SolutioNS 17 - Moeller

www.moeller.netAutomation Solutions in Machine and System BuildingSolutions 17SmartWire DarwinNext Step

ContentsContents .............................................................................................. Pagenews....................................................................................................... 3-11Daisy Chain ........................................................................................ 12-13SmartWire Darwin - the next evolutionary stepWell sorted .......................................................................................... 14-15Waste sorting plant equipped with SmartWireFine cut................................................................................................. 16-17easySafety in high-speed cutting machineThrough thick and thin ...................................................................... 18-19xStart brings cutting machine up to speedGolden harvest ................................................................................... 20-21Electricity and heat from mini-CHPIt‘s all in the label................................................................................ 22-23easyRelay automates labelling system for round objectsFully charged ...................................................................................... 24-25Intelligent charging station for industrial batteriesUnder pressure ................................................................................... 26-27easy800 and MFD-Titan control pressure booster systemSpotless................................................................................................ 28-29EC4P compact controller for cleaning machineOn call....................................................................................................... 30Waste water alarm by SMSDanger detected, danger eliminated .................................................... 31Preventing injury to personnel and damage to property“Run for it”........................................................................................... 32-33Smoke free escape and rescue routesinfoboard ............................................................................................ 34-35ImprintMoeller Solutions is theMoeller customer publicationfor industrial automationPublished:Moeller GmbHEditors:Dirk Bolz (v.i.S.d.P)Christian BückerIntegral Dr. Schumacher ®Authors:Christian BückerSven CoesterLütfiye DönogluUwe FröhlichRonny HappDr. Monika SchumacherPaul KnodelErich NeuhauserJürgen VisariusDr. Frank VölkerHein-Moeller-Straße 7-1153115 BonnTel.: +49 228 602-0Fax : +49 228 602-62275E-Mail: info@moeller.netwww.moeller.net/solutionsThis customer publication is protectedby copyright, applicable to all articles,diagrams and photos. Moeller reservesall rights.KM 0213-4294GBArticle No.: 113791Layout: buntebrause agenturTranslated: Terry OsbornPrinted in Germany (04/08)

Solutions17N E W S+ + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + +Switchboard RoadshowMoeller is presenting with the SwitchboardRoadshow its product range of energy andservice distribution board systems as well asits new enclosure series. The flexible uses ofcircuit-breakers, contactors and other cleverproduct solutions are presented – in practicalapplications and fully installed.The Switchboard Roadshow will be presentat the Light & Building fair from 06.04. –11.04.2008 and the Hannover Fair from21.04. – 25.04.2008. More information onour switchboard products can be found atwww.moeller-systempartner-schaltanlagen.netor at www.moeller.net.With the Switchboard Roadshow, customersand prospective customers experiencethe Moeller world of switchboard products– based on over 100 years of experience insafe power distribution.NZM-C Competition:Inexpensive Switching and Protection with theNew Comfort SeriesThe competition organised by Moeller for itsnew NZM-C series was a total success. Alreadyin the first month over 162 participants aloneentered the competition via the websitewww.NZM-C.de examined the new circuitbreakerseries more closely. For most entrantsthe question “What is the maximum rateduninterrupted current of the largest circuitbreakerof the NZM Comfort series?” was nomajor obstacle, and all answered correctlywith the answer “500A”.The competition is now closed and thefollowing lucky winners were notified:1st PRIZEGötz Elektrotechnik GmbH SchaltanlagenbauPeter Götz, Weilheim / Teck2nd PRIZEtech control GmbHAutomatisierungsanlagenHelmut Richtscheid, Nossen3rd PRIZEPD Elektrotechnik GmbHPeter Groth, SchenefeldMoeller wishes the winners much fun withtheir prizes. The winner of the first prize willtake part in an adventure weekend in Austria.We wish to thank all entrants for their interestand participation in the competition.The new NZM-C from theMoeller Comfort series

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E WxStart Contactors:The New GenerationOptimum contact throughknurled contact surfaces.Moeller has been continuously further developing DILM contactorssince their market launch four years ago. The new typesDILM15, DILM38, DILM72 and DILM170 add moreefficient and economical Eco contactors toMoeller‘s range: In addition to an improvedcontact design and the use of newcontact materials, it was also possible toincrease the performance.The new xStart generation now offers anoptimum cost/benefit ratio on the basisof intensive testing and a large number ofexaminations. The result is outstanding:Moeller has lowered the list prices for theratings of the Eco variants by up to 12 percent.The compact Eco contactors also allow usersto save space in the switch cabinet. With anelectrical lifespan of 500000 (DILM 38) and750000 (DILM15, DILM72, DILM170) switchoperations, Eco contactors are a genuinealternative to the established contactor seriesin most applications.xStart contactors offer other practical featuresin the series. For example, grooved contactsurfaces with eight contact points ensurereliable contacting with auxiliary contacts,even with small loads. Motor filters and otherauxiliary contacts, as well as accessories canbe plugged onto the contactor from the top,and all the required openings are perfectlyenclosed. Electronic circuits created by theuser can also be positioned on the contactorusing solder pin adapters.DIL contactors up to 170 A are provided withbox terminals with two terminal chambers. Allconnections can be arranged on the front andpacking density and enables the use of smallerpower supply units for the control current.This firstly optimises the space requirementsin the switch cabinet and secondly reducesthe heat that has to be removed by means offans or climatic units. Wide range coils coverall the voltage variants with only a few typesrequired. The basic unit of contactors DILM7to DILM38 features an integrated auxiliarycontact that can be designed as a break ormake contact.Contactors up to 38 A allow users to useMoeller‘s SmartWire technology: SmartWirereplaces conventional control circuit wiringOpen for different cable cross-Excellent protection thanksto the perfect enclosure ofopenings.sections: the two terminal chambersof the box terminals.xStart switching devices replace conventionalwiring with pluggable main and controlcurrent connections. While motor starterswere previously connected with cumbersomecables or bridges between motor-protectivecircuit-breaker and contactor, contact is nowimplemented by means of mechanical pluginmodules – they combine motor-protectivecircuit-breakers and contactors into stableunits. The tool-less connection technologyoffers fast and error-free wiring without theneed for any tools.are also accessible from here. Another userfriendlyfeature: contactors with AC and DCdrives have identical design geometries. Thismeans that contactor accessories, includingthe wiring systems, can be used irrespective ofvoltage type. All DC operated contactors arefactory shipped with an integrated suppressorcircuit. DC operated contactors also feature anelectronic drive.Contactors up to 38 A can be controlleddirectly from the PLC, thus eliminating theneed for coupling relays. The low sealingpower of the contactors allows a higherbetween the switchgear and the I/O modulesof the PLC. A SmartWire module is simplyplugged onto the conventional contactor andall SmartWire modules are interconnectedwith a pre-assembled SmartWire cable.Communication with the controller is thenimplemented with a CANopen or Profibusgateway. With SmartWire everything isplugged and not wired.Quicklink ID:MS1701

Solutions17S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SIEC/EN 60335 - Switchgear for Household Use:Safety of Household and Similar Electrical AppliancesMoeller‘s contactors and motor-protectivecircuit-breakers are also used for householddevices in addition to many industrialapplications. Electrical switchgear used onhousehold devices also has to comply with theIEC/EN 60335 specifications for the “Safety ofhousehold and similar electrical appliances”in addition to the tests in accordance withIEC/EN 60947 “Low voltage switchgear andcontrolgear”. IEC/EN 60335 covers “the safetyof household and similar electrical appliances”,with rated voltages not exceeding 250 V forsingle-phase devices and 480 V for otherdevices. Household appliances include forexample dishwashers, cookers, room heaters,water heaters, freezers and similar.The term “household use” is very widelyinterpreted in the standard. This covers alsodevices that are not exclusively used fordomestic purposes but which can represent ahazard for the general public. These includefor example devices that areused by unskilled personsin commercial buildingsor in agriculture such aslarge cooking devices,automatic baking machinesin supermarkets or petrolstations, ice cream machines,cleaning equipment forindustrial and commercialuse, as well as hairdresserequipment.Switchgear that is used inthese devices must pass additional tests for heatand thermal resistance in accordance with IEC/EN 60335. In the latest version of this standardof February 2007, devices with a current ofmore than 0.2A must undergo a glow wire teston plastic parts at 750°C, in which case anypossible flames produced must be extinguishedwithin 2 seconds.Moeller products such as the PKZM0 andPKZM01 motor-protective circuit-breakers, DILcontactors up to 15kW and the correspondingZ overload relay fully meet the requirementsof the EN 60335 household appliancestandard.DILA, DILM7 to DILM15 Contactors:Side-Mounted Auxiliary ContactMoeller‘s side-mounted DILA-XHI…-S auxiliarycontact is a perfect addition to its range ofcontactor accessories. The DILA-XHI…-S isideal for applications up to 7.5kW requiringtwo auxiliary contacts and where thecontactor mounting depth 75mm cannot besignificantly increased, such as on machineswith compact integrated switch cabinets.DILA-XHI…-S is designed as an auxiliary makecontact or as an auxiliary break contact, andis available either with screw or spring-loadedterminals. The DILA-XHI…-S is simply clippedon the left of the contactor.Smaller and More Compact:DILM570 for 315kWCompared to the previous well-establishedDILM580 contactor, the DILM570 offers aninexpensive alternative for common switchingrequirements up to 315kW / 400V / AC-3.The DILM570 combines a high performancewith compact dimensions at a low cost.Compared to the DILM580, Moeller‘s compactDILM570 has reduced the mounting width by36 percent. This saves valuable space in theswitching cabinet. With an electrical lifespanof 750000 operations, the DILM570 contactoris the first choice for most applications. TheDILM570 is designed for use in AC-1 and AC-3applications. The DILM570 contactor is availablein control voltages of 110-120V 50/60Hzand 220-240V 50/60Hz.Quicklink ID:MS1702

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E WNZM1 Circuit-Breakers:New connector technologyWith applications requiring a high level ofavailability, components are normally designedas plug connections. This allows devices to beexchanged quickly without any mounting or wiringtime required when the system is expanded or in theevent of damage. The new plug connection designfor the NZM1 circuit-breaker allows a maximumrated current of 125A. The narrow design does notrequire any additional space for engineering. Whenthe switch is exchanged, an automatic trip ensurescurrent interruption so that the exchange can becompleted safely. The plug socket is designed todegree of protection IP20 and thus offers a high levelof finger safety, even when the circuit-breaker isremoved. If required, one or twopadlocks can be used to preventany undesired plugging in of thecircuit-breaker. With the plugsocket, Moeller offers the samerange of connection designs asfor the NZM1 circuit-breaker.NZM1 Circuit-Breakers:New residual current protection modulefor welding applicationsThe circuit-breaker is an essentialcomponent for welding controls.Moeller‘s NZM circuit-breakershave a proven record overseveral years – particularly inautomotive production. Circuitbreakersare normally used asmain switches for system andpersonnel protection. The fastand automatic disconnection ofdangerous touch voltages protectspersons against electric shock. Inthe event of a fault, the powersupply must be disconnectedautomatically (in accordancewith IEC 364-4-41/ VDE 0100Part 410) as protection againstindirect contact. The residualcurrent module that is separatedfrom mains and auxiliary voltagestrips as soon as the definablerated current is exceeded. Thesummation principle makesthe module pulsating d.c. anda.c. fault current sensitive inthe range from 0 to 10 000kHz and thus also suitable for3-pole equipment with powerelectronics such as converters andfrequency inverters. A standardscompliant integrated shorttimedelay ensures protectionagainst nuisance tripping due tomomentary, pulsating residualcurrents and discharge currentswhich flow, for example, acrossthe suppression filter whenswitching on frequency inverters.NZM2 Circuit-Breakers:Rotary handle for machine control mainswitches for North AmericaMoeller has developed a newdoor coupling handle with anadditional handle directly onthe circuit-breaker in orderto address a standard NorthAmerican requirement of keepingan actuator element alwaysconnected with the circuitbreakerregardless of the positionof the switch cabinet door. Thisnew innovative construction thusalso provides compliance withthe latest requirements of NFPA79 and UL 508A with regard to“deliberate action”. If deliberateaction is required, the additionalhandle must be rotated byapprox. 20° in order for it to thenbe pushed in and further rotatedto switch on the circuit-breaker.The essential safety features, suchas means of actuation, switchposition indication and lockabilityare therefore provided twice, i.e.on the door coupling handle andalso inside the cabinet.

