Weidmüller Information & News | No. 15

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Complete control – with safety includedThe remote I/O solution u-remote includes risk protection

Bright future for plant efficiency LED system solution for wind power installations offers enlightening arguments

More best connections inside Let's connect.

WIN !

Permanently supplied Solutions for failsafe systems all over the world

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2 | Editorial

»Our expertise is based on engaging intensively with markets, technologies and, above all, people.«

Dear readers!

Our cover story provides you with in-depth insights into our aims and what we can offer in terms of power supply solutions that fit requirements perfectly. How do we cover the diverse needs of our focus industries

without overloading our product range? What role do our two switched-mode power supply unit families PROeco and PROmax play in this? And how do we manage to offer sophis-ticated automation systems with a standard solution that is anything but ordinary? Read the answers to these and other fascinating questions in the interview with the Head of our Infrastructure business unit.

In general, we associate the term “supply” with commodities or services that are essential to life, such as food or medical care. It's critically important in this context, as the supplier must know the exact requirements of the persons being supplied. Unless you familiarise yourself thoroughly with the nature of your role as a supplier, you will not be able to fulfil this satisfactorily.

We have applied this insight from the interpersonal sphere to automated systems. In order to keep lifelines such as data, signals and energy constantly available, supply solutions are required that address the specific requirements of the machine or system being supplied. Our expertise in this area is based on engaging intensively with markets, technologies and, above all, people. They know best how their automated systems work and what they need. We, on the other hand,

know how to make the power they require continuously available.

The other articles in this issue of WIN! also illustrate how we keep our finger on the pulse with our practical approach: for example, with functional safety solutions as an integrative component of our remote I/O system, with smart LED system solutions for wind power installations or with newly dimensioned service interfaces for cabinet walls. Be our guest and experience these and further highlights also at the SPS IPC Drives in Nürnberg. You will find us in Hall 9, Stand 9-351.

I hope you enjoy reading this issue and find it is filled with interesting ideas.

Let's connect.

Kind regards,

Volpert Briel Sales and Marketing Director

3Content |

WIN! on the web and as a newsletter The online version of our customer magazine WIN! keeps you regularly updated with news and stories from the world of Industrial Connectivity: ▶ www.weidmueller.com/win

You can also register there for the WIN! newsletter, which provides you with the latest articles four times a year.

The next print edition of WIN! will be appearing in April 2015.

Let’s connect.

In Brief 4 News and trends

The latest news on products, partnerships and events

In Focus 9 Permanently supplied

How do power supply solutions from Weidmüller keep systems running continuously all over the world? Dr.-Ing Kai Lorentz, Head of Infrastructure, provides the answers

In Action 12 Universal cabinet system: a solution based on partnership

Bosch Rexroth has used Weidmüller components to develop a self-monitoring control solution – offering impressive performance in a small package

18 Advantages that do not evaporate u-remote guarantees safe process cycles in the new compact vapor degreasers from two Dutch manufacturers

In Detail 14 In safe hands throughout the world

Critical to the success of assembled enclosure solutions from Weidmüller is the company's worldwide network of application centres

16 Complete control – with safety includedFlexible options for creating functional safety solutions are an established feature of the u-remote remote I/O solution

19 Bright future for plant efficiency LED system solution for wind power installations offers enlightening arguments

22 Control systems more efficiently Thanks to numerous possible combinations, highly flexible functionality and work-saving details, the FrontCom® Vario service interface sets new standards

Imprint

Editor Weidmüller Interface GmbH & Co. KG, Global Market Communication, Klingenbergstraße 16, 32758 Detmold, Germany

Editorial office Julia BusseLayout Marc LandermannContact win@weidmueller.dePictures Weidmüller Gruppe, Bayer AG (p. 4), Siemens AG (p. 7), Bosch Rexroth AG (p. 13)

© 2014 by Weidmüller Interface GmbH & Co. KG. Reproduction and publication, in full or in part, only allowed with express permission by the Editor.

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4 | In Brief4

More than a lightweightA glass-fibre reinforced polycarbonate from Bayer makes the housing of the PrintJet ADVANCED ink-jet printer especially light and robust

The advantages of structural foam injection moulding go way beyond simple weight reduction. This is clearly shown by the way in which the thermoplastic process has become a key element in the construction of the PrintJet ADVANCED housing. The developer of the polycarbonate, Bayer Materi-alScience, proudly exhibits the robust industrial printer as a reference object in its TechniKomm showroom.

Find out about PrintJet ADVANCED in the web special:▶ www.printjetadvanced.com/en

“The polycarbonate Makrolon® from Bayer MaterialScience provides the basis for meeting the demanding standards for production and component geometry,” says Thorsten Bett, Head of Business Unit Identification at Weidmüller. “Thanks to the plastic's high dimensional stability, we can position the fastening elements of the printer housing with exceptio-nal accuracy. Significantly reduced housing vibrations also improve printing precision even at higher speeds. Further-more, there are no problems with shrink marks or material shrinkage. With these properties, the material has provided us with an ideal basis for developing a durable industrial printer according to market requirements.”

