Exercises - Overview .......................................................................................................................

2
Optional exercises ............................................................................................................................ 3
Exercise 1: Getting to know the training device ................................................................................. 4
Exercise 2: Device activities without PG/PC ..................................................................................... 7
Exercise 3: Configuring a reversing starter ...................................................................................... 9
Exercise 4: Commissioning .............................................................................................................. 14
Exercise 5: Diagnostics with SIMOCODE ES ................................................................................... 20
Exercise 6: Analog value recording .................................................................................................. 24
Exercise 7: Signal interconnection .................................................................................................... 28
Exercise 8: Extended function .......................................................................................................... 31
Exercise 9: Troubleshooting ............................................................................................................. 32
Exercise 10: Safety functions ........................................................................................................... 33
Exercise 11: Communication ............................................................................................................ 43
Exercise 12: Preventing a continuous signal ..................................................................................... 50
Exercise 13: Saving the ON state ..................................................................................................... 52
Exercise 14: Acknowledging an overload fault .................................................................................. 55
Exercise 15: Multi-functional display ................................................................................................. 57
Exercise 16: Automatic acknowledgment of overload ....................................................................... 60
Exercise 17: Limiting the number of starts ........................................................................................ 62
Exercise 18: Latching button with LED indicator ............................................................................... 63

SITRAIN 14 - 1 Course SD-SIMOPRO

Trainingsunterlage Exercises
Area of application The exercise instructions are intended for:
• A course held by an instructor
• Activities performed on special training devices

Training The training equipment is operated under laboratory conditions.

Observe the safety instructions in the exercise instructions.
In case of doubt, always ask your instructor, particularly when handling
electrical current or moving parts.

In practice The safety instructions in the relevant product documentation must be followed
at all times when working autonomously on the devices outside the training
course.
Never rely on the training documents alone.

SITRAIN 14 - 2 Course SD-SIMOPRO

Trainingsunterlage Exercises
Selection You can select whatever interests you from the following collection of exercises,
provided there is still time available.

Benefits With these exercises, you can consolidate your knowledge of signal
interconnection and the use of free function blocks.

SITRAIN 14 - 3 Course SD-SIMOPRO

Trainingsunterlage Exercises
Potentiometer The case has three potentiometers:
• The set current Is for motor current simulation is 0.5 A.
• The current can be set with potentiometer I in the range from
approx. 40 to 270 % Is.
• The thermistor is simulated using potentiometer T.
• The left endstop of the potentiometer simulates a short-circuit in the sensor
cable. By turning potentiometer T to the right, you simulate a rising
temperature.
• The voltage is simulated using potentiometer U.
The voltage can be set in the range from 0 to approx. 300 V.

Power factor The demo case has a simulation of the phase angle (cos phi).
• Depending on the current, the phase angle changes within the range from
approx. 40 % to 80 % (= 0.4 to 0.8).
• From 100 % Is, the phase angle remains constant at 80 %.
This behavior corresponds in a simplified form to the actual behavior of a three-
phase asynchronous motor: At rated load, the power factor does not change
significantly, while operation without load or with a small load can be clearly
seen from the change in cos phi.

Circuit diagram The figure on the next page shows the external wiring. This is already created in
the training configuration with the exception of the bus connection.
Please note that the changeover from left to right (and vice versa) is initially only
possible via "Off".

SITRAIN 14 - 4 Course SD-SIMOPRO

Trainingsunterlage Exercises
 A reversing starter function has already been installed in your training device.

Task Check the reversing starter function!

1. Switch the motor with the buttons of the

case (Local control station)

>> Counter-clockwise / Off / Clockwise / Off

2. Switch the motor with the buttons on the operator panel with display (OPD):

>> Counter-clockwise / Off / Clockwise / Off

SITRAIN 14 - 5 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Evaluate the operating displays on the OPD!

Switch the motor on and calculate the following values:

1. Set rated current ………………..

2. Number of overloads ………………..

3. Operating hours ………………..

4. Number of starts ………………..

5. Motor stop time ………………..

6. Motor operating hours basic unit ………………..

7. PROFIBUS address ………………..

8. PROFIBUS baud rate ………………..

9. HW revision level ………………..

10. FW revision level ………………..

SITRAIN 14 - 6 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Carry out the following activities, and find out where the points are described!

1. Set bus address 2 with the addressing plug:

Course folder: ………………..

Manual: ………………..

2. Save the program to the memory chip

Course folder: ………………..

Manual: ………………..

3. Carry out a memory reset (factory default)

Course folder: ………………..

Manual: ………………..

SITRAIN 14 - 7 Course SD-SIMOPRO

Trainingsunterlage Exercises
 4. Carry out the three hardware tests of the SIMOCODE pro basic unit!

Course folder: ………………..

Manual: ………………..

5. Transfer the program from the memory chip

Course folder: ………………..