Solutions17S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SNZM2 Circuit-Breakers:New XRD remote operatorThe XRD remote operator is now availablefor standard network or load switching froma distance with the NZM2 circuit-breakers upto 300A. The on switching, off switching andresetting is executed with a permanent orpulse contact using a manual control circuitdevice or automated control commands. Themaximum ON/OFF switch time is 170 ms andis thus suitable for all standard applicationsfor automated or remotely operated energycontrol. If required, the remote operatorcan be opened out from the circuit-breakerin order to be able to access the installedauxiliary contact and voltage release. Thethree-position AUTO/MANUAL/Interlockedselector switch on the front of the driveallows operating positions to be distinguishedclearly. A padlocking feature offers additionalprotection: The padlocking secures locking inthe 0 position. Mounting does not require anyadditional space since the remote operator hasthe same mounting width as thecircuit-breaker itself. Moeller is offeringthe new NZM2-XRD remote operatorat a considerably lower price than itssynchronisable high-speed remote operatorNZM2-XR.New Features forNZM Circuit-BreakersNZM1-4 Circuit-Breakers:New insulating surroundsNZM3 Circuit-Breaker:New busbar adapterA new busbar adapter is availablefor NZM3 circuit-breakers witha rated current up to 630A. Thespecial feature of this device isthat the direction of the incomeror outgoer is optional, whichmeans that the incomer can bemounted from the top or thebottom. The connection betweenthe circuit-breaker and theadapter is implemented with arapid mounting internal tubecontact. The halogen-freebusbar adapter can be usedfor all busbar trunking systemswith a 60 mm centre spacing.The adapter is fastened usingterminal screw connections onto12 to 30 mm x 5 to 10 mm Curails as well as double and tripleT profiles.New insulating surrounds formounting in the switch cabinetdoors are now available forseries NZM1-4 circuit-breakerswith a toggle lever. The narrowlydesigned insulating surroundsallow side-by-side mountingwithout the need to spacecircuit-breakers with togglelevers. Mounting in a rectangularcutout with a material thicknessof 1 to 3 mm can be completedQuicklink ID:MS1703simply and quickly by turningthe locking catch. The variablefastening allows a mountingtolerance of up to 4 mm andguarantees protection to IP40.Additional label plates ZFS….-NZM for customised inscriptionare available for identifying thecircuit-breaker clearly from theoutside.

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E WM22 RMQ-Titan Joystick:For Creep/Rapid Motion and Setup ModeMoeller‘s new M22 RMQ-Titan joystick enablesusers to switch two positions (contacts) insuccession in one operating direction. In thisway, solutions for setup mode or creep/rapidmotion selection can be implemented easily.Moeller offers its joystick variants in differentoperating directions: a.) two directionsfor vertical operation (up/down), b.) twodirections for horizontal operation (right/left)and c.) four directions (up/down/right/left)- each with two switch positions per operatingdirection. Standard make contacts and earlymake contacts from the RMQ-Titan rangeof control circuit devices are used as switchcontacts. All devices are available immediately.The M22 RMQ-Titan joystick is protectedto IP66 and in accordance with the Atex(Atmospheres Explosibles) Directive 94/9 ECapproved for use in dust environments, zone22, category 3. It is used in areas susceptibleto explosions caused by dust.Quicklink ID:MS1704IP65 Multi-Function Display:Inexpensive CANopen interfaceSimple visualization tasks on CANopen cannow be implemented inexpensively with thenew CP4-CAN interface module. The devicefeatures an automatic baud rate detectionfunction. The station address can be setconveniently via the display. In combinationwith the MFD80 display, 4 lines of 16characters each can be used. The EC4P andXC100/200 controllers are controlled withready-to-use function block libraries for theeasySoft-CoDeSys programming system. Thesecontain different character sizes (single, twoand four line) and attributes, enabling severaldisplay screens to be managed. The user cancommunicate interactively via the displaybuttons, for example for entering parametersor acknowledging messages.CANopen I/O modulesRemote expansions of EC4 compact controllerscan be implemented easily with the twoEC4E-221-6T4R1 and EC4E-221-6T4T1 CANmodules. These modules provide 6 inputs and4 outputs (0.5A transistor, short-circuit-proof,or 8A relay). The modules can also beexpanded with an expansion module from theeasyRelay range. In this way, combinations ofup to 18 digital inputs and 12 outputs can becreated. These devices detect the baud rateautomatically, and the node address is set bymeans of DIP switches.Quicklink ID:MS1705

Solutions17S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SDigital and Analog I/O Modules Added to easy Family.Moeller is offering new digital and analogI/O modules for the local and remote I/Oexpansion of the easy family. The easyLinkinterface allows the remote operationof the modules directly on the easyRelay(easy700/800), easyHMI (MFD-CP8), easySafety(ES4P) or on the easyControl (EC4P) basicunit, as well as via the EASY200-EASY localexpansion module – at a distance of up to 30metres. The 4 width module housing (1 widthmodule: 17.5mm) offers two EASY410 digitalmodules with 6 inputs and 4 transistor relayoutputs and two analog modules.EASY406-DC-ME offers two 10-bit resolutionanalog inputs, configurable either as 0-10V(alternatively as digital inputs), as 0-20mAcurrent inputs or as Pt100 inputs. EASY411-DC-ME offers six analog inputs with a 10-bitresolution: two 0-10V (alternatively asdigital inputs), two 0-20mA and twoPt100 inputs.The analog modules also have one digitalinput each and two digital transistoroutputs, each for 1A, as well as ananalog output or two analog outputs(EASY411-DC-ME) for 0-10V and a 10-bit resolution. The digital inputs andoutputs are addressed via the R and Soperands, the analog inputs and outputs viapermanently defined marker bytes in thedevice and via the programming software.easyRelay and easyControl:easy Function Library for Microsoft Visual C++ and Visual BasicMoeller is offering adventurous programmersa special function library for creatingcustomised PC-based visualization solutionswith the easy family. The easy_com.dllcontains functions for communication witheasyRelay (easy500, 700, 800, MFD-CP8)and easyControl (EC4P-200). It can be usedboth for Microsoft Visual C++ V6.0 SP5, forMicrosoft Visual Studio 2005 SP1 and also forVisual Basic 6.0.• Unlocking and locking of a device witha system password protection,• Starting and stopping of programexecution,• Reading out and setting of deviceclock,• Reading out of the process image,• Writing to the marker range,• Reading out and writing of year timeswitch and 7-day time switch channels.The following functions are provided:• Connection setup via COM port (serial interface or USB converter) with automatic test ofthe relevant baud rates,• Connection setup via Ethernet and TCP/IP,• Simultaneous operation of several openconnections,• Communication with all easyNetstations via an open connection(Routing),easy_com.dll has been released forWindows 2000 (SP4), Windows XP (SP2) andWindows Vista (32-bit). Moeller is offeringusers the unrestricted, non-exclusive and freeright to use the easy_com.dll function libraryfor developing their own software.

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E WSmartWire DarwinDaisy Chain - The NextEvolutionary StepMoeller presented its Darwin technologyunder the slogan: “Connecting insteadof wiring”. Since then Moeller has beenworking further on the merging of itsautomation and switching devices. Thefirst step started with the connectionfor contactors and motor starters viaSmartWire. Stage 2 involving Darwinenabledcontrol circuit devices will bepresented at the Hannover Fair 2008. TheDarwin technology is basically open for allmanufacturers, and is aimed at achievinga high level of market penetration withcooperation partners.10“Darwin – the easy way to connect”. Moelleris developing its Darwin technology in linewith this slogan, and started with Smart-Wire. The editor of Moeller Solutions spoketo Karl-Heinz Arndt, head of development inCommand & Controls at Moeller about thepresentation of the next Darwin stage.The SmartWire Darwin ASIC in comparison.Question: Moeller is continuing to follow itsDarwin strategy. What has happened so far?Answer: Well over two years ago, we presentedour Darwin concept to customers for the firsttime. The aim was to merge the world ofswitching devices and automation. For this wereplaced the traditional control circuit wiringbetween I/O modules and switching deviceswith a new connection technology. We aim tosubstitute the I/O level in several evolutionarystages and achieve cost savings for the OEMbased on our “connection instead of wiring”principle.Moeller started its Darwin concept with Smart-Wire…… that‘s right. Let me summarise briefly. In thefirst stage, the motor starters were connecteddirectly to the controller via SmartWire.However, the remaining wiring of the controlcircuit devices was implemented in the usualway. With SmartWire we were already ableto drastically reduce the wiring requirementsfor contactors, motor starter and remote I/Oincluding terminals and connectors. SmartWirealso enabled the prevention of wiring errorsfrom the very start. Users were thus ableto simply fit a SmartWire module onto anystandard contactor of the xStart series. The I/Olevel could therefore be implemented directlyat the contactor. Up to now users can connecta total of sixteen modules with the preassembledSmartWire cables. Communicationwith the controller is implemented via agateway – either easyNet, CANopen orProfibus. The addressing of the modules isalso convenient and is completed by pressinga button. The gateway, the associated motorstarters and contactors are configuredautomatically. The SmartWire cable is usedto activate the contactors as well as to carrythe information about the switching statesof the motor starters. In this expansion stage,

