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© Siemens 2011. All rights reserved. Siemens tiastar TM Motor Control Center (MCC)
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© Siemens 2011. All rights reserved.
Siemens tiastarTM
Motor Control Center (MCC)
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tiastar ™ Arc Resistant MCCs
UL Validated Testing of Arc-Resistant Motor Control Centers
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Arc flashes are responsible for about 80 percent of electrical accidents in the U.S. each year1. In human terms, they are responsible for hundreds of deaths, thousands of serious injuries, and significant lost work time every year.2
____________________________Bureau of Labor StatisticsCensus of Fatal Occupational Injuries
tiastar ™ Arc Resistant MCCsStatistics
page 4
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Arc flashes are responsible for about 80 percent of electrical accidents in the U.S. each year.
Personal Protective Equipment (PPE) can help avoid or reduce the severity of injuries
Electrical equipment manufacturers have applied strengthened structural design to improve the safety potential of its Switchgears.
Standards for performance-testing arc-resistant features defined for switchgear not MCCs. Manufacturers are using those standards for testing arc-resistant MCCs.
tiastar ™ MCCsArc Flash
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The simplest and most effective measure to prevent an arc flash is to shut off all power to the equipment to be worked on.
Siemens advises that individuals should only work on MCCs or other electrical equipment after all power to the equipment has been turned off.
Arc flash prevention, safety training and PPE can only go so far in keeping workers out of harm’s way should an arc fault occur.
Although PPE can provide protection from an arc flash, it still cannot protect an operator from being struck by enclosure doors blown off or open from an arc flash – or from fragments ejected from a disintegrating enclosure.
tiastar ™ Arc Resistant MCCsPrevention
page 6
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Arc flash hazard mitigation and arc-resistant features.
Designed to complement each other.
Arc flash mitigation features:
To keep the workers beyond the Arc Flash Boundary
To shorten the arc flash duration
Arc resistant equipment:
To make sure that, in the event of an arc flash when the MCC’s doors are closed and latched, the equipment will contain the explosion, directing the arc blast, including its heat, plasma and pressure, away from workers.
tiastar ™ Arc Resistant MCCsArc Mitigation & Arc Resistant Equipment
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Arc Flash Hazard Mitigation Features available in tiastar MCC:
Dynamic Arc Flash Sentry (DAS): This is a patented feature available in both Siemens MCCs and type WL Low Voltage Switchgear.
DAS (alternate parameter settings) can be activated using a variety of activation methods (keyed switch, occupancy sensors, light curtains, etc.).
Visual verification of DAS activation can be as simple as a pilot light or more elaborate such as horn and strobe light.
tiastar ™ MCCsArc Flash Mitigation
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Normal Operation
Parameter A
Maintenance Operation
Parameter B
tiastar ™ Arc Resistant MCCsArc Flash Mitigation
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tiastar ™ Arc Resistant MCCsArc Flash Mitigation
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Siemens is the first manufacturer in the industry to have Underwriters Laboratories (UL) observe and validate the testing of its arc-resistant tiastarTM MCC model.
The tiastar arc-resistant MCC successfully met the testing criteria required by the standards, and a qualified, independent third-party has confirmed this satisfactory performance.
tiastar ™ Arc Resistant MCCs
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The new tiastar ™ product family: tailor made feature sets focused on your industry
Arc-Resistant MCC
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tiastar ™ Arc Resistant:Features that reach farther
Arc Flash Resistant
Setting a new safety standard, tiastar is the first IEEE C37.20.7 compliant arc resistant motor control center with UL-witnessed testing.
Decrease the risk of exposure to arc flash incidents to better protect personnel.
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tiastar ™ Arc Resistant:Protecting your most valuable asset – your personnel
• Reinforced enclosure and doors, with bolted rear covers: Increased hinge and latching locations combined with additional structural supports ensure sections will withstand, contain and re-direct internal arcing fault incident energy.
• Insulated vertical bus bar system: Isolates energized components preventing inadvertent contact and propagation of arcing faults.
• Automatic shutters in plug-in unit compartments: Isolates the plug-in location to prevent inadvertent access and lowers the risk to personnel.
