packaging machines - electrical components & …electrical/.../pct_391737.pdf · packaging...

CUSTOMER MAGAZINE EATON’S ELECTRICAL SECTOR EMEA

News: From Lean Connectivity to Lean Automation P. 5 | Cemented: SmartWire-DT controls conveyor belts for cement clinker P. 18 | Do Brasil: “Bom apetite”: Food production in Brazil P. 22 | Bello il sole: DC switchgear for photovoltaic applications P. 24

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Export Requirements forPackaging Machines

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ContentImprintSolutions is the customer publication of Eaton’s Electrical Sectors EMEA

Published: Eaton’s Electrical Sector EMEAEaton Industries GmbHHein-Moeller-Straße 7-1153115 BonnTel.: +49 228 602-0Fax: +49 228 602-62275E-Mail: [email protected]

www.moeller.net/solutions

Editors:Dirk Bolz (v.i.S.d.P)Christian BückerIntegral Dr. Schumacher®

Authors:Christian Bücker, Jan Carls, Mike Edelmann, Wolfgang Esser,Erwin Ooyman, Christian Stadler, Adriano Lobo de Souza, Dr. Monika Schumacher, Dr. Gottfried Tharang, Alessandro Valente

No. of copies: 17,000

This customer publication is protected by copyright, applicable to all articles, diagrams and photos. Eaton reserves all rights.

CS08703001Z-ENArticle No. 153565

Layout: buntebrause agenturPrinted in Germany (03/11)

Translator: Terry OsbornTRANSTech Translations

News... 4-14

The Drive of Young Researchers... 15 Cooperation between Company and School – Eaton

Supports High School Students in Stade

Sustainable Packaging... 16-17 SmartWire-DT ™ Optimizes Production Process

Cemented... 18-19 SmartWire-DT ™ Controls Conveyor Belts for Cement Clinker

The Power of Nature... 20-21Eaton Automation Technology Controls Hydro Power Station

Do Brasil: “Bom apetite”... 22-23 PKE Motor-Protective Circuit-Breakers with

SmartWire-DT ™ for Food Production

Bello il sole... 24-25 New DC Switchgear for Photovoltaic Applications

Packaging Artists... 26-27 Export Requirements of a High-Speed Horizontal

Flow Wrapping Machine

Soil Washing... 28-29 Soil Washing Plant Treats Polluted Mineral

Building Waste

Infoboard... 30-31

P. 20 P. 18

P. 24 P. 28

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CLEVELAND … Diversified industrial manufacturer Eaton Corporation (NYSE:ETN) this year celebrates its 100th anniversary of providing customers around the world with innovative and sustainable products and systems. Founded as a small axle business in 1911, Eaton has evolved to become a global power management company and a leader in energy-efficient technologies that help its customers use power more safely and effectively.

“Our company has grown and changed considerably during its first 100 years, but we remain dedicated to the spirit of innovation and ideals that inspired Joseph Eaton,” said Alexander M. Cutler, Eaton chairman and chief executive officer. “His investment in a new idea in transportation – the first gear-driven truck axle – established a foundation for growth that we continue to build upon today as a values-based, global company.”

Today Eaton’s four business groups – Electrical, Aerospace, Hydraulics and Vehicle – serve diverse global markets ranging from aviation, agriculture and construction to energy, infrastructure, healthcare and beyond. With customers in more than 150 countries,

Eaton generates more than 55 percent of its revenues from international markets.

Key technology and business highlights throughout Eaton’s first century include the following:

• Joseph Eaton’s 1911 investment in Torbensen Gear and Axle, the precursor to Eaton Corporation, led to commercialization of efficient, breakthrough technology in the truck market.

• Global growth began in 1946, when Eaton acquired an interest in a motor pump and gear company in the United Kingdom.

• The first passenger car air conditioner affordable enough for the average consumer was an Eaton product, introduced in 1952.

• Eaton was NASA’s choice in 1978 to design and build a new landing system for the space shuttle; in further collaboration, Eaton developed a prototype electric vehicle (EV) propulsion system, unveiled on NASA’s EV prototype in 1989.

• Shanghai was the site of Eaton’s first wholly owned business in China in 1997; Eaton in 2008 opened a new Asia Pacific regional headquarters in Shanghai that has received Gold-level Leadership in Energy and Environmental Design (LEED) certification.

ThE ComPANY

Eaton Corporation Builds on 100 Years of Innovative Ideas to Position Company for Continued Growth

Alexander M. Cutler, Chairman and CEO of Eaton

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ThE ComPANY

• Sustainable vehicle projects accelerated for Eaton in the early 2000s, as the company developed the first hydraulic hybrid power system for delivery trucks and brought its leading hybrid technology to fleets of city buses in China; today Eaton hybrid-powered commercial and transit vehicles have logged more than 100 million miles of service worldwide and reduced diesel fuel consumption by more than four million gallons.

• Eaton is working with the world’s leading aerospace manufacturers to make air transportation safer, more reliable and more energy-efficient; the company expanded that roster in 2010 by creating a joint venture to support China’s new aircraft industry.

• Eaton hydraulic equipment played a critical role in the dramatic rescue last fall of a group of trapped Chilean miners; rigs equipped with Eaton products drilled the initial bore hole that allowed rescuers to locate the miners and later were used to widen the shaft that eventually freed them.

• With recent hydropower installations in Vietnam, South Korea and the United States, Eaton is a leading supplier of hydraulic and electrical technology for hydroelectric projects worldwide.

• In the Netherlands, Eaton is helping to renovate the Amsterdam Metro system, providing new power distribution systems for improved and expanded subway stations.

• Eaton electrical products provide vital backup power protection for the massive new terminal at Delhi’s Indira Gandhi International Airport, the eighth largest airport in the world.

• Eaton’s vast service networks and advanced hydraulic and electrical technologies support wind turbine manufacturers virtually anywhere in the world, including recent deployments in China and Canada.

• With electric vehicles rapidly entering the market, Eaton is deploying its family of EV charging stations for use in homes, businesses and on the road, helping to build the infrastructure vital to the advancement of this new mode of transportation.

• Eaton’s new fully automated heavy-duty transmissions enable operators to drive and navigate a broad range of heavy-duty trucks safely and more efficiently.

“As we celebrate our company’s centennial, Eaton people around the world are building upon our heritage of innovation and expertise,” said Cutler. “We look forward to building further momentum for our most impactful technologies that will help our customers everywhere manage rising energy costs and address some of the world’s toughest power management challenges.”

Eaton Corporation is a diversified power management company with 2010 sales of $13.7 billion. Celebrating its 100th anniversary in 2011, Eaton is a global technology leader in electrical components and systems for power quality, distribution and control; hydraulics components, systems and services for industrial and mobile equipment; aerospace fuel, hydraulics and pneumatic systems for commercial and military use; and truck and automotive drivetrain and powertrain systems for performance, fuel economy and safety. Eaton has approximately 70,000 employees and sells products to customers in more than 150 countries.

For more information, visit www.eaton.com

Viggo Torbensen:

1900 Viggo Torbensen develops and patents the first geardriven rear truck axle.

J. o. Eaton:

1911 Viggo Torbenson and Joseph Oriel Eaton, founded the Torbensen Gear and Axle Company, the precursor of Eaton Corporation.

Torbensen Gear and Axle Company:

Torbensen Gear and Axle manufactures just seven axles in its first year, 1911 using specialized tools to handcraft them from raw materials.1920 – Eaton Axle builds an efficient new $1 million plant in Cleveland that conserves heat and maximizes natural light.

Nikola Tesla, the inventor and electrical engineer, worked for Westinghouse in 1889 at a factory in Pittsburgh. His invention of the electric AC generator helped the dominance of AC installations worldwide.

The Westinghouse Distribution and Controls Business Unit has been part of the Eaton Corporation since 1994.

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NEWS +++ NEWS +++ NEWS

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The book “The Machine That Changed The World – The Story of Lean Production”, published in 1990 was a groundbreaking influence on the field of industrial production. The scientists at MIT, the Massachusetts Institute of Technology, used this book to outline their research carried out over several years within the International Motor Vehicle Program (IMVP), which studied the different conditions for development and production in the automotive industry. In their publication they ascribed the term “lean production” to the principles of a high-level development and production system that was geared to efficiency and quality.

These principles have also not failed to influence trends in machine building. In this sector, “lean” also stands for the general principle of identifying every type of waste and thus continually and consistently optimizing every process.

Eaton has been offering solutions for machine building for over 20 years. In close cooperation with customers, Eaton has analyzed the main issues and identified the following trends in machine building: Energy efficiency and data transparency, standard and scalable solutions.

As well as the energy efficiency required in all sectors, the Machinery and Safety Directives stipulate a fundamental and essential objective – data transparency: Data transparency is required from the sensor of the individual machine right through to the PLC.

The standard solution is derived from the second key issue: Machine builders focus on the factors of cost reduction, increased performance and additional functionality. To achieve this, standard solutions frequently lead to customized solutions. A “customized design” is meant to save additional costs. However, this can

only be implemented when large unit volumes of machines are involved.

The third noteworthy and trendsetting issue is the development of scalable solutions: A series machine manufacturer normally offers an entire range of products. This normally ranges from a compact machine to the standard machine, then up to the universal machine, right through to the high performance solution, ultimately covering all applications. Of equal importance in the future are the buzz words “automation” and “motion control”, which are offered as scalable solutions with an open architecture.

Based on these findings and in partnership with customers, Eaton has developed an impressive and practical automation concept that offers significant benefits both to the series machine builder and the system builder: “From Lean Connectivity to Lean Automation”

This automation concept “slims down” control cabinets, simplifies wiring, increases data transparency, reduces engineering and commissioning requirements, increases performance and reduces costs – to an unprecedented degree. The “From lean connectivity

The Automation Concept of Eaton

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to lean automation” concept also means fewer sources of error and greater flexibility for modular machine concepts. “From lean connectivity to lean automation” is based on two core technologies: SmartWire-DT and the HMI/PLC.

The first core technology: SmartWire-DT

SmartWire-DT is a technology developed by Eaton that is fundamentally based on the principle of “lean connectivity”. SmartWire-DT is a seamless wiring and communication system – whether in a control cabinet, machine or local distribution box, the connection and communication technology is the same. SmartWire-DT replaces the control wiring in all components from the circuit-breaker to the motor starter and frequency inverter, right through to pilot devices and sensors. However, the system not only wires intelligent components, it is also designed as an open system, thus allowing the integration of third party products.

