The document describes an intelligent motor control center (MCC) system using SIMOCODE motor management and control devices. Conventional MCCs use discrete hardware components for protection, measurement, and I/O, whereas the intelligent MCC uses SIMOCODE pro controllers with integrated Profibus communication. This allows for online monitoring of motor parameters, centralized fault records, and control from a DCS without additional I/O wiring. The document outlines the components, functions, configuration, benefits and issues addressed during commissioning of the intelligent MCC system.

1. 1
NEW GENERATION MOTOR
CONTROL CENTER
-SIMO CODE SYSTEM

2. 2
Conventional MCC
Parts on Conventional MCC Feeders
Main Switch (Switch Fuse Unit / Circuit Breaker)
Power Contactor & Control Contactor
Thermal Over Load Relay
 Transducers with Analogue Signals
for Measurement (Optional)
 I/O Communication through Hardware (Control Cable)
Outgoing Terminals for Power & Control Cable

3. 3
Local Stop
MCC Stop
Interlock
Start
C
O/L relay
230V AC
C
Isolator
Overload
relay
Contactor ©

4. 4
Local Stop
MCC Stop
Interlock
O/L to DCS
Local Stop to DCS
MCC Stop to DCS
Control supply Healthy
ON Remote ONDCS ON
Local
DCS
Selector Switch
C
230V AC
Drive 1 to Remote
C

5. 5
Intelligent MCC
Parts on Intelligent MCC Feeders
Main Switch (Switch Fuse Unit / Circuit Breaker)
Power Contactor & Control Contactor
SIMOCODE pro & Complete Accessories
 I/O Communication through Profibus
Outgoing Terminals for Power Cable
SIMOCODE pro : Sirus Motor Management & Control Devices with a Profibus
DP interface

6. 6
Intelligent MCC
90 KW Motor Feeder with Internal Parts

7. 7
Intelligent MCC
SIMOCODE & Accessories
4 I / 3 O binary
Thermistor
PROFIBUS DP
24 V DC /
110 – 240 V AC/DC
Basic Unit
Current Measuring Module
0.3 A – 630 A Straight-Through/Busbar Connection Technology
Expansion Modules
 Additional binary I/Os
 3 x 0/4 – 20 mA I/Os
 3 x sensors Pt100/ Pt1000
 External earth fault via
summation current
transformer

8. 8
Operator Panel
with display
Operator Panel
5 buttons / 10 LEDs
Intelligent MCC
SIMOCODE & Accessories
Current/Voltage Measuring Module
0.3 A – 630 A /690 V Straight-through/ busbar connection technology
Connection Cable
In various lengths (up to 2.5 m)

9. 9
Intelligent MCC
Sub Divisions of SIMOCODE pro:
SIMOCODE pro C : A Compact System for Direct & Reversing Starter with
Monitoring & Communication of Current related Parameters only.
Typical SIMOCODE pro C Hardware Configuration

10. 10
Intelligent MCC
SIMOCODE pro V : A Variable System, which offers numerous in addition to all of
the SIMOCODE pro C Functions.
1. Expandable Binary Input / Output Modules
2. Current / Voltage / Power Related Measurements
3. Expandable Analogue Input / Output Modules
4. Earth Fault Detection
Typical SIMOCODE pro V Hardware Configuration

11. 11
Intelligent MCC
Applications of SIMOCODE / Intelligent MCC Feeder Module
Controlling, Protection, Measurement & Communication for
 Direct Online Starters
Star Delta Starters
Reversible Starter
Actuation through Soft Starters

12. 12
Intelligent MCC
Functions of SIMOCODE / Intelligent MCC Feeder Module
Protection Functions
 Thermal Over Load
 Unbalance Protection
 Stalled Rotor Protection
 Thermister Protection Based on Actual Temp. Measurement
 Upper Current Limits & Lower Current Limits
 Earth Fault Protection
 Under Voltage / Over Voltage Protection
 External Interlocking Through Digital Inputs

13. 13
Intelligent MCC
Functions of SIMOCODE / Intelligent MCC Feeder Module
Measurement Functions
 3 Phase Voltage
 3 Phase Current
 Active Power
 Apparent Power
 Power Factor
 Unbalance Current
 Thermal Model Memory
 Drive Operation Hours
 No. of Over Load Trips
 Last Trip Current
 Drive Stop Time