Solutions17S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SSmartWire has now been sufficiently testedand used successfully.What is the next step for SmartWire Darwin?At the Hannover Fair we are presentingfunctional SmartWire Darwin products for thefirst time. This now includes RMQ-Titan controlcircuit devices in addition to the motor startersand contactors. Whilst with the first Darwinstage, control circuit devices were still connectedwith I/O in the conventional manner, this levelhas now been fully removed in the second stage.Our contactors can now be connected directlywith the control circuit devices using SmartWireDarwin. This allows us to save around 50 percentof the space previously required in the controlcabinet. At our stand we will be showing twoidentical applications – one with conventionalwiring and one with SmartWire Darwin. Thisimpressively shows the benefits for customers.Up to now you used a green flat cable forSmartWire – what has changed with the newSmartWire Darwin device connection technology?are interconnected in the usual way using greenflat cables. The addressing of the individualdevices is implemented at the push of a buttonusing the daisy chain procedure. SmartWireDarwin now allows users to connect up to 100modules.How will Darwin be developed further? Whatcan customers expect?We will gradually “Darwinise” all otherswitching devices from our product range andin the final stage integrate all relevant productsfrom our business units into the new technology.In addition to the control circuit devices, themotor starters and contactors, the drives andthe circuit-breakers will be converted in a thirdphase. In future all Moeller controllers will alsobe fitted with a Darwin Asic. We will provide theinterface to the automation devices outside ofthe Darwin-enabled Moeller world in the formof gateways. We will ensure here that an OEMusing, for example, a Siemens controller with aProfibus interface in his control cabinet, will alsobe able to use the same Profibus configurator infuture and will not have to change his software.Has the Asic you mentioned been speciallydeveloped for Darwin? What can this Asic doexactly?Our Darwin Asic has been available since thebeginning of the year. We needed around twoyears for its development up to the productionstage. Price, functionality and size were primeobjectives in its development. It took virtually ayear to draw up the specifications for a futureproofAsic. After all, we require our Asic notonly to be used in our control circuit devices butalso in our devices all around the motor. Wehave implemented two direction requirementsin one Asic. On the one hand, the requirementsof the sensors/actuators involving a small datathroughput, i.e. communication requirementswhich are not particularly demanding but areprice sensitive. On the other hand, we havehigh-performance devices such as frequencyPreviously, the Moeller green flat cables for thecontactors were used with plug connectorsand fitted in the appropriate terminal socketsof the contactor modules. With SmartWireDarwin, users simply fit a device connector onthe SmartWire Darwin cable at any connectionposition they require and then press it gas tightwith crimping pliers. For this the wires of theSmartWire cable are contacted with V-shapedcontacts so that all cable impedances are zero.This has a positive effect on the cable length.The device plug connectors fitted on theSmartWire cable are then simply clipped ontothe RMQ control circuit devices, motor startersor contactors. Finally all control circuit devices11

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W12inverters, circuit-breakers and the PLCs, forwhich the data throughput is of a differentmagnitude, however with fewer price sensitiverequirements. We wanted our specification tocover both worlds and combine them in oneDarwin Asic. This challenging objective has beenachieved and we are proud of it. Our DarwinAsic is not purely a communication chip butan independent controller at the same time.However, there‘s one thing here we mustn‘tforget: A sensor-actuator supplier expects a priceand space optimised chip, and our Darwin Asicoffers this also. Within the scope of our partnerconcept, prospective customers for our Asicalso receive software that includes a library. Bythe end of the year we shall also be offering aDevelopment Kit.With these kinds of projects there is always therisk of developing singular, proprietary solutions.This isn‘t the case with us, since we are openfor collaboration with any other manufacturer.Darwin offers us the basis for a broad use ofthe Darwin technology. In the next step we areplanning the connection of switching devices ofother manufacturers to SmartWire Darwin. AnOEM will obtain the greatest benefit of Darwinthe greater the number of manufacturers thathave suitable products in their portfolios. Letme emphasise this clearly, we don‘t want toisolate ourselves with Darwin. On the contrary,we are currently talking with a number ofpotential cooperation partners. Some of thesecooperation partners have already been workingtogether with us for two years. Our Darwin Asicis based on the exchange of ideas and strategiesthat this kind of collaboration allows, and thisis now available for all other companies on themarket. The more companies use our Asic thebetter. The logic of this is clear to everyone – thehigher the quantity the lower the price.How easy is entry for prospective partners?We are planning a forum on the Internet basedon our easy concept, in addition to other largescalecommunication measures. For years now,all involved have told us that the easy forumis an impressive and successful project. Weconsider this exchange with others the best wayof learning how to use the Darwin technology.I‘ll give you an example to illustrate how we aremaking entry easier for users. As not only databut also energy is transferred via the serial bus, asatisfactory power supply for the stations in thenetwork must be ensured. For this we offer anenergy management software which supportsusers in the planning of their networks. It alsoprovides information whether the configurationis sufficiently fed with power. With a sampleconfiguration containing 32 modules, thecapacity would be reached by the driving powersupply unit and another would have to be set.This can be calculated in advance with thesoftware.How do you see your other steps with the Darwintechnology?After the “Darwinisation” of the control circuitdevices and the completed launch of easySafety,we will be consistently developing the area ofsafety bus systems. At present we can combineour conventional control circuit devices with theDarwin-enabled devices in the control cabinet,however, conventional wiring is still requiredfor emergency-stop circuits. Only the indicationthat a disconnection has been executed can betransferred via the bus system. In future we areplanning to connect safety and non-safety slavesto a SmartWire-D-Safety bus.Darwin will have to prove itself on the market……yes, we have now incorporated in our Asic thebest of all available fieldbus systems and fromour own world, for example the daisy-chainprocedure. We are therefore offering futureproofsolutions optimised for our customersin terms of project design, price, Asic size andperformance. In countries with several OEMssuch as Germany, Switzerland, Italy, Polandor Benelux, there has already been an activedemand for our Darwin-enabled products. Weare not actually starting now but have been inclose contact with our customers continuously.However, now we are being asked to supplythem with new products. We will be providingOEM customers with prototypes from theHannover Fair onwards, series products will beavailable from the middle of the year.Many thanks for talking to us.Quicklink ID:MS1707

Solutions17S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SRelaunch of the Moeller Homepage:Sector Portal Presents Industrial Applications & InformationMoeller is relaunching its homepage with anew industry sector portal. Applications andinformation from different industry sectorswill now be presented in a clearer and moreeffective way. With just a few clicks of themouse, visitors can navigate accurately inthe Moeller world. The sector portal doesnot highlight the individual components butrather their integration in a wide range ofapplications. At www.moeller.net/branchenvisitors to the Moeller homepage can finda selection of different industrial sectors.Clicking a sector calls up virtual tours ofthe different application worlds. Moellerswitchgear and automation devices for energydistribution and automation technologyhave applications in the food and packagingindustry, the automotive and shipbuildingindustry, as well as in airports and thelogistics sectors. In other words, wherever thedistribution of energy and the automation ofsequences and processes are required. All thisis made available according to application,enabling users to quickly find the rightsolutions for their tasks.Sector-specific informationMoeller‘s new portal alsoprovides sector-specificinformation. Referencereports from various sectorsare available for download.Visitors to the portal canalso find service offers foroptimum industry-specificservices. This ranges fromsupport for customisedcommissioning up to theworldwide after-salesservice. The sector portalalso provides visitors withall the dates and furtherinformation on Moellerpresentations at fairsworldwide. With eachindustry-specific application,links guide you precisely andquickly to product descriptions, data sheetsand detailed documentation. Naturally, thesector portal provides all the contact details ofMoeller sector specialists – an email or phonecall are enough…TouchPanel with 5.7 inch TFT DisplayShipping and ATEX ApprovalsThe MFD4 multi-function display fromMoeller’s easyHMI device series now featuresa full graphics 5.7 inch colour TFT display with256 colours, resistive touch, as well as a hostof communication and network options. TheMFD4 is now approved for use on ships and isalso suitable for use in dust environments inaccordance with the ATEX Directive 94/9/ECZone 22 Cat 3D.MFD4 comes with an Ethernet, CANopen/easyNet and RS232 interface.The Windows CE-based MFD4 device comeswith an integrated 64 MB SRAM, 2 MB Flashfor data / program memory, 6 MB for thevisualization and a battery-backed real-timeclock.The MFD4 multi-function display (320 x240 pixels) is designed as a single unit. TheeasySoft-CoDeSys software is also designedas one unit, combining the programmingsystem and the visualization in one, and thusallows direct access to PLC variables. The 1 33MHz, 32-bit RISC processor can also handlePLC tasks for smaller automation applications.Quicklink ID:MS170613

The CompaniesElektro-Herrmann GmbH in Bergen nearHannover has been a pioneer of innovativeelectrical engineering for more than 50years. Electrical installations, industrialassemblies and a widely establishedcustomer service are key elements inthe range of services on offer. Today themedium-sized company has operationsthroughout Europe beyond regionalborders. (www.herrmann-elektro.de).Sutco RecyclingTechnik GmbH in BergischGladbach is a company of the Ludden& Mennekes Group in Meppen and is aspecialist in tailored complete solutions forimplementing sophisticated treatment andrecycling technologies. (www.sutco.de).Tönsmeier Dienstleistung GmbH & Co.KG, Porta Westfalica, operates as a wastedisposal company throughout Europe witha wide range of services. With over 30treatment, sorting and recycling plants, theTönsmeier Group serves municipal clients,dual system carriers and customers fromindustry and commerce.(www.toensmeier.de).Well SortedWaste Sorting Plant Equipped With SmartWireProfibus DPIn today‘s world waste is not just disposed of but sortedprecisely and recycled. Automated sorting systems consistof several electrical conveyor belt drives that have tobe controlled by contactors and protected with motorprotectivecircuit-breakers. For the panel builder, the fittingand wiring required is a significant time and cost factor.In Oppin, Sachsen-Anhalt, time consuming and errorpronewiring has been replaced by convenient and safeplug connectors using Moeller xStart motor starters inconjunction with SmartWire.14

Solutions17The sieve drum from the outside:Over 300 motor starters were connected withSmartWire instead of wired.More space in switch cabinets and reducedmounting and wiring costs thanks to SmartWire.Early in 2008, the Oppin-based TönsmeierGroup put a new waste sorting system forlightweight packaging into operation. Theelectrical equipment was installed by Elektro-Herrmann. It was necessary to ensure a highlevel of cost efficiency for the switchboardpanels, whilst still providing high levels ofquality, functionality and flexibility for thecontrol components. For this reason, Moeller‘sxStart and SmartWire series were selected forthe electrical equipment. Other low-voltageswitchgear and controlgear from Moellersuch as circuit-breakers and fuse switchdisconnectors,as well as the SASY60i busbartrunking system were used to complete thesolution.Tool-less fitting of contactors andmotor-protective circuit-breakersxStart contactors and motor-protective circuitbreakersare designed as standard componentswhich can be flexibly arranged as individualdevices and also connected with conventionalwiring using standard terminals. Theseswitching devices also feature standard pluginsockets that can be connected as requiredwith contact modules without using any cablesor tools. These inexpensive contact modulesare available for DOL, reversing and star-deltastarter combinations.Elektro-Herrmann utilised the Moeller contactmodules in the Oppin waste recycling systemthroughout and was able install a largenumber of DOL and reversing starters withoutthe need for any complex wiring betweenthe motor-protective circuit-breaker and thecontactors. The standard components weresimply plugged together to form startercombinations. Customers that primarily supplyseries control systems can alternatively orderfactory-assembled switchgear assemblies usingthe catalogue, and even fully fitted on busbaradapters.Connecting instead of wiring PLC withswitchgearConventional control wiring requires a singlecable for each connection between the inputsand outputs of a PLC and the switchingdevices. With the large number of drives tobe controlled in a sorting system, the amountof time and investment required with aconventional wiring would be tremendous.Thanks to SmartWire, Elektro-Herrmann wasable to replace conventional control wiringwith a green flat cable for the around 300contactors installed.The design of SmartWire is astonishinglysimple since the user just has to provide aSmartWire module for each contactor ormotor starter. Like an auxiliary switch, theSmartWire modules are fitted onto thestandard contactors without any tools andinterconnected with the factory assembledSmartWire cables. The six-pole plug connectoris simply plugged on. Any possible wiringfaults are almost totally excluded. In order toensure flexibility in the device arrangement,Moeller offers pre-assembled SmartWirecables in different lengths from 85 mmto 2000 mm. The SmartWire module fitsuniversally on all size 1 and 2 xStart contactorsand thus enables a broad application rangeup to a rated motor current of 38A per drive.For larger drives and other applications, anI/O module is available which is fitted withfour digital inputs and two relay outputs, andwhich can also be integrated in the system,also using SmartWire cables. If required, thepower module allows emergency-stop groupsto be created.SmartWire is connected to the higher-levelautomation system via gateways to which upto 16 SmartWire modules can be connected.Gateways for Profibus-DP and CANopen/easyNet are available depending on the typeof master controller used. The SmartWireslaves are configured in the higher-level PLCfollowing normal fieldbus procedures. Thewaste sorting plant uses Profibus-DP, and sothe configuration is carried out in the PLCsoftware of the controller using the GSD filein the usual manner. The individual SmartWiremodules are automatically assigned addressesby simply pressing a button on the gateway.Quicklink ID:MS1708CONCLUSIONHelmut Helms, responsible projectmanager at Elektro-Herrmann explained:“We have already fitted smaller conveyorsystems with SmartWire and have beenvery pleased with the result. We cannow save on the I/O gateways previouslyinstalled in the field with their inputs andoutputs for controlling motor starters. Thecontroller is also connected simply andeconomically.” Wilfried Enghardt, headof panel building at Elektro-Herrmannadded: “Mounting using the modularsystem saves a considerable amount oftime. The use of standard componentsis extremely helpful in project-orientedpanel building. Either individuallyarranged or with plug connection design– conventionally wired or with SmartWire,we use xStart switchgear for a universalrange of applications.”15