As well as being a wiring system, SmartWire-DT is also an extremely powerful communication system. A key feature is the fact that SmartWire-DT uses one user software to cover a wide range of machines with different characteristics and add-ons in several possible variants. This enables machine builders, for example, to reserve space and install, cable and commission the individual components and the machine in the field. SmartWire-DT keeps mounting and wiring requirements to a minimum. The continuous green SmartWire-DT cable is a striking feature in the switchboard. It provides the communication link between the required components. SmartWire-DT furthermore eliminates the need for the entire control system wiring – the single SmartWire-DT cable normally provides the power supply required. Conventional I/O modules are also unnecessary since the I/O level on SmartWire-DT is directly integrated in the switchgear, thus totally excluding the possibility of faults.

SmartWire-DT is provided with remote intelligence since the ASIC integrated in each SmartWire-DT component is actually designed as a local controller. The ASIC forms the core of the system and is designed to provide the controller data, and to ensure efficient and high-performance communication. It was Eaton’s aim not to develop SmartWire-DT as a proprietary system but as an open technology. Eaton is therefore offering developer kits that provide a fast entry level for other manufacturers to integrate SmartWire-DT in their own products.

Second core technology – hmI/PLC

The second core technology is the HMI/PLC. This outstanding product philosophy offers visualization and conventional PLC functionality in a single device. Eaton has been working on this core technology for several years and is continuously making further optimizations. Eaton has now developed a 3.5 inch device which integrates PLC, visualization and communication in full. This in-house development forms the basis for lean automation. The Eaton device lines now offer HMIs from 3.5 inches to 15 inches with both resistive and infra-red touch technologies.

Based on RISC technologies, the devices make use of the standard WinCE operating system and offer a wide range of open communication options. Openness is our driving principle, thus enabling all commonly available PLCs and drive systems to be integrated in the system. Eaton uses a standard software package for the control and visualization of all devices.

Eaton also offers flexibility for the operator panel, thus enabling customers to design their own button layout or modular front panels as a kind of calling card for their machine. Each Eaton HMI/PLC is not only a visualization device but also a controller and communication device.

Development phases of the automation structure

original automation structure: hmI – Central PLC – Control wiringThis structure is found in many applications and is based on a central PLC that controls the machine. However, this automation structure is very personnel and work intensive: A production manager on site reads the production data at the machine, and a machine operator and mechanic are also required. The mechanic has to refit the entire machine when a new recipe is required. These systems typically involve the use of mechanical gears, cams that are controlled with a main drive – all these configured for a unique production task. As soon as production has to be changed, the machine is retrofitted in one or two days, after which it can be restarted. The PLC often involves complex local wiring systems: wiring systems in the junction box, sensors on the machine and also safety wiring connected in parallel.

SWITCH CABINETOPERATION MACHINE

REMOTE

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Operator console with:- Communication + data management- Remote intelligence- Fieldbus + SmartWire-DT via gatewayHMI/PLC

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2nd Automation structure: Touch display – Central PLC – Control wiring – Fieldbus – SmartWire-DT – Remote I/O

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1st Automation structure Touch display – Central PLC – Control wiring – Fieldbus – Remote I/oComplex wiring systems connected to the central PLC become unnecessary through the use of touch displays and remote I/Os. For the first time, the touch display also offers a communication link to an ERP system. An onsite production manager is no longer required here, and machine data can now be accessed remotely. Together with the fieldbus, remote I/Os are used to replace complex machine cabling. Remote I/Os function at the same time as data collectors that are interconnected by means of a fieldbus. These types of architectures are nowadays in widespread use. They also integrate components such as hydraulic valves. In other words, each innovation stage integrates more functions such as a hydraulic or electric drive. The significant feature here is that for the first time the data from the machine is now fed and made available to a higher-level system.

2nd Automation structure Touch display – Central PLC – Control wiring – Fieldbus – SmartWire-DT – Remote I/oThis automation structure is basically the same as the previously described structure, however with the key difference that the use of SmartWire-DT considerably reduces the wiring required for pilot devices, motor starters and circuit-breakers. For example, pushbutton actuators, indicator lights, and switching devices can be fed with the operational current and integrated in the communication structure via a single SmartWire-DT line. The clear and simple structure therefore shortens also the test and commissioning phase as well as the wiring required. SmartWire-DT is connected via gateways to Profibus or CANopen fieldbus systems. Compared to the overall engineering design, the requirements in the SmartWire-DT line are considerably reduced. Other components such as sensors and actuators are primarily connected via remote I/Os to fieldbus systems.

3rd Automation structure hmI/PLC with integrated SmartWire-DT – Fieldbus – Remote I/oThe touch display PLC replaces the central PLC. A gateway to the fieldbus is no longer required; the SmartWire-DT line is connected directly to the HMI-PLC. Operating data from the motor feeders, such as motor current, thermal motor load, switching states, trip indications such as overload, short-circuit, phase loss, is transferred via SmartWire-DT to the HMI/PLC. Servo drives, frequency inverters and some sensors are integrated

in the automation structure via standard fieldbuses. Electrical and hydraulic drives replace the mechanical system and thus enable flexible production without the need to retrofit mechanical equipment. The machine operator selects the production quantities and recipes via a touch display and the machine is reset automatically. Downtimes and changeover times become a thing of a past. This complete and fully automated total solution is already available from Eaton.

The vision – Lean Automation hmI/PLC – Remote intelligence with SmartWire-DTThis visionary “lean automation” structure eliminates the need for remote I/Os and any signal wiring to sensors or actuators. “Lean connectivity” brings SmartWire technology directly into the devices. The structure consists of an HMI/PLC with integrated SmartWire-DT and components with remote intelligence. Starting from the display, SmartWire-DT connects pushbutton actuators, indicator lights, switchgear right up to the sensors. Frequency inverters and safety systems, as well as hydraulic and electrical drives are integrated via SmartWire-DT. “Lean automation” finally brings together the world of hydraulics and the world of electrics in the automation world. To strengthen this vision, Eaton is also offering the SmartWire-DT technology to other manufacturers for the integration of their own components in SmartWire-DT. Manufacturers can thus obtain an implementation set to develop SmartWire-DT slave components.

Summary

A “lean automation” solution, consisting of SmartWire-DT and HMI/PLC technology “slims down” control cabinets, simplifies the wiring, increases data transparency, reduces engineering and commissioning requirements, increases performance and reduces the cost requirements, as well as bringing fewer fault sources and greater flexibility for modular machine concepts. In order to also make these significant benefits transparent in terms of expenditure, Eaton has developed its own software tool that compares different automation concepts with the Eaton “From lean connectivity to lean automation” solution. All prospective collaborators and third party manufacturers are called upon to take part in Eaton’s vision through discussions and/or their own components.

Quicklink ID: ES2301

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Operator console with:- Communication + data management- Remote control function- Remote intelligence- SmartWire-DT

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SmartWire-DT mit integrated Safety

The vision – Lean Automation: HMI/PLC – Remote intelligence with SmartWire-DT 3rd party

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From Lean Connectivity to Lean Automation

Eaton’s new XV102 touch display PLCs offer high-performance HMI/PLCs with an integrated SmartWire-DT master. SmartWire-DT is a comprehensive connection and communication technology from Eaton: The uniform and open system replaces the control wiring in all components, from the circuit-breaker to motor starters and frequency inverters, right through to pilot devices and sensors.

The new XV102 device series with a SmartWire-DT master is based on the XV100 HMI/PLC and stands out on account of its compact dimensions and high performance. This is provided by a 400 MHz RISC processor and a 128 MB onboard memory (also expandable as required with an SD memory card). All HMI/PLCs can also handle demanding PLC applications.

The SmartWire-DT master integrated in the device is a new feature: Previously, the connection required a gateway which was linked to the XV100 HMI/PLC via CANopen or Profibus. Eaton has now elegantly and efficiently designed the SmartWire-DT interface, and has integrated the master directly in the touch panel. Eaton will be launching five XV102 HMI/PLCs with a SmartWire-DT master from Q3/2011. The following display sizes and interfaces are available: A 3.5 inch as well as 5.7 inch and 7 inch screen with RS485 and CANopen or Profibus DP/MPI.

This SmartWire-DT master integration offers several user benefits. The SmartWire-DT line can be configured simply and conveniently via CoDeSys. The technical data of the SmartWire-DT interface is the same as that of the previous SmartWire-DT gateways, i.e. users can access the full range of functions and can connect up to 99 slaves to a SmartWire-DT master. In line with the “Connecting instead of wiring” principle, the SmartWire-DT interface connects all the way into the PLC without the use of an intermediate circuit. Users also save the additional device costs of a separate cabled gateway.

Eaton is covering a wide application range with the five XV102 HMI/PLC variants. The 3.5 inch device together with SmartWire-DT pilot devices, motor starters, contactors and remote SmartWire-DT I/Os is suitable for compact lean automation solutions. The 5 inch and 7 inch devices are ideal for medium-sized machines and systems. As well as having SmartWire-DT, two standard

fieldbuses, either Profibus DP and CAN, allow devices with standard fieldbus interfaces to be integrated in the automation concept.

Like all visualization devices of the xSystem product groups, the XV102 series HMI/PLCs can be programmed with the Galileo visualization software or CoDeSys visualization software, and programmed as a PLC with the CoDeSys-based xSoft-Codesys-2 programming system in accordance with IEC61131-3. Thanks to their small mounting depth, the panels can also be installed in confined spaces. All display fronts can be customized if required. XV102 devices support the trend towards scalable hardware and software solutions that allow machine and system builders to keep the requirements for engineering and system maintenance to a minimum. The XV102 series also supports the requirements for a modular machine design.

This visionary “lean automation” structure developed by Eaton eliminates the need for remote I/Os and any signal wiring to sensors or actuators. Lean connectivity takes the SmartWire technology directly into the devices, as is clearly demonstrated on the XV102 series. The structure consists of an HMI/PLC with integrated SmartWire-DT and components with remote intelligence. Starting from the panel, SmartWire-DT connects pushbutton actuators, indicator lights, and switchgear right up to the sensors. Frequency inverters and safety systems, as well as hydraulic and electrical drives are also gradually being integrated via SmartWire-DT. “Lean automation” will finally bring together the world of hydraulics and the world of electrics in the automation world.


