SIMOCODE pro

SIRIUS Motor Management

Unrestricted
How do you answer these…

How do I improve productivity?

How do I reduce cost?

How do I execute projects faster?

When should I take up the motor for maintenance?

Which fault is more frequent?

How do I avoid unplanned shutdowns?

SIEMENS answers the toughest questions with

SIMOCODE pro for Intelligent MCC
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What is an intelligent MCC?

An MCC in which individual motor feeders offer

Enhanced Motor Protection, Monitors and
Evaluate various operating parameters (e.g.
current, operating hours etc) of the feeders and
perform suitable action to pre-defined conditions
independent of the Automation system

Further it records and communicates early

warnings, diagnostics and statistics data for
predictive maintenance and analysis purpose

Slide 3/36 DF-CS-TR

 Why do we need Intelligent MCCs?
Of course, for continuous flow of process
– Without interruption!!
Further, for

n Enhanced protection of motors

n Faster diagnostics
n Reduced plant shutdowns
n Transparency in operation
n Easier engineering & commissioning
n Faster project completion
n Cost Savings

All of which means – Complete ‘Peace of Mind’

Slide 4/36 DF-CS-TR
SIMOCODE pro

Introduction
History / Philosophy
System
Components
Functions
Configuration / Integration
Practice
Cost Comparison
References
Conventional load feeder

Interlockings
Thermal Local control
overload relay Thermistor evaluation I/O modules
Main circuit Control circuit Automation system
L1
L2
L3
N
PE

-F1
Automation level
-Q1 -Q1

-F2

-F3 Signals Control commands

Thermistor
Overload
-S4 Auto

I-value
-K1 -K2

Auto
On1

On2
Off
Off -K40
S1
E1 E2
-K1 -K41 -K2 -K42
S2 S3 Terminal block / allocation
-K2 -K1
-F2

1U 1V 1W -K2
-K1 -K1 -K2 -S4 -F2 -F3 -K40-K41 -K42
M 1 4-20
mA
3~ -K1 -K2 -F3

Protecting Controlling Signalling

Slide 6/36 DF-CS-TR

Motor feeder (conventional)

I/O Marshalling Motor Control Cubicles

PLC Tier Tier

Hardwiring
Multi-Core Cable

Slide 7/36 DF-CS-TR

 Conventional Motor feeder in a process plant
Control Control SCADA
Cables Room

MCC Room
MCC Marshalling Panel

PLC / DCS
Panel

1 1 1
Multi-Core Cable
Slide 8/36 DF-CS-TR
Conventional MCC with Marshalling Panel

Slide 9/36 DF-CS-TR

Conventional load feeder – Limitations

Interlockings
Thermal Local control
overload relay Thermistor evaluation I/O modules
Main circuit Control circuit Automation system
L1
L2
L3
N
PE

-F1

Automation
-Q1 -Q1 level
-F2

-F3 Signals Control commands

Thermistor
Overload
-S4 Auto

I-value
-K1 -K2

Auto
On1

On2
Off
Off -K40
S1

E1 E2
-K1 -K41 -K2 -K42
S2 S3 Terminal block / allocation
-K2 -K1
-F2

1U 1V 1W -K2
-K1 -K1 -K2 -S4 -F2 -F3 -K40-K41 -K42
M 4-20
1 mA
3~ -K1 -K2 -F3

Slide 10/36 DF-CS-TR

SIMOCODE pro in Load Feeders
Current Basic unit with
measuring module local control station PROFIBUS DP
Main circuit Control circuit Automation system
L1
L2
L3
N
PE

Automation level

PROFIBUS-DP

M
3~

Slide 11/36 DF-CS-TR

Motor feeder with SIMOCODE pro

Motor Control Cubicles with

PLC I/O MC
Intelligent MPR
Tier Tier

PROCESS FIELD BUS

Intelligent,
Compact MCC

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 Intelligent MCC with SIMOCODE pro
Control SCADA
Room

MCC Room
MCC

PLC / DCS
Panel

1 1

Slide 13/36 DF-CS-TR

Motor feeder with SIMOCODE pro
System
main circuit control circuit

Benefit

PROFIBUS DP
§ Space-saving à Small dimensions
+ modular design

§ Enhanced protection and

monitoring à Wide functional
Protecting + Communi- range
Controlling
Monitoring cation § Less wiring à Control circuit is
SIMOCODE pro replaced by "software"

