Siemens Two-Way Radio SIMATIC PCS 7 User's Manual
Contents
1. Siemens AG 2011 Products and functions for efficient maintenance in the process automation at la lt 1 _ 7 pth F aa i _ x a aes ia a i Area 001 Sire Brochure October 2011 Maintenance System Answers for industry SIEMENS 2 Siemens AG 2011 Introduction Increase in productivity through intelligent maintenance How can the productivity of a plant with a high level of au tomation be increased even further Plant operators in all sectors consider increased availabili ty and shorter downtimes to be the most effective lever to ward increasing productivity Investigations have shown that downtimes are frequently the result of insufficient maintenance despite the fact that maintenance is alrea dy a significant portion of the lifecycle costs Intelligent maintenance strategies can make a significant con tribution toward increasing productivity e Failures can be prevented by monitoring the current plant condition e Maintenance can then be planned It does not wait until a fault has occurred but implements appropriate measures in advance for avoiding faults The timing of maintenance can be planned such that the existing resources can be used optimally e Innovative maintenance strategies pay for themselves twice planning security and the specific application of me thods reduces the direct maintenance costs e Plant availability is increased at the same time This m2. You find further information about the topic of Industrial Security on the Internet under www siemens com industrialsecurity SIMATIC PCS 7 Maintenance Station N 8 Siemens AG 2011 Visualization of information for maintenance In order to recognize the conditions of individual devices or components unequivocally a uniform symbol represen tation has been implemented There are symbols for the device status itself and also for the importance of a maintenance request In addition the status of a maintenance measure is displayed The conditions of all devices and equipment of the automation technology and of the plant components are indicated by these standardized symbols Good Maintenance L requirement low Simulation E Maintenance a Maintenance P request A job average e requested Local operator s Maintenance Maintenance control P alarm job high being processed Uniform symbols for the conditions of components and devices Maintenance 2 job unknown not requested Besides the uniform display of symbols a significant detail for the overview is a hierarchical structuring of information in which the maintenance engineer also has access to all requi red details of the components and devices based on an over view display plant view yy Plant view Overview Automation system AS Detailed view N Component o i t Device A a S g x x a r A n ee ee D Extract
3. In addition users have the opportunity of changing the priority level for each di agnostic alarm and thus define what is relevant to their own process Numerous EDDs are currently being upgraded to Enhanced EDDs They have the following advantages e New standardized look amp feel for all Siemens devices e Quick start wizards for faster commissioning e Improved representation of graphics for advanced diag nostic functions All of these functions help to reduce the maintenance costs by accelerating the diagnostic process When using PROFIBUS Asset Management functions can be used to greatest effect if the devices used conform to the PROFIBUS Identification and Maintenance specification as well as profile specification Version 3 01 Siemens devices conform to these standards and the following information is made available e Manufacturer e Order numbers e Description e Installation date e Serial number e Hardware and software modifications This information is read directly from the measuring instru ment and stored in the SIMATIC PDM Here the data can easily be recalled Monitoring and diagnostics Temperatu re measurement SITRANS T are the temperature measuring instruments for process engineering plants They support commissioning and maintenance in an optimum manner and can be used in diffe rent designs such as complete measuring point head moun ted transmitter DIN rail mounted or distributed de
4. The information is consistently structured and hierarchically organized The quantity of information displayed on each in dividual screen always remains manageable for the mainte nance engineer who nevertheless has easy access at any time to the complete information Siemens AG 2011 Maintenance Station User interface for maintenance The SIMATIC PCS 7 Maintenance Station software package is available as an alternative to SIMATIC PCS 7 for imple menting Plant Asset Management You can use this soft ware package to expand an Operator Station to a Maintenance Station The maintenance engineer can process the diagnostics messa ges and maintenance requests of the assets on the Maintenance Station Via the Maintenance Station the engineer can access e Electronic components of the process control system intel ligent field devices and I O modules field bus controller network components and plant bus as well as servers and clients of the operator systems e Mechanical components that do not belong directly to the process control system such as pumps motors centrifu ges heat exchangers or control loops passive or indirect assets These are represented by proxy objects in which the diagnostics rules are stored Monitoring and diagnostics of mechanical components For mechanical components without self diagnostics pumps heat exchangers valves compressors etc inadmissible ope rating states can be determined from
5. Components OK e Maintenance required e Failure e Functional check Introduction Information on the measured process tags is available for the plant operator Apart from the measured value itself and its status this may for example be the information on whether the measured value is still valid The focus of interest for the maintenance engineer is the sta tus of the production equipment that is reflected in the states of the devices and components used i e particularly in the states of the field devices Typical states in this respect inclu de Component OK Maintenance required Failure or Function check SIMATIC PCS 7 allows a clear classification of the information for the user groups Plant Operators and Maintenance Engi neers Siemens AG 2011 Asset management in production The term asset management comes from the world of finance and economics and refers to the manner in which a company deals with its long term and current assets These include the production equipment with its plant components such as ap paratus machines pipelines etc and the equipment and de vices for their automation All these are referred to as assets In association with production asset management covers all activities and measures which serve toward retaining or incre asing the value of a plant This is called Plant Asset Manage ment Benefits of Plant Asset Management Plant Asset Management allows the maintenanc
6. Monitoring and diagnostics of drive components Diagnostics of drives Hardly any other group of products influences plant availabili ty as much as drive engineering Production comes to a stand still when these products fail Such unscheduled plant down times cause expensive production outages unplanned re pairs and frequently consequential damage This is the reason why all drive systems and frequency conver ters of the SINAMICS MASTERDRIVES and MICROMASTER ran ges with their associated motors are integrated into the SIMATIC PCS 7 Maintenance Station This results in the com mon uniform presentation of maintenance relevant informa tion which permits preventive and prognostic maintenance strategies The components report autonomously that maintenance Is re quired One example are the medium voltage converters such as SINAMICS GM150 For instance by means of a differential pressure procedure the degree of contamination of the dust filters is determined In the water cooled version the analog conductivity measure ment continuously monitors operation of the ion exchanger and outputs an early warning message when the exchange Capacity decreases The operating fans for air cooling and the pumps for water cooling are equipped with operating hour counters that recommend checking of components on re aching a certain number of operating hours The CM 240NE chemistry module can be used in connection with the SINAMICS G120 Control U
7. The benefits of predictive maintenance are based on the fact that the corresponding components can be used for their en tire service life without the risk of failure or damage The dia gnostic functions in SITRANS VP300 and in SIPART PS2 also help with the early detection of impending damage to the drive or valve which can lead to a plant stoppage in the worst case scenario Thus information can be gained from the load factor which can be used to optimize the way in which the plant is operated or for advance maintenance In total this leads to an increase in the availability of the entire plant SIPART PS2 and SITRANS VP300 POSITIONERS SIEMENS Pinte Fest Tat ar Parke tiroke Test sHmias TF sn tr omen eee aa E i ST Varia ep Garii peri PST Vrinda PC pahan Gmt ag Abeta ig E aes PET i 7 3 Abgelauiene Zeit 5 SITRANS VP300 and SIPART PS2 offer a standard Partial Stroke Test in order to extend the maintenance interval of two position valves 21 22 Siemens AG 2011 Monitoring and diagnostics of 24 V load feeders In the process industry automation components are generally powered with 24 V DC With the SITOP PSE 200U selectivity module any 24 V load is reliably monitored for overload and short circuit and in the event of faults it is switched off A selectivity module monitors up to 4 load feeders which can also be connected in sequence following defined peri