14. 14
Intelligent MCC
Simplified Hardware Wiring – By Graphic Editor in the SIMOCODE

15. 15
Intelligent MCC
Profibus Networking – Line View

16. 16
Intelligent MCC
Profibus Configuration
Each Profibus Network shall have Maximum 126 Nodes (SIMOCODES).
DCBL, Kadappa Selected Max. 60 Nodes in a Network as Internal Standard.
For Each 30 Nodes (or) the Cable Length is more than 1500 Mtr., A Profibus
Repeater is Essential
2 3 30 31 32 60Nodes
Repeater
From Processor
EndTo
Work
Station SIMOCODE
Work Station

17. 17
Intelligent MCC
Monitoring of Last Trip Current – 498% of the Motor Rated Current

18. 18
Intelligent MCC
Monitoring of Measured Values

19. 19
Intelligent MCC
Maintenance Date / Statistical Data

20. 20
Intelligent MCC
Events List

21. 21
Intelligent MCC
Control Signals /Drive Status Indications & Digital Signals Status

22. 22
Intelligent MCC
Detailed Fault & Warning Information
Faults Warnings

23. 23
Intelligent MCC
Trend View of Measuring Parameters – For Close Monitoring & Detailed
Analysis
KVA
KW
Voltage
Max. Current
L1 Current

24. 24
Intelligent MCC Motor Protection Settings

25. 25
Intelligent MCC
Merits
 Sensitive Protection to the Motors like Over Current, Unbalance, Earth Fault, Starting
Current…
 Direct Communication to DCS & Load Center Workstation by Profibus (Controlling,
Measurement & Annunciations). Hence no Instrument I/O Panel is required.
 Reduces the Commissioning Time of 3 Weeks due to no I/O Panel and its Cabling /
termination
 Online Monitoring of all Motors like Running Status, Current and Power Datas at CCR
and Load Center Workstation.
 Retrieving of motor Trip Records
 Reduced Hardware wiring and hence reduced Maintenance & Breakdowns.
 Vide Range of Feeder Components, hence reduced inventory.

26. 26
Intelligent MCC
Demerits
 High Initial Cost
 Required Air Conditioned Substation
 Required UPS Power Supply for SIMOCODE Aux. Power
 If Profibus Communication Fails, Entire MCC Feeders will be affected.
 Delayed Communication in responses / feedbacks.
 Required High Skilled Man Power

27. 27
Sl.
No.
Description
Standard
MCC
Intelligent MCC
1
Total cost of the motor control centre
in a cement project
487.00 Lacs 567.00 Lacs
2
Total cost of DCS System in complete
Cement Plant
903.00 Lacs 886.00 Lacs
A) Sub Total - I 1390.00 lac 1453.00 lac
1
Cost of cables, cable trays (from MCC
panel to I/O panel) , cable glands and
other Hardwares
43.58 7.98
B) Sub Total - II 43.58 7.98
Total (A+B) 1433.58 1460.98
Increase in Total Cost 27.4 Lacs
Intelligent MCC
Cost Benefit Analysis – Ordering Stage

28. 28
Intelligent MCC
Cost Benefit Analysis – Commissioning Stage
Sl.
No.
Description
Standard
MCC
Intelligent MCC
1
Project Execution Time for Installation,
Testing & Commissioning of MCC’s and
Plant DCS system.
75 days 45 days
2
Per day loss due to delay in Plant
commissioning @ 50% Capacity
22 Lacs
3
Loss due to delay in Plant
Commissioning as above
660 lac 0
Hence, it is recommended that we shall go with Intelligent MCC for Cement Plant,
which is not impacting the project cost but tendering significant reduction in
Execution, Commissioning, Operation and Maintenance Cost

29. 29
Intelligent MCC
Problem Faced during Commissioning
 Feedback Fault due to Delayed Communication
Problem drastically reduced by fine tuning the Execution Time & Feedback Time Settings
 Communication Error
Solved by Ensuring Earthing Connectivity of Profibus Cable Shield at all Terminals
 Failure of Digital Expansion Modules
• Solved by Connecting all Earth Terminals of SIMOCODE to separate Earth Pit
• Solved by Connecting Surge Suppressors to the Power & Control Contactor Coil
Terminal and Suppressed the Surges during Switching.
• Tested all the Digital Modules (Measured Digital Input Energizing Current) and replaced
the Defective Digital Expansion Modules


30. 30