Test Diagram . . . . . . . . . . . . . . . . . . . 39
or fusible disconnect) . . . . . . . . . . . . . . . . . . . . . . . . 20 26 Latching/Holding Test Diagram . . . . . . . . . . . . . . . . . . 39
14 Power wiring for a single speed, non-reversing motor, 27 Typical 35 or 80 Amp SCR . . . . . . . . . . . . . . . . . . . . . 40
wired "In Line" with bypass contactor . . . . . . . . . . . . 21 28 Typical 130 or 240 Amp SCR . . . . . . . . . . . . . . . . . . . 40
15 Control wiring for a single speed, non-reversing motor, 29 Typical 420 or 720 Amp SCR . . . . . . . . . . . . . . . . . . . 40
wired "In Line" with bypass contactor . . . . . . . . . . . . 22 30 Mounting Lug on Controller Terminal . . . . . . . . . . . . . 43

List of Tables

Table Page Table Page

1 Controller Ratings for "In Line" 5 6-Lead Connections for Dual Voltage
Wiring Configurations . . . . . . . . . . . . . . . . . . . . . . . . 10 12-Lead Delta Motor . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Controller Ratings for "Inside Delta" 6 Potentiometer Setting Values . . . . . . . . . . . . . . . . . . . 27
Wiring Configurations . . . . . . . . . . . . . . . . . . . . . . . . 10 7 LED Fault Indications . . . . . . . . . . . . . . . . . . . . . . . . . 33
3 Terminal Screw and Ground Stud Nut Torque . . . . . . . 16 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 3-Lead Connections for 9 Inside Delta Wiring Problems. . . . . . . . . . . . . . . . . . . 36
Dual Voltage 9-Lead Wye Motor . . . . . . . . . . . . . . . . . 17 10 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
11 Lug Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Siemens Energy & Automation, Inc.

1 Introduction 2 Operating Principle

1.1 Scope of Manual 2.1 Function Overview

This manual provides an overview for the installation, setup The SIKOSTART 3RW34 controller utilizes a voltage ramp
and operation of the Siemens SIKOSTART 3RW34 controller. design to produce an output voltage to the motor that increas-
Maintenance data consists of troubleshooting and spare parts es from a customer selected initial voltage to full line supply
information. Note that the instructions in this manual do not voltage over an adjustable starting time. This “voltage ramp”
cover all details or variations in equipment, nor provide for produces a reduced current start (soft start) similar to a cur-
every possible contingency to be met in connection with rent limit start without the load dependence of the current
installation, operation, or maintenance. limit type start. Similarly, stopping time can be adjusted to
provide a soft stop for many pumping applications.
1.2 3RW34 SIKOSTART Features The SIKOSTART controller employs a DSP (digital signal
processor) to control the motor. This advanced type of micro-
The SIKOSTART 3RW34 product line is the next generation of processor allows the controller to “contour” the starting and
Siemens solid state reduced voltage controllers. This controller stopping ramps. This contour adjusts for the nonlinearities of
combines DSP microprocessor and SCR technologies to provide an induction motor to produce a smoother and more linear
AC induction motor starting and operation. The sturdy compact motor start and stop.
frame affords rugged, industrial grade reliability.
The SIKOSTART 3RW34 controller is a single ramp style con- 2.2 Functional Description
troller using phase control for the operation of three-phase
induction motors. The controller can be set to operate either Power Poles. As is shown in the block diagram of figure 1, the
wye (star) or delta type motors. Each unit includes soft start incoming main power (L1, L2, L3) is connected to the con-
and stop parameters plus fault detection. The controller can be troller’s three power poles which control the voltage to the
used with an electro-mechanical starter or, when combined motor windings. Each power pole consists of two SCR’s in a
with an overload relay, the controller can be used as a solid- back-to-back arrangement for each phase which allows alter-
state starter. nating current to pass to the motor.
The SIKOSTART 3RW34 controller is available as an open type Snubber PCB. The snubber printed circuit board(s) contains
(compact frame, no enclosure) or in a NEMA 1, 3R, 4, or 12 the trigger circuit for each SCR. The firing signal for each trig-
enclosure. The unit can be ordered as a starter with overload ger circuit is generated at the logic printed circuit board. The
relays or as a combination starter with disconnecting means snubber board sensing circuits send data to the logic board for
and circuit overload protection devices. Additional options are factoring into firing signal generation. The snubber board also
also available such as push buttons, pilot lights, and meters. includes an RC network for a degree of protection against
false firing of the SCR’s due to dv/dt and MOV’s for transient
protection.
1.3 Applications and Benefits

