Spot on with distributed drive technology: SIRIUS Motor Starter Applications. sirius

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1 Spot on with distributed drive technology: Motor Starter Applications sirius

2 4 Trends in drive technology 5 motor starter applications 6/7 Drives concentrated in an area with degree of protection IP20: SIMATIC ET 200S in the field 8/9 The SIMATIC ET 200S system 10/11 Drives concentrated in an area with degree of protection IP65/67: SIMATIC ET 200X in the field 12/13 The SIMATIC ET 200pro I/O system 14/15 Spatially distributed drives with degree of protection IP65/67: ECOFAST in use 16/17 The ECOFAST system 18/19 Supplementary components and services

3 Distributed drive technology: Solutions for conveyor systems Whether in automobile factories or in airports it is essential that all of the drives that are used for the conveyor systems have the highest degree of reliability. This is because plant and system downtimes have expensive consequences. These downtimes can be avoided by selecting the right products for the particular application. But not only this, flexible, standardized concepts allow distributed drive technology to be quickly and cost-effectively configured and expanded. The very wide range of applications also demands specific solutions: Drives concentrated in specific areas must be just as easy to handle as specified as those that are distributed over a wider area. This is either achieved using solutions with distributed control cabinets and enclosures or with systems in a high IP65/67 degree of protection that are not installed in a control cabinet. In addition to maximum reliability, the main emphasis is also on cost-effectiveness. The main trends in drive technology today and tomorrow will be presented on the following pages. And using our motor starter applications we will show you how you are optimally equipped for each and every requirement. Examples from an extremely wide range of conveyor applications underline in detail the convincing advantages of our products and solutions. Motor starters in Totally Integrated Automation With its Totally Integrated Automation, Siemens is the only company that can supply a unified and integrated range of products and systems to automate the complete production workflow. The complexity of automation solutions is reduced thanks to this unique range of unified products and systems. Engineering time and costs are minimized, commissioning is simplified and the availability increased as a result of the unified diagnostics functionality. Motor starters that are integrated in Totally Integrated Automation fully leverage all of the advantages of this leading-edge technological concept. These can also be integrated into STEP 7 using a standard programming and configuring environment. Plain text parameters support this approach. 2 3

4 Optimally utilize potential: Trends in drive technology Some basic trends can be identified in drive technology. From decentralization through modularization up to distributed power distribution. The integration of safety systems often represents an additional challenge. Carve out functions increase flexibility: Decentralization Distributed solutions help to significantly increase the flexibility and drastically reduce the implementation times for new plants and systems. Further, carving out functions reduces costs and space in the control cabinet. Distributed drive concepts are especially predestined for plants and systems that are spread out over a wide area for instance conveyors and assembly lines. Higher reliability, lower costs: Modularization Combining an extremely wide range of functions in pre-tested, mechatronic units can significantly reduce engineering and commissioning costs. The basis to achieve this is tailored software, electronic and mechanical components. The basic philosophy to use standardized functional units has already been proven many times over in large and complex applications involving conveyor systems with decisive success. In the meantime, even complete conveyor systems have been able to be configured by combining standard modules. Value added through integration: Safety Integrated Safety Integrated stands for safety technology but without any additional costs. This means that neither separate components nor communication networks are required. Standard products can be simply combined with safetyorientated modules. Safety-relevant and conventional communications can be realized along one and the same bus. This results in significant cost savings but still maintaining the same high degree of safety. Optimum local supply: Distributed power distribution With the introduction of line-type configurations with power bus and outgoing load feeders, complex cable assemblies in control cabinets or in the field are a thing of the past. Standard connection systems guarantee fast and error-free installation in the field, while powerful engineering tools effectively support the user when designing systems in compliance with the appropriate Standards and when electrically dimensioning these plants and systems. Summary: From the actual plant or machine control through the power supply up to plant and machine safety: Decentralized systems allow signals to be simply pre-processed therefore relieving the central control. Thanks to the expanded diagnostic functions, they also allow predictive, proactive service and maintenance. Seen as whole, distributed drive solutions play their role in guaranteeing smooth operation of plants and systems.

