When It Comes To Motor Management Systems, The Best Just Keeps Getting Better
Nearly a decade ago, Siemens introduced SIMOCODE-DP, replacing the need for space-eating, high-density relay panels with a microprocessor-based motor management system that communicates over Profibus-DP. It revolutionized traditional Motor Control Center (MCC) structure by combining the circuit overload protection and control (that were formerly separate entities), as well as integrating communications capability, all in one convenient package. Of course, a lot of things have changed since then; and SIMOCODE has capitalized on all the latest technologies to not only keep pace, but also push the envelope with new innovations. That led to the introduction of the SIMOCODE pro motor management system a little less than two years ago. With its basic SIMOCODE pro C system for routine applications, and its SIMOCODE pro V system for more complex applications requiring the ultimate in flexibility and functionality, we again moved motor management capability to a new industry level. Now we are introducing further enhancements for our SIMOCODE pro V that keeps us far out in front of any competition.
Before discussing these enhancements in detail, a quick review of the SIMOCODE Pro, and the SIMOCODE concept in general is in order, particularly to those not fully familiar with SIMOCODE.
SIMOCODE Basics First, there is a huge amount of savings in both space and installation time requirements. SIMOCODE eliminates the tremendous amount of wiring that used to be required between the MCCs and the I/O cabinets. This is because the SIMOCODE modules have their own on-board I/O, and the I/O cabinets have been replaced with individual points in each bucket. A second feature of SIMOCODE is that integration between the automation system of a process and its control system has become much easier. With SIMOCODE, the system installer needs only |  |
pull a single Profibus-DP cable to the MCC to provide the communications connectivity. Combined with the robust nature of the RS-485 network, the startup and commissioning have been greatly simplified. It didn’t stop there, however. Integrating automation and control was further simplified by the fact that with SIMOCODE only one motor management tool needs to be utilized for each load, except for variable frequency drives. This means the engineers save time on programming the logic into the automation system.
In many ways, the SIMOCODE pro motor management system emulates a “mini-PLC” by giving the programmer an ample amount of simple local logic in the SIMOCODE base unit. This built-in local logic can be used to configure basic discrete function control and other more powerful analog logic functionality. In fact, with SIMOCODE ES Professional, each check box in the configuration tool can represent twenty-five lines of ladder logic that do not have to be programmed at the actual controller level. This helps to dramatically reduce the overall engineering time for a project, and takes burden and overhead off the PLC/DCS system. |
 A third powerful feature of SIMOCODE is the amount of information it can monitor, collect and communicate. Traditional I/O solutions were very limited, but with SIMOCODE, a high degree of detail on status and performance of each motor load is now possible. This includes measured values like actual motor current, motor voltage, loss of load CosΦ, RTD temperatures and even analog input mA values. With the system’s simple-to-read display, these values can be displayed as well as displaying service and statistical data such as number of starts, number of stops, motor run time, and number of overload trips. Because of the SIMOCODE pro large itemized binary status reporting capability, faults, warnings, motor direction, phase status, overload status, hardware problems and even reporting an open circuit event on one of the analog inputs is possible. All this information gives the end-user the ability to troubleshoot a motor load failure before the failure actually occurs.
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A fourth and very important feature is the fail-safe security of built-in redundancy. Although this is usually done at the Distributed Control System (DCS) level with dual processors, dual code, and dual networks, SIMOCODE pro gives the end-users the ability to do cellular process control should there be an automation system or network failure. At the occurrence of such an event, SIMOCODE pro takes over its single function until the automation system gets back online. Component level redundancy for certain applications is already a standard practice; however it requires engineering time and integration of many discrete devices. Now SIMOCODE pro gives a more elegant bump-less transfer of control by maintaining the portions of the process that must continue throughout interruptions, and it works immediately out of the box. |
SIMOCODE pro Enhancements | |
Now we come to the enhancements of the latest version of Siemens SIMOCODE pro V. Never mind the list of features already introduced, the BEST just became BETTER. The new enhanced version includes a LCD text display operating panel (OP) packed with extended features. The new display has 20 pre-defined display profiles, a graphic LCD for indication of measured values, status and diagnostic information. There are 4 freely |  |
assignable buttons and LEDs, 4 menu and scroll buttons and 3 status LEDs. There are also sheets of pre-punched legend strips that can be customized using a conventional computer printer. It also includes a new decoupling module (DCM) for measuring voltage in ungrounded systems.
In addition, Siemens has extended the overload protection to a higher amperage level and added scaling capability, as well as increasing the system’s reporting features. Now standard interposing current transformers for each of the three phases can be used in conjunction with the Siemens CT modules, which gives the new enhanced SIMOCODE pro V the ability to handle and fully protect up to 8kA on the primary side. The SIMOCODE ES Professional software now can scale the primary-to-secondary ratios while maintaining very accurate thermal overload curves for these larger amperage loads. Reporting power consumption is now also available. The enhanced version can now integrate the KW over time to report measured power usage in kilowatt-hours (KWh). There is also an online strip chart viewing functionality built into the system software. Up to five strip charts can be included in the same y-t diagram that is displayed. Values are made available with the SIMOCODE ES Professional software. The new enhanced SIMOCODE pro V also boasts arithmetic function blocks so that any analog value can be adjusted and or converted to another analog value. This makes common process requirements such as converting Kelvin (K) to Fahrenheit (°F) or converting % of current ratio for the set current (ls) to full load current in amps (A) something easily handled at the system’s component level and not the higher controller level. The enhanced version is suitable for all S7-300/400 PLCs with net routing capability and can be integrated as an S7-slave (OM object in HW). When using a 3TK safety relay in combination with SIMOCODE pro C & V, it is now available for Safety Category 2 and 4 with monitored start, and it is suitable for FVNR, FVR, wye/delta, pole changing, and Dahlander starting. For more information on this product, contact: Matthew Thornton, Senior Controls Specialist, Power Distribution & Controls Division, Siemens Energy & Automation, Inc. (matthew.thorton@siemens.com) |