AUMA SIMA 2 User manual

Control
Profibus DP
→Modbus RTU
SIMA² Master Station
for AUMA actuator controls
MODBUS RTU and MODBUS Loop
with
MODBUS RTU, MODBUS TCP/IP to DCS
Montage und InbetriebnahmeOperation instructions

Read operation instructions first.
●Observe safety instructions.
●These operation instructions are part of the product.
●Store operation instructions during product life.
●Pass on instructions to any subsequent user or owner of the product.
Target group:
This document contains information for assembly, commissioning and maintenance staff.
Reference documents:
Manual (Device integration) SIMA²
Reference documents can be downloaded from the Internet (www.auma.com) or ordered directly from AUMA
(refer to Addresses).
Table of contents Page
41. Safety instructions................................................................................................................. 41.1. Basic information on safety 41.2. Range of application 51.3. Warnings and notes / symbols and text design
62. Identification........................................................................................................................... 62.1. Important terms (terminology) 92.2. Name plate 102.3. Short description
123. Transport, storage and packaging........................................................................................ 123.1. Transport 123.2. Storage 123.3. Packaging
134. Assembly................................................................................................................................ 134.1. Notes for installation 134.2. Dimensions 164.3. SIMA² system components
175. Electrical connection and fieldbus connection................................................................... 175.1. Electrical connection 175.2. Earth connection 175.3. Shield connection 175.4. Lightning protection 185.5. Interface and communication to the actuators via Modbus RTU 195.6. Interface to the distributed control system 195.7. Fieldbus cable specifications 195.8. Redundancy change-over
206. System configuration............................................................................................................. 206.1. Settings
217. Indications.............................................................................................................................. 217.1. Indications on the housing 227.2. Indications on the system components
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SIMA² Master Station
Table of contents MODBUS RTU, MODBUS TCP/IP to DCS

268. Commissioning...................................................................................................................... 268.1. User level 268.2. Actuator status 278.3. Time synchronisation 278.4. Configuration
319. Servicing and maintenance................................................................................................... 319.1. Lithium battery
3310. Technical data......................................................................................................................... 3310.1. Technical data SIMA² Master Station
3811. Certificates.............................................................................................................................. 3811.1. EU Declaration of Conformity
39Index........................................................................................................................................
41Addresses...............................................................................................................................
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Table of contents

1. Safety instructions
1.1. Basic information on safety
Standards/directives Our products are designed and manufactured in compliance with recognised
standards and directives.This is certified in a Declaration of Incorporation and an
EU Declaration of Conformity.
The end user or the contractor must ensure that all legal requirements, directives,
guidelines, national regulations and recommendations with respect to assembly,
electrical connection, commissioning and operation are met at the place of installation.
They include among others applicable configuration guidelines for digital
communication interfaces.
Safetyinstructions/warn-
ings All personnel working with this device must be familiar with the safety and warning
instructions in this manual and observe the instructions given. Safety instructions
and warning signs on the device must be observed to avoid personal injury or property
damage.
Qualification of staff Assembly, electrical connection, commissioning, operation, and maintenance must
be carried out by suitably qualified personnel authorised by the end user or contractor
of the plant only.
Prior to working on this product, the staff must have thoroughly read and understood
these instructions and, furthermore, know and observe officially recognised rules
regarding occupational health and safety.
Commissioning Prior to commissioning, it is important to check that all settings meet the requirements
of the application. Incorrect settings might present a danger to the application, e.g.
cause damage to the valve or the installation.The manufacturer will not be held
liable for any consequential damage. Such risk lies entirely with the user.
Operation Prerequisites for safe and smooth operation:
●Correct transport, proper storage, mounting and installation, as well as careful
commissioning.
●Only operate the device if it is in perfect condition while observing these instruc-
tions.
●Immediately report any faults and damage and allow for corrective measures.
●Observe recognised rules for occupational health and safety.
●Observe national regulations.
●The housing heats up during operation.The ventilation slots must not be covered
to ensure sufficient air circulation.
Protective measures The end user or the contractor are responsible for implementing required protective
measures on site, such as enclosures, barriers, or personal protective equipment
for the staff.
Maintenance To ensure safe device operation, the maintenance instructions included in this manual
must be observed.
Any device modification requires prior consent of the manufacturer.
1.2. Range of application
SIMA² controls the complete fieldbus communication with AUMA actuators.Availability
of fieldbus communication to the actuators can be considerably increased thanks to
manifold redundancy options. All these redundancy options are monitored during
running operation by SIMA² thanks to efficient troubleshooting mechanisms allowing
to introduce countermeasures if required and to automatically switch without delay
to alternative communication channels or communication systems. Operation of
other field devices or actuators require projecting and must be agreed with AUMA.
SIMA² is appropriate for control and supervision of AUMA actuators with Modbus
RTU interface.
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SIMA² Master Station
Safety instructions MODBUS RTU, MODBUS TCP/IP to DCS

