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AUTOMATION CONCEPTSFOR THE PROCESS INDUSTRY / Page 12

direct processInformation for Power and Process Technology, October 2012

SAILING THE SEAS WITH SOLAR POWER / Page 04

PHOTOVOLTAICS ARE RADIATING ENERGY/ Page 06

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SAILING THE SEAS WITH SOLAR POWER Page 04

PHOTOVOLTAICS ARE RADIATING ENERGY Page 06

CURRENT TRANSFORMER TERMINAL BLOCKS ADDED TO PROGRAM Page 09

TO-PASS WEB CONNECTOR Page 09RURAL COMMUNITY INVESTS IN NEW SYSTEMS FOR WATER SUPPLY Page 10

AUTOMATION CONCEPTS FOR THE PROCESS INDUSTRY Page 12

PUMPING OUT WATER IN THE LAUSITZ MINING AREA Page 16

DISCONNECT TERMINAL BLOCKS TESTED UP TO 1,500 VDC Page 18

EXCELLENT STANDARD Page 19

Ex i COUNTER FOR NAMUR-COMPLIANT SIGNALS Page 19

CONTROLLING PROCESSES REMOTELY Page 20

REMOTE MONITORING OF CUSTOMER PROCESSES Page 22

IMPRINT Page 24

CONTENTS

PHOTOVOLTAICS ARE RADIATING ENERGY/ Page 06

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Dear Readers,

The Tranor Planetsolar has successully completed its 60,000 kilometer-long

trip around the world. For 19 months, this solar-powered catamaran was

on the high seas. For the crew, it was indisputably an extremely long time;

or the automation technology on board not so much. For in comparison,

process-technical systems are generally in use uninterrupted across several

decades. We are proud, however, that WAGO components have proven

themselves in both areas on the Tranor Planetsolar and in the process

world.

For decentralized automation has long since made its entry into process tech-

nology. For users especially with respect to the long lie cycles the ocusis on unctionality, saety, a long lie span, and the universal applicability o

the components. The multitude o dierent signals and parameters rom the

measurement and control technology must be received saely and reliably,

processed, and transmitted to the superior control technology architec-

ture. At the same time, the units, drives, and valves are activated by the

control system in connection with the control on-site. Required recipe

adjustments or production changeover as well as the temporary

storage and archiving o data in the process underscore the

demand or the greatest exibility in automation solutions. We at

WAGO take on your individual challenges and ormulate sustain-

able solution concepts.

This also in the area o renewable energies. With our direct

current measurement, or example, operators o photovoltaic

systems now have the opportunity to get reliable data about

the eed-in power without interrupting the string lines. In

addition, our TOPJOB S Series has expanded urther; the

new disconnect terminal blocks, which

are tested and approved or up to 1,500

VDC, ensure absolutely sae connections

in generator connection boxes and set

new standards with their unction. The

articles in this WAGOdirect processare only a small selection rom a large

product range, which is guaranteed to include

the appropriate solution or your requirements.

With innovative greetings,

Kay Miller

Market Management Industry & Process

Water

EDITORIAL

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The capacity o alternative energy sources is demonstrated in

a ew spectacular projects. An example is the solar-powered cat-

amaran Tranor Planetsolar, which circumnavigated the globewith only the power of the sun. To use the energy on board es-

pecially efficiently, the developers incorporated numerous new

ideas into the ship. For the drive control, the engineers trusted

WAGOs control technology.

The Tranor Planetsolar started its around-the-world journey from

Monaco in September 2010. Across the Atlantic, Pacific, China

Sea, Indian Ocean, and the Red See, the team reached Monaco

on May 4, 2012 after sailing approximately 60,000 km.

Energy eciency as the key to successAlthough nearly the entire surface of the ship is covered with

solar cells, energy efficiency on board is especially important.

Under optimal conditions, the solar cells generate 120 kW of

power. High-quality lithium-ion batteries are necessary to ensure

that the ship can also sail at night and in poor weather. Fully-

charged, they can power the ship for two to three days.

For the drives, especially efficient technology is used. So-called

surface-cutting propellers with a comparatively large area and

low speed are highly efficient. The propellers, whose angle can

be adjusted, are mounted on the two floats at the height of the

waterline. This way, only half of the propeller is ever in the wa-ter. With the 120 kW from the solar panels, the ship can reach

a maximum speed of 14 knots.

Control without rudder

Since both propellers also create thrust across the direction of

movement, they turn in opposite directions. These cross compo-

nents can be used to control the direction of the ship by changing

the angle and/or the speed of one or both propellers. A custom-

ary rudder system is thus no longer required. The ship is steered

using the change of speed, direction, and angle of the two pro-

pellers. The direction control works with the set working point

of the speed as basis. By generating a difference between the

two propellers, the controller sets an apparent rudder angle.

The four adjustment variables that control the sailing of the ship

SAILING THE SEAS

WITH SOLAR POWERHighly-efcient drives with WAGOcontrol technology

require a new form of control since the two subprocesses cannot

be separated. The complexity of the resulting controller for the

ship requires a control system that is operated by the sailors likea customary system with propeller and rudder blade.

