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Information for Power and Process Technology, October 2012

AUTOMATION CONCEPTS FOR THE PROCESS INDUSTRY / Page 12

SAILING THE SEAS WITH SOLAR POWER / Page 04

PHOTOVOLTAICS ARE RADIATING ENERGY / Page 06

CONTENTS
SAILING THE SEAS WITH SOLAR POWER PHOTOVOLTAICS ARE RADIATING ENERGY CURRENT TRANSFORMER TERMINAL BLOCKS ADDED TO PROGRAM TO-PASS WEB CONNECTOR RURAL COMMUNITY INVESTS IN NEW SYSTEMS FOR WATER SUPPLY AUTOMATION CONCEPTS FOR THE PROCESS INDUSTRY PUMPING OUT WATER IN THE LAUSITZ MINING AREA DISCONNECT TERMINAL BLOCKS TESTED UP TO 1,500 VDC EXCELLENT STANDARD Ex i COUNTER FOR NAMUR-COMPLIANT SIGNALS CONTROLLING PROCESSES REMOTELY REMOTE MONITORING OF CUSTOMER PROCESSES IMPRINT Page 04 Page 06 Page 09 Page 09 Page 10 Page 12 Page 16 Page 18 Page 19 Page 19 Page 20 Page 22 Page 24

PHOTOVOLTAICS ARE RADIATING ENERGY / Page 06

EDITORIAL
Dear Readers,
The Tranor Planetsolar has successfully completed its 60,000 kilometer-long trip around the world. For 19 months, this solar-powered catamaran was on the high seas. For the crew, it was indisputably an extremely long time; for the automation technology on board not so much. For in comparison, process-technical systems are generally in use uninterrupted across several decades. We are proud, however, that WAGO components have proven themselves in both areas on the Tranor Planetsolar and in the process world. For decentralized automation has long since made its entry into process technology. For users especially with respect to the long life cycles the focus is on functionality, safety, a long life span, and the universal applicability of the components. The multitude of different signals and parameters from the measurement and control technology must be received safely and reliably, processed, and transmitted to the superior control technology architecture. At the same time, the units, drives, and valves are activated by the control system in connection with the control on-site. Required recipe adjustments for production changeover as well as the temporary storage and archiving of data in the process underscore the demand for the greatest flexibility in automation solutions. We at WAGO take on your individual challenges and formulate sustainable solution concepts. This also in the area of renewable energies. With our direct current measurement, for example, operators of photovoltaic systems now have the opportunity to get reliable data about the feed-in power without interrupting the string lines. In addition, our TOPJOB S Series has expanded further; the new disconnect terminal blocks, which are tested and approved for up to 1,500 VDC, ensure absolutely safe connections in generator connection boxes and set new standards with their function. The articles in this WAGOdirect process are only a small selection from a large product range, which is guaranteed to include the appropriate solution for your requirements. With innovative greetings,

Kay Miller Market Management Industry & Process Water

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SAILING THE SEAS WITH SOLAR POWER

Highly-efficient drives with WAGO control technology
The capacity of alternative energy sources is demonstrated in a few spectacular projects. An example is the solar-powered catamaran Tranor Planetsolar, which circumnavigated the globe with only the power of the sun. To use the energy on board especially efficiently, the developers incorporated numerous new ideas into the ship. For the drive control, the engineers trusted WAGOs control technology. The Tranor Planetsolar started its around-the-world journey from Monaco in September 2010. Across the Atlantic, Pacific, China Sea, Indian Ocean, and the Red See, the team reached Monaco on May 4, 2012 after sailing approximately 60,000 km. Energy efficiency as the key to success Although nearly the entire surface of the ship is covered with solar cells, energy efficiency on board is especially important. Under optimal conditions, the solar cells generate 120 kW of power. High-quality lithium-ion batteries are necessary to ensure that the ship can also sail at night and in poor weather. Fullycharged, they can power the ship for two to three days. For the drives, especially efficient technology is used. So-called surface-cutting propellers with a comparatively large area and low speed are highly efficient. The propellers, whose angle can be adjusted, are mounted on the two floats at the height of the waterline. This way, only half of the propeller is ever in the water. With the 120 kW from the solar panels, the ship can reach a maximum speed of 14 knots. Control without rudder Since both propellers also create thrust across the direction of movement, they turn in opposite directions. These cross components can be used to control the direction of the ship by changing the angle and/or the speed of one or both propellers. A customary rudder system is thus no longer required. The ship is steered using the change of speed, direction, and angle of the two propellers. The direction control works with the set working point of the speed as basis. By generating a difference between the two propellers, the controller sets an apparent rudder angle. The four adjustment variables that control the sailing of the ship require a new form of control since the two subprocesses cannot be separated. The complexity of the resulting controller for the ship requires a control system that is operated by the sailors like a customary system with propeller and rudder blade. Redundancy prescribed The normal classification regulations for ship approvals do not cover the particularities of this system. Therefore, an error mode and effect analysis was conducted jointly with Germanischer Lloyd. Based on this analysis, technical and functional specifications were formulated for the control system. A result is that there are two electric motors per propeller, so that the maneuvering capability is retained even if one motor should fail. The total system of the controller is approved by Germanischer Lloyd for ship use (86249-09 HH). The similarly-required redundancy of the control system is realized using two follow-up controllers. On the bridge of the ship, the drive and direction are set using an azimuth operating lever. The control system converts the set specifications for the speed and the direction (rudder angle) into the required variables speed and angle. In order to guarantee the redundancy of the main control system, all components of the control structure