Other (software) applications using SIMA² require explicit (written) confirmation by
the manufacturer.
No liability can be assumed for inappropriate or unintended use.
Observance of these operation instructions is considered as part of the device's
designated use.
1.3. Warnings and notes / symbols and text design
Warnings and notes
The following warnings draw special attention to safety-relevant procedures in these
operation instructions, each marked by the appropriate signal word (DANGER,
WARNING, CAUTION, NOTICE).
Indicates an imminently hazardous situation with a high level of risk. Failure
to observe this warning results in death or serious injury.
Indicates a potentially hazardous situation with a medium level of risk.Failure
to observe this warning could result in death or serious injury.
Indicates a potentially hazardous situation with a low level of risk. Failure to
observe this warning could result in minor or moderate injury. May also be
used with property damage.
Potentially hazardous situation. Failure to observe this warning could result
in property damage. Is not used for personal injury.
Arrangement and typographic structure of the warnings
Type of hazard and respective source!
Possible consequence(s) in case of non-observance (option)
→Measures to avoid the danger
→Further measure(s)
Safety alert symbol warns of a potential personal injury hazard.
The signal word (here: DANGER) indicates the level of hazard.
Symbols and further notes in the text
The following references and symbols are used in these instructions:
Information The term Information preceding the text indicates important notes and information.
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Safety instructions

2. Identification
2.1. Important terms (terminology)
This chapter includes the key terms and the terminology required for the basic
understanding of SIMA² installations.All other terms are explained in the respective
chapters.
Information The simplified term SIMA² is used to refer to the SIMA² Master Station.
SIMA² Master Station The SIMA² Master Station communicates to the field actuators using a standardised
fieldbus protocol.This protocol is used by SIMA² to transmit the respective operation
commands to the connected actuators.In turn, they send their respective status
signals to the SIMA² at cyclic intervals. Both actuator signals and diagnostic
information of SIMA² and the used communication interfaces are visualised by means
of an integrated web server and the multi-touchscreen at SIMA².
Generally, SIMA² communicates via a standardised communication protocol with a
host receiving all essential status signals and issuing the operation commands to
SIMA² for transmission to the individual actuators.Both, communication to actuators
and communication to the host can be arranged in redundant topology. In addition,
the SIMA² Master Station as such can be arranged in redundant topology. For more
details, please refer to hot standby system redundancy.
SIMA² Master Station offers easy, fast and detailed diagnostics of all connected
actuator interfaces as well as self-diagnostics.SIMA² further allows data concentration
of actuator feedback signals to relieve the host, a stand-alone mode as well as
protocol conversion and manages all redundancy properties.
Depending on the configuration, SIMA² Master Station is composed of one or two
SIMA² subsystems.Up to 4 networks are possible for each SIMA².
Figure 1: Single Master Station
SIMA² subsystem Typically, a SIMA² subsystem consists of a power supply unit, a multi-touchscreen,
CPU and the interfaces required for communication to the actuators and to the host.
For hot standby system redundancy, two separate SIMA² subsystems are used.The
versionwithout hotstandbysystem redundancy onlyconsistsofoneSIMA² subsystem
and is also named single master station.
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SIMA² Master Station
Identification MODBUS RTU, MODBUS TCP/IP to DCS