Redundancy prescribed

The normal classification regulations for ship approvals do not

cover the particularities of this system. Therefore, an error mode

and effect analysis was conducted jointly with Germanischer

Lloyd. Based on this analysis, technical and functional specifica-

tions were formulated for the control system. A result is that there

are two electric motors per propeller, so that the maneuvering ca-

pability is retained even if one motor should fail. The total system

of the controller is approved by Germanischer Lloyd for ship use(86249-09 HH).

The similarly-required redundancy of the control system is real-

ized using two follow-up controllers. On the bridge of the ship,

the drive and direction are set using an azimuth operating lever.

The control system converts the set specifications for the speed

and the direction (rudder angle) into the required variables

speed and angle. In order to guarantee the redundancy of the

main control system, all components of the control structure

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are doubled. The control system is implemented with WAGOs

PLC and IPC components. A follow-up control string consists ofa WAGO 758-875 IPC for executing the control functions. Using

the specifications for speed and direction, the IPC calculates the

parameters for speed and angle of the propellers and transmits

these to the frequency inverter and the drives.

The display and operating elements of the main control stand are

connected to the two control strings using 750-337 CANopen

fieldbus couplers independent of one another. The redundant

actual value display of the drives and that of the controller-in-

dependent fault indicating system and the angle control of thedrives are implemented via 750-871 PLC. WAGOs automation

components are certified by Germanischer Lloyd and can there-

fore be used in the marine sector.

Successully sailing all the worlds seas

During the circumnavigation, both innovative drive system and

hardware/software for redundant control proved themselves. For

current news about the Tranor Planetsolar and the logbook from

the circumnavigation, visit www.planetsolar.org.

Text: Roland Lck, Marine and Automation Technology

Matthias Markert, Hochschule WismarPhoto: Planetsolar

The control system is implemented withWAGOs PLC and IPC components

Complete system approved byGermanischer Lloyd

The ship is steered using the change o

speed, direction, and angle o the twopropellers

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The transition in energy supply sources is a done deal. However,

the mere expansion of the electrical grid is not enough to ensure

that renewables remain successful on the market, and that coal,

uranium, and company can be strongly renounced in the future as

well. Renewable energy sources must be employed far more effi-

ciently, particularly in those cases, as is the case for photovoltaics,

that have low levels of efficiency. This foundation will be created

through the integration of PV plants into the intelligent electrical

grid as well as continuous monitoring of modules and inverters.

Two-thirds of clean energy is currently harvested from wind power

systems and hydroelectric power systems. At just over 15 percent,photovoltaics produce the smallest proportion, which can be at-

tributed primarily to their low efficiency, averaging only 15 to 20

percent. The high loss of earnings in this sector is doubly embarrass-

ing. On the one hand, the sun provides an amount of energy that

exceeds the annual needs of Germany by a factor of 80; on the

other hand, the electricity gained in this highly inefficient manner

is not even used sufficiently efficaciously. Since there is no compre-

hensive management, much too much energy is lost in the wilds of

the electrical grid.

The legislators have finally reacted with a revision of the Renew-

able Energy Sources Act. Beginning in January 2012, photovoltaicsystems with an output of more than 30 kW must be provided with

a technical interface that enables remote controlled power reduc-

tion by the network operator. This limit was previously 100 kW.

As a second step, operators of PV plants that produce more than

PHOTOVOLTAICS ARE RA

100 kW are obligated to disclose their feed-in power to the network

operators. The goal of these measures is both to strengthen network

stability by avoiding frequency fluctuations that lead to power fail-

ures, and to make it easier on the part of the network operators to

effectively manage the growing number of different energy sources.

Virtual networking o real plants

There are decisive advantages to integrating decentralized energy

generators with low outputs into one so-called virtual power plant.

Under central management, small wind and hydroelectric plants,

combined heat and power plants, biogas, and even photovoltaic

plants are put in a position in which they can collectively replace thepower available from large power plants. Temporary fluctuations in

the electrical grid can be smoothed out by the availability o capacity

from the power plant. When decentralized energy generators are

bundled in this fashion, they appear, when viewed from the out-

side, as a single plant. Their integrated total output can thus also

be managed on the electricity market. This means that the energy

they generate can be marketed by the electricity traders, which was

previously almost never worthwhile for the small, individual plants.

However, not all problems will be solved by the simple integration

of energy producers. Only when the electrical grid operators are

able to assume a regulating influence can an efficient and stablepower supply be constructed. One of the most press-

ing challenges at present is that many thousand,

mostly privately owned, PV plants feed-in di-

rectly to the grid. At peak times, this means

Direct current measuring without interruption of the branch cables: The 789-620 Current Sensorhas a measuring range rom 0 to 80 A, and the 789-621 has a measuring range rom 0 to140 A.

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DIATING ENERGY

that there is often an energy glut, which, due to a lack of storage

capacity, leads to instability. A virtual power plant would be control-

lable by the network operator for just such a case; according to the

EEG, a graduated series of power reductions, of 0%, 30%, and60%, is provided for these periods. A technical prerequisite for this

type of regulation is recourse to the decentralized energy produ-

cers. So-called smart grids form the communicative foundation for

regulating electrical generation, storage, electricity consumers, and

grid operating means.