Thermal fixing, which is an integral feature of the printer and results in particularly durable marker results, requires temperatures of around 120 °C or more. The material is able to resist these temperatures due to excellent flame-retardant properties in the foamed state. Finally, the production process has also had positive effects in terms of processing and plant engineering. It means, for example, that a lower clamping force can be used, which in turn reduces power consumption.

Reliable signal transmission in sensitive processesSIL-certified signal converters for areas with a poten-tially explosive atmosphere are the newest addition to the Weidmüller solution package for safety-related signal circuits in the process industries and energy technology The safety functions in explosive zones, e.g. the switching on and off of aggregates, the surveillance of actuators or the monitoring of temperature and pressure, require signal con-

Head of Global Industry Management, Christoph Zöller, and Product Manager, Sascha Dreifert, explain the

backgrounds of the extended offering in an interview: ▶ www.weidmueller.com/sil_interview

verters that have a SIL certification. Here, together with the SAFESERIES safety relays and surge protection devices from the VARITECTOR program that are also SIL certified, the ACT20X signal converters allow a complete safety circuit to be set up according to SIL 3: from safe receipt and transfer of the signals on the sensor through safety-oriented shut-down if conditions become critical up to the setting up of protective measures for long signaling pathways.

Weidmüller solution package for safety-related applications: SIL-certified signal converters, safety relays and surge protection devices

Franz-Josef Bergmann and Thorsten Bett from Weidmüller and Matthias Bredehorst from Bayer MaterialScience are proud of the printer housing that is lighter, more rigid and less prone to distortions thanks to foam injection moulding technology

5In Brief |

Conditions exist in car body production that make it impos-sible to use every kind of marking for wires or components. This is where MetalliCard, with its ability to create perma-nent marking in harsh production environments, scores. Car maker Daimler therefore employs the marking system from Weidmüller as standard for labelling inside and outside control cabinets.

“We meet Daimler's labelling requirements with seven listed MetalliCard variants, five of which were specifically develo-ped for this customer,” says Faysal Dogan from Weidmüller's Identification Systems Unit. “Daimler benefits from standar-disation in the context of the Integra standard, especially in relation to Daimler suppliers of control systems and plant. Many of these already deploy our PrintJet ADVANCED printer and are therefore able to continue to use their proven printer and software package without new investments.”

With a comprehensive solution consisting of markers, printer and software, Weidmüller offers users a process-reliable system, which requires little manual input and, above all, independence from external service providers. Smooth data transfer from the CAE system with the M-Print® PRO software generates substantial time savings. “For Daimler a decisive advantage,” says Weidmüller Industrial Manager Hans-Peter Best. “Another big selling point was our international pre-sence. Wherever in the world Daimler has a manufacturing plant, Weidmüller is not far away. This means we are able to support our customer effectively all over the world.”

MetalliCard as standard at DaimlerThe Daimler Group relies on metal markers from Weidmüller for plant and cable labelling at its worldwide production facilities

Find out about Weidmüller’s systemised marking system: ▶ www.weidmueller.com/marking

Permanent identification with all the information required by Daimler's Integra standard – no problem with razor-sharp two-line marking on metal

AppGuide: product recommendations for applicationsWeidmüller provides device developers with a unique selection tool that lets them find the right connection system for their application in just a few steps

“The AppGuide is an additional service for our OMNIMATE programme,” says Dennis Kräft, Head of Product Manage-ment, Device Connectivity. “The web-based selection tool complements our well-established 72-hour sample service ideally.”

The AppGuide section of the Weidmüller website offers a selection of relevant device applications and their associated functions, such as motor connection, DC intermediate circuit, external I/O components and power supply. When users click the function they want, they get detailed recommen-dations for the most suitable connection solution. These are designed to meet their requirements – in terms of handling, size, safety, processing costs and standard compliance – to optimum effect. All they have to do to test the component they have found as quickly as possible is click again. Within 72 hours, developers receive the recommended product as a free design-in sample – wherever they are in the world. “From the application-oriented product recommendation to

sampling, we guide our customers quickly and highly effici-ently with these two service packages,” emphasises Kräft. “From this point onwards, our experts locally provide further support for the design-in process.”

The OMNIMATE AppGuide is available here: ▶ www.weidmueller.com/appguide

“We make recommendations rather than just let people search” – Dennis Kräft indicates how Weidmüller does this for its customers with the AppGuide

6 | In Brief6

Strip hard, halogen-free cable insulation with easeCost-efficiency, elevated safety standards and the trend towards application-specific cables raise the complexity of wire insulation. Weidmüller meets the challenge with precision tools for highest standards

EX areas, US standards in mechanical engineering and plant manufacture, special safety standards in the rail industry or elevated temperature demands in wind power installations: On account of the varying mechanical loads, standardisation systems and fire protection regulations, different cable characteristics are applicable in each field of application. This gives rise to a virtually endless abundance of cable types: with extremely hard or soft, very thick or thin insu-lation, with a range of tensile strengths and various materials. This diversity makes simple and clean stripping a challenge.

