Professional Documents
Culture Documents
SOLUTIONS 22
Solar power stations: Parabolic trough solar collector uses air as heat transfer medium P. 10 | Pack it:
Smart-Wire-DT controls packaging machines P. 12 | Photovoltaic roofs: Always tracking and facing the
sun P. 16 | State of the art: Motor and pump test bench with SmartWire-DT P. 20 |
P. 22
info@moeller.net · www.moeller.net
P. 10 P. 18
P. 20 P. 12
Content
Imprint
Solutions is the customer
publication of Eaton’s Moeller
business
2 SolutionS 22
THE COMPANY
SmartWire-DT™ in Practice
With its official presentation of SmartWire-DT at the Hannover
Fair 2009 Eaton set the most important milestone in the
market launch of the product. The Solutions editor spoke
to Karl-Heinz Arndt, head of SmartWire-DT development
at Eaton, and Dr. Martin U. Schefter, Business Unit Manager
for Industrial Automation and General Manager of Eaton
Industries Holding GmbH, about customers’ experiences
with SmartWire-DT and further development steps in the
technology.
Dr. Martin U. Schefter Karl-Heinz Arndt
SmartWire-DT has been available on the market for well over Dr. M.U. Schefter: We are currently in discussions with several
a year. What conclusions can you now draw and what has partners. We are offering a SmartWire-DT development kit in
been the response of the market to the new technology? 2011, enabling 3rd party users to integrate SmartWire-DT into
their products.
K.H. Arndt: The sales figures are surprisingly positive. In the first
nine months alone, customers have implemented around 25,000 SmartWire-DT eliminates the need for the I/O level on the
connections. This does not include the North American market central controller so this benefit was already announced to
since we will not approach this market until the SmartWire-DT users. Does this visionary goal still stand and when do you
system has UL/CSA approval. We are planning the market launch think it will become reality.
in North America for the beginning of 2011.
K.H. Arndt: SmartWire-DT was designed in this way from
At the start of the launch you offered both the switching and the start, and this benefit is a key element of our technology.
protective devices as well as the pilot devices all equipped All applications already implemented to date have shown
with the communication system. What does the time scale emphatically that the I/O level is no longer needed. In order to
look like for future product groups? further advance this vision, we will be expanding the 2011 product
range by providing the control relays (easy), CoDeSys-based PLCs
K.H. Arndt: We are making rapid progress. This year we have and HMIs with integrated SmartWire-DT. This is interesting for
fitted part of the circuit-breaker series and the PKE electronic small to medium-sized applications as the user no longer needs a
motor protection from 12A to 32A with SmartWire-DT. The PKE gateway.
range up to 65A will be completed in the coming year. We will
also include the DS7 soft starter in the SmartWire-DT system in When will your frequency inverters have the interface?
2011.
Dr. M.U. Schefter: We will also be fitting our M-Max and H-Max
In order to get a better picture and perspective, what frequency inverters with a SmartWire-DT interface within the
percentage of switching devices, protective devices and pilot next 18 months. It is not our aim to replace established fieldbus
devices sold today are networked via SmartWire-DT? systems with SmartWire-DT. We will continue to offer switchgear
with fieldbus interfaces such as Profibus-DP, CANopen … Our
Dr. M.U. Schefter: Our expectations are realistic. The percentage priorities are the reduction in wiring and design engineering on
is currently in single figures but this is increasing strongly. the one hand and cost-effective diagnostics on the other. This
particularly applies to the control circuit devices and the motor
In order to make SmartWire-DT broadly available on the starters that do not have any fieldbus interface and require a lot
market, you announced last year the wish to form strategic of wiring.
partnerships with well-known companies. How far have these
talks developed?
SolutionS 22 3
NEWS +++ NEWS +++ NEWS
The Automation Award is the most important prize in the At this year’s Hannover Fair, Orhan Erenberk, general manager
automation sector. At the 2009 SPS/IPC/Drives fair in Nuremburg, of Thomas Industrial Media GmbH, Hattingen, presented the TR
the technical publication “elektro Automation” of the Konradin Award (www.technische-revue.eu) for a “particularly innovative
media group held the Automation Award competition for particularly product” to Dr. Martin U. Schefter, Business Unit Manager
innovative products. All exhibitors at the fair were able to compete Industrial Automation and managing director of Eaton Industries
with their innovative new products. A jury made up of the VDMA, Holding GmbH and Karl-Heinz Arndt, SmartWire-DT development
ZVEI (German Electrical and Electronic Manufacturers’ Association) manager at Eaton Automation.
and the editor team of elektro Automation nominated the “Top10
products” for the Automation Award 2009 from the 78 products
submitted. The nominated products were then exhibited at the
stand of the Konradin media group over the course of the SPS/
IPC/Drives fair. Visitors were then able to vote for their personal
favorites from these “Top10 products”. After the participation of
around 2200 visitors at the SPS/IPC/Drives fair, the result of the
Automation Award 2009 was as follows: The winner was Eaton
Moeller with SmartWire-DT and 21.5 percent of the votes.
4 SolutionS 22 News
NEWS +++ NEWS +++ NEWS
The film ‘SmartWire-DT – That’s Life’ was chosen for this year’s
ITVA Award for exemplary audio-visual communication solutions
in the sales promotion/marketing category and was awarded
the Bronze Pyramid. The presentation ceremony took place on
September 24 2010 during a gala event at the Photokina trade fair
in Cologne. The jury praised the clear comparison of the old, very
work intensive switch panel technology and the new SmartWire-
DT technology, as well as the attractive and new interpretation of
the evolutionary concept. The film takes up a quotation of Charles
Darwin which states that it is not the strongest that survives,
but the one who is flexible and can adapt to change – both in
professional and in private life. This year over 100 companies
competed for the much sought after Pyramid awards. The ITVA
Award is presented each year by the largest association of audio
visual communication, the ITVA, and is one of the most important
media prizes in Germany. The 3:25 minute long film was produced
for Eaton Industries by LAKRITZ.Film GmbH in Leonberg, and
filming was carried out in Cologne and at Eaton in Bonn.