Manual: ………………..

6. Carry out the three hardware tests of the SIMOCODE pro basic unit
(with load and without load)
- Lamps/LED test
- Device function test
- Relay test

SITRAIN 14 - 8 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Now create the device configuration.

Connect the PC cable with the system interface on the operator panel.
Start the SIMOCODE ES configuring software.

Open the file vorgabe-übung-4 in the path D:\Simocode

Save the parameter as a file (name-today's date)
under D:\Simocode\ and continue working with that.

Define the device configuration by selecting the following modules:

1. Activate the thermistor.

2. As a current measuring module, configure the module for 0.3 to 3 A.

3. Please configure the digital module 1 as monostable.

4. Activate the operator panel.

5. Activate voltage measurement.

SITRAIN 14 - 9 Course SD-SIMOPRO

Trainingsunterlage Exercises
 The aim of the exercise is to parameterize SIMOCODE pro for a simple
reversing starter application with a local control station.

Task Set the parameters for motor protection!

1. Insert the "Extended protection" block. Double-click the block and set the
following parameters:
Set current: Is = 0.5 A

2. All other parameters in this dialog are appropriately set.

3. So that you don't have to wait 300 s (default value for the cooling time) after
an overload trip in the following exercises, please change the cooling time to
the smallest possible value: 60 s.

To make these settings also visible in the graphical view, change to the graphic
editor, and drag the "Extended protection" block from the parameter tree to the
work sheet.
Do the same with the "Thermistor" block that you have already activated in the
device configuration, and check the settings.

4. Double-click on the "Thermistor" block to check the following parameters:

- Response to trip level: tripping
- Response to sensor fault (short-circuit/wire break): warning

SITRAIN 14 - 10 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Configure the device-internal connections for the contactor control:
= Assignment of connector  socket
= Assignment of block Output  Basic unit output

1. Drag & drop the BU outputs block to the work sheet:

>> Parameter tree > Outputs > BU outputs

2. Configure the following connections:

- Basic unit output 1:  Contactor control QE1 (K1, clockwise contactor)
- Basic unit output 2:  Contactor control QE2 (K2, counter-clockwise
contactor)

Note The device outputs that control the motor contactors must always be connected
to the QE outputs of the control function (Protection/Control block).
The meaning of the QE outputs (sockets) depends on the control function set.
For the assignment, please refer to Table A1 of the manual, p. A-2.

SITRAIN 14 - 11 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Configure the device-internal connections for operation

1. Drag & drop the BU Inputs block to the work sheet:

>> Parameter tree > Inputs > BU inputs

2. Configure the following connections:

- Local control station [LC] On<:  BU (basic unit) input 1
- Local control station [LC] Off:  BU (basic unit) input 2
- Local control station [LC] On>:  BU (basic unit) input 3

3. Additionally configure the operator control enable for the local [LC] control
station for the Local 2 operating mode (S1:0; S2: 1).
>> Double-click on the "Control stations" block

SITRAIN 14 - 12 Course SD-SIMOPRO

Trainingsunterlage Exercises
 The connection between the inputs of the control function (Protection/Control
block) and the outputs of the control stations (enabled control command) is
already included in the template for the reversing starter control function.

Task Check the default values of the control commands

1. Select:
>> Device parameters > Motor control > Control function
- Control commands: ON<:  Enabled control command On<
- Control commands: OFF:  Enabled control command OFF
- Control commands: ON>:  Enabled control command ON>

2. Save the parameters as a file:

>> Switching device > Save as

3. Select the following as the interface for transferring to the device:

- RS232 interface.

4. Transfer the file to the device:

>> Target System > Load to Switching Device

5. Check the parameterized function.

SITRAIN 14 - 13 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task You can also view signal flows and signal states online.
Use the online representation of SIMOCODE ES Graphic to check the
parameterized Function1

1. Go online with the SIMOCODE ES Professional software.

>> Switching device > Open online

2. Change to the view "SIMOCODE ES Graphic".

3. Activate the online representation using one of two methods:

- View > Signal flows and signal states
- Button (symbol)

SITRAIN 14 - 14 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Use the online functions of SIMOCODE ES to observe measured values of the
SIMOCODE device

1. Change to the SIMOCODE ES view.

2. Open the following online dialogs of SIMOCODE ES:

- Target System  Control/status information
- Target System  Faults/Warnings/Status Information
- Target System Measured values
- Target System  Service Data/Statistical Data

3. Arrange the window in such a way that you can see all the information at the
same time.

4. Start the motor using the pushbutton of the Local control station.

5. Observe the status messages in the window

"Control / Status messages"

6. Observe the motor current in the window "Measured values"

SITRAIN 14 - 15 Course SD-SIMOPRO

Trainingsunterlage Exercises
 7. Use the potentiometer to set the maximum current Imax for current
simulation to approx. 100 %.

