SOLUTIONS 13 - Moeller Electric Parts

Automation Solutions in Machine and System Building 

SOLUTIONS 13 

easy Control 

meets 

CoDeSys 

For Moeller Electric Sales and Support call KMparts.com (866) 595-9616 

www.moeller.net

2 

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 

News . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 

XC100-FC lights up wind turbine systems . . . . . . . . . . . . . . . . . . . 10-12 

Modular PLC with FO fieldbus interface 

XC200 modular PLC binds the reading world . . . . . . . . . . . . . . . . . 13-15 

Fully automated brochure & book binding 

Environmentally friendly football stadium – simply easy . . . . . . . 16-17 

easy800 controls rain water harvesting system 

Automation in laboratory and pharmaceutical technology . . . . 18-19 

Constant air changing despite nonlinear curve using MFD-Titan 

MFD-Titan and easy control oil starters 

for heavy duty motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 

State-of-the-art control technology for rugged starting resistors 

No operation too far . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23 

Field Service – active round the world 

NZMs supply Spanish railway line . . . . . . . . . . . . . . . . . . . . . . . . . 24-25 

1000 NZM circuit-breakers of 1000 V for the AVE Madrid-Lleida 

An addition to the circuit-breaker series . . . . . . . . . . . . . . . . . . . . 26-27 

NZM extended with new device versions and accessories 

Imprint 

Moeller Solutions is the Moeller 

customer publication for industrial 

automation 

Published: 

Moeller GmbH 

Editors: 

Dirk Bolz (v.i.S.d.P.) 

Christian Bücker 

Integral Dr. Schumacher® 

Stefanie Böttner 

Authors: 

Erich Neuhauser 

Reinhard Pförtner 

Dr. Monika Schumacher 

Frank Spelter 

Jürgen Visarius 

Dirk Wunder 

Hein-Moeller-Straße 7-11 

53115 Bonn 

Tel.: +49 228 602-0 

Fax : +49 228 602-62275 

E-Mail: info@moeller.net 

www.moeller.net/solutions 

Copyright 2006 by Moeller GmbH 

KM0213-4281GB 

Article no. 106771 

Layout: buntebrause agentur 

Printed in Germany (04/2006) 

For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

NEWS 

SOLUTIONS13 

www.moeller.net 

+++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ 

Moeller XC100-FC: Modular PLC 

Now with FO Fieldbus Interface. 

XC-CPU101-FC is the name of the 

powerful modular PLC with the 

CANopen fibre optic fieldbus 

interface from the Moeller XC100 

range of programmable 

controllers. This ensures highly 

noise-free data transfer – even in 

environments with excessive 

electromagnetic interference. 

Connections are made using 

plastic fibre optic cables. 

The PLC comes with eight digital 

inputs and six short-circuit-proof 

outputs already onboard. Four 

inputs are designed as interrupt 

inputs, thus enabling a simple 

and direct response to events, 

irrespective of the cycle time. 

Other features include an 

integrated real-time clock as well 

as a slot for Multi-Media Memory 

Cards (MMC with standard file 

system). Operating systems and 

application programs can be 

updated via the MMCs, and they 

can also be used for the 

processing of recipe data or the 

storing of measured values or 

operating data. 

The modular PLC can be 

expanded locally with up to 15 

XIOC signal modules. A wide 

range of digital, analog or 

communication modules are 

available for use. 

The XC100-FC has an 

outstandingly compact design 

with a 60 millimetre mounting 

width and 100 millimetre height. 

These reduced device volumes 

are thus in line with the trend 

towards more compact machine 

designs requiring less space for 

the control electronics. This is 

supported by high density XIOC 

I/O modules that can house up to 

Customisation Kit for Moeller 

XC100 and XC200 PLCs. 

Moeller's XC100 and XC200 

controllers are factory shipped 

with a wide range of functions: 

depending on the equipment 

selected, the controllers feature 

integrated serial, fieldbus and 

Ethernet interfaces as well as a 

web server. Customers can also 

choose from a wide range of 

digital, analog, technology and 

communication modules for the 

standard controllers. Up to 15 

XIOC signal modules can be 

connected centrally to the CPU. 

The CoDeSys programming 

environment is enhanced with a 

wide range of libraries for 

communication, closed-loop 

control and positioning. Moeller 

is now offering a technology kit 

that enables customers 

themselves to 

implement the 

required features 

that are not 

covered by the 

standard range. 

For this Moeller 

provides all the 

necessary 

information for 

developing and 

producing 

custom modules 

that are 

compliant with the Moeller 

controller family. This ranges 

from a description of the 

32 I/O with a mounting width of 

only 30 mm. Nearly 500 I/O can 

be implemented with a maximum 

expansion of 510 mm. 

Programming is carried out via 

the serial programming interface 

or alternatively via the CANopen 

fieldbus. In this way, the PLC can 

also be programmed and 

hardware and software interfaces 

to the provision of specific 

components for production. 

The necessary mechanical 

components such as housing 

parts and other special 

mechanical components are 

provided for creating the 

hardware, whilst the supplied 

documentation contains 

information on PCB dimensions, 

blocking layers, geometries, as 

well as other mechanical 

requirements. The electrical 

interface is also described. To 

ensure successful 

implementation, circuit 

suggestions are supplied for 

connecting a bus for which 

ready-to-use communication 

interfaces in the PLC operating 

system are also suitable. 

With regards to software 

development, Moeller also 


operated in networked 

applications via a central access 

point. XC100-FC uses the XSoft 

(CoDeSys) programming system. 

MS1307 

provides suitable generic 

configuration and communication 

modules for the different bus 

interface variants; customised 

operating systems are therefore 

unnecessary. 