8. VP300 For detecting positions the device uses a permanent magnet on the spindle of the drive and sensors in the interior of the positioner If the magnet is physically moved or missing this is detected and signaled by the positioner In addition the Par tial Stroke Test is optionally SlL certified SIPART PS2 In addition to detecting pneumatic leaks the device is also ca pable of performing a solenoid valve test If a suitable soleno id valve is used it is thus possible to make a reliable statement about the correct functioning of the connected solenoid val ve These faults are reported based on their severity and conse quently the urgency of maintenance they require using the 3 stage evaluation scale of the SIMATIC PCS 7 Maintenance Sta tion The faults are also displayed and analyzed on the on site display Thus faults can be detected early long before failures or even plant stoppages occur With regard to preventive maintenance measures the fol lowing values are also monitored and a 3 stage message can sometimes be output as described above e Operating hours also differentiated by temperature ran ges and adjusting ranges e Operating temperature current and min max e Stroke counter stroke integral e Number of changes in direction Monitoring and diagnostics The most important status parameters can be visualized using a suitable HMI tool e g SIMATIC PDM both in trend view and in histogram view
9. and network statistics are compiled by means of auto discovery Siemens AG 2011 These can be displayed graphically and if desired also supple mented using individual diagnostics screens In addition at runtime cyclical data from Ethernet participants is queried and network alarms are reported Websites are used to present and pass on the information Furthermore the software offers an e mail client function and OPC server in order to forward network data and alarms to other systems SINEMA Server can be easily integrated in HMI Human Machine Interface and vi Sualization systems such as SIMATIC WinCC Changes in the network are also accordingly logged and archived in a databa se For the analysis of past network failures or as evidence of network availability the database information can be prepa red and documented as reports for any configurable period of time The SINEMA user interface and its available features are accessible via the browser from any computers on the net work Pecan Pees i jies The following components can be diagnosed e SCALANCE X W and S network components e SIMATIC NET Industrial Ethernet CPs e SIMATIC S7 with integrated PROFINET interface e PROFINET IO devices e g ET 200 e Other Ethernet devices SNMP OPC server The SNMP OPC Server enables diagnostic and configuration data to be read from any Ethernet devices and displayed on the Maintenance Station Alongside standard maintenance d
10. diagrams photos manuals and the like ETT Sarvar Eiin PrejektePnecersManapemen AAAA Active Pia M Orders d e LE Veer bert Dim Wroga ff oO xE w i Farrag tiem pang c i i Ml Mega AOC AT ALT Venu yin ints a a L001 GD A T os AIK Rardkparrung pron PO GOADEN T TOOS Gere aipruturgy Rie cere tsa iret PRS Promi schacte Ghia LICH BA AUC MMOD TD Sehuubes anata LA ar La da te AEETI GO AEG ea Motes uimhir ODI ED AM Prani bhiin a Sehi ME au E mia n a eee or LAETI aT AOA TIE 11 LOY ES A Te Peik pohly lances chipni Tth iiral prue uiii Aii Ain T ii i E et PM MAINT status window Archiving of maintenance data All maintenance activities are logged in an archive Analysis of the archive enables maintenance operations to be assessed in detail providing for continuous improvement Further information www siemens com pm maint Siemens AG 2011 Monitoring and diagnostics for industrial PCs SIMATIC IPCs are rugged industrial PCs for professional au tomation solutions in 24 h operation Because of their high system availability in PCS 7 systems they are often used for example as operator or Maintenance Station or also as engineering station or OPC server The SIMATIC IPC DiagMonitor monitoring and signaling soft ware recognizes possible hardware and software faults at an early point in time and provides corresponding messages for the Maintenance Station In connection with severa
11. seat as well as caking fouling deposits are the most common signs of wear for valves ValveMon monitors the valve status according to specific process values and enables the detection of mal functions and impending failures at an early stage Heat exchanger monitoring with the block HeatXchMon The main problem with heat exchangers is fouling Fouling re sults when residues of the process medium are deposited on the transfer surfaces and thus impair efficiency HeatXchMon determines deviations of the current heat flow from the refe rence heat flow in the clean state The current degree of fou ling the energy loss and daily costs can thus be precisely cal culated and displayed E AB pHa gE teat nkire ee apc iiaa h pii Bian MS ee aa m r 1 _ oa kiasia HEH AH The HeatXchMon block not only indicates the current performance capa bility of the heat exchanger it also calculates the daily energy loss due to the degree of fouling SIMATIC PCS 7 Maintenance Station O 10 Siemens AG 2011 Performance monitoring of turbo compressors with the block CompMon Depending on the type of medium the aerodynamic perfor mance of a turbo compressor can be impaired by fouling caking or abrasion The location of the operating point can also be affected by variances in the state of the medium being pumped in depending on temperature pressure and compo sition or by changes to the flow resistance on the load side T
12. various measured values that already exist in a process control system using special di agnostic blocks Deviations from an established normal status can be used for this for example Pump monitoring with the block PumpMon The diagnostic block PumpMon is used for e Warning of pump damage when there is blocking dry run ning gas in the transported substance cavitations over load or improper running e Early detection of initial pump damage such as wear or de creasing pump efficiency e Long term optimization the pump design by means of sta tistical analysis of the operating data for example recor ding the load spectrum Exceeding the limits of the pump s rated operating range and deviations from the anticipated characteristic curve are repor ted to the user as maintenance alarm via the PumpMon block The block outputs are simultaneously made available for further processing In this way the user gets the opportunity to intervene in a preventive way to prevent damage to the pumps which helps to reduce plant downtimes and increase its availability It also allows the pump layout to be optimized Wit E PIH UPumpihan Cr ec Chg inary Mpini Abra i ETE EI mep 1 283 41 284 00 Height SF Deisien pacia a Ha Ii 4am a x PumpMon block Too PEE curve with current operating point Valve monitoring with the block ValveMon Abrasion cavitation corrosion of the valve plug or
13. Density of fluid and temperature limits e Measuring range limits The user specific settings are compared with the actual values to determine an optimal setting Faults caused by mechanical vibrations cavitation or pump noises can affect the measure ments Extended diagnostic functions in the MASS 6000 transmitter by means of intrinsic sensor resonance frequency pick up am plitudes and signal phase can identify these influences As NAMUR NE 107 is supported extensive diagnostic func tions are available in the Maintenance Station This enables the maintenance personnel to adopt the necessary measures From this standardized information type and frequency of the alarms the user can draw conclusions that indicate immi nent failure or predictive maintenance This enables step to be performed to improve the measurement quality or prevent a loss of production Monitoring and diagnostics Level measurement Four different technologies are available for level measure ment Radar capacitance ultrasonic and Guided Wave Radar technology Level measurement with contactless radar technology e SITRANS LR400 LR460 LR560 with FMCW radar Frequency Modulated Continuous Wave e SITRANS LR200 LR250 LR260 pulse radar e SITRANS Probe LR pulse radar radar measuring instruments are available with PROFIBUS PA and with HART protocol Level measurement with contactless ultrasonic technology e SITRANS Probe LU is available either with PR
14. Monitoring of limit values and output via HART or signaling relay e Runtime meter for electronics SITRANS TH400 SITRANS TW Siemens AG 2011 Pressure absolute pressure differential pressure flow and hydrostatic level measurement SITRANS P is a family of pressure measuring instruments The SITRANS P DS III and P300 digital transmitters are suitable as universal transmitters for measuring gauge pressure absolute pressure and differential pressure and also for flow and hyd rostatic level measurement They have a series of integrated diagnostic and simulation functions that allow the user to assess the specific state of the device or of the whole measurement point during commissio ning servicing and maintenance operations The preventive maintenance is supported by functions such as e Operating hours counter for measuring cell and electronics e Event counter for upper and lower limit violation e Min max pointer for pressure sensor temperature and electronics temperature and e Two freely parameterizable timers that can set off a war ning or an alarm on reaching a preset threshold As part of the corrective maintenance the device diagnostics effectively support the clearance of faults For this the fol lowing are cyclically monitored e Memory integrity of RAM ROM and EEPROM by means of checksum method e Correct program sequence in microcontroller due to targe ted approach to checkpoints watchdog e