New XV102 HMI/PLCs Integrate SmartWire-DT™ Master

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New input/output modules can now be connected to the SmartWire-DT connection and communication system. A 4-channel input module with a 3-wire connection and integrated short-circuit proof power supply, as well as an 8-channel output module (8 *24 VDC, 0.5 A) have been added to the range of digital modules.

Several modules for connecting analog sensors and actuators are new: Firstly, an input module with 4 inputs for the variable measuring of current and voltage signals (0-20mA, 0-10V). Secondly, an input module with 2 inputs and 2 outputs, for the variable measuring and outputting of current and voltage signals (0-20 mA, 0-10 V). Thirdly, an input module with 5 temperature inputs with 2/3-wire technology for PT100, PT1000, Ni1000 sensors. Users can connect the modules to the SmartWire-DT communication system at any position in the control cabinet. This creates flexibility for the optimum use of space in the control cabinet and reduces the wiring required to the digital and/or analog sensors and actuators.

When functions have to be retrofitted on a plant, modifications to the hardware configuration and program expansions normally involve considerable costs. The universal modules of Eaton’s SmartWire-DT communication system now offer a very simple solution for these requirements.

SmartWire-Darwin is designed as an intelligent communication system for simple pilot devices as well as contactors and motor-protective circuit-breakers. It replaces the previously required control wiring so that the associated PLC inputs/outputs also become unnecessary. SmartWire-DT universal modules can be used as a substitute for devices (such as pilot devices, motor-protective circuit-breakers, I/O modules) that are configured but are only planned in the installation for expansions. This enables users to design and program the full configuration in the PLC configuration and in the user program. The hardware required for expansions does not yet have to be physically present. In

this way, installation sections can be expanded at a later time as required by replacing the universal slave with the configured device, without having to change the program or hardware configuration.

New I/O Modules for SmartWire-DT™

SmartWire-DT™ Universal Modules For Simple Plant Modifications



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Rapid Link 4.0: New Decentralized Electronic Drive System

The Rapid Link decentralized drive system will enter its second generation from April 2011, bringing with it an extended performance range. The latest motor starters and frequency inverters stand out on account of their improved operating values so that Rapid Link 4.0 offers a real added value with regard to engineering and plant installation.

Thanks to a new housing concept, Rapid Link 4.0 is impressive in every respect. The motor starters and frequency inverters up to 2.2 kW thus have the same fixing dimensions. As only one fixing bracket is required for the entire range, this simplifies plant design. The benefits are also apparent during installation and commissioning: The swapping of a frequency inverter for a motor starter requires little effort since both the dimensions and all connections are identical.

The rectangular housing style also allows the feeding in of the power and motor cable from the left or right and not only from the bottom. In this way, the operator level and the cooling fins of the frequency inverter are always in the optimum position. Any derating of the electrical values for the side entry of power and motor cables is unnecessary. A guard ring largely protects the operating elements and electronic terminals from mechanical damage.

A new feature of the housing concept is also the optionally integrated and lockable isolating switch. This enables the Rapid Link unit itself and also the connected motor to be disconnected safely from the mains supply for maintenance tasks. All sizes and variants are still provided with IP65 protection.

With considerably improved electrical values, Rapid Link 4.0 offers an outstanding performance during operation. The RAMO4 motor starter is suitable for motors up to 3 kW. Thanks to the electronic motor start, the lifespan of the new devices has been considerably increased compared to the RAMO3 series, and has tripled with up

to 10 million operating cycles at 3 kW. An operating frequency of up to 3000 operations per hour is also possible, as well as a motor load of 2.2 kW. Furthermore, one single frame size now covers the range from 0.3 to 3 kW. This is also the case in an increased temperature range up to 55°C without derating. The RA-SP4 frequency inverter can now be switched from V/f mode to speed control, thus reducing the number of variants required. In addition to the previous frame sizes for 0.75 kW, 1.1 kW and 2.2 kW Eaton is also offering a 1.5 kW rating class. All frame sizes have the same mounting dimensions, thus improving engineering and flexibility during commissioning. The external fan unit with IP65 protection is standard for frame size 2.2 kW, and it can be used for all other frame sizes, thus expanding the temperature range to 55°C without derating.

In addition to the well-known Quick Stop function, users can now program cyclical sequences with fixed frequencies in the RA-SP4. Repeating sequences can thus be stored in the RA-SP4, so that the processing required in the PLC is reduced. Another highlight of the new RA-SP4 series is the integrated brake chopper which can be factory shipped for any frame size. In this way, time consuming installation work on site is no longer necessary.

Communication via AS-I has also been improved. Eaton has ensured with the 7.4 protocol compatibility with previous versions. This also opens up a number of new communication options between the PLC and the motor starter. These include enhanced diagnostics messages such as motor currents or the transfer of parameter data. Users can now change the set frequencies via the fieldbus, such as the RA-SP.


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The majority of pump and fan applications make use of an asynchronous three-phase motor. The characteristic feature of this type of motor is the fact that its speed depends on the frequency of the mains supply, which in Western Europe is normally 50 Hz. The motor is then dimensioned in such a way to achieve the maximum required output. However, as a pump and a fan seldom have to deliver the maximum delivery volume, users install valves to limit the flow. This means then that the lost energy is often greater than the actual effective energy. State-of-the-art frequency inverters save a considerable amount of this energy. Eaton’s Energy Savings Estimator is an easy-to-use calculation tool that enables users and planners to calculate the savings potential of individual mechanically controlled fans and pumps and those controlled electronically with a frequency inverter. Only some basic specifications of the system in question are required.

In order to compare different control technologies in a system some information needs to be entered. This includes the energy costs per kWh, the required output of the system and the flow volumes over time. The Energy Savings Estimator is a free software tool that enables users to compare the energy efficiency of pumps or fan systems quickly and clearly with and without a frequency inverter with only a few entries required, and print out the results as a document for customers or plant operators.

The Eaton Energy Savings Estimator is a program that determines the motor data, the load profile and the operating hours with only a few inputs required. The tool shows the following savings options: Expected energy and CO2 saving (foot print) as well as the payback times when using alternative drive solutions. The program takes all important factors into account such as running time, output requirements, energy or investment costs. The energy savings report also offers several graphic representations that can be selected by the user. The program also creates additional charts that are made available by simply clicking the appropriate buttons. The Eaton tool can be downloaded at: www.moeller.net/support.

Software Tool: Eaton Energy Savings Estimator



E67 Photoelectric Sensor with Background Suppression

The E67 photoelectric sensor with background suppression belongs to Eaton‘s Long Range Perfect Prox series. E67 models are used for example in applications where distant objects that are difficult to detect or are transparent such as window panes have to be detected. Some sensors available on the market

detect these types of objects incorrectly because insufficient light is reflected back to the sensor. The light is either deflected away from the sensor, thus deactivating it or reflections in the background impair the correct detection of the object.

The E67 sensor is available with a large sensing range up to 200 cm and is thus suitable for pallet wrapping machines. The E67 also offers convenient factory settings that enable reliable object detection regardless of the color, degree of reflection, contrast and shape.

Photoelectric sensors basically convert optical information into electrical signals that can be evaluated. The E67 uses an infra-red sensing beam for this purpose with an excess gain so that it is ideally suited for detecting objects that are difficult to detect. The E67’s timing logic and redundant error checking prevent errant signals due to instantaneous conditions caused by rotating objects.

Eaton‘s E67 sensor uses the proprietary dual channel perfect prox technology to eliminate specular and non-uniform targets. It ensures that only target objects inside the detection range are detected and that objects in the background such as fork lifts or workers are masked out.

The sensors feature a bipolar transistor output (NPN and PNP) and are designed for 18-30V DC. All E67 sensors operate reliably in a broad temperature range from -35 C° to +55 C°. They are NEMA approved and conform to degrees of protection 1, 2, 3, 4, 4X, 6, 12 and 13. CE conformity is in preparation. This will be available from Q3/2011.



New Switch-Disconnectors for Photovoltaic Applications up to 1600A / 1500 V DC

The constantly growing requirements placed on the efficiency of PV installations require operating voltages above the previously usual limits of 1000 VDC. Eaton has consequently further developed its proven DC switch-disconnector product series. Switches for up to 1500V DC with rated operational currents up to 1600 A are now available. Switches and accessories are now suitable for ambient temperatures up to 65°C. Typical applications for example are switch-disconnectors in generator terminal boxes, as well as isolating main switches that are suitable for use as maintenance and repair switches on the incoming side of the DC/AC inverter.

The switches are based on 4-pole switch-disconnectors from the AC range which have been optimized in terms of their creepage and clearance distances and the contact elements in order to control the increased load placed on switching and quenching behavior with voltages up 1500V DC at a full rated current.

All switches meet the requirements of EN 60947-3 and comply with utilization category DC-22A for switching mixed resistive and inductive loads, including the fourfold overload with an L/R ratio of ≥2ms. These conditions ensure that the contacts achieve an electrical lifespan of up to 2500 operations – at the full rated current. The mechanical and de-energized lifespan achieves values up to 20,000 operations. The switches thus provide sufficient reserve capacity to perform the standard duties of isolating

maintenance and repair switches reliably and safely over many years.

Extremely compact bridge kits with contact protection up to IP2x are available for connecting switch contacts in series. These bridges are suitable for ambient temperatures up to 65°C, are factory tested in combination with the switches and enable rapid mounting in restricted space. All the modules from the standard range required for automated use can be combined as accessories, such as rotary drives and remote operators, voltage releases and suitable connection terminals depending on the cable type.


The soft starter is increasingly becoming established as an alternative to the star-delta starter. Eaton also has proven soft starters in the range and from Q3/2011 is expanding its DS7 series with devices up to 200 A. Users are thus provided with a complete system from 4 to 200 A with a standard actuation and functionality that will fully replace the previous DS4 and DS6 series. The supply voltage on the DS7 ranges from 200 to 480 V, and versions with 24 V AC/DC and 110-230V AC actuation are available.

The special starting method (asymmetrical trigger control) for the soft starter function prevents DC components that normally occur with a two-phase controlled soft starter (Eaton EU patent EP12 40706B1). This prevents the formation of elliptical rotation fields which cause uneven motor startups and unnecessarily long starting times. The smooth starting behavior of the DS7 is thus similar to that of a three-phase soft starter.

The compact DS7 starters are ideally designed for regular applications such as pumps, fans and small-scale conveyor belts. The DS7 will soon also be available with a SmartWire-DT interface for automation solutions, thus simplifying wiring and increasing functionality.

