Siemens SIRIUS 3RW55 User manual

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Industrial Controls
Soft starters and solid-state
switching devices
SIRIUS 3RW55 soft starter
Manual
08/2018
A5E35630887002A/RS
-AB/002
Description
1
Safety information
2
Mounting and dismantling
3
Connecting
4
Parameter assignment
5
Commissioning
6
Functions
7
Messages and diagnostics
8
Maintenance and service
9
Technical specifications
10
Dimension drawings
11
Circuit diagrams
12
Example circuits
A

Siemens AG
Division Digita
l Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E35630887002A/RS-AB/002
Ⓟ
08/2018 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.

SIRIUS 3RW55 soft starter
Manual, 08/2018, A5E35630887002A/RS-AB/002 3
Table of contents
1 Description.............................................................................................................................................. 9
1.1 Hardware configuration...........................................................................................................10
1.2 Operating principle..................................................................................................................11
1.3 Interaction interfaces...............................................................................................................13
1.4 Operating modes and master control function........................................................................14
1.5 Device versions.......................................................................................................................16
1.6 Areas of application / load types.............................................................................................18
1.7 Selection of the soft starter using the Simulation Tool for Soft Starters .................................19
1.8 Structure of the article number ...............................................................................................20
1.9 Accessories.............................................................................................................................22
1.9.1 3RW55 soft starter accessories..............................................................................................22
1.9.2 3RW5 communication module................................................................................................24
1.9.3 SIRIUS Soft Starter ES (TIA Portal) .......................................................................................25
1.10 Additional documentation .......................................................................................................26
1.11 Siemens Industry Online Support ...........................................................................................28
1.12 Technical Assistance ..............................................................................................................30
1.13 Siemens Industry Online Support app ....................................................................................31
2 Safety information ................................................................................................................................. 33
2.1 ESD Guidelines.......................................................................................................................33
2.2 Five safety rules for working in or on electrical systems ........................................................35
2.3 Reactive power compensation................................................................................................36
2.4 Electromagnetic compatibility (EMC) according to IEC 60947-4-1 ........................................37
2.5 Security information ................................................................................................................38
2.6 Recycling and disposal ...........................................................................................................39
3 Mounting and dismantling ..................................................................................................................... 41
3.1 Mounting the 3RW55 soft starter ............................................................................................41
3.2 Mounting the fan cover ...........................................................................................................42
3.3 Mounting the 3RW55 soft starter on a level surface...............................................................43
3.4 Installing / mounting / removing 3RW5 HMI High Feature .....................................................45
3.4.1 Removing the 3RW5 HMI High Feature .................................................................................45
3.4.2 Installing the 3RW5 HMI High Feature in the 3RW55 soft starter ..........................................46
3.4.3 Installing the High Feature 3RW5 HMI on a flat surface ........................................................47
3.4.4 Installing the 3RW5 HMI High Feature in the control cabinet door ........................................48
3.4.5 Replacing the hinged cover of the 3RW55 soft starter ...........................................................51

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4 Connecting ........................................................................................................................................... 53
4.1 Overview of all connections ................................................................................................... 53
4.2 Connecting the 3RW55 soft starter........................................................................................ 54
4.3 Connect the 3RW55 soft starter to the main circuit connection (line side / motor side) ........ 55
4.4 Mounting terminal covers on main circuit connections .......................................................... 57
4.5 Replacing the terminals on size 2 devices............................................................................. 58
4.6 Connecting the control terminals (screw terminals)............................................................... 60
4.7 Disconnecting the control current form the screw-type terminals.......................................... 61
4.8 Connecting the control terminals (spring-type terminals) ...................................................... 62
4.9 Disconnecting the control current from the spring-loaded terminals ..................................... 63
4.10 Replacing the control terminals.............................................................................................. 64
4.11 Installing the cover for the control cable duct ........................................................................ 66
4.12 Removing the cover of the control cable duct........................................................................ 67
5 Parameter assignment .......................................................................................................................... 69
5.1 Parameterizing the 3RW55 soft starter.................................................................................. 69
5.2 Motor parameters................................................................................................................... 72
6 Commissioning ..................................................................................................................................... 75
6.1 Commissioning the 3RW55 soft starter ................................................................................. 75
6.2 Application wizard .................................................................................................................. 76
6.3 Sealing the soft starter (optional)........................................................................................... 77
7 Functions.............................................................................................................................................. 79
7.1 Last changed parameters ...................................................................................................... 79
7.2 Start-up .................................................................................................................................. 80
7.2.1 Starting modes....................................................................................................................... 80
7.2.2 Automatic parameterization ................................................................................................... 81
7.2.3 Soft starting with voltage ramp............................................................................................... 83
7.2.4 Soft starting with torque control ............................................................................................. 86
7.2.5 Soft starting with voltage ramp and current limiting ............................................................... 89
7.2.6 Soft starting with torque control and current limiting.............................................................. 91
7.2.7 Direct-on-line starting............................................................................................................. 92
7.2.8 Motor heating ......................................................................................................................... 93
7.2.9 Breakaway pulse for startup functions................................................................................... 94
7.3 Run-down............................................................................................................................... 96
7.3.1 Types of soft stop................................................................................................................... 96
7.3.2 Coasting down ....................................................................................................................... 97
7.3.3 Torque control ........................................................................................................................ 98
7.3.4 Pump stop ............................................................................................................................ 100
7.3.5 DC braking with external braking contactor ......................................................................... 102
7.3.6 Dynamic DC braking without contactor................................................................................ 104
7.3.7 Voltage ramp........................................................................................................................ 106
7.3.8 Alternative stopping ............................................................................................................. 107