15. NCE X 300 ma naged product line combines the firmware functionality of SCALANCE X 400 with the compact design of SCALANCE X 200 The SCALANCE X 300 switches thus offer expanded ma nagement features and firmware functionality in comparison with the SCALANCE X 200 switches Moreover electrical and optical Gigabit Ethernet ports are available as well the XR 300 Rack Switches as versions in 19 inch design SCALANCE X 400 managed Layer 3 For use in high performance plant networks e g with high speed redundancy Due to the modular design the switches can be adapted to the task at hand Due to the support of IT Standards e g VLAN IGMP RSTP the seamless integration of automation networks into existing office networks Is possi ble Routing functions on Layer 3 support communication bet ween different IP subnets SCALANCE W Thanks to wireless communication an even higher level of plant flexibility can be achieved maintenance work is simpli fied and service times and downtimes are reduced The IWLAN solution from Siemens Industry makes these advanta ges available through a coordinated portfolio of WLAN equip ment for industrial use even for fail safe communication in the context of operator and machine safety This includes IWLAN access points and client modules SCALANCE W Monitoring and diagnostics Selection of network components with diagnostics capability wireless connections for PROFIBUS and distributed I Os mo
16. OFIBUS PA or HART Level measurement with contacting capacitance measuring technology e POINTEK CLS 200 300 e SITRANS LC 300 500 POINTEK CLS 200 300 is available with PROFIBUS PA SITRANS LC 500 is available with HART Level measurement with contacting Guided Wave Radar technology e SITRANS LG 200 SITRANS LG 200 is available with HART Most Siemens level measuring instruments offer e Meaningful error messages to speed up troubleshooting e Maintenance timers built into the measuring instrument for easy changes e Internal electronics temperature sensor for advance war ning before an electronics failure occurs e Recording of minimum and maximum values of internal temperature and process variables for easier troubleshoo ting e PROFIBUS PA Condensed Status Easy filtering of alarms sent to the operator or mainte nance engineer the right alarm to the right person Full control of all alarms in the measuring instrument This lets the user turn off all alarms that do not concern his respective application e Enhanced EDDs electronic device descriptions Harmonized look and feel of different Siemens level measuring instruments and even of different Siemens measuring instruments Quick start wizard for easy configuration and fewer setup errors Echo profiles can be stored for faster troubleshooting Siemens AG 2011 Gas analyzers Siemens offers a wide range of gas analyzers e CALOMAT 6 62 Thermal conductivi
17. ST80_X_00422 Process Device Management Overview of components on a PROFIBUS segment with symbol displays There are additional views depending on the diagnostics capa bility of a device For example in the component operating display for intelligent field devices DP PA HART additional information is output that the Process Device Management PDM makes available Changes in the parameterization are managed in a change logbook and can be called up from the Maintenance Station In this case the time and name of the responsible operator are output Symbol displays and component faceplates The conditions of the compo nents or also of subordinate com ponents are visualized using Standardized symbol displays in the diagnostics displays The symbol displays of the compo nents contain m Symbol display of a component Configuration changes can also be output The diagnostic in formation of intelligent field devices is determined with the PDM on the basis of the EDD of a field device In the EDD the device manufacturer also specifies for example the supple mentary information to be provided in the event of faults This can also display the cause a trend statement and instructions for clearing the fault In addition PDM can be called directly from the faceplate This call makes all vendor specific informa tion and documents incorporated by the vendor available for e Bitmap of component e Tag designation of component e M
18. Sensors for breakage and function of the linearization cal culation In addition simulation functions are available for checking the configuration of the transmitter and of the connected control system input These also contribute to fast and definitive trou bleshooting and thus to greater efficiency in the maintenance operations From the combination of the stated functions measures can be derived that contribute to the prognostic maintenance and thus increase plant availability even further and help to raise productivity SITRANS P DS III SITRANS P300 digital display Flow measurement For flow measurement Siemens offers various contactless measurement procedures e SITRANS F M MAGFLO magnetic inductive flow meters e SITRANS F C MASSFLO Coriolis mass flow meters The devices are flexible in their application and can be positi oned at any point in the installation MAGFLO and MASSFLO flow meters provide excellent correct and predictable information about the HART or PROFIBUS Pro fil interfaces The latest MASSFLO version SIMATIC SIFLOW FCO70 Coriolis transmitter can be directly integrated into the SIMATIC system via the backplane of the SIMATIC module SIMATIC SIFLOW FCO70 has a SIMATIC S7 300 environment The SIMATIC SIFLOW FCO70 permits seamless integration into the automation system MAGEFLO flow meters are used for applications with conducti ve liquids and MASSFLO flow meters for example for non conductive l
19. a watchdog user software sured data timeout e Maintenance intervals freely selectable e Web server e SIMATIC Maintenance Station The SIMATIC IPC DiagMonitor supports fast detection and efficient avoidance of potential system failures Monitoring and diagnostics 13 Siemens AG 2011 Monitoring and diagnostics of networks SIMATIC PCS 7 communicates with the subordinate com ponents of Totally Integrated Automation via Industrial Ethernet and PROFIBUS and uses the network components and communications processors CPs of SIMATIC NET In addition to reliable communications these also offer the facility for network diagnostics during runtime Monitoring of PROFINET Industrial Ethernet Network components Network components are SCALANCE X Industrial Ethernet switches SCALANCE W Industrial WLAN and SCALANCE S Industrial Security SCALANCE X 200 managed Universally applicable from machine level applications to networked plant sections Configuration and remote diag nostics are integrated in the STEP 7 engineering tool This in creases plant availability Devices with a high degree of protec tion permit a cabinet free construction Appropriate switches SCALANCE X 200IRT are also available for use in plant sec tion networks with hard real time demands and maximum availability SCALANCE X 300 managed Networking of subsystems plant sections as well as for con necting to the enterprise network The SCALA
20. aintenance state display e Group display for maintenance messages from subordinate components Clicking an element in the symbol display either opens the subordinate hierarchy level or a component faceplate This faceplate contains various views of the respective component in which further device specific information can be output There are three standard views Identification Depending on the component the identification view displays all information available from the hardware configuration or via SIMATIC PDM in the device description of the Electronic Device Description EDD In addition the maintenance status is displayed and if available the status of a redundant compo nent Messages The Messages view displays diagnostics error messages ope rator inputs and maintenance requests Maintenance The Maintenance view is used for the response of the operator to a maintenance request of a component Maintenance work can be requested The status of the work can also be specified intelligent field devices F Communication via PEM F r Device status via FOM r r p r r m r r r r r r F es SIMATIC_400 1 1 2 10 Pointek_CLS_20_1 Fa Sy gd Diagnostic x Message bext via POM Good m Falled k gt Maintenance der ande F The rod is strongly polluted The degree ofthe pollution is 81 Acusted limit alarm 55 Device We mismatch gt Dismount the device and clean the rod Maintenance alan Mainlen
