Flexible, comprehensive and customized.

Automation solutions for the Glass Industry.

totally integrated
 Your competent partner in
automation
Siemens – a name recognized all over the world. A name Glass is one of the important materials influencing human

that stands for innovation, customer orientation, and global evolution. It impacts people’s daily lives in a very unspec-

competitiveness. Not only for over 400,000 employees and tacular way, but is gaining more and more importance.

millions of customers, but also for hundreds of thousands

The way glass is produced has remained unchanged for
of suppliers and partners in more than 190 countries.
years, but the production process now faces new challenges:

Siemens also embodies the timeless vision of its founder,

The demand is for increased productivity and improved
Werner von Siemens: “Progress serving mankind”.
glass quality, where production costs need to be significantly

Siemens Automation and Drives (A&D) is one of the largest reduced.

groups within Siemens AG. As a technology and market

This requires advanced ideas and innovative solutions. All
leader in automation and drive technology, we are
phases of glass production need to integrate in order to
continually driving forward progress in this field – and
achieve optimum production results. A close cooperation
steadily setting new standards. Siemens A&D offers a
of glass manufacturing companies and automation suppliers
unique, complete range of innovative products, systems,
serves as a base to understand and to solve the
and solutions. Totally Integrated Automation (TIA) and
requirements.
Totally Integrated Power (TIP) form the backbone of our

portfolio – and the basis for customer-specific solutions Finally, the seamless interaction of various solutions –

in the field of automation and energy distribution. energy distribution, automation, field instrumentation and

drives while extensively using the advantages of information

technology – lead to significant advantages.

2
Industry Suite Glass –
plant-wide integrated solution

In the Industry Suite Glass, the worlds of automation and

power engineering merge into one comprehensive and
modular offer for your needs – including the specific services
across the entire life-cycle of your plant.

Industry S
Totally Integrated Automation

Optimization of the complete workflow

With Totally Integrated Automation (TIA),
Siemens is the only supplier of an integrated
range of products and systems for automa-
tion of glass manufacturing to processing –
from raw material to final products. From
the field level and production control level
to the enterprise level. Your benefit: consi-
derably lower life-cycle costs for the plant,
shorter time-to-market and consequent im-
provement of your competitiveness.

Process know-how
Based on comprehensive industry know-how, we implement
process solutions that guarantee optimum fit and maximum
transparency for your plant – while requiring a minimum of
manpower.

Tailor-made energy concepts

With tailor-made energy concepts environmentally friendly
operation of your plant becomes child play – resulting in
sustainable advantages.

Optimize your process with MES solutions

Our MES solutions are essential to enable you to optimize
your processes throughout the plant. They ensure integrated
data transfer – vertically from the field to the enterprise
level and horizontally from your suppliers to your consumer.

3
s for your industry

Basis of the Industry Suite Glass: Totally Integrated

Automation and Totally Integrated Power – plus our compre-
hensive know-how in your industry, from manufacturing
to processing.

Suite Glass
Totally Integrated Power

Power management and distribution

from a single source
On the basis of Totally Integrated Power
(TIP), we implement integrated solutions for
power distribution across all production units
and industrial buildings, from the medium-
voltage supply to the outlet. Equipped with
the same communication standards as Totally
Integrated Automation, all resources – for
automation, power distribution, energy ma-
nagement and building automation – can
be seamlessly integrated and comprehensive
solutions can be implemented in your plant.

Cost-effective drive solutions

Innovative technology, precisely coordinated components
and comprehensive engineering know-how will meet your
requirements – in terms of performance, torque, dynamics,
availability and advanced diagnostics.

Life cycle services

The comprehensive range of services is an efficient lever
ensuring continuous optimum performance of your plants.
With our solutions we cover the entire life-cycle of your
plants – from planning and implementation to modernization
and maintenance.

System integration
In addition to our own established competence and expertise
in the field of system integration we work closely together with
Siemens Solution Partners. The result: a global network of
automation professionals that you can use to your advantage.
Throughout the world, the quality seal of Siemens Solution
Partners has long been a guarantee for world-class services.
Content
Your Partner in Automation .............................. 2

Industry Suite Glass .......................................... 3

Totally Integrated Automation .......................... 4

Process Competence ......................................... 6

Process Control System ..................................... 8

SCADA System ................................................... 10

Manufacturing Execution System ..................... 11

Field Devices .................................................... 12

Industrial Communication ................................ 14

Drive Systems .................................................. 16

Process Instruments and Analytics ................... 18

Industrial Controls ............................................ 22

References ....................................................... 24
 Improve your competitiveness with
Totally Integrated Automation
With Totally Integrated Automation (TIA), Siemens is the only supplier to

offer an integrated portfolio of products and systems for the implemen-

tation of automation solutions. TIA combines Siemens technology and

products with an impressive and unique level of integration into an auto-

mation system. This not only reduces the number of interfaces, but also

ensures maximum data transparency across all levels – from the field,

through the production level to the management level. From the inbound Totally Integrated Automation in the
logistics (batch area) over the process (utilities, hot end, cold end) to the Glass Industry

outbound logistics (further processing). You benefit with TIA throughout Based on Totally Integrated Automation,
we implement solutions that are perfectly
the life-cycle of your plant – from the first planning stages, through tailored to your special requirements in the
Glass Industry and which are characterized
operation to modernization. We offer you a high security of investment
by their excellent integration. In this way,
with the unique transparency and interoperability of our products and TIA makes an essential contribution to the
optimization of your production processes.
systems – by avoiding unnecessary discontinuities in the system.

ERP
Enterprise
Resource
Planning Ethernet

Production Material Plant

MES Order Management Information
Totally Integrated Manufacturing
Management
SIMATIC IT Framework
Manage-
ment

Automation Execution
Systems
Ethernet
Production Equipment
Production Modeler
Detailed
Operations Management Production
Recording Scheduling

SIMATIC NET SINAUT Telecontrol SIMATIC SIMATIC Controllers/

Control Industrial System Software Automation System
Communication

SIMATIC PCS 7
SIMATIC SENTRON
Circuit Breakers Process Control System
Sensors
PROFINET

Industrial
Ethernet
Safety Integrated

PROFIBUS PC-based Automation Field Instru-

mentation/
Analytics

HART
AS-Interface
Building
Technology
KNX/ EIB

GAMMA instabus ECOFAST IP65 SIMOCODE pro SIRIUS

Micro Automation and Distributed Motor Manage- Soft SIMATIC
PROFIBUS PA
Actuator-Sensor Interface Level Automation System ment System Starter Distributed I / O

4
 The answer to growing demands
The Glass Industry is moving in a constant area of tension between
optimum quality, lower costs and shorter time-to-market. Whether you
are a plant operator, system integrator or plant and machine constructor:
the solution to this problem is Totally Integrated Automation.