SolutionS 22 News 5
NEWS +++ NEWS +++ NEWS
Highspeed PLC
XC202 with Variable IP Addresses
Eatons XC-CPU202- cards or USB sticks can be used as the memory medium for data.
EC4M-XV rounds off The required operating system update (Windows CE 6.0) can be
the high end of its XC carried out via the Ethernet interface as well as via these memory
controller series. The media.
XC202 is designed as
a high performance Besides the Ethernet and combined CAN/easyNet interface,
PLC: A high-speed RSC the XC202 also features a serial interface. This is designed for
processor (532 MHz) programming but also as a transparent interface for connecting
and a larger memory (4 MB) provide considerably greater barcode readers, printers or other devices. The interface can be
resources for communication tasks. Compared to an XC-CPU201, programmed easily by means of a browser command for the
the XC-CPU202 thus offers around a six to eight times faster required mode.
processing speed.
The controller also comes with a web server which enables
The high performance controller is now available and features it to be accessed via the Internet. Users can easily call up all
an integrated Ethernet interface for programming access and visualization pages created with the CoDeSys programming
data exchange in the network. The special feature of the new software using of a web browser. This type of web visualization is
controller is the fact that users can access it via different also ideal for remote maintenance tasks.
IP addresses. For example, one can be configured as a
programming port whilst another is provided solely as a data As well as the Ethernet interface (with a display of the Link/
interface. A special function allows both the IP address and the communication status) and the CANopen/easyNet interface (with
subnet address of the controller to be defined individually. This a switchable bus terminating resistor), a 29-bit CAN identifier and
enables the controller to be integrated simply in an existing a USB interface (2.0 Host), the high performance PLC comes with
corporate network. eight digital inputs and six digital outputs on board.
MFD-CP10
multi-function display
Low-cost visualization with twice the performance
and an enhanced range of functions
6 SolutionS 22 News
LOREM+++
NEWS IPSUM
NEWS
DOLOR
+++ NEWS
XV-150
New High-End XV150 Touch Display Series
from Eaton with an Aluminum Front
Unlike PKZM4 motor- protective devices (BCPD) in feeder and branch circuits. The
protective circuit-breakers, switches can also be used for protecting non-motor loads. In order
the PKZM4-..-CB circuit- to use the PKZM4-CB, contactors and frequency inverters must be
breakers are provided with approved for protection by circuit-breakers. Motors will continue
large creepage and clearance to be switched and protected by the Type E and Type F motor
distances at the incoming starters based on UL 508.
and outgoing main current
terminals. The new device Three types are on offer: Firstly PKZM4-16-CB (adjustable
height is therefore 165 mm. 10 - 16 A), secondly PKZM4-25-CB (adjustable 18 - 25 A) and thirdly
These changes and extensive PKZM4-32-CB (adjustable 24 - 32 A).
testing have made it possible
for the switches to be approved The SCCR (short-circuit current rating) of the circuit-breakers is
as fully-fledged circuit-breakers 65 kA for 480Y/277 V and 22 kA for 600Y/347 V, and they have a
to UL 489 / CSA C22.2-5.09. device width of only 55 mm. They are consequently turning into
On the PKZM4-..-CB, the genuine problem solvers thanks to the high SCCR and suitability
current flow direction can be for 600Y/347 V.
set as required – as is the case
with the entire Eaton range of
circuit-breakers.
SolutionS 22 News 7
NEWS +++ NEWS +++ NEWS
8 SolutionS 22 News
APPLICATION
SmartWire-DT™
Güstrow Vocational College Uses
SmartWire-DT™ Model Installation
In order ensure the long-term
competitiveness of Germany as a
place to do business, it is important
to work at the base, i.e. ensure that
a high standard of education is in
place. What, however, makes up a
the feedback function of the
good education? Mechatronics trainees at the Güstrow contactors to activate control
vocational college HIS (Mecklenburg-Vorpommern) signal lamps via SmartWire-
define good education as follows: “A good education is DT. This training step is used
to demonstrate the scanning
based in practice, combining theoretical knowledge with of contactor states and allows
practical application and giving trainees a wide range of comparisons of the actual and
skills and abilities.” target configuration.
SolutionS 22 9
APPLICATION
Today’s parabolic trough power plants use either steam, an area of 600 x 600 km would be enough to cover the total
thermal oil or liquid salt as a circulating heat transfer world’s energy requirement. Large desert regions in northern and
southern Africa, in Mexico, the Arabian Peninsula, as well as some
medium. However, these types of media have the
regions of India and Australia would be suitable for locating large
disadvantage that they circulate in the solar field at high power stations.
pressure. In the event of a leak therefore both persons
and the environment are at risk. For example, around Airlight Energy chose air as the absorber medium and can thus
make use of two particular benefits: Air enables temperatures
one million liters of thermal oil are used for a 50 MW of over 600° C to be reached, and also the use of air as the
power station. heat transfer medium provides the option of storing the energy
recovered in a store filled with pebbles. At night the flow direction
The Swiss company Airlight Energy Manufacturing SA based in is thus simply reversed and the stored heat is taken from the
Biasca designed quite a revolutionary concept for how electrical pebbles. In this way, solar energy can be generated as needed.
energy can be generated from the sun in future using parabolic
trough power plants – in an environmentally safe way and with With this development, Airlight Energy is working to achieve
a high level of personal safety. Based on current calculations, technological simplicity, reduced costs and to increase the overall
10 SolutionS 22
INfO
The Company: www.airlightenergy.com Airlight Energy Holding SA and pursues the aim of finally being
its subsidiary Airlight Energy able to create an environmentally
Manufacturing SA, based in friendly and economical system
Products: PLSM miniature circuit-breaker Biasca/Switzerland was founded of producing electricity from solar
PFIM residual current circuit-breaker in January 2007 by five Swiss energy. The project is supported
private investors who financed the by the Swiss Federal Office of
initial development phase. Another Energy.