21. ance demanded Maintenance required Local override Simulation cr aub stitute val Out of service Configuration failure Configuration waming Configuration changed Process value alarm Prozess value warning Good last check 03 03 2005 10 26 33 C_ refiesh A Faceplate detail view of a component SIMATIC PCS 7 Maintenance Station 11 Siemens AG 2011 Add ons as options for the SIMATIC PCS 7 Maintenance Station Alarm Control Center alarm management system The WinCC Alarm Control Center ACC alarm management system transmits alarms from visualization and control sys tems to mobile receivers such as cellphones or pagers The messages are automatically sent to the responsible per son or group of people If no response is received within a pro grammable period of time from a notified person such as a text message other people are notified In conjunction with the escalation system alarm scenarios can be implemented for a wide range of requirements Even the basic package incorporates a shift management faci lity enabling personnel to be assigned depending on the time and the day of the week Text messages are sent via ISDN analog modem or GSM mo dem For additional requirements transmission channels are available for systems including VOIP voice and PABX systems Configuration and user control is web based via LAN or Wire less LAN Further options allows the Alarm Control Center to be adapted to individual requir
22. and maintenance e There is a close link between automation and asset ma nagement functions because for example the current control strategy of the plant plays an important role for the assessment of a component status e Engineering data for automation can also be used for main tenance e Simplified handling of the system since users need only be acquainted with the engineering operator control and mo nitoring tools of a single system The process control special interest group of the pharmaceuti cals industry NAMUR has formulated essential requirements NE 91 from the user s viewpoint This attaches special signi ficance to the integration of the Plant Asset Management into the process control system e Plant Asset Management is a part of the process control system e Recording and assessing the status of the assets e Inclusion of all assets process control devices and plant components e Separation of maintenance relevant information and pro cess data e Uniform visualization for all assets e No limitation to selection of field devices Introduction In addition there is a requirement NE 107 that all field de vices must provide standardized status messages about their Status as follows e Good No known restriction of function e Uncertain Operation outside the specified range e Device failure Need for maintenance e Maintenance required Function check process value manipulated e Function check local op
23. ata simple plant network problems such as failure of a line can be quickly and easily detected by means of this software Device configuration is integrated into STEP 7 Ethernet de vices can be read from a STEP 7 project or using the autodis covery function directly from the live network The user can easily add all devices detected there to the device list for mo nitoring on the OPC Server Then this configuration data is ex ported into the Maintenance Station where tags alarms and faceplates are automatically created for the devices concer ned Monitoring of PROFIBUS Online diagnostics with diagnc eater Particularly i in the case soi DN stress e g trailing cables or strong vibrations frequent inspection of the cables is recommended to reduce failures to a minimum The diag nostic repeater is available for this purpose It is integrated as an RS 485 repeater in the PROFIBUS network and also has po werful features for the diagnosis of cable faults The diagnostics repeater determines the bus system topology If there is a fault a standard diagnostic message is automati cally transmitted to the master This means that even sporadic cable faults can be detected and signaled Even maintenance engineers without PROFIBUS expertise can also quickly and reliably locate and fix bus cable faults Diagnosis of optical PROFIBUS links with OLM To set up optical PROFIBUS connections optical link modules OLMs are used They of
24. bi le operator panels planning software and extensive accesso ries SCALANCE S The SCALANCE S security modules enable logging of access data in one log file syslog protocol These data show how when and by whom the network has been accessed Attack attempts can be detected early and appropriate preventive measures taken Network management The integrated network management with the standard SNMP Simple Network Management Protocol in SCALANCE X and W provides information for device diagnostics The network management products SINEMA E SIMATIC Net work Manager Engineering SINEMA Server Management and the SNMP OPC server provide support in the planning and simulation or monitoring and diagnosis of wireless and wired networks in the industrial environment SINEMA Server is specifically used in larger networks and for extensive network management The SNMP OPC server is used exclusively for the processing of SNMP message frames and their transfer to be represented in other systems SINEMA Server network management The SINEMA Server Simatic Network Manager network ma nagement software diagnoses and visualizes Ethernet net works It continuously logs network activities using various protocols such as SNMP DCP and LLDP and makes them available to users and other systems on the network e g HMI software such as WinCC for evaluation and further proces sing Devices their properties and their topology are recog nized
25. e engineer e to unambiguously identify and evaluate the assets this me ans the production equipment and its components e to carry out the appropriate measures in the case of devia tions from the desired or expected state As a result of monitoring i e the recording and evaluation of status variables the condition of a component or device can be determined It can be recognized for example that no signal is received from the sensor resulting in the diagnosis Open circuit This result triggers a maintenance request and maintenance must then be carried out to eliminate the open circuit This measure replacement of a faulty line in this example ensures that the component Is returned to the desired condi tion and closes the maintenance cycle This means that Plant Asset Management is the basis for increased productivity Maintenance measure Monitoring Maintenance request Diagnostics Introduction OV Siemens AG 2011 Intelligent maintenance in process engineering Despite the different tasks of operators and maintenance Staff it is meaningful and necessary to map the informati on of both staff groups within one process control system and not to use different systems There are various reasons for this e Uniform visualization for all components and devices e No limitation to selection of field devices e The same information sources field devices are relevant to both automation
26. eans that consequential costs resulting from failures such as quality deficiencies or loss of image are reduced Totally Integrated Automation supports intelligent mainte nance strategies The SIMATIC Maintenance Station is of signi ficant importance and presents the information relevant to maintenance from all automation components in a uniform and clear manner thus providing the maintenance engineer with valuable support for making decisions Maintenance strategies There are two maintenance strategies response to failures or taking preventive measures In the case of failure oriented corrective maintenance measures are only initiated when a fault has occurred i e failures are acceptable in this case and may be minimized by a redundant plant design The objective of preventive strategies is to carry out mainte nance measures before faults even occur in order to avoid possible downtimes This strategy can be satisfied using time dependent and load dependent measures Regular maintenance work is an example of time dependent measu res The load state is determined from the number of swit ching operations operating hours or load peaks Introduction Benefits of intelligent maintenance Continuous plant monitoring m Reduces the risk of failures and increases the availability m Enables maintenance to be planned Optimized use of maintenance resources m Increases maintenance quality m Achieves cost savings The potentia
27. ements The Replication option enables high availability redundant systems to be configured The dialog module permits active contacting of participants e g to log off a station by remote configuration or to query pro cess values Advanced call archive analysis enables detailed logs to be generated and supports other quality assurance measures Further information www siemens com alarmcc PM MAINT intelligent maintenance management The PM MAINT add on supplements the SIMATIC Maintenance Station with the following functions Maintenance planning PM MAINT can be used for planning based on performance data or calendar intervals so as to define clearly when which maintenance tasks are to be carried out Damage reports and repair jobs from the SIMATIC Maintenance Station also enable unforeseen maintenance work to be scheduled SIMATIC PCS 7 Maintenance Station interval counter Recommended M Date interval data PM MAINT Running Time _ Operating Cycles Calendar Anticipatory planning with the help of performance and calendar information Management of supplementary information Data essential to effective maintenance can be entered rela ting to the maintained plant and machinery In addition to component manufacturer and sourcing data electronic do cuments can also be linked to the items and related mainte nance jobs This provides maintenance staff with direct access to aids such as repair instructions circuit