Eaton DS7 soft starters are suitable for a number of applications such as three-phase inductive loads, noise-free and smooth motor

starting in transport and conveyor systems, or a wear-free pump start, which reduces the load on the entire installation (water hammer). DS7 starters are also predestined for starting fan drives with less wear on the drive belts.

Electronic soft starters meet the customer requirements for jerk-free torque increases and selective current reduction in the startup phase. They control the supply voltage of the three-phase motor in the startup phase so that the motor is adjusted to the load behavior of the working machine. This enables the speed of mechanical equipment to be increased gently. The use of the soft starter reduces the load on all operating characteristics and operating sequences so that the associated components have a longer service life with a resulting reduction in costs. DS7 soft starters fully meet the product standard for electrical soft starters (IEC / EN 60 947-4-2).

DS7 Soft Starter Series Extended with Devices up to 200 A


Configuration Software for Circuit-Breakers/Switch-Disconnectors

The new intuitive NZM/IZM Configurator tool enables circuit-breakers, switch-disconnectors and appropriate accessories to be selected and configured easily from a database containing several thousand MCCB/ACB items. Any switchgear configuration can be selected in just a few clicks of the mouse without any special knowledge of the system. All items are then transferred to parts lists or ordering lists. All permissible combinations are stored in the software logic so that only error-free orders can be completed, thus considerably simplifying the task for the user.

The software leads the user through the switchgear offered and the appropriate accessories in logical steps. The selection process starts with the required regulatory scope, IEC or UL/CSA, followed by the required rated operational voltage and rated frequency. In the next step the user sets the number of poles and then chooses the circuit-breakers or switch-disconnector, as well as any cable protection, motor protection, with either thermomagnetic or electronic operation. After selecting either a fixed mounting or drawout design, the configuration of the application-specific connection method and switch configuration is completed.

If necessary, the configuration is continued by adding any accessories required. As well as additional connection accessories such as terminal shrouds, users can select different auxiliary contacts and voltage releases. Rotary handles, remote operators, interlock and locking devices can also be combined simply and effectively. The final configuration stage involves the selection of different mounting components and busbar adapters.

The resulting ordering data is then stored in a shopping basket and in a parts list which the user can convert to an Excel file at the click of the mouse. An individual price list with catalogue and net prices is read in so that the Excel list also contains the corresponding commercial data and thus form a project-specific order and parts list, including all relevant price information.


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The Dumeco switch-disconnectors are suitable for various applications, in motor control centers, in switchboards and as main switches in diverse equipment and machines. The molding design of the range Dumeco switches guarantee a reliable application under severe circumstances. As a result the switch-disconnectors are very suitable as motor (emergency) switch. High performance plus a compact design enable easy fitting into most panels and machine designs, and this is complimented by a wide choice of models and associated accessories. All these benefits and features are provided with the Eaton Dumeco switch-disconnectors. The innovative idea in switching, that is big on safety and small on dimensions.

Dumeco switch-disconnectors, assure high levels of reliability – even when performance demands are at their toughest. There is choice of 2-, 3- and 4-pole switches, as well as a 3-pole version with a solid neutral, for the DMV up to 2000 A. Different AC categories – 21, 22 and 23 – can be handled, as well as voltages that range from 230 V up to 690 V. Eaton can thus offer customers a reliable switch-disconnector solution for every requirement.

Dumeco type switch-disconnectors have excellent short-circuit making capacities, due to their parallel knife contacts with a double break for each phase. On each of the 8 models in the DMV range, contact separation is visible. One glance through the unique ‘DMV windows’ is all you need to see if contact is made or not. What’s more, Dumeco switches are also designed so that a padlock can be fitted; this ensures that only authorized key holders can operate the switch.

Needless to say, the whole range of Dumeco switch-disconnectors are KEMA approved and fully comply with the IEC 60947-3 standard.

With Eaton Dumeco switch-disconnectors, a complete range of matching accessories is also available. This includes auxiliary contacts, protective covers, change-over mechanisms, metal operating shafts, and a wide variety of operating knobs with all sorts of shapes and methods of locking.

Complete Range of Switch-Disconnectors – 40 to 3150 A




The Power Xpert® UX is an innovative and compact withdrawable medium-voltage air insulated switchgear system designed and built in accordance with IEC 62271-200. The UX switchgear system features the latest in withdrawable vacuum circuit-breakers. The complete system made up of three product lines UX12, UX17 and UX24 for use on supply voltages of 12 kilovolts, 17.5 kV and 24 kV. Power Xpert® UX is designed for use in distribution substations and main stations and as a connection to industrial and energy providers. Applications areas are for example power distribution, water and waste water treatment, mining, commercial buildings, industrial facilities, oil and gas (onshore and offshore), the marine sector, airports and hospitals.

Complete compact and user friendly range

The UX system has been designed to offer the benefits of simple cable connection, compactness, operational reliability and user-friendliness with a single busbar system. The UX comes in a range of designs up to 4000 A and with a rated short-time withstand current up to 50 kA for 3 s at 17.5 kV and 25 kA for 3 s at 24 kV. Panel widths are only 600 mm up to 1250 A, 800 mm up to 2000 A and 1000 mm up to 4000 A. Incorporated at the heart of the Power Xpert® UX is Eaton’s newest range of withdrawable vacuum circuit-breakers type W-VACi.

Reliable and safe in operation

The UX has been designed to prevent the initiation of an internal arc under normal operation and maintenance. It ensures the highest degree of safety to personnel at the front, sides and rear of the switchgear (in accordance with the IEC standard of the AFLR).

New Generation - Power Xpert® UX


Next Generation of Withdrawable IEC Medium-Voltage Switchgear

W-VACi MV circuit breakers 12 kV, 17.5 kV and 24 kV

The new and extensive line of W-VACi compact MV vacuum circuit-breakers with IEC ratings of 12 kV, 17.5 kV and 24 kV are part of Eaton’s comprehensive product portfolio. This series is designed for electrical applications with line frequencies of 50 Hz and 60 Hz, such as in the industrial, commercial, utility, mining, marine and offshore sectors.

Eaton is offering a complete portfolio of IEC-compliant vacuum circuit-breakers, specifically designed for the requirements of several customized applications.

W-VACi circuit-breakers provide you with:

• Reliability, safety, and performance The W-VACi IEC circuit-breakers offer numerous safety features for maximum protection. Eaton also offers here the highest level of quality and product reliability. Each W-VACi circuit-breaker is tested mechanically and electrically before it leaves the ISO 9001 certified factory. All V-VACi circuit-breakers are compact, user-friendly and cost effective.

• Environmentally friendly design Eaton’s vacuum and solid insulation technology is free of SF6 gas. SF6 gas contributes significantly to the greenhouse effect and associated climate change.

• Conformance to the latest IEC standards The IEC circuit-breakers of the W-VACi series are designed and third party tested to the latest IEC 62271-100 and IEC 62271-1 standards. All W-VACi circuit-breakers meet or exceed the electrical and mechanical endurance requirements of E2 and M2 in accordance with IEC 62271-100.

• Versatile and flexibie W-VACi circuit-breakers are designed for use in a wide range of applications such as the protection of transformers, capacitor banks, motors and cables. They can withstand harsh environmental conditions such as high altitude, shock, vibration and high ambient temperature.

Environmentally-friendly, reliable performance in a compact package


15

Cooperation between Company and School – Eaton Supports High School Students in Stade

According to the Jugend forscht e. V. institute in Hamburg, Germany‘s most popular young researcher competition is making a new record for the number of entrants this year. Exactly 10,677 young people want to participate, a record figure in the 46 year history of the “Jugend forscht” programme. The national competition represents the high point, involving all the young researchers that won first prize in “Jugend forscht” competitions at state level.

Dipl.-Phys. Knut Langhans is a high school teacher and director of studies at the Vincent-Lübeck high school in Stade, who has been actively engaged for several years with a young working group with an average age of 15. The new project is the “Voice control of any mechanical system.” The basic idea is the linking of the Dialog OS voice recognition software to a commercial robot control system. This would enable any machine to be voice controlled. Application examples would be a lift or wheelchair, or machines that are fitted with sensors and actuators. According to the research group, there are currently no solutions on the market for these kinds of tasks, and so they were highly motivated to create a link between these two worlds (voice <-> machine) within the scope of a research project. The ambitious aim is ultimately to open up new markets for machine builders.

As the predecessor project was awarded the second prize at last year‘s Jugend forscht district competition, the project is to be continued with the linking of voice control to a commercial PLC (Codesys V2.3).

Experimentation began with a Lego RCX robot which was first of all programmed in C. The young researchers then advanced to the newer Lego NXT robot which they were able to voice control using Dialog OS.

In the current project the students are controlling via a headset a model of a high-bay warehouse built with the Fischertechnik construction

system. A standard PC is used which integrates the voice recognition and the Soft-PLC robot control, as well as remote bus terminals and drivers, which the students have developed themselves. The high-bay warehouse is connected via an I/O module. Short voice commands are enough to approach the objects precisely and then move them. The high-bay warehouse model is used here to simply illustrate the new voice-based control system called “Vincent Voice Control”.

The project was developed by students of the Vincent-Lübeck high school in Stade and electronics trainees from Dow Stade Produktions GmbH, a company based in Stade. Reinholz Software und Technology, a solutions partner of 3S, was responsible for the coaching of the Java program. 3S Smart Software Solutions provided the licenses of the required software. The CAN bus PCI card came from Peak System. The XION stations (two XI/ON stations – XI/ON modular I/O system, XION CAN gateway for CANopen and XION Profibus for Profibus DP) come from the Eaton Electrical Sector, Bonn. Prestigious companies have thus joined forces within the scope of the project, fully supporting “enterprise and schools cooperation”.

www.vincent-voice-control.de

The Association for the Promotion of Young Science Research set up by the high school teacher Dipl.-Phys. Knut Langhans at the Vincent-Lübeck high school in Stade has been active for the second time with this group in the “Jugend forscht – Young Researcher” competition. The latest project is a system for the voice control of any machine or plant, demonstrated by a model of a high-bay warehouse. Various international companies are supporting the project, for example by providing hardware and software or training seminars. This also includes Eaton who is providing two XI/ON stations (XI/ON modular I/O system, XION CAN gateway for CANopen and XION Profibus for Profibus DP).