Typical applications for the SIKOSTART 3RW34 controller are

to soft start and soft stop AC induction motor driven equip-
ment such as fans, pumps and compressors. Applications
also include controlling machines with gearbox, belt or chain
drive elements, such as: conveyors, sanders, planers, saws,
packaging 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 result-
ing 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.

Siemens Energy & Automation, Inc. 5

Figure 1 3RW34 SIKOSTART Block Diagram Logic PCB. A The three sets of numbered output terminals are for customer
power supply on the logic printed circuit board accepts control control devices related to Motor Running (e.g., start / stop
power (X1, X2) and provides power to the central processing devices), Motor Running at Full Voltage (e.g., to drive a bypass
unit (DSP), support circuitry, and cooling fan(s). The input coil contactor), and Fault (e.g., phase loss or shorted SCR).
terminals (A1, A2) are for commanding the motor to RUN and Setup Controls. Setup controls are connected to the logic
STOP. board but are accessible from the controller’s front cover.
Three potentiometers 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. motor type: wye (star) or delta
4. Fault output: opens or closes on fault.

2.3 Three-phase Systems

Since the controller can be used with either wye or delta

motors, 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 sys-
tem 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 120I. Likewise, Ub leads Uc by 120I, and
Uc leads Ua by 120I.

Figure 1

Figure 2 Basic Three-phase Waveforms

6 Siemens Energy & Automation, Inc.

2.3.1 Wye Connection 2.3.2 Delta Connection

Figure 4a represents a three-phase wye-connected motor Figure 4b represents a three-phase delta-connected motor.
with three sources connected to supply voltages, U1,2, U2,3, The three sources are connected to supply voltages, U1,2,
and U3,1. The SIKOSTART controller is connected in line with U2,3, and U3,1. The SIKOSTART controller is connected inside
the motor windings. of the delta in series with the motor winding.
As can be seen, the source current, the SIKOSTART current, As can be seen, the source or line current is split between
and the motor winding current are all equal. 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 magni-
tude of a winding and SIKOSTART current by a factor of the
square-root-of-three (1.73). This allows the SIKOSTART con-
troller to operate a motor of a higher current rating when con-
nected inside of the delta.

Figure 3a

Figure 4a

Figure 3b

Figure 4b

Figure 4 Three-phase Delta-connected Arrangement

Figure 3 Three-phase Wye-connected Arrangement

Siemens Energy & Automation, Inc. 7

2.3.3 Controller-to-Motor Connections 2.4 AC Motor Starting and Stopping

Wye Motor. The controller can be used for either a three- lead Figure 6 shows three torque/speed curves (a, b, c) for a typi-
or nine-lead wye motor. Connecting the controller to a wye cal induction motor.
motor inserts the SCR’s directly in the line wiring, referred to a This curve shows the torque/speed relation when the
as “In Line” wiring. motor starting voltage, U, is 100% of line voltage (Ue).
Delta Motor. The controller can be used for either 6 or 12 b This curve shows the relation when the controller voltage
lead delta motors. If the motor is hard wired as delta, the con- potentiometer, U (initial soft start voltage setting) is set
troller must be connected and sized with “In Line” wiring as for 75% of line voltage.
shown in figure 5a.
c This curve shows the relation when the controller voltage
Figure 5b shows the controller connected with the thyristors potentiometer is set for 50% of line voltage.
inside the delta, referred to as “Inside Delta” wiring. For
Inside Delta wiring, the controller power rating may be The curve a motor (without soft starting) produces a very high
increased (line current = 1.73 phase current, figure 4) relative torque across most of the speed range, whereas, the curves
to the In Line power rating. b and c motors (with soft starting) produce a much lower and
adjustable torque. This allows slower and smoother accelera-
tion of the motor and its load.