28. entation SIMATIC Sensors www siemens com simatic sensors Plant Asset Management with Totally Integrated Automation components 27 Siemens AG Subject to change without prior notice Industry Sector PDF 6ZB5310 OMG02 OBA6 Postfach 48 48 3P 8301 36 18 Dispo 26100 90026 NURNBERG BR 1011 28 En GERMANY Produced in Germany Siemens AG 2011 Www siemens com automation
29. eration Failure process value invalid Processing plants whose open and closed loop control is per formed with SIMATIC PCS 7 and components of Totally Integ rated Automation satisfy the user requirements formulated by NAMUR The resulting information is divided up to prevent the plant operators and maintenance staff from being flooded with in formation To achieve this a Maintenance Station MS is int roduced in addition to the operator station OS Mainte nance relevant information is kept away from the operator Station This information is collected and presented on the Maintenance Station The same HMI tools are used for the operator station and the Maintenance Station and the HMI philosophy is identical Plant Asset Management with SIMATIC PCS 7 m Process engineering plants with SIMATIC PCS 7 and com ponents of Totally Integrated Automation meet the re quirements of NAMUR m Automation and Plant Asset Management run on the Same system m The information for plant operators maintenance staff is divided between the operator station and the Mainte nance Station m Shared configuration and uniform user interfaces mini mize the expense of an effective Plant Asset Manage ment Siemens AG 2011 SIMATIC PCS 7 Maintenance Station More productivity with Totally Integrated Automation Integrated plant and cross system maintenance Plant Asset Management is only truly productive if mainte nance staff can view diagn
30. fer the following diagnostic options e Function monitoring by means of signaling contact e Signaling of the fiber optic cable quality with LEDs for channel monitoring e Analog value signaling of the fiber optic line quality evalu ation with voltmeter via measurement terminal or reading to the PLC via analog module Benefits of network monitorit ig an d diagnostics e High o availability cian eNA aar aa locali zation of faults e Documentation of network activities for analysis and verifi cation of network availability e Monitoring and improvement of the network capacity utili zation e Automatic recognition of new or faulty participants e Integration of diagnostics data in automation and visualiza tion systems e Detailed and clear graphical network representation Monitoring and diagnostics 15 16 Siemens AG 2011 Monitoring and diagnostics for process instrumentation and process analytics Standardized and meaningful diagnostics alarms are a part of the electrical device description EDD SIMATIC PCS 7 utilizes the EDD and forwards the relevant message automatically to the Maintenance Station The user recei ves information not only about which problem is involved but also on how to resolve it The PROFIBUS profile specification 3 01 supplies an upgrade of the status byte now designated Condensed Status The purpose of the Condensed Status is to reduce the number of alarms and make them more user friendly
31. fic components such as pumps and general sensors who se measured values are recorded via analog inputs In many cases the analysis of the described acquisition variables de pends on the user s estimation Acquisition variables which can be provided by Siemens protective devices and control cabinet devices RLT stands for remaining life time monitoring ar power contactor is needed to activate the motor Monitoring and diagnostics 23 Siemens AG 2011 Motor contactor with RLT SIRIUS compact starter and infeed system for 3RA6 SIRIUS motor starter M200D innovative solution for dis tributed drive technology 3RW44 soft starter SIMOCODE pro 3UF7 Se Bri E a b mim 24 Monitoring and diagnostics m Tried and tested SIRIUS technology m 3 sizes S6 S10 S12 55 to 250 kW at 400 V m Can be used up to 60 C without derating Long electrical service life m Replaceable main current contacts LED display of the remaining life time of the main current contacts 60 40 20 m With 20 or less remaining life time a message Is sent via AS Interface m Connection via AS Interface Compact starter up to 32 A as direct and reversing starter 45 90 mm wide m Only one weld free clearance instead of circuit breaker contactor and overload relay Electronic trigger with wide setting range 1 4 5 versions Integrated overload function with differentiated fault message Infeed system up
32. from the hierarchical visualization of the maintenance information SIMATIC PCS 7 Maintenance Station The overview display uses the standardized symbols to visua lize the condition of a component itself and also provides coll ective information on the conditions of all devices in the sub ordinate hierarchies The collective condition message shows the OK condition or the seriousness of a possible problem in red yellow or green as per a traffic light A button can be used to access all subor dinate hierarchy levels step by step down to the bottom de vice level Further views of the maintenance information are available in addition so that the maintenance engineer has a complete overview of all current information of the asset relevant to maintenance This permits assessment of the plant status at a glance Maintenance group display Maintenance state display Operate state display A rte jage Diagnostic PA Slave DP YO link DP_Mastersysten X sa SIMATIC ACOM G1 O Pointek_ ELS _70_1 mie EL ident Component TAG Pointek CLS 2000 4 maintenance required Descriptor __Level switch Message _ Simatic POM Product designation Pointek CLS200 ManuFac liner Siemens Milltironics Ordernumber TMLSS Device Serial Num 0 Installation Date 28 08 2004 Es 001 Hardware Revision Software Revision Identification of device as Detailed view of a component 0300 01 02 G_ST80_XX_00421
33. he CM240NE chemistry module IEC motors The SINAMICS family Monitoring and diagnostics 25 26 Siemens AG 2011 Using the example of a mixer drive the maintenance with Drive ES PCS 7 is represented In time the material to be mixed Starts setting in the agitator Until now the agitator was clea ned at planned regular intervals to guarantee its availability With the aid of new functions in the Maintenance Station the cleaning can in future be performed as and when required The frequency converter offers the option of load torque mo nitoring and the type of reaction when the limit is exceeded Within the load limits the mixer works without any problem With regard to the mixer it is known that the degree of pollu tion has an indirect effect on the torque characteristics of the frequency converter On exceeding the limit an alarm is re ported to the controller Maintenance Station e g initiate cleaning of the mixer WH Industrial Ethernet Drive ES PCS 7 Message to Maintenance Station Mi PROFIBUS Mixer drive generates signal in case of limit violation Schematic flow of information using example of a mixer drive Monitoring and diagnostics From this alarm of the converter Drive ES PCS 7 generates a corresponding maintenance display for the Maintenance Sta tion Now the cleaning of the mixer can be performed on the basis of need Additionally it is possible to record the frequency of clea
34. he block CompMon calculates performance characteristics e g conveyance or efficiency and issues a warning if the cor responding values indicate damage to the compressor caking by pollutants on the runner or erosion of the blades from the fluid Standard diagnostics functions In order to obtain information on the diagnostics status of in dividual plant areas or components maintenance engineers can change from the overview display to the respective diag nostics display of the subordinate hardware level If a fault is signaled in the overview display the loop in alarm function permits rapid switching to the diagnostics faceplate of the as sociated component The information is filtered according to the area of responsibility of the user The following information can be offered e Display of diagnostics status determined by the system e Information on the component such as process tag name manufacturer or serial number e Display of diagnostics messages of a component e Visualization of type and current state of initiated mainte nance measure Design of a Maintenance Station The SIMATIC PCS 7 Maintenance Station is of modular design In small plants it is possible to install the operator station and the Maintenance Station on the same PC Just like the opera tor system the Maintenance Station can be expanded into a client server application with multi client operation The sig nals and messages from the components and dev
35. ices which are relevant to maintenance are collected and saved on the server of aclient server application They are displayed on the client The SIMATIC PCS 7 Maintenance Station is based on standard SIMATIC products e SIMATIC PCS 7 ES OS for configuration and HMI functions e SIMATIC PDM for connecting the field devices and e SIMATIC SNMP OPC Server for interfacing network components SIMATIC PCS 7 Maintenance Station VF a a Go Gel ae E EF EF H i a a N S ii Wa ma i ua G 9 w 6 aa A m amn am i 3s cm ee gt D p dP dine ee Configuring a Maintenance Station When setting up a Maintenance Station the user only has to assign the corresponding attribute once during the con figuration This automatically generates a technological hier archy for diagnostics displays The diagnostics displays can be subsequently expanded by project specific contents Technological plant view Maintenance Station B i Mulhaazet Asaba Fi SS ee ee Diagnose EHA AS Obekte E SIMATIC_400 1 01 EHE OP Mastersystem 1 E 151 21 EHE m 15210 L A AWARE HARTI EHA 153 2 Redundari 3 jf AIZRHART__Ex a eS It_157_Redundare d Transfer of maintenance relevant information to the Maintenance Station H UA H Metz Objedbe fj PIC Stationen z a Operator r ape 3 i a i Station a EF Gi S EHEJ Conto el EHE veni E Kontakt W When configur