“With stripax® ULtimate we complement our program with a stripping tool that strips almost all cable types. Its specially shaped blade makes it easy to cleanly remove the insulation from halogen-free and similar conductors,” describes Product Manager Sven Hinrichs the core bene-fits of the new stripping tool. New components, improved materials and precisely matched parts make stripax® ULtimate an especially robust stripping tool with which users can completely satisfy their professional requirements in various indust-rial fields.

Facilitating the transformation of the energy systemAt the newly launched WindEnergy trade fair in Hamburg, Weidmüller exhibited pioneering solutions for the installation and operation of wind power installations

A total of 1,200 international exhibitors presented their latest technologies and products for generating wind energy, taking up 65,000 square metres of exhibition space. The highlight at the Weidmüller stand was a tower almost ten metres high, which sparked lively interest from visitors. “We recreated the tower of a real wind power installation, com-plete with a ladder and cabling,” says Hans Schlingmann, Business Development Manager, Wind. “It was a highly effective way to demonstrate our lighting system.”

More on products and solutions for the wind energy industry: ▶ www.weidmueller.com/wind

Delighted with their success at the trade fair: Weidmüller's wind team in front of the demonstration tower at WindEnergy

7In Brief |

Express connections By using RockStar® HighPower connectors, the new ICx high speed trains from Siemens can be put together particularly quickly and flexibly

As the fourth generation of ICE high speed trains, the new ICx will form the future backbone of the Deutsche Bahn’s intercity services. Entering service for the first time in 1989, the aerodynamic train sets have since undergone continuous further development. Weidmüller’s wagon-to-wagon connectors support the high flexibility demands.

“It used to take days to put a train together according to the number of expected passengers. Thanks to our new connection system, RockStar® HighPower, the new ICx will be ready for service within hours,” explains Detmar Saalmann, Head of Industry Management Transportation. Deutsche Bahn has ordered around 300 of the ultramodern ICx trains from Siemens. From 2016, they will be in use on Germany's rails.

More on secure power distribution for wagon-to-wagon couplings: ▶ www.weidmueller.com/highpower

Discover stripax® ULtimate and other stripping tools as well online:▶ www.weidmueller.com/stripping

8 | In Brief

Industry 4.0 – heading towards the Smart Factory togetherTargeted transparency for more efficient management of production processes – Weidmüller presents a pioneering control unit for the digitisation of analogue production data

Explore Weidmüller's contributions to Industry 4.0 in detail at: ▶ www.weidmueller.com/industry40

In light of Industry 4.0, customised, highly flexible and self-controlling production units still often seem like a vision for the future. As a progressive, pioneering company, Weidmüller already offers concrete solutions that enable manufacturing companies to prepare themselves for the In-ternet of Things and allow them to manage production relia-bly from the cloud – using their existing range of machinery.

“At this year's SPS IPC Drives, we are presenting a control unit that converts analogue machine data to digital data by means of the network-capable ACT20C signal converter and the Power Monitor energy meter,” says Dr Jan Stefan Michels, Head of Standard and TechnologyDevelopment at Weidmüller. “The centralised storage and processing of complex data is particularly easy using stan-dardised OPC UA Services. User-oriented visualisations via web applications provide relevant information to any loca-tion. This targeted transparency of critical parameters makes both manual and automated optimisation of the manufactu-ring process considerably simpler.”

Secure communication with simpler addressingWeidmüller’s new router model is the most efficient choice for integrating systems with the same IP address space

Outstanding performance: Thanks to gigabit Ethernet interfaces, the new firewall/NAT router enables a very high data throughput

Industrial routers typically support a wide range of functions. Depending on the respective application, however, only a few of these features are actually required. Focusing on the essentials is essential if the amount of work required for IP integration of machines in higher level networks is to be minimised.

So you do not have to forego a high degree of network security, Weidmüller has specifically designed a new firewall/NAT router for applications in which the priority is on network security and network address translati-on (NAT). By means of the integrated stateful packet inspection firewall with flexible 2-way packet filtering (WAN/LAN inbound and outbound), the router reliably protects industrial IP networks. Via the functions 1:1 NAT and IP forwarding/virtual mapping, you can flexibly integrate equivalent IP subnetworks without needing to adjust the machine network in a higher level production network.

Find out about further innovations on our online platform: ▶ www.weidmueller.com/best-connections

Dr Jan Stefan Michels is convinced of the production of the future

Innovations and system solutions from Weidmüller up close at Europe's leading exhibition for electrical automation

Interview

Without the necessary power, robot arms will not move, conveyor belts will not roll, and valves will not open. Dr.-Ing Kai Lorentz, Head of Infrastructure, explains how Weidmüller goes about keeping systems running continuously all over the world.

Permanently supplied A multi-faceted claim

9In Focus |

10 | In Focus

WIN! Weidmüller has positioned itself as a partner providing power supply solutions that fit require-ments precisely. What lies behind this claim?

Lorentz: The term “supply” is generally associated with the provision of the fundamental resources required for life. This existential meaning can readily be applied to automation as well. And that makes it clear why we can never be too ambi-tious in our aim to provide a reliable power supply.