Quicklink ID: ES2208 [www.moeller.net] investor joined the company
in May 2007. Airlight Energy
efficiency of the parabolic trough power plants. Andrea Pedretti, High innovation partnered by specialists
head of technological development at Airlight Energy, explained
that the basic idea arose in a phone call from a student in As an additional step, Airlight Energy developed its own supporting
Australia, who asked how it might be possible to use membranes structure: The use of light precast concrete elements on site
for solar collectors. significantly eliminated the maintenance work required. This allows
the supporting structures to be rotated on the foundation with
very little energy required. The mirror can track the position of the
Virtually perfect parabola sun precisely at any time thus ensuring optimum use of the sun’s
radiation. Data from NASA as well as from meteorological stations
The suggestion proposed in the form of a question gave the is used and evaluated in the main computers in order to calculate
initial spark: A parabolic reflector could be built from a coated, the optimum inclination of the collector. At wind speeds over
expandable membrane made from Mylar film. This enables 25 m/s, the collector is moved into the safe horizontal position.
solar energy to be produced reliably and cost-effectively in
power stations. The basic concept included the simple idea The R & D work is partnered by specialists from the SUPSI
of using air pressure to shape a foil fixed at both ends into a technical university in Tessin, the Swiss Federal Institute of
“perfect” curvature. However, the air pressure applied to the Technology Zurich (ETHZ), as well as the Paul Scherrer Institute.
reflector foil required an enclosed space, i.e. a cover foil that The project is also supported by the Swiss Federal Office of Energy.
spanned over the collector. The pressure chamber thus formed
is pressurized to a few millibars using a variable speed fan. A test programme is currently being completed at the installation
The cover foil is made from a transparent, low refractive ETFE site of the 3rd prototype in Biasca, where the relevant data is
(ethylene tetrafluoroethylene) material offering high light and UV also being collected and the mathematical models validated. All
permeability as well as a low tare weight. A silicon fiber glass essential indicators such as temperatures in the collector and
fabric is tensioned onto the base structure to thus produce a in the storage bed are recorded, documented and visualized on
2-volume-pillow system. Thanks to further innovations from screens in the control room.
Airlight Energy it was possible to achieve an almost perfect
parabolic curve that ensures a high radiation concentration onto
the receiver. Reliable miniature circuit-breakers and
residual current devices
SolutionS 22 11
APPLICATION
Pack It
SmartWire-DT™ Controls Packaging Machines
Gillenkirch Packaging Systems is a family business based in Dinslaken that develops and produces sorting and
packaging plants and systems for the fruit and vegetable market worldwide, such as for the processing or freezing of
potatoes, onions, carrots, tomatoes, apples or citrus fruits. Gillenkirch machines and systems are offered as bespoke
customer solutions and meet rigorous requirements in terms of capacity and hygiene. Specially developed processes
ensure that products are handled quickly and gently and thus secure product quality during the entire
packaging process.
Optimally efficient
switchboard design:
All motor starters were snap fitted
to the vertically installed busbar
system using busbar adapters. The
control system was implemented
with SmartWire-DT. The otherwise
standard terminal strip was not
required since all motors were
connected directly to the motor
starter.
SolutionS 22
12
INfO
The Company: www.gillenkirch.com Gillenkirch Packaging Systems is taking up the challenge
GmbH is a family business of offering top products for
based in Dinslaken (North Rhine- worldwide use with customized
Products: SmartWire-DT, PKE motor-protective circuit-breaker Westphalia). Since the seventies products and systems.
MSC motor starter, XC200 modular PLC complete sorting and packaging
M-Max frequency inverter systems have been developed
and manufactured for the fruit
and vegetable industry, with
Quicklink ID: ES2209 [www.moeller.net] applications worldwide. Gillenkirch
The latest example is an installation designed as a complete the connection between motor starters and SmartWire-DT – thus
solution for a Swiss customer. The potatoes supplied locally by eliminating the need to use a screwdriver 3240 times, as required
the growers are first tipped into a silo, from where conveyor for 270 drives using the conventional method.
belts take them to a washer and move them finally to a polishing
and drying system. Before the potatoes are stored in the silo, The combined assembly of the control cables with the power
they are put through a quality control. The potatoes are taken supply in the SmartWire-DT system also results in an increased
from the different silos for particular varieties and fed to a scales Performance Level as the energy for the individual drive is isolated
and packaging machine. The entire process is controlled and twice as it were in the event of an emergency-stop: A 65 A
monitored by a process control system. contactor disconnects the supply conductor to the 400 V AC main
distribution busbar and the motor contactor is also switched off
The core of the control system is made up of an 8 meter wide by disconnecting the power supply from the 24 V DC network of
switchboard containing the following Eaton components: circuit- SmartWire-DT.
breakers and motor-protective circuit-breakers, contactors,
compact PLCs, the SmartWire-DT connection and communication Thanks to the high short-circuit rating of the PKE motor-protective
system as well as frequency inverters and soft starters. circuit-breakers, an additional back-up fuse was unnecessary. The
consistent use of the bus systems down to the field level and
The open-loop and closed-loop control of system sections is the extensive modular design result in a significant reduction in
implemented with the XC200 modular PLC which is connected costs – equally in terms of design, mounting and quotations as
to the system via its integrated Ethernet and CANopen interface. well as in terms of shorter delivery times.
The data is exchanged with the touch displays and the higher-
level control system via Ethernet. The fieldbus level is addressed
via CANopen. As a special feature, all 270 contactor-controlled
drives use PKE/SmartWire-DT to provide current measuring for
preventative maintenance. In order to shorten installation times on
PKE motor-protective circuit-
site, all motor feeders are fitted with plugs which can be plugged
onto the contactor directly without any intermediate terminal strip.
breakers with SmartWire-DT™
Gillenkirch developed a metal support especially designed for
technology
fastening the motor cables in the switchboard so that 60 motor Motor starter combinations with PKE together with SmartWire-
starters can be assembled compactly DT allow integration into the automation world: The modular
in each section. The modular approach PKE-SWD-32 COM interface is used to implement different
not only reduces mounting times in the signalling functions such as diagnostics, status or overload signals,
workshop, but also simplifies the writing of as well as the actual current flow of the PKE. The data can be
future quotations. transferred directly to the controller and is made available to the
entire installation. The data transparency thus created increases
In order to work with as many identical the efficiency and operational reliability of the drives in the area
parts as possible when assembling the of the motor-protective circuit-breaker. PKEs – integrated in the
switchboards, Eaton’s value added logistics SmartWire-DT system – increase system availability by transferring
fitted the motor starters with a standard process data, reduce the wiring in the control circuit and save
contactor size on the busbar. time-consuming troubleshooting during commissioning and
maintenance.
