SIRIUS InnovationsSystem Manual 11/2009 Industrial Controls Answers for industry.SIRIUS Innovations Industrial controls

SIRIUS Innovations System Manual 11/2009 A8E56203870002-01 System overview 1SIRIUS 3RT2 contactors/contactor assemblies 2 SIRIUS 3RF34 solid-state switching devices 3SIRIUS 3RV2 motor starter protectors 4SIRIUS 3RU2/3RB3 overload relays 5SIRIUS 3RA21/22 load feeders 6SIRIUS 3RA28 function modules for mounting on 3RT2 contactors 7 SIRIUS 3RR2 current monitoring relays 8Appendix A A Legal information 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 with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. 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 for the specific task, 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 adhered to. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of the 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. Siemens AG Industry Sector Postfach 48 48 90026 NRNBERG GERMANY Ordernumber: 3ZX1012-0RA01-1AC1 02/2010 Copyright Siemens AG 2010. Technical data subject to change SIRIUS Innovations System Manual, 11/2009, A8E56203870002-015 Table of contents 1System overview...................................................................................................................................... 19 1.1Introduction ..................................................................................................................................19 1.1.1Modular system for SIRIUS .........................................................................................................19 1.1.2SIRIUS Innovations......................................................................................................................20 1.2Safety instructions........................................................................................................................22 1.3Standards and approvals.............................................................................................................23 1.3.1Standards.....................................................................................................................................23 1.3.2Approvals, test certificates, characteristics..................................................................................24 1.4Overview......................................................................................................................................25 1.4.1SIRIUS modular system...............................................................................................................25 1.4.2Content of SIRIUS Innovations System Manual ..........................................................................27 1.5System properties........................................................................................................................28 1.5.1System properties........................................................................................................................28 1.5.2Modular system design................................................................................................................29 1.5.3Switching technology ...................................................................................................................30 1.5.4Uniform connection system..........................................................................................................32 1.5.5Flexible assembly methods..........................................................................................................33 1.5.6Performance capability ................................................................................................................33 1.5.7Assembly and mounting...............................................................................................................34 1.5.8Load feeders ................................................................................................................................34 1.5.9Application monitoring..................................................................................................................36 1.5.10Communication............................................................................................................................37 1.5.11Safety applications.......................................................................................................................38 1.5.12Environmental protection .............................................................................................................38 1.5.13Energy efficiency..........................................................................................................................38 1.6Customer benefits........................................................................................................................40 1.7Components and combinations ...................................................................................................42 1.7.1Switching and starting..................................................................................................................42 1.7.1.1SIRIUS 3RT2 contactors..............................................................................................................42 1.7.1.2SIRIUS 3RF34 solid-state switching devices...............................................................................48 1.7.1.3SIRIUS 3RW30/40 soft starters ...................................................................................................49 1.7.2Protecting.....................................................................................................................................51 1.7.2.1SIRIUS 3RV2 motor starter protectors ........................................................................................51 1.7.2.2SIRIUS 3RV2917 infeed system..................................................................................................54 1.7.2.3SIRIUS 3RU2/3RB3 overload relays ...........................................................................................55 1.7.3Monitoring ....................................................................................................................................57 1.7.3.1SIRIUS 3RR2 current monitoring relays......................................................................................57 1.7.4Feeders........................................................................................................................................59 1.7.4.1SIRIUS 3RA21/22 load feeders ...................................................................................................59 1.7.4.2SIRIUS 3RA6 compact starters ...................................................................................................61 1.7.5Function modules.........................................................................................................................65 1.7.5.1SIRIUS 3RA28 function modules for mounting on SIRIUS 3RT2 contactors..............................66 1.7.5.2SIRIUS 3RA27 function modules for connection to the automation level ...................................68 1.7.6Device combinations....................................................................................................................70 Table of contents

SIRIUS Innovations 6System Manual, 11/2009, A8E56203870002-01 1.8Mounting and disassembly ..........................................................................................................72 1.8.1Screw mounting ...........................................................................................................................72 1.8.2Snap-on mounting........................................................................................................................72 1.9Connection...................................................................................................................................74 1.9.1Connection systems.....................................................................................................................74 1.9.1.1Screw connection.........................................................................................................................74 1.9.1.2Spring-loaded connection ............................................................................................................75 1.9.1.3Ring cable lug connection............................................................................................................79 1.9.2Conductor cross-sections ............................................................................................................79 1.9.2.1Conductor cross-sections for screw-type connection systems....................................................80 1.9.2.2Conductor cross-sections for spring-loaded connection systems ...............................................82 1.9.2.3Conductor cross-sections for ring cable lug connection system..................................................84 1.9.3Image database ...........................................................................................................................85 1.10Connection to the higher-level control .........................................................................................86 1.10.1Connection to the higher-level control .........................................................................................86 1.10.2IO-Link..........................................................................................................................................89 1.10.2.1Overview......................................................................................................................................89 1.10.2.2Benefits ........................................................................................................................................90 1.10.2.3Applications..................................................................................................................................91 1.10.3AS-Interface .................................................................................................................................94 1.10.3.1Overview......................................................................................................................................94 1.10.3.2Benefits ........................................................................................................................................95 1.10.3.3Operating modes .........................................................................................................................95 1.10.3.4Process communication and field communication.......................................................................96 1.10.3.5System components ....................................................................................................................97 1.10.3.6Technical data..............................................................................................................................98 1.10.3.7More information..........................................................................................................................99 2SIRIUS 3RT2 contactors/contactor assemblies ..................................................................................... 