Hot standby
System redundancy If two SIMA² subsystems are jointly operated, this redundant configuration is
designated as hot standby system redundancy. Both SIMA² subsystems can either
be located in a joint housing or in two separate housings.
In this version, both SIMA² subsystems are identified by SIMA A or SIMA B.Each
of these two SIMA² subsystems functions completely independently of the other
subsystem, since each system is equipped with an own power supply as well as
separate multi-touchscreens.
In standard operation, SIMA A always adopts system control while SIMA B is working
in standby mode, continuously monitoring the overall system. If SIMA A fails, SIMA
B takes over control and thus ensures the complete function including the
communication to the actuators and the host.
When selecting the configuration with separate housings, up to four loops are
supported. In turn, the configuration with one joint housing only supports one loop.
Figure 2: Hot standby system redundancy in separate housings (example)
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Identification

Figure 3: Hot standby system redundancy in a joint housing (example)
Single Master Station SIMA² in non-redundant version with only one SIMA² subsystem for fieldbus
communication.Controls of a Single Master Station are always located on the left
side, whereby the multi-touchscreen is located on the right side of the housing.
SIMA A / SIMA B SIMA A or SIMA B is a clear designation of both physical subsystems when SIMA²
is arranged in hot standby system redundancy.
Host Superordinate automation system. Also referred to as DCS or SCADA.
In sites without superordinate automation system (host), SIMA² is deployed in the
so-called stand-alone mode.
Stand-alone mode Application of SIMA² without host.Operation commands for the actuators are specified
manually by the user either via the multi-touchscreen or via the integral web server.
Status or diagnostic signals of actuators are visually monitored by the user.
Figure 4: Stand-alone mode (example)
Loop redundancy A fieldbus cable is led from the SIMA² to the first actuator and then to the next actuator
until reaching the last actuator and back to SIMA², thus arranged in loop configuration.
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SIMA² Master Station
Identification MODBUS RTU, MODBUS TCP/IP to DCS

In case of interruption or short-circuit within the loop system, communication to the
actuators is maintained.
AUMA redundancy As an alternative to loop redundancy, the fieldbus connection to the actuators can
also be designed as line topology. In this case, two separate fieldbus cables are
installed in line topology to each actuator.
Auto configuration Automated procedure during commissioning of loop redundancy whereby the fieldbus
addresses are automatically assigned on the basis of the actuator sequence within
the loop.
Network Physical arrangement of actuators connected to SIMA² (line topology or loop
topology).With Modbus RTU, up to 247 actuators are supported for each SIMA²
network.
2.2. Name plate
Data for identification Each SIMA² is equipped with a name plate.The name plate is located at different
positions: for rack mounting or as bench device on the rear, for devices in wall
mounting version at the left side of the device.
For unambiguous assignment of SIMA², the following data is required:
Figure 5: Data for identification
[1] SIMA² PO number
[2] Order number
[3] Wiring diagram number
[4] Power supply
[5] Equipment of fieldbus interface to the DCS
[6] Equipment of fieldbus interface to the field devices
[7] Redundancy
[8] Serial number of SIMA A
[9] Serial number of SIMA B
[10] Identification number (system name)
Information The numbers can be directly read on the display via the SIMA² menu and sub-menu
Info.
[1] SIMA² PO number SIMA² PO number encodes the device’s hardware configuration.
[2] Order number This number is used to request any order-related information.
[3]Wiring diagram num-
ber Assignment of SIMA² wiring diagram is specified by the configuration of the fieldbus
interfaces and can be identified from the PO number on the name plate.
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Identification