5 Close to the trend: motor starters Whether modularization or decentralization: With our extensive portfolio of high-performance, communications-capable motor starters, we can provide you with the ideal prerequisites so that you can apply and benefit from the wide range of drive trends. Our portfolio includes: Tailored to your requirements motor starters are tailored to precisely match the requirements of your conveyor systems. Three versions of distributed, communications-capable motor starters are available: A complete range of motor starters from controls with basic functionality up to highfeature solutions with a wide range of diagnostic capabilities. Fieldbus systems proven worldwide PROFIBUS DP and AS-Interface for reliable and unified communications State-of-the-art field and power bus technologies to expand the possibilities in machines and plant construction Distributed automation systems for the widest range of tasks in industry Integrated safety technology Safety Integrated at the device level as well as at higher levels Based on our extensive range of well-proven products and systems for conveyor systems, a multitude of efficient motor starters and frequency converters secure optimum operation of all of the drives involved. Depending on the type of plant, drive lines can be used as stand-alone or island solution in either IP20 or IP65 degree of protection. IP65 IP65 IP20 SIMATIC ET 200S for drives concentrated in a specific area low IP20 degree of protection SIMATIC ET 200pro for drives concentrated in a specific area high IP65 degree of protection ECOFAST motor starters for spatially distributed drives high IP65 degree of protection 4 5

6 Ethernet Drives concentrated in a specific area in degree of protection IP20: SIMATIC ET 200S in use Drives concentrated in specific areas are involved if several inputs and outputs, sensors and actuators as well as drives are combined in a distributed drive solution whether in a control cabinet or directly in the field in enclosures. The finely modular, distributed SIMATIC ET 200S I/O system is predestined for such applications. It comprises a wide range of I/O modules, motor starters and frequency converters that can be combined. This allows users to implement a space-saving, highby-flexible function unit with optimized costs. Esco s cost-effective salt retrieval operation with a high degree of availability The European Salt Company (esco) in Borth on the Lower Rhine retrieves 1.5 million tons of stone salt every year from a depth of 740 meters. The raw salt is transported to the mine shaft along conveyor belts and is then brought to the surface facility for further processing. When it came to the automation, esco was looking for a solution that not only reduced the engineering and installation costs, but also increased the availability of all of the production equipment involved. Further, the conventional controls were to be incorporated in the unified, seamless automation level and therefore able to be simply connected to the higher-level supervisory system. This is the reason that the motors and loads up to 7.5 kw are directly connected to PROFIBUS DP and in turn through SIMATIC S7 controllers to the SIMATIC PCS 7 process control system via the intelligent SIMATIC ET 200S High Feature generation of motor starters. The motor starters are simply parameterized using the SIMATIC Manager. Industrial PROCESS FIELD BUS SIMATIC PCS 7 process control system S7 400/H ET 200M Industrial Ethernet S5 135U PROFIBUS ET 200S Distributed Automation station Operator station I/O

7 Reduce costs, increase availability Just a missing fuse in the main circuit can, for conventional control systems, falsify the message when it comes to the On motor state. For ET 200S motor starters, the current is electronically sensed. This means that the On/Off evaluation is directly derived from the actual current flow. Drive safety is also increased by evaluating defined current limits of the parameterizable electronic overload protection. For the high degree of availability demanded as is the case for the salt mine in Borth when current limits are violated, ET 200S sends the appropriate signals to the higher-level supervisory system. These can also be parameterized as direct shutdown commands. In turn, the motor starter additionally provides a high degree of flexibility for the particular application. All of the motor protection functions can be defined by simply parameterizing them. Full speed ahead in BMW wheel assembly Just in time is not just a catchword in the BMW Munich plant, but is lived every day. So when it comes to assembling wheels, the following always applies: Every wheel for a particular vehicle must be available at the correct location on the assembly line and at precisely the right time. BMW uses a distributed automation model with PROFIBUS DP and SIMATIC ET 200S remote I/O to further optimize this operation. A total of four SIMATIC ET 200S stations with motor starters are installed directly at the conveyor system. The stations equipped with reversing and direct starters now transfer the commands from the central control to all of the drives involved along the transport route. The concept was spot on The advantages already became quite clear during the commissioning phase that was completed in just 3 weeks. This is because the ET 200S stations were already pre-configured, wired and tested. This meant that the motor starter and the electronic modules only had to be plugged onto the terminal modules just like electronic modules and tested. In addition to the time saving as a result of the simple cabling, the solution was convincing thanks to the low space requirement, the especially compact, distributed control enclosures. This is truly a well-rounded total concept. S7 400 PROFIBUS DP ET 200M ASM 470 PROCESS FIELD BUS MOBY-E DP/ DP coupler Advantages that speak for themselves The automation solution with SIMATIC ET 200S not only proved itself to be favorably priced, but also provides some noticeable advantages as a result of its consequential unified approach: complete transparency and therefore minimized costs when it comes to service and maintenance, fault analysis and updating the system. DP/AS-i Link TP 27 ET 200S AS-Interface to additional systems 6 7

