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Energy-efficient controls:
SIRIUS brings down energy costs
Energy management in industry
Whether you are a plant operator, planner or machine manufacturer: Energy-efficient production is a challenge and an opportunity in equal measure.
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Product development and production process
Energy-efficient production as a success factor
In order to harness energy potential, with our vast portfolio, we always maintain a clear view of the overall product development and production process. Because maximum energy efficiency in production can only be achieved through perfect interaction of all components.
That is why it is important to first create an awareness for existing energy-saving potential, recognize (identify) and assess (evaluate) opportunities for optimization through precise analysis. Finally, appropriate measures must be implemented (realized).
With our full-range portfolio of energy-efficient drive solutions, automation and services, you too will reach maximum energy efficiency, higher productivity and lasting competitiveness in your company.
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Three columns of energy efficiency with products from the SIRIUS modular system
Energy-efficient products – SIRIUS reduces power loss
SIRIUS controls (3RM1 motor starters, 3RR2 monitoring relays, 3RB3 overload relays, 3RT2 contactors, 3RW soft starters, and 3RV2 motor starter protectors/circuit breakers) as well as the ET 200SP motor starters are characterized by extremely low intrinsic power loss. This not only lowers energy costs, but also reduces the amount of waste heat in the control cabinet. This then translates to a higher packing density and a reduction in the required cooling performance.
Energy-measuring products
Energy management can be instrumental in increasing plant productivity to bring about a significant improvement to the competitive ability of a company – in all industries.
Energy data acquisition represents an important component of the overall energy data management process here. Through transparency right down to the loads, it is possible to identify and utilize potential energy savings.
With communication-capable SIRIUS switching devices you can acquire energy data from the drive train without any additional effort.
In addition to SIRIUS controls, SENTRON measuring devices help you make energy flows visible.
Best drive solutions in terms of energy
In order to design processes for optimal energy efficiency, it is not enough to simply measure the energy flow and deploy energy-efficient products. The greatest lever for saving energy can be derived from closely examining the application.
SinaSave energy efficiency tool:
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Amortization calculator for energy-efficient drive systems
The SinaSave energy efficiency tool determines energy saving potential and amortization times based on your individual conditions of use and therefore offers practical assistance in making decisions about investments in energy-efficient technologies.
In SinaSave, the drive systems to be compared and the relevant drive component parameters are displayed graphically. The various control types and comprehensive product combinations for drive solutions for pump and fan applications can be adapted in your application.
The product portfolio comprises not just SIRIUS controls, but also motors and SINAMICS converters, thus offering a comprehensive range of comparison possibilities – according to your individual requirements.
SinaSave, the free amortization calculator for energy-efficient drives, see www.siemens.com/sinasave.
Energy management with SIRIUS:
Integration in energy management software
SIMATIC Energy Suite
High energy consumption and automated production processes are typical for many industries.
If you want to keep your energy costs under control in the long term and you are already focusing on the digital future, it's a good idea to equip your plant with integrated energy measuring technology, thus anchoring energy management into the automation of your production processes – which is where most energy is consumed.
SIMATIC Energy Suite as an integrated option for the TIA Portal efficiently links energy management with automation, thus creating energy transparency in the production system.
The considerably simplified configuration of energy measuring components from the product families SIMATIC, SENTRON, SINAMICS, SIRIUS and SIMOCODE significantly reduces the configuration costs.
Thanks to the end-to-end connection to SIMATIC Energy Manager PRO (innovative successor to SIMATIC B.Data) or cloud-based Service Energy Analytics, you can seamlessly expand the recorded energy data to create a cross-site energy management system.
This also enables companies to fulfill all economic and energy management requirements – from purchasing of energy through planning to energy controlling.
The advantages at a glance:
- Simple and intuitive configuration instead of programming
- Automatic generation of the PLC energy program
- Convenient integration of measuring components from the Siemens portfolio and from the portfolios of other manufacturers
- Integrated in the TIA Portal and automation
- Archiving on WinCC Professional or PLC
- Seamless connection to Energy Manager PRO and Energy Analytics
For more information on SIMATIC Energy Suite, see www.siemens.com/energysuite.