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7.4 Motor protection ....................................................................................................................108
7.4.1 Motor overload protection .....................................................................................................109
7.4.2 Thermistor motor protection with temperature sensor..........................................................112
7.5 Intrinsic device protection .....................................................................................................114
7.6 Creep speed .........................................................................................................................115
7.7 Condition Monitoring .............................................................................................................117
7.7.1 Condition Monitoring for plant monitoring.............................................................................117
7.7.2 Current monitoring ................................................................................................................118
7.7.3 Active power monitoring........................................................................................................120
7.7.4 Switching frequency monitoring............................................................................................122
7.7.5 Starting time monitoring........................................................................................................125
7.7.6 Pump cleaning function.........................................................................................................126
7.8 Asymmetry ............................................................................................................................129
7.9 Ground fault ..........................................................................................................................130
7.10 Emergency start....................................................................................................................131
7.11 Number of parameter sets ....................................................................................................133
7.12 Inputs ....................................................................................................................................134
7.12.1 Overview of the input functions.............................................................................................134
7.12.2 Process data and process images........................................................................................136
7.13 Outputs .................................................................................................................................139
7.13.1 Digital outputs .......................................................................................................................139
7.13.2 Analog output........................................................................................................................141
7.13.3 Cyclic send data....................................................................................................................142
7.14 Additional parameters...........................................................................................................143
7.15 Setting the date and time......................................................................................................146
7.16 User account administration .................................................................................................147
7.16.1 General advice on using PINs ..............................................................................................149
7.17 Trace function .......................................................................................................................150
7.18 3RW5 HMI High Feature.......................................................................................................151
7.18.1 Design and operator controls of the High Feature 3RW5 HMI .............................................151
7.18.2 Configuring favorites keys F1 - F9........................................................................................154
7.18.3 Configure start key................................................................................................................155
7.18.4 Main menu ............................................................................................................................156
7.18.5 Monitoring .............................................................................................................................160
7.18.5.1 Monitoring the measured values of the 3RW55 soft starter with the 3RW5 HMI High
Feature..................................................................................................................................160
7.18.5.2 Monitoring the process image of the 3RW55 soft starter with the 3RW5 HMI High
Feature..................................................................................................................................161
7.18.6 Control ..................................................................................................................................162
7.18.7 Parameterizing the 3RW5 HMI High Feature .......................................................................163
7.18.8 Overview ...............................................................................................................................165
7.18.9 Security .................................................................................................................................166
7.18.9.1 General advice on using PINs ..............................................................................................166
7.18.9.2 Defining the local access protection (PIN)............................................................................167
7.18.9.3 User login and logout ............................................................................................................169
7.18.10 Micro SD card .......................................................................................................................170