[5] [6] Equipment ( inter-
faces) Name plate print indicates the equipment (configuration) of the interfaces.
Configurationof interfacesis also encoded bytheSIMA²POnumber[1] on the name
plate.
[7] Redundancy The redundancy indicates whether the current system is a Single Master Station or
a hot standby system redundancy setup and whether the system is arranged in one
joint housing or in two separate housings.
[8] [9] Serial number Each SIMA² can be unambiguously identified by this number.
Table 1:
Serial number example: 0319WI40040
KW 03Week0319WI40040
2019Year of production0319WI40040
Wenden / GermanyLocation of production0319WI40040
SIMAProduct series0319WI40040
40040Consecutive number0319WI40040
[10] Identification num-
ber The identification number informs on the production week and comprises information
on the version.
Table 2:
Identification number example: SIMA0119-01A/B
JanuaryMonths of productionSIMA0119-01A/B
2019Year of deliverySIMA0119-01A/B
01Consecutive number in the current
month for each SIMA²
SIMA0119-01A/B
Single Master Station or SIMA A for hot
standby system redundancy (in separate
housings)
ASIMA0119-01A/B
For redundancy only:SIMA B (in separate
housings)
B
Hot standby system redundancy in a joint
housing
A/B
2.3. Short description
Communication with
other actuators SIMA² controls electric actuators and offers the possibility to operate the overall
fieldbus system.With the standardised connection to the host or easy external
operation via web server or direct on-site operation, SIMA² is the ideal solution to
connect actuators with the host fieldbus interfaces.SIMA² allows integration of AUMA
actuators in different distributed control systems.The complete communication
between host and actuators are controlled by SIMA².
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SIMA² Master Station
Identification MODBUS RTU, MODBUS TCP/IP to DCS

Figure 6: SIMA² system overview (example)
Hardware
Hot standby
System redundancy Generally, actuators are controlled by SIMA² via a redundant fieldbus connection.
To increase communication availability to the actuators, different redundancy options
are available. A special configuration is the hot standby system redundancy. SIMA
B operates as backup in hot standby operation to SIMA A.In case of SIMA A failure,
SIMA B immediately takes over control of actuators.
Fieldbus interfaces Into the field:Modbus RTU (single-channel or redundant), Modbus loop redundancy
●Supporting up to 247 actuators per network.Maximum 4 networks are possible
for each SIMA².
To the host: Modbus RTU and TCP/IP (respectively single-channel or redundant)
●Operation variants: By means of integrated touchscreen and remote operation
via web browser (computer/laptop/smartphone/tablet)
●Access to all control and interface components as well as operation elements
from the front panel.
Software
●Intuitive, graphic user interface.
●Complete operation of field devices via operation window.
●Monitoring host signals, control commands, status and warning signals
●Supports several languages
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Identification

3. Transport, storage and packaging
3.1. Transport
For transport to place of installation, use sturdy packaging.Preferablyuse packaging
of delivery.
3.2. Storage
Danger of corrosion due to inappropriate storage!
→Store in a well-ventilated, dry room.
→Protect against floor dampness by storage on a shelf or on a wooden pallet.
→Do not store below –20 °C since this could damage the display.
→Cover to protect against dust and dirt.
→Appropriate storage of all accessories supplied.
3.3. Packaging
Our products are protected by special packaging for transport when leaving the
factory.The packaging consists of environmentally friendly materials which can easily
be separated and recycled.We use the following packaging materials: wood,
cardboard, paper, and PE foil. For the disposal of the packaging material, we
recommend recycling and collection centres.
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SIMA² Master Station
Transport, storage and packaging MODBUS RTU, MODBUS TCP/IP to DCS

4. Assembly
4.1. Notes for installation
SIMA² is available in the following variants:Standard housing for 19”rack mounting,
as bench device, for wall mounting or top-hat rail mounting (on request).
When used as bench device, the standard housing can be equipped with stands
elevating the SIMA² housing.
Information When installing or setting up, the following must be heeded:
●Housing, components and mains connector require sufficient space.
●Housing and components require sufficient ventilation.
●Doors of standard housing require space for swinging open.
●Optional handles increase space requirements at the front.
4.2. Dimensions
The following drawings indicate the dimensions of the various SIMA² variants.
Information The illustrations show an example of SIMA² in version “hot standby system redund-
ancy in one joint housing”.
Standard housing
Figure 7: SIMA² standard housing, top view with open doors
Table 3:
Legend
444.8 mm[1]
340 mm[2]
19.1 mm[3]
172 mm[4]
35°[5]
205 mm[6]
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Assembly