Ecient generation, ecient use

The most widely differing input and output parameters must be

transmitted for the integration of PV plants into smart grids and

for permanent monitoring of the plants. In order to most easily

configure communication from these points with the control center,

WAGO has correspondingly further developed its controls: WAGO

offers a standardized and easily applicable interface for users,

which is based on the IEC 60870-5-101/-104 and IEC 61850

telecontrol protocols. More than 400 input and output modules are

available within the I/O system for use at the field level. In addition,

there are also diverse specialty modules, among them the 3-phase

power measurement module for energetic monitoring of transformerstations, or serial I/O modules for connecting S0 counters, M-Bus

counters and current sensors.

Telecontrollers or IPCs take on communication between field and

control levels. Programmable logic controllers (PLCs) transmit all

relevant measured values, such as current, voltage, or (reactive)

power and receive switching orders from the higher-level con-

trol center; these commands are then implemented by the input

and output modules arranged in series. The concrete automation

tasks are defined in the controllers according to IEC 61131 using

CODESYS. For this purpose, a configuration interface is integrated

into the CODESYS development environment for each of the two

telecontrol protocols, IEC 60870 and IEC 61850. By this means,

the user avoids the relatively expensive programming labor, as the

entire IEC communication can be parameterized.

Example o a virtual power plant

Pump storage

Cold store

Heat pump

Combined heat andpower plant

Hydroelectric plant

Current ow with lack o powerCurrent ow with excess power

Control power or the ree market (electricity stock exchange)

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Maintain attractiveness, increase development

The proportion of renewable energy as part of the more than 600

terawatt hours, which are annually required in Germany, must and

will increase in the future. By employing automation components

from WAGO, the technical prerequisites for an efficient usage of

electricity are already available. By this means, photovoltaics re-

main attractive despite a drop in guaranteed feed-in compensa-

tion. This is of decisive importance: Only if this technology contin-ues to radiate power, will the expansion from private households

and corporations also maintain support.

Text: Manuel Schmidt, WAGO

Photo: WAGO

Integration o PV systems into smart grids

Remote communication via IEC 60870and IEC 61850

Competition or large power plants:virtual power plants

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Telecontrol and monitoring o remote sites or mobile devices is no

problem at all orTO-PASS. Via GPRS and Internet, aults are trans-

mitted just as reliably to the WAGO-I/O-SYSTEM as process and posi-

tion data. TO-PASS Web Connector now takes this to new heights: it

can be used to integrate the WAGO telecontrol modules even betterinto the control center.

The heart o this Web connector is a special unction block or the

CODESYS development topology. This unction block registers the

HTTP queries rom the telecontrol modules, saves the process image

in a global variable list and transmits a corresponding acknowledge-

ment. The received data can then be processed by the WAGO-I/O-

SYSTEM as needed. Economical, bidirectional transmission using the

Web connector is also used by network service providers to comply

with the renewable energy act: The power reduction required by this

act based on IEC 60870-5-104 is achieved by technical means by

private power producers using TO-PASS.

For additional inormation, visit www.wago.com/telecontrol.

TO-PASS WEB CONNECTOREasy integration o ault detectors into control technology

WAGO expands its TOPJOB S range to include rail-mount termi-

nal blocks or simple measurement in current transormer circuits and

or automatic short-circuiting o transormers.

The new 2007 Series Disconnect/Test Terminal Blocks are specially

designed or use in current and voltage transormer circuits. They

eature a highly unctional design and are just 99.6 mm long and

8.0 mm wide. Intuitive orange disconnect links simpliy operation:

Closing the link automatically short circuits the transormer via in-

serted adjacent jumper or switch lever.

The circuit state can be easily, saely and reliably determined via

open, touch-protected design. The 2007 Series also includes

through and ground terminal blocks with identical proiles. All o the

terminal blocks are designed or 30 A and 500 V based on IEC and300 V based on UL. The maximum nominal cross section or erruled

conductors is 6 mm (AWG 10) and 10 mm (AWG 8) or solid and

ine-stranded conductors.

CURRENT TRANSFORMER TERMINALBLOCKS ADDED TO PROGRAM

Disconnect/test terminal blocks or current and voltage transormer circuits

join the range o TOPJOB S rail-mount terminal blocks.

The TOPJOB S current transormer terminal blocks combine an

extremely compact design with a high level o unctionality, such

as automatic transormer short-circuiting, declares BurkhardNiemann, Product Manager orELECTRICAL INTERCONNEC-

TIONS at WAGO Kontakttechnik GmbH & Co. KG.

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In the Swiss community o Wahlen, parts o the local sys-

tems or water treatment and water distribution were out o date.

Endress+Hauser developed an appropriate modernization con-

cept, which in addition to new measurement equipment and the

P-View control system also includes a control system based on

WAGO controllers.

In order to supply a community or city with hygienically-acceptabledrinking water, reliable systems for monitoring and distribution are

required in addition to the water itself. In the village of Wahlen,

at the foot of the Strmenkopf in Canton Basel-Landschaft, parts

of the systems as well as the control unit for the water supply

were no longer up-to-date. Well-master Rainer Schmidlin turned

to Endress+Hauser with respect to new measurement equipment.

Since this company has been familiar with Wahlens water supply

for many years, the new project team created a non-binding plan

for modernization. In addition to new field devices, it also provided

a new control system.

I/O system replaces discrete wiring

The old control system consisted of different components, some

of which were analog, which were wired discretely. A multitude

of relays and contactors controlled pumps and older systems.