Advantages for plant operation

Thanks to the system-oriented engineering
environment as well as the integrated com-
munication and diagnostics options of TIA,
your plant will benefit at every stage of the
life-cycle. What is more, the consistency in
the continuing development offers you max-
imum security of investment in the event of
modernization.
Product Specification
Management System
Laboratory Information
Management System
The growing global competition does not stop with the Glass Industry –
quite the opposite. For you as a plant operator, this is expressed in a
keenly fought price war and in the need to bring new products into the
market in ever shorter cycles. At the same time, the legal obligations are
increasing – as is the complexity within your plants.
Totally Integrated Automation is the foundation for:
Automation solutions tailored perfectly to the specific requirements
Optimized machine and process operation
Protection of investment and intellectual capital
Reduced expenditure on the construction and maintenance of plants.
Advantages for system integration
Growing pressure on the production side, ever shorter product life-cycles,
rising production demands and an ever greater complexity: The end
customer demands made on you as a system integrator are immense.
The demand is for solutions with which you can process your customers
orders more quickly, precisely and economically – from the design to
commissioning.
Totally Integrated Automation is the foundation for:
Shorter time-to-market from the planning to the delivery
Higher system availability and flexibility
Improved quality
Less expense for development and commissioning
Cost savings.

Advantages for the EPC and OEM

As an EPC (Engineering, Procurement & Construction) or OEM (Original
Equipment Manufacturer), you must respond to a continuously rising
SIMATIC HMI SIMOTION SINUMERIK competitive pressure. At the same time, more is being expected of your
Human Machine Motion Control Computer
Interface System Numeric Control solutions all the time. The demands that you must meet are growing
increasingly complex.
Totally Integrated Automation is the foundation for:
Higher quality
Improved system availability
Lower production costs
Shorter time-to-market –
from planning to commissioning on the customer premises
Drive Systems/
SINAMICS SINAMICS SIMODRIVE SINAMICS Greater flexibility.

5
Integrated process solutions for the Glass Industry

Glass, an inorganic solid material that is usually clear or New process technologies are: the continuously fired rege-

translucent, is considered to be a super-cooled liquid rather nerative furnace developed by Friedrich Siemens in 1856,

than a true solid. It solidifies from a molten state into an the revolutionary float process developed by

amorphous rather than a crystalline structure. It is hard and Sir Alastair Pilkington in 1959, as well as new processing

brittle and withstands the effects of wind, rain, and sun. techniques, like the first automatic bottle making machine

invented 1903 by Michael Joseph Owens.

Glass has been used for centuries in various kinds of bottles,

utensils, mirrors, windows, and many other objects. It is To ensure economic success in the glass business, you need

thought to have been first artificially created by man as early top productivity, highest flexibility, maximum safety and the

as 5000 B.C. However, the glass of today has come a long efficient use of resources in all your production processes.

way from the earliest pieces found in Egypt and Mesopotamia This is the only way to meet the demands for fast delivery,

in the 16th century B.C. high and constant quality, and competitive prices.
Typical process areas in glass plants Cooling

Batch After forming, the finished glass product is cooled down.

This takes place in small, medium-sized or up to 170 m long
The quality of the batch determines the quality of the final cool ovens.
product, which is why batch manufacturing must meet the
highest standards at all times. Quality inspection

Furnace Air inclusions, tension or unevenness are detected and sorted

The furnace is the heart of every glass factory – and it's
where the course for quality is defined. Depending on the
quantity of glass to be melted, small continuously working
melters process around 1 ton of ultra-thin glass per day, 300
tons of casting glass per day, 250 to 600 tons of hollow glass
every day or even up to 1000 tons of float glass each day.
Small quantities of glass are usually melted in electrically
heated melters. A greater number of tons per day can be
achieved using recuperative or regenerative heated melters.
These are fueled with fossil fuels like oil and/or gas.
out during the quality control inspection, ensuring the end
products are supplied in the required quality.
Cutting and further processing float glass
On the cutting line, the endless glass band is cut into indi-
vidual glass panels 3.20 m x 6.00 m in size. Depending on
whether the glass is being produced for the automobile,
construction, or furniture industries it is then supplied accor-
dingly to further processing stages, like, e.g. cutting, bending,
drilling, grinding, printing or coating.

Forming
Dependent on the respective end products, various forming
techniques are used in glass production, like for example
Tin bath for float glass
IS machine for hollow glass
TEL or SILAN processes for glass wool
Danner, Schuller or Vello processes for glass tubes
Presses for glass blocks and CRT monitors
Rollers for cast glass and u-shaped glass
Pulling, blowing or spinning processes for glass fibers
Overflow or float for ultra thin glass.