The control system is implemented with WAGOs PLC and IPC components Complete system approved by Germanischer Lloyd The ship is steered using the change of speed, direction, and angle of the two propellers

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

are doubled. The control system is implemented with WAGOs PLC and IPC components. A follow-up control string consists of a WAGO 758-875 IPC for executing the control functions. Using the specifications for speed and direction, the IPC calculates the parameters for speed and angle of the propellers and transmits these to the frequency inverter and the drives. The display and operating elements of the main control stand are connected to the two control strings using 750-337 CANopen fieldbus couplers independent of one another. The redundant

actual value display of the drives and that of the controller-independent fault indicating system and the angle control of the drives are implemented via 750-871 PLC. WAGOs automation components are certified by Germanischer Lloyd and can therefore be used in the marine sector. Successfully sailing all the worlds seas During the circumnavigation, both innovative drive system and hardware/software for redundant control proved themselves. For current news about the Tranor Planetsolar and the logbook from the circumnavigation, visit www.planetsolar.org.
Text: Roland Lck, Marine and Automation Technology Matthias Markert, Hochschule Wismar Photo: Planetsolar

In 19 months the Tranor Planetsolar circled the globe using only solar energy.

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PHOTOVOLTAICS ARE RA
The transition in energy supply sources is a done deal. However, the mere expansion of the electrical grid is not enough to ensure that renewables remain successful on the market, and that coal, uranium, and company can be strongly renounced in the future as well. Renewable energy sources must be employed far more efficiently, particularly in those cases, as is the case for photovoltaics, that have low levels of efficiency. This foundation will be created through the integration of PV plants into the intelligent electrical grid as well as continuous monitoring of modules and inverters. Two-thirds of clean energy is currently harvested from wind power systems and hydroelectric power systems. At just over 15 percent, photovoltaics produce the smallest proportion, which can be attributed primarily to their low efficiency, averaging only 15 to 20 percent. The high loss of earnings in this sector is doubly embarrassing. On the one hand, the sun provides an amount of energy that exceeds the annual needs of Germany by a factor of 80; on the other hand, the electricity gained in this highly inefficient manner is not even used sufficiently efficaciously. Since there is no comprehensive management, much too much energy is lost in the wilds of the electrical grid. The legislators have finally reacted with a revision of the Renewable Energy Sources Act. Beginning in January 2012, photovoltaic systems with an output of more than 30 kW must be provided with a technical interface that enables remote controlled power reduction by the network operator. This limit was previously 100 kW. As a second step, operators of PV plants that produce more than 100 kW are obligated to disclose their feed-in power to the network operators. The goal of these measures is both to strengthen network stability by avoiding frequency fluctuations that lead to power failures, and to make it easier on the part of the network operators to effectively manage the growing number of different energy sources. Virtual networking of real plants There are decisive advantages to integrating decentralized energy generators with low outputs into one so-called virtual power plant. Under central management, small wind and hydroelectric plants, combined heat and power plants, biogas, and even photovoltaic plants are put in a position in which they can collectively replace the power available from large power plants. Temporary fluctuations in the electrical grid can be smoothed out by the availability of capacity from the power plant. When decentralized energy generators are bundled in this fashion, they appear, when viewed from the outside, as a single plant. Their integrated total output can thus also be managed on the electricity market. This means that the energy they generate can be marketed by the electricity traders, which was previously almost never worthwhile for the small, individual plants. However, not all problems will be solved by the simple integration of energy producers. Only when the electrical grid operators are able to assume a regulating influence can an efficient and stable power supply be constructed. One of the most pressing challenges at present is that many thousand, mostly privately owned, PV plants feed-in directly to the grid. At peak times, this means

Direct current measuring without interruption of the branch cables: The 789-620 Current Sensor has a measuring range from 0 to 80 A, and the 789-621 has a measuring range from 0 to 140 A.