101 2.1Standards...................................................................................................................................101 2.1.1General regulations and standards............................................................................................101 2.1.2Protective separation .................................................................................................................102 2.1.3Positively driven contact elements/Mirror contacts....................................................................103 2.2Product description ....................................................................................................................104 2.2.1Overview of the contactor range................................................................................................104 2.2.2Device versions..........................................................................................................................104 2.2.2.13RH2 contactor relays ...............................................................................................................105 2.2.2.23RT2 power contactors..............................................................................................................107 2.2.2.33RA23 reversing contactor assemblies .....................................................................................110 2.2.2.43RA24 contactor assemblies for star-delta (wye-delta) start.....................................................111 2.2.2.5Drive options ..............................................................................................................................112 2.2.3Applications................................................................................................................................113 2.2.4Performance features ................................................................................................................114 2.3Product combinations ................................................................................................................115 2.4Configuration..............................................................................................................................116 2.4.1Overview of applications for contactors and contactor assemblies...........................................116 2.4.2Drive system/Coil selection........................................................................................................117 2.4.3Application environment.............................................................................................................118 2.4.3.13RH2 contactor relays ...............................................................................................................118 2.4.3.23RT2 power contactors..............................................................................................................118 2.4.3.3Contactors for railway applications ............................................................................................121 2.4.3.4Installation altitude .....................................................................................................................122 2.4.4Switching motorized loads .........................................................................................................123 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-017 2.4.5Switching resistive loads............................................................................................................124 2.4.6Changing the polarity of hoisting gear motors ...........................................................................125 2.4.7Switching in the auxiliary circuit .................................................................................................126 2.4.8Contactors with extended operating range................................................................................127 2.4.8.1Overview....................................................................................................................................127 2.4.8.2Contactors with UC drive ...........................................................................................................127 2.4.8.3Contactors for railway applications ............................................................................................128 2.4.8.4Coupling relays ..........................................................................................................................130 2.4.9Operation of a motor in two directions of rotation (3RA23 reversing contactor assembly) .......132 2.4.10Starting three-phase motors with reduced starting current peaks (3RA24 contactor assembly for star-delta (wye-delta) start) ..................................................................................135 2.4.10.1Technical background information.............................................................................................136 2.4.11Using long control cables...........................................................................................................141 2.5Mounting ....................................................................................................................................147 2.5.1Mounting ....................................................................................................................................147 2.5.1.1Mounting options........................................................................................................................147 2.5.1.2Mounting position.......................................................................................................................147 2.5.1.3Mounting on mounting plate.......................................................................................................148 2.5.1.4Snapping onto DIN rail (snap-on mounting) ..............................................................................149 2.5.2Replacing magnet coils..............................................................................................................149 2.6Connection.................................................................................................................................152 2.7Accessories................................................................................................................................154 2.7.1Accessories overview ................................................................................................................154 2.7.2Auxiliary switch blocks ...............................................................................................................160 2.7.2.1Description .................................................................................................................................160 2.7.2.2Configuration..............................................................................................................................163 2.7.2.3Mounting/Disassembly...............................................................................................................166 2.7.3Surge suppressor.......................................................................................................................169 2.7.3.1Description .................................................................................................................................169 2.7.3.2Configuration..............................................................................................................................170 2.7.3.3Mounting ....................................................................................................................................177 2.7.4EMC suppression module..........................................................................................................178 2.7.4.1Description .................................................................................................................................178 2.7.4.2Configuration..............................................................................................................................179 2.7.4.3Mounting ....................................................................................................................................181 2.7.5OFF-delay device.......................................................................................................................182 2.7.5.1Description .................................................................................................................................182 2.7.5.2Configuration..............................................................................................................................182 2.7.5.3Mounting ....................................................................................................................................182 2.7.6Mechanical latch ........................................................................................................................184 2.7.6.1Description .................................................................................................................................184 2.7.6.2Mounting/Disassembly...............................................................................................................184 2.7.6.3Operation ...................................................................................................................................186 2.7.7Additional load module...............................................................................................................187 2.7.7.1Description .................................................................................................................................187 2.7.7.2Mounting ....................................................................................................................................187 2.7.8Control kit for manual operation of contactor contacts ..............................................................188 2.7.8.1Description .................................................................................................................................188 2.7.8.2Mounting ....................................................................................................................................188 2.7.9Coupling link for PLC.................................................................................................................189 2.7.9.1Description .................................................................................................................................189 2.7.9.2Mounting ....................................................................................................................................190 2.7.10LED display indicator module ....................................................................................................191 2.7.10.1Description .................................................................................................................................191 Table of contents