THE COMPANYFine CuteasySafety in high-speed cutting machinePOLAR was founded in 1906 as „AdolfMohr, Maschinenfabrik“. Today highspeedcutters are marketed worldwideunder the brand name POLAR for thegraphic industry, peripheral equipmentfor all operations around cutting,labelling systems and pile turners. Thefamily-owned company POLAR-Mohris based in Hofheim/Taunus and isrepresented worldwide. Since 1949around 120000 high-speed cutters havebeen delivered. (www.polar-mohr.com)16Common to all books, brochures, catalogues and printed matter is the fact that they have to becut to format during the production process. The cutting quality and handling capability of acutting machine, as well as its ability to be linked in a system with other processing machines isparticularly important here. POLAR-Mohr, a family-owned company based in Hofheim/Taunus, hasdedicated over 100 years to the “perfect cut” and is one of the leading suppliers worldwide. Toensure safe machine operation in spite of the sharp blades used, POLAR-Mohr has recently startedto use Moeller‘s easySafety.

Solutions17The cutA precise cut not only requires a sharp bladebut also an optimum cutting pressure whichis between 150 and 4500 N, depending onthe material to be cut. High-speed cutters,such as the mostly used type POLAR 115,are primarily used for the print size 70 cm x100 cm. However, not only cutting pressureand cut but also easy material handling arekey factors in ensuring efficient production.For example, sizes with a maximum diagonalof 1150 mm can be turned easily in the highspeedcutter, and automatically if required.POLAR-Mohr high-speed cutters can alsobe fitted with peripheral equipment such asstack lift, automatic jogger, buffers, grippertransport system and unloading systems toform complete cutting systems.The riskAs with every machine that is sold in theEuropean economic area, high-speed cuttersalso have to observe the requirements ofMachinery Directive 98/37/EC. This will bein force from the end of 2009 as a revisedversion under the designation 2006/42/EC.The Machinery Directive defines only thebasic requirements and does not cover thequestion of the individual verification ofmachine safety. For this testable requirementsare prescribed in the European standards (EN).The Machinery Directive must be observed.Although, however, standards are notmandatory requirements, they should be fullytaken into account. This can be essential forthe clarification of any liability issues.The safety standardEN ISO 13849-1 was officially passed inOctober 2006 as the successor to the EN954-1 standard. Like its “predecessor” EN954-1, the standard applies to safety-relatedparts of a control system (SRP/CS = safetyrelatedpart of a control system) and differentmachine types. EN ISO 13849-1 stipulates aquantitative assessment of the safety functionsin addition to the qualitative approach ofEN 954-1. To reduce the calculated risk formachines, the first priority is to implementdesign measures and then secondly toconsider technical guards for the remainingrisks. The Risk assessment process is iterativefor each individual hazard. If, for example, ahazard is to be prevented by means of safetyrelatedparts of a control system (SRP/CS), therequired performance level PLr then has tobe determined. This is carried out using thenew risk graph from EN ISO 13849-1. Thus: PL>= PLr. For the high-speed cutter previouslymentioned, a PLr “d” is required.The solution: easySafetyIn order achieve the required performancelevel PLr = d, it was previously only necessaryto provide one safety relay for the evaluationof all safety circuits (up to category 3 inaccordance with EN 954-1). Nowadays severalevaluation units are required for the sameapplication. With high-speed cutters, a twohandcontrol and emergency-stop safetycircuit is required, for which several safetyrelays have to be used. In order to reducethe considerable engineering and installationwork required, Moeller is now offering theeasySafety control relay which meets therequirements of category 4 to EN 954-1, PL eto EN ISO 13849-1, SILCL 3 to EN IEC 62061and SIL 3 to EN IEC 61508. easySafety devicescomply with the highest safety requirements.The 14 safety inputs provided as standardfeatures enable two-channel monitoring of upto seven safety sensors. Thanks to easySafety,the new safety requirements can be observedwithout any effort, using test signal outputsthat can be used for cross-circuit or cable faultdetection, and safety relay and/or transistoroutputs for disconnecting the hazardousmotor. At the same time, the easy circuitdiagram language reduces the wiring requiredand potential wiring faults. The easySoft-Safety PC configuration software with anintegrated simulation tool is used for creatingthe circuit diagram.The safety function blocksDevices of the easySafety series feature asstandard a host of conventional safety relaysin the form of safety function blocks suchas emergency-stop, guard door monitoringoptionally with the monitoring of guardlocking, light curtain with and withoutmuting, two-hand control button, safetyswitch mat, enable switch, safety foot switch,operating mode selector switch, zero speedand overspeed monitoring, external devicemonitoring, safety timing relays and safetymarkers.However, easySafety offers more than a standalonesafety control relay. In addition to thesafety circuit diagram contained in the safetyconfiguration, the safety control relay alsoprocesses a standard circuit diagram. Thiscan be used for standard tasks such as theprocessing of diagnostics or general controltasks on a machine. If there are not enoughinputs and outputs available for standardtasks, users can simply add a standardexpansion device from the easyRelay seriesand connect it to the easySafety device.An easy719-DC with a local I/O expansioncontrols the high-speed cutter.CONCLUSION“When selecting machines, our customersplace importance in quality and usemarket leaders, and so we have to dothe same in the selection of all machinecomponents,” Gerd Gottschalk,responsible for control technology atPOLAR, explains: “When it comes tosafety technology, we rely on Moeller‘seasySafety. The device combines severalsafety functions so that we can use thesame device for different machine types.”Quicklink ID:MS170917

Through Thick and ThinxStart Brings Cutting Machine Up To SpeedThe HSC machines developed by Röders in Lower-Saxony first went into operation over 15 yearsago. This was also the case with the software, which enabled a connection between HSC cuttingmachines and 3D-CAD/CAM. Röders HSC machines still continue to sethigh standards worldwide in terms of precision, dynamics and controltechnology. To achieve this and to maintain its technology leadership,Röders continuously further developed its HSC machines. It thus soonbecame clear to those responsible at Röders that xStart switchgear withits tool-less plug connectors offers considerable benefits compared to theprevious wiring solutions. As xStart meets all national and internationalrequirements, there were no objections to installing it in the HSCmachines which are sold worldwide.18Plug connections not screw connectionsxStart switching devices replace conventionalwiring with pluggable main and controlcurrent connections. While motor starterswere previously connected with cables orbridges between motor-protective circuitbreakerand contactor, contact is nowimplemented by means of mechanical plug-inmodules – combining motor-protective circuitbreakersand contactors up to 15.5 A intostable units. The entire unit is then simplysnap fitted securely onto a top-hat rail.Compact starters have been available in aunit for a long time. However, these kinds ofspecial systems have a switch drive that is notidentical to the standard individual contactorsin use. Moeller‘s new tool-less plug connectorsallow standard individual contactors andmotor-protective circuit-breakers to be used.Only the correct connection kit is additionallyrequired although the savings achieved bythis considerably cancel out the cost. Allconventional wiring options are retainedsince conventional connection terminals areprovided on the switchgear in addition theplug connectors.Tool-less mountingThe new plug connectors are mountedwithout the need for any tools. A removedplug connector also acts as a clear isolatinggap. Furthermore, no wiring means no errors.The benefits of tool-less mounting can beclearly seen on the reversing starters thatRöders uses on its HSC machines. This uses awiring kit which contains additional electricaland mechanical connections for the additionalreversing contactor. The electrical interlocksare therefore also provided via the integratedbreak contacts of the reversing starters inaddition to the main circuit connections.When creating star-delta combinations withthe plug connection technology, the use of theplug connections for main circuit and controlcircuit also proves to be considerably betterthan conventional wiring.With only four frame sizes, xStart is ableto cover a rating range up to 170 A. Threedifferent mounting widths (45 mm up to 38A,55 mm up to 72A and 90 mm up to 170 A)ensure optimum packing density. The coilterminals of the contactors are arranged onthe front, like the main circuit terminals, thusconsiderably simplifying a wiring test. TheHSC machines made by Röders use both ACand DC actuated contactors. DC contactors inthe range up to 65 A normally have a largermounting depth than AC contactors. Not sowith Moeller, since the DC contactors have thesame dimensions as the AC versions.xStart contactors offer other practicalfeatures in the series. For example, knurledcontact surfaces ensure reliable contactingwith auxiliary contacts. A suppressor circuitintegrated on the DC actuated contactorsreduces transient voltage peaks. Motorfilters and other auxiliary contacts, as well asaccessories can be plugged simply onto thecontactor from the top, and all the requiredopenings are perfectly enclosed. Electronic