8. Observe the power factor cos phi and the power dependent on the current.

9. Switch the motor off and then on again in the opposite direction.

10. Observe the start counter in the window "Service Data / Statistical Data"

11. Increase the motor current to slightly more than 115 %.

12. Observe the displays in the window "Control / Status messages" and
"Control/Status messages" > "Warnings" tab:
- General warning
- Prewarning overload (I>115 %)

SITRAIN 14 - 16 Course SD-SIMOPRO

Trainingsunterlage Exercises
 The information displayed online with SIMOCODE ES is also available on the
operator panel with display (OPD) completely without additional software.

Task Observe the information in the operating display

1. Select Status messages in the menu "Status".

2. Observe the motor current in the menu "Measured values".

3. Use the potentiometer to set the rated current for current simulation to
approx. 100 %.

4. Observe the power factor cos phi and the power dependent on the current.

5. Switch the motor off and then on again in the opposite direction.

6. Observe the start counter in the window "Statistics / Maintenance"

SITRAIN 14 - 17 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Simulate the faults and observe the operating display

1. Increase the motor current further to approx. 150 % and observe in the
window "Measured values" the value "Time to trip".
After expiry of this time, the motor switches off with a general fault.
2. Determine the cause of the shutdown.
3. Acknowledge the fault with the blue "TEST / RESET" button on the basic
unit.
4. Observe the LED "GEN. FAULT".
Continuous light means: Fault acknowledged but still active.
5. After an overload trip, the motor must cool down before you can switch it on
again.
Observe the remaining cooling time in the window Measured values, and
wait for this time.
6. Switch on the motor again.
7. Increase the temperature by turning the potentiometer T clockwise until the
motor is switched off with a general fault.
8. Determine the cause of the shutdown.
9. To do so, use the operator panel with display, and acknowledge on the
operator panel.
10. Reduce the temperature by turning the potentiometer T counter-clockwise
until the LED "GEN. FAULT" goes out.
The motor is now cooled.
11. Now turn the potentiometer T to the left endstop, and simulate in this way a
short-circuit in the sensor cable of the thermistor.
12. Observe the display in the window:
>> Faults/ warnings / status information > Warnings tab

SITRAIN 14 - 18 Course SD-SIMOPRO

Trainingsunterlage Exercises
 In the online dialog "Service Data / Statistics Data" you can not only find out the
current counter states, you can also set them to any values.

Task Reset the following values because, for example, the motor or the contactor has
been replaced

1. Enter the new values in the white input fields.

Operating hours motor:

The replaced motor has already been in operation for 1580 hours

Reset number of overload trips:

This provides information on the dimensioning and fault susceptibility of the
motor feeder. Set to "0" when the motor is re-installed.

Number of starts:
Set to "0" when installing new contactors or contact elements.

2. Transfer the new values to the device by clicking the "Set" button.

SITRAIN 14 - 19 Course SD-SIMOPRO

Trainingsunterlage Exercises
 9. Now actuate a contactor mechanically.
10. Which fault is displayed?

……….……….……….……….….……….……….……….……….……….
11. Acknowledge the fault.
Where do you find information in the manual? ………………..

12. Switch the motor on (e.g. counter-clockwise)

13. Now simulate a welded contactor by blocking it mechanically.

Switch the motor off while you keep the contactor blocked.
14. Which fault is displayed?

……….……….………….……….……….……….……….……….……….
15. Acknowledge the fault.
Where do you find information in the manual? ………………..

16. Now switch the motor on in the opposite direction (e.g. clockwise) while you
keep the counter-clockwise contactor blocked.
17. What do you find? Why does SIMOCODE pro not switch the clockwise
contactor on?
……….……….………….……….……….……….……….……….……….

SITRAIN 14 - 20 Course SD-SIMOPRO

Trainingsunterlage Exercises
 SIMOCODE pro has a test function with which the status of any outputs and
inputs of function blocks can be tested.

Task Set and read the inputs and outputs with the test function.

1. Open the following online dialog of SIMOCODE ES:

>> Target System > Test

2. Under "Read function block output", select, for example, the buttons of the
operator panel, and observe their current status.

3. Under "Read and set function block input", select, for example, the outputs
of the basic unit and observe their status.

Note Please note that what is meant here are outputs and inputs of blocks
(= functions), and not outputs or inputs of the SIMOCODE device.
Examples:
• An output of the basic unit (BU output) is
an input of a block (in other words, a "plug")
• A button of the operator panel (OP button) is
an output of a block (in other words, a "socket").

SITRAIN 14 - 21 Course SD-SIMOPRO

Trainingsunterlage Exercises
 The inputs of function blocks (and thus, for example, the outputs of the basic
unit) can also be set under certain conditions.
In the PLC world, this is known as "forcing" or "modifying" variables.
However, because switching a SIMOCODE pro relay output can result, for
example, in a motor being switched on, this function is only available in the "test
position".
This is defined via "test position feedback" (TPF), in other words, it is only
possible when the main circuit is open. The TPF function is already defined in
SIMOCODE pro as a standard function.