SIRIUS Innovations 8System Manual, 11/2009, A8E56203870002-01 2.7.10.2Mounting ....................................................................................................................................191 2.7.11Solder pin adapter......................................................................................................................192 2.7.11.1Description .................................................................................................................................192 2.7.11.2Mounting ....................................................................................................................................193 2.7.12Coil terminal module ..................................................................................................................194 2.7.12.1Description .................................................................................................................................194 2.7.12.2Mounting ....................................................................................................................................195 2.7.13Cover for ring cable lug..............................................................................................................196 2.7.13.1Description .................................................................................................................................196 2.7.14Sealable cover ...........................................................................................................................197 2.7.14.1Description .................................................................................................................................197 2.7.14.2Mounting ....................................................................................................................................197 2.7.153-phase infeed terminal .............................................................................................................198 2.7.15.1Description .................................................................................................................................198 2.7.15.2Mounting ....................................................................................................................................198 2.7.16Parallel switching connectors.....................................................................................................199 2.7.16.1Description .................................................................................................................................199 2.7.16.2Configuration..............................................................................................................................199 2.7.16.3Mounting ....................................................................................................................................200 2.7.17Link module for two contactors in series....................................................................................201 2.7.17.1Description .................................................................................................................................201 2.7.17.2Mounting ....................................................................................................................................201 2.7.18Link module for motor starter protector......................................................................................203 2.7.18.1Description .................................................................................................................................203 2.7.19Pneumatic timer .........................................................................................................................204 2.7.19.1Description .................................................................................................................................204 2.7.19.2Mounting/Disassembly...............................................................................................................204 2.7.19.3Operation ...................................................................................................................................205 2.7.20Insulating stop............................................................................................................................206 2.7.20.1Description .................................................................................................................................206 2.7.21Terminal module for contactors with screw connections...........................................................207 2.7.21.1Description .................................................................................................................................207 2.7.21.2Mounting ....................................................................................................................................207 2.7.223RA27 function modules for connection to the automation level (AS-Interface or IO-Link) ......209 2.7.22.1Description .................................................................................................................................209 2.7.233RA28 function modules for mounting on 3RT2 contactors......................................................210 2.7.23.1Description .................................................................................................................................210 2.7.24Assembly kit for reversing contactor assemblies.......................................................................211 2.7.24.1Description .................................................................................................................................211 2.7.24.2Mounting ....................................................................................................................................211 2.7.25Assembly kit for contactor assemblies for star-delta (wye-delta) start ......................................218 2.7.25.1Description .................................................................................................................................218 2.7.25.2Mounting ....................................................................................................................................220 2.8Technical data............................................................................................................................227 2.8.1Contactors for switching motors (3RT20) ..................................................................................227 2.8.1.1Rated data for auxiliary contacts................................................................................................227 2.8.1.2Contact service life of auxiliary and main contacts....................................................................229 2.8.1.3General data and short-circuit protection for 3RT201. contactors without overload relay ........231 2.8.1.4Actuation - 3RT201. contactors .................................................................................................233 2.8.1.5Main circuit - 3RT201. contactors (current carrying capacity for alternating current and direct current) .............................................................................................................................235 2.8.1.6Conductor cross-sections - 3RT201. contactors........................................................................241 2.8.1.7General data and short-circuit protection for 3RT202. contactors without overload relay ........242 2.8.1.8Actuation - 3RT202. contactors .................................................................................................244 2.8.1.9Main circuit - 3RT202. contactors (current carrying capacity for alternating current)................247 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-019 2.8.1.10Rated data for auxiliary contacts (CSA and UL) ........................................................................250 2.8.1.11Main circuit - 3RT202. contactors (current carrying capacity for direct current)........................251 2.8.1.12Conductor cross-sections - 3RT202. contactors........................................................................253 2.8.1.13Rated data (CSA and UL) for 3RT201. and 3RT202. contactors ..............................................255 2.8.2Contactors for specific applications (3RT23 and 3RT25) ..........................................................257 2.8.2.1General data, short-circuit protection for contactors without overload relay and actuation (3RT231. and 3RT232. contactors) ...........................................................................................257 2.8.2.2Main circuit - 3RT231. and 3RT232. (current carrying capacity for alternating current and direct current) .............................................................................................................................260 2.8.2.3General data, short-circuit protection for contactors without overload relay and actuation (3RT251. and 3RT252. contactors) ...........................................................................................262 2.8.2.4Main circuit - 3RT251. and 3RT252. (current carrying capacity for alternating current and direct current) .............................................................................................................................263 2.8.3Contactors with extended operating range................................................................................265 2.8.3.1Contactors for railway applications ............................................................................................265 2.8.3.2Coupling relays ..........................................................................................................................266 2.8.43RH2 contactor relays ...............................................................................................................270 2.8.4.1Permissible mounting position, positively driven operation of contacts and contact reliability of 3RH2 