7
 SIMATIC PCS 7: distributed control system for
the Glass Industry – core of Totally Integrated Automation
Siemens automation solution with SIMATIC PCS 7
The Siemens Distributed Control System (DCS) –
SIMATIC® PCS 7, fully integrated into TIA, uses standard
hardware and software components which can easily be
connected to the Management Execution System level
(MES).
PCS 7 offers benefits for the Glass Industry sector such as:
One common engineering tool PCS 7-ES for the complete
process – saves engineering time
One common visualization of all data in all PCS 7 oper-
ators stations with a standard alarm visualization – reduces
production downtimes
Configuration can be controlled from all operator stations.
This minimizes the overhead
Preset function blocks and programs, adapted to different
industry segments, simplify configuration
High-speed automation systems with S7-400 controller
on Ethernet 10/100 Mbps. At the field bus level, PROFIBUS
is provided, both are available with fiber optic, to avoid
any electromagnetic interference
Redundant controller and PROFIBUS communication for
high-availability processes keep the process running and
reduce production downtimes
Field devices are connected to the PROFIBUS DP and PA
Standard and safe remote I/O modules on PROFIBUS DP
ensure reliable transmission and diagnosis of data.
ET 200M remote I/O modules provide a large number of
digital and analog input and output channels. Field devices,
sensors, motors and drives are fully integrated into Totally
Integrated Automation and PCS 7.
Stand-alone systems Production facilities
Scalable from small applications
8
As a result of its modular and open architecture that is based
on selected hardware and software components from the
standard SIMATIC range, SIMATIC PCS 7 can be applied
effectively in small and large plants alike. It allows easy
expansion or system modification (online) to enable
customers to meet the changing production requirements
of their facility.
SIMATIC PCS 7 is scalable from a small single system such
as might be used for a utility or batch plant, up to a distributed
multiuser system with client/server architecture, such as
might be used for automation of a very large production
plant or for groups of connected facilities. Depending on the
plant’s requirements, the user and the planning engineer
can select from various automation systems with graded
performance characteristics.
Incorporate distributed (remote) or central I/Os step by step
or design an optimum architecture for the operator system
from single-user stand-alone stations up to a distributed
multiuser system. Modular engineering and runtime system
software according to the size of the system (scaled by
process objects), configure communication networks and
determine network components to support required levels
of redundancy and availability, extend the functionality
of the operator stations by adding various hardware and
software modules, integrate applications for connecting
SIMATIC PCS 7 to the IT world.
Various plants of a production site
… to the distributed system in client/server
Maximum plant availability, with overall redundancy
through all levels
Availability is one of the most important criteria in glass
production, and consequently the availability of the auto-
mation solution itself plays a key role in the economical
effectiveness of the plant. On the one hand the capital
investment for a glass plant is extremely high, and on the
other hand, any production loss due to shut-down and start-
up operations can imply huge economical loss. Plant shut-
downs must then be avoided. To guarantee the highest
availability of the automation system, all system facettes
have to be taken into consideration: starting from the con-
Redundant OS clients
trollers up to the operator level and including the whole
plant communication networks, from the field to the produc-
tion control level. Depending on each of your specific re-
quirements, environmental and vulnerability aspects of your OS-LAN (Ethernet)
plant, TIA and SIMATIC PCS 7 can provide you the best segment 1
adequate redundancy configuration. Based on a flexible,
comprehensive concept we can offer up to the highest OS server
availability levels, seamlessly integrating all plant levels.
Double redundant Industrial Ethernet plant bus
Asset Management for systematic automation and
maintenance of plants
Siemens offers an efficient solution for plant maintenance: S7-400H
optionally high-availability automation system
SIMATIC PCS 7 Asset Management. The particular highlight with redundant
here is that the new feature is simply integrated into the power supply
SIMATIC PCS 7 process control system. No additional hardware ET 200M
or software tools are required. Plant operators and mainte-
Redundant PROFIBUS DP

nance engineers use the same SIMATIC PCS 7 tools and ET 200M
operator interfaces with information that has been filtered
and prepared for the relevant application area. ET 200M

Complete integration of field devices Redundant

DP/PA Link PROFIBUS PA
SIMATIC PCS 7 is optimized for integration of distributed
field equipment into the process control systems, and is
based on PROFIBUS technology. It supports redundancy and
fail-safe architectures, in addition to online expansions,
and can be used in standard environments or in hazardous Y-Link
areas. The plant can be equipped with conventional Connection of
SIMATIC ET 200 distributed I/Os, or with state-of-the-art, non-redundant
PROFIBUS DP devices
intelligent field devices, such as sensors, actuators or drives. on redundant
PROFIBUS DP

