Siemens SIRIUS 3RW52 User manual

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Industrial Controls
Soft starters and solid-state
switching devices
SIRIUS 3RW52 Soft Starter
Manual
01/2019
A5E35630451002A/RS
-AD/004
Description
1
Safety information
2
Mounting and dismantling
3
Wiring
4
Parameter assignment
5
Commissioning
6
Functions
7
Messages and diagnostics
8
Maintenance and servicing
9
Technical specifications
10
Dimension drawings
11
Circuit diagrams
12
Example circuits
A
Third-party software
B

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E35630451002A/RS-AD/004
Ⓟ
01/2019 Subject to change
Copyright © Siemens AG 2018.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Manual, 01/2019, A5E35630451002A/RS-AD/004 3
Table of contents
1 Description.............................................................................................................................................. 7
1.1 Target group .............................................................................................................................7
1.2 Device design ...........................................................................................................................8
1.3 Operating principle....................................................................................................................9
1.4 Interaction interfaces...............................................................................................................11
1.5 Operating modes and master control function........................................................................12
1.6 Device versions.......................................................................................................................14
1.7 Areas of application / load types.............................................................................................16
1.8 Selection of the soft starter using the Simulation Tool for Soft Starters .................................17
1.9 Structure of the article number ...............................................................................................18
1.10 Accessories.............................................................................................................................20
1.10.1 Accessories for 3RW52 soft starter ........................................................................................20
1.10.2 3RW5 communication module................................................................................................22
1.10.3 SIRIUS Soft Starter ES (TIA Portal) .......................................................................................23
1.10.4 3RW5 HMI ..............................................................................................................................24
1.11 Additional documentation .......................................................................................................27
1.12 Siemens Industry Online Support ...........................................................................................29
1.13 Support Request.....................................................................................................................31
1.14 Siemens Industry Online Support app ....................................................................................31
2 Safety information ................................................................................................................................. 33
2.1 ESD Guidelines.......................................................................................................................33
2.2 Reactive power compensation................................................................................................35
2.3 Electromagnetic compatibility (EMC) according to IEC 60947-4-1 ........................................35
2.4 Security information ................................................................................................................35
2.5 Recycling and disposal ...........................................................................................................36
3 Mounting and dismantling ..................................................................................................................... 37
3.1 Installing the 3RW52 soft starter.............................................................................................37
3.2 Mounting the fan cover ...........................................................................................................38
3.3 Mounting the 3RW52 soft starter on a level surface...............................................................40
3.4 Installing / mounting / removing 3RW5 HMI ...........................................................................42
3.4.1 Installing the Standard 3RW5 HMI in 3RW52 soft starter ......................................................42
3.4.2 Removing Standard 3RW5 HMI .............................................................................................43
3.4.3 Installing the High Feature 3RW5 HMI in the 3RW52 soft starter ..........................................44
3.4.4 Removing the High Feature 3RW5 HMI .................................................................................45

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3.4.5 Installing the Standard 3RW5 HMI into the control cabinet door........................................... 46
3.4.6 Installing the High Feature 3RW5 HMI in the control cabinet door........................................ 49
3.4.7 Installing the Standard 3RW5 HMI on a flat surface.............................................................. 53
3.4.8 Installing the High Feature 3RW5 HMI on a flat surface........................................................ 55
3.4.9 Cut out the hinged cover for 3RW5 HMI................................................................................ 57
3.4.10 Replacing the hinged cover of the 3RW52 soft starter .......................................................... 58
4 Wiring ................................................................................................................................................... 59
4.1 Connections ........................................................................................................................... 59
4.1.1 Overview of all connections ................................................................................................... 59
4.1.2 State diagrams of the inputs and outputs .............................................................................. 61
4.2 Connecting the 3RW52 soft starter........................................................................................ 63
4.3 Connect the 3RW52 soft starter to the main circuit connection (line side / motor side) ........ 64
4.4 Mounting terminal covers on main circuit connections .......................................................... 66
4.5 Replacing the terminals on size 2 devices............................................................................. 67
4.6 Connecting the control terminals (screw terminals)............................................................... 69
4.7 Disconnecting the control current form the screw-type terminals.......................................... 70
4.8 Connecting the control terminals (spring-type terminals) ...................................................... 71
4.9 Disconnecting the control current from the spring-loaded terminals ..................................... 72
4.10 Replacing the control terminals.............................................................................................. 73
4.11 Installing the cover for the control cable duct ........................................................................ 75
4.12 Removing the cover of the control cable duct........................................................................ 76
5 Parameter assignment .......................................................................................................................... 77
5.1 Setting elements on the 3RW52 soft starter .......................................................................... 77
5.2 Overview of parameters......................................................................................................... 80
5.3 Suggested settings ................................................................................................................ 81
5.4 Parameterizing the 3RW52 soft starter.................................................................................. 82
5.5 Setting RESET MODE and Soft Torque ................................................................................ 83
5.6 RESET MODES..................................................................................................................... 85
5.7 Parameterizing output 13 / 14 (output signal ON or RUN) .................................................... 86
6 Commissioning ..................................................................................................................................... 89
6.1 Commissioning the 3RW52 soft starter ................................................................................. 89
6.2 Sealing the 3RW52 soft starter .............................................................................................. 90
6.3 First commissioning of the High Feature 3RW5 HMI............................................................. 91
7 Functions.............................................................................................................................................. 93
7.1 Soft starting............................................................................................................................ 93
7.2 Current limiting function ......................................................................................................... 96
7.3 Soft stopping .......................................................................................................................... 98