contactor relays (4- and 8-pole)....................................................................270 2.8.4.2General data, rated data (CSA and UL), and data relating to short-circuit protection for 3RH2. contactor relays ..............................................................................................................271 2.8.4.3Conductor cross-sections - 3RH2. contactor relays ..................................................................273 2.8.4.4Actuation - 3RH2. contactor relays ............................................................................................274 2.8.4.5Load side of 3RH2. contactor relays..........................................................................................276 2.8.5Accessories for 3RT2 contactors and 3RH2 contactor relays ...................................................278 2.8.5.1General data - Pneumatic timer 3RT2926-2P. ..........................................................................278 2.8.5.2General data - OFF-delay device 3RT2916-2B. ........................................................................279 2.8.5.3General data - Terminal module for contactors with screw connection.....................................281 2.8.5.4General data - Mechanical latch 3RT2926-3A...........................................................................283 2.8.5.5General data - Control side and load side - coupling link 3RH2924-1GP11 .............................284 2.9Dimension drawings (dimensions in mm) ..................................................................................286 2.9.1Contactors and contactor relays (size S00)...............................................................................286 2.9.2Contactors (size S0) ..................................................................................................................290 2.10Circuit diagrams .........................................................................................................................293 2.10.1Contactors and contactor accessories.......................................................................................294 2.10.2Reversing contactor assembly (S00/S0) ...................................................................................308 2.10.3Contactor assemblies for star-delta (wye-delta) start ................................................................309 3SIRIUS 3RF34 solid-state switching devices ......................................................................................... 313 3.1Safety instructions......................................................................................................................313 3.1.1Standards...................................................................................................................................315 3.2Product description ....................................................................................................................316 3.2.1Device versions..........................................................................................................................316 3.2.2Applications................................................................................................................................318 3.2.3Application environment.............................................................................................................319 3.2.4Solid-state switching devices.....................................................................................................320 3.2.5Device labels..............................................................................................................................322 3.2.6Advantages of solid-state switching devices .............................................................................325 3.3Product combinations ................................................................................................................326 3.4Functions....................................................................................................................................327 3.4.1Actuation of solid-state switching devices .................................................................................328 Table of contents

SIRIUS Innovations 10System Manual, 11/2009, A8E56203870002-01 3.5Planning/configuring ..................................................................................................................329 3.5.1Selecting solid-state switching devices......................................................................................329 3.5.2Configuration: Selecting solid-state contactors for motors ........................................................330 3.5.3Short-circuit protection...............................................................................................................334 3.5.3.1Mounting accessories for the load feeder conforming to IEC....................................................334 3.5.3.2Mounting accessories for the load feeder conforming to UL .....................................................336 3.6Application planning...................................................................................................................339 3.6.1Application areas .......................................................................................................................340 3.6.1.1Switching motors........................................................................................................................340 3.6.1.2Use in a photovoltaic plant.........................................................................................................340 3.7Mounting ....................................................................................................................................341 3.7.1Mounting instructions.................................................................................................................341 3.7.2Screw mounting .........................................................................................................................343 3.7.3Snapping onto/off DIN rail (snap-on mounting) .........................................................................343 3.8Connection.................................................................................................................................344 3.8.1Solid-state contactor ..................................................................................................................344 3.8.2Solid-state reversing contactor ..................................................................................................345 3.9FAQs - Frequently asked questions ..........................................................................................346 3.10Accessories................................................................................................................................347 3.10.1Accessories overview ................................................................................................................347 3.10.2Insulating stop............................................................................................................................347 3.10.2.1Description .................................................................................................................................347 3.10.3Link module for motor starter protector......................................................................................348 3.10.3.1Description .................................................................................................................................348 3.10.3.2Mounting/Disassembly...............................................................................................................349 3.11Technical data............................................................................................................................350 3.11.1General data ..............................................................................................................................350 3.11.2Conductor cross-sections for solid-state contactors..................................................................352 3.11.3Conductor cross-sections for solid-state reversing contactors..................................................353 3.11.4Solid-state contactors 3RF34, 3-phase, screw connection .......................................................354 3.11.5Solid-state contactors 3RF34, 3-phase, spring-loaded terminals..............................................355 3.11.6Solid-state contactors - fuseless design with CLASS 10 motor starter protector ......................356 3.11.7Solid-state contactors - fused design with 3RB30 overload relay .............................................357 3.11.8Solid-state contactors - main circuit, 2-phase controlled...........................................................358 3.11.9Solid-state contactors with control circuit...................................................................................358 3.11.10Solid-state reversing contactor with integration of four current paths to form a single reversing circuit ..........................................................................................................................359 3.11.11Solid-state contactors - fuseless design with CLASS 10 motor starter protector ......................359 3.11.12Solid-state contactor - fused design with 3RB30 overload relay ...............................................360 3.11.13Solid-state reversing contactor - main circuit, 2-phase controlled.............................................360 3.11.14Solid-state reversing contactor with control circuit.....................................................................361 3.11.15Characteristics - switching frequency/load ................................................................................362 3.11.15.1 Characteristics for the solid-state contactor...............................................................................362 3.11.15.2 Characteristics for the solid-state reversing contactor...............................................................367 3.12Dimension drawings (dimensions in mm) ..................................................................................372 3.12.1Solid-state switching devices.....................................................................................................372 3.12.2Link module for motor starter protector......................................................................................373 3.13Circuit diagrams .........................................................................................................................374 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-0111 4SIRIUS 3RV2 motor starter protectors................................................................................................... 