8 Diverse range of options, flexible use: the SIMATIC ET 200S system For distributed drive solutions that are concentrated in a small area where several motors, sensors and actuators are to be controlled from a local control cabinet or enclosure in the field solutions based on the finely modular SIMATIC ET 200S system with degree of protection IP20 are ideal. An extensive range of motor starters is also part of the range of system modules. Finely modular and versatile: the SIMATIC ET 200S system The ET 200S system for PROFIBUS DP offers an extensive range of I/O modules (digital and analog), motor starters (mechanical and electronic) as well as frequency converters. The system can be centrally accommodated in a control cabinet or also in a distributed architecture in local control enclosures. Automation islands, optimally harmonized to the particular application, can be configured and supplemented by additional customer-specific functions using as basis the versatile range of ET 200S modules that can be flexibly combined. Implemented in stainless steel enclosures, this solution is also suitable for the food and beverage environment. Sustainable savings: Potential in each and every application The finely modular design permits fast and optimum adaptation to the requirements of conveyor systems: Fewer spare parts No superfluous control cables Plant equipping times can be significantly reduced, even for frequently changing requirements, by replacing or combining various peripheral modules. ET 200S means that you can reduce your wiring time and costs by up to 80%: All of the power supply voltages are only connected once and are automatically connected to the next module when the modules are lined up. All motor starters are, up to the motor connection, completely pre-wired. With conventional designs, up until now, 15 cable connections have to be made. Just one energy bus that can handle up to 50 A supplies the individual motor starters. All of the connecting terminals are similar to series terminals signal and motor cables can be directly connected to the SIMATIC ET 200S without any intermediate terminals. The safety technology is an integral system component and is therefore also pre-wired. Compact design, modules are lined up flush with one another, various cable ducts are eliminated, series terminals are removed: when all is said and done, SIMATIC ET 200S also saves a lot of space in control cabinets and enclosures. Or more precisely for consequentially distributed topologies directly at the machine, generally only the supply connection and higher-level control remain in the control room itself representing a space saving of up to 50%.

9 SIMATIC ET 200S Motor starter Failsafe is also suitable as safety-relevant central switching element for distributed drive concepts. For the power distribution, every ET 200S motor starter switches the 400 V AC power bus of a distributed drive segment. ET 200S Failsafe with PROFIsafe for distributed drive concepts F-PLC PROFIBUS DP ET 200S PM-D F EMERGENCY STOP Powerbus 400 V AC Motor starter/ converter Motor 1 Motor 2 Standard and High Feature: Motor starters for SIMATIC ET 200S Any three-phase load can be protected and controlled using SIMATIC ET 200S motor starters. The completely pre-wired motor starters are available as direct, reversing or soft starter in various power classes: Motor starter Standard up to 5.5 kw (direct and reversing starters) Motor starter High Feature up to 7.5 kw (direct, reversing and soft starters) Motor starter Failsafe up to 7.5 kw (direct and reversing starters) The motor starters can be directly parameterized via PROFIBUS. Their additional plus: Integrated safety technology We can offer you the optimum solution for every safety-relevant application using the safety-relevant SIMATIC ET 200S motor starters that are communications-capable. Starting with the especially cost-effective entry-level version through the PROFIsafe solution that can be used in conjunction with safetyrelevant controls up to the high-end version for external safety systems. The graduated safety concept ensures the maximum degree of flexibility in all safety issues. With communications-capable motor starters for safety-relevant applications, when an EMERGENCY STOP is issued, individual loads can be directly shut down the same goes for individually combined load groups. Configurations using the SIMATIC ET 200S I/O system can achieve Category 4 according to EN or SIL 3 according to IEC as a result of the integrated safety technology. The advantage significantly lower wiring costs. At a glance: Highlights of ET 200S motor starters Flexibility as direct, reversing or soft starter Motor starter High Feature with a combination of starter protective switch, electronic overload protection and contactor or soft starter up to 7.5 kw With a self-establishing 40/50 A power bus, i.e. the load voltage is only connected once for a group of motor starters Hot swapping is permissible Inputs and outputs to control and signal the status are already integrated Full diagnostics capability to actively monitor the protective and switching function More possibilities can be combined with various expansion modules and safety technology 8 9