The exchangeable bimetal block of the
PKE could be fitted at a later time after the
motor list is approved by the end customer.
This enables the drives to be pre-installed –
even without a knowledge of the exact CONCLUSION
current values – so that the system could
be shipped quickly to the Swiss customer. Oscar Manteca, partner at Gillenkirch had this to say: “We
set high standards in quality, reliability and service for all
All controlled drives are implemented system sections. Innovations such as SmartWire-DT help us
via frequency inverters of the M-MAX to continuously further develop our product range and keep
series, which are also connected to the it in line with the latest state-of-the-art. As we were able
modular PLC via CANopen. These have to impressively reduce the installation times, it was even
the task of optimally adapting the conveyor possible to supply the system described here before the
speeds and water volumes to the relevant agreed date. The integrated current measuring of all loads
production process. enables the direct signalling of different load states on the
process control system. The system operator carries out any
The PKE enhanced with SmartWire-DT optimization online and thus avoids production downtimes.
enables all switching states of the We are very satisfied with the new SmartWire-DT solution.”
contactors and motor-protective circuit-
breakers to be signalled and shown in the
higher-level production control system
without the need for complex wiring. Pre-
assembled cables/connectors are used for
SolutionS 22 13
APPLICATION
Mediterranean Lifestyle
Eaton SmartWire-DT™ automates a grape pressing system
for Italian wine production
It’s a well-known fact that wine, bread and olive oil are some of the essential foods in southern countries like Italy –
things that help to make up the Mediterranean lifestyle. Italy is one of the major wine producing countries in Europe,
with more than 60 million hectoliters of wine being produced in an area of over 908,000 hectares (as at 2000). The
Italian company Pimmel Automazioni uses Eaton automation technology to ensure the high level of quality in
wine production.
Pimmel S.r.l., an Italian company based in Gaiarine Treviso, started highly specialized electrical systems and automation solutions
in 1986 with heating control concepts for wine production and for for industrial and building applications. Nowadays, Pimmel meets
the production of sparkling wine in autoclaves. Control systems every customer need, from the traditional electrical system up to
were also developed for other phases of the wine making process the management of electrical systems and machines equipped
such as feeding, grape pressing, the filtering and stabilizing of with high-tech automation controllers and personal computers.
production processes. The company now primarily develops
14 SolutionS 22
INfO
The Company: www.pimmel.it Pimmel S.r.l., an Italian company in the production process. The
based in Gaiarine Treviso, was company guarantees top product
founded in 1987 and primarily quality standards through heavy
Products: SmartWire-DT, operates in the field of highly investments in new production
HMI/PLC XV-102, specialized electrical systems technologies. It also offers
SLX and M-Max frequency inverters and automation solutions. The excellent pre-sales and post-sales
company covers here both the services. Moreover, Pimmel
industrial and the building sector. fosters an optimum working
Quicklink ID: ES2210 [www.moeller.net] With its extensive know-how environment for its keen and
Pimmel offers fully developed conscientious employees as well
solutions on the market that as the further development of a
meet virtually every requirement quality culture.
The main control panel manages the entire power section for
the stemmer-crusher machines and those for stalk and vinasse
extraction. The three secondary panels house remote I/O
stations which control the electropneumatic valves of the product
sorting section and the mashing and sanitization section. The
communication between the main panel and the three peripheral
panels is implemented via CANopen.
Users are impressed by the very simple SmartWire-DT
Pimmel has already been relying on the automation devices of technology: Without any additional and special automation know-
Moeller and Micro Innovation for several years. Both companies how, every slave on the SmartWire-DT line can be automatically
now belong to Eaton, a leading global power management assigned an address on the gateway at the push of a button, in
company worldwide. Pimmel uses the remote I/Os of the XI/ the order of the slaves connected. The individual slaves, such as
ON series, HMI/PLCs of the XV series, as well as low-voltage contactors or indicator lights are not activated until the address
switchgear such as circuit-breakers and motor starters. is called. The maximum length of the SmartWire-DT bus is 600
meters inside or outside of the switching cabinet, connecting
Inside the main panel, a XION remote I/O station is used for the up to 99 slaves. Pimmel was also able to considerably simplify
acquisition and management of all the signals coming from the all wiring and testing processes for the automation of its grape
process. The higher rated motors above 7.5 kW are fed from SLX press plant – thanks to the flexible and easy-to-use SmartWire-
frequency inverters, while M-MAX frequency inverters and DS4 DT communication system. This includes clear status LEDs that
soft starters are used for all the other smaller motors. are integrated in all connected SmartWire-DT slaves. Pimmel
customers, whether from Italy, Europe or overseas, gave an
Pimmel also chose Eaton’s SmartWire-DT intelligent extremely positive response to the use of SmartWire-DT.
communication system for switchgear and control circuit devices.
All motors and the pushbutton actuator field on the operator
panel are controlled via SmartWire-DT, since the key benefit
of SmartWire-DT results from the elimination of control circuit
wiring and simpler commissioning and engineering. Several
SolutionS 22 15
APPLICATION
Photovoltaic Roofs
Always Tracking and Facing the Sun
Farmbau Fertigsysteme is a company that has now developed the Vario Sun House,
a house with an adjustable photovoltaic roof, having already developed the rotatable
photovoltaic Sun House that fully follows the position of the sun. The Vario Sun
House follows the course of the sun on two axes – the inclination and the cardinal
direction. Unlike the rotatable Sun House, the building stays in the same position
and only the roof changes its angle. The Vario Sun House is either supplied as
a bungalow with a flat roof and roof garden or with a second penthouse floor
and roof garden area that is easier to integrate. For all its control components and
corresponding automation software Farmbau relies on top quality and cost-efficient
technologies from Eaton.