379 4.1Standards...................................................................................................................................379 4.2Product description ....................................................................................................................380 4.2.1Introduction ................................................................................................................................380 4.2.2Versions .....................................................................................................................................381 4.2.3Applications................................................................................................................................382 4.2.4Motor starter protectors..............................................................................................................383 4.2.5Performance features ................................................................................................................384 4.3Product combinations ................................................................................................................385 4.4Functions....................................................................................................................................386 4.4.1Overload and short-circuit protection.........................................................................................386 4.4.1.1Tripping classes .........................................................................................................................386 4.4.1.2Tripping characteristics..............................................................................................................388 4.4.2Phase loss sensitivity.................................................................................................................390 4.4.3Protecting single-phase loads or DC loads................................................................................390 4.4.4Test function...............................................................................................................................390 4.5Configuration..............................................................................................................................391 4.5.1Short-circuit protection...............................................................................................................391 4.5.2Motor protection.........................................................................................................................391 4.5.3System protection ......................................................................................................................391 4.5.4Motor protection with overload relay function ............................................................................392 4.5.5Short-circuit protection for starter combinations ........................................................................392 4.5.6Transformer protection...............................................................................................................393 4.5.7Main switch ................................................................................................................................393 4.5.8Use in IT systems ......................................................................................................................393 4.5.9Switching direct current..............................................................................................................394 4.5.10Devices for North America (UL/CSA) ........................................................................................395 4.5.10.1Approved according to UL 508/CSA C22.2 No. 14....................................................................395 4.5.10.2Approval as "circuit breaker" according to UL 489/CSA C 22.2 No. 5-02 .................................396 4.5.11Application environment.............................................................................................................396 4.5.12Selecting the motor starter protectors........................................................................................398 4.5.13Project guidelines for use downstream of frequency converters/inverters with pulsed voltage........................................................................................................................................398 4.5.13.1The effects of high-frequency currents on the thermal overload release ..................................398 4.5.13.2Capacitive leakage currents.......................................................................................................399 4.5.13.3Speed control of motors with characteristic-controlled frequency converters ...........................400 4.6Mounting ....................................................................................................................................401 4.6.1Standard mounting.....................................................................................................................401 4.6.1.1Minimum clearances and mounting position..............................................................................401 4.6.1.2Mounting ....................................................................................................................................402 4.6.2Mounting in limiter circuit ...........................................................................................................403 4.7Connection.................................................................................................................................403 4.8Operation ...................................................................................................................................404 4.8.1Setting the current......................................................................................................................404 4.8.2Testing the overload release......................................................................................................405 4.8.3Testing the overload relay function (3RV21) .............................................................................405 4.8.4Securing.....................................................................................................................................406 4.8.5Reclosing after tripping ..............................................................................................................406 4.9Accessories................................................................................................................................407 4.9.1Accessories overview ................................................................................................................407 4.9.2Installation rules/Component rules ............................................................................................409 Table of contents

SIRIUS Innovations 12System Manual, 11/2009, A8E56203870002-01 4.9.3Auxiliary switch...........................................................................................................................410 4.9.3.1Description .................................................................................................................................410 4.9.3.2Mounting ....................................................................................................................................411 4.9.3.3Disassembly...............................................................................................................................412 4.9.4Signaling switch .........................................................................................................................413 4.9.4.1Description .................................................................................................................................413 4.9.4.2Mounting ....................................................................................................................................414 4.9.4.3Disassembly...............................................................................................................................414 4.9.4.4Operation and diagnostics .........................................................................................................415 4.9.5Auxiliary release.........................................................................................................................416 4.9.5.1Description .................................................................................................................................416 4.9.5.2Auxiliary release voltage ranges................................................................................................417 4.9.5.3Mounting ....................................................................................................................................418 4.9.5.4Disassembly...............................................................................................................................418 4.9.6Disconnector module .................................................................................................................419 4.9.6.1Description .................................................................................................................................419 4.9.6.2Mounting ....................................................................................................................................419 4.9.6.3Isolation and shut-off..................................................................................................................421 4.9.7Phase barriers/UL 508 "type E" terminals .................................................................................422 4.9.7.1Description .................................................................................................................................422 4.9.7.2Mounting UL 508 "type E" terminals ..........................................................................................423 4.9.7.3Mounting phase barriers ............................................................................................................423 4.9.8Door-coupling rotary operating mechanism...............................................................................424 4.9.8.1Description .................................................................................................................................424 4.9.8.2Mounting ....................................................................................................................................425 4.9.8.3Operating the door-coupling rotary operating