36. ing PCS 7 the technological plant view automatically becomes its own maintenance area Visualization in the Maintenance Station In the operating state the Maintenance Station s client re quests cyclic data from the associated server The client can additionally access hardware components and field devices di rectly by means of an online connection so that the mainte nance engineer has the relevant information available at all times Various components with highly different diagnostics capabilities are used for SIMATIC PCS 7 However from the vie wpoint of maintenance all components are displayed in the Same manner Therefore the maintenance and diagnostics conditions of the components are represented by standar dized symbols Siemens AG 2011 This is recorded and signaled in the symbols A work instruc tion number and a comment can still be entered for each work request The instruction number has no effect within the Maintenance Station and is only included in the report This can be used for transfer to maintenance planning Block icon Device faceplate E Message Diagnostic PA Slave DP WO link DP_Mastersystem Ei SIMATIC _400 1 1 a1 OVP ointek_CLS_20_1 Pee E maintenance x ___ Request Operator Component Request number 78626 Za maintenance demanded Pree Request In progress Completed Cancel Request via pnmnier fa peut TEA view st e E lel ee iit GiB S F e l G_
37. ions Current limit overload Temperature Ground fault detection int ext Underload performance measurement Maintenance timer General sensor technology via analog inputs Number of overload tripping operations Overload tripping operations can have different causes They can give information about the condition of the machine or plant or they can signal an incorrect setting or motor selec tion If necessary the motor size should be changed Current limit overload Gradual changes in the overall application environment such as pollution or bearing damage can cause increased current consumption Preventive maintenance can be planned and carried out so that faults such as those caused by an overload can be prevented Temperature Corresponding sensors in the switchgear environment can give information about the condition of the contacts War ming of the ambient air can indicate that the switchgear is too heavily utilized One remedy is to avoid simultaneous activa tions if applicable The temperature of the motor or machine can also indicate wear Ground fault or insulation detection In isolated IT networks faults can be detected in the motor or supply line Underload performance measurement Performance measurements on machines can indicate broken couplings torn belts slippage in the coupling bay dry run ning of pumps or fan filter contamination In addition there is a series of special acquisition variables for speci
38. iquids high precision requirements or in proces ses in which the process parameters are subject to severe fluc tuations MAGFLO flow meters are not sensitive to fluctuations in tem perature pressure viscosity or electrical conductivity min 5 uS cm guaranteed The device is equipped with a host of diagnostic functions that are displayed in plain text and stored in a logbook In this way sporadically occurring faults can also be located These faults are automatically sent to the system in accordance with the standards of the diagnosed requirements of NAMUR NE 107 The measuring transducer including outputs is monitored The pickups are continuously checked and empty pipe detec tion is performed In addition MAGFLO flow meters offer the option of checking the entire measurement system with an external verifier Monitoring and diagnostics 18 Siemens AG 2011 SITRANS F M MAGFLO SITRANS FC MASSFLO MASSFLO flow meters are not sensitive to fluctuations in pres sure temperature density electrical conductivity or viscosity An ASIC guarantees improved reaction to discontinuities The devices are practically unaffected by external noise an es sential requirement for raising the dynamic range MASS 6000 monitors both application dependent faults and those device settings selected by the user e Excessive air in the measuring tube e Empty tube detection e Unstable flow signal e Zero point error e
39. l SIMATIC IPCs client server network architectures can be set up via LAN and can centrally monitor all SIMATIC IPCs in plant facilities using DiagMonitor The integrated webserver lets you view and manage data via an internet browser Efficient service structures can be established by integrating automated com munication paths e g by means of Ethernet e mail or text messages phone DiagMonitor supplements the operating data of the monito red PCs with text messages transmits them via the SNMP OPC server and outputs them in the associated asset management view e The Monitoring 1 view indicates the number of operating hours of the SIMATIC IPC and the interior unit temperature at different measurement points in the device e g at the processor and at the motherboard e In two additional views the speeds of the fans are output or diagnostic data and information on the status of the drives is displayed It is then possible for example for the user to replace hard disks as a preventive measure before a loss of data occurs preventive maintenance www siemens com diagmonitor Mainboard C VO Chip C 20 Go a co w Go MAX max 37 max Betriebsstunden h ev E ev E MIN 25 MIN 22 ou 5 20 eu o Operating hours and device internal temperatures in Monitoring 1 view In addition the user is warned in good time of fan or hard disk failures preventive maintenance In the event of an ala
40. l for savings arises m During maintenance itself and m by avoiding consequential costs Condition Monitoring that is to say status monitoring aims to detect imminent faults at an early stage It provides infor mation on the remaining duration of use In the case of con dition based maintenance the maintenance measures are only initiated when the period of use has expired It has been shown in practice that optimum results can be achieved through intelligent combination of the different stra tegies Maintenance Corrective Preventive Time dependent Load dependent Condition based G_ST80_XX_00410 Maintenance strategies Siemens AG 2011 Contents Introduction Increase in productivity through intelligent maintenance eee eee eee Plant level asset management as a maintenance task 0 cc cece eee 4 Intelligent maintenance IN process engineering eee ee ee es 6 SIMATIC PCS 7 Maintenance Station More productivity with Totally Integrated Automation 7 Visualization of information for maintenance o eae ae a a aa e 8 Maintenance Station User interface for maintenance 9 Add ons as options for the SIMATIC PCS 7 Maintenance Station 0 eee eee Monitoring and diagnostics ROMA CS Will PCS Meee sie r E e e E va emia OMG LW OIK Sapa eee eta E pana eae for process instrumentation and analytics 16 for p
41. ning demands and to deduce process optimizations or anticipatory maintenance scenarios Thus maintenance can as well be optimized for moving de vices and availability and efficiency of the plant can be increa sed Load torque monitoring This gives an idea of for instance the degree of pollution of the mixer G_ST80_XX_00417 Siemens AG 2011 Plant Asset Management with Totally Integrated Automation components Benefits m Plant wide and uniform display of diagnostics and maintenance states m Integrated support of condition based maintenance m Optimization of complete workflow from diagnostics up to termination of maintenance measure m Maintenance functionality integrated into the sys tem no additional engineering overhead For additional information on this subject please visit www siemens com automation maintenance SIMATIC HMI www siemens com simatic hmi SIMATIC PC DiagMonitor www siemens com diag monitor SIMATIC NET www siemens com simatic net PROFIBUS www siemens com profibus PROFINET www siemens com profinet SITOP select www siemens com sitop select AS Interface www siemens com as interface ET200pro motor starters www siemens com sirius motorstarter Low voltage switchgear www siemens com lowvoltage Drive technology www siemens com drives Process analytics www siemens com processanalytics Process instrumentation www siemens com processinstrum
42. nit CU 240S DP F The che mistry module includes a terminal strip that meets the NAMUR specifications and thus the essential requirements of the chemical industry An ATEX certified PTC thermistor analy sis function for thermal motor protection via PTC thermistors built into the motor is integrated The drive systems are incorporated into the maintenance sta tion using the DriveES PCS 7 an add on package for SIMATIC PCS 7 DriveES PCS 7 allows Siemens drives to be controlled via SIMATIC PCS 7 using standard function blocks and operated and controlled in the operator station by means of faceplates Status assessment of high voltage machines An established procedure for assessing the condition of high voltage machines is partial discharge diagnostics PD which is carried out as an offline or online measurement depending on the application This is an important measu re within reliability based maintenance strategies for large drives In order to measure the PD signals as an option the paten ted SIEMENS Insulator Integrated Coupling Units can be installed in high voltage motors at the factory The post insulators in the terminal box are simply replaced by the Insulator Integrated Coupling Units This results in decisive benefits Simple low cost installation No change in terminal box necessary Rugged mechanical design Highest and tested safety of the insulation distances Direct interface to condition diagnostics T
