AUTOMATION CONCEPTS FOR 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 09 RURAL 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 Tûranor Planetsolar has successfully 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; for 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 Tûranor 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 life cycles – the focus is on functionality, safety, a long life span, and the universal applicability of the components. The multitude of different signals and parameters from the measurement and control technology must be received safely 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 for production changeover as well as the temporary storage and archiving of data in the process underscore the demand for the greatest flexibility in automation solutions. We at WAGO take on your individual challenges and formulate sustain-able solution concepts.

This also in the area of renewable energies. With our direct current measurement, for example, operators of photovoltaic systems now have the opportunity to get reliable data about the feed-in power – without interrupting the string lines. In addition, our TOPJOB® S Series has expanded further; the new disconnect terminal blocks, which are tested and approved for up to 1,500 VDC, ensure absolutely safe connections in generator connection boxes and set new standards with their function. The articles in this WAGOdirect process are only a small selection from a large product range, which is guaranteed to include the appropriate solution for your requirements.

With innovative greetings,

Kay MillerMarket Management Industry & ProcessWater

CONTENTS EDITORIAL

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■ The capacity of alternative energy sources is demonstrated in a few spectacular projects. An example is the solar-powered cat-amaran Tûranor Planetsolar, which circumnavigated the globe with 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 WAGO’s control technology.

The Tûranor 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 efficiency 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 rudderSince 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-efficient drives with WAGO control 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 like a customary system with propeller and rudder blade.

■ Redundancy prescribedThe 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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In 19 months the Tûranor Planetsolar circled the globe using only solar energy.

are doubled. The control system is implemented with WAGO’s PLC and IPC components. A follow-up control string consists of a 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 the drives are implemented via 750-871 PLC. WAGO’s automation components are certified by Germanischer Lloyd and can there-fore be used in the marine sector.

■ Successfully sailing all the world’s seasDuring the circumnavigation, both innovative drive system and hardware/software for redundant control proved themselves. For current news about the Tûranor Planetsolar and the logbook from the circumnavigation, visit www.planetsolar.org.

Text: Roland Lück, Marine and Automation Technology Matthias Markert, Hochschule Wismar

Photo: Planetsolar

On May 4, the crew in Monaco was able to celebrate the successful circumnavigation.

The control system is implemented with WAGO’s PLC and IPC components

Complete system approved by Germanischer Lloyd

The ship is steered using the change of speed, direction, and angle of the two propellers

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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, photovoltaic systems 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 DIATING ENERGY100 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 of real plantsThere 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 the power available from large power plants. Temporary fluctuations in the electrical grid can be smoothed out by the availability of 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 stable power 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 Sensor has a measuring range from 0 to 80 A, and the 789-621 has a measuring range from 0 to 140 A.

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PHOTOVOLTAICS ARE RA 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%, and 60%, 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.

■ Efficient generation, efficient useThe 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 transformer stations, 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 of a virtual power plant

Pump storage

Cold store

Heat pump

Combined heat and power plant

Hydroelectric plant

Current flow with lack of powerCurrent flow with excess power

Control power for the free market (electricity stock exchange)

■ Maintain attractiveness, increase developmentThe 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, WAGOPhoto: WAGO

Supporting the IEC 60870-5-101/-104 and IEC 61850 telecontrol protocols: the 750-872 and 750-880/025-001 Telecontrollers as well as the 758-874 and 758-875 Telecontrol IPCs.

Integration of PV systems into smart grids

Remote communication via IEC 60870 and IEC 61850

Competition for large power plants: virtual power plants

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■ Telecontrol and monitoring of remote sites or mobile devices is no problem at all for TO-PASS®. Via GPRS and Internet, faults 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 better into the control center.The heart of this Web connector is a special function block for the CODESYS development topology. This function block registers the HTTP queries from 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 information, visit www.wago.com/telecontrol.

TO-PASS® WEB CONNECTOR Easy integration of fault detectors into control technology

■ WAGO expands its TOPJOB® S range to include rail-mount termi-nal blocks for simple measurement in current transformer circuits and for automatic short-circuiting of transformers.