mechanism........................................................426 4.9.8.4Operating the door-coupling rotary operating mechanism for arduous conditions....................429 4.9.9Enclosures and mounting accessories ......................................................................................432 4.9.9.1Description .................................................................................................................................432 4.9.9.2Mounting ....................................................................................................................................433 4.9.10Sealable cover ...........................................................................................................................436 4.9.10.1Description .................................................................................................................................436 4.9.10.2Mounting ....................................................................................................................................436 4.9.11Insulated 3RV19 3-phase busbar system..................................................................................437 4.9.11.1Description .................................................................................................................................437 4.9.11.2Versions .....................................................................................................................................438 4.9.11.3Mounting ....................................................................................................................................439 4.9.128US busbar adapter...................................................................................................................440 4.9.12.1Description .................................................................................................................................440 4.9.12.2Versions .....................................................................................................................................440 4.9.12.3Mounting ....................................................................................................................................442 4.9.12.4Disassembly...............................................................................................................................444 4.9.133RV2917 infeed system.............................................................................................................446 4.9.13.1Description .................................................................................................................................446 4.9.13.2Derating......................................................................................................................................449 4.9.13.3Mounting ....................................................................................................................................450 4.9.14Link module for attaching a contactor........................................................................................452 4.9.14.1Description .................................................................................................................................452 4.9.14.2Mounting ....................................................................................................................................452 4.10Technical data............................................................................................................................453 4.10.1Performance features ................................................................................................................453 4.10.23RV2 motor starter protectors....................................................................................................454 4.10.3Rated data for auxiliary and signaling switches.........................................................................456 4.10.4Auxiliary switches, front-mounted, transverse ...........................................................................456 4.10.5Auxiliary switches, transverse, solid-state compatible...............................................................457 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-0113 4.10.6Auxiliary switches, lateral and signaling switches......................................................................457 4.10.7Auxiliary releases.......................................................................................................................458 4.10.8Short-circuit protection for auxiliary and control circuits ............................................................458 4.10.9Conductor cross-sections main circuit .......................................................................................459 4.10.10Conductor cross-sections auxiliary and control circuits.............................................................460 4.10.11Short-circuit breaking capacity...................................................................................................462 4.10.11.1 Short-circuit breaking capacity for motor starter protectors.......................................................462 4.10.11.2 Short-circuit breaking capacity for motor starter protectors in the IT system............................464 4.10.11.3 Short-circuit breaking capacity for motor starter protectors with limiter function.......................467 4.10.12Permissible rated data of approved devices for North America (UL/CSA) ................................467 4.10.12.1 Approved according to UL 508/CSA C22.2 No. 14....................................................................467 4.10.12.2 Approval as "circuit breaker" according to UL 489/CSA C 22.2 No. 5-02 .................................476 4.11Dimension drawings (dimensions in mm) ..................................................................................478 4.11.1Dimension drawings for 3RV2 motor starter protectors.............................................................478 4.12Circuit diagrams .........................................................................................................................482 5SIRIUS 3RU2/3RB3 overload relays...................................................................................................... 485 5.1Standards...................................................................................................................................485 5.1.1Standards...................................................................................................................................485 5.2Product description ....................................................................................................................486 5.2.1Introduction ................................................................................................................................486 5.2.2Versions .....................................................................................................................................487 5.2.3Applications................................................................................................................................488 5.2.43RU21 thermal overload relays .................................................................................................490 5.2.53RB30/3RB31 solid-state overload relays.................................................................................491 5.3Product combinations ................................................................................................................493 5.4Functions....................................................................................................................................494 5.4.1Protection against overload, phase failure, and phase asymmetry...........................................494 5.4.1.1Functional principle....................................................................................................................494 5.4.1.2Time-delayed overload release..................................................................................................495 5.4.1.3Tripping classes .........................................................................................................................495 5.4.1.4Tripping characteristics..............................................................................................................496 5.4.2Ground-fault protection (3RB31 only) ........................................................................................499 5.4.3Auxiliary contacts .......................................................................................................................500 5.4.4Indication of the operating state.................................................................................................501 5.4.5Self-monitoring (3RB30/3RB31 only).........................................................................................501 5.4.6Additional functions....................................................................................................................502 5.5Configuration..............................................................................................................................503 5.5.1Overload relays in motor feeders...............................................................................................503 5.5.1.1Overload relays in motor feeders...............................................................................................503 5.5.1.2Normal and heavy-duty starting.................................................................................................504 5.5.1.3Contactor assembly for star-delta (wye-delta) start ...................................................................505 5.5.1.4Operation with frequency converters.........................................................................................505 5.5.2Short-circuit protection...............................................................................................................506 5.5.3Protecting explosion-protected motors ......................................................................................506 5.5.4Application environment.............................................................................................................506 5.6Mounting ....................................................................................................................................508 5.6.1Mounting options........................................................................................................................508 5.6.2Minimum clearances and mounting position..............................................................................508 5.6.3Mounting/Disassembly...............................................................................................................509 5.7Connection.................................................................................................................................513 Table of contents