DIATING ENERGY
Example of a virtual power plant

Pump storage

Hydroelectric plant

Cold store

Combined heat and power plant

Heat pump

Current flow with excess power

Current flow with lack of power

that there is often an energy glut, which, due to a lack of storage capacity, leads to instability. A virtual power plant would be controllable by the network operator for just such a case; according to the EEG, a graduated series of power reductions, of 0%, 30%, and 60%, is provided for these periods. A technical prerequisite for this type of regulation is recourse to the decentralized energy produ cers. So-called smart grids form the communicative foundation for regulating electrical generation, storage, electricity consumers, and grid operating means. Efficient generation, efficient use The most widely differing input and output parameters must be transmitted for the integration of PV plants into smart grids and for permanent monitoring of the plants. In order to most easily configure communication from these points with the control center, WAGO has correspondingly further developed its controls: WAGO offers a standardized and easily applicable interface for users, which is based on the IEC 60870-5-101/-104 and IEC 61850

Control power for the free market (electricity stock exchange)

telecontrol protocols. More than 400 input and output modules are available within the I/O system for use at the field level. In addition, there are also diverse specialty modules, among them the 3-phase power measurement module for energetic monitoring of transformer stations, or serial I/O modules for connecting S0 counters, M-Bus counters and current sensors. Telecontrollers or IPCs take on communication between field and control levels. Programmable logic controllers (PLCs) transmit all relevant measured values, such as current, voltage, or (reactive) power and receive switching orders from the higher-level control center; these commands are then implemented by the input and output modules arranged in series. The concrete automation tasks are defined in the controllers according to IEC 61131 using CODESYS. For this purpose, a configuration interface is integrated into the CODESYS development environment for each of the two telecontrol protocols, IEC 60870 and IEC 61850. By this means, the user avoids the relatively expensive programming labor, as the entire IEC communication can be parameterized.

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 Maintain attractiveness, increase development The proportion of renewable energy as part of the more than 600 terawatt hours, which are annually required in Germany, must and will increase in the future. By employing automation components from WAGO, the technical prerequisites for an efficient usage of electricity are already available. By this means, photovoltaics remain attractive despite a drop in guaranteed feed-in compensation. This is of decisive importance: Only if this technology continues to radiate power, will the expansion from private households and corporations also maintain support.
Text: Manuel Schmidt, WAGO Photo: WAGO

Integration of PV systems into smart grids Remote communication via IEC 60870 and IEC 61850 Competition for large power plants: virtual power plants

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

CURRENT TRANSFORMER TERMINAL BLOCKS ADDED TO PROGRAM

WAGO expands its TOPJOB S range to include rail-mount terminal blocks for simple measurement in current transformer circuits and for automatic short-circuiting of transformers.
The new 2007 Series Disconnect/Test Terminal Blocks are specially designed for use in current and voltage transformer circuits. They feature a highly functional design and are just 99.6 mm long and 8.0 mm wide. Intuitive orange disconnect links simplify operation: Closing the link automatically short circuits the transformer via inserted adjacent jumper for switch lever. The circuit state can be easily, safely and reliably determined via open, touch-protected design. The 2007 Series also includes through and ground terminal blocks with identical profiles. All of the terminal blocks are designed for 30 A and 500 V based on IEC and 300 V based on UL. The maximum nominal cross section for ferruled conductors is 6 mm (AWG 10) and 10 mm (AWG 8) for solid and fine-stranded conductors. The TOPJOB S current transformer terminal blocks combine an extremely compact design with a high level of functionality, such as automatic transformer short-circuiting, declares Burkhard Niemann, Product Manager for ELECTRICAL INTERCONNECTIONS at WAGO Kontakttechnik GmbH & Co. KG.

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

TO-PASS WEB CONNECTOR

Telecontrol and monitoring of remote sites or mobile devices is no problem at all for TO-PASS. Via GPRS and Internet, faults are transmitted just as reliably to the WAGO-I/O-SYSTEM as process and position data. TO-PASS Web Connector now takes this to new heights: it can be used to integrate the WAGO telecontrol modules even better into the control center. The heart of this Web connector is a special function block for the CODESYS development topology. This function block registers the HTTP queries from the telecontrol modules, saves the process image in a global variable list and transmits a corresponding acknowledgement. The received data can then be processed by the WAGO-I/OSYSTEM as needed. Economical, bidirectional transmission using the Web connector is also used by network service providers to comply with the renewable energy act: The power reduction required by this act based on IEC 60870-5-104 is achieved by technical means by private power producers using TO-PASS. For additional information, visit www.wago.com/telecontrol.