Figure 5a

Torque of the motor in the case of Relationship of voltage and

a direct-on-line starting speed with respect to time
@Um (0) = 100% Ue in the case of soft - starting.
b starting with 3RW34 Showing the effect of the
Figure 5b @Um (0) = 75% Ue potentiometers Um and tr
c startingwith 3RW34 located on the front panel of
Figure 5 Wye and Delta Motor Connections
@Um (0) = 50% Ue the devices.

Figure 6 Typical Torque/Speed Curves for Motor at Reduced Voltages

8 Siemens Energy & Automation, Inc.

2.4.1 Soft Start with Coast to Rest 2.4.2 Soft Start with Soft Stop

Figure 7 shows the relationship of voltage and speed with Figure 8, like figure 7, shows the voltage and speed curves for
respect to time when a soft start is used with coast to rest. a soft start but with controlled deceleration. The potentiome-
The controller potentiometers have been set as follows. ters have been set as follows.
U The initial voltage is set at approximately 30%. U The initial voltage is set at approximately 30%.
T1 The start time setting is greater than 0. T1 The start time setting is greater than 0.
T2 The stop time is set at 0 which allows the motor to T2 The stop time setting is greater than 0 which allows the
coast to a stop. motor to soft stop.
On the voltage/time graph, the voltage starts at U when the The motor starting ramp is similar to the one shown in figure 7.
run coil is energized and increases to 100% within the T1 time But, when the run coil is de-energized, a motor stopping ramp
setting. The voltage immediately drops to zero when the run is formed where the motor voltage starts at 100% and
coil is de-energized. decreases to 80% of U (the initial start voltage) within the T2
The “speed/time” graph shows the motor accelerating from 0, time setting. Then the voltage immediately drops to zero. The
when the run coil is energized, to operating speed. The time time required to decelerate may be more or less than the T1
required to accelerate may be more or less than the T1 setting setting depending on the connected inertia.
depending on the connected inertia. The motor speed coasts When the run coil is de-energized, the speed decreases
to zero when the motor is de-energized. 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