Figure 8: SIMA² standard housing with handles (option)
Bench device
Figure 9: SIMA² bench device (standard housing with stands and handles), front
view
Table 4:
Legend
177 mm[1]
Figure 10: SIMA² bench device (standard housing with stands), rear view
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SIMA² Master Station
Assembly MODBUS RTU, MODBUS TCP/IP to DCS

Table 5:
Legend
165.1 mm[1]
76.2 mm[2]
465 mm[3]
483 mm[4]
Connection for 110 –240V AC +/–10 %, 50/60 Hz +/–10 %[5]
Connection for 24V DC (option)[6]
Figure 11: SIMA² bench device (standard housing with stands and handles), side
view
Table 6:
Legend
85 mm[1]
7.2 mm[2]
40 mm[3]
Wall mounting
Figure 12: SIMA² wall mounting
Table 7:
Legend
Mounting bores[1]
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Assembly

Figure 13: SIMA² wall mounting, side view
Table 8:
Legend
Connection for 110 –240V AC +/–10 %, 50/60 Hz +/–10 %[1]
Connection for 24V DC (option)[2]
4.3. SIMA² system components
Figure 14: Overview system components (example)
Table 9: DescriptionNo.
CPU1
Additional IEEE 802.3 module (depending on the configuration)2
Power supply3
Further interfaces like communication interfaces or I/O interfaces4
2x IEEE 802.3 ports5
Battery housing6
2 x USB ports (not appropriate for mouse and keyboard)7
CF card with SIMA² software8
2x IEEE 802.3 ports9
Operation mode switch
Factory set, must not be modified!
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SIMA² Master Station
Assembly MODBUS RTU, MODBUS TCP/IP to DCS

5. Electrical connection and fieldbus connection
5.1. Electrical connection
Live parts are opened. Risk of direct contact!
Failure to observe this warning result in death, serious injury, or property damage.
→The electrical connection must be carried out exclusively by suitably qualified
personnel.
→Prior to connection, observe basic information contained in this chapter.
The connecting cables must comply with the requirements in terms of electrical
connection data and load (mechanical, thermal and chemical). It is recommended
to use shields for all connecting cables with the exception of the main power supply
and to use the provided terminals for the shield.
Wiring diagram/terminal
plan The relevant wiring diagram/terminal plan for SIMA² is supplied in a separate cover
and may also be requested when indicating the order number (refer to name plate).
Power supply SIMA² Master Station can be provided for different supply voltages. Prior to
connection, check whether the supply voltage matches the specified voltage.
For further details, please refer to technical data.
Mains connection Ensure that the device’s power switch is set to OFF prior to connecting the power
supply.
The voltage values for the device supplied are available on the name plate.
Depending on the mounting position, lateral mounting of the mains cable is possible.
However, this modification may only be performed by the AUMA Service.
5.2. Earth connection
The SIMA² housing must be earthed using the earth wire available with the connecting
cable or via the earth connection via a separate cable.
Figure 15: Earth connection
5.3. Shield connection
The fieldbus cable shield must be connected at both ends.The shield brackets within
SIMA² or appropriate EMC cable glands at the control cabinet input can be used for
connection.
5.4. Lightning protection
EIA-485 interfaces are galvanically isolated from the remaining electronic components
of SIMA².Additional lightning protection measures are not available with the standard
SIMA² version.If stronger lightning protection is required, further protective measures
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Electrical connection and fieldbus connection