Put simply, it is our declared aim to offer our customers reliability by ensuring that their systems are provided optimal protection against downtime caused by voltage drops and interruptions in supply. We achieve this by closely exami-ning the requirements of our fo-cus industries all over the world – and then meeting them.

WIN! How do you manage to meet all of the diverse requirements of your focus industries without at the same time overloading your product range?

Lorentz: We strike a chord with our target groups by developing everything from typical power supply units to comprehensive system solutions. Our switched-mode power supply unit families PROeco and PROmax provide the foundation for this: they are a perfect fit for their intended uses.

In order to have the flexibility to meet all requirements for reliability, we recommend that our customers use redun-dant circuitry and uninterruptible power supplies or DC/DC

converters. The extension modules required for this are an essential part of our modular supply concept and can be combined with our switched-mode power supply units to suit requirements.

WIN! You say that PROeco and PROmax form the basis of your supply solutions. What types of require-ments do these two families of switched-mode power supply units cover?

Lorentz: As the name suggests, PROeco is our most econo-mical family: for outstanding performance on a tight budget. The switched-mode power supply units offer all the basic

functions and come into their own where space is limited and user friendliness and efficiency are key requirements.

These qualities mean that PROeco is used in many Asian countries, for example, to sup-ply power in accordance with the industry standard for lifts and escalators as well as for infrastructure applications such as ticket machines and parking meters. In addition to typical

applications in series machine manufacturing, we thus also open up niche markets.

PROmax, on the other hand, is our “powerhouse” and copes easily with factors such as vibrations, fluctuations in power supply and temperature differences. This makes the switched-mode power supply units in this family particu-larly resilient and versatile. In short, they are just perfect for demanding automation applications.

»We strike a chord with our target groups by developing

everything from typical power supply units to comprehensive

system solutions.«Dr.-Ing Kai Lorentz, Head of Infrastructure at Weidmüller

The “powerhouse” PROmax and the economical PROeco family form a strong foundation for power supply solutions

from Weidmüller that meet requirements precisely

11In Focus |

.WIN! Demanding automation ap-plications – what does that mean for you exactly?

Lorentz: By that, I mean typical mechanical and plant engineering applications. In other words, machine tools, conveying systems, the food and beverage industry and automotive engineering. However, the renewable energy industry and simple systems in the process industry, such as water treatment systems, are also target segments.

We achieve the aim of implementing an uncompromisingly robust, resilient power supply with PROmax, for examp-le, by complying with Category IIIfor overvoltage protection on the input side. Transients that develop within the system thus cannot affect the switched-mode power supply units, and a reliable supply is maintained. With a constant output of up to 120% at temperatures of up to 45°C and high output peaks of up to 300%, PROmax ensures reliable operation even at the limits of the range.

WIN! You say that PROmax is also suitable for simple process ap-plications. Which of the family's features meet the specific require-ments of these applications?

Lorentz: PROmax meets the deman-ding conditions in process applications with certification to Class I, Division 2, for example. Together with UL approval, this makes the switched-mode power supply units ideal, in particular, for ha-zardous applications in North America. Moreover, thanks to GL approval, there is nothing to stop them being used in international shipbuilding applications – and thanks to EMC1, they can also be used for bridge applications.

As well as having all these approvals, PROmax also comes in a wide range of variants – with output current from 3 A to 40 A and output voltages from 5 V DC to 48 V DC. Consequently, there is a huge variety of potential applications, wherever a particularly robust, resilient power supply is required.

In short, thanks to their peak load ca-pability, space-saving housing design, wide temperature range and exten-sive international approvals, PROmax switched-mode power supply units can be used universally all over the world.

WIN! With these qualities, PRO-max offers much more than just basic functionality. But you still refer to the family as a standard solution. How do these two state-ments go together?

Lorentz: They go extremely well together! PROmax goes beyond what is usually expected, but at the same time it is not overloaded with special func-

tions. Rather than offering a special solution for premium requirements, we provide PROmax, which is a versatile standard solution for use in large me-chanical engineering applications and energy and process facilities. If you take our economical basic version, PROeco, into account as well, it becomes clear that PROmax is ideal for a wide range of applications where there are justifia-bly high demands for a robust, effective power supply.

Dr.-Ing Kai Lorentz knows what's needed for reliable system operation

More on the modular power supply concept: ▶ www.weidmueller.com/powersupply

Self-Testing Safety System (STSS) for power plant applica-tions monitors itself continuously and creates an ongoing log of the results. This means that operators have a trace-able record at all times to show that their safety equip-ment is working at the moment. One of the positive ‘side effects’ is, for example, that the time between proof tests can be up to six times longer, reducing load and costs. It is obvious that when taking such an approach, we placed a lot of importance on using reliable components.”

Functionality guaranteed, even in an emergency

Where there is a need for continuous control and monito-ring, this is dependent on there being a permanent supply available. In order to identify the best possible solution, Bosch Rexroth subjected all possible switched-mode power supplies to rigorous testing. And the result was

T he control of crane and hoisting technology in off-shore applications, flood relief with retaining dams and steam pressure control in power plants have one thing in common: they all call for automated safety

equipment that can be relied on without question, at all times. Bosch Rexroth has met this demand with a new type of system solution.