Task Set the outputs of a function block using Test position feedback (TPF).

1. Drag & drop the "TPF" block to the work sheet:

>> Parameter tree > Standard functions > TPF

2. Connect the input with "fixed level – 1".

3. Open the main circuit by switching the circuit breaker off so that no current
can flow as a result of switching on the contactor.

4. Set output 1 of the basic unit in the online dialog "Test".

5. Then deactivate the standard function TPF again by deleting the TPF block.

SITRAIN 14 - 22 Course SD-SIMOPRO

Trainingsunterlage Exercises
 SIMOCODE pro has an error buffer in the device in which the last
20 faults are saved with a time stamp.
The time stamp specifies a relative time and refers to the operating hours of the
device.
The event "power-on" is also logged. It is thus possible to specify the fault event
in relative terms following the last power-on.

Task Work with the error buffer with SIMOCODE ES and with the operator panel.

1. Open the following online dialog of SIMOCODE ES:

>> Target System > Error buffer/error protocol

2. Check the last entries from the previous exercises.

3. To check the entries use the "Error buffer" menu in the operator panel with
display.

SITRAIN 14 - 23 Course SD-SIMOPRO

Trainingsunterlage Exercises
 SIMOCODE pro V offers a function integrated into the device for recording
analog values.
With this function, up to 60 values of an analog variable available in the device
(e.g. max. motor current) can be recorded with an adjustable sampling rate and
saved in the device.

Task To enable use of analog value recording, it must be configured with

SIMOCODE ES.
1. Select the following in the parameter tree of the graphic editor:
>> Device parameters > Analog value recording > Block Record.

2. Connect the assigned analog value with the maximum motor current, for
example.

3. Connect the trigger input with the output of the block, for example:
Extended protection > Prewarning "Overload > 115 %"

4. Set the sampling rate to 0.5 s.

With this setting, 60 x 0.5 s = 30 s can be recorded.

5. If you also want to record values before the trigger event occurs, set the
parameter Pre-Trigger accordingly:
e.g. 25 %, which would be 7.5 s here.

6. Transfer the parameterization to the device:

>> Target System >> Load to Switching Device

SITRAIN 14 - 24 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Test analog value recording.

1. Switch the motor on and set the current to approx. 100 %.

2. Now go online with the SIMOCODE ES Professional software:

>> Switching Device > Open Online

3. Open the online dialog of SIMOCODE ES:

>> Target System> Analog value recording

4. Now increase the motor current slowly and observe the trigger display in the
window.

5. The trigger signal Prewarning overload > 115 % starts analog value
recording. From this point, the course over time of the max. motor current is
recorded for 30 s.
Change the motor current within this time.

6. You can read out the values recorded in the device at any time. This is done
with:
>> Upload values

7. With Save, the recorded values can be exported to a .csv file that can then
be further edited with Microsoft Excel, for example.

SITRAIN 14 - 25 Course SD-SIMOPRO

Trainingsunterlage Exercises
 With the SIMOCODE ES online function "Trend display", up to five analog
values can be represented over a period of up to 15 min. in a y-t diagram.
With this trend display, it is thus possible, for example, to record and evaluate
the start-up characteristic of a motor or its behavior under different load
conditions.

Task Record the most important signals with the trend display.

1. Go online with SIMOCODE ES

>> Switching Device > Open Online

2. Select the function

>> Target System > Trend Display

3. Use the "Selection" button to define which analog measured values are to be
represented in the y-t diagram, e.g.,
- Current Imax
- Thermal motor model
- Time to trip
- Voltage UL1
- Active power

Note Please note that the data are only recorded in the software and not in the
device.

SITRAIN 14 - 26 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Scale the trend display to obtain a better overview.

1. Define the range by double-clicking the relevant Y scale:

- Current Imax of 0... 200 %
- Thermal motor model from 0... 100 %
- Time to trip 0... 60s
- Voltage UL1 0... 300V
- Active power 0... 2kW

2. Define a range of 5 mins, for example, by double-clicking the time scale.

3. Now switch the motor on, and increase the motor current with the
potentiometer I, so that a trip due to overload results.

4. Observe the course of the curve.

SITRAIN 14 - 27 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Create an internal signal interconnection for controlling the LEDs.
The aim is to display the state of the motor (on, off) via the lamps in the
illuminated pushbuttons and on the LEDs of the operator panel.
Control of the lamps in the pushbuttons of the local control station:

1. Connect the output of the basic unit:

- BU output 3:  Display output (Protection/Control block)
QLE< (H1)
All outputs of the basic unit are now wired.