The new 2007 Series Disconnect/Test Terminal Blocks are specially designed for use in current and voltage transformer circuits. They feature a highly functional design and are just 99.6 mm long and 8.0 mm wide. Intuitive orange disconnect links simplify operation: Closing the link automatically short circuits the transformer via in-serted adjacent jumper for switch lever.

The circuit state can be easily, safely and reliably determined via open, touch-protected design. The 2007 Series also includes through and ground terminal blocks with identical profiles. All of the terminal blocks are designed for 30 A and 500 V based on IEC and 300 V based on UL. The maximum nominal cross section for ferruled conductors is 6 mm² (AWG 10) and 10 mm² (AWG 8) for solid and fine-stranded conductors.

CURRENT TRANSFORMER TERMINAL BLOCKS ADDED TO PROGRAM

Disconnect/test terminal blocks for current and voltage transformer circuits join the range of TOPJOB® S rail-mount terminal blocks.

“The TOPJOB® S current transformer terminal blocks combine an extremely compact design with a high level of functionality, such as automatic transformer short-circuiting,” declares Burkhard Niemann, Product Manager for ELECTRICAL INTERCONNEC-TIONS at WAGO Kontakttechnik GmbH & Co. KG.

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■ In the Swiss community of Wahlen, parts of the local sys-tems for water treatment and water distribution were out of 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-acceptable drinking 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 Stürmenkopf 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 Wahlen’s 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 wiringThe 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 doesn’t 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 INVESTS IN NEW SYSTEMS FOR WATER SUPPLYNew controller and new control system provide detailed information

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RURAL COMMUNITY INVESTS IN NEW SYSTEMS FOR WATER SUPPLYNew controller and new control system provide detailed information

■ Controlling operation easily with the control systemEndress+Hauser’s 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 Wahlen’s 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.

■ ConclusionWith 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, WAGOPhoto: WAGO

WAGO-I/O-SYSTEM replaces discrete controller structure

ETHERNET Controller and pluggable I/O modules

P-View control system from Endress+Hauser

The new UV sterilization system is incorporated into the monitoring, sensors provide the measurement data.

Where previously a discrete structure with contactors and relays filled the cabinet, now the WAGO programmable ETHERNET Controller takes on the control functionality. The data is incorporated via plugged I/O modules.

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AUTOMATION CONCEPTS FOR THE PROCESS INDUSTRY

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■ Modular concepts ensure great flexibility, reusability, and finally also lower costs in software 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, the individual 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

AUTOMATION CONCEPTS FOR THE 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 systems and 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 approachFor a while now there have been efforts in the process industry to build modular systems. With the designation F3, a consortium 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, Fast and 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 communicationA “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 point from 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 lion’s 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 of automation technologySince 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 system’s ETHERNET controllers or IPCs.

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Module concept in the process industry

Automation of “package units”

High requirements for components and systems

■ ConclusionThe 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 automation technology, this creates new opportunities.

Text: Jörg Lantzsch, professional journalist from WiesbadenPhoto: WAGO

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PUMPING OUT WATER IN THE LAUSITZ MINING AREA■ To ensure the proper function of conveyor systems in surface min-ing, vast amounts of water must be continuously lifted and diverted. For efficient drainage of their storage facilities in the Lausitz mining area, Vattenfall Europe Mining AG together with the automation company BEA TDL of Spremberg implemented new system technol-ogy. Standard drive solutions with modular controllers from WAGO and new communication technologies now simplify the operation of drainage systems.

To convey coal at depths of 35 to 120 meters, Vattenfall operates more than 2,500 filter wells to drain the mining area. In the mining area, the filter wells are arranged in a linear structure as a barrier. Due to continuous coal mining, the active surface mining area ad-vances in the direction of 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 for the automation equipment. To make the drainage operation even more efficient in the future, Vattenfall de-cided to replace the existing systems technology. State-of-the-art electrical and field device technology, as well as controller and pro-cess control technology should take its place.