§ 10x more data/ information per

motor feeder à Profibus DP

Motor/
Application

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Introduction
History / Philosophy
System
Components
Functions
Configuration / ntegration
Practice
Cost Comparison
References
 The history of SIMOCODE
SIMOCODE - More than 30 years of experience with motor management systems

3UF2 DP 3UF5 pro 3UF7 pro Safety pro V PN pro S

PROFIBUS PROFIBUS DP PROFIBUS DP PROFINET IO PROFIBUS DP

FMS

3UF1

SINEC L2

1986 1996 2004 2011 2012 2013

Slide 16/36 DF-CS-TR

Introduction
History / Philosophy
System
Components
Functions
Configuration / Integration
Practice
Cost Comparison
References
The system SIMOCODE pro
The powerful Pro V
Choice of system to match your need

SIMOCODE Pro

The cost-effective
Pro C
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The design of SIMOCODE pro motor feeders
SIMOCODE pro C – Compact

Main circuit Control circuit Automation system

Connection

Cable

Current Measuring Operator

Basic Unit 1
Module Panel*
*) Optional

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The design of SIMOCODE pro motor feeders
SIMOCODE pro V – Variable

Main circuit Control circuit Automation system

Connection

Cable

Current/Voltage Basic Unit 2 Operator

+ Expansion
Measuring Module* modules* Panel*
*) Optional

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SIMOCODE pro – system overview
Current Measuring Module Basic Unit Operator Panel Expansion modules
+ Voltage detection Digital Earth Temperature Analog
Modules Leakage Module Module
Module

PROFIBUS DP

SIMOCODE pro C

SIMOCODE pro V

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Introduction
History / Philosophy
System
Components
Functions
Configuration / ntegration
Practice
Cost Comparison
References
The components
SIMOCODE pro C – Compact

Current Basic Unit pro C

Measuring Module 4 DI / 3 DO
0.3 A – 630 A Thermistor
Straight-through/ PROFIBUS DP
busbar connection 24 V DC /
technology 110 – 240 V AC/DC

Operator Panel
5 buttons / 10 LEDs

Connection Cable
In various lengths
(up to 2.5 m)

Slide 23/36 DF-CS-TR

The components
SIMOCODE pro V – Variable
Current Measuring Module Basic Unit pro V
4 DI / 3 DO
0.3 A – 630 A Thermistor
Straight-through/ PROFIBUS DP
busbar connection 24 V DC /
technology 110 – 240 V AC/DC

Connection Cable
In various lengths
(up to 2.5 m)

Current/Voltage
Measuring Module
Operator Panel
with display Expansion modules
0.3 A – 630 A / n Additional Digital I/Os
690 V n 3 x 0/4 – 20 mA I/Os
Straight-through/ n 3 x sensors Pt100/ Pt1000
busbar connection n Earth leakage protection
technology via external summation
current transformer
Slide 24/36 DF-CS-TR
SIMOCODE pro C/V basic unit

4 digital inputs

3 relay outputs Thermistor connection

LED displays System interface

Test/Reset button

110-240 V UC / 24 V DC PROFIBUS DP

System interface for current

measuring

Slide 25/36 DF-CS-TR

The current ranges
Current Measuring Modules for all motor currents
Widths:
45 mm 55 mm 120 mm 145 mm

0.3 – 3 A 10 – 100 20 – 200 A 63 – 630 A

2.4 – 25 A A *)
Straight-through transformer
Busbar connection

Slide 26/36 DF-CS-TR

The voltage range
Current/ Voltage Measuring Modules
Widths:
45 mm 55 mm 120 mm 145 mm

0.3 – 3 A 10 – 100 A 20 – 200 A 63 – 630 A*)

2.4 – 25 A / 690 V / 690 V / 690 V
/ 690 V
Straight-through transformer
Busbar connection

