Siemens ET 200S and ET 200SP motor starters: comparison and selection
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The motor won’t start and the cabinet holds a Siemens ET 200S starter? A comparison of ET 200S motor starters (direct-on-line and reversing) with ET 200SP, a pre-replacement checklist and general steps.
Siemens ET 200S and ET 200SP motor starters: comparison and selection
A motor that does not start or trips for no apparent reason stops the whole machine, and in the cabinet the culprit is often the motor starter. A motor starter in a distributed I/O system starts the motor and protects it. It is usually mounted in the control cabinet and connected to the PLC over a fieldbus. Older installations with Siemens ET 200S motor starters are still running in many plants, so maintenance staff regularly face repairing or replacing them.
When replacing one, the question arises whether to stay with ET 200S or move to the newer ET 200SP system. Answering it requires understanding the differences in design, configuration and documentation. In this article we compare the ET 200S starters (direct-on-line and reversing) with the ET 200SP motor starter, relying solely on the manufacturer's documentation. At the end you will find a checklist for before the replacement and the general steps of the work.
Models at a glance
ET 200S starters come as direct-on-line (DS1) and reversing (RS1), while the ET 200SP motor starter belongs to the newer system and has a different design and configuration method.
| Model | Data from the sources |
|---|---|
| ET 200S direct-on-line starter (DS1) | 2DI COM control module intended for, among others, the DS1e-x and DSS1e-x versions; UL 508 registered (Industrial Control Equipment) |
| ET 200S reversing starter (RS1) | 2DI COM control module intended for, among others, the RS1e-x versions; UL 508 registered (Industrial Control Equipment) |
| ET 200SP motor starter | Module width 30 mm; faster configuration in TIA Portal; easy module replacement; automatic parameter transfer; motors up to 5.5 kW |
ET 200S: direct-on-line and reversing starters
In the ET 200S system, motor starters come as direct-on-line and reversing, and also in fail-safe versions. The manufacturer lists the versions DS1e-x, DSS1e-x, RS1e-x, and F-DS1e-x and F-RS1e-x. The PM-D power module is intended for direct-on-line and reversing starters, so when selecting components it is worth starting by establishing which variant is installed in the cabinet.
For ET 200S starters, the documentation gives a current measurement accuracy of 3 %. According to the manual, the series of starters, fail-safe starters and the safety-integrated system has UL 508 registration (Industrial Control Equipment) and a CSA C22.2 Number 142 test (Process Control Equipment). The ET 200S system can operate on a PROFIBUS network, has CSA and UL approvals, and meets the requirements of the CE mark.
For local operation and diagnostics, the manufacturer offers separate accessories. The 2DI COM control module is intended for, among others, the DS1e-x, DSS1e-x and RS1e-x versions, as well as F-DS1e-x and F-RS1e-x. The PC LOGO! cable is used to connect a computer to the 2DI COM module, and the "Motor Starter ES" software is used for diagnostics and commissioning. The kit for manual operation of the contactors and the control unit for direct control of the contactor coils are indicated only for the DS1-x and RS1-x versions.
ET 200SP: the starter in the newer system
ET 200SP is a scalable, versatile distributed I/O system for connecting process signals to a higher-level controller over a fieldbus. CPUs and interface modules are available for PROFINET IO or PROFIBUS DP. The system has an IP20 degree of protection and is intended for mounting in a control cabinet, and wiring is made easier by the Push-in terminal. The push-in terminal allows a wire to be connected without a tool, and a screwdriver is enough to remove the wire.
ET 200SP starters are used to start and protect single-phase and three-phase motors with a power of up to 5.5 kW. The manufacturer gives four setting ranges and standard and fail-safe versions. The module is 30 mm wide, which saves space in the cabinet. The manufacturer also indicates faster configuration in TIA Portal and faster maintenance thanks to automatic parameter transfer.
An important feature of the ET 200SP station is the replacement of several modules at the same time while the system is running (Multi Hot Swapping), that is, hot swapping during operation. According to the manufacturer, only the modules being replaced drop out, not the whole station. In the case of an IO-Link Master module, the parameters of the devices and of the master are saved automatically, so replacement is possible without a programming device.
ET 200SP e-Starter and safety functions
The SIMATIC ET 200SP e-Starter is a separate, fully electronic motor starter from the ET 200SP family. It uses SiC MOSFET and, according to the manufacturer, switches off a short circuit in less than 5 µs. The Smart Start function limits the starting currents and torque when the motor starts, and the standard submodule enables a safe shutdown (Safe Torque Off) through the F-DI fail-safe digital input. The manufacturer states compliance with SIL 3 and PL e (category 4). This data applies to the e-Starter and is not transferred to the ET 200S starters.
In the area of safety, in addition to the ordinary fail-safe DI and DO modules, ET 200SP also offers a fail-safe power module for the safe shutdown of standard modules, and a relay module. Their functional safety is certified according to EN 61508, and the modules are intended for applications up to SIL 3 according to EN 62061 and PL e according to ISO 13849. ET 200SP starters have a fail-safe version, and safety solutions can be implemented through a SIMATIC F-CPU or a SIRIUS 3SK safety relay.
What to watch for when replacing
Replacement within ET 200S and a move to ET 200SP are different tasks. The points below come from the manufacturer's data; the documentation does not state that modules or power supplies are interchangeable between models, so do not assume it.
- Module width (ET 200SP): the ET 200SP starter is 30 mm wide. Measure the space on the rail and plan the layout in the cabinet.
- Configuration in TIA Portal (ET 200SP): the manufacturer indicates faster configuration in TIA Portal, so prepare the project and access to the tool before the replacement.
- Firmware version (ET 200SP): the manual describes starters with firmware V1.1.0 or newer. Check the version of the installed or purchased module and compare it with the scope of the manual.
- ET 200S variant: before ordering a replacement, establish whether the cabinet contains a direct-on-line, reversing or fail-safe variant. The PM-D power module supports both types (direct-on-line and reversing).
- 2DI COM module (ET 200S): the manufacturer assigns it to specific versions (DS1e-x, DSS1e-x, RS1e-x, F-DS1e-x, F-RS1e-x). The manual operation kit and the coil control unit apply only to DS1-x and RS1-x.
In addition there are checks from general practice: inspecting the housing, connectors and contacts, checking the LEDs, reading the version labels on the housing, and a bench test if possible. For used parts, document their origin. Before any replacement, make a backup of the configuration.
General steps for replacing a starter
A replacement needs a sequence that limits the risk of errors and downtime. Start with a backup of the configuration and parameters and with establishing the installed variant. Select the replacement according to the manufacturer's documentation, not by the similarity of the housing. If the station is running, read the hot-swapping rules described in the manual of the given system.
Before installation, switch off the power and secure the installation against being switched on again. Mount the module, connect the wires according to the diagram and the labels in the cabinet, and then check the connections. Start the system, then test the inputs and outputs and the communication with the controller. Finally, update the installation documentation: variant, version and date of replacement.
Summary
First establish which ET 200S variant is in the cabinet, and make a backup. If you are considering ET 200SP, check the space for a module 30 mm wide, access to TIA Portal, and the firmware version described in the manual. Order parts based on the manufacturer's documentation, not on assumptions about interchangeability.
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