43. ntenance team The SIMATIC Maintenance Station for SIMATIC PCS 7 and SIMATIC WinCC makes a significant contribution to incre asing maintenance productivity and thus to increasing the availability of the overall plant Optimizing instead of repairing The task of maintenance is not only to avoid unscheduled pro duction downtimes but also to optimize the running of the plant Optimization must be based on analysis of traceable processes The Maintenance Station offers the basic data set for integrated analysis of all weak points This is not unusual in a process control system However in inbound and out bound processes diagnostics are often restricted to signaling a fault and then forgetting about it as soon as it has been re paired With Totally Integrated Automation the Maintenance Station becomes the basis for Total Productive Maintenance Maintenance Station Client Internet Maintenance Station Maintenance Station Server WinCC Inbound process Server SIMATIC PCS 7 Productions process Maintenance i Station Client Web Server DN Maintenance Station Server WinCC Outbound process G_ST80_XX_00337 SIMATIC Maintenance Station Collecting diagnostic information from the entire process chain centrally even via the Web Suitable protective measures among others IT Security e g network segmentation have to be taken up to ensure a safe operation of the plant
44. ods in order to offload the power supply Monitoring currents are ad justable between 0 5 to 3 Aand 3 to 10A The electronic sys tem allow short current spikes such as making current swit ching spikes but longer lasting overloads or short circuits are switched off If one of the four outputs is switched off a sum signaling con tact is activated and can be evaluated by the higher level au tomation system The service technician recognizes on site which 24 V feeder is concerned since each output has a mul ti color LED to indicate the current operating status Besides fast error detection and localization this leads to a reduction of downtimes Set O ki tU i lt m 1 SITOP PSE200U selectivity module Monitoring and diagnostics Monitoring and diagnostics of wear in the motor and its vicinity In the vicinity of motors there are a number of wear fields the power distribution the motor feeder or converter the motor itself the supply lines and the machine that the motor drives For the user it is of great benefit if routine visual inspections by the servicing personnel e g in order to determine the con dition of the main contacts of contactors can be omitted and the device can diagnose its own condition Condition monitoring records the wear with the aid of measu red values which can be used to determine the condition of the affected components Thus depending on this condition it is possible to dete
45. ositioners and control valves 21 of 24 V load teeders ars ins ee ener tee 22 Ole Weal il We motor aaa a co cgeeonenes nee aa 22 ON drive components 4 18 1 a a eee eee 25 Plant level asset management with Totally Integrated Automation components 27 Introduction 3 aN Siemens AG 2011 Plant Asset Management as a maintenance task General information Various tasks have to be handled during the operating phase of a plant for which different groups of persons are responsib le The production personnel operate and monitor the plant and make sure that the desired products are produced with the ap propriate quality in the defined quantity at a specified time and with minimum resources with respect to personnel raw materials energy costs etc Maintenance staff must e ensure a high availability of the plant e ensure this availability in the long term by implementing optimization measures and e carry out maintenance measures with minimum use of per sonnel material energy costs etc As a result of their different tasks these two groups of persons have different information requirements Different demand for information at the plant Plant operator Information on the process such as e Recipe parameters e Temperature characteristic e Pressure values e Raw material stocks e Output Maintenance personnel Information on the state of the production equipment such as e
46. ostic information relating to the en tire process chain In practice this means that the same main tenance team that Is responsible for the actual process can support inbound and outbound processes such as logistics bottling and packaging plants without having to build up a great deal of additional expertise If the process control sys tem and the controllers of the upstream and downstream sys tems originate from different vendors different alarm sys tems can cause considerable additional expense If a plant is automated with SIMATIC PCS 7 therefore it is wor thwhile for the plant operators to select machines and sys tems that are automated with SIMATIC and visualized with SIMATIC WinCC for their inbound and outbound processes as then they can exploit all the advantages of Totally Integrated Automation If machines or systems for inbound outbound processes are operated and monitored by means of SIMATIC WinCC then the SIMATIC Maintenance Station presents itself as an option to SIMATIC WinCC for maintenance relevant information Central control room with plant wide maintenance overview The integrated functionality of Totally Integrated Automation also makes it possible using the SIMATIC PCS 7 Maintenance Station to monitor the packaging or bottling line by means of a client Display logic and message management are identi cal The uniform look and feel saves on overhead and genera tes a high degree of acceptance within the mai
47. put for the control of the device condition sta tus e Via detailed diagnostics of the device condition device specific e For devices with an AS Interface connection the integra tion into the Maintenance Station takes place via suitable SIMATIC S7 communication processors CPs or AS i links Siemens AG 2011 G_ST80_XX_00427 Wear fields in the motor environment Acquisition variables for wear fields Contact erosion The contact condition and thus the remaining life time of a contactor can be determined directly based on the degree of contact erosion You can simultaneously use this to make a de termination about the condition of the power distribution the motor feeder or the converter Number of starts breaking current The number of starts or the level of the breaking current indi rectly gives you information about the erosion of the swit ching contacts empirical values manufacturer s informati on Using empirical values it is also possible to make state ments about the load of the driven machine Number of operating hours with without limit value The runtime effects the wear of the motor and the machine The need for maintenance can be determined based on empi rical values user knowledge or manufacturer s information Contact erosion end of service life Current detection Performance recording power factor Number of starts breaking current Number of operating hours Number of overload tripping operat
48. rm the DiagMonitor can also start autonomous programs such as spe cial PC tools or user specific applications for individual response to alarms Prevention of potential failures e Diagnostics and signaling functions for PC temperature fan drives system status watchdog e Operating hours counter for preventive maintenance e Recording and evaluation of operating data e Integral log function comprehensive text messages and online help in German and English Possibilities for minimizing PC downtimes e Product Equipment Data is an online service tool for simple and quick information about the equipment configuration in the delivery condition The information also supports the procurement of spare parts www siemens com ped e The after sales information system for SIMATIC IPC PG of fers product and contact information on the Internet in one central location www siemens com asis PC hardware functions Overshoot undershoot LAN e Diagnostic LEDs on each e Activates reset e Interior unit tempera of permissible operating e Text message to mobile unit watchdog ture temperature phone e Local on own monitor e Runs programs e Device fan e Fan failure fault e E mail to alert designa e Via LAN on the central automatically e Drive state e Drive problems ted person server batch executable files e System states e Program interruption e OPC and or SNMP to e Graphic display of mea Records events log file e Runtime meter following