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7.4 Motor protection ......................................................................................................................99
7.4.1 Electronic motor overload protection ......................................................................................99
7.4.2 Thermistor motor protection with temperature sensor (optional)..........................................100
7.5 Intrinsic device protection .....................................................................................................101
7.6 Soft Torque ...........................................................................................................................102
7.7 Additional parameters...........................................................................................................104
7.8 Standard 3RW5 HMI.............................................................................................................105
7.8.1 Design of the Standard 3RW5 HMI ......................................................................................105
7.8.2 Standard 3RW5 HMI menu...................................................................................................107
7.9 High Feature 3RW5 HMI.......................................................................................................110
7.9.1 Design and operator controls of the High Feature 3RW5 HMI.............................................110
7.9.2 Main menu of the High Feature 3RW5 HMI with the 3RW52 soft starter.............................112
7.9.3 Parameterizing the High Feature 3RW5 HMI .......................................................................116
7.9.4 Monitoring .............................................................................................................................117
7.9.4.1 Monitoring the measured values of the 3RW52 soft starter with the High Feature
3RW5 HMI ............................................................................................................................117
7.9.4.2 Monitoring the process image of the 3RW52 soft starter with the High Feature 3RW5
HMI........................................................................................................................................118
7.9.5 Parameterizing analog output AQ via the High Feature 3RW5 HMI ....................................119
7.9.6 Overview ...............................................................................................................................121
7.9.7 Defining the local access protection (PIN)............................................................................122
7.9.8 Micro SD card .......................................................................................................................124
8 Messages and diagnostics .................................................................................................................. 127
8.1 Diagnostics options...............................................................................................................127
8.2 LED display...........................................................................................................................128
8.2.1 Overview of the device LEDs of the 3RW52 soft starter ......................................................128
8.2.2 Status and error displays ......................................................................................................129
8.2.3 LED STATE / OVERLOAD ...................................................................................................130
8.2.4 Overview of LEDs on Standard 3RW5 HMI..........................................................................131
8.2.5 Overview of LEDs on High Feature 3RW5 HMI ...................................................................132
8.3 Warnings and remedial measures ........................................................................................133
8.4 Faults and remedial actions of the 3RW52 soft starter.........................................................134
8.5 Faults and remedial actions on the 3RW5 HMI High Feature ..............................................138
8.6 RESET MODES....................................................................................................................139
8.7 Diagnostics of the 3RW52 soft starter with the 3RW5 HMI High Feature ............................140
8.8 Diagnostics of communication with the High Feature 3RW5 HMI ........................................142
8.9 Execute HMI diagnostics with the 3RW5 HMI High Feature ................................................142
8.10 Logbooks ..............................................................................................................................143
9 Maintenance and servicing.................................................................................................................. 145
9.1 Maintenance and repairs ......................................................................................................145
9.2 User test................................................................................................................................146
9.3 Firmware update ...................................................................................................................149