must be introduced at the cable entry to the control cabinet housing the SIMA².
Overvoltage protection modules for fieldbus cables are available on request.
5.5. Interface and communication to the actuators via Modbus RTU
The interface between SIMA² and the actuators of the AUMA Group is the open and
internationally standardised Modbusprotocol.ThephysicalModbus RTU connection
between SIMA² and the actuators complies with the EIA-485 standard.
Information Heedthe installation instructions forEIA-485 based fieldbussystemsand the correct
implementation of the communication connections for all fieldbus devices.
All connections to the actuators are made via cables without connectors.The EIA-485
interface module utilised a proven system of spring clamp terminals.To this end, the
stripped cable ends are directly inserted into the corresponding spring clamp terminal.
Each interface module corresponds to one Modbus interface.
Figure 16: EIA-485 interface module (extract)
Information Verify addressing of fieldbus devices!
●Refrain from assigning twice the Modbus addresses within one network!
●Setting of baud rates and parity bits must be identical for all actuators.
EIA-485 termination resistor
The EIA-485 interface module is equipped with an integral fieldbus termination
resistor.The fieldbus termination resistor can be activated and deactivated using a
switch at the lower interface side.The letter Tis illuminated at the LED display once
the fieldbus termination resistor is activated.Fieldbus termination resistors are set
in the factory and may not be modified.
Typical cycle time
The cycle for reading any required information depends on the baud rate, the data
volume to be read and the number of connected actuators.
Typical cycle times for searching the actuator position and reading of the most
important status information:
Table 10:Typical cycle times
Typical cycle times (approx.) [ms]
Number of actuatorsBaud rate
[kbit/s] 604020
900600300115.2
1,20080040057.6
1,5001,00050038.4
2,0001,40070019.2
3,3002,2001,1009.6
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SIMA² Master Station
Electrical connection and fieldbus connection MODBUS RTU, MODBUS TCP/IP to DCS

Typical transmission time for an operation command to an actuator:
Table 11:Transmission time Transmission time for an actuator [ms]Baud rate [kbit/s]
15115.2
2057.6
2538.4
3519.2
559.6
The communication parameters to the actuators are set in the factory as follows:
Baud rate: 115.2 kbit/s
Format: 8 data bits, even parity with 1 stop bit
5.6. Interface to the distributed control system
Connection between the DCS and SIMA² can be made either via a Modbus RTU
line, ModbusTCP/IP or a combination of both protocols.These connections can also
be provided in redundant topology. In this case, the host can exchange data
independently via both cables (by using channels A or B).
For redundant connection to the DCS, SIMA² is equipped with respectively two RJ45
slots or EIA-485 interface boards.
Figure 17: RJ45 connections of SIMA²
Information Check configuration!TheDCSsettings mustbeperformed accordingtothe available
SIMA² configuration.
5.7. Fieldbus cable specifications
Fieldbus cables characteristics must be as follows. Stranded in pairs and shielded
copper cables must be used.
Table 12:
Cable recommendation
Only cables complying with the recommendations of EIA-485 specifications should be used for Modbus
wiring.
135to 165Ohm, ata measurementfrequency between3and 20MHzImpedance
< 30 pF per metreCable capacity
> 0.64 mmWire diameter
> 0.34 mm², corresponds to AWG 22Cross section
< 110 Ohm per kmLoop resistance
CU shielding braid or shielding braid and shielding foilScreening
5.8. Redundancy change-over
If an active SIMA² in hot standby version fails, the passive SIMA² automatically takes
over communication.The active SIMA² answers all requests of the DCS and controls
fieldbus communication to the actuators.The passive SIMA² receives simultaneously
all DCS requests without responding.The passive SIMA² monitors the active SIMA²
by means of a redundancy link (synchronisation cable). If the active SIMA² fails, the
passive SIMA² completely takes over all functions and changes into active mode
without change-over delay.
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SIMA² Master Station
MODBUS RTU, MODBUS TCP/IP to DCS Electrical connection and fieldbus connection

6. System configuration
6.1. Settings
SIMA² can be preconfigured based on the order information.This information must
be subject to prior consent with the plant operator as well as the DCS supplier.
The information includes:
●Number and type of actuators (or other field devices)
●BaudrateandIPaddress/Modbusaddressof SIMA² for communicationtohost.
●Baud rate for communication to actuators
●Highest Station Address (HSA)
●Timeout values for communication to actuators and host
●Limits for repeated attempts for establishing communication to the actuators.
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SIMA² Master Station
System configuration MODBUS RTU, MODBUS TCP/IP to DCS