Solutions17THE COMPANYRöders GmbH has been run by thefounder family for six generations andnow operates in three business fields:Machines for high speed cutting,blow moulding for PET bottles suchas household items and items of dailyuse with sophisticated designs madefrom tin. The company headquartersis in Soltau, Lower-Saxony, and has areputation for its new developments,as well as for the high intrinsic valueand long service life of its products.(www.roeders.de)circuits created by the user can also bepositioned on the contactor using solder pinadapters.Energy-saving contactor drivesThe DC sealing power is only 0.5 to 2.1 Wattsfor all contactor drives from 7 to 170 A.Contactors up to 38 A can be controlleddirectly from the PLC, thus eliminating theneed for coupling relays. The low sealingpower of the contactors allows a higherpacking density and enables the use ofsmaller 24 V DC power supply units for thecontrol current. This firstly optimises thespace requirements in the switch cabinetand secondly reduces the heat that has to beremoved by means of fans or climatic units.Customer-friendly orderingMoeller offers xStart in different versions:With orders in the range up to 38A, customersstate whether a make or break contact shouldbe integrated as an additional auxiliarycontact. The normal combination optionswith two or four-pole auxiliary contacts arealso possible. Customer options are alsoavailable with regard to connection design:Box terminals with two separate chambers areavailable as standard. Alternatively, screwlessspring-loaded terminals can be provided onall auxiliary terminals and the main currentterminals up to 12 A. These also have separateopenings for two cables each.SmartWire – connecting instead of wiringThe plug connectors for Moeller‘s xStart don‘tjust end with the tool-less plug connectiontechnology. Following the “connectinginstead of wiring” principle, SmartWirereplaces conventional control circuit wiringbetween the switchgear and the I/O modulesof the PLC. A SmartWire module is simplyplugged onto the conventional contactor andall SmartWire modules are interconnectedwith a pre-assembled SmartWire cable.Communication with the controller is thenimplemented with a CANopen or Profibusgateway. SmartWire reduces costs forI/O modules, mounting, wiring and designengineering, as well as completely excludingwiring faults.Quicklink ID:MS1710CONCLUSIONSven Hofhammer, responsible for panelbuilding at Röders summarises: “Moellersupplies contactor and motor-protectivecircuit-breaker combinations assembledfrom the individual xStart devices, suchas motor and reversing starters, factoryshippedas a completely mounted unit.This shortens mounting and wiring timesand offers us stockkeeping and planningbenefits in equal measure. Completeunits can be managed in our seriesmachines with only a few order typesrequired. For years, Moeller has offeredus high quality service, reliable consultingand logistics.”19

Golden HarvestElectricity and Heat from Mini-CHPTHE COMPANYSailer GmbH was founded by thebrothers Roland and Wolfgang Sailerin 1997 in Schelklingen. Within a fewyears the company grew to becomea global player. Today Sailer is nowbased in Ehingen, with a productionplant for heat accumulators, solarheating, cogeneration systems,photovoltaics, energy saving heatingand plant construction.(www.sailergmbh.de)The need to reduce CO2 emissions worldwide requiresconsiderable efforts to be made in all areas. In this respect,the use of regenerative energies and a more efficient use ofexisting energy carriers are a high priority. Cogeneration systemsare able to achieve a particularly high level of efficiency. Saileris a company based in Ehingen which supplies systems in therating classes 5 kWel to over 60 kWel forregenerative heat recovery using easydevices from Moeller for controllingits systems. Sailer‘s CHPs not onlysupply public buildings, industrial andcommercial plants, restaurants andhotels, but also private houses andapartment blocks regardless of age.20

Solutions17High efficiency - using energy carriersefficientlyCogeneration systems utilise the primaryenergy in use with an outstanding level ofefficiency. It uses the combustion motoras a drive machine for a generator whichsupplies electricity. However, combustionmotors discharge the major part of theenergy into the environment in the form ofheat, and this radiated heat is mostly unusedwith conventional electricity generation.Cogeneration systems, on the other hand,utilise the radiated heat for water heating andfor general heating.Cogeneration systems in residential areas areprimarily designed for the optimum supplyof room heating and hot water. If the designis correct, the profits that can be achievedby feeding electricity into the public supplynetwork can cover a major part of the costsfor the fuel required. The electricity supplycompensation is regulated by the RenewableEnergy Law (EEC) and currently offersattractive rewards that can be calculatedreliably. Sailer systems use natural, renewableplant oils as fuel.easyRelay and easyHMI control mini-CHP unitA combustion motor forms the central hub ofa CHP unit, and a diesel motor is best suitedas the combustion motor for rape seed oil.This drives a pole-changing asynchronousgenerator which feeds the electricity intothe public mains network. The rating to beused depends on the heat requirements. AnMFD-Titan networked with an EASY819-DC-RC device controls the system. The controllerstarts up the diesel motor as soon as heat isrequired. After a short warm up phase, thisruns up to the operating speed of the firstoutput level. Once the synchronous speed of1500 rpm is reached, the generator connectsto the mains network. The system activatesthe second output level if the set temperaturein the heat accumulator is not reached aftera defined period. For this the speed of thefirst output level is firstly reduced and thegenerator is removed from the mains networkat a low synchronous speed. The diesel motorthen accelerates to the operating speed of thesecond output level. The generator is oncemore connected to the mains network whenthe synchronous speed of the higher level isreached. The system switches off automaticallyas soon as the required temperature in theheat accumulator is reached. However, thecombustion motor is not switched off abruptlybut is run down gently at low speed after adefinable cooling.The Sailer system is equipped with a sootparticle filter in keeping with the current stateof the art. A phase for the regeneration ofthe soot filter is provided in the controllerprogram. The control relay also handles theautomatic control of the starter. If the motordoes not start up in the set starting time, thestarter is switched off in order to protect itand is then restarted after a user-definableinterval. The system switches off with anappropriate error message if a certain numberof unsuccessful startups have been exceeded.Measuring, monitoring and signallingThe temperatures of cooling water, motor,exhaust gas and heat accumulator aremeasured by Pt1000 thermocouples withmeasuring transducer and analog inputsof the MFD-Titan or EASY820-DC-RCX.The scaling and arithmetic functions in theeasySoftPro control relay software allow theprocess variables to be displayed immediatelywithout any problems, or processed furtherin the program. One of the four high-speedcounters in the control relay is used for thispurpose. Each counter can detect signals upto 5kHz.The EASY820-DC-RCX control relay measuresand processes the speed as well as executingthe connection and disconnection with themains network. The other functions of thesystem are controlled by the MFD-Titan HMIunit, consisting of the MFD80-B, (graphicalbacklit display with 132 x 64 pixels), MFD-CP8-NT (power supply/CPU module) and anMFD-R16 (I/O module 12DI/4 relay outputs).These communicate via the easyNet networkwhich is integrated as a standard featurein the devices. All current operating data isdisplayed in the MFD display. The relevantinformation is also stored in the retentivememory of the easy control relay andmade available to the connected TIXI alarmmodem for remote diagnostics. In this way,troubleshooting in the event of malfunctioncan be carried out quickly and any faultsrectified without delay. All the data requiredInside the mini-CHP: combustion motor, coolingcircuit and generator.for operation is monitored continuously andwarning messages output immediately on thedisplay in the event of any deviations from theset parameters. After a fault is detected, thesystem is either switched off immediately orafter a cooling phase, depending on the typeof fault concerned. The system is equippedwith other Moeller components such as theDILM contactor, PKZM motor-protectivecircuit-breaker and the P/T main switch inaddition to the core elements provided by theMFD-Titan and EASY820-DC-RCX controllers.Quicklink ID:MS1711CONCLUSIONeasy control relays offer the idealcontroller platform for applications inthe price-sensitive field of cogenerationfor private houses and apartment blocks.Wolfgang Sailer, development engineerand director of Sailer GmbH, summarisesas follows: “For us the outstandingprice/performance ratio as well as simpleparameter assignment and programmingare key features in the system control.For us, the networkable devices as well asthe remote diagnostics and maintenanceoptions make easy into an attractivedevice. If necessary, we also need the fastsupport that Moeller provides us with.We really have made the right decision bychoosing easy products.”21

It‘s All inThe LabeleasyRelay Automates LabellingSystem for Round ObjectsNowadays, high quality products and theirindividual components are permanently markedso that they can be identified clearly at any time.Design & Engineering is a company based in Merklingen thatproduces standardised systems for industrial product labellingand identification. The company specialises in the labelling ofround or virtually round cross-sections, as well as the sealingof packaging and safety-related containers. The companydeveloped a special and patented automatic labelling machineusing banner labels for round cross-sections. The Swabiancompany uses other Moeller components in addition to thedevices from the easy family, including components from theRMQ-Titan range and signal indicators.THE COMPANYDesign&Engineering is a new companybased in Merklingen. The companyfocuses on process-oriented machinebuilding and supplies standard stationsand units for processes such as metering,sticking/sealing, laser inscription, marking/labelling/ticketing. The products rangefrom handling units to labelling and laserinscription systems to robot gripper andtransport systems. The company has itsown patents in these sectors. (www.design-engineering-online.de)22

Solutions17Permanent labelling with banner labelsThe automatic labelling of round and virtuallyround cross-sections normally presents aspecial challenge. This type of machineis therefore designed for the permanentlabelling of cable harnesses, pipes and similarobjects. The labelling process consists of thefollowing three basic steps: Firstly the creationof the label, secondly the transfer of thelabel using an application unit and thirdly theaffixing of the label to the object concerned.After printing, a label is picked up with thestamp gripper, placed on the part to belabelled and then rolled on. In this process, itmust be ensured that the application is free ofwrinkles and the printed code is 100 percentlegible. In a new version, the stamp for thecable marking was successfully used in cablepreparation: This allows the label to be rolledround the cable as a banner label and thenstuck together. The stamping tool can also beused for flat cable. It can also be used to affixa seal label to two-section packaging. Semiautomatedworkstations are also available inaddition to the labelling modules integratedin fully automated production plants. Thesesystems, compared to manual labelling, payfor themselves very quickly and offer thebenefit of a constantly high level of quality.Continuous labellingThe Design & Engineering cable labellingsystem combines a thermo transfer printingsystem with an application unit. The cablesto be labelled are fed manually to the gripperand retaining system through a slot in theguard panel. Users start the labelling processwith two buttons - the cable is then markedwith a printed banner label. The length of thebanner depends on the length of the label andthe diameter of the cable. The cable labellingsystem can either be used as a stand-alonedevice for preset print jobs or online, allowingthe individual entry of label variables. The easyto use cable labelling system can be integratedwithout any problems in many productionprocesses and can be refitted for new materialin a very short time. Customised adaptions canbe implemented on request.The layout of the label is designed usinga proprietary graphical software. The usercan simply store the created layouts on thememory card of the printer. The print job,consisting of the layout and the number oflabels to be printed, can be issued manually orautomatically as required.Controlling and printingStepper motors are used to position thestamping unit. Depending on the machineversion and the customer applicationconcerned, the control is handled by theMFD-Titan HMI system, the easyControl EC4Pcontroller, or for larger systems, the MFD4touch display.With simpler systems, an MFD-Titan controlsthe process, using two EASY821-DC-RCXcontrol relays and one EASY618-DC-RC. Theuser enters the production data on the MFD-Titan. The display unit not only shows displayscreens but also warning and error messages.easy control relays control two stepper motorsand six solenoid magnets. The controllerfor the stepper motor controls all the datarequired for positioning. The printed labelsin the printer system fetch the necessary datadirectly from the memory card on the printer.This is where MFD-Titan and easy controlrelays really show their strengths, since theynot only provide a wide range of options forcontrolling and visualization tasks, but alsoensure trouble-free data exchange at the sametime.The larger labelling systems are fitted in partwith the EC4P programmable controller andoccasionally with the MFD4 touch display PLCat the same time. These device combinationsare ideal for integrating the labelling unit intoan existing system. The peripheral devicesand also the stepper motors can then benetworked via CANopen or Profibus. Thedata is exchanged with the printing unitvia the serial interfaces provided. This alsoallows customers to make use of technologieswhich will be used increasingly in the future,such as RFID. Systems of this size require thedocumentation of various processes for qualitymanagement: Data logging functions allow allthe relevant information to be recorded andprovided for use by higher-level systems viaEthernet and OPC.CONCLUSIONReiner Wörtz, owner of Design & Engineering,summarised: “Our work focuseson the development and productionof standard machines and units for theelectronic and packaging industry as wellas for special machine construction. Weuse Moeller products because of theiroutstanding quality, price/performanceratio and support. The components fromthe easy family fit ideally in our multimodularconcept.”Quicklink ID:Smaller labelling machines are controlled with easy control relays, larger ones with easyControl.MS171223