Textüberhang 

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NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEW 

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From the Control Relay to the Automation System 

The control relays of Moeller's easy series enjoy a high 

level of popularity and success worldwide. In the last 

few years, the range has been continuously expanded 

and functionality enhanced. CPU types are thus 

available today with several equipment versions, 

together with a wide range of I/O modules and 

network interfaces to well-established fieldbus systems 

such as Profibus, AS-Interface, DeviceNet and 

CANopen. >>> 


Devices can also be connected to Ethernet, 

and user-friendly programming with easy Soft 

CoDeSys provides effective support for 

creating user programs. It has been optimally 

designed for electricians and newcomers to 

automation technology and is the ideal tool 

for implementing simple applications on easy 

controllers. 

When the level of automation and also the 

complexity of the application increases, 

programming systems are required that meet 

the requirements of the international standard 

EN61131-3. The programming languages 

provided here – instruction list, ladder diagram, 

function block diagram, sequential function 

chart and structured text, as well as tools for 

structuring the task definition effectively – 

provide the support necessary for implementing 

more demanding application solutions. Moeller 

has been using the renowned CoDeSys 

programming system from 3S for several years 

for its XC100/200 PLCs and XV touch display 

PLCs. Its widespread use, outstanding features 

and simple handling are the guarantee for 

implementing automation projects successfully. 

easy Control meets CoDeSys 

Moeller's new powerful easy Control series 

now links the well-established and simple easy 

concept with the benefits of standard 

programming to EN61131-3. The CoDeSys 

programming system is also naturally used 

here. easy Soft CoDeSys brilliantly develops 

the features of the new easy Control 

controllers so that they can be used for new 

medium-complexity applications. The 

performance potential here goes far beyond 

the standard requirements of EN61131-3. The 

freely definable function block chart (CFC) 

language is provided as well as the 

programming languages defined in the 

standard. Options for simulating the user 

program, the integrated fieldbus configurator, 

the very powerful test and commissioning 

functions, as well as the integrated 



S +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS +++ NEWS 

visualization tool, ensure that application 

requirements can be implemented rapidly and 

simply. With only two programming standards, 

easy Soft and easy Soft CoDeSys, Moeller can 

therefore cover entire the automation range. 

Systematic integration 

The new easy Control controller series fits 

seamlessly into the existing easy system, and 

the EC4-200 controllers make use of the wide 

range of easy products already available. The 

large number of I/O expansion modules can be 

used equally as well as the slave network 

modules provided for connecting to higherlevel 

fieldbus masters. The easy Control 

devices also naturally come with the increased 

temperature range from -25 to +55 degrees. 

Lots of power in the compact class 

EC4-200 compact controllers are designed for 

use in small to medium-sized automation 

solutions. The 16-bit processor ensures high 

CPU performance and thus short cycle times. 

Program and data memory are also generously 

sized with 256/224 KB. The EC4-200 

controllers are available in a number of 

different versions. The devices feature 12 

digital inputs of which up to four can be used 

as analog inputs. Eight transistor outputs or six 

relays are provided on the output side. 

Versions with or without integrated display, as 

well as different versions for analog processing 

and different communication interfaces 

provide additional options for selecting exactly 

the right device for the application at hand. A 

total of sixteen device versions are on offer, 

and all devices come with a real-time clock. 

The devices are maintenance free and do not 

require any batteries. 


5


CANopen and easy-NET 

The simple easy-NET interface is a feature 

well-known to easy users, providing simple 

network communication thanks to its plug 

and play technology. Up to eight devices can 

be interconnected over a distance of up to 

1000 metres. However, a standard fieldbus 

system is required if users wish to connect 

standard fieldbus devices. A standard 

CANopen fieldbus master is integrated on all 

EC4-200 devices in addition to the easy-NET 

network. Connection to a wide range of 

fieldbus stations such as visualization systems, 

remote I/O systems or drives considerably 

expands the range of applications possible. 

The controllers can likewise be accessed via 

the network. Subordinate controllers can also 

be programmed and diagnosed easily from a 

central location. 

Memory card with standard file system 

Memory cards enable user program or recipe 

updates to be carried out simply at the device. 

However, the memory card of the easy Control 

devices offers several other functions. The 

standard file system enables data to be read 

and stored on the memory card by the PLC and 

by any PC. This allows recipe data or measuring 

and operating values stored by the PLC to be 

read out and further processed so easily. 

Ethernet onboard 

The large range of possibilities and resulting 

benefits of Ethernet are being exploited more 

and more in the automation field. A large 

range of infrastructure components enables 

suitable networking structures to be created 

simply. However, what users are missing are 

affordable compact controllers with an 

integrated Ethernet interface that can be 

installed in these networks directly. Current 

implementations consist of using additional 

converters that convert the commonly 

available serial interface of the PLC to 

Ethernet, and this naturally increases the costs 

of the automation system considerably. The 

EC4-200 versions with an integrated Ethernet 

interface therefore provide exactly the right 

solution. Remote programming from any 

location, data exchange to higher-level 

systems (e.g. via OPC), faster processing speed, 

simple connection to the office world are 

typical applications. An inexpensive and simple 

integration into an Ethernet environment is 

now possible without any difficulty for even 

smaller applications. 

CONCLUSION 

With the introduction of the easy Control 

devices, Moeller is closing the gap 

between the control relay and the 

programmable logic controller. Its wellknown 

simple handling is combined 

together with the product features 

required of PLC systems. The use of the 

entire easy product range guarantees a 

wide application spectrum. The powerful 

easy Soft CoDeSys programming system, 

standard communication interfaces 

provided such as Ethernet and CANopen, 

or the file and recipe handling on the 

standard memory card are just some of 

the outstanding product features for this 

performance class. They form the basis 

for implementing innovative solutions. 


