Siemens tiastar TM Motor Control Center (MCC)

Transcription

1 Siemens tiastar TM Motor Control Center (MCC) Page 1 Siemens All rights reserved.

2 tiastar Motor Control Centers Smart tiastar Motor Control Centers Smart June 2013 Page 2

3 tiastar Motor Control Centers Smart A Smart MCC is a networked NEMA/EEMAC compliant MCC that can communicate. It incorporates intelligent devices at the bucket level to control and monitor motor operation, energy consumption, and power quality. It rapidly communicates with a PLC or process control system via a data network. Page 3

4 tiastar Motor Control Centers Smart Historically MCCs have played a limited roll in monitoring system operation. providing basic information to the PLC M OL Example - start-stop motor control circuit PLC inputs are connected to normally open auxiliary contacts. M contact closes when the motor starter coil energizes. OL contact closes when an overload occurs. Page 4

5 tiastar Motor Control Centers Smart Traditional Wiring Hard Wired MCC 1 motor starter requires 6 wires minimum OFF ON FAULT Motor RUN Output MStarter Run and Trip Input Signals DCS 4-20mA Analog Current (when required) Page 5

6 tiastar Motor Control Centers Smart Say you had 25 motor starters (125 Wires) Page 6

7 tiastar Motor Control Centers Smart Traditional Wiring Hard Wired MCC Downside with Hardwiring: Lots of wires and labor intensive Potential for wiring errors Troubleshooting difficulty Page 7

8 tiastar Motor Control Centers Smart Traditional Wiring Hard Wired MCC OFF WARNING FAIL TO START UNDER LOAD ON JAM PHASE LOSS OVER TEMP FAULT AUTO CONTROL POWER??? Mostly due to cost, conventional wiring will give only basic status for a typical FVNR Mostly due to cost, conventional method will not provide these important data points Page 8

9 tiastar Motor Control Centers Smart First Quality Tissue Typical FVNR Starter Page 9

10 tiastar Motor Control Centers Smart First Quality Tissue Typical FVNR Starter Page 10

11 tiastar Motor Control Centers Smart FVNR Circuit Using SIMOCODE pro Page 11

12 tiastar Motor Control Centers Smart First Quality Tissue Typical FVNR Starter Pull Apart Terminal in MCC Unit (3) Connections Terminal in DCS Compartment (2) connections Terminal on Device (1) connection Number of Wires = 6 Number of Connections = 17 Page 12

13 tiastar Motor Control Centers Smart A better solution to conventional wiring is using a PROFIBUS networked Smart MCC. PROFIBUS-DP Network RVSS RVSS VFD with PROFIBUS WL SIMOCODE SIMOCODE SIMOCODE SIMOCODE SIMOCODE SIMOCODE PLC /DCS (controller) SIMOCODE SIMOCODE RVSS SIMOCODE SIMOCODE SIMOCODE SIMOCODE SIMOCODE SIMOCODE SIMOCODE PROFIBUS is the leading fieldbus system in the world market with more than 30 million installed nodes. SIMOCODE Page 13

14 tiastar Motor Control Centers Smart Components Smart MCC uses SIMOCODE in the buckets to give the customer a true motor management system. Page 14

15 tiastar Motor Control Centers Smart Components SIMOCODE Siemens Motor Management and Control Device - PROFIBUS, PROFINET, Modbus RTU, Ethernet IP Communication Page 15

16 tiastar Motor Control Centers Smart Components Pro S and Pro C The compact system for: Direct starters Reversing starters Page 16

17 tiastar Motor Control Centers Smart Components Pro V The variable system: Page 17

18 Electric Motor Failures Motor Protection Programs can increase the service life of a motor by 75% 92% of electric motor failures occur at start-up. Most of these failures occur due to low resistance, but mechanical failure, and over-current failures are also very common. They re over 50 different failure modes that electric motors are susceptible to, but the most common and categories these modes can take typically fall into these 6 categories: Over-Current Low Resistance Over Heating Dirt Moisture Vibration Also known as Electrical Overload. Overload protection devices limit these situations from occurring (Overload Relays, Current Limiting Breakers or Fuses) Insulation resistance degrades overtime causing more current and possible phase to phase shorts, or phase to ground failures. Insulation performance monitoring is needed. For every 10 degree centigrade rise, insulation life is cut in half. Example, a 20 year rated motor running at 40c over temperature has a service life of 1 year. Contamination can cause significant cooling issues on the outside of the motor, not to mention havoc inside of the motor. Proper cleaning is required for long life Is a leading cause of corrosion of shafts, bearings, and rotors; it can also lead to insulation failure of a motor. Typically caused by misalignment, but also affected by contamination, and pending bearing failures. Restricted Siemens AG 2013 All rights Maintenance reserved. Technology Article Page 18 IEEE Petro-Chem Paper PCI-94-1 IEEE Petro-Chem Paper PCIC-94-1 root cause analysis to determine failure mode.