2. Wire the outputs of digital module 1

- DM output 1:  Display QLA (H2)
- DM output 2:  Display QLE>(H3)

3. Configure the green LEDs of the operator panel as follows:

Outputs  operator panel LEDs
- LED green 2:  Display QLE< (counter-clockwise)
- LED green 3:  Display QLE> (clockwise)
- LED green 4:  Display QLA (Off)

SITRAIN 14 - 28 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Extend your configuration to the control station operator panel.
Use signal interconnection to the buttons of the operator panel for this purpose

1. Wire the buttons of the operator panel as follows:

- Control station operator panel [OP] ON<:  OP (operator panel) button 2
- Control station operator panel [OP] OFF:  OP (operator panel) button 4
- Control station operator panel [OP] ON>:  OP (operator panel) button 3

2. Now configure the operator control enable for the operator panel [OP]
control station for the Local 2 operating mode (S1:0; S2: 1).

Note If you are connected to the SIMOCODE pro system interface via the PC cable,
you can use the operator control enable for the operator panel to also
simultaneously activate the buttons for switching the motor on and off in the
online dialog:
>> Target System > Control / status information

SITRAIN 14 - 29 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Save your parameterization and test the function.

1. Save the parameters as a file:

>> Switching Device > Save as

2. Transfer the file to the device:

>> Target System > Load to Switching Device

3. Check the parameterized function.

To do so, use the online representation of the signal states in SIMOCODE
ES Graphic.

4. Then program the memory module with the current device parameters.

5. Remove the memory module again and carry out memory reset.

6. Now read the memory module in again, and check the function.

SITRAIN 14 - 30 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Extend your program as follows:
In the case of a thermal overload trip, the thermal memory must be cleared via
button 1 of the operator panel.
The thermal memory can be cleared with the function "Emergency start".

1. Find out where the function description can be found in the manual:

……….….……….……….……….……….……….……….……….……….

2. With which function can button 1 of the operator panel be found:

……….….……….……….……….……….……….……….……….……….

3. Save the previous parameterization as a file under:

>> D:\Simocode\übung-8-0 "Today's date"
Continue working with this.

4. Parameterize the function expansion:

5. Save your parameter assignments.

6. Test the function.

SITRAIN 14 - 31 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Find the error in an existing parameterization.
You will find the correct project on your training PC.

1. Open the file "Übung-5" in the path D:\Simocode and download this to your
device.
Save the parameters as a file (Übung-9-0 Today's date) under D:\Simocode\
and establish the function in accordance with Exercise 8.
2. What status display appeared on the device?

……….………….……….……….……….……….……….……….……….

3. With which function do you find the cause of the fault?

……….………….……….……….……….……….……….……….……….

4. What is the cause of the fault?

……….………….……….……….……….……….……….……….……….

5. Which function do you use to find the fault?

……….….……….……….……….……….……….……….……….……….

6. How can you correct the fault?

………….……….……….……….……….……….……….……….……….

………….……….……….……….……….……….……….……….……….

SITRAIN 14 - 32 Course SD-SIMOPRO

Trainingsunterlage Exercises
Training device The demo case "Direct starter with EMERGENCY STOP SIL 3 / PL e" enables
simple understanding of the fundamental SIMOCODE pro safety function with
the DM-F Local fail-safe digital module.
The set current Is for motor current simulation is 0.5 A.

Sequence For this motor feeder, you will create the parameterization in the following.

Circuit diagram The figure below shows the external wiring as found in the training
configuration.

SITRAIN 14 - 33 Course SD-SIMOPRO

Trainingsunterlage Exercises
SITRAIN 14 - 34 Course SD-SIMOPRO
Trainingsunterlage Exercises
Task Load the prepared parameterization "Safety engineering application".

1. Connect the PC cable with the system interface on the operator panel and
with the serial interface of the PC.

2. Start the SIMOCODE ES configuring software.

3. In the application selection dialog, select the tab "Safety engineering" and
then the application Direct starter (DM-F Local).

Note When the application is selected, a series of connections and parameters are
already preset.
Example:
• The inputs of the control stations are connected with the inputs of the basic
unit and the operator panel.
• The contactor control is connected with the output of the DM-F.

SITRAIN 14 - 35 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Now define the device configuration if this has not already been set by the pre-
selection.
Select the following modules for this purpose.

1. As a current measuring module, configure the module for 0.3 to 3 A.

2. Configure digital module 1 as DM-F LOCAL

3. Activate the operator panel.

4. Activate voltage measurement.

5. Define the parameters for motor protection.

Enter a set current of 0.5 A.
All other settings have already been appropriately preset.

SITRAIN 14 - 36 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Configure the signal flow with the "Graphic Editor".