6 For Moeller Electric Sales and Support call KMparts.com (866) 595-9616




Primary Switched-Mode Power Supply Units – Ideal Suppliers 

for 24V DC Controllers. 

Primary switched-mode power 

supply units are essential 

components in today's power and 

automation technology. These 

devices stand out on account of 

their high efficiency and the fact 

that heat and power losses are 

kept to a minimum. Moeller's new 

SN3 switched-mode power supply 

units are available in six versions. 

The wide input voltage range for 

both AC and DC power supplies 

guarantees world-wide use, even 

with severely fluctuating power 

networks and battery operated 

systems. 

Moeller's new devices come 

with output reserves of up to 

50 % already integrated so that 

overdimensioning for heavy 

loads is unnecessary. They are also 

no-load and overload protected 

and feature permanent shortcircuit 

proofing. The output 

voltage of SN3 devices can be 

adjusted to enable adaptions for 

specific applications, such as the 

balancing out of voltage drops 

over long cable lengths. An 

additional snap-on annunciation 

module with a remote function is 

also available for these power 

supply units. This module can be 

used for external on and off 

switching, as well as functioning 

as a relay output for indicating 

input/output states and thus 

optimising the monitoring 

features of the controller. Up to 

five primary switched-mode 

power supply units can be 

connected in parallel. All SN3 

power supply units are protected 

to IP 20 and come with UL 

approval. 

Touch-Panel for Innovative Communication Concepts. 

With its new XV200/400 touch 

display series, Moeller is offering 

a scalable and future-proof 

device generation. HMI or 

combined HMI-PLC are based on 

one hardware platform. With the 

XV series, the user can determine 

at the point and at any time 

whether it is to function as an 

elementary HMI or combined 

HMI-PLC. Initial training in 

different hardware and software 

for HMI or HMI-PLC applications 

is unnecessary. Project design, 

device ordering or logistics is 

restricted to just one device 

series, thus reducing costs. 

The XV400 device series is 

available with display sizes from 

5.7, 10.4 and 12.1 inch in two 

touch technologies. The infra-red 

touch is provided with a rugged, 

scratchproof front made of safety 

glass. The resistive touch device 

features a plane, seamless front 

that simplifies cleaning. A host of 

onboard interfaces, such as 

CANopen, Ethernet, USB Device, 

USB Host and RS232 enable 

communication with the devices 

of the XV400 series. Two slots for 

communication modules offer 

the possibility of additional 

interface options. 

The new XV200 touch display 

series offers a fully graphical 5.7” 

LCD mono display with four 

greyscales, resistive touch 

technology and a host of 

communication and networking 

options. All devices feature an 

Ethernet and USB device 

interface. The three available 

device versions differ in the 

additional interface they provide – 

either RS232, CAN or MPI. 

The RS232 interface enables 

XV200/400 series devices to 

communicate directly with 

Moeller's easy800 devices. 



The XSoft-Professional 

programming system is used 

for programming, testing and 

commissioning the PLC, is 

compliant with IEC 61131 as 

well as offering a number of 

impressive features. Your goal: 

Reducing the time required for 

project design and diagnostics, 

and thus saving time. With the 

MS Windows based, intelligent 

and interactive XSoft-GALILEO 

visualization tool, users can 

create HMI projects simply and 

effectively for machines, plants 

and buildings. Several functions, 

such as UNICODE support, 

password management (200 

levels, 500 users), online project 

simulation on the PC, alarm and 

history functions, recipe 

management and printer 

functions, provide for virtually 

all customer requirements. 


7


8 

www.trainingscenter.moeller.net 

The Online Training Center 

for easy and MFD-Titan 

Need a temperature control for a greenhouse? 

Moeller's easy compact controllers have enjoyed a high level of popularity and success on the market, 

and have recently become available in a new product generation consisting of more powerful, more 

flexible and faster controllers. To support this, Moeller is now providing a web-based information and 

training platform that offers a host of examples, tips and tricks. The website is tailored to meet the 

wishes and requirements of easy or MFD-Titan customers for both small and large-scale applications. 

The Online Training Center offers all users simple and direct support for all devices and the easy Soft 

project design software, and without the need for any manuals. 





Step 1: Select the required application 

Starting easy – made easy 

The Online Training Center is divided into four 

main areas: Products, Functions, Applications 

and Software. The first area presents the device 

classes, with a clearly structured overview of 

device hardware, possible configurations, 

performance levels and accessories. All relevant 

documentation, such as mounting instructions, 

operating manuals and product information 

relating to the device concerned can be 

accessed by mouse click. 

Functions – the key to fast design 

Moeller's easy Soft project design software 

can be downloaded as a demo version free of 

charge from the Online Training Center, and 

offers over 54 pre-programmed function 

blocks. These range from small to complex 

function blocks that help users to implement 

solutions simply and quickly. 

All functions are sorted according to the 

performance level of the easy devices 

concerned. Only those functions are displayed 

Step 3: Download program, adapt - done 

Step 2: Select Greenhouse temperature control 

that are supported by the selected controller. 

Moeller developed new icons for the individual 

functions in order to simplify navigation and 

facilitate fast selection. 

For each of the 54 easy Soft functions offered, 

Moeller also provides a compact easy example 

program. All example programs are 

documented with detailed function 

descriptions, and illustrated with screenshots 

from the easy Soft software. The examples are 

available as a compressed Zip file in the 

Download center. Specially created Flash 

programs provide an animated display of how 

to create the individual functions with easy 

Soft. 

Ready-made applications – help in designing 

your first project 

The new Online Training Center helps you to 

find initial ideas or program sections in order to 

reach a solution quickly. In the Applications 

section, the Online Training Center offers users 

a host of pre-programmed ready to use 

applications that are commonly or frequently 

used with easy or MFD- 

Titan. 