9
 SIMATIC WinCC:
perfect operating and monitoring of glass processing
To produce windshields for cars or glass plates to cover
houses, some as windows, different processing steps are
necessary (cutting, grinding, coating, ...). A solution to fulfill
the process requirements is a modular and flexible SCADA
system. The system has to cover all aspects from operating
only one small machine to a complete plant.
SIMATIC WinCC stands for Windows Control Center. This
innovative visualization software for all machine-oriented
applications are a complete operation and monitoring
package. Open interfaces and wide-range scalability are key
features for nearly all processes.
WinCC offers the following features and customer benefits:
Runs on standard Windows operating systems
Scalable for single and multiuser solutions (redundancy)
for highest flexibility; easily integrated with open inter-
faces to any automation solution and to TIA, saving time
and money
No new automation installation is needed
Remote operation and monitoring by web technology
reduces maintenance costs
WinCC add-ons meet the glass-specific requirements for
documentation, service and maintenance management
and maximize the integration and use of the product.
10
SIMATIC HMI: complete range of operator panels
All SIMATIC operator panels are suitable for all processes in
harsh industrial environments – extremely vibration-resistant,
with safe data storage (flash). They can be operated without
a fan, with IP65 degree of protection on the front and high
electromagnetic compatibility. Open connections to any
controllers and all the necessary interfaces, such as
PROFIBUS DP, MPI, Ethernet for multi panels, are on board.
SIMATIC WinCC flexible:
engineering tool for operator interfaces
Siemens supplies a complete range of coordinated com-
ponents for automation systems from a single source.
SIMATIC WinCC® flexible, the new engineering tool of the
SIMATIC HMI operator interfaces and innovative successor
to ProTool, is an integral part of this world. It offers crucial
advantages. Thanks to the unique consistency in configura-
tion/programming, data management and communication,
the engineering and life cycle costs of an automation solution
are considerably reduced. WinCC flexible can be integrated
into SIMATIC STEP 7, SIMOTION Scout and SIMATIC iMap.
Open for a wide variety of automation systems
Interface options to SIMATIC S7 via PPI, MPI, PROFIBUS DP,
PROFINET and Industrial Ethernet, to controllers from leading
manufacturers via a wide array of drivers, and universal com-
munication via OPC ensure the right interface every time,
no matter what the automation solution.
Operator interfaces on machine level
For operator control and monitoring at machine level,
SIMATIC HMI® offers the complete product range from a
single source: from Push Button Panels, Panels and Multi
Panels to Mobile Panels and PC-based systems. The innovative
hardware and software solutions are scalable not only in
price and performance, but also in the degree of their open-
ness and expandability. As the world market leader, hundreds
of thousands of SIMATIC operator interfaces are in use in a
vast range of applications and industries.
SIMATIC IT:
the basis for tailored MES solutions
SIMATIC IT optimizes production processes. The success story
of Totally Integrated Automation continues with SIMATIC IT.
Full integration, extensive support of all industrial standards
and a component-based solution; that is SIMATIC IT.
With Framework and SIMATIC IT Components, SIMATIC IT
provides a wide portfolio for successful E-manufacturing.
This integrates all production-relevant applications and
activities which enable company-wide communication and
coordination. By the exchange and cooperation of various
factory plants in a Collaborative Manufacturing Execution
Exchange the supply chain requirements can be met effi-
ciently and an increase in performance and production quality
achieved.
SIMATIC IT Framework implements E-manufacturing and
takes care of system integration in a factory, the standardi-
zation of the production throughout the company and the
adaptation of the production processes to the activities of
the supply chain. With its various modules, the framework
takes both production-oriented and IT-oriented perspectives
into account and thus offers a complete production manage-
ment solution.
The production modeler is responsible for the entire manage-
ment of an operation. It synchronizes and coordinates people,
machines and applications. An S95 plant model serves as a
basis. The IT server takes care of component integration with
each other and in an existing IT environment. With the
Production Modeler, for example, it is possible to create a
line configuration of a cutting line graphically from a pre-
fabricated library, parameterize the respective units automa-
tically and generate a configuration file. Changes in the con-
figuration can be converted easily later in the Production
Modeler. The standard products SIMATIC IT Components
provide a number of functions for executing production such
as material tracking and history, preventive maintenance,
batch management and many other components.
11
 SIMATIC S7: the comprehensive range of controllers –
highly reliable and powerful
SIMATIC S7 controllers provide powerful control, network
communication, IT service functionality among other func-
tions. That is why SIMATIC S7 controllers have become the
PLC product with the highest global market share.
SIMATIC S7 controllers can be installed and operated in
different environmental conditions, such as dry tropical, low
temperature, humid tropical etc. As part of Totally Integrated
Automation, a long product life is insured. SIMATIC S7
controllers meet the following standards: DIN, EN, IEC, UL
certification, CSA certification, Class FM1 Sec.2; group A, B,
C, D, temperature group T4 (°<135 °C) and marine classifi-
cation certifications.
12
SIMATIC S7-400: powerful for system solutions in
large-scale installations
Large memory, high quantity of I/Os and an extremely high
speed, they ensure high tech combined with economical
benefits for any automation solution.
SIMATIC S7-400H: high-availability processes without
process stops
Controllers that keep your process running with hardware
redundancy (hot standby). Redundant I/Os and PROFIBUS
complete the high availability functionality.
SIMATIC S7-300: modular and versatile for high-
performance processes
A controller that increases productivity by reducing runtime
cycles by 25–33%. Easy to use with an enhanced memory,
the complete STEP 7 package with complex engineering
tools, like SCL, simplifies operation, maintenance and docu-
mentation. Cost reduction is the major benefit. Reduced
cabinet space requirements save money due to the smaller
CPUs (reduced from 80 mm to 40 mm). Flexibility by using
the micro memory card, especially in any services. Program
updates are easy to perform and a battery is no longer
required.
SIMATIC ET 200:
decentralized field devices for all demands

SIMATIC ET 200 distributed I/O modules can all be connected
to PROFIBUS DP, some of them like ET 200S can even be
connected to PROFINET. They are used to connect various
field devices in the industrial control system, such as drives,
switches, sensors, push buttons, indicator lamps or valve
positioners.
SIMATIC ET 200 offers a complete product range for any
application needs – ET 200M with multi channel design,
ET 200S for bit granular I/Os and function modules, ET 200pro
for high protection in IP65/67 and ET 200eco in a cost-
effective design with IP65 protection.
Advantages
Powerful functional modules provide capabilities far beyond
simple I/Os, including
SIMATIC ET 200S motor starters:
for simple configuration and detailed diagnostics
The communication-capable motor starters of the distributed
I/O system ET 200S offer integrated safety and diagnostic
functions in one device. The motor starter is a pre-wired and
remote-parameterized unit consisting of a circuit breaker,
an electronic overload relay and a contactor or soft-starter,
switching the motors up to 7.5 kW. By means of PROFIBUS
the motor starter reports all diagnoses, for example short
circuit, phase asymmetry, operating current or overload, to
the control system. “High-Feature” motor starters are deployed
wherever failures of systems cause high downtime costs.
SIMATIC ET 200S frequency converter:
completely integrated with distributed I/Os

Motor starters With the ET 200S FC a completely integrated frequency

converter (up to 4 kW) is available for the distributed I/O
Frequency converters
system. The converter controls the speed of asynchronous
Standard and safety I/Os motors steplessly, solves drive tasks ranging from simple
Communication interfaces frequency control through to stringent vector control.

CPUs and intelligent coprocessors.

Modules are designed for quick maintenance to keep
operator costs to a minimum.
Powerful system diagnostics offer troubleshooting infor-
mation at several levels depending on the modules used:
At the I/O station level including bus communication
At the module level
At the channel level for the sensor circuit.
This means that faults are immediately detected and can be
solved easily, resulting in lower service and maintenance
costs.