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8 Messages and diagnostics...................................................................................................................173
8.1 Diagnostics options .............................................................................................................. 173
8.2 LED display .......................................................................................................................... 174
8.2.1 Overview of the device LEDs of the 3RW55 soft starter...................................................... 174
8.2.2 Status and error displays ..................................................................................................... 175
8.2.3 Overview of LEDs on High Feature 3RW5 HMI................................................................... 176
8.3 Warnings and remedial measures of the 3RW55 soft starter.............................................. 177
8.4 Faults and remedial actions of the 3RW55 soft starter........................................................ 179
8.5 Faults and remedial actions on the 3RW5 HMI High Feature ............................................. 182
8.6 Performing 3RW55 soft starter diagnostics with the 3RW5 HMI High Feature ................... 183
8.7 Diagnostics of communication with the High Feature 3RW5 HMI ....................................... 185
8.8 Execute HMI diagnostics with the 3RW5 HMI High Feature ............................................... 186
8.9 Logbooks.............................................................................................................................. 187
9 Maintenance and service .....................................................................................................................189
9.1 Firmware update .................................................................................................................. 190
9.2 Performing firmware update with micro SD card (3RW5 HMI High Feature) ...................... 191
9.3 Restoring factory setting ...................................................................................................... 192
9.3.1 Restoring the factory settings via High Feature 3RW5 HMI ................................................ 193
9.3.2 Restoring the factory settings with the Master RESET button via 3RW5 HMI High
Feature................................................................................................................................. 194
10 Technical specifications .......................................................................................................................195
10.1 Technical data in Siemens Industry Online Support............................................................ 195
11 Dimension drawings.............................................................................................................................197
11.1 CAx data .............................................................................................................................. 197
12 Circuit diagrams...................................................................................................................................199
12.1 CAx data .............................................................................................................................. 199
A Example circuits...................................................................................................................................201
A.1 Main circuit connection ........................................................................................................ 201
A.1.1 Feeder assembly, type of coordination 1 fuseless............................................................... 201
A.1.2 Feeder assembly, type of coordination 1 with fuses............................................................ 202
A.1.3 Feeder assembly, type of coordination 2............................................................................. 203
A.1.4 Inside-delta circuit ................................................................................................................ 204
A.2 Control circuit connection..................................................................................................... 207
A.2.1 Control by PLC..................................................................................................................... 207
A.2.2 Control by means of switch with optional pump cleaning function ...................................... 208
A.2.3 Actuation of a line contactor................................................................................................. 209
A.2.4 Connecting the temperature sensor .................................................................................... 210
A.2.5 Connecting the evaluation unit to the analog output............................................................ 211

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A.3 Special applications ..............................................................................................................212
A.3.1 3RW55 soft starters in inline circuit and stopping function, DC braking with a braking
contactor ...............................................................................................................................212
A.3.2 3RW55 soft starters in inline circuit and stopping function, DC braking with 2 braking
contactors .............................................................................................................................214
A.3.3 3RW55 soft starter in inline circuit with soft starting and stopping and additional creep
speed function.......................................................................................................................217
A.3.4 Control via fieldbus with switchover to manual local operation ............................................220
A.3.5 Reversing duty ......................................................................................................................222
A.3.6 3RW55 soft starter for serial starting with 3 parameter sets.................................................223
A.3.7 3RW55 soft starter with direct-on-line starting (DOL) as emergency start ...........................228
A.3.8 EMERGENCY STOP shutdown to SIL 1 or PL c with a 3SK1 safety relay..........................229
Glossary ............................................................................................................................................. 231
Index................................................................................................................................................... 233

Table of contents
SIRIUS 3RW55 soft starter
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SIRIUS 3RW55 soft starter
Manual, 08/2018, A5E35630887002A/RS-AB/002 9
Description
1
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
1.1 Hardware configuration
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1.1
Hardware configuration
①
Main circuit connection (mains supply)
②
3RW5 HMI High Feature
③
Diagnostics LEDs
④
Eye for lead seal
⑤
Slot for 3RW5 communication module (accessory)
⑥
Connectable conductor cross sections
⑦
Main circuit connection (motor)
⑧
Control terminals (inputs / outputs)
⑨
Control cable duct with cover

Description
1.2 Operating principle
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1.2
Operating principle
Soft starters are used to start three-phase induction motors with reduced torque and reduced
starting current.
The 3RW5 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 3RW5 soft starter features internal start-up detection. 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 soft starter in 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 until the end of the stopping
time is reached (t4to t5). It may take longer for the motor to actually coast down to a standstill
(t6).
①
Speed
t5
End of the set stopping 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
1.2 Operating principle
SIRIUS 3RW55 soft starter
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Functions
●Parameterizable
soft starting
for a smooth drive startup
●Parameterizable
soft stopping
for a smooth drive stop
●Parameterizable
current limiting
for avoiding current peaks
●
Integrated electronic motor overload protection
with adjustable trip class
(OFF, CLASS 10A, 10E, 20E, 30E)
●Universal
intrinsic device protection
protects the 3RW55 soft starter against overload
●Extended full motor protection by means of
thermistor motor protection
for connection of
a temperature sensor
●
Analog output
for displaying a set measured value using an external display device
●
Automatic parameterization
simplifies the system commissioning
●
Current limit monitoring
with 4 separate limit values
●
Monitoring of switching frequency
in order to comply with application-dependent wait /
cooling times
●
Condition Monitoring
for plant monitoring
●Parameterizable
digital inputs and outputs
●Basic unit with
trace functionality
(evaluation via Soft Starter ES)
●Connection options of motor in
inline circuit
or in
inside-delta circuit
●The
emergency start function
allows the system to continue being operated in the event
of a system fault
●
Phase asymmetry monitoring
protects the motor from asymmetrical current consumption
●
Motor heating
for minimizing condensation inside the motor for drives outdoors
●
Pump cleaning function
for removing blockages and dirt from water pipes, filters, and
pump blades
●
Breakaway pulse
for overcoming high stiction, e.g. in mills
●
Access protection
by PIN and user accounts
●Micro SD card for
saving data
●Optional
communication module
●
Creep speed function
in applications with a low counter-torque, e.g. positioning of
machine tools
●
Application wizard
supports the commissioning of various applications
●
Parameter set change
for applications with different load conditions
●
Cascade connection
for connecting the output of a 3RW55 to the input of further soft
starters
●
Serial switch-on
can switch on and off as many as 3 different motors one after the other