10 Spatially concentrated drives in degree of protection IP65/67: SIMATIC ET 200X in use Many applications require that spatially concentrated drive solutions be configured in the plant but without any control cabinet or enclosure. The distributed SIMATIC ET 200X I/O system with a high IP65/67 degree of protection offers the optimum solution: a wide range of modules with a high degree of protection. These also include motor starters to simply and quickly engineer cabinetless drive solutions in degree of protection IP65. Optimally organized buffer system for Audi In the automobile industry, precisely the right customer-specific parts and components must be available at the assembly line for every vehicle. Individual engine components are therefore produced in defined batch quantities for the various types, kept in a buffer zone and are then called from there to the final engine assembly station. The buffer zone in the Audi engine production facility in Ingolstadt can accommodate up to 1800 different cylinder heads. It has a modular design in roller tracks that operate as dedicated system module and can buffer up to 100 cylinder heads. PROFIBUS DP PROCESS FIELD BUS ET 200X Reduce costs, minimize space A SIMATIC PLC controls the complete Audi buffer zone. All of the process signals distributed through the complete buffer zone are acquired and controlled with the decentrally installed I/O via PROFIBUS DP. The distributed SIMATIC ET 200X I/O in a high IP65/67 degree of protection plays an important role in the automation of this buffer system.

11 ET 200X stations in various configurations are used for almost the complete I/O at the rolling buffer areas. The modular principle means that the wide range of process requirements can be addressed using just a few standard components. Due to the fact that the drives are distributed throughout the plant combining the controls for four motors in one unit proved to be the optimum solution. This is the reason that the ET 200X station comprises three input modules and four load feeders. Advantages that are worth mentioning The control cabinet size was able to be reduced by completely shifting the I/O directly to the machine. The devices can be quickly installed and wired-up at the machine through the standard connector system. The modularity of the automation concepts and the fact that they can be expanded creates significant cost advantages as the individual peripheral nodes can be sustainably optimized. Further, commissioning is fast and service straightforward by using standard, individual components. This also means that the individual plant sections can already be tested in advance thus significantly reducing commissioning time and costs. Cost-effective conveyor technology in the meatprocessing industry WVG Kainz GmbH has made a special name for itself in the meat-processing industry with fully automated conveyor and washing systems to handle Euro transport containers. This is because this medium-sized company has always placed considerable significance on continuing optimization for more than 20 years now. The main difficulties the tough ambient conditions as well as the unsuitable container design that still exists today. Blockages on conveyor belts or damage to the equipment itself must be avoided at all costs both for the operational safety as well as for the cost-effectiveness of the operation. Compactness and modularity are additional essential parameters of the equipment so that it can be quickly and smoothly integrated into the facility or when expanding the system. In order to optimally fulfill these requirements, WVG Kainz GmbH selected PROFIBUS DP and the distributed SIMATIC ET 200X I/O station. This is not only the ideal basis for a modular plant configuration, but as a result of its high IP65 degree of protection it is admirably suited for use close to the process and under tough ambient conditions. PROFIBUS DP Separate feed to each motor starter/ frequency converter Separate feed to each ET 200X Feed to the first motor starter PROCESS FIELD BUS ET 200X Tangible benefits The SIMATIC ET 200X permits distributed signal processing and control architecture to be flexibly and cost-effective implemented and it is absolutely optimized for machines. Integrated load feeders allow sensors and controls to be configured together in a local function unit. This significantly reduces the signal and power cabling and eliminates control cabinets. Only the complex industrial washing machine requires its own control cabinet. In a nutshell: a real plus when it comes to saving space and being cost-effective