16
INfO
The Company: www.farmbau.eu Farmbau Fertigsysteme GmbH adapted for office buildings, halls
is based in Langenburg and was and private homes. Today the
founded in 1997 by Wolfgang Sun House and the Vario Sun
Products: Touch display PLC Maier. Success started with round House now represent milestones.
easy800 control relay reinforced concrete tanks, for Farmbau places importance on its
XV100 visualization, Galileo which an infinitely variable round own know-how, ranging from the
shell was developed. Farm shed pre-assembly plant in Insingen,
buildings made from thermally the planning office, the statics
Quicklink ID: ES2211 [www.moeller.net] insulated concrete sandwich panel department, right through to the
structures represent another competent team, that offers the
source of business. These were state-of-the-art building.
gradually optimized and also
Photovoltaic systems use virtually every ray of the sun to turn Users value the tried and trusted easy800 I/O modules due
its energy to electricity and thus to financial benefit. Buildings to their simple networking capability: This allows up to seven
with a monopitch roof construction produce a large usable area modules to be connected on the XV panel via the easyNet, thus
for installing modules. The autotracking of the photovoltaic creating up to 280 I/Os. Their small standard front dimensions
area will then obviously produce a higher yield. With Farmhaus enable them to be mounted in subdistribution systems. They are
prefabricated systems, owners themselves decide whether the available in AC and DC versions that can also be used together.
roof is to be fitted with standard, high performance or partially The maximum expansion in the easyNet is up to 1000 meters.
transparent glass modules, thus determining the possible financial
yield. Farmhaus offers the Vario Sun House in a range of sizes and
with different features. Visualization with Galileo
The entire roof area of the Vario roof is moved hydraulically using Galileo is an easy-to-learn, and nevertheless powerful and
four cylinders. A lattice girder system transfers the static forces comprehensive project design environment, ideally suited for
into the four fulcrums. Two cylinders are moved in on each all machine and process-oriented applications in system and
fulcrum and stabilize the system. The other two cylinders tilt the machine building. With its non-sector specific design, Galileo
roof according to the position of the sun, following the cardinal offers seamless project design for all graphical operator units
direction in three stages, east, south and west. from the Eaton HMI product range as well as for PC single-user
solutions. Galileo always provides the project designer with
The building envelope is state-of-the-art: effective thermal the full functionality without any graduated restrictions on tags
insulation, modern heating systems, unrestricted scope for design (variables) or screens, according to the performance specifications
and a square ground plan for optimum room utilization with small of the panel used.
exterior wall areas. The photovoltaic roof above the building also
protects the roof garden and creates additional usable space. Galileo can be connected simply and safely to both the control
level or the office world. With this full range of functions it is
possible to fulfill virtually any wish: Drag & drop positioning
(wysiwyg) of the objects, simple object parameterization,
enhanced password handling with complex password and aging
function, comprehensive recipe handling, alarm handling (with
time stamp, history and diagnostics support with picture display),
convenient series assignment of texts and pictures to variables,
many graphical objects (such as bar graph, slide adjuster, graph
plotter, curve chart, camera etc.), dynamic switching of units of
measure, direct printing on the panel (reports, forms), import of
15 different picture formats, simple import of PLC tags, online
language change, Unicode support (also Asian character sets), text
import/export in XML format (e.g. Excel).
CONCLUSION
SolutionS 22 17
APPLICATION
Pico Breweries
Brewing Beer Yourself
Beer is a drink enjoyed all over the world. It has a tradition that goes back centuries. In Germany, the use of pure
ingredients for top quality brewing was ensured very early on with the Bavarian Purity Law of 1516, which stipulated
that only water, hops and the malt produced from barley could be used in the process. Whilst beer is currently
enjoying an increase in demand, it is nevertheless produced as a bulk product. However, many beer lovers appreciate
a more individual taste. This is why Pico brewing systems allow you to brew virtually any beer yourself using the same
methods as the small craft breweries. Highly reliable Eaton components are used for the visualization, operation and
control of the Pico brewing systems.
18 SolutionS 22
INfO
The Company: www.picobier.de The Tuttlingen-based engineering its employees. The construction of
office ProDesign GmbH was compact brewing systems for the
founded in 2007 and designs catering sector was an additional,
Products: Touch display PLC XV100 and develops (special) machines and yet important and constantly
xSoft CoDeSys as well as complete production growing area of the company.
systems, particularly in the food
and medical technology sectors.
Quicklink ID: ES2212 [www.moeller.net] Its development, design and
production know-how are based on
the many years of experience of
Galileo: Eaton’s interactive visualization tool is an easy-to-learn An easy800 can be connected simply and conveniently to the
and nevertheless powerful and comprehensive project design panels of the XV series via easyNet. The CAN-based protocol
environment. With its non-sector specific design, Galileo offers is event-triggered and also offers a very high transfer speed
seamless project design for all graphical operator units from the even with low baud rates. On the face of it, the idea of using
Eaton HMI product range as well as for PC single-user solutions. an easy800 for the I/O level of the Pico brewing systems
Galileo always provides the project designer with the full seems somewhat unconventional, since the easy800 itself is
functionality without any graduated restrictions on tags (variables) an intelligent control relay. However, the easy800 offers some
or screens, according to the performance specifications of the impressive benefits: An excellent price/performance ratio, 12
panel used. inputs (of which four can be used as analog inputs), 8 outputs
(of which one can be used as an optional analog output), high-
CoDeSys Target visualization: For the visualization objects of speed inputs up to 5 KHz (high-speed counters, frequency
a project the CoDeSys programming system creates ST code measuring, incremental encoders) and last but not least intelligent
(structured text) which can be loaded onto the controller together preprocessing.
with other program blocks. If the functions are supported
correctly, the visualization can be started directly on the controller.