1. Start the Graphic Editor by double-clicking the entry in the parameter tree.

2. Look at the representation of the digital module.

From the perspective of SIMOCODE ES, the fail-safe digital module DM-F
Local has the following inputs and outputs:
- 2 relay outputs
- 6 inputs

SITRAIN 14 - 37 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Ensure the QE outputs of the "Protection/Control" block are connected with
the relay outputs of the DM-F module that are shut down in a fail-safe
manner.
The relays represented in SIMOCODE-ES are not themselves the fail-safe
relay enabling circuits, but they are shut down by these circuits in a fail-safe
manner.

Notes Please note that the contactors that are to be shut down in a fail-safe manner
must always be connected to the DM-F.
This is ensured with your demo case.

Please note that with SIMOCODE ES no parameters are set in a safety-related

sense.
The fail-safe relay enabling circuits of the DM-F module are not represented in
SIMOCODE ES since their functionality is not configured here.

SITRAIN 14 - 38 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Configure the response of the SIMOCODE pro control function in the case of
safe shutdown!

1. Plan the setting of the safety relay function by creating the following target
configuration with SIMOCODE ES:
 EMERGENCY OFF sensor (2-channel with 2 NC contacts)
 Cross-circuit monitoring of the sensor circuit
 Sensor circuit with monitored start
 No checking of the sensors following power failure
 No automatic connection of the enabling circuits following power failure

2. Transfer the parameterization to the device.

SITRAIN 14 - 39 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Now set the pre-selection made as the target configuration via the DIP
switches of the DM-F LOCAL.

4. Check whether the planned configuration agrees with the effective

configuration.

If this is not the case, you can find the appropriate information under:
>> Target system > Faults / warnings / status information > Status
information tab

Note Regardless of the settings that can be configured with SIMOCODE ES, the
relay enabling circuits and relay outputs of the DM-F module are always
switched off when the safety function is requested.
The setting "Response: tripping" results in SIMOCODE pro shutting down
the QE outputs and displaying a general fault.

SITRAIN 14 - 40 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Check your set safety function.

1. Unlatch the EMERGENCY STOP

2. Switch on the incoming supply contactor.

3. Observe the state with the inputs and outputs of the DM-F with SIMOCODE
ES Online:
>> Target System > Hardware inputs and outputs

4. Switch on the motor for normal operation.

5. Actuate the EMERGENCY STOP.

6. Observe the state with the inputs and outputs of the DM-F with SIMOCODE
ES online:
>> Target System > Hardware inputs and outputs

7. Observe the LED indicators and the display of the operator panel.

8. Restore the initial state (motor running).

SITRAIN 14 - 41 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task A welded motor contactor represents a typical fault. Simulate the behavior.

1. Simulate a welded motor contactor by placing the Control Kit (yellow plastic
part) on the motor contactor.

2. Now switch off normally (button 0).

What do you observe?

……….………….……….……….……….……….……….……….……….
3. Now actuate the EMERGENCY STOP button to shut down the motor.

4. Again observe the state with the inputs and outputs of the DM-F with
SIMOCODE ES online:
>> Target System > Hardware inputs and outputs

5. Observe the LED indicators and the display of the operator panel.

6. Try to switch the motor on again (with blocked motor contactor).

What do you observe?

……….………….……….……….……….……….……….……….……….
7. Why can the enabling circuits not be closed while the motor contactor is
welded?

……….………….……….……….……….……….……….……….……….

SITRAIN 14 - 42 Course SD-SIMOPRO

Trainingsunterlage Exercises
 Precondition for that SIMOCODE pro can communicate with a PLC or a PC
(e.g. SIMOCODE ES Professional) via PROFIBUS DP is a unique PROFIBUS
address in the PROFIBUS network.

Task Connect all training devices like shown in the plan.

Change the bus address of your training device according to the plan.
Commissioning of the bus.
Parameterization of the cyclic data exchange.
Commissioning and test by means of RT-Visualization with WinCC Flexible.
Settings for the faulty behavior

SITRAIN 14 - 43 Course SD-SIMOPRO

Trainingsunterlage Exercises
 A PROFIBUS address that is unique PROFIBUS-wide is required for
SIMOCODE pro to be able to communicate with a PLC or PC (e.g. SIMOCODE
ES Professional) via PROFIBUS DP.

Task Change the default address 126 for this purpose.

1. Open the SIMOCODE pro parameter file from the previous exercise, or read
out the parameters from the device online.

2. Agree your bus address with the other course participants to avoid
duplication of addresses.

3. Parameterize a bus address with SIMOCODE ES (in the example 3, 4, 5, 6

or 7):
>> Device parameters > Bus parameters

SITRAIN 14 - 44 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task As an exercise, please re-establish the connections!