■ New system concept simplifies draining operationThe technical office at Vattenfall required direct access from the con-trol station to sensors based on ETHERNET technologies from the new system design. As Vattenfall tendered Project 2007, automation specialist BEA came out on top in competition with other suppliers and was awarded the contract for a pilot installation at the Reich-walde opencast mine. Those responsible selected the WAGO-I/O-SYSTEM for the automation components with programmable 750-841 ETHERNET Controller for pump control and 758-870 I/O-IPC in the bolt control cabinet. The advantage of this system is its modu-larity and the large selection of I/O modules such as a 4–20 mA analog input module with HART protocol and various interface 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 configure operating data and communication with intelligent field devices in CODESYS,” summarizes Armin Noack, project manager at BEA. The requirement for a modular design was met in many system components from the medium-high voltage and low-voltage switchgear to the hardware

Barrier with multiple filter wells in a line safely hold back the ground water from the surface mining area.

In the barrier control cabinet, the I/O-IPC is used for data management with the individual pump controllers, for information exchange with the sen-sors and actuators and the client terminal.

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PUMPING OUT WATER IN THE LAUSITZ MINING AREA

and software in the automation part. Starting from a core configura-tion, for example, the switchgear and controllers can be torn down and setup up based on the use cases to be expected. “With modu-lar components such as the WAGO-I/O-SYSTEM, sustainable sys-tems can be implemented because they allow further development and can be quickly replaced in case of breakdown,” explains Henry Hanschke, Water Technology BU Manager at BEA.

■ Configuration instead of programmingThe barrier and pump controls can be designed as a configurable software system that simplifies system engineering significantly. When first commissioning or modifying 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 configured via a single engineering tool and have an inte-grated web server on which device- and application-specific HTML pages are saved. As a result, any controller on the client terminal can be easily configured from clear user interfaces via the network and requires no additional special knowledge. If 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 fieldAfter the pilot system was proven in practice, those responsible trans-ferred 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 for high system availability under mining conditions. “As a result, the joint development contributes to meeting the hydrological require-ments of surface mining,” summarizes project engineer Jürgen Karas of Vattenfall Europe Mining AG. He adds, “The automation solution achieved has become the standard at Vattenfall.”

Text: Klaus Dreiskemper, WAGOPhoto: WAGO

Bluetooth® communication for the parameterizing of operating data

Direct access from the control desk to the sensor

Modular structure with ETHERNET controllers and IPCs

Armin Noack of BEA TDL demonstration: From an outdoor PDA, the operator reads the flow volume while he activates or disables the valve manually.

The filter wells are controlled by a WAGO ETHERNET Controller. A CODESYS program in the controller integrates HART communication in the MODBUS/TCP protocol.

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DISCONNECT TERMINAL BLOCKS TESTED UP TO 1,500 VDCIdeal for applications in the renewable energy sector: Disconnect ter-minal blocks up to 1,500 VDC for the TOPJOB® S 2006 Series of rail-mounted terminal blocks

■ The cut-off voltage required in photovoltaic and wind turbine sys-tems far exceeds that demanded in classic industrial systems. WAGO has therefore developed rail-mounted terminal blocks that are ap-proved for 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 2006 Series Disconnect, Carrier and Through Terminal Blocks not only make them easy to use, but also provide for safe and reliable handling as well.

The suitability of these terminal blocks for 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 for photovoltaic systems. The maximum nominal cross section for fer-ruled conductors is 6 mm² (AWG 10) and 10 mm² (AWG 8) for solid and fine-stranded conductors. The new terminal block versions can be combined with the existing TOPJOB® S terminal block line and are available in gray and blue.

Approved for higher cut-off voltages: Disconnect, carrier and through terminal blocks for up to 1,500 VDC, tested in accordance with IEC.

“The ongoing technical development of renewable energy sources demands connection technology for voltages of 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 for up to 1,500 VDC,” states Burkhard Nie-mann, Product Manager for ELECTRICAL INTERCONNECIONS at WAGO Kontakttechnik GmbH & Co. KG in Minden.