Siemens Energy & Automation, Inc. 9

3 Controller Selection 4 Installation
Each controller has two ratings: “In Line” and “Inside Delta.” 4.1 Incoming Inspection
Inside Delta ratings are higher than In Line ratings. Be sure
to select equipment with the proper ratings for the type
of connections used.
Tables 1 and 2 list the SIKOSTART controller partial catalog
Heavy equipment.
numbers and ratings at various rated voltages.
May cause injury or property damage.
Table 1 is for “In Line” wiring configurations only and shows
current and horsepower ratings for units at various rated volt- To avoid personal injury or controller
ages. damage, do not use the controller cover
as a handle when moving and/or posi-
Table 2 is for “Inside Delta” wiring configurations only and
tioning the unit.
shows current and horsepower ratings for units at various
rated voltages.
1.Unpack the controller from the carton and inspect for ship-
Table 1 Controller Ratings for “In Line” Wiring Configurations ping damage. Check that the items on the packing list agree
with the order. File claims for loss or damage with the freight
50°C at Listed Voltage carrier immediately.
2. If the controller will not be installed immediately, it should
“In Line” be stored in a clean, dry area where the ambient temperature
Catalog Wiring Horsepower at Voltage
Number Amps 200V 230V 460V 575V is between 0IC and 70IC. Avoid storage environments with
corrosive atmospheres or high humidity.
3RW3452... 35A 10 10 25 30
3RW3454... 57A 15 20 40 50
3RW3455... 69A 20 25 50 60
3RW3456... 80A 25 30 60 75
3RW3458... 105A 30 40 75 100
3RW3465... 131A 40 50 100 125 Voltage or fire hazard.
3RW3466... 195A 60 75 150 200 Can cause death, serious injury, or
3RW3467... 248A 75 100 200 250 property damage.
3RW3472... 361A 125 150 300 350
3RW3483... 480A 175 200 400 500 To prevent electrical shock or burns,
3RW3484... 720A 250 300 600 700 do not leave foreign objects (wire clip-
3RW3486... 960A 350 400 800 1000 pings, metal chips, etc.) either inside
or on top of the controller during
installation procedures.
Table 2 Controller Ratings for “Inside Delta”
Wiring Configurations Note: Installation must be performed by qualified personnel as
50°C at Listed Voltage indicated on page 2 of this manual.
3. The carton and packing materials should be retained in case
"Inside
there is a future need to return the controller to the factory for
Delta"
Catalog Wiring Horsepower at Voltage
service or repair. The carton and packing material are especial-
Number Amps 200V 230V 460V 575V ly fitted to protect the controller from shipping damage.
3RW3452... 57A 15 20 40 50 If these materials are not used for shipping, claims for ship-
3RW3454... 105A 30 40 75 100 ping damage may be rejected by the freight carrier.
3RW3455... 131A 40 50 100 125
3RW3456... 165A 50 60 125 150
3RW3458... 195A 60 75 150 200
3RW3465... 248A 75 75 200 250
3RW3466... 361A 100 125 300 350
3RW3467... 414A 125 175 350 400
3RW3472... 602A 200 250 500 600
3RW3483... 720A 250 300 600 700
3RW3484... 1200A 400 500 1000 1200
3RW3486... 1600A 500 600 1300 1700

10 Siemens Energy & Automation, Inc.

4.2 Mounting 4.3 Installation Precautions

1. Section 8 of the manual contains controller mounting The following precautions are intended for use as guidelines
dimensions and data. Air flow through the unit is vertical, for proper installation of the controller. Because of the variety
from bottom to top. of applications, all of these precautions may not pertain to
your system and they are not all-inclusive. In addition to the
following, refer to codes and standards applicable to your par-
ticular system.

Fire hazard.
Can cause death, serious injury, or 4.3.1 Motor Branch Circuit
property damage.
To prevent a fire, the controller, espe-
cially a non-fan-cooled unit, must be
mounted with its fins in a vertical direc-
tion only. Side ways mounting and
improper ventilating can result in fire. Hazardous voltage.
Can cause death, serious injury, or
property damage.
To avoid electrical shock, this controller
2. Adequate cooling is essential for proper operation. Leave at MUST be wired with motor disconnect-
least 6 inches of clearance above and below the unit to allow ing means and branch circuit protection
unimpeded convection or fan air flow. Wire bending because the controller does not provide
allowance may require more than this recommended mini- electrical isolation to the motor when
mum clearance. the controller is OFF.
3. When mounting the controller in an enclosure, the enclo-
sure must be properly sized or ventilated to provide cooling The National Electrical Code (NEC) and local regulations govern
for the continuous power dissipation in the thyristors, approxi- the installation of the SIKOSTART controller and the motor it
mately 3 watts per ampere of continuous rating. The follow- will control. Refer to NEC Article 430 for requirements and
ing vent areas are required for each inlet and each outlet on data regarding 1) motor disconnecting means, 2) motor branch
customer furnished NEMA 1 enclosures, motor control cen- circuit short circuit and ground fault protection, and 3) motor
ters, etc. overload regulations. Figure 10 shows the components gen-
erally required to meet the various regulations. The overload
relay indicated in the figure is necessary but the standard
Vent Area Continuous Amps HP at 460V
SIKOSTART controller is not furnished with an overload relay.
not req’d up to 57A 40 HP
20 sq. in. up to 131A 100 HP The SIKOSTART controller does not utilize electronic means to
40 sq. in. up to 248A 200 HP protect itself from damage due to short circuits applied to the
80 sq. in. up to 480A 400 HP motor terminals or from the motor terminals to ground.
120 sq. in. up to 960A 800 HP Suitable branch circuit protection must be provided per NEC
code.
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 NEMA 12 enclosures use bypass contactors or heat
exchange devices to maintain the integrity of the NEMA 12
rating. Establish a maintenance schedule for enclosures with
heat exchangers. Equipment cleaning frequency should be
based on the operating environment.