• Internal venting system: The structure components are designed to vent and channel arc flash gasses to the back and out the top of the MCC.
page 14
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ANSI/IEEE Type 2 arc resistance to protect personnel at the front, back and sides of the equipment
Reinforced enclosure to withstand pressure from internal arcing faults
Internal venting system with pressure vents to channel the flow of arc fault gases and vent these gases out the top of the gear and away from personnel
tiastar ™ Arc Resistant MCCsFeatures
page 15
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Reinforced front with doors with extra hinges and stronger latching systems
Reinforced bolted rear covers
tiastar ™ Arc Resistant MCCsFeatures
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Insulated bus bar system
Automatic Shutters
tiastar ™ Arc Resistant MCCsFeatures
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Arc flashes present a serious safety risk.
The best protection is prevention by enforcing strict safety rules, mandate proper maintenance, and support that with regular safety training.
Advances in technology have enabled electrical equipment the means to design and engineer much more arc flash safety features into their products and systems such as switchgear and MCCs.
While standards continue to evolve, they inherently follow these kinds of innovations.
It is important that the application testing of new safety features be validated by a qualified third-party like UL to ensure that the safety features work as intended and to prevent tragic accidents.
tiastar ™ Arc Resistant MCCsFeatures
© Siemens 2011. All rights reserved.
Smart Motor Management
page 19
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A smart MCC can communicate via a network by incorporating intelligent devices to: control motors monitor motor operation monitor energy consumption monitor power quality monitor system operation communicate with a data network
Smart MCCsWhat is a Smart MCC?
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HistoricallyMCCs have played a limited roll in monitoring system operation.
providing basic information to the PLC
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.
Smart MCCsMonitoring System Operation
M OL
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Historically• basic information to the adding to the initial cost of the system
Smart MCCsMonitoring System Operation
Conventional Wiring for 1 motor starter (5 wires minimum)
Remote PLC /DCS
Motor Starter
Run and Trip Input Signals
Motor RUN Output
ON OFF FAULTFAULT
page 22
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Page 22
Remote PLC / DCS
Motor Starter
Remote PLC / DCS
Motor Starter
Remote PLC / DCS
Motor Starter
Remote PLC / DCS
Motor Starter
Remote PLC / DCS
Motor Starter
5 Motors – 25 Wires
Smart Motor Control Centers:What is the cost?
page 23
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Page 23
PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
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PLC / DCSMotor Starter
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PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
25 Motors – 125 Wires
Smart Motor Control Centers:What is the cost?
page 24
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PLC / DCSMotor Starter
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Smart Motor Control Centers:What is the cost?
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Historically• basic information to the PLC adds to the initial cost of the system
• PLC • wiring• labor
Smart MCCsMonitoring System Operation
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Historically• Increase system complexity • Increase the number of wires• Increase cost to gain limited information
NOWSmart MCCs incorporate intelligent devices• Providing expanded protection to motors• Communicate information previously difficult to obtain or unavailable
• Motor Operation• Power Conditions• Status of External Events
Smart MCCsMonitoring System Operation
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PROTOCOLMany different protocol exist
PROFIBUS PROFINET Industrial Ethernet AS-Interface
PROFIBUS DP is the primary network used internal to a tiastar SMART MCC
PROFIBUS DP is an open network based on the IEC 61158/61784 standard.
tiastar ™ Smart MCCsNetwork Communication
page 28
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Page 28
PLC / DCS
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Motor Starter
Smart Motor Control Centers:What is the cost?
Assuming 25 starters and 100’ between mcc units and the PLC/DCS:
(25) SIMOCODEs
(0) Starter aux. contacts
(0) Overload alarm contacts
(0) Digital PLC input points
(0) Digital PLC output points
200 feet PROFIBUS cable and connectors
Approximately $12500
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Intelligent Components• Simocode • VFD • Power Meter
• WL CB •RVSS
tiastar ™ Smart MCCsMonitoring System Operation
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Pro CThe compact system for: Direct starters Reversing starters
SIMOCODE – Siemens Motor Management and Control Device
Pro VThe variable system for:• all control functions• extendable additional functions
tiastar ™ Smart MCCs
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Conventional Information
ON
OFF
FAULTFAULT
Additional desirable information, such as ……
UNDER UNDER LOADLOAD
AUTOAUTO
JAMJAM
WARNINGWARNING
OVER OVER TEMPTEMP
CONTROL CONTROL POWERPOWER
PHASE PHASE LOSSLOSS
FAIL TO FAIL TO STARTSTART
??????