Easy integration of fault detectors into control technology

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RURAL COMMUNITY INVE IN NEW SYSTEMS FOR WA

In the Swiss community of Wahlen, parts of the local systems for water treatment and water distribution were out of date. Endress+Hauser developed an appropriate modernization concept, which in addition to new measurement equipment and the P-View control system also includes a control system based on WAGO controllers. In order to supply a community or city with hygienically-acceptable drinking water, reliable systems for monitoring and distribution are required in addition to the water itself. In the village of Wahlen, at the foot of the Strmenkopf in Canton Basel-Landschaft, parts of the systems as well as the control unit for the water supply were no longer up-to-date. Well-master Rainer Schmidlin turned to Endress+Hauser with respect to new measurement equipment. Since this company has been familiar with Wahlens water supply for many years, the new project team created a non-binding plan for modernization. In addition to new field devices, it also provided a new control system. I/O system replaces discrete wiring The old control system consisted of different components, some of which were analog, which were wired discretely. A multitude of relays and contactors controlled pumps and older systems. In the course of modernization, the community replaced some field devices as well as the sterilization system with ultraviolet radiation. According to the plan, Endress+Hauser replaced the discrete control structure with three WAGO I/O nodes combined with the P-View control system. Within the WAGO-I/O-SYSTEM, a decision was made in favor of the ETHERNET Controller and pluggable I/O modules. They record the field-side measurement values such as flow quantities, pressure, as well as messages from fire extinguishing flaps and the system that measures the cloudiness of the water. In total, three distributed programmable ETHERNET controllers (750841) control the process stages in the pump station, the reservoir, and in the administration building. The communication with the control system takes place via an ETHERNET network that has modems and 2-wire copper lines in the external stations. For remote access by the well-master and remote maintenance by Endress+Hauser, a DSL connection was installed in the administration building. The control system handles the logging and alarming as well as the monitoring of the reservoir chambers. The new controller saves so much space that it doesnt even take up half the space in the existing system cabinets. At the same time, operation via P-view is easy and provides very detailed operating data, which I can also call up from home, reports Rainer Schmidlin with satisfaction.
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New controller and new control system provide

STS ATER SUPPLY

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

Controlling operation easily with the control system Endress+Hausers P-View control system works with OPC servers and supports many industrial communication protocols. It is based on open standards with respect to the software and hardware components used and it can be attuned very flexibly to the requirements in question. With these criteria, it is very well-suited for the tasks demanded. Within the P-View-Scada package, there are pre-configured overview pictures available. The system enters limit violations in the alarm list and informs the user via screen display. Alternatively, the control system also sends messages via SMS and e-mail. In order to adapt the controller perfectly to the needs of Wahlens water supply, Rainer Schmidlin worked closely with project director Roger Jaggi of Endress+Hauser. He adapted the programming in CODESYS according to the specifications and started the stations up after successful test runs. This was done during operation in order to spare the residents of Wahlen from having to turn off the water supply. That the control system also sends important messages via SMS is a wonderful thing for us. I am informed immediately if there is a fire alarm, for example, reports the well-master and demonstrates the service on the triggering station in the administration building. Conclusion With selected components, an out-of-date controller can be modernized. The project team from Endress+Hauser relies in its plan on flexible components, both for automation as well as for the control system. The fieldbus-independent modular WAGO-I/O-SYSTEM replaces the discrete wiring in an elegant manner. Now programmable ETHERNET controllers in the respective stations take over the control of the I/O signals, which allows them to remain independent and also functional in case of a failure of the transmission path.
Text: Renate Klebe-Klingemann, WAGO Photo: WAGO

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

WAGO-I/O-SYSTEM replaces discrete controller structure ETHERNET Controller and pluggable I/O modules P-View control system from Endress+Hauser

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AUT FOR T

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TOMATION CONCEPTS HE PROCESS INDUSTRY

Modular concepts ensure great flexibility, reusability, and finally also lower costs in software development and the automobile industry. In the process industry, there is also a trend towards dividing systems into so-called package units. As a consequence, the individual units also require largely autonomous automation technology, which exchanges information with a central control system. Here manufacturers of automation technology are required to fulfill the high requirements of the process industry with their components and systems. The life cycle of a system in the process industry is relatively long. A typical production system in the chemical industry is frequently designed so that it remains practically unchanged across a period of several decades. Despite regular maintenance work and the possible replacement of individual components, the basic structure of the system frequently remains unchanged across the life cycle. The systems demonstrate a high degree of automation. A small operating team is often sufficient to operate large systems safely. The typical structure of an automation system is the classic control system architecture. Sensors for chemical and physical process parameters as well as for the states of the system components transmit their values to the control station. There, central computers process the data and control the actuators such as pumps, stirrers, and heaters. The entire intelligence of the measurement, control, and regulation technology is in the central control system. The disadvantage of this architecture is the great amount of work required for the wiring. For large systems, several thousand sensors and actuators can be required, which must all be wired into a central point. The control system architecture is also relatively