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LoREm IPSum DoLoRAPPLICATIoN

The young project team (students and trainees) with teacher and trainer: Back row (from left to right) Eike Dralle, Lennart Struve, Knut Langhans, Gerd von Borstel, Volker Grünhagen, Front row (from left to right) Jannek Hoops, Henning Mergard, Stephanie Hilck, Annelie Menck, Jannes Menck

The Drive of Young Researchers

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Sustainable Packaging

SmartWire-DT™ Optimizes Production ProcessHuhtamaki Nederland b.v. is based in Franeker and is part of the Finnish packaging group Huhtamaki. Huhtamaki Nederland develops, produces and sells environmentally friendly packaging materials for fruit, eggs, vegetables and industrial products. These products are sold accordingly both on the Dutch and foreign markets. Huhtamaki successfully upgraded its production of sustainable packaging using Eaton’s SmartWire-DT technology.

As a raw material, Huhtamaki Nederland uses recycled paper which is milled into fibers with the warm feedback water from the drying process. This fiber mush is shaped into packaging and then finished to customer specifications, such as for egg packaging. It is often also very important to react quickly to the rapidly changing requirements of the customer in order, for example, to make time-to-market responses. Besides producing packaging for eggs, Huhtamaki also develops molds to produce industrial packaging. These are mainly used to pack mobile phones, televisions and consumer electronics products. Form, robustness, look and feel are factors for the success of a fiber mold application. This is

why Huhtamaki already values a highly efficient state-of-the-art approach in the development phase.

The process of molding the paper fiber, drying, pressing and finishing, demands a highly automated production process. Huhtamaki uses innovative PLCs and operator panels to manage and control this process. All the components required for the production process, such as motors and local operator stations, have to be robust and functional in the industrial environment. For example, warm humid air, shock and vibration must not have any effect on the production process.

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INFo

The Company: www.huhtamaki.com

Products: SmartWire-DT, PKZ motor-protective circuit-breakers, PKE motor-protective circuit-breakers with wide range overload protection, DILM contactors, RMQ pilot devices

Quicklink ID: ES2313 [www.moeller.net]

Huhtamaki Nederland b.v. is an internationally operating company and part of the Finnish packaging group Huhtamaki. The company is based in Franeker and develops, produces and sells environmentally-friendly packaging material for fruit, eggs, vegetables,

industrial products and many other goods. Huhtamaki Nederland has over 200 employees and is renowned for its quality, flexibility and innovation.

The Franeker plant contained many machines with RMQ actuators which were wired up with the PLC over long distances. This meant that the testing of a machine in the production line was very time consuming, simply due to the number of wires involved. Huhtamaki therefore used SmartWire-DT in order to once and for all avoid the time consuming testing of all the control wires between the PLC and the RMQ pushbuttons and motor starters. The intelligent and easy-to-use SmartWire-DT connection and communication technology made an immediate impression – both during the engineering phase, during the installation and during commissioning. Thanks to the SmartWire-DT Profibus gateway, the coupling to the Mitsubishi PLC could also be completed without any problems.

After this successful and pleasing introduction, Huhtamaki developers Albert Bruining and Sido Douma looked for other applications of the SmartWire technology. The aim was to provide the existing switch panel and cabinet with more functionality. However, with very little space in the switchboard available to them this would be difficult. Even here SmartWire-DT provided the solution: The PKZ M/DIL M motor starter combination, like the RMQ pushbuttons, is equipped with SmartWire-DT function modules and is connected by a single green SmartWire-DT cable. This eliminates the need for I/O channels on the PLC. It also significantly reduces the cross ducting of cabling because considerably fewer control wires are used that take up space in the switchboard. In short – SmartWire-DT created even more space in the existing cabinet for additional components such as soft starters.

Impressed with the expandability of SmartWire-DT, the developers at Huhtamaki then got to know Eaton’s new PKE electronic motor-protective circuit-breaker. As the PKE can not only be used for protecting the motors but also for measuring the motor current, the company also saves on buying current transformers. Furthermore, the operators have a direct overview of the actual and set current values as well as having phase-loss protection. The PKE in SmartWire-DT system therefore offers several unique functions.

To increase the sustainability of the present production process, Huhtamaki wanted to log and control the actual energy consumption of its systems. Thanks to the intelligent NZM XSWD-704 current measuring module in combination with the NZM circuit-breaker, the operators at Huhtamaki have a direct overview and control over power consumption and actual values like the current, voltage and power factor (cos φ) behavior of their installation. These can be compared with the previously calculated power assumptions, thus enabling the operator to adjust or revise their installation when required.

CoNCLuSIoN

Electrical engineer Sido Douma from Huhtamaki Nederland b.v. summarized as follows: “The introduction of the SmartWire-DT software, SW-Assist (version 1.2), has enabled us to implement a considerable expansion of functionality. We can now carry out diagnostics on all devices connected with SmartWire-DT. In the development phase, the software offers an overview of the project, and shows whether it is properly designed electrically. The software also checks whether the power consumption of the gateway and power feeders is properly engineered. Already before the Factory Acceptance Test /Site Acceptance Test (FAT/SAT), it allows the panel builder to check the panel, without connecting the PLC to a fieldbus such as Profibus-DP or CANopen. The SW-Assist software offers additional diagnostic functions in the field, even when the process and installation are running. Control panel assembly and prewiring can be carried out externally, along with the programming of the PLC. This saves us a lot of valuable engineering time and speeds up the development of new features in the system.”

The PKZ M, DIL M motor starter combination and all RMQ pushbutton actuators are fitted with SmartWire-DT function modules and are interconnected via a single green SmartWire-DT cable.

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SmartWire-DT™ Controls Conveyor Belts for Cement ClinkerHolcim (Deutschland) AG is a subsidiary of the international Holcim Ltd. building materials group. The largest supplier of building materials in North Germany started 150 years ago as a cement manufacturer. Today the strong and independent product sectors for cement, gravel and aggregates, as well as ready-mix concrete are the key sectors of the group of companies. Complete building material solutions and services complete the range on offer. The conveyor system for transporting cement clinker at the Lägerdorf production plant of Holcim (Deutschland) AG uses SmartWire-DT, Eaton’s innovative connection and communication technology.

Clinker is a raw material from which cement is later manufactured. The lime is first of all excavated from Holcim’s own lime quarry and mixed with clay and sand. This mixture is then sintered in the oven. The result is the raw material clinker: The granular cement clinker is between three and five centimeters in diameter. In the next process, the clinker is ground in a ball mill to produce cement as the final end product. SmartWire-DT is used on the conveyor line for transporting the clinker from the oven to the storage silos and for distribution into the silos using slides.

Efficiency, transparency and reliability

Recording process states and creating a clear and transparent monitoring of production processes are requirements that are gaining increasing importance. These aim to ensure the early detection of process faults or even process downtimes in order to

make timely interventions and implement appropriate preventative measures. For this Eaton is offering a perfect solution made up of the PKE electronic motor-protective circuit-breaker, the NZM circuit-breaker and the SmartWire-DT connection and communication system.

The PKE reliably protects and monitors motor feeders up to a rated current of 32 A. Consisting of a PKE basic unit and the PKE trip block the modular switch can be flexibly adapted to the current range to be monitored. The wide current setting ranges of the trip blocks also cover a number of equivalent, conventional bimetal overload relays which considerably simplifies the engineering of the main circuit. The NZM circuit-breaker is used for protecting higher rated motors and systems up to 1600 A. Like the PKE, an NZM with an electronic release can cover several conventional bimetal circuit-breakers thanks to its large current setting ranges. In conjunction with SmartWire-DT both switching

Cemented

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INFo

The Company: www.holcim.de/de

Products: SmartWire-DT, PKE motor-protective circuit-breakers,MSC motor starters, NZM circuit-breakers


Holcim (Deutschland) AG is a subsidiary of the international building materials group Holcim Ltd. The largest producer of building materials in North Germany, the company started 150 years ago as a cement manufacturer. Today the strong and independent product sectors

for cement, gravel and aggregates, as well as ready-mix concrete are the key sectors of the group of companies. Complete building material solutions and services complete the range on offer.

devices only require a few simple operations to integrate into the control system. This gives you the option to transfer data about the state of the motor feeder and sections of the system to the higher-level controller. At the Lägerdorf plant NZM2 and motor starters (reversing starters and DOL starters) were each used with a PKE electronic motor-protective circuit-breaker.

SmartWire-DT is based on standard fieldbus systems such as Profibus DP or CANopen, thus enabling a simple integration into standard PLC programming systems (such as CoDeSys and STEP7) and SCADA systems. Each slave on the SmartWire-DT is automatically assigned an address on the gateway at the push of a button and in the order in which the slaves are connected. The individual slaves are not activated until the address is called. The SmartWire-DT software (SWD-Assist) supports the user during planning. It offers help in correctly selecting the function elements, suggests accessories and carries out plausibility checks. For network configurations (such as Profibus configurations) the software can also be used to create specific device description files (GSD file) which are then simply imported into the appropriate programming system.

SmartWire-DT keeps mounting and wiring requirements to a minimum. The continuous green SmartWire-DT cable is a striking feature in the switchboard. It provides the communication link between the required components. SmartWire-DT furthermore eliminates the need for the entire control system wiring – the single SmartWire-DT cable normally provides the power supply required. Conventional I/O modules are also not used since the I/O level on SmartWire-DT is directly integrated in the switchgear, thus totally excluding the possibility of faults.

SmartWire-DT therefore opens up the problem-free control and reading of process data. With the PKE and NZM this consists of both simple

binary data such as switch positions and also more extensive messages such as causes of tripping and also analog data such as motor currents and the thermal load of a motor. The differentiated transmission of data provides users with new possibilities in monitoring and controlling processes. These range from increased transparency in manufacturing processes (monitoring) to the early detection of critical states or failures right through to preventative maintenance management.

CoNCLuSIoN

Gerd Sievers, in charge of system planning and engineering at the Lägerdorf plant, summed up as follows: “We were looking for an intelligent motor starter for controlling the conveyor belt for our clinker production. We found what we were looking for at Eaton. The SmartWire-DT system currently integrated in our switchboards offers us a high level of reliability and secures product quality. Even more important for us was the fact that SmartWire-DT enables us to design our process with greater efficiency, transparency and clarity. If required, it is also possible to exchange components during operation. We were able to fully implement our switchboard concept with SmartWire-DT. The host of functions provided exceeded our initial planning specifications, such as the system-immanent manipulation protection, the extremely precise diagnostics or the presettable values in the SCADA system – SmartWire-DT offers us considerable added value.”