SIRIUS Innovations 14System Manual, 11/2009, A8E56203870002-01 5.7.1Connection of 3RU21 overload relay.........................................................................................514 5.7.2Connection of 3RB30/3RB31 overload relays ...........................................................................515 5.8Operation ...................................................................................................................................516 5.8.1Setting the current......................................................................................................................516 5.8.2Setting the tripping class/ground-fault detection (3RB31) .........................................................517 5.8.3RESET after release..................................................................................................................517 5.8.4TEST function ............................................................................................................................520 5.8.5Response of the auxiliary contacts ............................................................................................522 5.9Accessories................................................................................................................................523 5.9.1Accessories................................................................................................................................523 5.9.2Terminal support for stand-alone assembly...............................................................................524 5.9.2.1Description .................................................................................................................................524 5.9.2.2Mounting/Disassembly...............................................................................................................524 5.9.3Mechanical remote RESET (release slide)................................................................................527 5.9.3.1Description .................................................................................................................................527 5.9.3.2Mounting/Disassembly...............................................................................................................527 5.9.4Mechanical remote RESET (cable release)...............................................................................529 5.9.4.1Description .................................................................................................................................529 5.9.4.2Mounting/Disassembly...............................................................................................................530 5.9.5Module for electrical remote RESET (3RU21 only) ...................................................................531 5.9.5.1Description .................................................................................................................................531 5.9.5.2Connecting the remote RESET..................................................................................................531 5.9.5.3Mounting/Disassembly...............................................................................................................532 5.9.6Sealable cover ...........................................................................................................................533 5.9.6.1Description .................................................................................................................................533 5.9.6.2Mounting ....................................................................................................................................533 5.9.7Covers for ring cable lug connections........................................................................................535 5.9.7.1Description .................................................................................................................................535 5.10Technical data............................................................................................................................536 5.10.1Performance features ................................................................................................................536 5.10.1.1General data ..............................................................................................................................536 5.10.1.2Protection functions - overview..................................................................................................536 5.10.1.3Equipment ..................................................................................................................................537 5.10.1.4Configuration of load feeders.....................................................................................................537 5.10.1.5Features of overload relays .......................................................................................................538 5.10.23RU21........................................................................................................................................539 5.10.2.1General technical data...............................................................................................................539 5.10.2.2Main circuit .................................................................................................................................540 5.10.2.3Conductor cross-sections main circuit .......................................................................................541 5.10.2.4Auxiliary circuit ...........................................................................................................................543 5.10.2.5Conductor cross sections, auxiliary circuit .................................................................................544 5.10.33RB30/3RB31............................................................................................................................546 5.10.3.1General technical data...............................................................................................................546 5.10.3.2Main circuit .................................................................................................................................548 5.10.3.3Conductor cross-sections main circuit .......................................................................................549 5.10.3.4Auxiliary circuit ...........................................................................................................................550 5.10.3.5Conductor cross sections, auxiliary circuit .................................................................................551 5.11Dimension drawings (dimensions in mm) ..................................................................................552 5.11.1Dimension drawings for 3RU21 thermal overload relays ..........................................................552 5.11.2Dimension drawings for 3RB30/3RB31 solid-state overload relays ..........................................556 5.12Circuit diagrams .........................................................................................................................559 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-0115 6SIRIUS 3RA21/22 load feeders ............................................................................................................. 563 6.1Standards...................................................................................................................................563 6.2Product description ....................................................................................................................564 6.2.1Overview....................................................................................................................................564 6.2.2Device versions..........................................................................................................................564 6.2.2.1Pre-assembled complete devices..............................................................................................566 6.2.2.2Self-assembled load feeders .....................................................................................................567 6.2.3Applications................................................................................................................................568 6.2.4Application environment.............................................................................................................568 6.3Product combinations ................................................................................................................569 6.4Functions....................................................................................................................................570 6.5Configuration..............................................................................................................................571 6.6Mounting ....................................................................................................................................572 6.6.1Installation guidelines.................................................................................................................572 6.6.1.1Minimum clearances (400 V AC) ...............................................................................................572 6.6.2Mounting and disassembling load feeders ................................................................................576 6.6.2.1Overview....................................................................................................................................576 6.6.2.2Load feeder with screw-type connection system.......................................................................577 6.6.2.3Load feeder with spring-loaded connection system ..................................................................579 6.6.2.4Load feeder with hybrid connection...........................................................................................589 6.6.3Mounting and disassembling the assembly types .....................................................................593 6.6.3.1On DIN rail without DIN rail adapter ..........................................................................................593 6.6.3.2On DIN rail with DIN rail adapter................................................................................................594 6.6.3.3On busbar