In the course of modernization, the community replaced some

field devices as well as the sterilization system with ultraviolet ra-

diation. According to the plan, Endress+Hauser replaced the dis-

crete control structure with three WAGO I/O nodes combined

with the P-View control system. Within the WAGO-I/O-SYSTEM,

a decision was made in favor of the ETHERNET Controller and

pluggable I/O modules. They record the field-side measure-

ment values such as flow quantities, pressure, as well as mes-sages from fire extinguishing flaps and the system that measures

the cloudiness of the water.

In total, three distributed programmable ETHERNET controllers (750-

841) control the process stages in the pump station, the reservoir,

and in the administration building. The communication with the con-

trol system takes place via an ETHERNET network that has modems

and 2-wire copper lines in the external stations. For remote access

by the well-master and remote maintenance by Endress+Hauser,

a DSL connection was installed in the administration building. The

control system handles the logging and alarming as well as the

monitoring of the reservoir chambers. The new controller saves so

much space that it doesnt even take up half the space in the existing

system cabinets. At the same time, operation via P-view is easy and

provides very detailed operating data, which I can also call up from

home, reports Rainer Schmidlin with satisfaction.

RURAL COMMUNITY INVEIN NEW SYSTEMS FOR WNew controller and new control system provid

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STSTER SUPPLYdetailed information

Controlling operation easily with the control system

Endress+Hausers P-View control system works with OPC servers

and supports many industrial communication protocols. It is based

on open standards with respect to the software and hardware com-

ponents used and it can be attuned very flexibly to the requirements

in question. With these criteria, it is very well-suited for the tasks

demanded. Within the P-View-Scada package, there are pre-config-

ured overview pictures available. The system enters limit violations

in the alarm list and informs the user via screen display. Alterna-tively, the control system also sends messages via SMS and e-mail.

In order to adapt the controller perfectly to the needs of Wahlens

water supply, Rainer Schmidlin worked closely with project director

Roger Jaggi of Endress+Hauser. He adapted the programming in

CODESYS according to the specifications and started the stations

up after successful test runs. This was done during operation in or-

der to spare the residents of Wahlen from having to turn off the wa-

ter supply. That the control system also sends important messages

via SMS is a wonderful thing for us. I am informed immediately

if there is a fire alarm, for example, reports the well-master and

demonstrates the service on the triggering station in the administra-tion building.

Conclusion

With selected components, an out-of-date controller can be mod-

ernized. The project team from Endress+Hauser relies in its plan on

flexible components, both for automation as well as for the control

system. The fieldbus-independent modular WAGO-I/O-SYSTEM

replaces the discrete wiring in an elegant manner. Now program-

mable ETHERNET controllers in the respective stations take over the

control of the I/O signals, which allows them to remain indepen-

dent and also functional in case of a failure of the transmission path.

Text: Renate Klebe-Klingemann, WAGO

Photo: WAGO

WAGO-I/O-SYSTEM replaces discretecontroller structure

ETHERNET Controller and pluggableI/O modules

P-View control system from Endress+Hauser

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AUFOR T

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Modular concepts ensure great exibility, reusability, and fnally

also lower costs in sotware development and the automobile indus-

try. In the process industry, there is also a trend towards dividing

systems into so-called package units. As a consequence, theindividual units also require largely autonomous automation tech-

nology, which exchanges information with a central control sys-

tem. Here manufacturers of automation technology are required

to fulfill the high requirements of the process industry with their

components and systems.

The life cycle of a system in the process industry is relatively long.

A typical production system in the chemical industry is frequently

designed so that it remains practically unchanged across a period

of several decades. Despite regular maintenance work and the

possible replacement of individual components, the basic structure

of the system frequently remains unchanged across the life cycle.The systems demonstrate a high degree of automation. A small

operating team is often sufficient to operate large systems safely.

The typical structure of an automation system is the classic control

system architecture. Sensors for chemical and physical process

parameters as well as for the states of the system components

transmit their values to the control station. There, central computers

process the data and control the actuators such as pumps, stirrers,

and heaters. The entire intelligence of the measurement, control,

and regulation technology is in the central control system.

The disadvantage of this architecture is the great amount of work

required for the wiring. For large systems, several thousand sen-

sors and actuators can be required, which must all be wired into

a central point. The control system architecture is also relatively

TOMATION CONCEPTSHE PROCESS INDUSTRY

inflexible if changes to or expansions of the system are planned

because the PMC (Process Measurement and Control) technol-

ogy of the central system must always be adapted. Another disad-

vantage is the varying life cycles of automation-technical systemsand process-technical systems. However the concept of the central

control system also has advantages. Safety, which is especially

important in the chemical industry, can be guaranteed ideally this

way. System availability also a central requirement in the pro-

cess industry is very high this way.

Modular approach

For a while now there have been efforts in the process industry to

build modular systems. With the designation F3, a consor tium was

established in 2009 that consists of companies from the chemi-

cal industry and research institutes in various European countries.

The goal of the F3 project, whose name stands for Flexible, Fastand Future Factory, is the development of concepts for modu-

lar production systems in the process industry. The idea behind

the project is to build chemical production facilities according to

the modular principle. It should be possible to combine individual

module package units here according to the plug-and-play prin-

ciple. Thus individual system parts can be replaced more easily,

if, for example, the automation technology is out of date or the

field units reach the end of their life span. The maintenance of the

individual package units can also be uncoupled from the rest of

the system. In the future, the system engineers will no longer build

a complete system; instead, individual specialized suppliers will

deliver different package units, for example mixers or fermen-

ters, which are then combined into a complete system.