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9.4 Performing firmware update with micro SD card (3RW5 HMI High Feature) ...................... 150
9.5 Restore factory setting ......................................................................................................... 151
9.5.1 Restoring the factory settings via High Feature 3RW5 HMI ................................................ 152
9.5.2 Restoring the factory settings with the Master RESET button via 3RW5 HMI High
Feature................................................................................................................................. 153
10 Technical specifications .......................................................................................................................155
10.1 Technical data in Siemens Industry Online Support............................................................ 155
11 Dimension drawings.............................................................................................................................157
11.1 CAx data .............................................................................................................................. 157
12 Circuit diagrams...................................................................................................................................159
12.1 CAx data .............................................................................................................................. 159
A Example circuits...................................................................................................................................161
A.1 Main circuit connection ........................................................................................................ 161
A.1.1 Feeder assembly, type of coordination 1 fuseless............................................................... 161
A.1.2 Feeder assembly, type of coordination 1 with fuses............................................................ 162
A.1.3 Feeder assembly, type of coordination 2............................................................................. 163
A.1.4 Inside-delta circuit ................................................................................................................ 164
A.2 Control circuit connection..................................................................................................... 167
A.2.1 Control by pushbutton.......................................................................................................... 167
A.2.2 Control by switch.................................................................................................................. 168
A.2.3 Switching with the control supply voltage ............................................................................ 169
A.2.4 Control by PLC..................................................................................................................... 171
A.2.5 Actuation of a line contactor................................................................................................. 172
A.2.6 Wiring for remote RESET .................................................................................................... 174
A.2.7 Connecting the temperature sensor .................................................................................... 175
A.2.8 Connecting the evaluation unit to the analog output............................................................ 176
A.3 Special applications ............................................................................................................. 177
A.3.1 Controlling a motor with a magnetic parking brake.............................................................. 177
A.3.2 EMERGENCY STOP shutdown to SIL 1 or PL c with a 3SK1 safety relay......................... 179
A.3.2.1 Wiring of the 3SK1 safety relay SIL 1 with line contactor .................................................... 181
A.3.2.2 Wiring of the 3SK1 safety relay SIL 1 without line contactor ............................................... 182
A.3.3 EMERGENCY STOP shutdown to SIL 3 or PL e with a 3SK1 safety relay......................... 183
A.3.3.1 Wiring of the 3SK1 safety relay SIL 3 with line contactor .................................................... 185
A.3.3.2 Wiring of the 3SK1 safety relay SIL 3 without line contactor ............................................... 186
A.3.4 Contactor for emergency start ............................................................................................. 187
B Third-party software .............................................................................................................................189
B.1 Information about third-party software ................................................................................. 189
Glossary ..............................................................................................................................................193
Index ...................................................................................................................................................195

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Description
1
1.1 Target group
Target group
The manual is intended for everyone involved in the following tasks:
●Planning and configuring systems
●Installation
●Commissioning
●Service and maintenance
Requirements for use of 3RW5 soft starters
Basic knowledge of the following areas:
●General electrical engineering
●Drive technology
●Automation technology
●Handling the automation system and the software used

Description
1.2 Device design
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1.2 Device design
①
Main circuit connection (mains supply)
②
Slot for 3RW5 HMI Standard or 3RW5 HMI High Feature (accessories)
③
Interface for 3RW5 HMI Standard or 3RW5 HMI High Feature (accessories)
④
Setting elements for parameter assignment
⑤
MODE key
⑥
Slot for 3RW5 communication module (accessory)
⑦
Connectable conductor cross sections
⑧
Scale of the setting element Ie
⑨
Diagnostics LEDs and RESET key
⑩
Eye for lead seal
⑪
Main circuit connection (motor)
⑫
Control terminals (inputs / outputs)
⑬
Control cable duct

Description
1.3 Operating principle
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1.3 Operating principle
Soft starters are used to start three-phase induction motors with reduced torque and reduced
starting current.
The 3RW52 soft starter starts the motor as soon as the switch-on command is issued (t1).
During the ramp-up time (t1to t3), the current is conducted via power semiconductors which
start the motor up smoothly.
The 3RW52 soft starter features internal run-up recognition. If it detects that the motor has
reached its rated operating speed before the ramp-up time expires, the motor voltage is
immediately increased to 100 % of the line voltage (t2). The internal bypass contacts close
and the power semiconductors are bypassed. The 3RW52 soft starter is then in bypass
operation.
Coast-down to zero speed is activated when the switch-on command is cancelled (t4) and
the motor is shut down. The power semiconductors also ensure that the motor coasts down
smoothly to a stop. The power supply to the motor is maintained (t5) until the end of the
ramp-down time is reached (t4to t5). It may take longer for the motor to actually coast down
to a standstill (t6).
①
Speed t5End of the set ramp-down time
(t5-t4)
②
Voltage
t6
Motor at standstill
t1
Motor start-up with set starting voltage US
US
Set starting voltage
t2
Rated speed neachieved
Ue
Rated operational voltage
t3End of the set ramp-up time
(t3-t1)
neRated motor speed
t4Switch-on command is cancelled, motor is
switched off