“Power plants were the initial application for us. Until now, the operators of such plants were required to carry out annual checks on the safety equipment while the plant was running. This not only represents a cost factor and results in a heavy load being placed on both the plant and the net-work – the benefits are also limited. The only outcome of the tests is the knowledge that the safety equipment has worked during the previous twelve months. Only assumptions could be made about what might happen in the future,” reports Project Manager Dirk Bracht from Bosch Rexroth. “Our

Universal cabinet system A solution based on partnershipIn order to comply with the high demands placed on the functionality of safety equipment, Bosch Rexroth has developed its own, self-monitoring control solution. A lot of performance is packed into a small space. The recipe for success lies in deploying an efficient combination of components from the partners Bosch Rexroth and Weidmüller.

The Self-Testing Safety System (STSS) for power plant applications: a self-monitoring control device for control and switching valves, which combines the electrics, software and hydraulics into a universal concept

12 | In Action

that the PRO-M range from Weidmüller with its high degree of efficiency, overload resistance and high perfor-mance reserves ticked all the boxes. The switched-mode po-wer supply unit’s outstanding stability against surge voltage and mains transients was particularly impressive, which ope-ned up broad deployment options, even in special applica-tions. In order to ensure that full power remains available for the controller, in spite of the high MTBF (mean time between failures) of one million hours and even in the case of the failure of a power supply unit, PRO-M had redundancy and parallel switching by means of a diode module designed in.

The control of external actuators is also safeguarded by components from Weidmüller. Here, the just 6-mm wide relay modules from the TERMSERIES and, in the case of Ex applications in process automation, the intrinsically safe signal converters from the ACT20X range are deployed. Vibration-resistant electrical cabling is achieved by the use of “PUSH IN” modular terminals from Weidmüller. The protec-tive frame for the system is provided by a Klippon® TB MH stainless steel enclosure that can withstand all that even the toughest, explosive environments can subject it to. And last but not least, Weidmüller is taking on the complete, application-specific installation – both the high-level versions for power plants and offshore applications and the standard versions for further industrial areas such as rolling mills.

More safety with less plant downtime

“High pressure, extreme temperatures, security requirements in accordance with SIL 3 – we are best equipped to handle these conditions,” explains Key Account Manager Christian Deppermann from Weidmüller. “And that is why we could offer Bosch Rexroth multiple-tested components for the construction of the universal control cabinet concept. Added to this are our many years of expertise in the assembly of turnkey enclosure solutions, even for deployment in extreme conditions. With this breadth of offering, we are able to give optimum support to the modular concept with which Bosch Rexroth offers its customers not only safety but also a high degree of flexibility.”

1. In the case of installations on the high seas, such as offshore wind power installations, it is a question of ensuring the straight, swing-free lowering of loads that can weigh up to several tons. By using active sea-state compensation, the self-monitoring control solution equalises the effects of the waves and, thanks to its performance level, achieves the highest safety requirements. 2. Retaining dams represent a further possible application area. Here, if the water level is too high, the water is run off through corresponding valves. This mechanism must be 100%-reliable at all times as in the case of a defect, the complete bursting of the dam could be the disastrous result. The regular preventative maintenance is made intelligent through the deployment of the Bosch Rexroth system. 3. The system also checks similar safety requirements when used in power plants. The high-level version with redundant power supply and intrinsically safe signal converters from Weidmüller ensures higher plant availability, lowers overall operating costs and improves performance. 4. With an eye to the requirements of these and further industrial applications: project team members from Bosch Rexroth and Weidmüller visiting the Klippon® enclosure production facility.

13In Action |

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In safe hands throughout the world Custom enclosure solutions for global requirementsAssembled enclosure solutions from Weidmüller are used in more and more industrial applications to reduce vertical integration and save on production costs. Critical to their success is the company's worldwide network of application centres.

15In Detail |

“Our experts in photovoltaic solutions are based in Barcelona. Germany, Dubai, Singapore and Australia speciali-se in the process industry, among other things,” reports Jose Maria Castellvi, who is responsible for Weidmüller's global application network. “Our ap-plication centres are located wherever there are large markets to be served locally. This allows us to address local conditions and avoid having to create enclosure solutions that have to be delivered all over the world.”

Compliant with worldwide standards

Enclosures have played an important role at Weidmüller since the 1960's. It is not for nothing that the name Klippon® has now become synony-mous with ATEX and stainless steel enclosures. Weidmüller's enclosure system has all the approvals required for use in industrial environments. That includes IECEx, the global approval framework for potentially explosive atmospheres. These housings can thus be used in industrial applications all over the world: from car manufacturing to traffic systems, wind power installati-ons and refineries. The flexible enclo-sure system is designed in such a way that any adjustments always remain in compliance with the applicable appro-val regulations.