inflexible if changes to or expansions of the system are planned because the PMC (Process Measurement and Control) technology of the central system must always be adapted. Another disadvantage is the varying life cycles of automation-technical systems and process-technical systems. However the concept of the central control system also has advantages. Safety, which is especially important in the chemical industry, can be guaranteed ideally this way. System availability also a central requirement in the process industry is very high this way. Modular approach For a while now there have been efforts in the process industry to build modular systems. With the designation F3, a consortium was established in 2009 that consists of companies from the chemical industry and research institutes in various European countries. The goal of the F3 project, whose name stands for Flexible, Fast and Future Factory, is the development of concepts for modular production systems in the process industry. The idea behind the project is to build chemical production facilities according to the modular principle. It should be possible to combine individual module package units here according to the plug-and-play principle. Thus individual system parts can be replaced more easily, if, for example, the automation technology is out of date or the field units reach the end of their life span. The maintenance of the individual package units can also be uncoupled from the rest of the system. In the future, the system engineers will no longer build a complete system; instead, individual specialized suppliers will deliver different package units, for example mixers or fermenters, which are then combined into a complete system.

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 Automation and communication A package unit includes not just the mechanical unit, but also the electrical installation, the sensors, and the automation and control technology. An important prerequisite for ensuring that such a concept works is the precise definition of the interfaces. In addition to the standardized mechanical and electrical interfaces, the interfaces of the automation technology are of great significance here. In the new concept, a central control station is still the point from which the personnel operate and monitor a system. However, a big part of the intelligence wanders to the package units. The job of the central automation technology become easier thanks to this concept since the package units take care of the lions share of the PMC tasks directly. Another big advantage of this decentralized automation architecture is the reduction of the effort required for wiring the sensors and actuators. Communication with the central control system is handled by bus systems, for example PROFIBUS DP or PROFINET. Requirements of automation technology Since the automation hardware is moving closer to the process, there arise new requirements for the individual components. Thus controllers must tolerate the harsher environmental conditions that can prevail near the process. These range from large temperature fluctuations to stresses due to humidity and dust on through to vibrations and shocks. Another requirement is the problem-free processing of the signals that arise and the possibilities of communicating via the various bus systems. Manufacturers of automation technology such as WAGO Kontakttechnik GmbH & Co. KG offer a wide-ranging portfolio of products for the process industry. With the WAGO-I/O-SYSTEM and the associated controllers, manufacturers of package units can incorporate nearly all sensors and actuators. The spectrum ranges from analog/digital inputs and outputs on through to the incorporation of nearly all common fieldbus systems. The WAGO-I/O-SYSTEM is approved for use in Zone 2 hazardous areas. Intrinsically safe digital and analog I/O modules also allow connection to peripherals in Zones 0 and 1. The automation functions can be implemented easily with the systems ETHERNET controllers or IPCs.

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 Conclusion The future in the process industry lies in the area of modular systems. So-called package units consist not just of mechanical and electrical components, they also contain the automation techno logy. This brings an essential change for the architecture of the automation systems, for a big part of the intelligence wanders to the package units. For the manufacturers of package units, system engineers, and operators, as well as for the suppliers of automation technology, this creates new opportunities.
Text: Jrg Lantzsch, professional journalist from Wiesbaden Photo: WAGO

Module concept in the process industry Automation of package units High requirements for components and systems

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PUMPING OUT WATER IN THE LAUSITZ MINING AREA

To ensure the proper function of conveyor systems in surface mining, vast amounts of water must be continuously lifted and diverted. For efficient drainage of their storage facilities in the Lausitz mining area, Vattenfall Europe Mining AG together with the automation company BEA TDL of Spremberg implemented new system technology. Standard drive solutions with modular controllers from WAGO and new communication technologies now simplify the operation of drainage systems. To convey coal at depths of 35 to 120 meters, Vattenfall operates more than 2,500 filter wells to drain the mining area. In the mining area, the filter wells are arranged in a linear structure as a barrier. Due to continuous coal mining, the active surface mining area advances in the direction of mining and the systems technology has to be repeatedly dismantled and rebuilt. In addition to structural measures, dismantling and rebuilding the systems also requires considerable programming work for the automation equipment. To make the drainage operation even more efficient in the future, Vattenfall decided to replace the existing systems technology. State-of-the-art electrical and field device technology, as well as controller and process control technology should take its place. New system concept simplifies draining operation The technical office at Vattenfall required direct access from the control station to sensors based on ETHERNET technologies from the new system design. As Vattenfall tendered Project 2007, automation specialist BEA came out on top in competition with other suppliers and was awarded the contract for a pilot installation at the Reichwalde opencast mine. Those responsible selected the WAGO-I/OSYSTEM for the automation components with programmable 750841 ETHERNET Controller for pump control and 758-870 I/O-IPC in the bolt control cabinet. The advantage of this system is its modularity and the large selection of I/O modules such as a 420 mA analog input module with HART protocol and various interface modules. The I/O system with ETHERNET Controller and IPC meets many of the required criteria innately. Thanks to its programmability, Bluetooth communication can also be implemented to configure operating data and communication with intelligent field devices in CODESYS, summarizes Armin Noack, project manager at BEA. The requirement for a modular design was met in many system components from the medium-high voltage and low-voltage switchgear to the hardware

Barrier with multiple filter wells in a line safely hold back the ground water from the surface mining area.
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In the barrier control cabinet, the I/O-IPC is used for data management with the individual pump controllers, for information exchange with the sensors and actuators and the client terminal.