Description
1.3 Operating principle
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Functions
●Soft starting with parameterizable starting voltage and starting ramp time
●Soft stopping with parameterizable ramp-down time
●Parameterizable current limiting function
●Soft torque for smooth ramp-up and ramp-down (avoiding torque peaks by means of
torque limitation)
●Integrated motor overload protection with adjustable trip class (Off, Class 10A, 10E, 20E)
●The intrinsic device protection protects the 3RW52 soft starter against overload.
●Ramp-up detection
●Extended operating and diagnostic functions provided by the optional 3RW5 HMI
Standard or 3RW5 HMI High-Feature
●Connection to motor in inline circuit or inside-delta circuit
●Adjustable RESET MODE (manual RESET, remote RESET, auto RESET) for the
functions of motor protection
●Extended full motor protection via optional thermistor motor protection for connection of a
temperature switch (e.g. Thermoclick) or a thermistor (e.g. PTC type A) (alternative to
analog output)
●Optional analog output for output of a measured value (alternative to thermistor motor
protection)
●Optional 3RW5 communication module for integration into bus systems
●Firmware updates upgrade the firmware of the respective device.
Further details can be found in Chapter Functions (Page 93).

Description
1.4 Interaction interfaces
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1.4 Interaction interfaces
①
SIRIUS 3RW52 soft starter
②
LED display on 3RW52 soft starter
③
Fieldbus (via optional communication module)
④
PC or programming device with configuring software of controller (e.g. STEP 7)
⑤
Programmable logic controller (e.g. SIMATIC S7-1500)
⑥
PC with SIRIUS Soft Starter ES (TIA Portal) Premium via 3RW5 communication module
⑦
Motor
⑧
PC with SIRIUS Soft Starter ES (TIA Portal) via local interface on 3RW5 HMI High Feature
⑨
3RW5 HMI High Feature (accessories)
⑩
3RW5 HMI Standard (accessories)
3RW5 HMI
High Feature
3RW5 HMI
Standard
SIRIUS Soft
Starter ES
(TIA Portal)1)
Fieldbus via 3RW5
communication
module
3RW52 soft starter
Monitoring ✓✓✓✓(via user
program)
LEDs
Diagnostics
✓
✓
✓
✓
LEDs
Control
✓
✓
✓
✓
Via input IN
Parameter
assignment
-2), 3) -3) - - Setting elements
1)
Via local interface on 3RW5 HMI High Feature or via 3RW5 communication module.
2)
Analog output (for device version with analog output only) and ON / RUN relay output parameterizable.
3) Station address for PROFIBUS is adjustable.

Description
1.5 Operating modes and master control function
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1.5 Operating modes and master control function
The following modes are available (in ascending order of priority):
Mode
Control source
Control of the 3RW5 soft starter
Priority
Automatic Fieldbus
PROFINET and PROFIBUS: PLC controls
Lowest
Modbus: Modbus client (e.g. PLC) controls
Manual
operation bus
(depending on
the 3RW5
communication
module)
-
-
Connection abort
↓
PC controlled Fieldbus SIRIUS Soft Starter ES (TIA Portal) Premium
controls
↓
Manual
operation local
Input controlled
Digital inputs
Input actions control
↓
3RW5 HMI
controls
3RW5 HMI 3RW5 HMI controls ↓
PC controlled
Local interface
SIRIUS Soft Starter ES (TIA Portal) controls
Highest
If the connection to the control source is aborted, the control priority automatically switches
back to the lowest priority of the current mode.
Sets the operating mode
A higher-priority mode can actively take over as master control from a lower-priority mode at
any time; the reverse is not possible.
The master control function can only be returned to the mode with the lowest priority. Control
sources with higher priority must take the master control function from the mode with the
lowest priority.
A mode with lower priority can only take the master control function back while the motor is
switched off.
The mode with higher priority takes over or receives the master control function from the
current mode in the following ways:
●The mode with higher priority actively takes over the master control function:
–3RW5 HMI: With the action "LOCAL / REMOTE"
–SIRIUS Soft Starter ES (TIA Portal)
●The digital inputs receive the control priority from an operating mode with lower priority
via the following options:
–Via the "Manual operation local - input controlled" bit in the process image output
(PIQ) or in the data table "process image output (PIQ)" (depending on the 3RW5
communication module). You will find more information on the process images and
data tables in the manual for the 3RW5 communication module in question.
–SIRIUS Soft Starter ES (TIA Portal) (depending on the 3RW5 communication module)

