Smart Motor Management
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Smart Motor Management How data-driven visibility can help protect both processes and motors in key industrial applications
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” Item Item Item
Traditional motor control circuits use thermal, or electronic, overload relays to protect electric motors from the effects of heat generated from mechanical or electrical overload conditions.
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When the overload trips …. what happens to the process??
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When the overload relay detects an overload condition of sufficient magnitude and duration, a normally closed contact on the overload relay opens, turning the protected motor off.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” Item Item Item Item Item Item
When the overload trips …. • Was it caused by a mechanical load problem? (bearing, poor maintenance, etc.) • Was it caused by a motor problem? • Was it caused by an electrical power problem?
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• What was happening when the motor tripped?
What needs to be corrected to restore the process?
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” Item Item Item Item Item Item Item Item
A tripped overload relay causes: • Unexpected shut downs • Unidentified reason for the trip • Potentially hazardous conditions
• Potential scrapped material
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• Potential lost production
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Time Based or Preventive Maintenance Item Item Item Item Item Item Item Item
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Time based maintenance does not “wait ‘til it trips”. It is: • based on a presumed schedule, much like the maintenance schedule for a car. • often scheduled around planned shut downs. • can lead to unnecessary maintenance.
• not able to identify parts that are nearing the end of their service life.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” or Preventive Maintenance Item Item
Traditional motor maintenance relies on traditional motor protection devices.
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Thermal overloads (bimetallic) and basic electronic overloads (ESP200) provide limited protective functions. The additional protective functions on ESP200 do not annunciate the reason for the trip.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance “Wait ‘til it trips” or Preventive Maintenance Item Item Item Item Item
Traditional motor maintenance • Relies on traditional motor load protective devices. • Offers little help in troubleshooting the cause of the trip.
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• Does little to prevent unwanted shut downs caused by dynamic changes to the protected loads.
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item
Condition based, or Predictive Maintenance is based on historical load information, such as:
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• Operating hours • Number of starts • Number of trips
• Load data ($$$)
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item
Condition based, or Predictive Maintenance requires gathering information. But how?
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Traditional devices only indicate the present condition of the connected load.
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item Item Item Item Item Item
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Condition Based, or Predictive Maintenance requires that operating information for the connected load be gathered and stored to identify conditions that require maintenance. More information leads to more effective predictive maintenance.
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item
Intelligent, communicating overload devices offer a wide range of selectable protective functions. Siemens SIMOCODE pro Motor Management device can provide all of the functions listed below.
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item Item Item Item Item
Enhanced capabilities allow the user to: • tailor protective functions to the load. • get warnings of developing problems before a trip occurs. • gather dynamic load information.
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• select the response of the protective device. • know why the device tripped.
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item Item
SIMOCODE pro C V Current Current Voltage Power Power Factor
(Motor Overload) Inputs
Local Logic
I/O Expansion
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PROFIBUS
Outputs
Digital Analog Temperature Ground Fault
© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item
SIMOCODE pro V in a typical tiastar™ unit
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item
SIMOCODE pro Standard Protective Functions
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item
SIMOCODE pro Standard Protective Functions
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item
SIMOCODE pro Optional Protective Functions – Voltage Based
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item
SIMOCODE pro Optional Protective Functions – Analog
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item
SIMOCODE pro
Available Data Number of Overload Trips
Individual Event Messages (62)
Number of Parameterizations
Individual Warning Messages (33)
Motor Stop Time
Individual Trip Messages (48)
Operating Hours
Motor Current (%FLA)
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Device Operating Hours
Motor Voltage
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Number of Starts
Motor Power (W & VA)
Number of Starts Left
Power Factor (COS Phi)
Number of Starts Right
Time to Trip
Consumed Energy (kWh)
Cool Down Period
Individual Status Messages (29)
Last Trip Current
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© Siemens Industry, Inc. 2011
Smart Motor Management vs. Traditional Maintenance Condition Based (Predictive) Maintenance. Item Item Item Item
There are significant benefits from employing a Condition Based Predictive motor maintenance program: • Smart motor management provides real time, dynamic motor and load
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data to facilitate Predictive motor and load maintenance.
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• Smart motor management includes enhanced monitoring and protective functions.
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• Smart motor management allows selected responses to monitored motor or load conditions. • Smart motor management can alert the user to an impending problem and prevent unwanted shutdowns. •Smart motor management alerts the user as to the cause of a trip or warning, simplifying maintenance.
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© Siemens Industry, Inc. 2011
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