13
 SIMATIC NET:
industrial communication for plant-wide automation
The business drivers in industrial communication are
improved efficiency and safe data transfer in the plant.
These criteria are crucial to ensuring that process in your
plant works perfectly. This can be achieved by using
open, transparent communication not just on the process
level, but also through ERP systems.
The SIMATIC NET industrial communication products
provide the technology you need to:
Realize true distributed automation
Enable data transparency from the field level through
to the management level
Integrate IT technologies.
Industrial Ethernet: today’s leading local area
and cell network
Across all applications, Ethernet is number one worldwide
in today’s LAN landscape. Ethernet provides important
features and performance characteristics which can
provide many important benefits for your application:
Virtually unlimited communication capabilities and
scalable performance
Company-wide communication thanks to Wide Area
Network (WAN) technologies.
SIMATIC NET provides important additions to traditional
Ethernet technology for use in industrial environments:
Network components designed for use in rugged
industrial environments
High-availability networks using redundancy
Constant monitoring and diagnostics of network
components
Fast on-site industrial cable assembly.
14
SIMATIC NET communications processors:
connecting controllers, computers and notebooks
to Industrial Ethernet
Utilize Industrial Ethernet for programming, monitor-
ing, peer-to-peer communication, connection to IT
Ability to function as Web and FTP server and client
for communication of production information
OPC server included with the communications
processor.
SCALANCE W: industrial mobile communication
Install a plant-wide Ethernet network without running
any wires
Wireless flexibility with the reliability of a wired network
Eliminate wireless “dead zones” with active antenna
diversity – the strongest signal is constantly used
Deterministic data transmission allows time-critical
connections to be realized
Industrial WLAN adheres to the specifications defined
in IEEE 802.11 and Wi-Fi 802.11 in order to enable a
high degree of interoperability
Security wizard enables Wi-Fi Protected Access (WPA)
with encryption for maximum security
Designed for industrial applications with enhanced
resistance to vibration, shock, and environment (IP65,
temperatures from –20 to +60 degrees Celsius) with
options for redundant power supply.
SCALANCE X: switches for Industrial Ethernet
This product family provides a graduated portfolio of indus-
trial switches, some of which feature comprehensive diag-
nostic functions via PROFINET, SNMP and the Web, for a
variety of requirements (e.g. network structure, data rate,
degree of protection, number of ports). These network
components are optimally tuned to one another. They have
been designed for a rough industrial environment and
facilitate consistent, flexible and safe structuring of high-
performance networks.
PROFIBUS: the world’s leading field bus
PROFIBUS network technology provides rich benefits for
almost any application in industrial automation. Devices
such as remote I/Os, drives, controllers, identification sys-
tems, motor starters, weighing & dosing systems, human
machine interfaces etc. are connected via a single cable.
PROFIBUS is primarily used at the field level with interfacing
capabilities downward to the sensor/actuator level as well
as upwards to the production and enterprise levels.
SIMATIC communications processors:
connecting controllers to PROFIBUS
Utilize PROFIBUS for connecting distributed devices,
peer-to-peer communication, and programming
Independent communications coprocessor ensures
consistent scanning of distributed devices regardless
of controller scan
Multiple communication processors can be used to
segment distributed devices
Support for redundant I/Os in conjunction with
redundant controller
OPC server included with the communications
processor.
15
 Drive systems: reliable, precise and efficient
In the whole process of glass production motion control
and drive systems are used for many applications.
SINAMICS: the new drive family
All members of the new SINAMICS drive generation profit
from the same core technology and have the same “look &
feel”. An example are the standard engineering tools –
SIZER to engineer drives and STARTER to commission them.
In addition, all high-power cabinet units of SINAMICS are
equipped with an AOP 30 operator panel with its self-
explanatory menu prompts, which are output in plain text
via the user-friendly graphic display. This permits extremely
simple operator control and diagnostics.
16
Variable-speed operation: exact and efficient
Starting with dosing and mixing in the Batch House, where
speed controlled applications with offset shaft geared
motors will be needed, the MICROMASTER 440 is the best
selection. For higher powers, for instance furnace fans, the
SINAMICS G150 with a range between 75 and 1500 kW
the SINAMICS G150 is the right way.
It controls the speed of low-voltage asynchronous motors,
as they are used for example in the big fans of the glass
plant. The variable-speed operation allows much more
precise flow control than the mechanical concepts as valves
or dampers. In addition, the soft start-up takes off the load
of the entire drive-line and extends its life. Last but not
least the variable-speed drive system uses, compared with
a fixed-speed drive, up to 50 percent less energy. The
SINAMICS G150 stands out due to its clear, well-structured
design, which makes the unit rugged and reliable. In addition
to the simple engineering, commissioning and operation
as a part of the SINAMICS concept, SINAMICS G150 cabinet
units have a footprint that is up to 70 percent smaller than
the footprint of conventional converters. Noise levels of
69 db(A) during full operation, even in the case of cabinet
units with a power output of several 100 kW, makes addi-
tional soundproofing measures unnecessary. Because a
PROFIBUS interface and a variety of analog and digital
interfaces are standard, the units can be easily integrated
in higher level programmable controllers.
Drive systems with SINAMICS S120:
for all more demanding applications
SINAMICS S120 is the modular drive system in the SINAMICS
family for demanding drive tasks such as precise and dyna-
mic to high-dynamic positioning and motion control appli-
cations in machine and plant construction.
The drive system is suitable for single-axis applications and
for multiple-axis applications. Since SINAMICS S120 supports
not only vector and servo control but also V/f control, all
the drive tasks in a machine or line can be solved universally,
including speed control, positioning tasks, and – in connec-
tion with SIMOTION – motion control tasks right up to
high-precision axis synchronization.
In combination with 1FK7 and 1PH7 servo motors you
get a high-performance motion control system for the
Glass Industry.
Motors: the base of a high plant availability
With its low- and high-voltage motors, Siemens has the
optimum product for all glass applications. They set stan-
dards, when it comes to the overall envelope dimensions
and weight for a particular power rating. This saves space
and makes it easier to integrate the motors into the plant
or system. Furthermore these motors boast low noise level,
vibration and operating costs. And last but not least, Siemens
motors are characterized by the highest achievable avail-
ability. The MICALASTIC insulation system ensures excellent
corona shielding, is insensitive to environmental and ambient
effects and stands for the absolute highest endurance. All
these features are complemented by monitoring devices –
included as standard – for the bearings and windings. The
high efficiency improves the energy balance sheet and thus
reduces operating costs.

SIMOTION: the motion control system for

time-critical applications
SIMOTION integrates motion control, logic and technology
functions in one uniform system. This eliminates time-
critical interfaces between the individual components,
thereby facilitating efficient engineering – covering con-
figuration, programming and parameterization, through
to testing, commissioning and diagnostics.
These are the functions needed in the cutting area of float
glass applications and in IS machines for hollow glass
applications as well.