CONCLUSION
SolutionS 22 19
APPLICATION
The company Dipl.-Ing. Kögel & Ernst & Co. GmbH Kögel & Ernst operates in the field of repair and maintenance of
based in Sinzheim is fitting Eaton’s SmartWire-DT in its electric motors, generators, servo drives, lifting equipment, pumps
(drives) as well as in the construction of transformer stations
own motor and pump test benches which it uses for and industrial controls (energy / automation technology). The
in-house requirements. The SmartWire-DT connection motor and pump test bench designed as a showcase installation
and communication system is used for controlling the successfully handled a wide range of test tasks. Different rotary
converter sets and a rotary transformer are switched alternatively
test bench. In addition to the basic functions, the test to a test outlet. The voltage, current and frequency are measured
bench is said to also serve as a showcase installation of at the test outlet itself. Flow and pressure are additionally
the in-house panel building department. The test bench measured on the pump test bench at six different measuring
sections. The pump test bench is designed for machines up to
can thus also be presented to potential customers as an
1200 kW.
example of “state of the art” efficient panel building. At
present SmartWire-DT is already being used to evaluate The showcase installation has a decentralized structure. The
analog values (currents and load) in the PLC from NZM2 control panel with the SmartWire-DT components is thus located
directly at the converter sets on the upper floor, thus allowing
circuit-breakers and PKE electronic motor-protective short power connections between these and the control panel.
circuit-breakers. The control is implemented via SmartWire-DT with a Profibus
interface to the central PLC, and a touch panel is connected
via Ethernet. The test stations are located in a hall on the
ground floor, the pump test bench is located in the covered
courtyard area.
20 SolutionS 22
INfO
The Company: www.koegel-ernst.de Lukas Kögel and Wolfgang The company has developed to
Ernst founded the company become a competence center
“Elektromaschinenbau Dipl.-Ing. in the central Baden area for
Products: SmartWire-DT, Kögel & Ernst” in Baden-Oos in customer-oriented solutions for
HMI/PLC XV-102, 1955. At the beginning of 1994, drive engineering with motors,
SLX and M-Max frequency inverter the founders handed over all pumps, system building, frequency
company shares to Hannes Kögel, inverters, transformer stations and
who assumes sole corporate panel building, control engineering
Quicklink ID: ES2213 [www.moeller.net] management. Kögel & Ernst, and automation.
based in Sinzheim, has been
authorized for a long time to
repair explosion proof machines.
Kögel & Ernst chooses its main suppliers carefully and negotiates
trusted and long-standing collaborations as well as a continuous
transfer of know-how regarding technical developments. The
fitting of SmartWire-DT in its motor and pump test bench was
therefore a logical step for Kögel & Ernst. For this various
DILM contactors, NZM circuit-breakers and PKE electronic
motor-protective circuit-breakers were used. These all have a
SmartWire-DT connection.
SolutionS 22 21
APPLICATION
Münsterland Brewery
xEnergy Ensures Optimum Availability
The Rolinck brewery based in Steinfurt can look back on a long tradition: The clarinetist
Alexander Rolinck (1782-1849) was appointed to court musician and cup bearer of
Prince Ludwig of Bentheim-Steinfurt in 1800. From 1820 onwards, he dedicated his
life to his new passion – the brewing of beer. In order to meet the requirements of the
continuously growing production process, a new and highly reliable energy distribution
system was critical. xEnergy was chosen with its high level of availability.
Since the founding of the brewery there have naturally been production plant. Whilst the BBC
several changes and new products, in addition to the main brand power distribution system in place
of smooth bitter Rolinck Pilsener, which is still on offer. Today the at the Rolinck plant in Burgsteinfurt
traditional brewery’s range now includes alcohol-free pilsner, Alex since 1974 still supplied power
Rolinck fine lager beer, a beer cola mix (Bastard) and the calorie for the production machines, it
reduced Rolinck Radler shandy beer. With these brands, the was increasingly more difficult
brewery is able to meet the changing demands of its customers to connect new consumers, let
in terms of quality and taste. Rolinck has been part of the alone ensure the long-term 24h availability of the plant. Additional
Krombacher brewery since 2007 and not only brews its regional production machines ultimately made it necessary to install a new
Westphalian regional beer. All Krombacher bottles destined for power distribution system. The old installation was designed as
export are bottled at Rolinck, and this includes the share of malt a TN-C system. Today many consumers in the production area
beer which Krombacher sells in collaboration with other breweries have a 5-pole connection. “On the other hand, old machines
under the brand name Vitamalz. (power outgoers) are still designed as four-pole systems with a
conventional PEN conductor,” Markus Wietkamp, head of electrical
installations at Rolinck, explained. For this reason, the new xEnergy
System installation with no delays system is designed as a TN-C-S system with a PEN and a PE rail.
The aim is to achieve a gradual changeover to an EMC compliant
An extended product portfolio as well the increased production installation in the TN-S system. For this purpose, the PEN bridge
volume called for new concepts in the energy supply of the was removed and the PEN labeled as a neutral rail.
22 SolutionS 22
INfO
The Companies: www.rolinck.de Rolinck has been brewing pilsner in Anton Uhlenbrock GmbH based
www.uhlenbrock.org Steinfurt/Munsterland since 1875, in Steinfurt is a company serving
and this is still the main brand of the industrial sector for industrial
Products: xEnergy low-voltage power distribution system the brewery today. In January 2007, installations and machine
P switch-disconnector the A. Rolinck private brewery building. Uhlenbrock handles all
was sold to Krombacher, one of project phases such as planning,
the largest private breweries in commissioning, maintenance and
Quicklink ID: ES2214 [www.moeller.net] Germany. modernization.