Siemens Energy & Automation, Inc. 11

4.3.2 Controller Protection such as an accidental spray of gas, liquid or solid particles or
inadvertent contact with moving machinery. Since the con-
troller’s start/stop control circuitry includes solid-state compo-
nents, a potentially hazardous environment may require the
installation of an additional hard wired emergency stop circuit
Hazardous voltage. that will either disconnect AC input power to the SIKOSTART
Will cause death or serious injury. controller or disconnect the motor from the controller.
To avoid electrical shock or burn, do Multiple Motors. When the controller is used for more than
not touch controller output terminals one motor, be sure the combined full load current (sum of indi-
when voltage is applied to the
controller. Output terminals will have vidual motor FLA’s ) does not exceed the controller’s rated out-
voltage present even when con- put current. Each motor requires separate overload relay pro-
troller is OFF. tection.
Bypassing the Controller. When the controller is mounted in
a sealed enclosure, a bypass contactor generally is used to
When planning your installation, be aware of potential hazards prevent heat from being generated by the thyristors during
to personnel and to the controller that can be caused by con- running. If not bypassed during operation, supplemental cool-
trol devices used in the system or by unique system features. ing may be required depending on operating current and
enclosure size and type.
Motor Disconnect. When any motor disconnect device con-
nected to the controller output (motor) terminals is opened
during operation, the controller continues to source full volt- 4.3.3 Electrical Noise Suppression
age if running. If the disconnect device is reclosed, the motor
will be restarted at full voltage. When the disconnect device Noise usually enters solid-state controls through power supply
is opened, a hazardous voltage is present at the controller out- lines, input lines and output lines. Sources of electrical noise
put terminals due to thyristor and snubber leakage. which can be suppressed within the power distribution system
Motor Start/Stop. For normal operation, the controller is include:
designed to start and stop the motor by using signals that are 1) inductive loads, such as relays, solenoids, motors, and
input to the controller's circuitry. Do not use the device that motor starters operated by hard-contact devices, such as push
disconnects and reapplies line power to the controller for ordi- buttons or selector switches,
nary starting and stopping of the motor. 2) AC feeders,
Asymmetric Motor Windings. Some delta motors are 3) high level noise generators, such as arc furnaces, high-fre-
wound (or re-wound) asymmetrically. This can cause low quency welders, large AC machinery, etc.; consider electrostat-
available starting torque and noisy starting operation. ically shielded power transformers for suppression.
The most reliable way of minimizing noise coupling is to iso-
late the noise generating devices and associated wiring from
sensitive control wiring. Group components and wires accord-
Hazardous voltage. ing to signal levels and connect noise suppressors close to the
May cause property damage. noise generators. Noise suppressors are electric components
To avoid damaging solid-state which are used to filter, or minimize, the effect of indirect
power devices, do not connect (capacitive or inductive) coupling.
power-factor-correcting capaci- Recommended suppression practices for the noise sources
tors to the load side of the listed above are:
controller.
1) For an inductive load, refer to paragraph 4.4.4.
2) On AC feeders, use RF line filters.
Power-factor-correcting (PFC) Capacitors. Do not use PFC 3) On high level noise generators, use electrostatically shield-
capacitors at the controller output terminals. Connection to ed power transformers.
the output terminals will damage the controller. If PFC capac-
itors are used, they must be connected on the line side of the
controller. 4.4 General Wiring
When an isolation contactor is used with the controller, the
PFC capacitors must be disconnected from the controller Many startup difficulties are due to incorrect wiring. Observe
when the isolation contactor is open (see figure 10). the following general instructions as well as the specific
Hazardous Environment. Depending on the system environ- instructions in later paragraphs and in system instructions.
ment, consideration must be given to unexpected hazards