19 SIMOCODE Pro V Your electronic Motor Protection Program in a box Over- Current Low Resistance Also known as Electrical Overload. Overload protection devices limit these situations from occurring (Overload Relays, Current Limiting Breakers or Fuses) Insulation resistance degrades overtime causing more current and possible phase to phase shorts, or phase to ground failures. Insulation performance monitoring is needed. Over Heating Dirt Moisture Vibration Page 19 For every 10 degree centigrade rise, insulation life is cut in half. Example, a 20 year rated motor running at 40c over temperature has a service life of 1 year. Contamination can cause significant cooling issues on the outside of the motor, not to mention havoc inside of the motor. Proper cleaning is required for long life Is a leading cause of corrosion of shafts, bearings, and rotors; it can also lead to insulation failure of a motor. Typically caused by misalignment, but also affected by contamination, and pending bearing failures. When your machine or process has no time for downtime look to SIMOCODE pro V for your Motor Protection Program in a box! No electronic device is a substitute for hands on preventative maintenance programs, but SIMOCODE provides real-time, 24/7/365 control and monitoring capability that integrates easily into your enterprise monitoring solution. This gives you eyes and ears into the internal and external operating conditions your motors. Adding SIMOCODE to your current preventative maintenance program

20 SIMOCODE pro The intelligent interface between pump application and controller Application Example: Pump / Motor Control & Monitoring Control & Monitoring Controller Operator Panel SCADA Wireless Remote Access SIMOCODE SIMOCODE pro Basic unit -Protection - Control - Interlockings - Monitoring - Communication Temperature module Analog module Digital modules Pump Application Protection against overload, stall, phase failure, Monitoring of power, Cos-Phi motor idling, rotational direction Temperature monitoring e.g. of the bearings, windings, medium, cooling fluid Monitoring e.g. of the filling level, filter dirt, flow rate, run dry protection, Pressure of the cooling fluid or gear oil Monitoring/Status e.g. overflow, run dry protection, Check-back signals: Open, Closed, On, Off Page Pump Flow rate Filter

21 SIMOCODE pro The intelligent interface between fan application and controller Application Example: Fan & Heating Controller Control & Monitoring Operator Panel SCADA Wireless Remote Access SIMOCODE SIMOCODE pro Basic unit -Protection - Control - Interlockings - Monitoring - Communication Temperature module Analog module Digital modules Fan & Heating Application Protection against overload, stall, phase failure, Monitoring of power, driving belt slippage, rotational direction Temperature monitoring e.g. of the bearings, windings, incoming air, exhaust air Monitoring of e.g. pressure, filter dirt, volume flow Monitoring/Status e.g. Check-back signals Open, Closed, On, Off Connection of the heating to Profibus via SIMOCODE, Protection, Switching, Monitoring completely in SIMOCODE Fan Volume flow Filter Damper Heating Page 21 21

22 SIMOCODE pro The intelligent interface between motor operated valve application and controller Application Example: Motor Operated Valve (MOV) Wireless Control & Monitoring Controller Remote Monitoring Historian Enterprise SIMOCODE SIMOCODE pro Basic unit -Protection - Control - Interlockings - Monitoring - Communication Analog module MOV Application Connection of the positioner to Modbus RTU via SIMOCODE, Interlocking, Protection against blocking and monitoring of the limit switches and torque switches by SIMOCODE Evaluation e.g. current position of the positioner via analog sensor Page MOV

23 SIMOCODE pro The intelligent interface between soft starter, circuit breaker and controller Controller Control & Monitoring Operator Panel SCADA Wireless Remote Access SIMOCODE SIMOCODE pro Basic unit - Control - Interlockings - Monitoring - Communication Temperature module SIMOCODE pro Basic unit - Control - Interlockings - Monitoring - Communication Softstarter & Circuit Breaker Application Connection of the Soft starter to Profibus via SIMOCODE: Control via Profibus, Monitoring of faults, status signals, Measuring of current, voltage, power Temperature monitoring e.g. of the bearings, windings Soft Starter 3RW40 Connection of the Circuit breaker to Profibus via SIMOCODE: Switching via Profibus, Monitoring of faults, status signals, Measuring of current, voltage, power Circuit Breaker 3VL Page 23 23

24 How to find SIMOCODE pro Application 1) Find out as much about the application as possible Diagnostics Monitoring Network Supported Control Protection Page 25

25 Diagnostics Events that usually have happened in the past What are their most common failures? How are they currently detecting that error? Is it with a separate device? How long does it take to fix that error? How much down time costs them? Are they trying to reduce that cost? Page 26

26 SIMOCODE pro Faults Page 27

27 Monitoring Events happening now or in the future What s the difference between Monitoring and Measuring? Measuring only supplies the value Monitoring also provides the comparison of the value Do they want to measure motor current? Yes - Find out why No Find out why not Do they want to measure voltage/power/power factor? Yes - Find out why No Find out why not Page 28