49. rmine the optimal time for maintenance Continuous system monitoring allows for intelligent mainte nance with the optimized use of maintenance resources For the motor environment Siemens offers a series of condition monitoring capable protective devices and switching devices Intelligent maintenance with protection and switching devices Siemens protection and switching devices are e Powerful products for industrial controls with comprehen sive basic functions and e Information for condition monitoring In these devices the data or acquisition variables needed for the basic functions are also used for condition monitoring or condition monitoring statements can be derived from this da ta The devices also have additional analog inputs to which special sensors for condition monitoring analyses can be con nected example SIMOCODE Only when a large number of measured values must be recor ded or they reach a very high degree of complexity special de vices purely for the purpose of condition monitoring are nee ded for monitoring bearings or pumps for example Communication capability and integration in the Maintenance Station In addition to the condition monitoring capability of the de vices they also have corresponding communication functions so that they can be optimally integrated into systems and plants In addition they are integrated in the Maintenance Station as follows e Via device ID IMO e Via driver out
50. several simple simultaneous measurements is possible MicroSAM A compact space saving gas chromatograph to the fast dis continuous analysis of gaseous samples The use of standar dized application modules permits the easy replacement of modules instead of repair on site SITRANS CV A gas chromatograph specially developed for precisely deter mining calorific values Based on the proven microsystem technology of the MicroSAM and suited for custody transfer Comprehensive maintenance and diagnostics information is made available to the Maintenance Station via an OPC server or via Modbus Monitoring and diagnostics Process gas chromatography Analyzer System Management ASM is a SIMATIC WinCC based software system that was de veloped to monitor validate and conduct performance checks on various types of analyzers facilitate maintenance work and to record trends The complete range of functions of an ASM system encompas ses an independent analyzer network and programmable con trollers to integrate third party devices as well as engineering that allows the customer specific plant requirements to be dis played in the ASM system ASM can be integrated on a SIMA TIC PCS 7 platform or it can be implemented on its own work Station as an independent solution Remote service The remote service combines process analytics with state of the art information technology Thus various services which previously required on si
51. te intervention can now be offered via a data line Siemens provides a remote service center from which the analyzers can be directly accessed for preventive and correcti ve measures Currently this service is offered for the MAXUM MicroSAM and SITRANS CV gas chromatographs and for the LDS6 diode laser gas analyzer For optimal data security proven mecha nisms such as encryption VPN or call back functions are used Advantages Significantly improved system availability and ef ficiency of the analytics with reduced downtimes Siemens AG 2011 Monitoring and diagnostics for positioners and valves SITRANS VP300 and SIPART PS2 are intelligent electro pneumatic positioners for control valves and two position valves in the process industry Both devices can be used very flexibly in various processes In addition to the standard function of each positioner i e controlling process valves both devices also have comprehen sive diagnostic functions which can indicate critical statuses of the drive or valve at any time during operation of the plant The following functions are available in both devices e Slow movement of a valve e Clogging of a pipeline e Tear off of the valve plug e Wear of the valve seat or valve plug e Adhesion of the stuffing box e Partial stroke test for two position valves In addition both devices offer other individual functions for detecting critical statuses of the control valve SITRANS
52. to 70 mm and 100A Connection via AS Interface Degree of protection IP65 allows application oriented setup without a control cabinet Protects switches and monitors the motor and application Parameterization via STEP 7 HW Config Connection to AS i PROFIBUS and PROFINET Little variance for all motor starter versions Manual operation and main switch are integrated Electronically controlled start up and coasting of asynchro nous motors Integrated jumper contact system Integrated motor overload intrinsic device protection Adjustable current limiting Integrated status and fault monitoring Torque control Integrated braking function superimposed DC braking Compact design 5 sizes for the power range from 15 to 710 kW Recording the active power Connection via PROFIBUS Intelligent connection of distributed drives to the control level Autonomous function without PLC or bus Comprehensive monitoring functionality Graphical parameterization Analog inputs outputs for application monitoring Integrated inputs outputs for motor and application monito ring m Can be used for all motor applications Flexible motor management system with integrated protec tion control and monitoring functions m Intelligent pre processing is possible Modularly expandable system Outputs for activating motor contactors m Connection via PROFIBUS m can also be used for safety functions locally or via PROFIsafe Siemens AG 2011
53. ty gas analyzers for determining the quantity of hydrogen or helium in binary gas mixtures e FIDAMAT 6 Cumulative measurement of hydrocarbons according to the flame ionization principle e OXYMAT 6 61 Gas analyzers for measuring oxygen according to the para magnetic principle e OXYMAT 64 SITRANS LG200 Guided Wave Radar level measuring instruments Gas analyzers for measuring trace oxygen by means of ZrO gt sensors e ULTRAMAT 6 One and two channel gas analyzers for highly selective measurement of infrared active components e ULTRAMAT OXYMAT 6 Combination of OXYMAT 6 and ULTRAMAT 6 in one device e ULTRAMAT 23 Gas analyzers for measurement of up to three infrared ac tive components and oxygen e LDS6 In situ gas analyzer for the measurement of O tempera ture NH3 HCI HF H20 CO CO and special applications in flue gas before and after purification Further applica tions are possible in the chemical and petrochemical indus tries steel production and cement and paper mills e SITRANS SL New diode laser in situ gas analyzer for fast contact free measurements designed for operating in adverse ambient conditions consisting of a transceiver unit sensors for each measuring point comprehensive integrated monito ring control and communication functions SITRANS LC capacitive level measuring instruments Gas analyzers Monitoring and diagnostics 19 20 Siemens AG 2011 The gas analyzers have extensi
54. ve functions for device diag nostics and thus for corrective maintenance In addition they are capable of detecting functional irregularities These ap pear as a maintenance requirement or as a failure alarm in the display of the Maintenance Station at the signal output or they are signaled via PROFIBUS PA DP to higher level systems The messages are recorded in a logbook Possible causes for maintenance requests include e Calibration tolerance exceeded due to pollution of measu rement chamber drift or change of the calibration gas e Use of incorrect test or comparison gas e Detector defective or comparison gas failed e Monitoring of external interfering signals e g for sample preparation for the OXYMAT 6 Maximum sample chamber or measuring head tempera ture exceeded Heating is defective Zero or comparison gas contains too much oxygen Monitoring of the magnetic field e For FiiIDAMAT 6 Combustion gas failure or flame extinguished e For ULTRAMAT 6 and ULTRAMAT 23 Flow monitoring Monitoring of the chopper motor e For LDS6 Monitoring of the transmission of the transceiver unit Process gas chromatography MAXUM edition II A universal usable gas chromatograph which provides nu merous analytical options thanks to its modular structure This means that widely varying measuring tasks can be implemen ted using only one device platform Parallel chromatogra phy in which a complex analytical task is divided into
55. vice For preventive maintenance for example the following functions are available e Universal connection of resistance thermometers thermoele ments resistance type transmitters and DC voltage signals e Monitoring of the measuring point for short circuit and open circuit e Min max pointer for monitoring the electronics and sensor temperature The following devices are available as head mounted trans mitters or integrated into a complete measuring point IA DT J es 4ART device SITRANS TH300 the The operating hours counter evaluates the temperature valu es of the sensor and electronics edits them and displays them in eight temperature classes The measured values can be ar chived The sensor temperature can indicate aging processes and can be used for anticipatory maintenance The output current is monitored cyclically simulated as a fixed value or ramp function e Memory function of RAM ROM EPROM according to checksum method e Program sequence due to targeted approach to check points watchdog SITRANS TH400 for PROFIBUS PA Possibility of connecting two sensors in redundant mode The profile 3 0 device ensures easy interchangeability With FISCO certification use in potentially explosive areas is uncomplica ted SITRANS TW for rail mounting For installation on mounting rail with integrated power sup ply SITRANS TW is a universal 4 wire temperature transmitter for mounting in control cabinets e
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