FullyChargedTHE COMPANYGFS Stromversorgungstechnik GmbHwas founded in 1984 and is basedin Gottenheim near Freiburg. Thecompany now owns two subsidiaries.The main GFS plant develops, designsand produces power supply systemsfor use in power stations, industrialplants, hospitals, assembly rooms,supermarkets or public buildings.Continuous further developmentand a rapid implementation of newtechnologies ensure state-of-the-artfunctionality and efficient applicationsolutions. (www.gfs-gmbh.de)Intelligent Charging Station for Industrial BatteriesBatteries are made from lead electrodes with a very large surface that ensure the occurrence of thechemical reaction over a maximum area. Relatively solid lead alloy carrier elements and the so-calledactive compound of oxidised lead powder are used in the manufacturing process. The final structureand the chemical properties are achieved after the first charge – the so-called formation charge. Thisproduces several different structures in the electrodes as a result of the different charging currents used.This particularly applies to the first charging phase. GFS Stromversorgungstechnik, a company based inGottenheim near Freiburg, uses easy products in its intelligent charging cabinets for the formation ofPzS lead battery cells and is completely satisfied with the price/performance ratio of the current solution.24

Solutions17The tasks involved in the construction ofintelligent charging cabinets for the formationof PzS lead battery cells are multilayered, andthe requirements of the system were relativelyhigh. It was thus necessary to implement afully automated control function based ondifferent parameters that could be adjusted.The following parameters were involved:manual/automatic mode, charging in severalphases, charging per time/per charge factor/depending on temperature, infinitely variableintervals between charge operations, entry ofall necessary parameters, password protection,display of all faults in plain text, display ofcurrent/voltage/charge capacity/chargingtime, an overview display after the chargingoperation, charge report for issuing tocustomers, simple self-explanatory operationand reference value entry, as well as theconnection to the control system via EthernetTCP/IP.The solution – simply the bestAfter an intensive search GFS found thatMoeller‘s easy products offered the mostattractive solution. The easyHMI MFD-Titancomes with all the functions required andat an extremely attractive price. With othersolutions, GFS would very quickly face a pricelevel hardly acceptable for customers, sincethe possible parameters involved required theapplication to have a sophisticated design.The parameters for capacity, number of cells,charging factors, voltage per cell, calculationfactors for the charging current, monitoringtimes, reduction of current in percentaccording to temperature error, charge andinterval durations, temperature limit values aswell as current and voltage in manual modehad to be integrated in a standard solution.When it comes to implementing individualrequirements, the easy series offers a highlevel of flexibility. The combination of 3 MFDmodules produced the ideal device for GFSwith power supply/CPU module (MFD-CP8-ME), I/O module with 12 DI/ 4DO and 4 AI/1AO (MFD-TA17) and the HMI unit (MFD-80B).The important parameters are now protectedby password. The password protected areaenables all parameters to be reset to defaultusing a single button. This considerablysimplifies initial commissioning.The charging process adjusts dynamicallyto the current conditions. If, for example,charging is interrupted due to thetemperature being exceeded, the currentis reduced by 20 percent in the subsequentcharging phase. If several temperature faultsoccur, the charge current is reduced graduallyin the current charging stage. The chargingof the lead battery cells is not completeduntil the desired capacity is reached. Duringthe process, the MFD-Titan display visualisesall the actual values precisely, as well as anymessages or faults. At the end of the chargingoperation, the display shows a summary ofthe parameters relating to charge capacity,charge duration and the number of faultsoccurred. The flexibly designed labelling of thedisplay to customer requirements allows theapplication to be largely self-explanatory.easyHMI MFD-Titan: rugged andcustomisableMulti-function displays of the MFD-Titanseries are optimally designed for industrialuse with appropriate protection to IP 65. Theyare fully functional over a wide temperaturerange from -25 to +55° C. Furthermore, allconnections are provided with maintenancefree and vibration-resistant spring-loadedterminals. The full-featured graphic displaywith 132 x 64 pixels also comes with abacklight that can be switched on as required.All MFD-Titan display fronts can be laserinscribed with customer labels. Symbols,company logos, logotypes, graphics orAsian, Cyrillic, Greek or Roman characterscan be inscribed as required. For this thecustomer simply produces a template withthe Labeleditor software on the PC. The labeltemplate thus produced is automatically sentby email to the Moeller production plantresponsible.Connected to the control systemAll MFD-Titan devices are connected viaEthernet TCP/IP to the GFS control system.This configuration is implemented with theeasy209-SE Ethernet module from the easymodular system. The easySoft programmingsoftware is used to create a symbol file aswell as configure the free OPC server, afterwhich the control system can access the dataof the MFD-Titan using the OPC standard.For GFS this option was an extraordinarilystraightforward and time saving solution.All charging stations are connected to the control system via Ethernet TCP/IP. Data exchange between MFD-Titan and the control system is implemented with the OPC standard.Ethernet TCP/IPCONCLUSIONThomas Spitzmüller, head of Sales atGFS had this to say: “By using easyHMItogether with our proven chargingsystem, we were able to implement acharging station which, in terms of flexibility,convenience and simplicity,was previously unavailable on the market.The extremely competitive pricingof the controller, as well as the minimumdevelopment costs required enabled usto offer the system to customers at aprice well below the standard pricingon the market.”Quicklink ID:MS171325

Under Pressureeasy800 and MFD-Titan Control Pressure Booster SystemThe Seebach district waterworks in Osthofen, supplies drinking water from the Osthofen andBechtheim-West waterworks to a widely distributed supply network around 470 km in lengthwith over 18000 household connections. The company operates 25drinking water tanks in the Seebach area, which in recent years wererenovated, automated and connected to a data transmissionsystem. The company now uses devices of the easy series forthe pressure booster system: easy800and MFD-Titan multi-function display.THE COMPANY26The beginnings of the Seebach districtwaterworks go as far back as 1899.At that time only two communities inthe Worms district had a central watersupply. In 1904 the Osthofen councilapproved the finances for developinga group water supply project. In 2001the new main pumping station on thegrounds of the Osthofen waterworksand the water reservoirs were put intooperation. A new standby generatoralso guarantees operation of the supply,treatment and pressure booster systemsin Osthofen in the event that the powersupply is missing. In 2005 the newtransport line between the Osthofenwaterworks and Eich was inaugurated.This provides the communities of Eich,Hamm and Worms-Ibersheim fromthe source area in Osthofen with aconsiderably lower water hardness(www.wzs-osthofen.de)The Hochborn pressure booster system wasdesigned with conventional technology.Previously any necessary modification in thecontrol cabinet was impossible due to thespace required. The control cabinet in thefield was fully fitted out and was not ableto take any more relays. Certain buildingrelated factors made any enlargement of thecontrol cabinet impossible. In his search fora solution, Hermann Hofmeister, responsiblefor electrical engineering at the waterworks,took part in an MFD-Titan workshop. Thisgave birth to the idea of implementing therequired conversion with easy and MFD-Titan. As well as replacing the conventionaltiming relays, the easy solution consisting ofan MFD-Titan, an easy800 and an expansiondevice, now provides the entire monitoring,fault indication and control of the plants.easy replaces a host of devicesThe control cabinet for the pressure boostersystem houses three pump controls. Twoare speed controlled and are connectedalternately to a frequency inverter, changingover after every stop. This alternateconnection of two pumps to the frequencyinverter ensures sufficient safety reserves. Ifone of them is faulty, the other can operatewithout any interruption. The water supplyand the required pressures are thus ensured.At night the small pumps are disconnected.The third pump control is activated anddeactivated with a soft starter for fire fightingoperations. The speed of the small pumps isregulated by the pressure and the regulatorcould be replaced with easy. The same appliesto the fire extinguishing pump, which is

Solutions17regulated by the flow. easy could replace theswitch relays that switched according to aspecific analog value (flow rate).In all easy was able to replace a large numberof devices: A two-channel time switch, severaltiming relays (on and off-delayed), a singlepulse relay, some contactor relays and variousrelays that switched according to a 4-20mAsignal. The fire extinguishing pump is switchedon briefly each day in order to ensure itsoperational readiness. Now message textssuch as operational and fault messages or apressure display are output via MFD-Titan.This was previously implemented in part usinglights.easy800 and MFD-TitanMoeller control relays are all designedfor simple operation and maximum userconvenience. Parameters are also assignedto easy800 in ladder logic: Like with aconventional circuit diagram, users wire breakcontacts, make contacts and contactor coils.The devices allow the wiring of up to 128 or256 rungs. Series and parallel connections thatnormally represent a large part of the controlsystem can thus be created so easily andwithout any programming knowledge.For the Seebach district waterworks, thecombination of easy800 and MFD-TitanHMI unit with an expansion device is anotably simple solution that meets all therequirements in full. In addition to the basicfunctions such as counters, analog valuecomparators, time switches and many others,the easy800 also offers function blocks suchas PID controllers, arithmetic function blocksand value scaling. easy800 features twelveinputs, six relays or eight transistor outputs.Mathematical tasks or value comparisons in32-bit format are no problem for easy800.With easy800, applications with over 300 I/Opoints can be implemented thanks to thepossibility of networking up to eight devicesvia easy-NET. The control can be implementedeither using a single local program ordistributed over several devices. The networkcan cover distances of up to 1000 metres.The control relays can also be integratedsimply into higher-level automation conceptsusing network modules. Furthermore, theserial interface of the MFD-Titan enables thecreation of a point-to-point connection withan easy800 or another MFD-Titan device.MFD-Titan is designed as an industrialdevice for rugged operating conditions. Theoperating temperature range is thus from-25 to +55 °C. Furthermore, all connectionsare provided with maintenance free andvibration-resistant spring-loaded terminals.The full-featured graphic display (IP65) with132 x 64 pixels also comes with a backlightthat can be switched on as required. Theoperator keypad can also be configured toindividual requirements and factory shippedwith customised laser inscriptions.CONCLUSIONHermann Hofmeister, responsible for theelectrical engineering and maintenanceat the Seebach district waterworkssummarised: “Moeller‘s easy control relayallowed us to replace our previous timingrelays, relays, contactor relays, limit switches,the time switch and the FI controller,and thus not only save on the mountingand wiring of individual components butalso considerable space in the controlcabinet. We were also able to add anotherpump to the system and integrate theanalog processing for flow rate andpressure in the easy800. Combined withthe MFD-Titan multi-function display, wewere also able to implement a powerfulvisualization system. We are now alsofuture proof: Any modifications orexpansions of the easy concept can becarried out at any time.”Quicklink ID:BeforeAfter with easy800MS171127