17
 Process instrumentation and analytics: the full range for
measuring, positioning, recording and controlling
Plant-wide engineering and asset management with
seamless field integration
Glass production is a continuous process which requires
the highest availability of the electrical and instrumentation
equipment and at the same time it is subjected to extreme
requirements. Furnaces usually run for more than 10 years
with 24-hour production cycles. A single day downtime in
a float glass plant can result in extremely high losses. Our
field devices with modern diagnostics and maintenance
functionalities, used in conjunction with our Totally
Integrated Automation asset management concept, pro-
vide increased availability and reduce shutdown times,
thus enabling effective maintenance strategies, and thus
reveal one of the most effective catalysts for increasing
productivity.
Engineering with field device management tool
SIMATIC Process Device Manager (PDM) is a powerful
software tool for easy manufacturer-independent field
device operation, including: configuration, adjustment,
commissioning, diagnostics and maintenance of any intel-
ligent process PROFIBUS DP/PA or HART devices. It can be
used either as stand-alone on a single-PC or programming
device, or seamlessly integrated with PCS 7 process control
system and maintenance stations.
Used in conjunction with our asset management approach,
our process devices with enhanced maintenance-oriented
functionalities provide an efficient lever to globally improve
the plant availability and reliability.
18
Asset management and maintenance strategies
Whether an immediate response to failure is required or
preventive maintenance has to be planned: our plant asset
management concept and process devices enable the
appropriate actions and reactions to ensure the highest
plant availability.
Monitoring, recording and assessment of field devices
Initiation of the appropriate measures to eliminate or
avoid failures
Support in the implementation of preventive measures.
The seamless integration of process devices diagnostics
and functionalities and asset management with the process
control system present the following benefits:
Prevent the plant operators and maintenance engineers
from being flooded with information and uniform
visualization for all components and devices
Keep the overhead for configuration of the plant asset
management as low as possible
No limitation in supported field devices
Higher data consistency and reduced engineering, since
automation engineering data are made available for
maintenance
Faster and improved assessment, due to a closer link
between automation and asset management, the status
of a component being related to the current operating
mode of the plant
Simplified operating and minimized training, since users
only need to be acquainted with the engineering and
HMI tools of one single system.
Our process field instruments provide extensive diagnostics
and simulation functions which support users to specifically
assess the status of a device during commissioning, servicing
and maintenance and provide a useful help in developing
predictive or corrective maintenance strategies.
Some examples of the available functionalities for preventive
maintenance:
Operating hours counters for measuring cell and
electronics
Event counters for limit violations
Maximum pointers for pressure, sensor temperature and
electronics temperature measurement to monitor process
extremes
Assessment of the signal quality with respect to trust-
worthiness and signal level.
Some examples of device diagnostics which effectively
supports troubleshooting in the context of corrective main-
tenance (cyclical monitoring):
Program execution monitoring (watchdog)
Sensor breakage and linearization calculation function
Simulation functions are additionally available for che-
cking the internal electronics components from the sensor
onwards.

19
 Our Siemens field devices provide the full range of process
measurements required in glass manufacturing: Pressure,
level, temperature, flow, weighing systems and scale belts,
as well as stand-alone controllers and process recorders.
Pressure/Temperature
SITRANS P DS III is a range of pressure measuring devices
for pressure, absolute pressure, differential pressure, flow
and hydrostatic level measurements. SITRANS T is a range
of temperature measuring devices, SITRANS TW as rail-
mounted universal four-wire temperature transmitter for
rail mounting (resistance thermometers, thermocouples
and resistance-type sensors, but also DC voltage or direct
current signals). SITRANS TK-sensor head mounted tem-
perature transmitters for all standard type sensors.
Level
Different technologies are available for level measurement:
Non contacting radar technology with FMCW radar, SITRANS
LR400 (Frequency Modulated Continuous Wave) and pulsed
radar with SITRANS LR200, LR300, continuous capacitance
level measurement with SITRANS LC300/500 and capaci-
tance point level detection, POINTEK CLS 200/300/500.
Weighing components and continuous weighing
systems
SIWAREX includes weighing and dosing electronics and
load cells perfectly fitting into the SIMATIC S7 controllers
and SIMATIC PCS 7 process control systems.
Single-belt scales for high-accuracy weighing of solid raw
material flows, also for extra heavy duty loading. Twin-belt
scales for simultaneous control of glass batch materials
and cullet. Weigh feeders with various belt widths are also
available.
20
Wide range of flowmeters
The SITRANS F M electromagnetic flowmeter is used for
flow measurement in water and binder applications. The
unit can be used for flowrates of up to 12 m/s. Available
diameters range from DN 2 to DN 2000. This system can
be used to measure the flow of electrically conductive
fluids, from 0,008 µS/cm. SITRANS F C coriolis mass
flowmeters are used to measure liquids and gases. High
accuracy – 0.1% of mass and repeatability – ensure maxi-
mum quality and reduced waste. Multiparameter measure-
ment for mass flow rate, volumetric flow rate, density,
fraction flow and temperature.
Positioners
Low air consumption SIPART PS2 electro-pneumatic posi-
tioners for valve actuator control and monitoring. For
example with the SIPART PS2 valve positioner, the most
frequently used intelligent positioner for linear and part-
turn pneumatic actuators. Leakages at valve drives can
be detected immediately and specific automatically gen-
erated warning message helps the maintenance team to
keep the process in optimized run.
Stand-alone process controllers
The SIPART DR range of stand-alone process controllers are
the ideal solution for independent loop-control and super-
vision in small and medium-sized glass production facilities,
or can also be used as backup controller, connected for
example via PROFIBUS to SIMATIC PCS 7 or SIMATIC S7 PLC.
For example the SIPART DR 24 provides an economic and
compact solution for complex and highly specific multi-
variable control loops.