Slide 27/36 DF-CS-TR

SIMOCODE pro device family
SIMOCODE pro components

Motor management system for low-voltage motors up to 630 A - Current measuring

module and current/voltage module for SIMOCODE pro

Sizes
45 mm 55 mm 120 mm 145 mm

• 0,3 A to 3 A ** • 10 A to 100 A • 20 A to 200 A • 63 A to 630 A

• 2,4 A to 25 A • 110 V to 690 V * • 110 V to 690 V * • 110 V to 690 V *
• 110 V to 690 V *

Straight-through current transformer

Busbar connection

* current/voltage module only

** with interposing current transformer 3UF18 up to 820 A

Slide 28/36 DF-CS-TR

Variably expandable additional functions
Expansion modules for SIMOCODE pro V
n Up to 5 expansion modules can be connected

ü Digital Modules for: Max.2

§ Additional Digital I/Os (4 DI & 2 DO in each)

§ Bistable relay outputs
§ Externally supplied inputs
(24 V DC or 110 – 240 V AC/DC)

ü Earth Leakage Module for: Max.1

§ Expansion of the internal earth fault monitoring

by a sophisticated external monitoring with
summation current transformer

Slide 29/36 DF-CS-TR

Variably expandable additional functions2-
Expansion modules for SIMOCODE pro V
n Up to 5 expansion modules can be connected to the
Basic Unit 2:
ü Temperature Module for: Max.1

§ Temperature monitoring of up to 3 analog

temperature sensors (e.g.: Pt100/ Pt1000)

ü Analog Module for: Max.1

§ Input/output and monitoring of analog signals

(0/4 – 20 mA) for, e.g., filling level/flowrate
monitoring or the actuation of a display unit

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Introduction
History / Philosophy
System
Components
Functions
Configuration / Integration
Practice
Cost Comparison
References
Complex hard-wires (Y-D Starter)

Slide 32/36 DF-CS-TR

Flexible Software (Y-D Starter)

Slide 33/36 DF-CS-TR

Data/ information
Even more detailed information on the motor feeder.
Operating data Service data
n Motor switching state n Motor operating hours
(on, off, left, right, slow, fast) n Motor stop times
n Current in phase 1, 2, 3 and max. current n Number of motor starts
n Voltage in phase 1, 2, 3 n Number of overload trips
n Effective power n Device-internal storage of comments
n Apparent power n Device operating hours
n Power factor n Etc.
n Phase unbalance
n Phase sequence Diagnostics data
n Time to trip n Numerous detailed early warning and fault
n Motor model heating messages, also for further processing within
n Remaining motor cooling time the device or the control system
n Temperature (e.g. motor temperature) n Device-internal fault logging with time stamp
n Current analog signal value n Time stamp marking of individually selectable
n Etc. status, warning and fault messages
Communication n Value of the last tripping current
n Check back faults (e.g. no current flow in the
n 12 Mbps , automatic baud rate detection main current circuit after ON control command)
n Time synchronization via Profibus n Etc.
n Cyclic and acyclic services

Slide 34/36 DF-CS-TR

Functions separated by device series

Control functions pro C pro V

n Direct starters n n
n Reversing starters n n
n Star-delta starters n
n Star-delta starters with rotat. direction rev. n
n Two speeds, (pole changeover switch), n
also with rotat. direction rev. n
n Two speeds, (Dahlander), n
also with rotat. direction rev. n
n Solenoid valve actuation n
n Positioner actuation n
n Circuit-breaker actuation n n
n Softstarter actuation n
n Softstarter actuation with rotat. direction rev. n

Flexibly adjustable thanks to:

n n n
Ø Logic modules (truth tables, counters, timers,
edge evaluation, limit monitors...)

Ø Standard functions (power supply failure monitoring, n n n

emergency start, external faults ...)