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Automation and communication

A package unit includes not just the mechanical unit, but also

the electrical installation, the sensors, and the automation and con-

trol technology. An important prerequisite for ensuring that such

a concept works is the precise definition of the interfaces. In addi-

tion to the standardized mechanical and electrical interfaces, the

interfaces of the automation technology are of great significance

here. In the new concept, a central control station is still the pointfrom which the personnel operate and monitor a system. However,

a big part of the intelligence wanders to the package units.

The job of the central automation technology become easier thanks

to this concept since the package units take care of the lions

share of the PMC tasks directly. Another big advantage of this de-

centralized automation architecture is the reduction of the effort re-

quired for wiring the sensors and actuators. Communication with

the central control system is handled by bus systems, for example

PROFIBUS DP or PROFINET.

Requirements o automation technology

Since the automation hardware is moving closer to the process,there arise new requirements for the individual components. Thus

controllers must tolerate the harsher environmental conditions that

can prevail near the process. These range from large temperature

fluctuations to stresses due to humidity and dust on through to vibra-

tions and shocks. Another requirement is the problem-free process-

ing of the signals that arise and the possibilities of communicating

via the various bus systems.

Manufacturers of automation technology such as WAGO Kontakt-

technik GmbH & Co. KG offer a wide-ranging portfolio of products

for the process industry. With the WAGO-I/O-SYSTEM and the as-

sociated controllers, manufacturers of package units can incor-porate nearly all sensors and actuators. The spectrum ranges from

analog/digital inputs and outputs on through to the incorporation

of nearly all common fieldbus systems. The WAGO-I/O-SYSTEM is

approved for use in Zone 2 hazardous areas. Intrinsically safe digi-

tal and analog I/O modules also allow connection to peripherals

in Zones 0 and 1. The automation functions can be implemented

easily with the systems ETHERNET controllers or IPCs.

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Module concept in the process industry

Automation o package units

High requirements or components andsystems

Conclusion

The future in the process industry lies in the area of modular sys-

tems. So-called package units consist not just of mechanical and

electrical components, they also contain the automation techno-

logy. This brings an essential change for the architecture of the au-

tomation systems, for a big part of the intelligence wanders to the

package units. For the manufacturers of package units, system

engineers, and operators, as well as for the suppliers of automationtechnology, this creates new opportunities.

Text:Jrg Lantzsch, proessional journalist rom Wiesbaden

Photo: WAGO

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PUMPING OUT WATER IN

THE LAUSITZ MINING AREA

To ensure the proper unction o conveyor systems in surace min-

ing, vast amounts o water must be continuously lited and diverted.

For eicient drainage o their storage acilities in the Lausitz mining

area, Vattenall Europe Mining AG together with the automation

company BEA TDL o Spremberg implemented new system technol-

ogy. Standard drive solutions with modular controllers rom WAGO

and new communication technologies now simpliy the operation o

drainage systems.

To convey coal at depths o 35 to 120 meters, Vattenall operates

more than 2,500 ilter wells to drain the mining area. In the mining

area, the ilter wells are arranged in a linear structure as a barrier.

Due to continuous coal mining, the active surace mining area ad-

vances in the direction o mining and the systems technology has to

be repeatedly dismantled and rebuilt. In addition to structural mea-

sures, dismantling and rebuilding the systems also requires consider-

able programming work or the automation equipment. To make the

drainage operation even more eicient in the uture, Vattenall de-

cided to replace the existing systems technology. State-o-the-artelectrical and ield device technology, as well as controller and pro-

cess control technology should take its place.

New system concept simpliies draining operation

The technical oice at Vattenall required direct access rom the con-

trol station to sensors based on ETHERNET technologies rom the

new system design. As Vattenall tendered Project 2007, automation

specialist BEA came out on top in competition with other suppliers

and was awarded the contract or a pilot installation at the Reich-

walde opencast mine. Those responsible selected the WAGO-I/O-

SYSTEM or the automation components with programmable 750-841 ETHERNET Controller or pump control and 758-870 I/O-IPC

in the bolt control cabinet. The advantage o this system is its modu-

larity and the large selection o I/O modules such as a 420 mA

analog input module with HART protocol and various interace

modules.

The I/O system with ETHERNET Controller and IPC meets many of the

required criteria innately. Thanks to its programmability, Bluetooth

communication can also be implemented to conigure operat ing

data and communication with intelligent field devices in CODESYS,

summarizes Armin Noack, project manager at BEA. The requirementor a modular design was met in many system components rom the

medium-high voltage and low-voltage switchgear to the hardware

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and sotware in the automation part. Starting rom a core conigura-

tion, or example, the switchgear and controllers can be torn down

and setup up based on the use cases to be expected. Wi th modu-

lar components such as the WAGO-I/O-SYSTEM, sustainable sys-

tems can be implemented because they allow urther development

and can be quickly replaced in case o breakdown, explains Henry

Hanschke, Water Technology BU Manager at BEA.

Coniguration instead o programming

The barrier and pump controls can be designed as a conigurable

sotware system that simpliies system engineering signiicantly.