Description
1.5 Operating modes and master control function
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The mode with the lowest priority receives or takes over the master control function from the
current mode in the following ways:
●The mode with higher priority actively returns the master control function:
–3RW5 HMI: With the action "LOCAL / REMOTE"
–SIRIUS Soft Starter ES (TIA Portal)
●With control priority of the digital inputs or in the event of a connection abort, the
operating mode with the lower priority can actively retrieve the control priority:
–Via the "Manual operation local - input controlled" bit in the process image output
(PIQ) or in the data table "process image output (PIQ)" (depending on the 3RW5
communication module). You will find more information on the process images and
data tables in the manual for the 3RW5 communication module in question.
–SIRIUS Soft Starter ES (TIA Portal) (depending on the 3RW5 communication module)

Description
1.6 Device versions
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1.6 Device versions
Size 1
Size 2
Size 3
Size 4

Description
1.6 Device versions
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Size 1
Size 2
Size 3
Size 4
Ie
Rated operational current
P
Rated power
The stated power ratings apply to a rated operational voltage of Ue= 400 V in a standard circuit.

Description
1.7 Areas of application / load types
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1.7 Areas of application / load types
Conveyor belts
Pumps
Compressors
Agitators Fans Saws
Starting of a motor causes a rapid change in the load current. The resulting torque impulses
place severe stresses on the mechanical parts of a machine or plant. Moreover, voltage dips
can occur in the power supply system which can have a negative influence on other devices:
●Flicker in lights
●Influence on computer systems
●Contactors and relays dropping out
The 3RW52 soft starter controls the voltage continuously. The torque and the current are
thus also increased continuously. The power supply system is safeguarded against peak
loads and the drive train is protected against damage:
●Smooth starting / stopping, e.g. for conveyor belts
●No pressure surges, e.g. for pumps
●Increased service life of the pipe system, e.g. for compressors
●Reduced starting current, e.g. for agitators
●Reduced stress on gearbox and V belt, e.g. for saws

Description
1.8 Selection of the soft starter using the Simulation Tool for Soft Starters
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1.8 Selection of the soft starter using the Simulation Tool for Soft
Starters
The soft starter can be configured with the STS (Simulation Tool for Soft Starters) software.
The STS suggests suitable soft starters for the respective application based on the entered
motor and load data and application requirements, as well as providing information on the
parameterization.
The Simulation Tool for Soft Starters (STS) can be downloaded from the Internet
(https://support.industry.siemens.com/cs/ww/en/view/101494917).

Description
1.9 Structure of the article number
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1.9 Structure of the article number
Digit of the article number
1st-4th
5th
6th
7th
8th
9th
10th
11th
12th
SIRIUS 3RW soft starter
3RW5
2
C
Size and rated operational current Ieof the soft starter x* x**
Connection system •Applies to sizes 1 / 2
•Main circuit: Screw terminals
•Control circuit: Screw terminals
1
•Applies to sizes 3 / 4
•Main circuit: Bus connection
•Control circuit: Spring-type terminals
2
•Applies to sizes 1 / 2
•Main circuit: Screw terminals
•Control circuit: Spring-type terminals
3
•Applies to sizes 3 / 4
•Main circuit: Bus connection
•Control circuit: Screw terminals
6
Control terminals with
Analog output
A
Thermistor motor protection T
Rated control supply voltage US
24 V AC / DC
0
110 V - 250 V AC
1
Rated operational voltage Ue200 -
480 V AC
4
200 -
600 V AC
5
*see table below.

Description
1.9 Structure of the article number
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Table 1- 1 Size and rated operational current at Ue= 400 V and TU = 40°C and in a standard circuit
Rated operational current Ieof
the soft starter
Rated operating power Peof
the soft starter
x* x**
Size 1
I
e
= 13 A
P
e
= 5.5 kW
1
3
Ie= 18 A Pe= 7.5 kW 1 4
I
e
= 25 A
P
e
= 11 kW
1
5
Ie= 32 A
Pe= 15 kW
1
6
I
e
= 38 A
P
e
= 18.5 kW
1
7
Size 2
Ie= 47 A
Pe= 22 kW
2
4
I
e
= 63 A
P
e
= 30 kW
2
5
Ie= 77 A
Pe= 37 kW
2
6
I
e
= 93 A
P
e
= 45 kW
2
7
Size 3
Ie= 113 A
Pe= 55 kW
3
4
I
e
= 143 A
P
e
= 75 kW
3
5
Ie= 171 A
Pe= 90 kW
3
6
Size 4
I
e
= 210 A
P
e
= 110 kW
4
3
Ie= 250 A
Pe= 132 kW
4
4
I
e
= 315 A
P
e
= 160 kW
4
5
Ie= 370 A
Pe= 200 kW
4
6
I
e
= 470 A
P
e
= 250 kW
4
7
Ie= 570 A
Pe= 315 kW
4
8

Description
1.10 Accessories
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1.10 Accessories
1.10.1 Accessories for 3RW52 soft starter