The TOPJOB® S rail-mounted terminal block systemCovering a range of wire sizes from 0.14 mm² to 95 mm² (AWG 24-4/0), TOPJOB® S, along with POWER CAGE CLAMP, is the rail-mounted terminal block system that offers the widest range of products for industry, buildings and traffic applications. Thanks to CAGE CLAMP® S technology, the TOPJOB® S rail-mounted terminal blocks are the industry’s most compact. These terminal blocks are suitable for all types of conductors; solid, stranded and fine-stranded conductors with ferrules can also be connected simply by pushing them in. The TOPJOB® S rail-mounted terminal block system is round-ed out by the fastest and most economical marking system and by a comprehensive jumper system for any conceivable application.

PACK

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■ WAGO has developed an Ex i up/down counter (750-633) as I/O module for the WAGO-I/O-SYSTEM 750. The counter records binary signals with NAMUR-compliant levels and transmits the sys-tem’s counter state to a WAGO programmable controller or to the higher-level control system via coupler and fieldbus. The counting direction 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 frequency of the counter is 20 kHz. The 24 mm wide module indicates its status on LEDs: green for Up/Down input active, CLK input (counter input) active, and DO switched, as well as red for wire break/short-circuit of the Up/Down and CLK signal lines. The field and system level are electrically isolated and the output is short-circuit-proof. The module is supplied by a separate 24 VDC feed in an Ex i version.

Ex i COUNTER FOR NAMUR-COMPLIANT SIGNALS

WAGO’s new intrinsically safe up/down counter re-cords binary signals with NAMUR-compliant levels.

■ Defined interfaces, defined data: the Weihenstephan Standards (WS) form the basis for a manufacturer-independent coupling of ma-chines and superior production management systems: WS Pack for beverage filling and packaging systems and WS Food for food 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 for quality assurance and increased efficiency, the prize explicitly acknowledged the pre-competitive in-volvement of all participants: the industrial partners, the German Engineering Federation (VDMA), and the Science Foundation of the German Beer Brewing Industry (WiFö). WAGO has supported the Weihenstephan Standards since early 2011 as an official partner en-terprise and, as part of this involvement, has developed the necessary software components for their ETHERNET controls and ETHERNET industrial PCs.For additional information, visit www.wago.com/food.

EXCELLENT STANDARD “International FoodTec Award 2012” in Gold for the Weihenstephan Standards

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■ A central process control system is not sufficiently flexible or too expensive for many companies. The engineering office for process au-tomation/control, pac GmbH here relies on control units by WAGO. In a project for biotechnology at Novartis, a remote system had to prove itself as a control unit for process systems in conjunction with a central monitoring system.

Novartis operates many multi-purpose systems in the field of biotech-nology, which are not geared to mass production with fixed produc-tion processes. Production and processes change regularly, a central process control system is therefore too inflexible. According to the re-quirements of ERES (Electronic Records – Electronic Signatures) and the FDA (Food and Drug Administration), 21CFR Part11, data and user interventions, such as settings and configurations, however, would have to the recorded during production and stored securely. This log-ging was previously associated with a great manual effort.

■ Autonomous automation solutionAs an alternative to a central process control system, Novartis decided to set up a remote process controller by pac GmbH using the tech-nique of 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, faults and user input according to 21CFR Part11.“The WAGO IPC is predestined to be a decentralized process control-ler thanks to three particular features,” says Jürgen Sütterle, the CEO of pac GmbH. From his point of 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 of a classic PLC: it is robust, small, and program-

CONTROLLING PROCESSES REMOTELYmable according to IEC 61131 like a programmable logic controller. Finally, as an IPC it integrates the open standards of the PC world.”

■ Flexible and modular control unit“In process automation, we frequently need an alternative for large and complex control systems. This easy to use PLC, however, must still meet the highest quality demands. The WAGO system has positioned itself here and proven itself in practice. It uses standard hardware, standard protocols, as well as standard interfaces. We therefore can select various suppliers for the peripherals. If a terminal malfunctions, 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-effective,” added the manager of the engineering office. He especially appreciates the flexibility in the integration of sensor and actuator signals.