Intelligent motor starters with PKE:

SmartWire-DT transfers diagnostics, status and overload messages on the actual flow to the process control system and also offers a

system-immanent manipulation protection.

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The Power of NatureEaton Automation Technology Controls Hydro Power Station

The Ziegler private hydroelectric power station in Todtnau (Black Forest) is equipped with two turbines and generators as well as a trash rack installation and weir. Prior to modernization, all three sections of the plant – turbines, trash rack and weir were controlled separately with island solutions. The turbines were controlled via a 19 inch card controller from Walcher, combined with a Moeller PS306 / PS3 PLC for the periphery. The trash rack installation was implemented solely for sluice gate control, and the weir control was likewise implemented with the combination of Walcher and Moeller components. The new concept, devised by the operator in collaboration with Easyway Automation, was to replace the “old control system” in order to achieve greater operational safety and energy efficiency – whilst simplifying operation and monitoring. Three Eaton XV controllers, the XVS400, XV100 7-inch wide screen and the XV100 3.5-inch HMI-PLCs, are now used.

Teleservice made easy:

Access to the PLC is password-protected via a standard Internet browser. Plant images can also be accessed via webcam or locally via the touch display PLCs.

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The Company: www.easywayautomation.com

Products: HMI-PLC XVS400 XV100 7" wide screen XV100 3.5" HMI-PLCs


Easyway Automation is a company based in Todtnau in the Black Forest, which provides existing hardware with new control technology and implements the conversion and expansion of existing machines. As well as providing support in sub areas, the company also implements

new installations. The company focuses on customized solutions and tailored functions. It also provides extensive support as well as long-term customer care.

The new concept of the Ziegler hydroelectric power station in Todtnau uses Eaton XV HMI-PLCs with a Profibus interface. The weir, the trash rack and the machine house are designed as island solutions with a remote peripheral connection via Profibus. The controllers (PLC and visualization) are interconnected via Ethernet FO. Closed-loop and open-loop control data is exchanged on the PLC level. Thanks to the Ethernet network the relevant information each PLC is made available to all three visualizations. This means that all the relevant measured values and status information is directly available, and even important operations or parameterization tasks can be completed from all locations. This considerably simplifies both the control and the operation of the system – even via the Internet by means of a remote client if required. Webcams were also installed at all essential locations, and these can be accessed via the Internet or via the visualization in the machine house. Fault messages reach the operator by different routes: Firstly via an automatic telephone dialler, and secondly via SMS and/or email, which are sent directly from the PLC.

Converting the weir

The weir itself consists of inlet gates as well as a lateral spillway for controlling floods. The weir has two tasks: to protect the channel from flooding during high water and to provide a minimum water level to the original river bed at low water, thus metering the water supply to the channel.

The weir system control was retrofitted with a XV100 3.5 inch touch display PLC and Profibus. The PLC programming is implemented with XSoft CoDeSys in accordance with IEC 61131; the Galileo software is used throughout the entire installation for visualization. The PLC is connected to the turbine and trash rack control via Ethernet. As previously mentioned, all relevant operating steps and parameter settings for turbines and the trash rack installation can be carried out from this controller – based on the latest measured values of the whole installation. Measured values such as the water level are shown graphically and can be called up as historical data. The same graphic includes other information such as the operating cycles of the weir gates in order to make retrospective assessments and any optimizations if necessary.

Converting the trash rack installation

The trash rack cleaner is designed as a chain machine and is activated automatically if the difference in levels before or after raking is too large. As the trash rack grill has an inherent flow resistance depending on the flow volume, this is adjusted dynamically according to the intake capacity of the two turbines. The start difference could not be dynamically adjusted before the controllers were networked.

An XV100 7-inch wide screen HMI-PLC with Profibus controls the trash rack installation. The larger display was used here since this location is the first to be viewed by the operator. All critical installation parameters are then visible at a glance.

Converting the turbine control

Two turbines and generators are installed, one is a Francis turbine (generator with 100kW output), and the other is an Ossberger turbine with two chambers (generator with 250kW output). Depending on the situation, the visualization can be used to select which of the two can be run as the base load generator, depending on the season, the possible degree of pollution or the currently available water volume.

The innovative control system with the XVS400 showed its strengths particularly for the turbine controls, with many improvements implemented. These include greater operating comfort as well as the long-term increased efficiency of the installation. As the channel also has an inherent flow resistance, provided there is sufficient water available an artificial gradient can be created in order to guide the water into the turbines for more efficient power generation. This requires the recording of all measured data and status information, and could also be implemented in the new concept. The turbines are also run in the ideal efficiency range for an optimized yield. Today it is possible to prevent any contamination that can cause a subsequent loss in output: The output of the Francis turbine is constantly controlled and the turbine is automatically purged.

CoNCLuSIoN

Christian Stadler, owner of Easyway Automation, summed up as follows: “The hydroelectric power station at Todtnau was equipped with a system that meets the latest state-of-the-art in automation technology. Onsite inspections by the customer are no longer necessary since he can monitor the installation at any time via the Internet, thus giving him worldwide access if necessary. Today the installation responds automatically with alternative routines to predefined faults in order to maintain constant electricity generation. Yield-optimized operation has now been ensured thanks to the seamless and perfectly matched communication variants of all three plant sections. The joint efforts of the operator and our company were particularly fruitful so that many new features were made possible.”

Renewable energy:

Two turbines with connected 100 kW and 250 kW generators convert hydro power into electricity.

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Do Brasil: “Bom apetite”PKE Motor-Protective Circuit-Breakers with SmartWire-DT™ for Food Production

The Brazilian company Frigorífico São Miguel Ltda, or more precisely “Fábrica de Produtos Suínos”, Miguel do Iguaçu, produces industrially processed food from pork, such as seasoned steaks, bacon, sausage and ham products as well as pure pork. The Friella label is synonymous with pork products, which are very popular with consumers, wholesalers, supermarkets and butchers alike throughout the whole of the country. All natural and processed meat products are inspected by the Federal-SIF authority. SmartWire-DT is used for the automated machine control in which 278 motors are controlled in four different areas and are networked via the connection and communication system.

CLP-IHM XV

CCm-09 Expedition 88 SW-DT motor starters

CCm-07 Cold Control 88 SW-DT motor starters

IHM-TouchSecondary Packing

IHM-TouchPrimary Packing

IHM-TouchCut Room

IHM-TouchSlaughter room

CCm-09 Dirty Zone 88 SW-DT motor starters

CCm-05 Room of machines32 SW-DT motor startersElipse Scada

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The Company: www.friella.com.br

Products: SmartWire-DTXV440 touch display PLCs XC200 PLC XI/ON remote I/O


The Brazilian company Frigorífico São Miguel Ltda, Fábrica de Produtos Suínos, Miguel do Iguaçu Paraná has been producing pork products for 37 years. Under the Friella label, Frigorífico São Miguel supplies fresh pork and industrially processed products to

wholesalers, supermarkets and butchers throughout Brazil. Friella was opened in 1994 and the plant meets the current state of the art.

The Friella processing plant carries out the complete processing of the pork meat: It starts in the pig sty, covers the processing in the slaughter house, the cutting room and processing machines, ranging from the primary to the final packaging. The process consists of the following stages: After being slaughtered, the pig carcasses are transferred via conveyor belts to the washing plant for cleaning. Other conveyor belts transport pork meat to the cutting room where it is cut into the required portion sizes. Depending on the processing required, the meat is then distributed to specific areas. After the final products are packaged, they are stored in refrigerators until the in-house forwarding department delivers the goods according to customer requirements.

Automated control via SmartWire-DT

The control system for the production, packaging and refrigeration machines consists of several Eaton components: NZM circuit-breakers, PKZ motor-protective circuit-breakers, DIL contactors, SmartWire-DT, PLCs, HMIs, Remote I/Os, power supply units as well as RMQ pilot devices.

An XC200 modular PLC controls the installation. It is networked with a SCADA system and nine XV440 touch panel HMIs installed in different areas. PLCs, HMIs, XION devices and SmartWire-DT are integrated in the entire system via Ethernet (FO) and CANopen.

The installation includes 278 motors. These are controlled and operated in four different areas, and are linked via the SmartWire-DT connection and communication system. Thanks to SmartWire-DT, all motors can be monitored completely from the control system, including the feedback signals such as states or other process data sent from the motor-protective circuit-breakers and contactors. This allows fast diagnostics and ensures an efficient production of the entire plant. The motor starters are fitted in compact switching cabinets to DIN rails. Today the installation requires fewer switching

cabinets, little maintenance, and components can be exchanged rapidly and simply if required.

The installation at the Friella plant had to be implemented with reduced wiring, in which highly reliable production had to be ensured as the highest priority. The SmartWire-DT technology was thus the ideal solution: It offers an optimum solution for MMC cabinets and switching cabinets for the automation. Today production monitoring is implemented via CoDeSys web visualization – an IEC 61131-3 programming system – which can also handle historical process data. In addition to field maintenance, the control system is also designed to allow remote access to the visualization objects (XML format) by means of a web server from any PC or web browser, irrespective of the platform.

CoNCLuSIoN

Cristiano Lewandoski, engineer and responsible for automation at Friella, looks back: “Our plant is designed for the slaughter of 750 pigs a day and for the processing of the meat into tasty products. Thanks to the Eaton solution we were able to increase the efficiency of our entire process and make considerable cost savings. SmartWire-DT offers the plant-wide automation system an excellent diagnostics system so that downtimes can be reduced to a minimum.”

PKE motor-protective circuit-breaker with SmartWire-DT™PKE motor starter combinations with SmartWire-DT provide the option of integration into the automation world: The PKE-SWD-32 modular COM interface also provides the actual current flow of the PKE as well as different signalling functions such as diagnostics, status and overload signals. The data can be transferred directly to the controller and is made available to the entire plant. The data transparency thus created increases the efficiency and operational reliability of the drives in

the area of the motor-protective circuit-breaker. PKEs, integrated in the SmartWire-DT system, increase plant availability through the transfer of process-relevant data, reduce the wiring in the control circuit and save time consuming troubleshooting during commissioning and maintenance. The control system is always provided with up-to-date and precise diagnostics data, and tripping and overload values can also be set for motor protection. A system-immanent manipulation protection with SmartWire-DT ensures a high level of safety.

SmartWire-DT reduces the time required for wiring, testing and commissioning by up to 85%.