Bluetooth communication for the parameterizing of operating data Direct access from the control desk to the sensor Modular structure with ETHERNET controllers and IPCs

and software in the automation part. Starting from a core configuration, for example, the switchgear and controllers can be torn down and setup up based on the use cases to be expected. With modular components such as the WAGO-I/O-SYSTEM, sustainable systems can be implemented because they allow further development and can be quickly replaced in case of breakdown, explains Henry Hanschke, Water Technology BU Manager at BEA. Configuration instead of programming The barrier and pump controls can be designed as a configurable software system that simplifies system engineering significantly. When first commissioning or modifying the system due to expansion or retreat, pump controls can be expanded, replaced or removed in the system with no programming required. All controllers including IPC are configured via a single engineering tool and have an integrated web server on which device- and application-specific HTML pages are saved. As a result, any controller on the client terminal can be easily configured from clear user interfaces via the network and requires no additional special knowledge. If communication with the

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

control cabinets or control station is interrupted, the controllers continue to run independently and the process can still be controlled locally. System concept proven in the field After the pilot system was proven in practice, those responsible transferred the new system concept to other mines in the area. In recent years, BEA has implemented other systems with more than 600 pumps and 30 barrier control cabinets, which meet the demand for high system availability under mining conditions. As a result, the joint development contributes to meeting the hydrological requirements of surface mining, summarizes project engineer Jrgen Karas of Vattenfall Europe Mining AG. He adds, The automation solution achieved has become the standard at Vattenfall. Text: Klaus Dreiskemper, WAGO Photo: WAGO

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

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DISCONNECT TERMINAL BLOCKS TESTED UP TO 1,500 VDC

Ideal for applications in the renewable energy sector: Disconnect terminal blocks up to 1,500 VDC for the TOPJOB S 2006 Series of railmounted terminal blocks
The cut-off voltage required in photovoltaic and wind turbine systems far exceeds that demanded in classic industrial systems. WAGO has therefore developed rail-mounted terminal blocks that are approved for up to 1,500 VDC by IEC and up to 1,000 VDC by UL. The integrated, orange disconnect links in the new TOPJOB S 2006 Series Disconnect, Carrier and Through Terminal Blocks not only make them easy to use, but also provide for safe and reliable handling as well.
The suitability of these terminal blocks for direct current levels up to 1,500 V and 30 A enables them to be used in applications requiring higher voltage and output levels, such as in generator terminal boxes for photovoltaic systems. The maximum nominal cross section for ferruled conductors is 6 mm (AWG 10) and 10 mm (AWG 8) for solid and fine-stranded conductors. The new terminal block versions can be combined with the existing TOPJOB S terminal block line and are available in gray and blue. The ongoing technical development of renewable energy sources demands connection technology for voltages of more than 1,000 V based on IEC and more than 600 V based on UL WAGO is stepping up to meet the challenges posed by this market with its new 2006 Series Terminal Blocks for up to 1,500 VDC, states Burkhard Niemann, Product Manager for ELECTRICAL INTERCONNECIONS at WAGO Kontakttechnik GmbH & Co. KG in Minden. The TOPJOB S rail-mounted terminal block system Covering a range of wire sizes from 0.14 mm to 95 mm (AWG 24-4/0), TOPJOB S, along with POWER CAGE CLAMP, is the rail-mounted terminal block system that offers the widest range of products for industry, buildings and traffic applications. Thanks to CAGE CLAMP S technology, the TOPJOB S rail-mounted terminal blocks are the industrys most compact. These terminal blocks are suitable for all types of conductors; solid, stranded and fine-stranded conductors with ferrules can also be connected simply by pushing them in. The TOPJOB S rail-mounted terminal block system is rounded out by the fastest and most economical marking system and by a comprehensive jumper system for any conceivable application.

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

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EXCELLENT STANDARD
Defined interfaces, defined data: the Weihenstephan Standards (WS) form the basis for a manufacturer-independent coupling of machines and superior production management systems: WS Pack for beverage filling and packaging systems and WS Food for food processing. What began as a university research project has developed into a true success story, which recently was awarded the gold medal in International FoodTec by the German Agricultural Society (DLG). In addition to the possibilities for quality assurance and increased efficiency, the prize explicitly acknowledged the pre-competitive involvement of all participants: the industrial partners, the German Engineering Federation (VDMA), and the Science Foundation of the German Beer Brewing Industry (WiF). WAGO has supported the Weihenstephan Standards since early 2011 as an official partner enterprise and, as part of this involvement, has developed the necessary software components for their ETHERNET controls and ETHERNET industrial PCs. For additional information, visit www.wago.com/food.