Process recorders
Despite increasing centralized process supervision and
electronic process data archiving, process recorders still
provide if necessary, useful local data visualization and
recording. Our range includes the traditional paper recorders
as well as the state-of-the-art SIREC DS/DM/DH, with 5” to
12.1” high-resolution color TFT-Display and electronic data
storage.
Process gas analyzers
Siemens analyzers have guaranteed quality, availability and
accuracy in the Glass Industry for over 30 years. There is a
solution for every application. All versions include PROFIBUS
DP/PA, with complete data integration in the process control
system.
Typical applications are the monitoring in exhaust gas with
OXYMAT 6 and ULTRAMAT 6 analyzers (SO2, O2, NO) or
float bath monitoring to avoid oxidizing atmosphere. The
gas analyzers have comprehensive functions for device
diagnostics, and thus for corrective maintenance.
SIMATIC Sensors:
for non-contact detection
Siemens offers you a comprehensive range of proximity
switches for the contactless recording, counting, measuring,
monitoring or positioning of solid, fluid or powdery objects.
A wide variety of designs and recording principles – optical,
inductive, capacitive or sonar – offers solutions for every
task.
For example sonar proximity switches are the first choice
for the reliable recording of levels or heights or measuring
distances. Special versions are also available for pump
control, for applications with automatic filling or emptying.
The robust design up to degree of protection IP69 and
ranges of up to 10 m permit a wide range of applications.
Using the IQ-Sense technology, SIMATIC Sensors proximity
switches are integrated directly into Totally Integrated
Automation. The intelligent communication between sensor
and SIMATIC controllers takes place on a low-cost two-wire
cable. Other advantages: sensor parameterization via the
controller, system diagnosis down to the individual sensors
and sensor replacement during operation without re-
parameterizing. These features reduce the engineering
and commissioning times as well as standstills.
21
 Industrial controls and power distribution

To an increasing extent, the data of the motor feeders is
also integrated into the process control system. Intelligent
motor management systems, communication-capable motor
starters and circuit breakers support this trend and make
all relevant data available to the control system via PROFIBUS.
This increases the transparency of your process and ensures
a significantly greater density of information in the control
system, at no extra cost. On the basis of Totally Integrated
Automation all data is integrated uniformly and consistently.
Standardized motor function blocks, for example, simplify
the integration and the engineering.
SIMOCODE pro: the flexible and modular motor
management system
SIRIUS motor management and control devices
(SIMOCODE pro) are the first choice for constant-speed
motors in the low-voltage range. SIMOCODE pro optimizes
the connection between control system and motor feeder,
increases the plant availability and, at the same time,
achieves considerable savings in the construction, commis-
sioning, operation and maintenance of a plant.
It also involves an extremely compact design, a straightfor-
ward and efficient service and maintenance as well as a
range of graduated functions. In addition, SIMOCODE pro
meets all requirements for future-proof energy management
and offers advantages in all areas: in process management,
operations management or in switchboards.
Some extensive features:
Multifunctional, electronic full motor protection,
independent of the automation system
Flexible software instead of hardware for the motor
control
Detailed operating, service and diagnostics data
Open communication via PROFIBUS DP
Integration and monitoring of additional process values
Detection and monitoring of power-related measurements
ATEX-certified (overload protection of explosion-protected
motors).
SIVACON systems: for customized communication
solutions
SIVACON systems are low-voltage communication-capable
switchboards and busbar trunking systems with a high
degree of flexibility and availability. All of these features
enable a seamless integration into the automation environ-
ment.
Using switchgear and switching devices we offer a universal,
integrated communication concept for customized solutions:
e.g. with SENTRON circuit breakers, SIMOCODE motor
management system and SIMATIC.
Now, using the new SIMOCODE pro with SIVACON, up to
40 communication-capable motor feeders can be integrated
in a control cubicle.
So SIMOCODE pro is likely to be used in SIVACON low-
voltage Motor Control Centers (MCC) and allows load feeders
to be configured. Load feeders that have a higher perfor-
mance and at the same time are extremely compact and
able to communicate.
The high degree of modularity allows all of the communi-
cation components to be simply retrofitted. Innovative
software products offer user-friendly parameterization,
diagnostics, operator control and visualization locally via
PROFIBUS DP or Ethernet/Internet.

22
 The parameterization, operation and monitoring of the
SENTRON circuit breakers can be handled over the PROFIBUS
DP network. SENTRON circuit breakers are completely inte-
grated into the SIMATIC world and the STEP 7 engineering
software. Data management, configuration and program-
ming is integrated into the automation project SIMARIS
manager – Power Management Software to manage energy
distribution systems.
This modular and integrated power management software
is based on SENTRON circuit protection devices and Totally
Integrated Automation. This not only facilitates efficient
diagnosis, alarm and maintenance of SENTRON circuit
protection devices as part of a Totally Integrated Power
solution but also optimizes laboratory, investment, and
energy supply costs through continuous analysis of energy
data.
SENTRON: power distribution
With only a few modular components, you have the possi-
bility of thousands of different combinations for all of your
energy distribution applications. The products in the
SENTRON circuit protection system tie into your automation
architecture giving you the power to increase production
system availability. In addition, you can further optimize
the energy distribution process with a networked power
management solution. Never before have circuit breakers
been so versatile and so simple.

SENTRON: optimized energy solutions

SENTRON circuit breakers address your critical needs for
less installation space, reduced operating costs, and opti-
mized energy usage from 16 A up to 1600 A or from
630 A up to 6300 A, connectable to the PROFIBUS DP.
The Breaker Data Adapter (BDA) is the first circuit-breaker
communication device with an integrated web server to
parameterize, operate and monitor SENTRON circuit
breakers. Circuit breaker data can be accessed from any
device supporting an Internet browser with Java Virtual
Machine. The BDA Plus incorporates an Ethernet interface
for direct connection to Ethernet/Intranet/Internet. Switch
ES Power, a configuration software, offers complete
integration into the automation engineering environment.

23
 Best practice example:
Glaverbel production site in Klin, Russia

Glaverbel, the European branch of ASAHI GLASS CO., had Trust and expertise
identified the huge opportunities in the Russian glass market Glaverbel and Siemens have already worked together suc-
at an early stage and acquired a holding in the country’s cessfully on previous projects, including the establishment
largest glass manufacturer, Bor Glassworks. Since then, the of glass plants in Iran and in Mol, Belgium. Another contrib-
company has concentrated on expanding glass production uting factor in the decision was the fact that Siemens works
in Russia in order to meet the expected rapid increase in with partners who have a very good reputation in their
demand. The company’s most recent project are production respective fields of expertise. These partners include AEG
lines for float glass, coated glass, and mirrors in Klin near as the supplier of the heating system for the float bath and
Moscow. STG Cottbus GmbH as the glass technology expert for the
Standardization of components melting furnace. The efficient method of cabling and the
outstanding relationship between quality and costs as
Siemens was placed in charge of the project because of well as the excellent on-site logistical support in Russia,
the company’s history of close cooperation with the Glass facilitating the speedy implementation of the project,
Industry and the comprehensive knowledge Siemens can were additional important factors in favor of Siemens.
offer on the processes used in Russia. The contract included
the complete development, installation, and commissioning
of the entire system including energy part (medium-voltage,
transformers, low-voltage distribution, emergency diesel
and uninterruptible power supply) and the automation part
(SIMATIC PCS 7 for glass manufacturing, SIMATIC S7 for
the utilities and all field instrumentations). The implemen-
tation will also involve the standardization of all compo-
nents, which is greatly facilitated by Totally Integrated
Automation.