Smaller examples of 

graphic display 

applications with MFD- 

Titan are also provided. All 

programs and functions 

have been fully tested by 

Moeller and are fully 

documented. This includes 

the function descriptions 

used, the wiring diagrams 

and the screenshots of 

relevant software 

positions in easy Soft. 

Software – one software for program design 

All projects and all easy devices are designed 

and configured with the one easy Soft 

software. The new version 6.11 supports up to 

13 definable languages and is therefore already 

suitable for worldwide use. Other languages 

shall be added in stages. Each user program 

created can be simulated with easy Soft on the 

PC before downloading to the easy device. 

Simulation on the PC shortens the testing stage 

and simplifies commissioning. easy Soft comes 

with an OPC server already integrated at no 

additional cost. The Ethernet gateway for easy 

devices and MFD-Titan is also integrated, thus 

making the possible networking options 

virtually limitless. 

Informing, discussing, exchanging ideas 

The Online Training Center always provides the 

latest updates, documentation, and device 

master data as well tips and tricks in the FAQ 

area. This also includes a link to the easy forum 

where around 1600 easy users discuss and 

exchange information about their own 

applications, raise questions and share ideas 

about all aspects of the easy compact 

controllers (www.easy-forum.net). Last but not 

least are the links to software for the compact 

controllers, as such as the Labeleditor for MFD- 

Titan. The Online Center is also equipped with a 

full text search function, enabling users to 

access all the relevant pages in the system. A 

Help form also allows you to send your latest 

questions to the team of Moeller experts. 



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Wind Power Turbines: 

Modular PLC with 

FO Fieldbus Interface 

Enercon develops and produce gearless wind power 

turbines that are still today setting standards on the market 

in terms of power, reliability and lifespan. Research and 

development at Enercon determine the level of innovation. 

The company's slogan clearly indicates its primary 

motivation: energy for the world. To meet its demanding 

requirements, Enercon chose Moeller's XC100-FC modular 

PLC with a fibre optic fieldbus interface for controlling 

and monitoring the aviation beacon system. 


Enercon places tremendous importance on high 

quality and ensures that only first class materials 

are used. With this in mind, the company 

collaborates closely with all its suppliers, and 

thus also with Moeller. Enercon wind turbines 

are equipped with state-of-the-art 

microelectronic control technology developed 

in-house. The main processing unit, which is the 

central element of the control system, is in 

continuous contact with the peripheral control 

elements, such as the yaw control and active 

pitch control system. Its function is to adjust the 

individual system parameters to ensure the 

wind turbines operate at optimum yield under 

all weather conditions. 

Preventing downtimes 

The correct feeding of electricity from the 

wind turbine into the grid requires the 

monitoring of the grid connection. Grid 

parameters such as voltage, current and 

frequency are measured on the low-voltage 

side between the turbine inverter and the 

system transformer. All measured values are 

continuously transmitted to the system 

control, enabling the turbine to react 

immediately to changes in the grid voltage or 

frequency. As soon as the defined limit values 

of the system protection are exceeded, the 

wind turbine is safely shut down and service 

is informed. When the voltage and frequency 

return to within the permissible tolerances, 

the wind turbine is automatically started up 

again, thus preventing lengthy downtimes. 

Optimising yield 

The Enercon control system ensures a yieldoptimised 

turbine operation under all weather 

conditions. The nacelle is therefore provided 

with adaptive yaw control for which 

measurement data from the wind sensor is 

evaluated constantly. A variable speed control 

is provided for optimum wind turbine 

efficiency at every wind strength, and 

eliminates any undesirable output peaks or 

high operating loads. The active pitch control 

system enables the ideal flow angle to be set 

at the rotor blades to ensure maximum yields 

and load reductions for the entire wind 

turbine. The Enercon brake system ensures 

maximum turbine reliability by means of three 

independently operating pitch mechanisms 

with standby power supply if the grid supply 

fails. Tower and generators are monitored by 

means of vibration and acceleration sensors to 

check the deflections in the tower. 

Temperature and air gap sensors measure 

other control parameters. 

Aviation beacons of the Enercon 

wind turbines 

Depending on the requirements of the 

authorities there are two types of aviation 

beacons – obstacle beacons and hazard 

beacons. Enercon offers both systems for its 

turbines. Obstacle warning lights are fixed red 

omnidirectional lights with a medium light 

intensity of at least 10cd in the horizontal 

beamspread (-2° to +8°). Obstacle warning 

lights are required if the distance between the 

rear lights and the tip of the vertical rotor 

blade is no more than 15 metres. Hazard 

beacons are red flashing or flashing strobe 

omnidirectional lights. Hazard beacon systems 

are normally required for wind turbines with a 

total height over 100 metres, since the 

unmarked section of the wind turbine extends 

by more than 15 metres. The obstacle and 

hazard beacon systems each consist of two 

lights placed on the roof of the nacelle that 

are run in synchronised operation. This 

excludes the possibility of a standing rotor 

blade from blocking the view of the beacon. 

The control, monitoring and possible standby 

supply is installed in a central control cabinet. 

This consequently reduces the external 

equipment required to a brightness sensor, the 

beacon lights themselves and, if necessary, a 

visibility meter. To keep the cabling for these 


components as short as possible, the control 

cabinet for the beacon system is housed in the 

nacelle. Control cabinets for beacons with a 

standby supply are located in an airconditioned 

control cabinet. 

The Moeller XC100-FC modular PLC with an 

FO fieldbus interface handles a host of 

different tasks. It controls and monitors both 

the grid supply as well as the standby supply. It 

is also responsible for the management of the 

accumulator. In addition to this, it handles the 

control and monitoring of the air 

conditioning, i.e. the heater and fan. 