SolutionS 22 23
APPLICATION
CONCLUSION
Erecting the drilling rigs for creating the freeze bore holes
24 SolutionS 22
INfO
The Company: www.thyssen-schachtbau.de Thyssen Schachtbau GmbH,
Kh. Pimeno-Cherny Kotelnikovsky
municipal district, RUS Volgograd
Services/Products: After Sales Service, Region
DM4 frequency inverter
SolutionS 22 25
APPLICATION
“We supplied the cruise ship with more than 20 double-conversion “Eaton’s answer is double-conversion online topology. All our
online UPSs, ranging from 1 kVA to 350 kVA. The UPS delivery is marine UPSs incorporate this; it can protect critical marine
without doubt the largest in our 40-year history of providing the equipment from all types of power interruptions that may occur in
marine industry with uninterruptible power systems,” says Rauli the ship’s supply network. To guarantee continuous, high quality
Lehtonen, Sales Manager at Eaton Power Quality. power to the most critical loads, the UPSs can be configured to
provide parallel redundancy,” Lehtonen says.
“The unparalleled size of the vessel and the variety of high-tech
applications on board posed remarkable challenges in terms of “Every Eaton marine UPS also has a hardened mechanical design,
power supply. One-hundred-percent reliable, continuous and shock absorbers and a drip-proof cover. What’s more, they also
clean power has to be guaranteed for the ship’s safety and employ the same global technical platform and the same core
cruising-related applications as well as commercial applications components as our standard UPSs. This enables the use of
that affect customer satisfaction the most. Our customer cannot common spare parts and accessories and leads to effortless
risk losing power in applications such as navigation equipment system upgrading, maintenance and service.”
and emergency power and lighting. A loss of load would result in
highly dangerous situations at sea,” explains Lehtonen. On board Oasis of the Seas, Eaton’s UPS systems protect critical
applications including emergency lighting, navigation equipment,
ship automation and HVAC applications as well as casinos,
Reliable power leads to an enjoyable experience theatres and other entertainment venues against disruptive power
interruptions. The delivery consisted of a set of Eaton 9395, 9390,
Conditions on board a ship differ significantly from those on 9355 and 9155 marine UPSs.
shore: the power distribution network is ungrounded, and the
electricity generated by the ship’s engines is not of uniform “The project was a new milestone for us, as it saw the installation
quality. That is why power needs to be double-converted for all of the largest marine UPS we have ever delivered – the 350 kVA
critical applications. Ship vibration, shocks, inclination, temperature Eaton 9395 Marine UPS. The two 9395s on board Oasis of the
variation and very limited space present further challenges for the Seas protect the most business-critical applications, including
setup. In addition, every device securing safety and cruise-related computer systems and energy-intensive cash registers,” Lehtonen
systems needs to meet the stringent requirements set by various explains.
classification organisations.
26 SolutionS 22
INfO
The Company: www.eaton.com/powerquality/marine Total power protection for the will also rely on Eaton’s expertise
world’s largest cruise ship. Eaton to secure power distribution
supplied more than 20 double- network on board.
Products: USV 9395, 9390, 9355, 9155 conversion online UPSs for this
giant of the seas. The Oasis’s
sister ship, Allure of the Seas, due
Quicklink ID: ES2216 [www.moeller.net] to be delivered by the end of 2010,
Eaton has a long and trusted partnership with both the owner
and builder of Oasis of the Seas. “We have worked with Eaton
for over 10 years in all of our most demanding cruise ship Giant of the seas in a nutshell
construction projects,” says System Coordinator Ville Talsi of
shipbuilding group STX Europe, Turku, Finland. “Their high quality • Ordered in February 2006, maiden voyage 5 December 2009
products and field services around the world have guaranteed • Length 361 m, width 66 m, height 72 m above sea level
an enjoyable cruise experience for passengers and uninterrupted (at highest point), gross tonnage 225,000
working for the sophisticated technology on board our ships.”
• Capacity up to 6,360 guests and 2,100 crew members
Eaton’s power protection solutions are employed in five of the • 16 passenger decks, 2,704 staterooms
Royal Caribbean International cruise line’s Voyager-class ships • Total power output 97,000 kW, power protection capacity
(completed in 1999–2002), three of its Freedom-class ships 2,000 kVA
(completed in 2006–2008) and in both of its Oasis-class ships.
• First ship to feature the cruise line’s neighbourhood concept of
Oasis of the Seas’ sister ship, Allure of the Seas, is due to be
seven distinct themed areas
completed in late 2010.
• Cruises the Caribbean from its home port in Fort Lauderdale,
Florida, US
• Sister ship Allure of the Seas due to be launched at
the end of 2010
• Founded in 1968, Royal Caribbean International is a global
cruise brand with 21 ships currently in service and one under
construction. The line also offers land-based cruise tour
packages in Alaska, Canada, Dubai, Europe, and Australia and
New Zealand.
SolutionS 22 27
APPLICATION
Battery
Eaton Hybrid System Controls
Supplier/OEM
Hybrid Drive Unit
Inverter/Controls
Hybrid
Control Module
E-Mobility –
Eaton’s “Green Solutions”
Over 50 Million Kilometers with Eaton Hybrid Drives
Since April 2008, Moeller has been a part of the Eaton achieved by vehicles that have to stop and start frequently, such
Electrical Sector of the Eaton Corporation. With Moeller, as city buses, refuse trucks, medium-sized delivery and off-road
vehicles, as well as other large vehicles. In order to develop an
Eaton has considerably expanded its product portfolio so
optimum hybrid solution for these utility vehicles, development
that almost half of the entire turnover was achieved in engineers at Eaton created exact motion profiles of customer
the Electrical Sector with 5.9 billion US dollars in 2009. vehicles. Using this data it was possible for Eaton to develop
51 percent of total turnover is generated in the Industrial several different hybrid drive concepts: a hybrid electric, a plug-in
hybrid electric, and a hybrid hydraulic drive.