SpotlessEC4P Compact Controller For Cleaning MachineThe special version of the Rosink Cleaner RC 850 is designedto wash ball bearings. Heavily greased components reduceproduction output, and for this reason ball bearings have to becleaned. The plant is designed for a three-shift industrial usethanks to the high outputs of the units and the strong stainlesssteel design. An easyControl from Moeller is used to control thecleaning machine for degreasing ball bearings. Rosink GmbH +Co. Maschinenfabrik is based in Nordhorn and chose easyControldue to the optimum results it produces with little installation orprogramming effort – as well as an attractive cost benefit ratio.Various Moeller contactors, as well as two-hand and emergencystoprelays are also used.THE COMPANYRosink GmbH + Co. Maschinenfabrikis a company based in Nordhorn whichsupplies service machines for spinningmills as well as high production can coilersand can changers . Since its founding,more than 35000 Rosink machines havebeen supplied worldwide. The productrange is being extended with systems forthe aqueous cleaning of industrial parts.The company has made a name for itselfas a supplier of renowned Europeantextile machine manufacturers. Rosinkuses state-of-the-art CNC machines inits production. Its textile machines areclearly designed, functional and visuallyattractive. (www.rosink.de)28

Solutions17Rosink systems don‘t mess about whenit comes to washing severely greasedcomponents. The Rosink Cleaner RC 850 onlyleaves a minimum of residual dirt, and this isensured by a cascade filter system with a filterfineness of 1 µm and the hot air dryer whichis provided with an air filter. After washing,the ball bearings are rinsed with desalinatedwater. A drum unit offers a uniformly highlevel of cleaning. The high oil content isremoved via the integrated oil separator. Awater treatment system is also available with amicro filtration unit.The details: The ball bearings that are to bedegreased are placed in the cleaning basketand conveyed to the cleaning machine.The safety door is closed via a two-handcontrol. Untrained personnel can also selectthe cleaning program with the MFD-Titanmulti-function display and start the cleaningoperation via a pushbutton. The cleaningbasket is then moved around a central jetfrom which the cleaning agent is sprayedonto the ball bearings at high temperatureand high pressure. The ball bearings are thenrinsed with desalinated water and dried witha hot air fan. After a cooling phase, the safetydoor is opened to remove the cleaning basket.easyControl with easySoftCoDeSysThe easyControl EC4P controls and monitorsall functions such as temperature, the drive ofthe cleaning basket, valve control of cleaningagent and rinse water, the heating, fan etc.The ESR4-NZ-21 24VDC safety relay controlsthe two-hand operation and the ESR4-NO-30-24VAC-DC 8 the dual-channel emergency-stopcircuit.Rosink uses easyControl because thecompany is already familiar with the CoDeSysprogramming system. The easyControlcompact controller is programmed inThe ball bearings to be cleaned are put in thecleaning machine in baskets.The „washing machine“ control is handled by an easyControl compact PLC with local I/O expansion.accordance with the international standardIEC 61131-3. In terms of its functionality, theeasySoftCoDeSys programming system offersfar more than required by the EN61131-3standard. easy Soft CoDeSys features all fiveprogramming languages in compliance withIEC61131-3 (IL, LD, FBD, ST, SFC), as well asthe graphical CFC continuous function charteditor. Rosink prefers to use the ST (structuredtext) programming language.With easyControl a project can also besimulated entirely without the PLC connected,i.e. fully offline. Other features includeits graphical PLC configuration, extensivedocumentation options, powerful testand commissioning tools, as well as flexibleonline modification. Remote programming isalso possible as well as the programming ofsubordinate controllers in a network.In addition to the I/O Assistant integratedin easySoftCoDeSys, a powerful closedloopcontrol and motion control toolbox isprovided, featuring a host of function blockssuch as closed-loop controllers, pulse widthmodulation, signal processing, simulation andmaths functions.The Rosink Cleaner RC 850 uses an EC4P-221-MRXD1 with an EASY 620 DC-TE expansiondevice. The integrated serial interface inthe device is used to connect the MFD 80-Xmulti-function display with MFD CP4-800 tothe compact PLC. The automation solutionrequires 15 digital inputs and 1 analog 0-10V input as well as 12 digital outputs (8 on thebasic unit and 4 on the expansion unit). Inaddition to implementing the control tasks,the analog signals have to be recorded andvisualized. The values for runtimes, faults,temperatures, general functional status areshown both on the display of the easyControland on the display of the MFD. The basicsettings are carried out directly on the deviceby qualified personnel. Machine operatorsonly have access to the enabled functions.Thanks to its very good range of featuresthe EC4P can be used at Rosink for severaldifferent tasks. Digital inputs/outputs,four integrated analog inputs and severalcommunication interfaces (RS232, Ethernet,CANopen, easyNet) are already provided inthe basic device. The serial interface can beused for logging the process precisely, eithervia PC, OPC server or printer, without the needfor any other additional devices.Quicklink ID:MS1715CONCLUSIONAndreas Jürkenbeck, responsible at RosinkMaschinenbau for project engineeringand electrical design explains: “Newtechnologies were a vital necessity forthe further development of a machinethat was both inexpensive and reliable atthe same time. As a full range supplier,Moeller could offer the ideal products inthe field of switching devices and compactcontrollers. With the easySoftCoDeSysprogramming software and the wellestablishedMoeller switchgear technology,we now offer a standard that ensures24-hour machine operation. The setpointentry directly on the PLC via the keypadprovided on the device and the integrateddisplay saves us the need for an expensiveexternal operator unit. Furthermore, assoon as a customer wishes to expand theI/O level, we can implement this at anytime using CAN bus or easyNet.”29

On callWaste Water Alarm By SMSSewage plants have an unlimited capacity. If the water level in the Regensburg sewage systemrises today, and the volume of water virtually exhausts the capacities of the local sewage plants,the inward flow is restricted by drainage controllers. A magnetic inductive measuring device (MID)detects the flowing water volumes. A controller monitors the measured values recorded in the MIDand restricts draining with an electric slide valve if a defined value is exceeded. If drainage controlby means of the electric slide valve is impeded or fails, a standby emergency service has to be calledout to rectify the fault in the field. However, the service personnel also require information about thefault itself to be precise and on time, as well as information about the fault location. An SMS alarm,implemented with Moeller devices and INSYS provides just-in-time information with understandableand clear fault messages.Insys GSM 4.1 easyMoeller easyAlarm as SMS, fax, emailPhone networkSwitching andscanning by SMSStandard SIM Karteeasy programming cableSwitching withDTMF tonesINSYS adapter cable30Fault signalling system active in the teamService personnel at the Mittelhessen districtwaterworks (ZMA) are notified by SMS alarmsin the event of a failure or malfunction. AnINSYS GSM 4.2 easy transmission device that isconnected with the controller of the electricalslide valve sends the SMS automatically. TheINSYS device is connected via an RS232 serialinterface to an easy 822-DC-TC compactcontroller from Moeller. Both have a compactand rugged design for use as rail-mounteddevices. INSYS Microelectronics has speciallyadapted the firmware of the GSM easy to theeasy controller. The devices have thus beencombined to form a reliable and inexpensivewireless fault signalling system in which theINSYS device monitors the internal markersand actual values of the controller. As soonas predefined values are exceeded, thecommunication device sends SMS alarms to thepersonnel of the standby service. Message textand receiver phone number can be preassignedhere individually for each monitored value.INSYS GSM 4.2 easy is also equipped with twoalarm inputs by means of which the watercompany can associate different events with upto 10 messages each.If necessary, the device can send up to 20different SMS messages or emails to up to20 recipients. The fault alarm system for theZMA is configured so that the sending of SMSalarms can only be acknowledged locally, i.e.directly at the device or stopped by meansof an SMS AT command. The INSYS GSM 4.2easy continues to send its messages cyclicallyuntil then. Connection setup to the fault alarmsystem is bidirectional: ZMA personnel in theworks not only receive information but alsocan access the controller by data callup. Forremote parameterisation tasks they use theINSYS Connect PC program that was developedby INSYS. All the values processed by the PLCare visualised in the works via the Moeller OPCserver integrated in the device.Versatile communication devicesThe GSM device 4.2 easy sends optionally SMSmessages as periodic sign of life signals orreports a restart, such as after a power outage.Password protected connection setup, securitycallback and remote control ensure the requiredlevel of security. The scanning of the inputs bySMS or DTMF is also password protected. INSYSGSM 4.2 can be configured locally with theHSComm configuration software.Quicklink ID:MS1716

Solutions17Danger Detected,Danger EliminatedPreventing injury to personnel and damage to propertyA power distribution system often has ashadow existence in machine and panelbuilding applications. It is often ignoredwhen installed in switch panels, in separaterooms or behind corners. Properly installedand regularly maintained switchboardsnevertheless ensure a high level of availabilityfor production. Even if switchboards containmaintenance-free components, regular testsand inspection procedures are required to testthe functionality of individual componentsand their combined operation. This proof offunction reliability – comparable with the MOTtest on a car – must be carried out regularly bythe owner or operator. This person can eithercarry this out on his own or delegate it to thecompetent bodies with the relevant know-how.It is actually clear to everyone that a switchgearassembly that has often been in use for 10,20 years or more, should not just be inspectedwhen the production facility is modernised.Moeller‘s Field Service offers individuallydesigned and comprehensive packages forpreventative maintenance, inspection andservice, including spare parts supply.Protection from undesirable consequencesEach owner or operator of machines andsystems carries out regular testing, not onlyto prevent injury to persons or damage tosystems or production failures, but also fortheir own protection. After all, maintenance toelectrical systems that has not been carried outproperly or on schedule can have far reachingconsequences. The costs involved can mountup to millions.The relevant DIN VDE 0105-100 (EN50110-2)standard states in paragraph 4: “Electricalsystems must be kept in a proper conditionin accordance with the relevant installationstandards.” The safety of persons is directlyrelated to the condition of the electricalinstallation. In Germany, this is covered byaccident prevention regulation BGV A3 (VBG4),which regulates the testing of electricalequipment. The regulations are legally bindingso that every owner or operator of electricalinstallations and equipment is responsible forkeeping them in a proper condition.Non-compliance with accident preventionregulations may have legal consequencesirrespective of whether any claims havearisen. Accordingly, absence of certifiableproof of maintenance may result directly inthe following: Insurance companies refuse topay, employers‘ liability insurance associationsretrieve from owners or operators anypayments made and a court shall deal withthis process at least in the event of injury topersons. Considerable civil action may result inaddition to any legal punish.German Industrial Safety Regulations (§ 26BetrSichV) stipulate that employers and/operators of systems requiring examinationcan be given a custodial sentence or fined ifthey breach their obligation to examine theirsystems, if as a result the life or health of othersor the property of third parties are put at risk.The special aspect of this regulation is that noactual damage to persons and/or property hasto occur in order to fulfill this condition.Moeller Field ServiceIn order to comply with the relevantregulations, owners or operators can alsodelegate responsibility to competent authoritiesand engage these, without themselves beingexperts in the legal requirements involved.Moeller‘s Field Service therefore offers theseservices for circuit-breakers and powerdistribution systems. It supports the responsiblepersons in the inspection/maintenance ofcircuit-breakers and low-voltage powerdistribution systems supplied by Moeller,determines the condition of the systems andcarries out the necessary work to schedule.The Moeller Field Service not only offersgreater safety and profitability, but also offersgenuine know-how which company ownersand operators can rely on. Just a phone callis needed to arrange an initial meeting at theinstallation.Quicklink ID:MS171731