Furthermore, the XC100-FC controls the 

beacon lights and records their operating 

hours, controls their intensity and monitors 

them. In addition to the beacon management 

THE COMPANY 

Enercon GmbH is based in Aurich and 

was founded in 1984 by Dipl. Ing. Aloys 

Wobben. In 1991, the research-based 

company developed and produced the 

first gearless wind turbine in the world. 

The technology is still well-established 

and sets standards in technology, quality 

and safety on all continents. The 

industrial series production of wind 

turbines followed in 1993. Enercon 

operates as a full-scale manufacturer: 

all key components such as rotors, ring 

generator and grid feeding system are 

all developed and manufactured inhouse. 

Enercon has been market 

leader in Germany for years and is 

third in the market worldwide. It has 

production sites in Germany (Aurich, 

Emden, Magdeburg), Sweden, Brazil, 

India and Turkey. As of March 2006 

Enercon had installed more than 8 600 

turbines worldwide with a total output 

of 8.8 GW. 


11

12 

system, the XC100-FC modular PLC also 

controls wind park synchronisation, 

communicates with the brightness sensor and 

the visibility meter. Visibility at hub height is a 

parameter used for controlling daytime 

lighting. This is a cyclical white strobe light 

with an intensity of 20 000 cd. In order to 

reduce any disturbing effects in the vicinity of 

the wind park, the intensity of the daytime 

lighting must be reduced to a rated light 

intensity of 30 percent when the measured 

visibility in the wind park is over five 

kilometres and 10 percent with a visibility of 

over 10 kilometres. The distance in a wind 

park between a wind turbine with a visibility 

meter and turbines without a visibility meter 

must not exceed 1500 metres. The most 

unfavourable value of all meters must be used 

for the entire wind park. If one of the meters 

or the management system fails, the beacons 

must be switch to 100% output. All visibility 

measurements are evaluated to form a mean 

value every ten minutes. XC100-FC provides 

detailed warning and fault indications for this. 

A central beacon management system must 

carry out essential tasks in accordance with 

the General Regulations for the Lighting of 

Obstacles to Aircraft September 2, 2004: It 

should thus synchronise the flash sequence in 

a wind park, and if necessary, manage the 

measurement of visibility and ambient 

brightness in order to control the beacons, as 

well as document the parameter-based 

control. 

Modular PLC with fibre optic 

fieldbus interface 

XC-CPU101-FC is the name of the powerful 

modular PLC with the CANopen fibre optic 

fieldbus interface from the Moeller XC100 

range of programmable controllers. This 

ensures highly noise-free data transfer – even 

in environments susceptible to excessive 

electromagnetic interference. 

As an alternative to the serial programming 

interface, the XC100 can also be programmed 

via the CANopen fieldbus, thus opening up 

the possibility of use in decentralised systems. 

The entire installation can thus be operated 

and programmed centrally as well as from a 

distance. Other features include an integrated 

real-time clock as well as a slot for a Multi- 

Media Memory Card (MMC with standard file 

system). MMC allows operating system, 

application program or even recipe data to be 

updated. 

The PLC comes with eight digital inputs and 

six short-circuit-proof outputs. Four inputs are 

designed as interrupt inputs, thus enabling a 

simple and direct response to events, 

irrespective of the cycle time. 

The modular PLC can be expanded locally with 

up to 15 XIOC signal modules. A wide range 

of digital, analog or communication modules 

are available for use. The high density XIOC 

I/O modules enable users to connect up to 32 

I/O points. The XC100-FC has an outstandingly 

compact design with a 30 millimetre mounting 

width and 100 millimetre height. All I/O 

signals are wired using pre-assembled cables 

thus saving valuable time. With the 

XC100/200 controllers, users can create a 

maximum expansion with up to 494 digital 

signals – with a mounting width of only 510 

millimetres. 

CONCLUSION 

Enercon has been a Moeller customer for 

years and appreciates the quality of its 

products, service and reliability. Enercon 

has therefore been using Moeller 

components, such as contactors and 

control circuit devices, for a long time. 

The automation solution in the wind 

turbines consists of several components 

networked together via fibre optic cables 

to ensure noise-immune data transfer. 

The XC100 with the fibre optic CANopen 

interface fitted into Enercon's automation 

concept perfectly. The fieldbus network 

also enables data transfer to higher-order 

systems as well as central programming. 

The flexible XIOC signal modules also 

ensure optimum adaptions to the task 

at hand. 



Fully Automated 

Brochure & Book Binding 

Sigloch Maschinenbau offers special machines for binding 

brochures and books. This ranges from gathering machines, 

adhesive binding machines, endpapering machines, to bookback 

gluing and back-lining machines, drying conveyors, nippers and 

ribbon inserting machines. The flexible individual components 

are integrated in a high-performance system. Moeller 

technology helps the automated machines achieve short 

resetting times, ensure convenient operation and optimum 

operational reliability. >>> 



13

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The processing of small print runs with short 

setting times economically, safely and reliably 

– this is the principle by which Sigloch builds 

its standard compliant machines for the low 

and medium performance range. When 

designing complete book production lines, 

Sigloch uses CAD system planning to ensure 

optimum production and material flow 

logistics with the space available. With many 

years of experience in the development and 

manufacture of complete systems, Sigloch also 

offers modified machines or implements 

special requirements in terms of formats. 