1. Establish the connection to the cyclic receive data.

Begin with the PLC/PCS control station under:
>> Device parameters > Motor controller > Control stations
- Control station PLC/PCS[DP] ON<:  Cycl. receive – bit
0.0
- Control station PLC/PCS[DP] OFF:  Cycl. receive – bit
0.1
- Control station PLC/PCS[DP] ON>:  Cycl. receive – bit
0.2

2. Remember here also the operator control enables for this PLC/PCS control
station.
Enable switching on and off in remote mode (S1=1; S2=2).

SITRAIN 14 - 45 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Establish the connection of the standard functions:
>> Other function blocks > Standard functions
- Test 1:  Cycl. receive – bit 0.3
- Reset 1:  Cycl. receive – bit 0.6
- Emergency start:  Cycl. receive – bit 0.4

4. Save the changes and transfer the parameters to the device.

5. Allow SIMOCODE pro to be controlled via the PLC, and test the functions.

SITRAIN 14 - 46 Course SD-SIMOPRO

Trainingsunterlage Exercises
 The start-up parameter block prevents the currently set device parameters
being overwritten during start-up with any parameters that may be saved in a
PLC.
If, on the other hand, SIMOCODE pro parameters saved in the PLC are to
become effective at start-up, the parameter block must not be set.

Task In the example, the parameterization is not to be used at start-up.

1. Activate the start-up parameter block.

2. Save the changes and transfer the parameters to the device.

3. Check that communication with the PLC is functional.

- If this is the case, the "BUS" LED on the basic unit or operator panel
shows a green light.
- If, on the other hand, the "BUS" LED flashes, this means the data transfer
rate has been detected on the bus, but there is no communication with
the PLC (DP master class 1).
- If the "BUS" LED remains dark, there is no connection to a DP master.

SITRAIN 14 - 47 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task 1. Check if the communication with the SPS works and watch the der LED
„BUS“ at basic unit
- In this case the LED „BUS“ at the basic unit or operator panel is
illuminated green.
- Is the LED „BUS“ blinking, so the transmission rate at the bus is
recognized, but there is no communication with the PLC (DM Master
<<class 1).
- Stays the LED „BUS“ dark, there is no connectivity to any DP Master.

2. Select at the Engineering station from the overview picture your training
device and check the function

SITRAIN 14 - 48 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task Define the response of the device in the event of a fault.
How SIMOCODE pro is to respond in "Remote" mode (mode selector switch
S1=1, S2=1) to the failure of PROFIBUS DP communication with a PLC, or to
the "STOP" state of a PLC.

1. Select the following dialog:

>> Standard functions > Watchdog

2. Define the response to "Monitoring bus":

- Active:
If communication with a PLC fails, SIMOCODE pro switches off a running
drive.
- Not active:
Failure of communication with a PLC has no effect on the switching state
of the drive.

3. Define the response to "Monitoring PLC/PCS":

- Active:
At the transition of the PLC to the "STOP" state, SIMOCODE pro
switches off a running drive.
- Not active:
Transition of the PLC to the "STOP" state has no effect on the switching
state of the drive.
- PLC/PCS monitoring input:
Connection of this input is only necessary for DP masters that do not
change PROFIBUS to the "clear" state at the transition to the "STOP"
state. Otherwise, connect a DP output of the PLC (e.g. Cycl. receive – bit
0.7).

SITRAIN 14 - 49 Course SD-SIMOPRO

Trainingsunterlage Exercises
 An external continuous signal can be unfavorable for different applications. It is
usually preferable to work with pulse signals.

Task Convert an active continuous signal to a pulse signal.

1. Which block is suitable for generating a pulse?

……….….……….……….……….……….……….……….……….……….

2. Interconnect the block with:

- ON control station block
- Protection / Control block

3. Parameterize the block:

……….….……….……….……….……….……….……….……….……….

SITRAIN 14 - 50 Course SD-SIMOPRO

Trainingsunterlage Exercises
 4. Also interconnect the feedback signal with another block for signal
conditioning.

5. Check the functioning of your interconnection.

SITRAIN 14 - 51 Course SD-SIMOPRO

Trainingsunterlage Exercises
 In many cases, the motor needs to return to the former operating state following
power failure or deliberate interruption.

Task How can the device be made to return to the previous operating state following
failure and restoration of the control voltage of the motor feeder?
In addition, it must also be possible to reset the saved state using the OFF
command and the general fault.

1. First, carry out signal conditioning.

2. Which blocks are suitable for saving a state?

……….….……….……….……….……….……….……….……….………

SITRAIN 14 - 52 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Connect the non-volatile elements with the ON commands.

4. Parameterize the blocks.

SITRAIN 14 - 53 Course SD-SIMOPRO

Trainingsunterlage Exercises
 5. Which block is suitable for differentiating different states?

……….……….……….…………….……….……….……….……….………

6. Insert this block into the signal flow for the OFF signal.

7. Set the suitable binary coding.

The ON commands ON< and ON> must be reset in the case of:
- OFF command
- General fault

8. Check the functioning of your circuit

SITRAIN 14 - 54 Course SD-SIMOPRO

Trainingsunterlage Exercises
 In many cases, only individual faults are to be selectively acknowledged, while
other faults are to remain active.