“Safety and efficiency in a wide variety of environmental conditions and, at the same time, compliance with all appli-cable standards, legislation, regulations and guidelines – these are the challen-ges our customers around the world

present us with,” reports Dirk van Vinckenroye, Head of Application- Specific Solutions at Weidmüller. “We provide custom assembled enclo-sure solutions of the highest quality for connection to the supply system, control systems, a range of testing and service units and protection and safety equipment. These allow operators to significantly improve the performance, durability and service friendliness of their systems and reduce assembly costs. With our coordinated range of products and assembly service, we offer the assurance that all of the rele-vant factors are taken into account right from the outset.”

A precise fit for any system architecture

Installers of photovoltaic systems also benefit from these advantages. Application-specific enclosure solutions are used here for generator junction boxes that ensure the best possible connections for the current between the solar modules and the inverter. As with its Klippon® housings, Weidmüller has developed numerous standard configurations based on recur-ring customer requirements. However, custom solutions to suit the individual architecture of a photovoltaic system are also created in close cooperation with the customer.

How is a generator junction box actually made? Take a look behind the scenes at the

application centre in Barcelona: ▶ www.weidmueller.com/pv_centre

Weidmüller offers housings in a variety of sizes with specific hole patterns, as required, which are equipped with modular ter-minals to create a typical distributor enclosure or with electronic devices to build an individual control enclosure.

1. An individual approach is adopted right from the initial idea through to delivery: the combination of advice and application and industry expertise is the key to an enclosure solution that meets specific requirements. 2. Development and production take place worldwide – close to the relevant markets. 3. Generator junction boxes at the application centre in Barcelona waiting for final assembly in the photovoltaic system.

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16 | Im Moment

solutions by cascading several modules. The switching output of a u-remote station thereby serves as the input for the next module, meaning that two stations are linked together and that linked protection zones can be created within one application.

“A load current up to 8 A can be safely shut down by a single u-remote safe power-feed module actuated by sen-sors,” says Rose. “And it is cost-effective: Standard output modules can be used. Our customer can thus operate both a DC motor drive with speed control and safely shut it down as well as switch the doubly redundant motor contactors. Even failsafe control of proportional valves with 4-20 mA input is possible. There is a choice between immediate and delayed disconnection.”

Fully designed with safety in mind

Using a standard PLC, machine operators achieve a ma-ximum degree of safety and complete control. All input sensors are independently supplied via separate voltage paths and report the current machine or system status to the control unit. Restart is performed either manually or via the auto-start function. All modules are certified by TÜV Nord (German Technical Inspectorate) and bear the “TÜV type test approved” symbol.

“Users receive complete status information about the inputs and outputs thanks to the complete integration of the safe power-feed modules in the u-remote system. In a solution relying on external devices this would not be possible in this form,” says product manager Andreas Hoffmann. “Configuration is also at least as easy as in a solution with safety switching devices – and with respect to wiring, it is definitely easier.”

Find out more about u-remote on the web: ▶ www.u-remote.net

“In an industrial context, the terms 'Safety' and 'Security' have closely related but nonetheless distinct meanings. Security means protection of the machine from people, whereas safety, i.e. functional safety is the protection of people from the machine,” says Gorm Rose, Weidmüller electronics developer with a focus on functional safety. “In order to reliably pre-empt hazards emanating from the machine, we have extended our u-remote product range to include safe power-feed modules. With a safety level of SIL 3 CL as per DIN EN IEC 62061 and Category 4, PL e as per DIN EN ISO 13849-1, we achieve the highest possible degree of protection in the area of machinery.”

Safety-driven shutdown with standard modules

Per safe power-feed module, two independent safety circuits can be created. These circuits can also differ tech-nically: for example, taking the form of an emergency stop chain with mechanical contacts and a contactless protective device with OSSD outputs, such as a laser

scanner or light curtain. There is also the possibility of providing functional safety in complex automation

Complete control – with safety! With u-remote, protection against hazards comes inclusiveVirtually any larger machine represents a potential hazard for its users, due to movements of the robot arms or hydraulic cylinders, for example. The many options for add-on functional safety solutions therefore form an integral part of Weidmüller’s remote I/O solution.

Integrated safety without the need for a safety controller and without any outlay – using safe power-feed modules as a fixed component of the u-remote system

Would you like to see how the safe power-feed modules work in practice? Then simply turn to the application report on the next page.

18 | In Action

Machines for industrial cleaning are one of the specialties of the Dutch company Servicing Europe NDT (SENDT). A new-ly developed vapor degreaser, jointly developed with partner company B & M Service, combines classic heating and modern ultrasonic technology, thus creating the patented “Vertrel Sion™” vapor, which can be condensed and reused.

Another distinctive feature of the new vapor degreaser: it is extremely compact. In order to achieve these particularly compact dimensions, SENDT and B & M Service have put a lot of emphasis on space-saving components – but without compromising functionality.