24 SolutionS 23

Bello il Sole

APPLICATIoN

Eaton is offering a complete range of DC and AC switchgear used in and around the power inverter for PV installations. A high level of quality, the durability of the components, and the expert advisory support in selection and application issues guarantee success and customer satisfaction.

The new Eaton range, designed for DC voltages up to 1000 V, consists of DC fuse switch-disconnectors, DC switch-disconnectors and DC circuit-breakers with IP20 protection or enclosed with IP65 protection, as well as DC compact circuit-breakers. Eaton is also offering powerful circuit-breakers for AC and DC applications with operating voltages up to 1000 V AC/DC and rated currents from 1 to 1600 A AC/DC.

The new DC switchgear for photovoltaic applications from Eaton is now increasingly being used in the PV inverters of different manufacturers. Their outstanding electrical features and the optional remote tripping are playing here a key role. A current example is the Italian company Gefran, which uses Eaton’s P-SOL60 switch-disconnector both in the 20 kW power inverter and in the generator string boxes.

New DC Switchgear for Photovoltaic Applications

Complete range of DC and AC switchgear

SolutionS 23 25

INFo

The Company: www.gefran.com

Products: P-SOL DC switch-disconnectorsN1, N3 DC switch-disconnectors NZM AC circuit-breakers DILM3000 contactors RMQ pilot devices


Gefran S.p.A., headquartered in Provaglio d’Iseo (BS), Italy, develops components and implements automation solutions for monitoring and controlling both industrial processes and machines. The range covers sensors, drive solutions (such as inverters, servo drives, and converters), semiconductor relays, meters and

programmable controllers, right through to software solutions and complete systems. Power inverters for solar installations are the latest product line. Gefran has 800 employees and seven production sites with operations worldwide.

The Italian company Gefran is headquartered in Provaglio d’Iseo and is a renowned manufacturer for drives, sensors, controllers and automation systems. The company started a few years ago with the development of photovoltaic power inverters based on devices for drives. A complete range consisting of nine types from 2 kW to 250 kW for industrial and residential applications has been on offer since March 2010. The power inverters operate both with and without transformers.

Gefran also offers a generator string box for eight strings. It can be expanded in combinations with 16 or 24 strings and with a switch-disconnector box. In the basic version, the inputs are brought together via string diodes and fuses. The more convenient version also features a current measuring function. The read data is fed to a central data acquisition and evaluation unit via an RS485 interface and Modbus protocol. This enables faulty modules to be detected early and yield losses to be prevented. The range is rounded off with a varistor overvoltage protection.

Eaton’s P-SOL60 DC switch-disconnector is integrated both in the APV 20K power inverter as well as in the JBX string boxes. It is used in the power inverter to isolate the DC input from the solar generator. One highlight is the fact that it causes the isolation of the power inverter using the attached shunt release and a DILM95 contactor on the AC side.

The majority of the P-SOL60s are used in the string boxes as DC switch-disconnectors in order to isolate the string group from the power inverter. Also here the combination with the undervoltage release is used in two versions, in order to open the switch-disconnector in the event of malfunctions on the module side, which the electronics reliably detects.

Gefran also uses other high quality switchgear from the Eaton range: N-S1-DC DC switch-disconnectors, DIL contactors, RMQ pilot devices, Xpole components and NZM circuit-breakers.

P-SoL DC switch-disconnectors

Eaton offers P-SOL DC switch-disconnectors for the rated current ranges 20 A, 30 A and 60 A. The DC isolators are available with IP20 protection for direct mounting in the power inverter or with IP65 protection for external mounting close to the power inverter. The high

switching capacity allows the switch to be actuated during operation – even under load. With extensive PV installations the integration of shunt and undervoltage releases allows an optional remote tripping of the (lockable) switch-disconnectors.

The solar installation, like the power inverter, is connected to the enclosed switch-disconnectors via the special solar plug connectors. Depending on the rating, two, four or eight solar strings can be connected on the incoming side via MC3 or MC4 plug connectors. Alternatively types are available for direct terminal connection and cable routing via M12, M16 or M20 cable glands. Eaton offers pre-assembled solutions for different installations, thus making the use of Y cables unnecessary. The rugged housing material also allows mounting in protected outdoor areas. Integrated pressure compensation elements prevent condensation. All enclosed switch-disconnectors are TÜV-certified.

CoNCLuSIoN

The long-standing and trusting relationship between Gefran and Eaton formed the basis for the current project. Marcello Baberini, head of Power Electronics Development at Gefran, summed up as follows: “The excellent quality of Eaton products, also with this project, was impressive. The ability of the DC switch-disconnectors to be actuated remotely if required is a particular benefit for our innovative solutions. As early as the development phase of the inverter we were working closely with the specialists at Eaton. However, we are now also pursuing new directions in the area of logistics. For example, we are purchasing the Eaton products required for an inverter as complete kits. Each kit, with only one order number, thus contains all the associated components. This saves us ordering several individual items separately and guarantees us the availability of all the Eaton components required for an inverter.”

Optimized for DC switching, the Eaton N3 DC switch-disconnector.

Photo left: PV central inverter

SolutionS 23

APPLICATIoN

Packaging ArtistsExport Requirements of a High-Speed Horizontal Flow Wrapping Machine

The meurer group has been producing high quality and flexible final packaging systems for more than 40 years, and its machines are used worldwide for a wide range of products and sectors. The company’s latest CM/HHS high-speed packaging machine groups aseptic carton packs automatically and packs them in a full wrap in shrink film. The highly flexible machine is designed for all typical market volumes between 100 and 500 ml. It offers an outstanding output of up to 160 triple-packs a minute, which corresponds to up to 30,000 single packs an hour. The flexibility of a packing unit offers an output of 2 to 18 drinks packs, depending on the output of the line. An automation system with a servo multi-axis system enables the machine to adjust itself virtually automatically and smoothly to the fed packaging volume of between 0 to 500 packages a minute.

The CM/HHS machine is operated via an Eaton XV400 touch display PLC. Besides the PLC, the HMI/PLC comes with an integrated 10.4 inch SVGA display with rugged infra-red technology. The innovative touch display provides clear and flexible menu guidance in several languages and enables meurer to sell machines worldwide using only one hardware and software solution.

The meurer group exports around 70 percent of its products, of which 5 to 10 percent are exported to North America. Two thirds of all machines are used for the secondary packaging of foods. In order to ensure a high level of machine quality and availability, meurer also offers additional worldwide services in addition to its large vertical range of manufacturing.

In the global environment the requirements placed on state-of-the-art filling machines are constantly changing. Today’s market requires high-speed systems that are also highly flexible and reliable. Any downstream final packaging machines must meet the same requirements and should ideally be approved by a ‘nationally recognized testing laboratory’ so that they can be accepted in the North American market without any problems. With its engineering design, the meurer group relies on Eaton’s extensive know-how of many years.

26

SolutionS 23 27

INFo

The Company: www.meurer-group.com

Products: XV400 touch display PLCRMQ pilot devices PKZ motor-protective circuit-breakers NZM circuit-breakers


The meurer group has its headquarters in Fürstenau and can boast a tradition going back more than 40 years. Today the meurer group consists of the companies meurer Verpackungssysteme GmbH and meurer Elektro- und Steuerungstechnik GmbH. The meurer group has around 500 employees and

a total manufacturing area of 27,000 sq m, split between two locations. From the beginning, the company has focused on delivering a high level of innovation, with its own in-house development team constantly striving for the technological edge.

However, the global sale of machines not only requires the use of components with UL/CSA approval such as Eaton’s circuit-breakers, miniature circuit-breakers and motor-protective circuit-breakers or contactors, but also a UL/CSA approved switchboard design with UL/CSA Type 4x protection, previously called NEMA 4x. After all, a product that has achieved recognition around the world does not necessarily meet the requirements of North American standards.

A one-off acceptance approval of a switchboard design by UL or CSA inspectors is a good basis for series production. However, all switchboard systems and the electrical equipment of machines and plants still have to be approved once more by local AHJ inspectors (AHJ = Authority Having Approval) at the point of installation. Without a successful AHJ approval, plant or machine operators cannot be supplied with power from utility companies and do not meet the requirements for obtaining insurance for the system. The operating approval is documented by the signature of the AHJ.

Both for customers and producers of a machine, it can still be a lengthy and costly process if local inspectors find that a switchboard system is not export compliant and the commissioning of the system / machine fails. As there are well over 2000 independent jurisdictions in North America which occasionally interpret the standards differently, producers can only assess the risks involved with an approval with great difficulty. However, these risks were reduced for the meurer group thanks to the cooperation with Eaton.

Competent partner in export matters

In order to ensure that its machines can be exported to North America, meurer uses the services of Eaton as a competent and reliable partner. Issues relating to exporting to North America involve however more than just UL/CSA components, which require for example larger creepage and clearance distances or specific AWG cable cross sections. What is required instead is a sound knowledge of the North American Codes and Standards (as well as NEC/CEC, UL 508/ CSA 22.2 No.14, UL 489/ CSA 22.2 No. 5-09, NFPA 79 (Industrial Machinery Panels), UL 508A (Industrial Control Panels)). Furthermore, North American electrical practices such as specifying the degree of protection to NEC/CEC (UL /CSA Type 12, 4X etc.) or the stating of the electrical specifications (in HP, Pilot Duties, AWG etc.) must also be taken into account.

An unrestricted approval of components does not allow the same degree of freedom in system design as it does in the IEC world: Different types of switchgear cannot be simply combined by the design engineer or manufacturer independently. North American regulations also require the testing of device combinations which have to be documented in a joint report. Even more reason therefore, to use approved device combinations such as those from Eaton.

Depending on customer requirements, meurer fits its packaging machines with various makes of switchgear and documentation, so that separate engineering designs have to be made on different CAD systems (such as ELCAD, ePLAN and E³). For this suppliers should follow a “do it right from the start” principle. Wolfgang Esser at Eaton Industries, Bonn, offers comprehensive support for MOEMs and panel builders on issues relating to exports to North America, such as project consulting and/our training seminars.

CoNCLuSIoN

Dipl.-Ing. Guido Grewe, team leader for electrical engineering at meurer, had this to say: “Our strategy aims to “inspire our customers with tailor-made solutions.” As this applies to customers worldwide we supply turnkey final packaging machines, so to speak, that are ready to use. The approval obstacles vary all over the world. Particularly when exporting to North America, we have relied for several years on the extensive expertise of Eaton (formerly Moeller).”