Specialists at Sigloch Maschinenbau also 

THE COMPANY 

The Sigloch Group, based in Blaufelden, 

has developed from a traditional book 

binder in 1883 into today's ultra-modern 

industrial company with different 

subsidiaries. Around 600 employees work 

in the business fields Bookbinders/ Edition, 

Distribution and Engineering. Sigloch has 

extensive experience in highly automated 

production systems for manufacturing 

brochures and for hardbound books, as 

well as in the requirements of cascaded 

production lines. They are designed to 

ensure optimum availability, reliability and 

service life. From the mechanical 

engineering workshop arose one of the 

leading machine builders for bookbinding 

machines with its own developed and 

future-oriented technologies that are used 

worldwide. The range of services also 

includes customer training seminars for 

machine operators. The Sigloch 

bookbinding centre also handles special 

formats such as atlases and multi-volume 

encyclopedias, such as the high quality 

Brockhaus edition. 

develop special connections and links for the 

optimum integration of third-party machines. 

Efficient control technology 

Two machine types illustrate the fully 

automated construction design: The ZTM 7043 

gathering machines and the KB 4300 perfect 

binder. The ZTM 7043 gathers the folded 

signatures or individual sheets in up to 24 

stations and passes them on to the binder via 

a link. A cascade control enables the machine 

to be filled or emptied automatically. The 

special features of the ZTM are the smooth 

removal of the product from the stacking 

magazine, the fast adjustment of the 

magazine to different formats, and also the 

adapted angle of the transport channel, as 

well as specially designed guide plates for lowfriction 

transportation. 

The 17-clamp KB 4300 perfect binder (4300 

cycles/h) is used for producing glue or thread 

bound brochures with the stations back 

processing, gluing, rotation cover feeder and 

press. Two back processing stations prepare 

the block for back gluing with hot melt or PUR 

adhesives. The cover is fed by the rotary cover 

feeder. Here the integrated scoring station 

prepares the cover for optimum positioning 

on the book block. The press station then fixes 

the cover to the block. A second press station 

integrated at the side of the discharge unit is 

used for processing difficult cover materials. A 

belt discharge system finally transfers the 

products to a conveyor system for transporting 

to the downstream processing systems. 

XC200 modular PLC and XVH300 touch panel 

Both machines use a similar automation 

solution. A Moeller XC200 is networked with 

several XI/ON remote I/O 

modules. CANopen is 

used inside the machine 

for communicating with 

the field modules. The 

intelligent drives are also 

connected via the 

CANopen bus system. 

Ethernet is used for the 

connection between the 

PLC and the HMI unit, 

and also for networking 

the machines. Moeller 

XVH300 and XV400 

touch panels are used 

for the HMI. 


The Easy PageMachine 

(EPAM) visualization tool 

is specially designed for 

graphical user guidance 

with touch systems, and

enables visualization parameters to be set 

without any extensive programming. The 

integrated RemoteControl client/server 

functionality can be used for mobile 

applications, particularly for the testing and 

commissioning of large-scale machines. This 

compresses the actual screen content of the 

field touch display and transfers it with a 

minimum data requirement via wireless LAN to 

the remote client. In this way, each application 

created with EPAM can be automatically 

“mobilised” without any additional 

engineering required. The RemoteControl client 

can be run on different standard devices based 

on Windows Pocket PC 2003 and WindowsCE, 

and so a PDA can be used, for example, as a 

mobile visualization device. The wireless 

communication from the touch panel to the 

PDA is implemented via a standard WLAN 

access point. Integrated password protection 

prevents unauthorised access to the system. 

The XC200 not only stands out in terms of 

classical PLC criteria such as memory and 

processing speed (512K program, 256K data) 

and processing speed. The multi-tasking 

operating system also makes optimum use of 

CPU resources. The XC-CPU-201-XV already 

comes with eight digital inputs and six digital 

outputs for connecting to the distributed I/O. 

Two of the inputs can be configured either as 

50 kHz counters, as two interrupt inputs and 

one as an incremental input, as required for 

positioning tasks. The PLC can be expanded 

locally with up to 15 XIOC modules. All 

connections can be implemented via pluggable 

screw and spring-loaded terminals. The XC200 

is also fitted with a slot for MultiMedia memory 

cards (MMC). These can store programs or 

recipe data which can be read into the PLC. 

Other features include the integrated batterybacked 

real-time clock and memory for up to 

32K retentive data. A freely programmable 

RS232 interface, a CANopen fieldbus master 

and an Ethernet interface are provided onboard 

for connecting distributed I/O. The Ethernet 

connection is also used for programming 

access, effective networking between the PLCs 

and for visualization. It also supports remote 

programming and diagnostics. The OPC server 

also simplifies the connection with standard 

OPC client applications. Furthermore, all XC- 

CPU-201…-XV devices come with an integrated 

web server. This allows user-defined web pages 

to be loaded without the need for any 

additional tools. These pages are simply created 

beforehand by the user in the easy Soft 

CoDeSys software. Any web browser can thus 

be used for displaying data from the PLC for 

diagnostics tasks, without the need for any 

special visualization tool. 

Moeller consistently developed the touch 

panels of the XV series to ensure optimum cost 

efficiency in machine building and industrial 

automation: XV panels are low-budget systems 

that are available with infra-red or resistive 

touch technology. They are used as HMIs for 

data management and for visualization. The 

touch panels come with integrated CANopen, 

Ethernet (10/100 MBit) and RS232 interfaces 

onboard for communication. The systems are 

provided with a RISC processor (32-bit) with a 

sufficiently sized memory of 64 MB. The 

removable CompactFlash offers a high level of 

flexibility: CompactFlash cards enable users to 

adapt the memory size for data, such as project 

or recipe data, to the requirements at hand. Its 

compact design and small mounting depth also 

allow the touch panels to be integrated in 

machines where space is at a premium. The 

touch panels (IP 65 front protection) have been 

developed for industrial use in international 

markets and also come with CE, UL/c-UL 

approvals, as well as explosion protection for 

Zone 22, category 3 D. 