Uncompromising functionality in a compact space

“Our biggest challenge was that we had very little space to accommodate the controller unit. At the same time, provi-ding reliable safety mechanisms is crucial in applications with cleaning vapors,” says Eric van Eijk of SENDT, summa-rising the various requirements. “After an intensive search for a suitable remote I/O solution, u-remote from Weidmüller convinced us with its very flexible and space-saving configu-

Reference

Advantages that do not evaporateOnly when cleaning vapor penetrates all nooks and crannies, perfect cleaning of metal parts is assured. u-remote guarantees safe process cycles in the compact vapor degreasers from two Dutch manufacturers.

ration. And even better: we were easily able to dispense with additional safety solutions, as these are already integrated in the system.”

Protection for man and environment

Putting the safe power-feed modules directly in front of the appropriate standard output modules made it especially easy for the developers of the vapor degreaser to develop a reliable safety solution. Using standard station modules and a Siemens SIMATIC S7-1200 PLC, linked via PROFINET to u-remote, status messages can be exchanged and actuators shut down safely in emergency situations. Even without the use of expensive safety PLCs or additional safety relays, it is thus ensured that the uncontrolled escape of vapor is preven-ted at all times.

“The advantages of u-remote were immediately obvious to us and have been proven in practice,” says van Eijk, adding with a smile: “The added value of the system does not evaporate – just like our cleaning solution.”

Passion and expertise in the fields of ultrasonic cleaning and engineering unite Eric van Eijk of SENDT (l.) and Bert van Dasselaar of B & M Service (r.), who have

now been successful project partners for more than eight years.

19In Detail |

Bright future for plant efficiency LED system solution offers enlightening argumentsOn the increasingly competitive wind power market it is more important than ever to guarantee maximum plant efficiency during the planning phase while incurring the lowest possible acquisition and follow-up costs. Business Development Manager Hans Schlingmann explains how Weidmüller’s LED system solution makes the interior lighting intelligent and thus offers high potential of cutting the total operating costs of a wind turbine.

For ensuring a practical design of the LED lighting solution, Hans Schlingmann (left) makes sure he gets

an accurate picture of the relevant application

20 | In Detail

WIN! With its cutting-edge and secure solutions for the harsh environment of wind power installations, Weidmüller is continually contributing to the compe-titiveness of wind applications throughout the world. What sets the new lighting system apart?

Schlingmann: Our goal is not only to supply customers with individual components, but also to develop innovative concepts that simplify work processes and enhance plant efficiency. This is exactly what we've done with our new FieldPower® Wind Energy lighting system for wind power installations. The core element is the use of LED lamps, which boast extremely low power consumption and long-lasting durability. Used together with a complete system for uninterruptible power supply, remote monitoring and optional outlets, this creates a ready-to-fit solution for lighting, optional emergency lighting and power supply of the entire plant. All the parts are proven and perfectly coordinated to one another, so the lighting system can be easily included in any application.

WIN! Switching from tried-and-proven technologies to new ones is a step often fraught with risks and a decision that shouldn't be taken lightly. What advan-tages does the LED technology offer compared with existing lighting solutions?

Schlingmann: Up until now, linear fluorescent luminaires were often used to provide interior lighting in wind power installations. Compared with LED technology, linear fluore-scent luminaires harbour a wealth of disadvantages during ongoing plant operation. In addition to their high power consumption, they are also very fragile and often result in unnecessary additional costs for maintenance and replace-ment. It certainly isn't uncommon for the actual installation and maintenance work to be preceded by unscheduled ser-vicing, as it is simply impossible to work safely in the towers without sufficient interior lighting.

In contrast, LED lamps are especially energy-efficient and boast a service life of up to 20 years. In developing our FieldPower® LED lamps, we have designed every detail to meet the extreme environmental conditions in wind power installations.

Full lighting performance along the ladder: The advantages of the practical LED lights already come to fruition during installation

»Thanks to our experience and expertise in the fields of power supply, data and signal

processing, we have developed a sophisticated solution: FieldPower® Wind Energy.«

Hans Schlingmann, Business Development Manager for the Wind Segment at Weidmüller

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WIN! What specific characteristics distinguish the lighting solution as particularly practical? Schlingmann: Already at first glance, this is evident thanks to the robust plastic housing with a protection class of up to IP 54 and the compact size. But the “inner values” are convincing as well: Our LED lamps contain no mercury and produce light that is free from UV and infrared. Unlike with conventional linear fluorescent luminaires, the full light out-put is available as soon as the lamps are switched on, regard-less of the temperature and without any annoying flickering. The light intensity of the LED lamps is consistent, even in emergency mode and with low power consumption.

We have developed two variants to cater to the particular requirements of the different areas in a wind power installati-on. Given its non-directional light incidence, the FieldPower® MONO LED is excellently suited to illuminating large spaces and work areas in the blade and nacelle, for instance. We designed the FieldPower® DUO LED, meanwhile, to respond especially to the requirement in ascent and decent areas. Its design means that it delivers directional light on two sides, thus guaranteeing optimum illumination along footways and ladders. WIN! In using LED lamps, you're choosing the efficient and secure option, but this solution also translates into higher procurement costs. How can Weidmüller's complete system help to cut operating costs in the long term?