The labels indicate that the switch cabinet was approved by ESA inspectors (Electrical Safety Authority).

SolutionS 2328

APPLICATIoN

In order to close the resource cycle for building materials and treat polluted mineral building waste, a new excavated soil washing plant was erected in Frauenfeld in the Swiss municipality of Gachnang. The Tollenmatt-based company Toggenburger AG replaced the existing plant with a more powerful washing facility, which was designed, supplied and erected in joint collaboration with Avesco AG. The new construction provided by Toggenburger protects the environment and carefully processes gravel resources and optimizes landfill volume. With an annual washing capacity of up to 120,000 tons of extracted material, a wide range of contaminated materials, such as from industrial sites, oil spills or shooting range backstops, can be converted into reusable sand and gravel fractions. The site offers easy rail or road access for extracted material delivered from the whole of Switzerland, primarily from the east of the country. Eaton received the order for the automation on account of its impressive solution.

Soil WashingSoil Washing Plant Treats Polluted Mineral Building Waste

The construction of the Toggenburger AG soil washing facility at the existing site started in August 2009. Avesco AG, a company based in Langenthal, received the order for the new construction. The last extraction was washed and treated in the old installation at the end of March 2010. Dismantling was started on April 1 and the site was prepared for the new construction. The aim was to put the entire plant into operation six months after planning permission had been obtained, and this was also successful. The operational plant was opened officially at the end of September 2010 and was given the name Liselotte. The first washing operation was largely successful.

Tailored process and system engineering

The washing plant can process extracted material, soil, backstop material, moraine gravel, pebbles and dry or wet broken concrete and rubble, whether in granular or broken form, with light or heavy contamination. The submitted material can also contain wood, plastic, bricks as well as other materials and metals.

The extracted material deposited on a star screen is transported to the turbo washer by means of a conveyor belt according to the specifications defined for plant operation. The gravel fractions are cleaned and classified

29SolutionS 23

Cabinet, water treatment system

Touch Panel 1 CPU 1 XC201-512MoRoS

Notebook

Touch Panel 2 CPU 2 XC201-512ASi controller

External cabinet

Switch

phone

Switch

Switch

External cabinet

Switch

Cabinet, press system

Cabinet, washing

Gateway Modbus / TCP

SwitchSwitch cabinet 1, Soil washing plant

HMI HMI

Switch


Switch

Cabinet A1 Soil washing plant

CPU 3 XC201-512

Switch

Cabinet H1 Soil washing plant

Cabinet, water treatment system


Switch

Cabinet V1Soil washing plant


Switch

Cabinet E1 Soil washing plant

PC user interface, soil washing plant

Control roomsoil washing plant


Switch

Cabinet S1 soil washing plant


INFo

The Company: www.toggenburger.chwww.avesco.ch

Products: XV400 touch display PLCXC200 modular PLC XI/ON remote I/O easySafety ES4P


Toggenburger AG, headquartered in Winterthur/ Switzerland, has a 75-year history and is now active in the field of gravel and concrete, renaturation/earthworks and environmental technology as well as in lifting and transportation. Around 250 employees provide an extensive service for the construction industry and specialist customer support.

The traditional family-run business Avesco AG based in Langenthal/Switzerland was founded over 130 years ago. Avesco – previously called Ulrich Ammann AG as a member of the Amman Group – is now an independent company. Avesco is a competent partner in the construction machine, civil engineering, plant construction, energy systems and material handling sectors, and offers tailored system solutions based on its broad product range.

over different screens and by a process density separation. The sand is also cleaned in an attrition process and sorted by density using spiral separators. These kinds of gravel/sand products are mostly used for in-house company operations. The accumulated filter cakes are normally used in cement works as raw material substitute or in landfill construction, depending on its quality and level of contamination. Four employees are provided for operating the plant with an annual running time of 2000 hours.

The plant – with a continuous material feed – is designed for a product range of 0/2, 2/4, 4/8, 8/16, 16/32 and 32/X millimeters. It has an output of 40 to 50 tons per hour. The sludge water treatment system is designed for a maximum capacity of 200 cubic meters. The electrical connection load of all plant components is 700 kW. The rainwater roof area is around 720 square meters – with a simple option for doubling it.

Single sourced automation solution

The Toggenburger excavated soil washing plant engaged the services of Eaton because of its innovative solution concept. Eaton’s products as well as its service and advisory support were outstanding. The specified plant washing capacity of 120,000 tons a year of excavated soil reconditions a wide range of contaminated materials into reusable sand and gravel fractions. This required a standardized process monitoring system that should also ensure increased functional reliability. A graphical visualization of all relevant process data and error messages was also required, as well as a simple operation facility using touch display and PC solutions.

Eaton’s automation solution met all the requirements in full, also significantly increasing the output of the plant. Today operation and visualization are implemented at all stations in the same way – both in the plant and in the office. All diagnostics data is provided immediately. Eaton’s Galileo interactive visualization tool ensures a clearly designed and user-friendly display. The following Eaton products were used for the control concept: Three XC200 modular PLCs, two XV440 HMI-PLCs, five XION gateways (Modbus-TCP) and an ES4P-221-DMXD1 easySafety control relay. An ASI controller was also used. The Eaton products had to process 350 inputs and 169 outputs (35 analog). The entire communication

between all controllers is implemented with Ethernet (Modbus TCP). Remote maintenance and diagnostics functions are also integrated and are implemented via the web interface of the XC200.

CoNCLuSIoN

Daniel Stutz, deputy plant manager at Toggenburger AG, looks back: “We are very pleased with the entire solution. Commissioning was completed without any problems and communication between all operating devices functioned directly at the start. The cause of any malfunctions that develop can be identified quickly thanks to the clear and uniform visualization. We can call up all process data, the batch number or the individual operating hours from any location.”

Daniel Stutz (left) and Alfred Leuenberger from Toggenburger are very pleased with the Eaton automation solution.

overview 1 Ethernet PLC Configuration of the Toggenburger Plant overview 2 Ethernet PLC Configuration of the Toggenburger Plant

Eaton Roadshow

Eaton Roadshow

07.03. – 06.04.2011 | Netherlands

11.04. – 15.04.2011 | Romania

18.04. – 22.04.2011 | Hungary

26.04. – 28.04.2011 | Slovakia

03.05. – 05.05.2011 | Austria

09.05. – 20.05.2011 | Germany

23.05. – 26.05.2011 | Norway

31.05. – 03.06.2011 | Ukraine

06.06. – 17.06.2011 | Poland

20.06. – 24.06.2011 | Germany

27.06. – 01.07.2011 | Baltics

(subject to change!) Quicklink ID: RoADShoW

30

SolutionS 23

INFo BoARD

Brand new Edition of the National Electrical Code (NEC 2011) for the uSA!

All versions of the highly popular UL 508 Type E – Manual Self-Protected Combination Motor Controllers – must be equipped, both in the US and in Canada, with a padlockable knob. All motor protective switches from Eaton have knobs that can be field exchanged with padlockable versions.


Important News Regarding Industrial Machinery Exports to North America!

New Selector Slide for Motor Starter Combination with Electronic Overload ProtectionFor dimensioning Electronic motor starter combinations with contactors DIL motor-protective circuit-breaker PKE, overload relay ZEB, ZEV and circuit-breaker NZM, the practical selector slide is now available with motor ratings of up to 250 kW. It enables the fast and clear selection of individual components for the drive solution – without the need for a PC or other tool. The new slide shows you directly the components for a complete drive train system, from the mains supply up to the motor feeder. Once the required motor rating is set, the corresponding products are shown immediately. The selector slide can be ordered free of charge. If you prefer to use the selection aid online, this is possible on the Internet at: www.moeller.net/select


Eaton Live:Germany12.05. – 18.05.2011 | Interpack, Düsseldorf

06.06. – 09.06.2011 | CIRED, Frankfurt

08.06. – 10.06.2011 | Intersolar, Munich

Europe12.04. – 15.04.2011 | Electron, Prague

12.03. – 13.04.2011 | Smart Grids Europe, Copenhagen

09.05. – 13.05.2011 | Elfack, Göteborg

07.06. – 09.06.2011 | PCIC, Rome

13.09. – 15.09.2011 | Energetab, Bielsko-Biala

13.09. – 16.09.2011 | IEAS, Bucharest

International12.04. – 15.04.2011 | elcom Ukraine, Kiev

02.05. – 05.05.2011 | Project Qatar, Doha

06.06. – 09.06.2011 | Elektro Moscow, Moscow

Quicklink ID: mESSEN

The Eaton Roadshow presents the new range of low and medium voltage switchgear systems. Eaton offers integrated solutions with busbar trunking systems, UPS systems and Service.

Quicklink ID: TRAINING

Seminars Offered at bfe-Oldenburg 2011In order to become acquainted with the Eaton automation world, the Federal Technology Center for Electrical Engineering and Information Technology, bfe-Oldenburg, offers a host of different training courses: Programming with CoDeSys for XC100/200, easy 500/700/800 control relays, MFD multi-function display.

SolutionS 23

ContactFurther information: Up-to-date and fast.

By fax, Internet, email and for download

FAX Reply: +49 (0)228 602-2275

Email: [email protected] | Internet: www.moeller.net, www.eaton.com

ordering information: literature.moeller.net

Electronic catalogue: ecat.moeller.net

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Eaton Moeller Industrial Main Catalogue

“From Lean Connectivity to Lean Automation”

XV100, XV150, XV200 Touch Display PLCs

Rapid Link 4.0

SmartWire-DT

Product information HMI/PLC with SmartWire-DT

Sensor product information

Dumeco switch-disconnectors

DC switch-disconnectors

Power Xpert UX

W-VACi

Motor starter selector slide

Quicklink Your goal’s just a click away.

1. All texts are provided with a 6-digit Quicklink number.

Quicklink ID: ES XXXX

2. At www.moeller.net enter the required Quicklink number in the entry box at the top right or enter a search term and confirm.

3. This takes you immediately to extensive product information.

SolutionS 2332

1874 1886 1911 19981893 19901962 19991983190819061899 1963

The power of fusion.

There’s a certain energy at Eaton. The energy created supports our commitment to powering business worldwide. From power distribution to power quality and control, Eaton allows you to proactively manage your complete power system by providing electrical solutions that make your applications safer, more reliable, and highly effi cient. Visit www.eaton.com/electrical.

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