24
Best practice example:
Isover production site in Yegorievsk, Russia

Isover, the insulation division of the French glass manufac- supervise the commissioning and installation of the systems
turer Saint-Gobain, has been active in the Russian market on site. Siemens Germany provided the SIMATIC PCS 7
for eight years and is the second largest supplier of insulating process control system and the entire field instrumentation,
materials in Russia. while Siemens Finland delivered the cabinets and operator
panels for the process control technology.
Customer requirements
In 2002, the company decided to build its own production Customer benefits
site in Russia on an old industrial site in Yegorievsk near SIMATIC PCS 7 is used throughout the plant. The process
Moscow. Initially only one line with a capacity of 20,000 devices are connected to the control system via PROFIBUS
tons of glass wool was to be built, but the plant’s premises DP – including SIPART PS 2 positioners. The uniform system
are large enough to house further glass lines. The first line architecture offers Isover several benefits: reduced commis-
went into operation in 2003, and a second production line sioning and fine-tuning time and costs, and simpler main-
is presently under construction. tenance and servicing. At the same time, Isover can be
certain that both the process control system and the process
Siemens solution instrumentation can be extended or modified at any time.
For the first new line, an energy-saving melting process,
sophisticated TEL machines, and efficient and reliable
automation technology were planned and implemented
by an international project team. The Siemens project
management team was responsible for the areas of auto-
mation, process instrumentation, and valve technology,
including the corresponding engineering and services. It
cooperated closely with a Russian engineering consultant
company, who performed the installation of the systems
on site in Yegorievsk. Siemens contracted its system partner
STG Cottbus GmbH to create the application software and

25
 Best practice example: Grenzebach production site,
Asbach-Bäumenheim/Hamlar, Germany

One of the critical elements of a glass line is the cutting
line. The Grenzebach company is a glass technology expert
for the cold end – which involves everything from float
glass and cutting lines right down to stacking and warehou-
sing.
Customer requirements
The Grenzebach float cutting system consists of two to
three longitudinal and a maximum of six transverse cutting
bridges. On the longitudinal cutting bridge, the glass web
gets one or two trimming cuts on the left and right or two
longitudinal dividing cuts before being divided on the
transverse cutting bridges. At the end of the cutting bridge
is the marking section. After leaving the marking section,
the glass plates are transported to the lift-off section.
In the cutting line, very high plant availability and extreme
accuracy are essential. Efficient production also depends
on optimizing the cutting of the glass web for the specific
job. Precision, speed, and maximum flexibility are essential
aspects of the process.
Customer benefits
Grenzebach is impressed by the new SIMOTION solution.
The modular design keeps availability very high because a
failure on one of the bridges has no influence on the other
bridges and may even be compensated for by them. In
addition, commissioning is much easier and quicker because
the individual modules can be started up separately, delivery
time is reduced considerably through the use of standard
devices, and troubleshooting is significantly improved.
Equally important is local support from the automation
provider, as 80 percent of the Grenzebach lines are destined
for export. Siemens can offer the necessary automation
expertise worldwide.

Siemens solution
In the automation of its lines, Grenzebach has relied for
years on an automation solution based on Totally Integrated
Automation. SIMOTION controllers are installed for control-
ling the cutting and marking bridges, SIMATIC industrial
PCs coordinate the processes of all bridges, and high-
available SIMATIC S7-400 controllers are implemented to
ensure minimum downtime of the cutting lines.

26
Best practice example: innovative glass transportation
solution in cooperation with Heye International GmbH,
Oberkirchen, Germany

An essential step in the demanding production of hollow Customer benefits

glass is the exact forming and cutting of the glass drop and
the loading of this drop into the production machine. High-
precision motion control with absolute reproducibility –
which is provided by an electronic cam disk – is necessary.
The slightest deviations show up in changes in the weight
of the glass mass, which in turn have a negative effect on
the productivity of the entire production line.
Customer requirements
Automation must also deal with challenging tasks in the
transportation of glass containers – for example, the exact
synchronization of the belts to the machine speed, the
angled synchronization of belts and reversers, and the
movement of the feeder. Integration into an existing envi-
ronment is frequently a major consideration as well.
The SIMOTION solution offered several significant advan-
tages. A large number of axes can be controlled and syn-
chronized accurately, and the system is also equally suitable
for other hollow glass production plant sections such as
plungers, shears, or drop distributors. Having a single
engineering system reduces training expenses and com-
missioning time, and standardized communication
via PROFIBUS means not only less wiring work but also
fewer interfaces and therefore fewer sources of error. The
system is open for interfacing with other automation levels.
Messages or alarms are sent to a master control or the
SIMATIC PCS 7 process control system, where they can
be analyzed and archived. This improves the overall perfor-
mance of the plant.

Siemens solution
Together with Heye International GmbH in Oberkirchen,
Germany, Siemens has developed an innovative automation
solution that will initially be used for belt drives. The global
provider of technologies, machines, and plants for the
container glass industry had the drive-based variant
SIMOTION D installed for motion control and logic functions.
All motion control functions are integrated directly in the
control module of the new SINAMICS S120 multiaxis drive.

27
Further information:
www.siemens.com/glass

Subject to change without prior notice 10/06 | Order No. E20001-A480-P200-X-7600 | Dispo 06303 | 41C9848 MK.GC.LT.YTIA.52.7.07 WS 10063. | Printed in Germany | © Siemens AG 2006

www.siemens.com/totally-integrated-automation

Siemens AG The information provided in this brochure contains merely general de-
scriptions or characteristics of performance which in case of actual
use do not always apply as described or which may change as a result
Automation and Drives
of further development of the products. An obligation to provide the
respective characteristics shall only exist if expressly agreed in the
terms of contract.

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