12 Siemens Energy & Automation, Inc.

4.4.1 Power and Motor Wiring 4.4.3 Control Wiring
The control wiring is connected at the logic board terminals
shown in figure 11.
Control Voltage. Each SIKOSTART controller is available in
several control voltage models. Ensure that the control volt-
Fire hazard. age and frequency supplied match the controller model.
Can cause death, serious injury, Wire Specifications. Each control terminal can accept a max-
or equipment damage. imum of two 14-AWG stranded wires. Be sure ring tongue
Welding cable requires crimp type terminals are sized correctly for the wire.
solderless terminals to prevent Labeling. Each wire should be appropriately labeled using
arcing and possible fire,
tape, shrink-tubing, or other dependable method.
Routing. All control wiring must be kept separate from power
Power supply and motor wiring ampacity should be based on and motor wiring and run in its own separate conduit. Keep
the current ratings of the motor as specified on the name- control wire bundles physically separated
plate and in compliance with NEC and local codes. Power from power wiring by at least 6 inches. Where control and
and motor supply wiring should be routed in its own separate power wiring must cross, they should intersect at right angles.
conduit or wireway. 4.4.4 Coil Suppression
Each SIKOSTART controller is available in several power sup- Relay, electromechanical brake, or solenoid coils produce elec-
ply voltage range models. Ensure that the supply voltage and trical noise transients (especially when being de-energized)
frequency are within the rated range of the controller. which can be coupled into the controller circuitry and cause
erratic operation. For all such devices connected to or near
When welding cable or other fine wire cables are used for
the controller or its wiring, see figure 9 and observe the fol-
power wiring, use crimp type solderless terminals due to the
lowing.
fine strand characteristic of this cable. Screw type compres-
sion terminals are not recommended. The fine wires can jam 24V DC Coils. Connect a diode directly across each DC coil.
the threads of the terminal and prevent sufficient compres- A 1N4004 diode is acceptable for most 24V DC applications
sion of the wire strands. In addition, the fine wires can relax up to 1.0A. A varistor or surge suppressor can also be used in
in the terminal, which can lower the compression of the place of the diode.
cable. If the contact ends of the cable are not properly com- 120V AC Coils. Use an R-C circuit (0.47 mfd, 600V capacitor
pressed, arcing can occur with the risk of a fire. in series with a 1/4 watt 220 ohm resistor) across each 120V
AC coil. An appropriately rated varistor or surge suppressor
4.4.2 Grounding can be used in place of the R-C circuit, however, R-C circuits
The controller enclosure and the motor frame must be proper- are recommended because they limit the rate of rise of noise
ly grounded in a manner that meets all applicable wiring and thus help eliminate high frequency components.
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 com-
mon 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 terminal barrier bussing point.

220 ohm

Figure 9 Inductive Load Suppression

Siemens Energy & Automation, Inc. 13

 L1
L2
L3
PE

Figure 10 SIKOSTART Power and Motor Connections

14 Siemens Energy & Automation, Inc.

 Control Power
Supply

Run Output
Contact

Motor at 100%
Voltage Output

Fault Output
Contact (see SW1-4
to set for OPEN or
CLOSE on Fault)

Figure 11 SIKOSTART Control Connections

Siemens Energy & Automation, Inc. 15

4.5 Power and Motor Connections 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.
Hazardous voltage. The voltage source must be correct because:
Will cause death or serious injury. a. Connecting the controller to a line voltage higher than its rat-
To avoid electrical shock or burn, ing will open the protective resistor in the snubber board and
turn off main and control voltages prevent controller operation; repair will be required before the
before performing installation or controller can be put into operation.
maintenance.
b. Connecting the controller to a line voltage lower than its rat-
ing will: 1) cause erratic controller operation resulting in dam-
age to the motor, or 2) prevent controller operation due to the
low control voltage lockout protective feature.
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 10). Observe the following:
1. Torque the power and motor terminal set screws according
to the wire size as indicated in table 3. Lug kits are listed in Hazardous voltage.
Section 10, Spare and Optional parts, of this manual. Can cause death, serious injury
2. Torque the ground stud nut according to controller opera-
or property damage.
tional current as indicated in table 3. The controller case must be
grounded to earth for operator’s
safety.