Task How can you ensure that only the blue reset button can be used to acknowledge
a subsequent fault?
Overload and / or thermistor

1. First, find out which reset options are available:

……….….……….……….……….……….……….……….……….………

……….….……….……….……….……….……….……….……….………

2. Where are the inputs?

……….…………….……….……….……….……….……….……….………

……….….……….……….……….……….……….……….……….………

3. Which blocks are suitable for differentiating different states?

……….…………….……….……….……….……….……….……….………

SITRAIN 14 - 55 Course SD-SIMOPRO

Trainingsunterlage Exercises
 4. Insert these blocks into the signal flow for the reset signal.

5. Set the appropriate binary coding for both blocks.

6. Check the functioning of your circuit

SITRAIN 14 - 56 Course SD-SIMOPRO

Trainingsunterlage Exercises
 For the operator of a plant, an approximate representation of the motor load, for
example, can be useful.

Task The motor current Is is to be represented via an LED:

• Up to 80 % flashing
• Up to 120 % continuous signal
• More than 120 % flickering
Parameterize the signal interconnection

SITRAIN 14 - 57 Course SD-SIMOPRO

Trainingsunterlage Exercises
 1. Insert the required input and output blocks:
- For the LEDs of the operator panel
- For flashing
- For flickering

2. Insert a truth table, and connect the signals.

SITRAIN 14 - 58 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Complete the truth table

4. Check the functioning of your circuit

SITRAIN 14 - 59 Course SD-SIMOPRO

Trainingsunterlage Exercises
 Different responses are required in practice, above all to the "overload" fault.
For example, it has to be possible to acknowledge a one-off overload
immediately, while a frequent overload shall result in a normal response with
waiting time.

Task One overload trip per hour (5 minutes in the example) is to be automatically
acknowledged by the SIMOCODE device immediately
If an overload occurs again within one hour, the cooling time must be allowed to
elapse. Only then can the Reset button be used to acknowledge.
Parameterize the signal interconnection

1. Which blocks do you require?

……….…………….……….……….……….……….……….……….………

……….…………….……….……….……….……….……….……….………

……….…………….……….……….……….……….……….……….………

2. Interconnect the blocks.

SITRAIN 14 - 60 Course SD-SIMOPRO

Trainingsunterlage Exercises
 3. Parameterize the counter

4. Parameterize the truth table

5. Check the functioning of your circuit

SITRAIN 14 - 61 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task The number of permissible starts within a time period must be limited:
• Time period: 1min
• Number of starts: 5
Further starts must not be possible until the time has expired.
The LEDs of the operator panel are to indicate whether another start is
permissible and when the number of permissible starts has been exceeded.
Parameterize the signal interconnection

1. Which block is suitable here?

……….….……….……….……….……….……….……….……….………

2. Parameterize the status monitoring block:

- Time range
- Response to overshoot
- Interlocking time

3. Connect the outputs to the LEDs of the operator panel.

4. Check the functioning of your circuit

SITRAIN 14 - 62 Course SD-SIMOPRO

Trainingsunterlage Exercises
Task A button of the operator panel is to have a "latching" effect:
1st time pressed: ON
2nd time pressed: OFF
Parameterize the signal interconnection

1. Which blocks do you require?

……….….……….……….……….……….……….……….……….………

……….….……….……….……….……….……….……….……….………

……….….……….……….……….……….……….……….……….………

SITRAIN 14 - 63 Course SD-SIMOPRO

Trainingsunterlage Exercises
 2. Carry out signal conditioning for "1st time pressed":
The LED is switched on.

3. Connect the input of signal conditioner 4 with button 1 of the operator panel.

SITRAIN 14 - 64 Course SD-SIMOPRO

Trainingsunterlage Exercises
 4. Connect the green 1 LED of the operator panel with the output of signal
conditioner 4

5. Parameterize the type of signal conditioner 4: Edge rising with memory

SITRAIN 14 - 65 Course SD-SIMOPRO

Trainingsunterlage Exercises
 6. Use counter 2 to count the actuations of button 1

SITRAIN 14 - 66 Course SD-SIMOPRO

Trainingsunterlage Exercises
 7. Connect the input + of counter 2 with button 1 of the operator panel.

8. Set the limit value of counter 2 to 2.

SITRAIN 14 - 67 Course SD-SIMOPRO

Trainingsunterlage Exercises
 9. Now carry out the parameterization so that following the 2nd actuation of
button 1 of the operator panel, signal conditioner 4 and counter 2 are reset.

10. Finally, check the functioning of your circuit.

SITRAIN 14 - 68 Course SD-SIMOPRO

Trainingsunterlage Exercises