■ Practical decentralized solution The decentralized process control has proven itself at Novartis. In a preparation system for the extraction of an active ingredient, first different media are added, and in another process they are stored and conditions in a second group of machines. The controller ensures that there is a ring line for the process-appropriate addition of com-mon resources such as cleanser, steam, and distilled water, and it per-forms coordination tasks such as filling in mobile containers, the trans-fer between the machine groups, and the control of valves. The production data is stored and evaluated centrally. Via view stations distributed 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 interface of the logging system has proven very helpful for the incorporation of different suppliers’ machine groups. A Siemens control unit can also be connected via a PROFIBUS coupling.

The process steps can be automated with a flexible decentralized process control system and manual efforts for the regulatory requirements can be simultaneously be reduced.

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Decentralized process control with the WAGO IPC

Production data according to FDA 21 CFR Part11

Manufacturer-independent connection to the controller

CONTROLLING PROCESSES REMOTELY

The challenge of changing system inserts and changing processes could also be easily solved with the decentralized approach. “The system control is cost-effective and functional due to the modular struc-ture. Control functions, such as ‘agitating’ are distributed into basic functions according to NAMUR recommendations and can be reused at another point. We were able to reduce the testing effort overall and the tests of individual modules by this copying effect” reports Jürgen Sütterle. From the view of the automation engineer, the easy and uni-form operating concept also on various equipment groups has contrib-uted essentially to the acceptance by the employees. The training effort was therefore kept at a minimum.

Text: Martin Ortgies, professional journalistPhoto: Novartis, WAGO “In process automation, we frequently need an alternative for large and

complex control systems. This easy to use PLC, however, must still meet the highest quality demands. The WAGO-I/O-SYSTEM has positioned itself here and proven itself in practice”, Jürgen Sütterle, Managing Director of pac GmbH.

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■ Having the customer profit from manufacturer’s expertise benefits everyone: with help from 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 process steps 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 company’s 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 processPretreatments, such as chromating or zinc phosphating, are com-

REMOTE MONITORING OF CUSTOMER PROCESSESplex 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 the “Lineguard 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 offers access from anywhere in the worldWorldwide support for process systems and technology is-sues play a major role in Henkel’s business model. Therefore,

The Lineguard Supervisor helps transfer Henkel manufacturer know-how to the customer and minimizes effort and expense at the same time. The TO-PASS® Dynamic Web Portal offers both sides access to the customer process without any engineering effort by the customer.

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REMOTE MONITORING OF CUSTOMER PROCESSES

As an intelligent I/O system, the WAGO I/O-IPC offers PLC functionality

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

TO-PASS® Dynamic Web Portal detects plugged I/O modules and processes large quantities of data

a Web-capable system was required, which Arkadon imple-mented by adapting the existing TO-PASS® Web 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 current process 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-performance control systemAs an intelligent I/O system, the 758 I/O-IPC offers PLC function-ality. Using CODESYS, it is possible to program a self-teaching controller 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 Wolfgang Laufmann, WAGO

Photo: Henkel, WAGO

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

ADDRESSES DWAGO Kontakttechnik GmbH & Co. KGPostfach 28 80, 32385 MindenHansastraße 2732423 MindenPhone: +49 (0)571 887-0Fax: +49 (0)571 887-169info@wago.com

AWAGO Kontakttechnik Ges.m.b.H.Laxenburger Straße 2441230 ViennaPhone: +43 1 6150780Fax.: +43 1 6150775info.at@wago.com

CHWAGO CONTACT SARte. de l’Industrie 19Case Postale 1681564 DomdidierPhone: +41/26 676 75 86Phone: +41/26 676 75 01info.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 of this content free of charge is possible. Contact: Torsten Schimanski. We assume no liability for unsolicited manuscripts and photos sent in. WAGOdirect process appears at irregular intervals.

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