When irst commissioning or modiying the system due to expansion

or retreat, pump controls can be expanded, replaced or removed in

the system with no programming required. All controllers including

IPC are conigured via a single engineering tool and have an inte-

grated web server on which device- and application-speciic HTML

pages are saved. As a result, any controller on the client terminal can

be easily conigured rom clear user interaces via the network and

requires no additional special knowledge. I communication with the

control cabinets or control station is interrupted, the controllers con-

tinue to run independently and the process can still be controlled lo-

cally.

System concept proven in the ield

Ater the pilot system was proven in practice, those responsible trans-

erred the new system concept to other mines in the area. In recent

years, BEA has implemented other systems with more than 600

pumps and 30 barrier control cabinets, which meet the demand or

high system availability under mining conditions. As a result, the

joint development contributes to meeting the hydrological require-

ments o surace mining, summarizes project engineer Jrgen Karas

o Vattenall Europe Mining AG. He adds, The automation solution

achieved has become the standard at Vattenall.

Text: Klaus Dreiskemper, WAGO

Photo: WAGO

Bluetooth communication or theparameterizing o operating data

Direct access rom the control deskto the sensor

Modular structure with ETHERNET

controllers and IPCs

Armin Noack o BEA TDL demonstration: From an outdoorPDA, the operator reads the ow volume while he activatesor disables the valve manually.

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DISCONNECT TERMINAL BLOCKSTESTED UP TO 1,500 VDCIdeal or applications in the renewable energy sector: Disconnect ter-

minal blocks up to 1,500 VDC or the TOPJOB S 2006 Series o rail-

mounted terminal blocks

The cut-o voltage required in photovoltaic and wind turbine sys-

tems ar exceeds that demanded in classic industrial systems. WAGO

has thereore developed rail-mounted terminal blocks that are ap-

proved or up to 1,500 VDC by IEC and up to 1,000 VDC by UL.

The integrated, orange disconnect links in the new TOPJOB S 2006Series Disconnect, Carrier and Through Terminal Blocks not only make

them easy to use, but also provide or sae and reliable handling as

well.

The suitability o these terminal blocks or direct current levels up to

1,500 V and 30 A enables them to be used in applications requiring

higher voltage and output levels, such as in generator terminal boxes

or photovoltaic systems. The maximum nominal cross section or er-

ruled conductors is 6 mm (AWG 10) and 10 mm (AWG 8) or solid

and ine-stranded conductors. The new terminal block versions can

be combined with the existing TOPJOB

S terminal block line and areavailable in gray and blue.

Approved or higher cut-o voltages: Disconnect, carrier and through terminal

blocks or up to 1,500 VDC, tested in accordance with IEC.

The ongoing technical development o renewable energy sources

demands connection technology or voltages o more than 1,000 V

based on IEC and more than 600 V based on UL WAGO is stepping

up to meet the challenges posed by this market with its new 2006

Series Terminal Blocks or up to 1,500 VDC, states Burkhard Nie-mann, Product Manager orELECTRICAL INTERCONNECIONS at

WAGO Kontakttechnik GmbH & Co. KG in Minden.

The TOPJOB S rail-mounted terminal block system

Covering a range o wire sizes rom 0.14 mm to 95 mm (AWG

24-4/0), TOPJOB S, along with POWER CAGE CLAMP, is the

rail-mounted terminal block system that oers the widest range o

products or industry, buildings and traic applications. Thanks to

CAGE CLAMP S technology, the TOPJOB S rail-mounted terminal

blocks are the industrys most compact. These terminal blocks are

suitable or all types o conductors; solid, stranded and ine-strandedconductors with errules can also be connected simply by pushing

them in. The TOPJOB S rail-mounted terminal block system is round-

ed out by the astest and most economical marking system and by

a comprehensive jumper system or any conceivable application.

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PACK

19direct process

WAGO has developed an Ex i up/down counter (750-633) as

I/O module or the WAGO-I/O-SYSTEM 750. The counter records

binary signals with NAMUR-compliant levels and transmits the sys-

tems counter state to a WAGO programmable controller or to the

higher-level control system via coupler and ieldbus. The countingdirection up or down can be set using the U/D input (Up/Down).

A control byte sets or resets the counter. The digital output (DO)

is enabled via control byte or is activated based on counter state.

The maximum switching requency o the counter is 20 kHz. The 24

mm wide module indicates its status on LEDs: green or Up/Down

input active, CLK input (counter input) active, and DO switched, as

well as red or wire break/short-circuit o the Up/Down and CLK

signal lines. The ield and system level are electrically isolated and

the output is short-circuit-proo. The module is supplied by a separate

24 VDC eed in an Ex i version.

Ex i COUNTERFOR NAMUR-COMPLIANT SIGNALS

WAGOs new intrinsically sae up/down counter re-

cords binary signals with NAMUR-compliant levels.

Deined interaces, deined data: the Weihenstephan Standards

(WS) orm the basis or a manuacturer-independent coupling o ma-

chines and superior production management systems: WS Pack or

beverage illing and packaging systems and WS Food or ood pro-

cessing. What began as a university research project has developed

into a true success story, which recently was awarded the gold medal

in International FoodTec by the German Agricultural Society (DLG).