CONCLUSION 

Otmar Weber, responsible for electrical 

engineering of the gathering machine 

and perfect binder at Sigloch, explains: 

“We also use Moeller technology for our 

newly developed machines. With the 

appropriate hardware and software, our 

customers are investing in products with 

the highest operating and safety 

standards. No wonder, since our 

machines often have to be kept running 

continuously for 10 to 15 years. In future 

we intend to initiate production in the 

machines and lines order-based from the 

control room via a data server. Our 

machine building and the automation 

from Moeller are already designed for 

this future option.” Markus Hesselmeier, 

head of electrical design at Sigloch 

Maschinenbau, is particularly proud of 

the control cabinets that have been 

reduced in size: “Thanks to our wiring 

with Moeller components, they can be 

considerably reduced compared to the 

previous volume.” 

Contact: www.sigloch.de 


15

16 

Environmentally Friendly 

Football Stadium – Simply easy 

New sports stadiums were built for the World Cup 2006 in Germany and others were modernised 

to meet the demanding requirements involved. This was also the case for the Gottlieb-Daimler 

stadium in Stuttgart, where environmental protection was also part of the extensive modernisation 

measures. Structures of this size represent a real challenge to the water supply and drainage 

system. ARIS, a leading manufacturer in rainwater harvesting systems, made use of Moeller's 

easy control relay. 

Picture: Landeshauptstadt Stuttgart, Sportamt 


Harvesting rainwater 

The Gottlieb-Daimler stadium in Stuttgart is 

now one of the most advanced and purposebuilt 

sports stadiums in Europe and will be the 

venue for six 2006 World Cup matches. The 

distinctive feature of the Gottlieb-Daimler 

stadium in Stuttgart is the steel cable truss 

construction of its membrane roof. The roof 

covers all the spectator seats with a total area 

of approximately 32 000 m 2 . When it rains, the 

large volumes of resulting surface water 

normally have to be removed via the drainage 

systems. The modernisation measures for the 

stadium included the construction of a 350 m 3 

underground cistern in which the rainwater 

from around 14 000 m 2 of roofspace is 

collected and stored. This stored rainwater is 

primarily used for watering the grass areas 

and rinsing the toilets. This saves the Gottlieb- 

Daimler stadium annually around 8 000m 3 of 

drinking water and is the equivalent of two 

thirds of the annual requirement. The 

harvested rainwater is filtered entirely 

mechanically without any external power 

source and is made available without any 

chemical treatment. 

The core of the fully automated rainwater 

centre of the ARIS modular rainwater 

harvesting system is the function tank that is 

specially designed for the building and is 

provided with a pressure booster system and 

drinking water supply. Four booster pumps with 

a delivery rate of 25 m 3 /h ensure a constant 

system pressure of 7.5 bar. The pumps are 

equipped with Moeller soft starters from the 

DS4 series in order to prevent water pressure 

surges caused in hydraulic systems during 

switching operations. During long drought 

THE COMPANY 

ARIS GmbH, is based in Wernau and was 

founded in 1997. It produces complete 

systems for rainwater harvesting, storage and 

drainage. Several related patents underline 

the competence of ARIS in this futureoriented 

branch. The services of ARIS range 

from consultation, support during planning 

and engineering via manufacturing, up to 

turnkey systems and service. The systems are 

installed via local specialist companies. 

Contact: www.aris-systeme.de 

periods and if the cistern is empty, the drinking 

water is topped up in the function tank by 

means of a solenoid valve. Another feature of 

the ARIS rainwater harvesting system is the 

patented KIM! sensor: KIM! stands for ‘cablefree 

integrated measuring process’ and 

therefore measures the level of the cistern 

without the need for any external sensors. 

easy controlling, monitoring and signalling 

An easy821-DC control relay controls the 

rainwater centre. The analog inputs of the 

easy device are used to monitor the system 

pressure and level in the function tank as well 

as in the cistern. The four booster pumps are 

controlled depending on the set pressure. The 

control relay switches the individual pumps on 

or off according to the pressure and also 

handles the exchanging of pumps. The control 

relay detects important system information 

such as leakages, any slight seepage in the 

system or pipe breaks and relays this 

information accordingly. 

Thanks to the analog inputs integrated in the 

easy device and the software functions, the 

levels in the function tank and in the cistern 

can be measured very cost-efficiently. The 

levels are evaluated internally in advance for 

the system control and indicated as a 

percentage in the display integrated in the 

easy device. All specific system parameters can 


be entered rapidly and simply in the 

parameter menu of the control relay. System 

states and operating data are shown in the 

display. The integrated KIM! sensor system 

allows straightforward and fast installation 

and commissioning of the system, even when 

the cistern is already filled. 

Open communication 

Communication modules can be used to 

connect the easy devices to Ethernet, Profibus 

DP, CANopen or DeviceNet. The OPC server is 

a standard feature of easy800 devices for 

simpler remote visualization and operation. An 

easy control relay can be integrated without 

any problem in the building services 

management system or connected to SCADA 

systems via the OPC server. 

CONCLUSION 

With easy, ARIS was able to replace the 

previous proprietary control system in its 

modular rainwater harvesting systems 

with a control relay that is widely used 

and well-established on the market. 

Decisive factors for their choice were its 

outstanding price/performance ratio and 

the ability to expand easy at any time. 

With Moeller's easy, ARIS was also 

investing in a future-proof system under 

continuous further development, which 

also allows data exchange to other 

controller systems and remote diagnostics 

and maintenance. 



Textüberhang 

17

18 

Automation in Laboratory 

and Pharmaceutical Technology 

The requirements placed on the equipment of 

laboratories for testing pharmaceutical products 

are increasing continuously, whilst maintaining 

the safety of all laboratory users remains a major 

importance. Ehret GmbH & Co. KG Labor- und 

Pharma- Technik has developed the "Biological Air 

System Bio.A.S" product series that fully meets 

these demanding requirements. 