Wrong power rating may cause injury 2. Connect the ground terminal (labeled with ground symbol)
or property damage. to earth ground.
Confirm that the correct HP rating for the
controller corresponds to the type of con- 4.5.2 Motor Connections
nections being used; e.g. don’t use
Inside Delta rating for a controller wired 1. The NEC motor overload protection requirement can be met
In Line. 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 correct
Table 3 Terminal Screw and Ground Stud Nut Torque for the type of connection required for the application; refer to
section 3.
3. For a dual voltage 9-lead wye motor (represented in figures
Threaded Torque 12 and 13), the 3-lead controller-to-motor terminal connections
Item (lb-in.)
are listed in Table 4.
Terminal Screw
Wire Size (AWG or MCM)*
6 to 4 .................................................................100
3 to 2.................................................................125
1 ........................................................................135
1/0 to 2/0...........................................................150
3/0 to 4/0...........................................................225
250 to 400.........................................................290
500 to 600.........................................................335
Nut on Ground Stud
Controller Operational Current
<= 105A ..............................................................75
>= 133A-248A ...................................................110
>= 361A ............................................................150

* for 75IC Aluminum or Copper Wire

16 Siemens Energy & Automation, Inc.

 Table 4 3-Lead Connections for Dual Voltage 9-Lead Wye Motor 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
High Voltage Wiring Low Voltage Wiring input of the multispeed starter. Individual motor overload pro-
Controller Motor Controller Motor tection should be supplied for each motor speed separately.
During speed transitions, control input (A1, A2) must be “off”
Terminal Terminal Terminal Terminal
for a minimum of 200 milliseconds.
T1 T1 T1 T1 & T7 7. When using the controller with part winding motors, these
T2 T2 T2 T2 & T8 motors must be connected in their full voltage run winding
configuration, and the three motor leads connected to the
T3 T3 T3 T3 & T9
controller output terminals.
T4-T7* T4-T5-T6* 8. The motor frame should be connected to the earth ground
T5-T8* terminal.
T6-T9*
* Jumper * Jumper 4.6 Control Connections

1. Connect the control power supply (Us) specified on the con-

4. A 6-lead delta motor connection is shown in figures 16 and troller label to the X1 and X2 terminals; see figure 11.
17. Connections from controller to motor are one on one, i.e., 2. Connect control circuit pilot devices in accordance with the
T1 to T1, T2 to T2, etc. application. Section 5 provides examples of several typical
5. For a dual voltage 12-lead delta motor (represented in fig- arrangements; section 6 describes the dip switch (SW-1) set-
ures 16 and 175), the 6-lead controller-to-motor connections tings.
are listed in Table 5.

4.7 Installation Check

1. Check that all wiring and power connections are secure and
Table 5 6-Lead Connections for Dual Voltage 12-Lead Delta Motor that mounting bolts are tight.
2. Remove all wire cuttings, installation particles, metal chips
and debris before energizing.
High Voltage Wiring Low Voltage Wiring
3. Shut enclosure doors to protect equipment from dust and
Controller Motor Controller Motor personnel from hazardous voltage.
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