THE COMPANYDr. ERMER GmbH is a Cologne-basedcompany and a full-range supplier in thespecialist field of smoke control systems.The medium-sized company belongs tothe European Mistral group of companiesbased in Switzerland, Austria and Spain.A further expansion in the EU is planned,since EN12101-6 sets a European-wideharmonised and mandated standardwhich will provide the legal basis forthe installation and operation of smokecontrol systems. (www.mistral-gmbh.com)“Run For It!”Smoke Free Escape and Rescue RoutesFires in residential buildings, old peoples homes orapartment blocks often cause deaths and injuries - mostlydue to smoke. The smoke spreads across stairwells andlandings, cutting off the route for escaping persons. Also forrescue teams, stairwells often cannot be accessed until thesmoke has been blown out. As stairwells and lifts connectthe floors vertically, the fire smoke can spread without anyobstruction. Over ten years ago, this problem caused Dr.ERMER GmbH in Cologne to introduce the pressurisationprinciple in escape routes. The company has alreadyinstalled several thousands of smoke control systems in alltypes of buildings and now uses Moeller‘s easyControl forthe demanding control tasks involved. The Cologne-basedcompany also uses Moeller‘s know-how with regard to DS 6soft starters, DF51 frequency inverters, circuit-breakers,CS steel cabinet enclosures and other components.32

Solutions17A fan module on the ground floor pressurises thestairwell in the event of fireDF6 frequency inverters ensure economical speed control for the fans.The idea of smoke free escape routes is basedon a simple physical fact: If an overpressureis generated in the stairwell opposite the firearea or burning floor, smoke cannot impedethe escape of fleeing persons, and rescueteams can carry out their work without delay.The following technical means are used togenerate the overpressure: A fan blows freshoutside air into the stairwell, whilst severalconditions are observed at the same time.The differential pressure with the doorsclosed must not go below 30 Pa, the force foropening doors must not exceed 100 N, andthe air speed in the door between the stairwelland the burning area must not be below1 m/s (DIN EN 12101 – 6). The measurementand control requirements involved are verycomplex. After smoke is detected, a fire alarmactivates the pressurisation system. Severalclosed-loop control processes are initiatedat the same time: An optional differentialmeasurement is used to increase thevolumetric flow rate at the fan, move the inletand exhaust flaps to the required positions,whilst doors are opened or closed accordingto the design of the system and the outletsare opened on the floor with the fire. Thecontrol time from the activation phase to thefull operation of the system must not exceedthree minutes.Mistral smoke control system.For the most demanding tasks - easyControlIn apartment blocks, a fan is usually installedon the ground floor which sucks in fresh airin the event of a fire and blows it into theescape route, such as a stairwell or lift shaft,thus creating an overpressure. All closedloopand open-loop control functions of thepressurisation system are housed in a singlecontrol cabinet, and all input and outputsignals are managed centrally.For demanding measurement and controltasks, a control cabinet is installed on everyfloor to act as a substation which is connectedto the central control cabinet. This substationmanages all the inputs and outputs such asfor smoke detection, flap actuation, dooropeners, pressure ratios etc. that are relevantto the floor in question. One easyControlhandles these control tasks on each floor.In the largest project implemented to date,27 easyControls were installed on 27 floorsand interconnected using CANopen. As theoperation of these kinds of systems involvesseveral different disturbance variables, such assuddenly opening doors or open windows, thepressure control is extremely sophisticated.When the smoke control system iscommissioned, the pressures for each floorhave to be measured, set and these valuesthen stored in the memory of the appropriateeasyControl. Up to 50 different localparameters can be required, dependingon the floor. easyControl‘s integrateddisplay with additional operator buttonsis extremely useful in this respect, as itsimplifies the entry and checking of data.The device display can be used to showtexts and screens for different parameterssuch as pressure values, control settingsfor frequency inverters as well as safetychecks.easyControl was chosen due to itshigh performance and extensiverange of features. The easyControlcontroller family combines the simpleeasy concept with the benefits ofEN61131- 3 programming. easyControluses the CoDeSys programming system andoffers an even greater functionality thanthat required by the EN61131-3 standard.easyControl also offers CFC (ContinuousFunction Chart) as an additional programminglanguage. EC4P controllers use the alreadyexisting extensive easy range. Their 16-bitprocessor ensures a high CPU performanceand thus shorter cycle times. Program anddata memory are also generously sized with256/224 KB. EC4P controllers are available in16 different versions. The industrial devicesare maintenance free and do not requireany batteries. A standard CANopen fieldbusmaster is integrated on all EC4P devices inaddition to the well-established easyNetnetwork. The EC4P versions with an integratedEthernet interface are a special technicalhighlight.The software benefits of the CoDeSysprogramming system are fully utilised. TheCologne-based company created its ownfunction block libraries based on the largerange of function blocks provided in theclosed-loop control and motion controltoolbox of easySoftCoDeSys. These can beexpanded as required. These function blockscan be locked so that the source code cannotbe seen in the runtime program in order toprotect proprietary software know-how.Quicklink ID:MS1715CONCLUSION“The EC4P with CANopen bus, theCoDeSys software and the associationwith the TreeSoft E-CAD program are forus the future way ahead. This enablesus to be optimally equipped for newapplications which can be implementedeconomically. We use Moeller componentsbecause of the fast onsite servicein Germany and overseas,” Ralf Pötzsch,head of development at Dr. ERMER,explains.33

Moeller InfoboardMoeller TrainingOnline Training CenterThe Online Training Center providesapplication examples, tricks and tipson products, functions, applications foreasyRelay, easyControl, easyHMI and infuture also for easySafety devices. Thisalso contains the easy forum.Quicklink-ID: OTCTRAINING CENTERMatch plan for VfL GummersbachA strong team: VfL Gummersbach and Moeller.Professionalism, team spirit and lots of practical experience – qualities that both VfL Gummersbach andMoeller have in common. As well as being based in Gummersbach: The club town of these players in thenational handball league is also the site of the most important factory for Moeller contactors.Good enoughreason for us to actively support VfL Gummersbach as its main sponsor and provide fresh power on thehandball pitch.26.04.2008 8:15 p.m. HSG Wetzlar - VfL Gummersbach Wetzlar14.05.2008 8:15 p.m TV Großwallstadt - VfL Gummersbach Großwallstadt17.05.2008 3:00 p.m. VfL Gummersbach - SC Magdeburg KölnarenaMoeller tipNew brochures on export/approval issuesBe more successful in exporting to NorthAmerica with thisexcellent publication onapproved components.Important safetyinformation on thesurface of the switchingdevice or contactor is nolonger understandable foreveryone. This brochure therefore providesexplanatory information on this issue.Export-related voltage information– the brochure coversexclusively low-voltagein public and industrialnetworks as well as theequipment they supply incommercial and industrialareas. It provides extractsof important informationfor companies exporting to America.Moeller LIVEFairs and ExhibitionsGermany09.09 -13.09. 08 | HUSUM WindEnergy | Husum23.09.-26.09.08 | SMM | Hamburg25.11.-27.11.08 | SPS/IPC/Drives | NurembergEurope26.05.-29.05.08 | Eliaden | Oslo02.09.-05.09.08 | IEAS | Bucharest14.09.-17.10.08 | EloSys | Trencin09.12.-11.12.08 | Elektro Vakbeurs | HardenbergQuicklink-ID: FAIRSEXPOLINER05.05.-09.05.08 | FinnlandUnder the slogan: “World of electricalengineering” the Expoliner will visitcustomers on request – the Moellercompany exhibition will come to everycompany site.Quicklink-ID: EXPOLINERSwitchboard Systems RoadshowGet to know the Moeller automationworld: The Moeller training centres inNorth and South Germany offer you thechance to access, brush up and deepen yourknowledge of Moeller products.Seminars offered at EAZ-Aalen:Programming withCoDeSys |08.05. + 09.05.08easy500 / 700 | 30.05.08easy800/MFD | 12.-13.06.08Profibus DP communication |30.06. + 02.07.08Testing, commissioning and servicingmachines and plants | 07.-09.07.08Seminars offered at bfe-Oldenburg:Quicklink-ID: TRAININGeasy500 / 700 | 04.11.08easy800 | 05.11.08MFD multi-function displayTitan | 06.11.08MFD-Titan workshop |07.11.08Programming to IEC 61131-3easySoft-CoDeSys (basic principles) |14. -16.05.08easySoft CoDeSys (switch) | 19.-20.05.08easySoft CoDeSys (follow-on) | 21.-23.05.08easySoft-CoDeSys (basic principles) |26.-28.11.08easySoft CoDeSys (switch) | 24.-25.11.08easySoft CoDeSys (follow-on) | 01.-03.12.08Design engineering with Moellercircuit-breakers | 06. -07.05.0834Quicklink-ID: EXPORTQuicklink-ID: RS

Solutions17FAX Reply+49 (0)228 602-2275Please send me Moeller Solutions regularlyCompany:Name/First NameDepartment/FunctionStreet:Post code/Town:Country:Telephone:E-mail:Please include mein the distribution list for yourelectronic Moeller newsletter.quicklinkYour goal‘s just a click away.1. All texts are provided with a 6-digitQuicklink number.MS XXXX2. At www.moeller.net enter the requiredQuicklink number in the entry box at thetop right or enter a search term andconfirm.MS XXXXMOELLERINFO SERVICEFurther information:Up-to-date and fast.By fax, Internet, emailand for downloadFAX Reply+49 (0)228 602-2275E-MAILinfo@moeller.netINTERNETwww.moeller.netNEWSLETTERinfo@moeller.netINFO REQUESTliterature.moeller.netELECTRONICCATALOGUEcatalogue.moeller.netPlease send me informationon the following topicsIndustrial Switchgear New Products Catalogue 2008.Industrial Switchgear Product OverviewNew Features for NZM Circuit-BreakersProduct Information for SmartWire DarwineasyHMI MFD4 Multi-Function DisplayDarwin TechnologyNew Features for xStart ContactorsDIL H ContactorseasyRelay, easyControl, easySafetySwitchgear and Switchboards for the World MarketElectronic Catalogue3. This takes you immediately to extensiveproduct information.35

www.moeller.netWith new power at the start.xStart – the newgeneration.New efficient solutions for the motor outgoerMoeller is always on the ball when it comes to leadingthe field in progress and innovation. This is why we havecontinually developed the contactor DIL M since its marketlaunch four years ago – co-operating hand-in-hand withour customers. And the result is impressive:• Economic switching with new compact Eco types foreach of the four sizes• Optimum contact assurance through knurled contactsurfaces featuring eight contact pointsFor further information contact:mailto: Info@moeller.netQuicklink-ID: SAFETY at www.moeller.net• Faster and error-free design of motor starters, andattachment of innovative accessories using tool-lessplug connections• Reduced wiring expense and elimination of a controlI/O level thanks to SmartWireA08/01K40 1 5 0 8 1 1 2 7 2 7 6Moeller Electric GmbHInfo-Service · 53105 BonnFax (0228) 602-2275