International FoodTec Award 2012 in Gold for the Weihenstephan Standards

PACK

Ex i COUNTER FOR NAMUR-COMPLIANT SIGNALS

WAGO has developed an Ex i up/down counter (750-633) as I/O module for the WAGO-I/O-SYSTEM 750. The counter records binary signals with NAMUR-compliant levels and transmits the systems counter state to a WAGO programmable controller or to the higher-level control system via coupler and fieldbus. The counting direction up or down can be set using the U/D input (Up/Down). A control byte sets or resets the counter. The digital output (DO) is enabled via control byte or is activated based on counter state. The maximum switching frequency of the counter is 20 kHz. The 24 mm wide module indicates its status on LEDs: green for Up/Down input active, CLK input (counter input) active, and DO switched, as well as red for wire break/short-circuit of the Up/Down and CLK signal lines. The field and system level are electrically isolated and the output is short-circuit-proof. The module is supplied by a separate 24 VDC feed in an Ex i version.
WAGOs new intrinsically safe up/down counter records binary signals with NAMUR-compliant levels.

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CONTROLLING PROCESS
A central process control system is not sufficiently flexible or too expensive for many companies. The engineering office for process automation/control, pac GmbH here relies on control units by WAGO. In a project for biotechnology at Novartis, a remote system had to prove itself as a control unit for process systems in conjunction with a central monitoring system.
Novartis operates many multi-purpose systems in the field of biotechnology, which are not geared to mass production with fixed production processes. Production and processes change regularly, a central process control system is therefore too inflexible. According to the requirements of ERES (Electronic Records Electronic Signatures) and the FDA (Food and Drug Administration), 21CFR Part11, data and user interventions, such as settings and configurations, however, would have to the recorded during production and stored securely. This logging was previously associated with a great manual effort. mable according to IEC 61131 like a programmable logic controller. Finally, as an IPC it integrates the open standards of the PC world.

Flexible and modular control unit In process automation, we frequently need an alternative for large and complex control systems. This easy to use PLC, however, must still meet the highest quality demands. The WAGO system has positioned itself here and proven itself in practice. It uses standard hardware, standard protocols, as well as standard interfaces. We therefore can select various suppliers for the peripherals. If a terminal malfunctions, we only need to replace it and not the entire assembly. Even the programming using standard tools such as CODESYS or MS- SQL server makes the solution much more cost-effective, added the manager of the engineering office. He especially appreciates the flexibility in the integration of sensor and actuator signals. Practical decentralized solution The decentralized process control has proven itself at Novartis. In a preparation system for the extraction of an active ingredient, first different media are added, and in another process they are stored and conditions in a second group of machines. The controller ensures that there is a ring line for the process-appropriate addition of common resources such as cleanser, steam, and distilled water, and it performs coordination tasks such as filling in mobile containers, the transfer between the machine groups, and the control of valves. The production data is stored and evaluated centrally. Via view stations distributed across the building, the system operators also have access to current and historic process data; mobile call-up stations via WLAN are also planned. The standardized interface of the logging system has proven very helpful for the incorporation of different suppliers machine groups. A Siemens control unit can also be connected via a PROFIBUS coupling.

Autonomous automation solution As an alternative to a central process control system, Novartis decided to set up a remote process controller by pac GmbH using the technique of WAGO. Industrial PCs control the individual systems. The control panels are on site. The control units are connected via ETHERNET. The sensors/actuators on the IPCs can be switched via I/O terminals. In addition, the IPC activates the Festo valve terminals via PROFIBUS. A central log server records the process data and logs all alarms, faults and user input according to 21CFR Part11. The WAGO IPC is predestined to be a decentralized process controller thanks to three particular features, says Jrgen Stterle, the CEO of pac GmbH. From his point of view, the IPC could also be called I/O-PC because it can be mounted directly on the 24-volt level on the top-hat rail and connected directly to I/O modules. Furthermore, it has the properties of a classic PLC: it is robust, small, and program-

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

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

Decentralized process control with the WAGO IPC Production data according to FDA 21 CFR Part11 Manufacturer-independent connection to the controller