Slide 35/36 DF-CS-TR

Functions separated by device series

Communication pro C pro V

n Baud rates up to 12 Mbps n n

n Automatic baud rate detection n n
n Cyclical services (DPV0) and acyclical services (DPV1) n n
n Operation behind Y-Link as DPV1-slave n n
n Alarms according to DPV1 n n
n Time synchronization via Profibus n
n 3UF50-Compatibility Mode n

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Introduction
History / Philosophy
System
Components
Functions
Configuration / Integration
Practice
Cost Comparison
References
Configuration with SIMOCODE ES

SIMOCODE ES
is an
Engineering Software
for
Configuration
Parameterization &
Diagnostics
of SIMOCODE
Slide 38/36 DF-CS-TR
Configuration with SIMOCODE ES

Easy & Fast

Parameterization
with
WINDOWS
like
User Interface

parameter tree dialog window

Slide 39/36 DF-CS-TR
Configuration with SIMOCODE ES
Easy Configuration with Graphic Editor

Slide 40/36 DF-CS-TR

 Configuration with SIMOCODE ES
Easy Diagnosis with Analog Value Recording & Online Trends
Analog value recording with SIMOCODE pro V
§ Recording of any analog value, (e.g. motor current, voltage,
power)
§ 60 measured values are stored in the device
§ Adjustable sampling rate 0.1... 50 s
§ Trigger event configurable

Slide 41/36 DF-CS-TR

Configuration with SIMOCODE ES
SIMOCODE ES - Versions

1. Basic
§ Access via System interface on SIMOCODE
§ Parameterization
§ Operation, diagnostics & test
2. Standard
§ All functions of BASIC, plus
§ Integrated Graphics Editor
§ Parameter export

3. Premium
§ All functions of Standard, plus
§ Configuration via PROFIBUS
§ Integrated STEP 7 Object Manager

Slide 42/36 DF-CS-TR

Integration of SIMOCODE pro

SIMOCODE is compatible with all the leading

automation (PLC / DCS) Suppliers

Slide 43/36 DF-CS-TR

Integration of SIMOCODE pro
Integration
With
SIMATIC PCS7
– Its a Child’s Play

Slide 44/36 DF-CS-TR

Integration of SIMOCODE pro
Easy System
integration into Engineering station Operator station Maintenance station

SIMATIC PCS 7
SIMOCODE pro with Block icons and System-level
SIMATIC PDM faceplates asset management

With Blocks for the Automation system

automation system
Optional
Libraries, Switchgear
Asset management

Blocks & e.g. for e.g. for e.g. for temperature …

pumps agitators detection

Face Plates Process

Slide 45/36 DF-CS-TR

Motor Blocks
For all SIMOCODE pro control functions

§ Motor blocks for all applications, e.g.

§ direct starters
§ reversing starters
§ motor valves

§ Standardized integration of pumps, fans, agitators, sliders, etc.

§ Minimum configuration expenditures thanks

to the integration of
§ signal processing and
§ technological function in a single block

§ In addition to overload protection:

§ motor current with adjustable limits

Slide 46/36 DF-CS-TR

Face Plates for Motor Blocks
For all control functions (example: reversing starter)
Faceplate

Operating and monitoring

Current limit values Maintenance Operating and

(monitored by device) monitoring

Block icon
Detailed diagnostics
(in plain text)

Slide 47/36 DF-CS-TR

Faceplate for the block of measured values
Representation of additional measurands
§ Analog process parameters are detected by SIMOCODE pro, e.g.
§ power
§ voltage
§ temperature
§ Limit values are configured and monitored in the device

Operating and monitoring

Slide 48/36 DF-CS-TR

Faceplate for statistics block
Representation of maintenance-relevant data
§ Maintenance-relevant data are already detected and, if required, also monitored by
SIMOCODE pro, e.g.
§ motor operating hours
§ motor stopped times
§ number of overload trips and starts

Operating and monitoring

Slide 49/36 DF-CS-TR

Integration / configuration - accessories
Small auxiliary equipment with large time-saving potentials.

Addressing Plug
for assignment of
PROFIBUS address
without PC/ PG
Assignment of a PROFIBUS
address to one or several
basic units within seconds.

Memory Module
for parameterization
without PC/ PG

Commissioning of a motor
feeder within seconds.