Typically not provided on most motors due to cost
tiastar ™ Smart MCCsMonitoring System Operation
page 32
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Configuring of the application within SIMOCODE pro possible Application remains available during fails of the automation or
communication system Profibus interface is the standardized interface between application and automation system
Engineering Station Maintenance Station Power ManagementOperator Station
+ Spannungserfassung
FilterFlow ratePump
SIMOCODE proBasic unit
Protection againstoverload, stall,phase failure,Monitoring of power, Cos-Phimotor idling,rotational direction
Digitalmodules
Monitoring/Statuse.g. overflow,
run dry protection,Check-back signals:
Open, Closed, On, Off
Analogmodule
Monitoring e.g.of the filling level,
filter dirt,flow rate,
run dry protection, Pressure of the cooling fluid or
gear oil
Temperaturemodule
Temperaturemonitoring e.g.of the bearings,
windings,medium,
cooling fluid
Application: Electrical pump (up to 550 kW)
- Protection- Control- Interlockings- Monitoring- Communication
tiastar ™ Smart MCCs
page 33
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PARTIAL LIST OF INFORMATION AVAILABLE
MOTOR OPERATION POWER CONDITIONS STATUS OF EXTERNAL EVENTS
OPERATIONAL STATUS PHASE CURRENTS DISCRETE INPUTS
NUMBER OF STARTS PHASE VOLTAGES ANALOG INPUTS
OPERATING TIME PHASE FAILURE RESULTS OF INTERNAL LOGIC
STOP TIME PHASE IMBALANCE
NUMBER OF FORWARD STARTS GROUND FAULT
NUMBER OF REVERSE STARTS ENERGY CONSUMED
MOTOR/BEARING TEMPERATURE REAL POWER
NUMBER OF OVERLOAD TRIPS APPARENT POWER
TIME TO TRIP POWER FACTOR
LAST TRIP CURRENT
COOL DOWN PERIOD
tiastar ™ Smart MCCs– Siemens Motor Management and Control Device
page 34
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integration to a larger system
SIMATIC WinCC SCADA system Configurable to provide complete operating and monitoring functionality
SIMATIC PCS 7 uniform data management, communication, and configuration capabilities open platform for solutions in batch, continuous, and hybrid process applications
tiastar ™ Smart MCCsProcess Visualization and Control
page 35
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Data Record Capability with Simocode ES software or S7300 PLC
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Data Record Capabilitywith S7400 PLC with PCS7
Standard-Control
Statistic
Trend
Limits-current limits
Maintenance-Local/Remote
Alarm- PCS7 Alarm logging
Faults
Warnings Batch Control- PCS7 Batch Control
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tiastar ™Smart Start
A truly plug-n-play option for tiastar Smart. Fully operational the moment you switch it on.
•Faster Start: Pre-programmed, pre-configured and pre-tested PLC and HMI combination reduces field engineering and commissioning times for quicker installation.
•Fast Access: Standardized PLC and HMI offer instant access and control of all the information in every PROFIBUS device from the moment the unit is switched on. Users can start, stop, test and verify all motor operations immediately after installation.
page 38
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Smart StartElevation Configuration
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Smart StartMain Screen, SIMOCODE View
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Smart StartMain Screen, Variable Frequency Drive View
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Smart StartMain Screen, RVSS View
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Siemens tiastar ™ Motor Control Centers
Base HD H2O Smart
Designed to meet your application requirements
Arc-Resistant
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The new tiastar ™ product family
HDSmallest Footprint Arc Resistant
Increased Operational Safety
H20Integrated Drives
SmartDiagnostics & Fast Start up
BaseAttractive Price Point
& Lead Times
page 44
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Field instrumentation Process analyzers Process control system SIMATIC PCS 7 PLC (SIMATIC S7) HVAC MES (SIMATIC IT)
Totally Integrated Automation and Totally Integrated Power
Automation
MESManufacturing Execution Systems
ERP Enterprise Resource Planning
MediumVoltage
LowVoltage
TIPTIA>=110kV
Drives (SINAMICS) Medium Voltage Switchgear WL Low Voltage Switchgear TIASTAR Motor Control Centers ACCESS Power Monitoring
page 45
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PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
PLC / DCSMotor Starter
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PLC / DCSMotor Starter
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PLC / DCSMotor Starter
Page 45
Smart Motor Control Centers:What is the cost?
Assuming 25 starters and 100’ average per wire length, the traditional wiring solution requires:
(25) Starter aux. contacts
(25) Overload alarm contacts
(50) Digital PLC input points
(25) Digital PLC output points
12,500 feet interconnect wire
Approximately $12500 (components, wire, installation)