12 Ruggedized: The SIMATIC ET 200pro distributed I/O If distributed drive solutions concentrated in an area are to be implemented without using a control cabinet, then we recommend using the rugged SIMATIC ET 200pro I/O system in degree of protection IP65/67 as successor to the SIMATIC ET 200X system with the matching motor starters. Even simpler, even more cost-effective: the SIMATIC ET 200pro system SIMATIC ET 200pro is a modular I/O device with a high IP65/67 degree of protection for PROFIBUS DP. Several expansion modules can be connected to the basis module. The stations can be configured in line with the particular function using modules that are orientated to specific technologies. The system replaces the previous SIMATIC ET 200X I/O system and allows an even simpler and more cost-effective configuration of distributed automation solutions without using control cabinets. The very compact and high-performance I/O system especially distinguishes itself as a result of its unique multi-functionality. Whether motor starter, the integrated safety technology, connection to PROFIBUS or PROFINET or simply just transferring digital and analog signals. And in the immediate future, frequency converters or a direct connection to the MOBY identification system will be possible. ET 200pro offers the optimum solution for almost every requirement: Cabinets are not required thanks to the high IP65/67 degree of protection Compact and rugged design Highest degree of flexibility through modularity Highly versatile through numerous integrated functions Simple and operator-friendly installation Flexible connection systems Extensive diagnostics concept High plant availability through hot swapping and pre-configured wiring Seamless standard and safety-relevant communications via PROFIBUS and PROFINET Load groups can be simply implemented

13 Exceptionally good: ET 200pro Motor starter The intelligent ET 200pro motor starters start and protect motors and loads up to 5.5 kw. They are available in the Standard and High Feature versions both as direct or reversing starter. Motor starter High Feature differs from Motor starter Standard as it has more parameters and four parameterizable digital inputs. SIMATIC Manager is used to simply parameterize the device in a user-friendly fashion. This new generation of motor starters is characterized by the high degree of functionality with a small footprint, simple and fast engineering and installation and due to the fact that it sustainably increases the availability of production plants. At a glance: Highlights of ET 200pro motor starters Digital inputs/outputs Analog inputs/outputs Motor starters up to 5.5 kw (optional braking contact) Direct starter (Standard or High Feature) Reversing starter (Standard or High Feature) Isolator module (optional) Safety technology (optional) Safety Local isolator module Fast mounting, precise diagnostics Compact motor starters for ET 200pro can be easily mounted in ET 200pro stations just a few manual operations are required. The integrated connector system allows the wiring costs to be significantly reduced: Motor connecting cables can be directly plugged onto the motor starter module. In the field, the compact configuration allows up to eight motor starters to be integrated in a station that is just one meter wide. The motor starters detect the actual current. The defined current limits of the parameterizable electronic overload protection are evaluated therefore increasing the availability of the drives the same is true for the reliable signals when setpoints are violated. The motor starters detect non-symmetrical load currents and, when required, they interrupt them. All of the motor-protective functions can be simply parameterized. The local control station for a drive, that is required for some applications, is achieved using the integrated four DI (Motor starter High Feature) and can therefore be easily integrated into the control. That certain extra: Integrated safety technology When configuring a solution with ET 200pro, the safety functionality can be directly implemented locally: an optional isolator module disconnects, for example, downstream starters from the line supply voltage. This function can also be used as short-circuit protection for the downstream loads with 25 A circuit-breaker. Safety Motor starter Solution local can be used for safety-relevant applications. In this case, a safety local isolator module (F-RSM) and a 400 V disconnecting module (ASM-400 V) are located in front of the motor starters. The 400 V supply voltage is connected to the isolator module, looped-through to the disconnecting module and is transferred from there to the motor starter. The EMERGENCY STOP pushbutton or the protective door contacts for the safety-relevant disconnecting function are connected to the isolator module. For the Safety Solution local, the 400 V power supply for the motor starter is disconnected twice and therefore fulfills a safety-relevant shutdown up to Category 4 according to EN The switched 400 V power bus can be routed to additional modules; this means that for these, neither an isolator nor a disconnecting module is required a real advantage. All 400 V components are equipped with connectors according to the ISO connection system V disconnecting module