Slide 50/36 DF-CS-TR

Introduction
History / Philosophy
System
Components
Functions
Configuration / Integration
Practice
Cost Comparison
References
Application: Electrical pump (up to 550 kW)
üOperator
Configuring
Station of the application within SIMOCODE
Engineering Station pro
Maintenance possible
Station Power Management

ü Application remains available during fails of the automation or

communication system
üProfibus interface is the standardized interface between application and
automation system
SIMOCODE pro Temperature Analog Digital
Basic unit module module modules
- Protection
- Control
- Interlockings
- Monitoring
- Communication

Protection against Temperature Monitoring e.g.

overload, stall, monitoring e.g. of the filling level, Monitoring/Status
phase failure, of the bearings, filter dirt, e.g. overflow,
Monitoring of windings, flow rate, run dry protection,
power, Cos-Phi medium, run dry protection, Check-back signals:
motor idling, cooling fluid Pressure of the Open, Closed, On, Off
rotational direction cooling fluid or
gear oil

Pump Flow rate Filter

Slide 52/36 DF-CS-TR

Application: Ventilator (up to 550 kW)
Operator Station Engineering Station Maintenance Station Power Management

SIMOCODE pro Temperature Analog Digital

Basic unit module module modules
- Protection
- Control
- Interlockings
- Monitoring
- Communication

Protection against Temperature Monitoring of Monitoring/Status Connection of

overload, stall, monitoring e.g. e.g. pressure, e.g. Check-back signals the heating to
phase failure, of the bearings, filter dirt, Open, Closed, On, Off Profibus via
Monitoring of windings, volume flow SIMOCODE,
power, driving incoming air, Protection,
belt slippage, exhaust air Switching,
rotational direction Monitoring
completely in
SIMOCODE

Ventilator Volume flow Filter Damper Heating

Slide 53/36 DF-CS-TR
Application: Mixer (up to 550 kW) / Positioner
Operator Station Engineering Station Maintenance Station Power Management

SIMOCODE pro Temperature SIMOCODE pro Analog

Basic unit module Basic unit module
- Protection - Protection
- Control - Control
- Interlockings - Interlockings
- Monitoring - Monitoring
- Communication - Communication

Protection against Connection of the Evaluation

overload, stall, positioner to e.g. current position
phase failure, Profibus via of the positioner
Monitoring Temperature SIMOCODE, via analog sensor
of power, monitoring e.g. Interlockings,
idling, of the bearings, Protection against
viscosity, windings, blocking and
rotational medium monitoring of the
direction limit switches
and torque
switches
completely in
SIMOCODE

Mixer Positioner

Slide 54/36 DF-CS-TR

Application: Actuation of a soft starter/ circuit
breaker
Operator Station Engineering Station Maintenance Station Power Management

SIMOCODE pro Temperature SIMOCODE pro

Basic unit module Basic unit
- Control - Control
- Interlockings - Interlockings
- Monitoring - Monitoring
- Communication - Communication

Connection of the Temperature Connection of the

Soft starter to monitoring e.g. Circuit breaker to
Profibus via of the Profibus via
SIMOCODE: bearings, SIMOCODE:
Control via windings Switching via
Profibus, Profibus,
Monitoring Soft Starter Monitoring of Circuit Breaker
of faults, 3RW40 faults, 3VL
status signals, status signals,
Measuring of Measuring of
current, voltage, current, voltage,
power power

Slide 55/36 DF-CS-TR

Standardized and easy integration in the automation
system independent of the application.
Operator Station Engineering Station Maintenance Station Power Management

SIMOCODE pro Commands, Commands, Commands, Commands, Commands,

provides a Status, Status, Status, Status, Status,
standardized Measured Measured Measured Measured Measured
interface values, values, values, values, values,
Diagnosis, Diagnosis, Diagnosis, Diagnosis, Diagnosis,
between Statistics Statistics Statistics Statistics Statistics
application and
PLC.

With regards to
the application
SIMOCODE pro can
be flexible used.
All functions
established in
SIMOCODE remain
available during
fails of the
communication
or the
automation
system.

Pump Ventilator Mixer Positioner Soft starter Circuit breaker

Slide 56/36 DF-CS-TR
SIMOCODE pro V– In a Panel

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SIMOCODE pro V – In a Panel

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SIMOCODE pro – In a Panel

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SIMOCODE pro C – In a Panel

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SIMOCODE pro C – In a Panel

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SIMOCODE pro Profibus cable routing

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SIMOCODE pro Profibus cable routing

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