In addition to the possibilities or quality assurance and increased

eiciency, the prize explicitly acknowledged the pre-competitive in-

volvement o all participants: the industrial partners, the German

Engineering Federation (VDMA), and the Science Foundation o the

German Beer Brewing Industry (WiF). WAGO has supported theWeihenstephan Standards since early 2011 as an oicial partner en-

terprise and, as part o this involvement, has developed the necessary

sotware components or their ETHERNET controls and ETHERNET

industrial PCs.

For additional inormation, visit www.wago.com/ood.

EXCELLENT STANDARDInternational FoodTec Award 2012 in Gold

or the Weihenstephan Standards

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A central process control system is not suciently exible or too

expensive or many companies. The engineering oice or process au-

tomation/control, pac GmbH here relies on control units by WAGO. Ina project or biotechnology at Novartis, a remote system had to prove

itsel as a control unit or process systems in conjunction with a central

monitoring system.

Novartis operates many multi-purpose systems in the feld o biotech-

nology, which are not geared to mass production with fxed produc-

tion processes. Production and processes change regularly, a central

process control system is thereore too inexible. According to the re-

quirements o ERES (Electronic Records Electronic Signatures) and

the FDA (Food and Drug Administration), 21CFR Part11, data and

user interventions, such as settings and confgurations, however, would

have to the recorded during production and stored securely. This log-ging was previously associated with a great manual eort.

Autonomous automation solution

As an alternative to a central process control system, Novartis decided

to set up a remote process controller by pac GmbH using the tech-

nique o WAGO. Industrial PCs control the individual systems. The

control panels are on site. The control units are connected via ETHERNET.

The sensors/actuators on the IPCs can be switched via I/O terminals.

In addition, the IPC activates the Festo valve terminals via PROFIBUS.

A central log server records the process data and logs all alarms,

aults and user input according to 21CFR Part11.The WAGO IPC is predestined to be a decentralized process control-

ler thanks to three particular eatures, says Jrgen Stterle, the CEO

o pac GmbH. From his point o view, the IPC could also be called

I/O-PC because it can be mounted directly on the 24-volt level on the

top-hat rail and connected directly to I/O modules. Furthermore, it

has the properties o a classic PLC: it is robust, small, and program-

CONTROLLING PROCESSmable according to IEC 61131 like a programmable logic controller.

Finally, as an IPC it integrates the open standards o the PC world.

Flexible and modular control unit

In process automation, we requently need an alternative or large

and complex control systems. This easy to use PLC, however, must still

meet the highest quality demands. The WAGO system has positioned

itsel here and proven itsel in practice. It uses standard hardware,

standard protocols, as well as standard interaces. We thereore can

select various suppliers or the peripherals. I a terminal malunctions,

we only need to replace it and not the entire assembly. Even the pro-

gramming using standard tools such as CODESYS or MS-SQL server

makes the solution much more cost-eective, added the manager o

the engineering oce. He especially appreciates the exibility in the

integration o sensor and actuator signals.

Practical decentralized solution

The decentralized process control has proven itsel at Novartis. In

a preparation system or the extraction o an active ingredient, frst

dierent media are added, and in another process they are stored

and conditions in a second group o machines. The controller ensures

that there is a ring line or the process-appropriate addition o com-

mon resources such as cleanser, steam, and distilled water, and it per-

orms coordination tasks such as flling in mobile containers, the trans-

er between the machine groups, and the control o valves. The

production data is stored and evaluated centrally. Via view stationsdistributed across the building, the system operators also have access

to current and historic process data; mobile call-up stations via WLAN

are also planned. The standardized interace o the logging system

has proven very helpul or the incorporation o dierent suppliers

machine groups. A Siemens control unit can also be connected via

a PROFIBUS coupling.

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Decentralized process controlwith the WAGO IPC

Production data according toFDA 21 CFR Part11

Manuacturer-independentconnection to the controller

ES REMOTELY

The challenge o changing system inserts and changing processes

could also be easily solved with the decentralized approach. The

system control is cost-eective and unctional due to the modular struc-ture. Control unctions, such as agitating are distributed into basic

unctions according to NAMUR recommendations and can be reused

at another point. We were able to reduce the testing eort overall and

the tests o individual modules by this copying eect reports Jrgen

Stterle. From the view o the automation engineer, the easy and uni-

orm operating concept also on various equipment groups has contrib-

uted essentially to the acceptance by the employees. The training

eort was thereore kept at a minimum.

Text: Martin Ortgies, proessional journalist

Photo: Novartis, WAGO

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Having the customer proft rom manuacturers expertise benefts

everyone: with help rom WAGO, the Lineguard Supervisor by

Henkel provides a compact, industrial process control system with

world-wide access.. This system optimizes metal pretreating pro-

cesses at the customer, enhancing both product quality and profit-

ability.

Optimal pretreatment of metallic surfaces has a major influence

on the properties of the final product. Here, flaws normally do

not become apparent until the next step in the process, for ex-

ample, during painting, making them impossible to correct. Adher-

ence that is meticulous and as accurate as possible to all processsteps is therefore a prerequisite for high, uniform product quality.

Henkel AG & Co. KGaA is the leading producer of chemicals for

treating metallic surfaces. This product segment accounts for a

substantial portion of the companys overall earnings. Henkel is

also the leader in process technology in this sector and operates

an in-house research and development center. It is here where

specific processes, such as Alodine, for pretreatment of aluminum,

or Bonderite NT for treatment prior to painting, are developed.