Description
1.3 Interaction interfaces
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1.3
Interaction interfaces
①
SIRIUS 3RW55 soft starter
②
3RW5 HMI High Feature
③
LED display on 3RW55 soft starter
④
Fieldbus (via optional 3RW5 communication module)
⑤
PC or programming device with configuration software of the controller (e.g. STEP 7)
⑥
Programmable logic controller (e.g. SIMATIC S7-1500)
⑦
PC with SIRIUS Soft Starter ES (TIA Portal) Premium via 3RW5 communication module
⑧
Motor
⑨
PC with SIRIUS Soft Starter ES (TIA Portal) via local interface at 3RW5 HMI High Feature
3RW5 HMI
High Feature
SIRIUS Soft Starter ES
(TIA Portal)1)
Fieldbus via
communication module
3RW55 soft starter
Monitoring
✓
✓
✓(via user program)
LEDs
Diagnostics
✓
✓
✓
LEDs
Control
✓
✓
✓
Via input IN
Parameter assignment ✓✓✓-
1) Via the local interface on the 3RW5 HMI High Feature or via a suitable 3RW5 communication module

Description
1.4 Operating modes and master control function
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1.4
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 controlled
Lowest
Modbus: Modbus client (e.g. PLC) controlled
Manual operation
bus
(depending on the
3RW5
communication
module)
-
-
Connection abort
↓
PC controlled Fieldbus SIRIUS Soft Starter ES (TIA Portal) Premium controlled ↓
Manual operation
local
-
-
Connection abort (depending on parameter assignment)
Input controlled
Digital inputs
Input actions controlled
↓
3RW5 HMI
controlled
3RW5 HMI 3RW5 HMI controlled ↓
PC controlled
Local interface
SIRIUS Soft Starter ES (TIA Portal) controlled
Highest
If the connection to the control source is aborted, the control priority automatically switches
back to the lowest priority of the current mode.
Depending on the parameter assignment, "Input controlled" has the lowest priority in the
"Manual operation local" mode In the following cases:
●Input action "Manual operation local" is parameterized and switched on.
●A controlling input action (e.g. "Motor CW") is parameterized, but the input action "Manual
operation local" is not parameterized.

Description
1.4 Operating modes and master control function
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Setting the 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:
–Digital inputs: By switching on the input action "Manual operation local", if this is
parameterized.
–3RW5 HMI: With the action "LOCAL / REMOTE"
–SIRIUS Soft Starter ES (TIA Portal)
●If the input action "Manual operation local" is not parameterized, the digital inputs obtain
the master control function from a mode of lower priority in one of the following ways:
–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)
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:
–Digital inputs: By switching off the input action "Manual operation local", if this is
parameterized.
–3RW5 HMI: With the action "LOCAL / REMOTE"
–SIRIUS Soft Starter ES (TIA Portal)
●If the input action "Manual operation local" is not parameterized, the mode with the lowest
priority can actively obtain the master control function from the digital inputs or on
connection abort:
–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 Device versions
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1.5
Device versions
Size 1
Size 2
Size 3
Size 4

Description
1.5 Device versions
SIRIUS 3RW55 soft starter
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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 an inline
circuit.

Description
1.6 Areas of application / load types
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1.6
Areas of application / load types
Conveyor belts
Roller conveyors
Compressors
Small / large fan
Pumps
Hydraulic pumps
Agitators
Centrifuges
Milling machines
Mills
Crushers
Circular saw / band saw
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 3RW55 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
1.7 Selection of the soft starter using the Simulation Tool for Soft Starters
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1.7
Selection ofthe 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
1.8 Structure of the article number
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1.8
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
5
H
A
Size and rated operational current Ieof the
soft starter
x*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-loaded
terminals
2
•Applies to sizes 1 / 2
•Main circuit: Screw terminals
•Control circuit: Spring-loaded
terminals
3
•Applies to sizes 3 / 4
•Main circuit: Bus connection
•Control circuit: Screw terminals
6
•Special connection 8
Rated control supply voltage Us24 V AC / DC 0
110 V - 250 V AC
1
Rated operational voltage Ue200 -
480 V AC
4
200 -
600 V AC
5
400 -
690 V AC
6
*see table below.