Sector with the Aerospace, Hydraulics and Vehicle
businesses. What might not be common knowledge
in Europe: Eaton is the only manufacturer in the world Hybrid electric system
to offer a complete range of hybrid systems for utility Hybrid electric drive systems have shown themselves to
vehicles and for buses. be ideal for vehicles with superstructures such as a crane,
which is normally driven by the idling combustion engine via a
Eaton started with the development of hybrid drive systems hydraulic system. Switching off the engine when the vehicle
twenty years ago, long before the hybrid drive system was a is at a standstill is one of the best ways to reduce both fuel
commonly established term. Today, the hybrid drive, as a generic consumption and system emissions equally. As soon as the
term for drive concepts with two different energy sources, is a auxiliary power is almost used up, the engine is automatically
leading technology for reducing the consumption and emission restarted to recharge the system accumulators in less than five
values of automotive vehicles. The greatest saving potential is minutes.
28 SolutionS 22
INfO
The Company: www.eaton.com/hybrid
Whilst the system accumulators of hybrid electric systems can Eaton’s parallel hybrid system reduces fuel consumption by up to
only be charged using brake operations or via the diesel engine, 35 percent, as well as emissions and noise. It has already been
the vehicles with a charging device – the so-called plug-in hybrid tested worldwide on more than 32 million kilometers. Eaton hybrid
electric system – make it possible to charge the vehicle batteries drive systems also increase the lifespan of the brakes and shorten
at a charging station (EV Quick Charger). the idle times of the combustion engine by up to 87 percent.
Different cities in Europe and Asia have already been using Eaton
Hybrid hydraulic system hybrid systems in their city bus fleets. This includes the buses
of BCI, Foton, Heng Tong, JNP, King Long, Shen Long, Solaris,
Eaton has developed hybrid hydraulic applications specially for Yutong and Zhongtong in the bus sector. Companies such as DHL,
frequent starting and stopping in order to meet the requirements FedEx, UPS, Coca-Cola Enterprises, PepsiCo and Wal-Mart are
of the different truck sectors. The system monitors and stores using delivery vehicles with Eaton hybrid systems. In addition to
brake energy of the vehicle and then use it for acceleration. this, the transporters of many service and telecommunications
companies in North America rely on Eaton hybrid drive systems.
Eaton calls its hybrid hydraulic technology Hydraulic Launch Some of Eaton’s customers in the utility vehicle sector include
Assist™ or HLA®, which consists of a “parallel” hybrid system as Daimler, Iveco/ Fiat, DAF/ Leyland, Freightliner, Ford, International,
it supplements the conventional powertrain in order to reduce fuel Kenworth and Peterbilt.
consumption. On a refuse truck, that stops and then continues
travelling every 25 or 30 meters, the HLA system basically In collaboration with all these customers and over a period of
recycles a major part of the brake energy and thus reduces the ten years, Eaton has documented the drive performance of over
fuel consumption of the engine. In addition to this, the lifespan 2400 delivery vehicles, buses and other utility vehicles that are
of the brakes has more than doubled thanks to the regeneration fitted worldwide with Eaton hybrid systems. In all, over 50 million
of the brake power, and the vehicle can make up to 50 additional kilometers have been driven with Eaton hybrid systems and
stops in one shift. All this increases the viability for the vehicle around 4.5. million liters of fuel and 12,000 tons of CO² have been
fleet owner. saved.
SolutionS 22 29
INfO BOARD
Eaton Live:
Circuit-Breakers for
Non-Motor Loads Germany
23.11. - 25.11.2010 | SPS/IPC/Drives, Nuremberg
23.03. - 25.03.2011 | Eltefa, Stuttgart
PKZM4 up to 32 A for the North American Market
04.04. - 08.04.2011 | Hannover Fair, Hannover
The export of electrical equipment for machines and plants 12.05. - 18.05.2011 | Intersolar, Munich
often proves to be a very difficult undertaking for European 08.06. - 10.06.2011 | Interpack, Düsseldorf
manufacturers, particularly with exports to North America. This
is due to the many legal and safety-related requirements such
as those of the NEC or CEC. For example, UL508 forbids the Europe
use in North America of motor-protective circuit-breakers for the
protection of cables and conductors, or for the short-circuit protection of frequency inverters. 09.11. - 11.11.2010 | ELEKTROTECHNIKA,
Ostrava
The brochure provides comprehensive background information on these issues and shows the
benefits of using the new PKZM4-…-CB circuit-breaker as the solution. 17.11. - 19.11.2010 | Elektrotechniek, Brussels
07.12. - 09.12.2010 | Elektro Vakbeurs
Hardenberg, Hardenberg
Quicklink ID: ES2218
March 2011 | Magyarregula, Budapest
12.04. - 15.04.2011 | Electron, Prague
Eaton OCC-Chopper
Eaton supplied several low-voltage use of capital, enhanced safety,
power distribution systems for the and risk mitigation, are added to
new headquarters of Orange County the paint on the gas tank and on
Choppers (OCC), a company based the fenders.
in Newburgh, New York. As a result OCC has developed an outstanding
of this project, Jason Pohl (senior reputation amongst motorcycle
designer at OCC) developed the manufacturers within a few years
concept for an Eaton PowerChain and has become a worldwide
Management Solutions® Chopper in collaboration with the Eaton project brand name thanks to the documentary TV series “American Chopper“.
team. The wheels with lightning bolt spokes are 3.5 inches wide at the Virtually all OCC models are handmade unique products, for which special
front and 300 mm wide at the rear. The air cleaner features an engraved importance for optimum quality and a unique design. The magazine
Eaton logo, and the coil cover is designed as a circuit breaker, heralding American Iron selected OCC as one of the twelve best motorcycle
Eaton’s lineage as one of the premier circuit breaker manufacturers in the manufacturers in the world.
industry. PowerChain Management Solutions icons, representing the five
key elements of greater reliability, operating cost efficiencies, effective Quicklink ID: ES2218
30 SolutionS 22
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SolutionS 22
The power of fusion.
1874 1886 1893 1899 1906 1908 1911 1962 1963 1983 1990 1998 1999
All of the above are trademarks of Eaton Corporation or its affiliates. Eaton has a license
to use the Westinghouse brand name in Asia Pacific. ©2009 Eaton Corporation.
32 SolutionS 22