14 Drives distributed over a wide area with degree of protection IP65/67: ECOFAST in use For plants and systems in which individual drives with just a few inputs and outputs are distributed over a wide area, then a solution based on ECOFAST motor starters is the optimum choice. The ECOFAST system (Energy and Communication Field Installation System) is available in two versions: with AS-Interface as communications bus or with PROFIBUS DP. AS-Interface can be used to implement a simple installation at a favorable price. This is clearly shown in the ECOFAST keeps things moving example. As soon as the application requires expanded diagnostics via the data bus, then the solution is called ECOFAST with PROFIBUS DP. ECOFAST with AS-Interface keeps things moving for DaimlerChrysler At its Bremen plant, DaimlerChrysler produces C-Class, CLK Coupé, SL Roadster and SLK Roadster models. The final assembly lines for the C and CLK Classes are distributed over two halls. This is the reason that the connecting conveyor uses an effective double roller track system. This roller-track system has a modular design comprising 65 individual roller tracks to transport vehicle bodies to the various stations. PLC ECOFAST motor starter AS-Interface Profit from decentralization, gain points through modularity Decentralization based on PROFIBUS DP and AS-Interface bus systems is an essential element of the plant. The coupling to the plant and the coupling between the operator station and the control are established through PROFIBUS DP. The complete safety technology (ASIsafe) and the sensors are coupled through AS-Interface as well as 65 distributed ECOFAST motor starters to control the motors that are used in the conveyor system. Every starter is responsible for one roller track. The consequential use of ECOFAST motor starters has a positive impact on the complete plant technology.

15 The modular design with identical roller tracks and standard cable lengths allows prefabricated cables to be used to connect up the system. Control devices, which are mounted directly at positions that are easy to access along the roller tracks, ensure a high level of service-friendliness. Only one standard switch type is required for all of the tasks. This means that spare parts stocking is extremely costeffective and straightforward. Just as simple: the complete plug-in connection system so that devices can be quickly and simply connected up. The sensors along the roller tracks are connected through integrated inputs on the starters that means that additional devices are superfluous. Value-added across the board DaimlerChrysler can now utilize all of the capabilities that AS-Interface offers through ASIsafe and the distributed motor starters. Pre-fabricated cables and standardized connection systems reduce costs for example, installation and cabling times during the commissioning phase can be reduced by up to 75%. And: ECOFAST offers the highest degree of flexibility for future plant expansions. Increased safety and productivity for Corning thanks to ECOFAST with PROFIBUS DP Corning GmbH is one of the main suppliers of vehicle catalytic converters in Europe. In order to expand their production capacity, the four year old saw system was expanded by automatic feed and removal devices and equipped with an improved safety concept. Further, the plant was split up into eleven safety circuits to achieve the optimum production utilization. The integrated concept is based on a failsafe SIMATIC S7-317F 2DP PLC and a distributed I/O with failsafe SIMATIC ET 200S I/O modules as well as distributed ECOFAST motor starters with integrated diagnostic functions. Now, individual safety zones can be individually programmed and disconnected. This means that the conveyor system can be stopped while the saws can continue to operate. Less stress on materials increased availability The failsafe PLC is connected to each robot cell and the field devices for the conveyor systems via PROFIsafe with the distributed I/O. The connection to the supervisory production computer and to old plant sections is established through an Ethernet connection. All 48 drives for the material flow, transporting the cut parts as well as the platform are decentrally controlled using Ecofast soft starters (R2SS and RSS). In addition to the typical ramp functions, he R2SS permit different fixed speeds which means that the drives start especially smoothly. Wear-free, electronic motor starters were used. The reason for this is that today and in the future it is expected that the equipment will be subject to high stress levels. In addition, when starting, the mechanical system is accelerated using the selected soft starter function therefore reducing stress on the material. This has a positive impact especially when feeding in the sinter products that are extremely sensitive to shock. Since using motor starters, Corning is no longer encountering material flaking and has therefore eliminated faulty catalytic converters. Enjoy the benefits The distributed solution provides Corning with significant service advantages. Important statistical data can be retrieved thanks to the improved diagnostic capabilities of ECOFAST motor starters. Not only this, the intelligence integrated in the soft starters significantly simplifies troubleshooting. A motor starter can be replaced in just a few minutes as the device is only retained using four screws and is connected up using prefabricated cables