SENTRON Powermanager
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SENTRON Powermanager
The SENTRON Powermanager energy monitoring software displays important characteristic quantities for individual devices and the entire system on a clearly organized dashboard and thus analyzes the energy consumption.
The advantages at a glance:
- Analyzing energy flows: Cost-saving measures can be derived directly and faults can be localized rapidly – for greater awareness regarding energy consumption and lower costs.
- Easy to get started: Can be added to existing hardware and available infrastructure.
- Fast savings: Analyzes power curve and detects load peaks.
- High plant availability: Continuous monitoring of power distribution ensures that critical system states are detected at an early stage.
The SIRIUS 3RW55 soft starter is integrated into SENTRON Powermanager by simple installation of an XML file, see https://support.industry.siemens.com/cs/ww/en/view/109798105.
For more information about SENTRON Powermanager, see www.siemens.com/powermanager.
Systematic industrial safety technology:
SIRIUS Safety Integrated
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SIRIUS Safety Integrated
Manufacturers and operators of machines must fulfill numerous requirements: reducing costs, improving productivity, and ensuring the safety of machines. The industrial safety technology from Siemens offers innovative, economical solutions for the functional safety of machinery.
Machine safety – compliance with legal requirements
Before any machines or plants can be supplied or operated, they must comply with the legal requirements. The Machinery Directive applies in the EU. Similar requirements apply in many other countries and markets.
To guarantee conformity with these requirements, it is recommended that the correspondingly harmonized standards IEC 62061 or ISO 13849‑1 are applied. This gives manufacturers and operators legal certainty regarding compliance with both national regulations and directives, which are confirmed by the manufacturer of a machine.
The aim of safety technology is therefore to protect people, machines and the environment and to enable statutory safety requirements to be satisfied.
The quick and easy way to safe machinery
In addition to the statutory regulations governing the protection of people there are also economic reasons for avoiding personal injury and the resulting downtimes, and for protecting both machinery and equipment from damage.
Safety Integrated benefits machine manufacturers and plant operators in many ways:
- Lower costs for hardware, assembly and engineering
- Higher availability thanks to faster diagnostics and fewer downtimes
At the same time, using modular safety concepts allows them to modernize their plants more easily and at lower cost.
Smart controls ensure the functional safety of machinery
Our SIRIUS Safety Integrated controls are a central element of the overall Siemens Safety Integrated concept, based on Totally Integrated Automation.
SIRIUS Safety Integrated, see www.siemens.com/safety-integrated.
Whether for reliable detecting, evaluating or reacting, our SIRIUS Safety Integrated controls (see tables below → "Devices with safety functions" and "Devices with safety functions for AS-Interface") provide cost-effective solutions for the safety of your machine or plant. Take the SIRIUS 3SK safety relays for example: They are modularly expandable, and can integrate compact motor starters such as the fail-safe SIRIUS 3RM1 very simply via the device connector (parameterization is performed easily with a screwdriver on the DIP switches or by drag and drop in the engineering software).
The SIMOCODE pro modular motor management system combines all required protection, monitoring, safety and control functions for motor feeders. It can be connected to fail-safe controllers via PROFIBUS or PROFINET and shut down motors in emergency situations.
SIRIUS Safety Integrated uses fail-safe communication via standard fieldbus systems, such as ASIsafe via AS-Interface and PROFIsafe via PROFIBUS and PROFINET, to solve even networked safety tasks of greater complexity. This opens the door to flexible safety solutions for compact machines or large-scale plants – naturally compliant with current standards up to SIL 3/PL e.
The first integrated ASIsafe connection to the distributed I/O system ensures even more consistency. With the SIMATIC AS-i F-Links, AS-i networks can be connected quite simply to safety controls via PROFIsafe via the SIMATIC ET 200SP.
Particular highlights are the 3RT contactors of sizes S2 to S12 with fail-safe control input, the SIRIUS ACT 3SU1 EMERGENCY STOP with PROFINET or PROFIsafe interface, and the fail-safe motor starters for ET 200SP and the 3RW55 fail-safe soft starters. With these products, seamless integration into fail-safe control systems is possible.