Schlingmann: Thanks to our experience and expertise in the fields of power supply, data and signal processing, we have developed a sophisticated solution:

FieldPower® Wind Energy. You no longer have to consider all the components individually. Instead, the entire system including the power supply can be integrated into the plant with ease, so that the time-consuming and costly process of coordinating interfaces and components becomes a thing of the past. Our service that offers free light simulation coordinated to the application also simplifies the customer's planning process.

The wide-range input from 24 to 120 V DC enables illumi-nation of large distances – in the tower of a wind power installation, for example. Even from a low conductor cross-section of 1.5 mm², up to 40 FieldPower® LED lamps can be supplied over a length of up to 230 m. Compared with the systems on offer at present, the use of a centralised, uninter-ruptible 24 V DC power supply minimises costs ranging from procurement and servicing to ongoing operation.

The entire circle of light can be monitored remotely when needed, making service operations more efficient and thus cutting costs. Also a luminous signal can be triggered by the circle of light to visually warn service staff when there are problems in the plant. At the moment, acoustic warning systems are used, but these can very quickly be drowned out by ambient noises.

To sum up, our unique combination of LED technology, application-specific power supply, automation and individual system design opens up fresh potential for optimising the efficiency in the illumination of wind turbines – for enlighte-ning arguments from planning to operation.

Hans Schlingmann, Business Development Manager for the Wind Segment at Weidmüller, explains the advantages of the innovative FieldPower® LED lighting system for wind power installations in an interview

| In Detail22

A multitude of factors to take into account during configuration

A socket and two data connectors, for USB and RJ45, for example – that's the typical configuration for a service interface. But what looks like a simple configuration at first glance, turns out to be more complex in practice. The choice of socket varies depending on the country in which it is to be used, and all aspects of the specific application have to be taken into account for the data connection. Is shielding required, for example? Which approvals are required? And what role does the ambient temperature play?

“With our configurator and over 5,000 options to choose from, designers and planners can put together a customised service interface. In three simple steps, you choose the frame, insert plates and interface inserts to suit your exact requirements,” says Leuchs, describing this intuitive configu-ration procedure. “Upon completion of the planning stage, FrontCom® Vario offers another pleasant surprise – the entire configuration takes up half the space that is normally required.”

The secret behind the success of this particularly compact design is that the family combines more functions in a single frame than a conventional service interface. Power-supply and signal and data-transmission components can thus be easily accommodated in half the previously required area. This makes the interface an ideal solution for access to distri-buted cabinets, where any space that can be saved in their design is welcome. Nevertheless, its compact dimensions and versatility make FrontCom® Vario an impressive option with central switch and control cabinets as well.

C ost-effective production thanks to high level of sys-tem availability – this can be a reality when you have constant access to your production data and can thus deal with problems as quickly as they arise. But

what should you do if the cabinet's safety functions or harsh environmental conditions prevent the cabinet door from being opened immediately during operation? The answer is protected service interfaces.

Through the cabinet or enclosure wall, diagnostic hardware, for example, can be connected via a data cable. Direct access can thus be gained to defined processes without the need to waste valuable production time waiting for an au-thorised service engineer. The guiding principle underlying the design of Weidmüller's FrontCom® Vario family of service interfaces is that they should save work.

It's all in the detail

“We designed every detail of FrontCom® Vario with the aim of making it as easy as possible for our customers to access control elements and functional electronic components,” explains Product Manager Klaus Leuchs. “This is reflected in product features such as the optional safety lock for preven-ting unauthorised access, the practical magnetic catch on the cover or the simplicity of identification with the aid of our systemised marking solution. We paid special attention to the configuration of the service interface, which is particular-ly easy to do with our new configurator.”

Control systems more efficiently A new dimension of service interfacesNumerous possible combinations, highly flexible functionality, work-saving details: with FrontCom® Vario, Weidmüller sets new standards for service interfaces. The new family offers tangible improvements in efficiency – from planning to operation.

Your direct route to the FrontCom® Vario configurator: ▶ http://galaxy.weidmueller.com/frontcom

With over 5,000 possible combination options, the FrontCom® Vario does its name justice. The modular service interface offers the perfect combination of single frame, communication and power inserts and an insert plate for virtually any configuration.

23In Detail |

1. Protected service interfaces give technicians rapid, safe access to cabinets at all times. 2. Situations in which authorised per-sonnel have to be called before control elements and functional electronic components can be accessed are thus consigned to the past. 3. Configuration is also easy – thanks to the FrontCom® Vario configurator, which helps planners get the service interface they need in three simple steps.

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Weidmüller Interface GmbH & Co. KGKlingenbergstraße 1632758 Detmold, GermanyTelefon +49 5231 14-0Telefax +49 5231 14-292083info@weidmueller.dewww.weidmueller.com

4 050118 360882

Weidmüller – Your partner in Industrial Connectivity

As experienced experts we support our customers and partners around the worldwith products, solutions and services in the industrial environment of power,signal and data. We are at home in their industries and markets and know thetechnological challenges of tomorrow. We are therefore continuously developinginnovative, sustainable and useful solutions for their individual needs. Together weset standards in Industrial Connectivity.

Your local Weidmüller partner canbe found on our website: www.weidmueller.com/countries