The company therefore not only serves as a supplier of chemicals,

but is also considered to be a service provider that passes its ex-

pertise along the entire process chain.

Compact dosing unit optimizes customer process

Pretreatments, such as chromating or zinc phosphating, are com-

REMOTE MONITORING OF

plex processes subject to short-term influences. Processes such as

these require that quality, profitability and environmental impact

be monitored constantly and kept in line. Only one lab analysis

per day is frequently the rule in normal practice, however. The

results of this analysis then define the proportioning and dosing

of the chemicals involved for the next few hours. Changes of the

bath composition that may be necessary are often not recognized

in good time, resulting in quality problems and elevated costs. Op-

erators frequently feel that the solution is to add more chemicals,

which may not always ensure better quality but always leads to

increased costs and greater environmental impact. To optimize

this procedure, Henkel, together with WAGO, developed theLineguard Supervisor. This is a compact, process control sys-

tem for dosing chemicals using remote access via a Web portal.

The central component of the dosing system is the WAGO I/O-

IPC. Analog and digital I/O modules and RS-232 interfaces can

be connected directly to the IPC in series as components of the

WAGO-I/O-SYSTEM. These modules record the signals from the

sensors and constantly determine the composition of the baths.

The system uses this data to define the optimal dosing of the

chemicals and monitors the bath for the correct mixture of the

chemicals using pulsed control activation of the dosing pumps.

Web portal oers access rom anywhere in the world

Worldwide support for process systems and technology is-

sues play a major role in Henkels business model. Therefore,

The Lineguard Supervisor helps transer Henkel manuacturer know-how to the customer and

minimizes eort and expense at the same time. The TO-PASS Dynamic Web Portal oers bothsides access to the customer process without any engineering eort by the customer.

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CUSTOMER PROCESSES

As an intelligent I/O system, the WAGOI/O-IPC oers PLC unctionality

WAGO-I/O-SYSTEM modules can beplugged directly into the WAGO I/O-IPC

TO-PASS Dynamic Web Portal detectsplugged I/O modules and processeslarge quantities of data

a Web-capable system was required, which Arkadon imple-

mented by adapting the existing TO-PASSWeb Portal into the

TO-PASS Dynamic Web Portal. This system is capable of pro-

cessing large volumes of data and making it available on a Web

portal. The Dynamic Web Portal also automatically recognizes

the I/O modules linked to the system based on the size of the

system. This considerably simplifies the integration effort required

and creates flexibility, in particular when the system is expanded

subsequently. Data is transferred via a GSM/GPRS router, which

sets up a secure VPN tunnel. This enables secure writing of all

relevant process data to the Web portal. A preprogrammed vi-

sualization function also provides a quick overview of the currentprocess activities and displays various standard functions graphi-

cally: Temperature progressions, violations of defined set points,

a comprehensive alarm management system with different alarm

classes, and a simple password assignment function. The results

are available as data worldwide in various views. The costs for

system integration and subsequent start-up are reduced since the

portal automatically adapts to the I/O-IPC configuration.

I/O-IPC: The high-perormance control system

As an intelligent I/O system, the 758 I/O-IPC offers PLC function-

ality. Using CODESYS, it is possible to program a self-teachingcontroller and the visualization according to IEC 61131-2. An

integrated Web server enables access via the intranet or Internet

using a PC with a Web browser, or via a local touch panel with

a DVI interface. For communication with higher-level systems and

the IT world, the I/O-IPC has two completely independent Fast

Ethernet interfaces, 2xUSB, RS-232 and a CompactFlash inter-

face. Thus it is the ideal link between the automation and IT levels.

An optional PROFIBUS DP or CANopen interface is available for

fieldbus communication. Nearly all the more than 400 input and

output modules from the portfolio of the WAGO-I/O-SYSTEM can

be used with the I/O-IPC.

Text: Dr. Lutz Huesemann, Henkel AG & Co. KGaA

Wolgang Laumann, WAGO

Photo: Henkel, WAGO

The core of the Lineguard Supervisor is theI/O-IPC from WAGO. I/O modules connected inseries to the I/O-IPC record signals from the sensors.

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ADDRESSES

D

WAGO Kontakttechnik GmbH & Co. KG

Postach 28 80, 32385 Minden

Hansastrae 27

32423 Minden

Phone: +49 (0)571 887-0

Fax: +49 (0)571 887-169

ino@wago.com

A

WAGO Kontakttechnik Ges.m.b.H.

Laxenburger Strae 244

1230 Vienna

Phone: +43 1 6150780

Fax.: +43 1 6150775

ino.at@wago.com

CH

WAGO CONTACT SA

Rte. de lIndustrie 19

Case Postale 168

1564 Domdidier

Phone: +41/26 676 75 86

Phone: +41/26 676 75 01

ino.switzerland@wago.com

IMPRINT

WAGOdirect process October 2012

Editor: Torsten Schimanski

(responsible editor)

Phone: +49 (0)571 887-531

Fax: +49 (0)571 887-305

Re-use o this content ree o charge is possible.

Contact: Torsten Schimanski. We assume no liability or

unsolicited manuscripts and photos sent in.

WAGOdirect process appears at irregular intervals.

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