Siemens Energy & Automation, Inc. 17

5 Wiring Diagrams Bypass Contactor. The applications shown in figures 13 and
15 include a bypass contactor (2M). The bypass contactor is
5.1 Typical Applications rated to handle the running current of the motor but not the
starting current. The bypass contactor remains open until the
This section contains four wiring diagram sets for typical appli- controller has soft-started the motor. Once the motor is oper-
cations as follows. ating at line voltage, the Up-to-Voltage contact closes and the
bypass contactor is energized causing motor current to flow
Figure 12 & 13 - Two Single Speed, Non-reversing Motors, through the bypass contactor rather than the controller.
Wired In Line, in a Vented Enclosure
A bypass contactor is useful when the controller is mounted in
Figure 14 & 15 - Single Speed, Non-reversing Motor, Wired In a NEMA 4, 12 or other airtight enclosure. When the motor cur-
Line, with Bypass Contactor rent is routed through the bypass contactor, no current is
Figure 16 & 17 - Two Single Speed, Non-reversing Motors, flowing through the controller SCR’s, and the controller gener-
Wired Inside Delta,in a Vented Enclosure, 1 with Isolation ates no heat.
Contactor, For both applications, the switch section SW1-1 is set to the
1 with Shunt Trip turn off delay position so that the bypass contactor de-ener-
Figure 18 & 19 Single Speed, Non-reversing Motor, Wired gizes before the controller (refer to paragraph 6.1).
Inside Delta, with Bypass and Isolation Contactors Isolation Contactor. The applications shown in figures 14 and
Each diagram set consists of two sheets: one showing the 15 include an isolation contactor. The isolation contactor is
power and motor connections and one showing the control energized when the controller is operating (RUN coil is On) and
wiring. The SW1 chart at the bottom of the power and motor provides power to half of the windings of the 6-lead delta
diagram indicates the switch settings required for that particu- motor. If a controller fault occurs, the fault contact opens
lar configuration (refer to paragraph 6.1). which de-energizes the isolation contactor and the motor
stops.
5.2 Circuit Devices 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 con-
Common Circuit Devices. Some circuit devices common to
troller (refer to paragraph 6.1).
each application shown include:
Shunt Trip. A shunt trip circuit breaker is used on the second
• an overload relay (1OL, 2OL) for motor protection;
motor in figure 14. The switch section SW1-4 is set to close
• either a circuit breaker (1CB) or a fused disconnect switch the fault contact on fault detection. With the circuit breaker
(1DS/1FU) to connect and disconnect main power to the appli- (1CB) closed and the controller operating (RUN coil is On), the
cation; shunt trip coil is de-energized. If a controller fault occurs, the
• a Start/Stop control that is connected so when the start fault contact closes to energize the shunt trip coil which trips
switch is pushed, the RUN coil in the controller is energized, open the circuit breaker and disconnects power to the con-
and the controller RUN interlock contact closes and latches in troller and motor.
the RUN coil. When the stop switch is pushed or power is The figure 14 application shows two methods of using the
lost, the circuit is broken and the controller drops out which controller fault contact to stop the motor when a fault occurs:
shuts off power to the motor. If a two wire Start/Stop control 1) the fault contact opens to de-energize the isolation contac-
connection is used, the motor may automatically restart when tor for the first motor (1MTR) and 2) the fault contact closes
power is restored to the controller. to operate the shunt trip on the circuit breaker for the second
motor (2MTR).

18 Siemens Energy & Automation, Inc.

 Figure 12
Power wiring for single speed, non-reversing motors, wired "In Line", in a vented enclosure (circuit breaker or fusible disconnect)

Siemens Energy & Automation, Inc. 19

 Figure 13
Control wiring for single speed, non-reversing motors, wired "In Line", in a vented enclosure (circuit breaker or fusible disconnect)

20 Siemens Energy & Automation, Inc.

 Figure 14
Power wiring for a single speed, non-reversing motor, wired "In Line" with bypass contactor

Siemens Energy & Automation, Inc. 21

 Figure 15
Control wiring for a single speed, non-reversing motor, wired "In Line" with bypass contactor

22 Siemens Energy & Automation, Inc.

 Figure 16
Power wiring for single speed, non-reversing motor, wired "Inside Delta" in a vented enclosure, with fusible disconnect and isolation contactor,
and shunt trip circuit breaker.

Siemens Energy & Automation, Inc. 23