28 SIMOCODE pro Warnings Page 29

29 SIMOCODE pro Measured Values Page 30

30 SIMOCODE pro Maintenance/Statistical Data Page 31

31 SIMOCODE pro Control Simplify the Control for the PLC Can PLC logic functions be put into the SIMOCODE? Use a smaller PLC/DCS Provide stand alone control if network is lost Can local logic help blend SIMOCODE into the existing architecture? Signal conversion Signal logic Do they have run permissive conditions? Yes - Find out which ones No Find out if they would like to Page 32

32 SIMOCODE pro Control Page 33

33 SIMOCODE pro Protection Protecting the Process instead of just the Motor What is their biggest cause of downtime? By combining Diagnostics, Monitoring and Control capabilities prove how SIMOCODE pro can increase their productivity/profitability Page 34

34 6) SIMOCODE pro Safety Fail-safe digital module DM-F Local Widths: For local applications or integration in F-PLCs without PROFIsafe Safety-related disconnection via an EMERGENCY-STOP sensor or via a fail-safe control's signal without PROFIsafe Parameterization of the safety function via DIP switch on DM-F LOCAL Diagnostics information is available in SIMOCODE ES in the form of standard signals Safety function up to SIL 3 / PL e with Category 4 Fail-safe digital module DM-F PROFIsafe For decentral, distributed applications with PROFIsafe Safety-related disconnection by means of the PROFIsafe signal via the F-PLC DIP switch on DM-F PROFIsafe for setting of the PROFIsafe address Evaluation of the PROFIsafe telegram in the DM-F no workload on SIMOCODE Safety function up to SIL 3 / PL e with Category 4 Page 35

35 6) SIMOCODE pro Safety SIMOCODE pro Safety Overview Easy implementation of safety-related solution with the DM-F fail-safe expansion module for SIMOCODE pro V Optimum integration of safety-related and functional switching in a system when functions are separate Motor management Safety technology Safety function only in the digital module, with no effect on SIMOCODE pro Integrated and comprehensive diagnostics of safety functions SIMOCODE pro V (PROFIBUS/Modbus) SIMOCODE pro V PN Functional switching by SIMOCODE pro in the fail-safe digital module Fail-safe digital module DM-F Page 36

36 with local, safety-related shutdown SIMOCODE pro Safety DM-F Local, Connection to PROFIBUS Page 37

37 with safety-related shutdown via failsafe hardware output SIMOCODE pro Safety DM-F Local, Connection to PROFIBUS Page 38

38 with safety-related shutdown via failsafe CPU and PROFIsafe SIMOCODE pro Safety DM-F PROFIsafe Page 39

39 tiastar MCC Product Updates in COMPAS SINAMICS G120 SINAMICS G120 is a modular drive inverter system that comprises various function units. These are essentially: Control Unit (CU) and Power Module (PM). SINAMICS G120 TECHNICAL DATA Compatible Power Modules Voltage and Power ranges PM240, PM240-2, PM V, 0.5 to 350 HP (LO) V, 0.5 to 300 HP (HO) Page 40

40 Smart Reduced Voltage Soft Starters (RVSS) Option for MCCs Horsepower at 480 V HP RVSS Type SIRIUS 3RW44 Characteristics LCD Display with door mount option 3-phase control technology Tightening torque control Integrated DC brake function Page 41 3RW44

41 tiastar Motor Control Centers Smart tiastar Motor Control Centers with PROFINET Communications June 2013 Page 42

42 tiastar Motor Control Centers with PROFINET Communications tiastar Motor Control Centers are now available with PROFINET (Industrial Ethernet 10/100 Mbit/s) communication. Siemens PROFINET communication features SIMATIC and SCALANCE components. Star and redundant ring communication topology options are available. PROFINET communication is available on MCC units equipped SIRIUS SIMOCODE prov Motor Management devices, SIRIUS 3RW44 Reduced Voltage Solid State starters and SINAMICS G120VFDs Page 43

43 tiastar Motor Control Centers Network Topology Typical star network topology utilizes a single network connection to each unit A star network topology allows the user to remove multiple units from the network without disrupting communication to the remaining units. Page 44

44 tiastar Motor Control Centers with PROFINET Communications PROFINET communication in tiastar motor control centers feature industrially hardened SCALANCE switches. Managed and unmanaged switches are available. Page 45

45 tiastar Motor Control Centers Network Topology A ring network topology utilizes both network connections to each unit. A ring network topology allows multiple communication paths (media redundancy) to ensure communication if a single point network failure occurs. Page 46

46 tiastar Motor Control Centers Network Infrastructure Tiastar MCC NEMA contactors and SIMOCODE prov SIRIUS 3RW44reduced voltage solid state starters SIMANICS G120 Variable Frequency Drives SCALANCE Industrial Ethernet Switches Industrially hardened Managed or unmanaged Industrial Ethernet 10/100 Mbit/s PROFINET Cable 600V and 75ºC rated Cables are shielded for noise immunity in industrial environments Factory assembled Page 47

47 New YouTube Videos Gw4xT0 Obi50 Page 48

48 Siemens tiastar TM Motor Control Center (MCC) Additional information: Page 49 Siemens All rights reserved.