16 Power and communications in one: The ECOFAST system The Energy and Communication Field Installation System ECOFAST with its motor starters is not only the ideal solution for spatially distributed drives, ECOFAST is simply the optimum system solution for automation without any control cabinets. This is because of its extensive range of automation, drive and installation components in a high IP65/67 degree of protection. Power and data are distributed and transferred using a line-type topology. Data transfer and power distribution in one: the ECOFAST system Controlling, switching, protecting, detecting and last but not least transferring data: with ECOFAST, everything is integrated in just one system. This also includes the complete power supply using just one cable to connect all of the devices. In conjunction with SIVACON busway systems, ECOFAST guarantees that every field device receives the correct power from the low-voltage transformer. This power is transferred interruption-free in a line-type topology using a power bus. And all of this is implemented across the board in a high IP65/IP67 degree of protection. ECOFAST is an integral part of Totally Integrated Automation and is open for manufacturers and users. Data is transferred along the standard PROFIBUS and AS-Interface fieldbuses. All of the interfaces are in compliance with ISO the new Standard for distributed configurations. This defines and standardizes interfaces for sensors, actuators, communications and power. ECOFAST ES is the ideal engineering tool for dimensioning and selecting the power bus as well as also checking the plausibility of the interfaces between the selected components.

17 This is because ECOFAST has a modular design and can be flexibly expanded as a result of the graduated range of motor starters and frequency converters. Not only this, ECOFAST is diagnostics-capable and communicates via standard fieldbus systems such as AS-Interface and PROFIBUS DP. Standard connection systems and the possibility of feeding-in and distributing power down to the field devices again significantly simplifies installation and at the same time drastically reduces the commissioning time. Further, these devices are so rugged that they can be mounted directly in or on the machine and therefore creating space-saving concepts that do not require a control cabinet. All of the ECOFAST devices fit perfectly together as standard plug-in connectors are used for both data and power. Not only this, in conjunction with the pre-fabricated cables, the complete cabling is quick, simple and mistakes cannot be made which drastically shortens cost-intensive cabling and installation times. In the ECOFAST system, switching devices such as load feeders are supplied with 400 V AC. When configuring the power bus you can select prefabricated cables to bypass the loads or you can connect a feeder at any location along a standard cable using a special adapter. At a glance: ECOFAST highlights ECOFAST offers the same tangible benefits for both manufacturers of machines and plants and the companies that operate them. And this over the complete process: For planning and engineering, for installation and commissioning. And naturally during operation: Shorter plant engineering times Shorter installation and commissioning times Lower cabling costs Higher plant availability through preventive diagnostics and shorter service times Smaller footprints Increased flexibility when installing Integrated intelligence: ECOFAST motor starter for IP65/67 Motor starters for ECOFAST are admirably suited for protecting, switching, and controlling applications in distributed architectures and therefore represent the solution for spatially distributed (single) drives that are frequently found in conveyor systems. The motor starters can be used as either reversing or soft starter directly at the motor using the PROFIBUS DP interface or AS-Interface. They can be simply and quickly commissioned as they are pre-tested in the factory. The standard connection system that is typical for ECOFAST ensures an even higher degree of efficiency. This applies both for power and data cables. Motor starters can be simply changed in operation. An even higher degree of flexibility is achieved as a result of the two or four digital onboard inputs from a basic clockwisecounterclockwise selection up to shutdown at end stops. The ECOFAST ES engineering tool makes planning and engineering fast and easy and it also generates complete parts lists. ECOFAST offers the highest degree of userfriendliness and security for the future. For example motor protection using thermistor evaluation, full motor protection and soft starting and stopping. The integration in Totally Integrated Automation supports the DP-V1 functionality from the availability of the actual motor current of every phase in the PLC up to expanded statistics, evaluation and diagnostics. Safe, fast, flexible: industrial communications with AS-Interface The lowest field level or the actuator/sensor level is the level where many devices exchange relatively little data in real time. This makes it the ideal level for the rugged AS-Interface which is extremely simply to handle, fast to install and is especially flexible. Safety incorporated: AS-Interface is embedded in the unique, higher-level Safety Integrated safety concept using ASIsafe. It is unique as the safety technology is already integrated into the standard components. With this as basis, Safety Integrated encompasses all of the necessary components from failsafe controls through failsafe communications via PROFIBUS and AS-Interface up to a complete portfolio for the actuator/sensor level