The Application Manual SIRIUS Safety Integrated (SIAM Safety Integrated Application Manual) provides users with comprehensive application examples for SIRIUS Safety Integrated products, see https://support.industry.siemens.com/cs/ww/en/view/81366718.
Your partner for machine and plant safety
With Safety Integrated, Siemens has provided the smart answer to constantly increasing requirements for the functional safety of a machine and for its cost-effectiveness and flexibility. Our comprehensive portfolio of safe controls, control technology and drive technology provides scalable solutions for precisely tailored safety concepts for protecting people, machines and the environment. Our products meet the current safety standards in the industry, including IEC, ISO, NFPA and UL.
As a partner for machine and plant safety, Siemens also supports users with examples of functions and up-to-date know-how concerning international standards and directives.
The Safety Selector (www.siemens.com/safety-selector) thus guides the user to the appropriate application example based on selection criteria to be assigned.
The free Safety Evaluation for evaluating safety functions in accordance with IEC 62061 and ISO 13849‑1 is integrated in the TIA Selection Tool, see www.siemens.com/safety-evaluation-tool.
Thus, the selection of components and their safety-related assessment are implemented in a coherent workflow.
Requirements-based training on CE marking, functional safety and risk assessment, and on our Safety Integrated products rounds off our portfolio.
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Devices with safety functions
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Detecting
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Evaluating
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Reacting
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Product
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Product
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Product
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3SE position and safety switches
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SIMOCODE pro 3UF7
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3RQ1 coupling relays
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Flexible thanks to modular design, suitable for offshore applications
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Fail-safe expansion modules DM‑F Local and DM‑F PROFIsafe, safe shutdown of motors up to SIL 3/PL e
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SIRIUS 3RQ1 force-guided coupling relays, fail-safe up to SIL 3/PL e
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3SE6 non-contact safety switches
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3SK safety relays
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3RW55 Failsafe soft starters
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Magnetically operated switches (degree of protection IP67) and RFID safety switches (degree of protection IP69)
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Key modules of a consistent and cost-effective safety chain.
Flexible thanks to input and output expansion units
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3RW55 Failsafe High Performance soft starters with STO
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3SU11 EMERGENCY STOP mushroom pushbuttons,
3SU18 two-hand operation console
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3TK2810 safety relays
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SIRIUS 3RM1 motor starters
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- High level of flexibility due to direct integration of the SIRIUS ACT EMERGENCY STOP via standardized, fail-safe communication protocols (PROFIsafe, ASIsafe)
- SIRIUS ACT two-hand operation console with user-friendly capacitive sensor keys
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Further modules of a consistent and cost-effective safety chain for fail-safe detection of standstill or speed
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Compact, narrow and fail-safe hybrid motor starters with degree of protection IP20
Easy configuration and low outlay for storage thanks to wide setting range of the overload release
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3SE71 cable-operated switches, 3SE29 safety foot switches
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3UG5 monitoring relays
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ET 200SP fail-safe motor starters
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- Cable-operated switches with latching and positive-opening NC contacts, in degree of protection IP65 or IP67
- Foot switches with cover, metal enclosure with degree of protection IP65
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Relays for fail-safe monitoring of supply system, current, active current, voltage, power factor, power, level or speed
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Compact, fail-safe hybrid motor starters for the ET 200SP system
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Devices with safety functions for AS-Interface
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Detecting
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Evaluating
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Reacting
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Product
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Product
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Product
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Safety modules/EMERGENCY STOP mushroom pushbuttons
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3RS2 temperature monitoring relays
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ET 200pro Safety motor starters Solution PROFIsafe
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- K45F and K20F compact safety modules for use in the field
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- SC17.5F SlimLine Compact safety modules for use in the control cabinet
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Relays for fail-safe monitoring of temperatures in solid, liquid and gaseous media
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Communication-capable motor starters with high degree of protection IP65
Special safety modules enable the highest safety levels
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CM AS‑i Master ST,
F‑CM AS‑i Safety ST
for SIMATIC ET 200SP
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3RT contactors from 18.5 kW (F‑PLC input)
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Optimum connection to the fail-safe controller as actuator in the safety chain
Considerable simplification of the application in large power ranges thanks to F-PLC input on the following contactors:
3RT203 and 3RT204,
3RT105 to 3RT107,
3RT145 to 3RT147
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- 3SU1 EMERGENCY STOP mushroom pushbuttons in the enclosure for AS-Interface
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Evaluation and processing of signals via a fail-safe SIMATIC or SINUMERIK control. Simple combination of the CM AS-i Master ST and F‑CM AS‑i Safety ST modules in one ET 200SP station results in a powerful, safety-oriented gateway between PROFINET (or PROFIBUS) and AS-Interface.