Text: Martin Ortgies, professional journalist Photo: Novartis, WAGO

In process automation, we frequently need an alternative for large and

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

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REMOTE MONITORING OF
Having the customer profit from manufacturers expertise benefits everyone: with help from WAGO, the Lineguard Supervisor by Henkel provides a compact, industrial process control system with world-wide access.. This system optimizes metal pretreating processes at the customer, enhancing both product quality and profitability. Optimal pretreatment of metallic surfaces has a major influence on the properties of the final product. Here, flaws normally do not become apparent until the next step in the process, for example, during painting, making them impossible to correct. Adherence that is meticulous and as accurate as possible to all process steps is therefore a prerequisite for high, uniform product quality. Henkel AG & Co. KGaA is the leading producer of chemicals for treating metallic surfaces. This product segment accounts for a substantial portion of the companys overall earnings. Henkel is also the leader in process technology in this sector and operates an in-house research and development center. It is here where specific processes, such as Alodine, for pretreatment of aluminum, or Bonderite NT for treatment prior to painting, are developed. The company therefore not only serves as a supplier of chemicals, but is also considered to be a service provider that passes its expertise along the entire process chain. Compact dosing unit optimizes customer process Pretreatments, such as chromating or zinc phosphating, are complex processes subject to short-term influences. Processes such as these require that quality, profitability and environmental impact be monitored constantly and kept in line. Only one lab analysis per day is frequently the rule in normal practice, however. The results of this analysis then define the proportioning and dosing of the chemicals involved for the next few hours. Changes of the bath composition that may be necessary are often not recognized in good time, resulting in quality problems and elevated costs. Operators frequently feel that the solution is to add more chemicals, which may not always ensure better quality but always leads to increased costs and greater environmental impact. To optimize this procedure, Henkel, together with WAGO, developed the Lineguard Supervisor. This is a compact, process control system for dosing chemicals using remote access via a Web portal. The central component of the dosing system is the WAGO I/OIPC. Analog and digital I/O modules and RS-232 interfaces can be connected directly to the IPC in series as components of the WAGO-I/O-SYSTEM. These modules record the signals from the sensors and constantly determine the composition of the baths. The system uses this data to define the optimal dosing of the chemicals and monitors the bath for the correct mixture of the chemicals using pulsed control activation of the dosing pumps. Web portal offers access from anywhere in the world Worldwide support for process systems and technology issues play a major role in Henkels business model. Therefore,

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

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CUSTOMER PROCESSES
a Web-capable system was required, which Arkadon implemented by adapting the existing TO-PASS Web Portal into the TO-PASS Dynamic Web Portal. This system is capable of processing large volumes of data and making it available on a Web portal. The Dynamic Web Portal also automatically recognizes the I/O modules linked to the system based on the size of the system. This considerably simplifies the integration effort required and creates flexibility, in particular when the system is expanded subsequently. Data is transferred via a GSM/GPRS router, which sets up a secure VPN tunnel. This enables secure writing of all relevant process data to the Web portal. A preprogrammed visualization function also provides a quick overview of the current process activities and displays various standard functions graphically: Temperature progressions, violations of defined set points, a comprehensive alarm management system with different alarm classes, and a simple password assignment function. The results are available as data worldwide in various views. The costs for system integration and subsequent start-up are reduced since the portal automatically adapts to the I/O-IPC configuration. I/O-IPC: The high-performance control system As an intelligent I/O system, the 758 I/O-IPC offers PLC functionality. Using CODESYS, it is possible to program a self-teaching controller and the visualization according to IEC 61131-2. An integrated Web server enables access via the intranet or Internet using a PC with a Web browser, or via a local touch panel with a DVI interface. For communication with higher-level systems and the IT world, the I/O-IPC has two completely independent Fast Ethernet interfaces, 2xUSB, RS-232 and a CompactFlash interface. Thus it is the ideal link between the automation and IT levels. An optional PROFIBUS DP or CANopen interface is available for fieldbus communication. Nearly all the more than 400 input and output modules from the portfolio of the WAGO-I/O-SYSTEM can be used with the I/O-IPC.
Text: Dr. Lutz Huesemann, Henkel AG & Co. KGaA Wolfgang Laufmann, WAGO Photo: Henkel, WAGO

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

As an intelligent I/O system, the WAGO I/O-IPC offers PLC functionality WAGO-I/O-SYSTEM modules can be plugged directly into the WAGO I/O-IPC

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

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ADDRESSES
D WAGO Kontakttechnik GmbH & Co. KG Postfach 28 80, 32385 Minden Hansastrae 27 32423 Minden Phone: +49 (0)571 887-0 Fax: +49 (0)571 887-169 info@wago.com A WAGO Kontakttechnik Ges.m.b.H. Laxenburger Strae 244 1230 Vienna Phone: +43 1 6150780 Fax.: +43 1 6150775 info.at@wago.com CH WAGO CONTACT SA Rte. de lIndustrie 19 Case Postale 168 1564 Domdidier Phone: +41/26 676 75 86 Phone: +41/26 676 75 01 info.switzerland@wago.com

IMPRINT
WAGOdirect process October 2012 Editor: Torsten Schimanski (responsible editor) Phone: +49 (0)571887-531 Fax: +49 (0)571 887-305 Re-use of this content free of charge is possible. Contact: Torsten Schimanski. We assume no liability for unsolicited manuscripts and photos sent in. WAGOdirect process appears at irregular intervals.

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