system......................................................................................................................598 6.6.3.4Wall mounting ............................................................................................................................605 6.7Connection.................................................................................................................................608 6.8Operation ...................................................................................................................................608 6.9Accessories................................................................................................................................609 6.9.1Overview....................................................................................................................................609 6.9.2Accessories for starter combinations.........................................................................................610 6.9.3Link modules..............................................................................................................................611 6.9.4Accessories for DIN rail mounting..............................................................................................614 6.9.5Accessories for busbar mounting...............................................................................................615 6.10Technical data............................................................................................................................616 6.10.1General data ..............................................................................................................................616 6.10.2Conductor cross-sections - main circuit .....................................................................................619 6.10.3Conductor cross sections - auxiliary circuit................................................................................621 6.11Dimension drawings (dimensions in mm) ..................................................................................623 6.12Circuit diagrams .........................................................................................................................637 Table of contents

SIRIUS Innovations 16System Manual, 11/2009, A8E56203870002-01 7SIRIUS 3RA28 function modules for mounting on 3RT2 contactors ...................................................... 641 7.1Standards...................................................................................................................................641 7.2Product description ....................................................................................................................642 7.2.1Device versions..........................................................................................................................643 7.2.2Performance features ................................................................................................................645 7.2.3Applications................................................................................................................................646 7.2.3.1Function modules for direct-on-line start ...................................................................................646 7.2.3.2Function modules for star-delta (wye-delta) start ......................................................................647 7.2.43RA28 function modules............................................................................................................649 7.3Product combinations ................................................................................................................650 7.3.1Product combinations ................................................................................................................650 7.4Functions....................................................................................................................................651 7.4.1Overvoltage protection...............................................................................................................651 7.4.2Time-delayed switching of contactors........................................................................................651 7.4.2.1Response delay .........................................................................................................................651 7.4.2.2OFF-delay with auxiliary voltage................................................................................................653 7.4.2.3OFF-delay without auxiliary voltage...........................................................................................654 7.4.2.4Star-delta (wye-delta) function...................................................................................................655 7.5Configuration..............................................................................................................................656 7.5.1Configuration..............................................................................................................................656 7.6Mounting ....................................................................................................................................660 7.6.1Mounting instructions.................................................................................................................660 7.6.2Minimum clearances and mounting position..............................................................................660 7.6.3Mounting ....................................................................................................................................660 7.6.3.1Function modules for direct-on-line start (solid-state timing relay with semiconductor output/solid-state time-delay auxiliary switch) ...........................................................................660 7.6.3.2Function module for star-delta (wye-delta) start ........................................................................662 7.6.4Disassembly...............................................................................................................................665 7.6.4.1Function modules for direct-on-line start (solid-state timing relay with semiconductor output/solid-state time-delay auxiliary switch) ...........................................................................665 7.6.4.2Function module for star-delta (wye-delta) start ........................................................................666 7.6.5Replacing the removable terminal .............................................................................................668 7.7Connection.................................................................................................................................669 7.7.1Connecting the function modules for direct-on-line start ...........................................................669 7.7.1.1Connecting the solid-state timing relay with semiconductor output...........................................669 7.7.1.2Connecting the solid-state time-delay auxiliary switch ..............................................................671 7.7.2Connecting the function module for star-delta (wye-delta) start ................................................672 7.8Operation ...................................................................................................................................673 7.8.1Setting the times ........................................................................................................................673 7.9Accessories................................................................................................................................674 7.9.1Sealable cover cap ....................................................................................................................674 7.10Technical data............................................................................................................................675 7.11Dimension drawings...................................................................................................................677 7.11.1Solid-state timing relays with semiconductor output and solid-state time-delay auxiliary switches .....................................................................................................................................677 7.11.2Star-delta (wye-delta) modules..................................................................................................678 7.12Circuit diagrams .........................................................................................................................679 7.12.1Internal circuit diagrams.............................................................................................................680 7.12.2Example circuit diagrams...........................................................................................................681 Table of contents

SIRIUS Innovations System Manual, 11/2009, A8E56203870002-0117 8SIRIUS 3RR2 current monitoring relays ................................................................................................ 683 8.1Standards...................................................................................................................................683 8.1.1Standards...................................................................................................................................683 8.2Product description ....................................................................................................................684 8.2.1Introduction ................................................................................................................................684 8.2.2Versions .....................................................................................................................................685 8.2.3Applications................................................................................................................................685 8.2.4The advantages of current monitoring relays ............................................................................686 8.2.53RR214.-.A.30 Basic analog setting current monitoring relay...................................................687 8.2.63RR224.-.F.30 Standard digital setting current monitoring relay...............................................688 8.3Product combinations ................................................................................................................689 8.4Functions....................................................................................................................................690 8.4.1Functions and parameters .........................................................................................................690 8.4.2Function charts for Basic analog