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Detection of safety-related signals via safe input slaves on the AS-Interface bus (field modules with degree of protection IP67, control cabinet modules with degree of protection IP20, EMERGENCY STOP mushroom pushbuttons in the enclosure with integrated ASIsafe slave with degree of protection IP69)
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3SF1 mechanical safety switches for AS-Interface
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Electronically configurable 8WD46 signaling columns
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Flexible thanks to modular design, degree of protection up to IP69, suitable for offshore applications
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Flexible and versatile thanks to modular design
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More safety through high locking forces, various release mechanisms
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IE3/IE4 ready:
SIRIUS controls for reliable switching and protection of highly efficient IE3 and IE4 motors
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IE3/IE4 ready with SIRIUS controls
We are IE3/IE4 ready and have AC-3e values
On July 1, 2021, the EU Regulation (EU) 2019/1781 on electric motors and speed controls came into force. This regulation requires:
- Compliance with the legally required minimum efficiency levels IE3 for outputs from 0.75 to 1000 kW
In the next stage as of July 1, 2023:
- Compliance with the legally required minimum efficiency levels IE4 for outputs between 75 and 200 kW.
From an electrical viewpoint, IE3 and IE4 motors behave differently than less energy-efficient models – they are characterized by higher startup currents and modified dynamic behavior. This entails certain challenges for our controls.
The SIRIUS switching and protection devices are ideally suited for use with Premium High Efficiency motors (IE3) or Super Premium Efficiency motors (IE4). This is further underlined by the new utilization category AC-3e for contactors, circuit breakers, motor starters and other devices.
They avoid false tripping due to higher inrush currents of IE3 and IE4 motors, offer optimized setting ranges for rated currents, and ensure reliable switching and protection in any situation – the best prerequisites for the use of modern IE3 and IE4 motors.
Highlights
- Comprehensive range of IE3 and IE4 motors for every application
- Siemens offers expertise through extensive analysis of IE3 and IE4 motors
- Optimized SIRIUS controls for use with IE3 and IE4 motors
- Easy selection thanks to consistently identical rated values of utilization categories AC-3 and AC-3e
Introduction of utilization category AC-3e
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Video: What is the purpose of the utilization category AC-3e?
More information
All IE3/IE4 ready products are marked in Catalog IC 10 with the symbol IE3/IE4 ready.
All products with the utilization category AC-3e are marked in Catalog IC 10 with the symbol AC-3e.
See
Catalog IC 10.
Innovative technology for saving energy:
Electronic starting with hybrid switching technology
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The hybrid switching technology uses low-wear semiconductor technology for switching the motor on and off, and in the operating phase it relies on energy-saving relay technology.
This ensures durability, especially with high switching frequency, and thus significantly reduces maintenance costs and extends the life of the motor starters.
In addition, due to the hybrid switching technology, motor starters have lower electromagnetic interference emissions, enabling you to increase your plant availability.
Further energy savings are provided by the integrated electronic overload protection.
This causes a lower intrinsic power loss than comparable motor feeders with thermal overload protection.
In this way, you benefit from reduced heat generation and therefore lower cooling power. And that saves energy.
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Highlights
Use of hybrid switching technology for:
- SIRIUS 3RM1 motor starters
- ET 200SP motor starters
- SIRIUS soft starters
Failsafe functionality for SIRIUS 3RW55 soft starters, SIRIUS 3RM1 motor starters and ET 200SP:
- Maximum safety: Safety function up to SIL 3/PL e
Additional benefits for SIRIUS 3RM1 motor starters:
- Using device connectors safety-related group shutdown with reduced wiring is possible
- Direct connection to the 3SK safety relay, without additional wiring
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