18 Everything from a single source: Supplementary components and services Profit from synergies: Partner management The optimum function of the individual processes is naturally extremely important that they seamlessly interact with one another is also just as important. This is the reason that all of our products are optimally harmonized with one another. In total, they form an extensive and complete portfolio of components for distributed drive technology. This portfolio is supplemented by additional components in order to address every particular aspect within the scope of complete plants and machines. This mainly involves the connection and power bus systems. Selected and certified Siemens system partners define and develop the associated components. The individual products should be directly purchased from these system partners. However one thing is quite clear our usual high quality is guaranteed just the same as full compatibility to our own components. Reduce engineering costs: ECOFAST ES Avoid costly over-dimensioning and increase the engineering quality this is all made possible by the innovative ECOFAST ES engineering software. The power side is graphically engineered. Tests and checks regarding overload and short-circuit protection, trip conditions, voltage drop as well as configuration rules are automatically executed. Not only this, specific product definitions can be automatically called up. The result costoptimized engineering, checked in accordance with all of the usual Standards, including the associated documentation and parts list generation. Summary real time saving across the board. Absolutely user-friendly, completely transparent: Motorstarter ES Whether commissioning, parameterizing, troubleshooting or carrying out preventive maintenance, Motorstarter ES is a real universal tool. Using the user-friendly parameterizing and diagnostics tool in addition to the Step 7 parameterization, all of the parameters can be set in plain text (via PROFIBUS DP or directly at the device itself). All operating data can be called up 1:1. Diagnostics is realized online via PROFIBUS DP or routing mechanisms.

19 Optimally supplied no matter what: Supplementary services Whether it involves designing complete parts of plants and machines or when just selecting individual components: with its well-founded industry-sector competence and projectspecific support, Siemens Automation and Drives provides its customers with extensive support in line with their actual requirements. Individual solutions can be flexibly scaled. The focus is always on costs and performanceoptimized products and systems. For OEMs and for end customers, this results in numerous supplementary benefits. Our harmonized portfolio, your advantage as OEM Maximum cost-effectiveness through Simple and fast installation Unified, standard interfaces Standardized ISO connection systems Rugged and reliable technology in a high degree of protection Efficient engineering using Well-founded concepts for distributed installation Support when engineering and dimensioning using engineering tools designed for the purpose Specific solutions based on high system solution and industry sector competence Designing the infeed and supply Short-circuit and voltage drop calculations Fully integrated and unified parameterizing, commissioning and troubleshooting Well-proven standard products Worldwide availability and 24 h service Optimum price-performance ratio Highest quality Complete product portfolio from a single source Well-conceived logistics reliable delivery times and spare parts supply Maximum investment security Our harmonized portfolio, your advantages as end user Plants can be quickly ramped up Retrofits in the shortest time Fast configuration without any additional costs Short commissioning times Low space requirement Optionally small control cabinets Compact design Shorter cable distances Extensive support Scalable services Worldwide training courses Additional plus points Maximum security of your investment through a globally active, successful community of partners Various possibilities to minimize energy costs 18 19

20 Ordering by fax +49/911/ CD/Z1250 Newsletter Please send the selected information to the following address: Industrial Controls Always up-to-date: Our regular Newsletter gives you current information about industrial controls and power distribution. Simply register under newsletter Company/Department Name Street, Postal Code/City Telephone/Fax STARTING PROTECTING SWITCHING DETECTING MONITORING AND CONTROLLING ENGINEERING SUPPLYING COMMANDING AND SIGNALING AND MORE Switching Protecting Starting Detecting Commanding and signaling Supplying Solid-state switching devices Infeed system Soft starter Motor management system SIMOCODE pro Position switches Pushbuttons and indicator lights SIVENT Fans Motor starter ES Soft starter ES Safety Integrated ECOFAST Engineering load feeders SIMATIC ET 200pro Signaling columns and integrated signal lamps SIDAC Reactors & filters SIMOCODE ES AS-Interface Modular system Motor starter Relays Safety Relays Cable-operated switches SIDAC & SIVENT Solutions Connection systems Subject to change without prior notice 11/05 Order No. E20001-A720-P305-X-7600 Dispo C9121 FGET WS Printed in Germany Siemens AG 2006 Siemens AG Automation and Drives Low-Voltage Controls and Distribution P.O. Box 48 48, NUREMBERG, GERMANY The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.