MFD-Titan: control, regulation and 

visualization in one 

The Air System Bio.A.S. requires a highly 

flexible closed-loop controller, for which 

Ehret chose Moeller's MFD-Titan. The multifunction 

display from the easy series is a very 

cost-efficient solution. Open-loop control, 

closed-loop control and visualization are 

combined here in one compact device. The 

range of options provided by MFD-Titan 

appealed to Ehret immediately. The device is 

able to handle all the functions that are 

important for Bio.A.S.: 

• Complete open-loop control 

• Display of alarms and messages 

• Operating hours counters (device, 

filter, maintenance) 

• Display of air changes, air volume, 

temperature and humidity 

• Complete parameter assignment 

of the Bio.A.S 

• PID controller for regulating the air change/h 

Messages that require an immediate response 

for the protection of persons and animals 

are relayed as alarms via the building services 

management system. Information messages 

that are not time-critical, which, for example, 

draw attention to maintenance intervals 

are only displayed on the MFD-Titan. The 

limit values that trigger alarms or information 

messages are password protected from 

unauthorised access: only the specialist 

personnel is able to modify values, parameters 

and display conventions. The normal operator 

level can be accessed on the other hand 

without a password. The patented Bio.A.S. is 

also available in other languages for 

international use. 

The full-featured graphic display meets the 

demanding industrial protection requirements 

of IP65. Two freely programmable status LEDs 

are used to display additional operating states 

and signal alarms. A user-friendly graphic 

THE COMPANY 

Ehret GmbH & Co. KG Labor- und 

Pharmatechnik is based in Emmendingen, 

and specialises in the manufacture and 

sale of laboratory and pharmaceutical 

equipment for science, research and 

industry. The product range consists of 

laboratory and pharmaceutical 

equipment, clean room and isolator 

technology, as well technology for animal 

protection, husbandry and research. 

editor considerably simplifies parameter entry 

and the on/off switching of auxiliary units, and 

allows the creation of up to 255 screens, each 

of which can be assigned with their own key 

functions. 

MFD-Titan can be integrated easily in larger 

automation solutions since the compact 

controller can handle all the relevant 

standards from Profibus DP, AS-Interface, 

CANopen, DeviceNet, OPC up to Windows 

DLLs. All maintenance-free and vibrationproof 

spring-loaded terminals ensure a high 

level of operational reliability. 

The highlight: the highly flexible 

PID controller 

The possibility of the integrated PID controller 

was of particular importance to Ehret. It comes 

as a fixed function block element in the MFD 

and is highly flexible so that all the individual 

closed-loop control components can be 

activated and deactivated individually. The 

closed-loop control parameters can be defined 

as constants or using variables. 

Freely configurable nonlinear conversion 

table for PI control 

The air change/h is a key factor in the 

regulation process, and varies according to the 

conditions of the system. For this reason, every 

system must be calibrated individually. The 

relationship between pressure and air change/h 

is nonlinear. The service technician decides 

how many interpolation points (3 to 8) are to 

be used, depending on the quality of the 

system. Commissioning is child's play since the 

pressure can be set as a percentage and the air 

Number of 

interpolation 

points 

Entry in 

menu 1 to 3 

ActVal: xx % 

Blower unit 

AC/h measuring 

cage 

ManVar. xx % 

(Blower output) 



change/h can be set as required at every 

support point. The MFD-Titan performs the 

conversion in both directions. 

CONCLUSION 

Günter Unmüßig, R & D: “The MFD-Titan 

combines open-loop control, closed-loop 

control and visualization functions in one 

device. The ability to adapt texts and 

symbols in the graphic display to the 

needs of laboratory customers and offer 

them in any language required are good 

reasons for using MFD-Titan in this price 

segment. A modern industrial controller 

had previously been used for the same 

closed-loop control task. This had 

performed the regulation function very 

well; however, it did not provide 

laboratory customers with the desired 

transparency in terms of operating and 

information options. The four basic 

features that attracted us to the MFD- 

Titan are the PID control, the multilingual 

option, the alarm and information 

messages, as well as the key feature of 

storing a nonlinear curve in the MFD from 

a calibration measurement at the 

installation. Higher-level process control 

systems are increasingly being used in the 

laboratory and pharmaceutical sector. For 

this the MFD provides an open OPC 

interface so that it can be integrated in 

any monitoring or control system.” 


1 2 3 4 5 6 7 8 

3 % 7 % 15 % 19 % 22 % 25 % 31 % 57 % 

17 AC 30 AC 49 AC 55 AC 59 AC 63 AC 69 AC 81 AC 

19 % 23% 25 % 28 % 34 % 48 % 74% 100% 


19

20 

MFD-Titan and easy: 

Modern Control Technology 

for Rugged Starting Resistors 

GINO starting resistors are used when large 

electrical machines cannot be switched with 

frequency inverters due to their power, difficult 

climatic conditions or due to fluctuating power 

supply networks. As they are frequently subject 

to extreme loads, control operation and 

visualization must also be implemented with 

rugged and maintenance free devices. The 

solution: MFD-Titan multi-function display and 

easy control relays. 


Large machines cannot always be started 

directly: many pumps, fans, and mixers, as well 

as belt drives and shredders can only be started 

with mains-friendly starters. For these kinds of 

applications, slip-ring motors with starting 

resistors are used. GINO manufactures rugged 

and maintenance-free oil and control starters 

that can withstand the extreme conditions. 

With a suitable design and control system, the 

starters can also be used for speed control. 

Oil or air-cooled? 

Starters are oil or air-cooled, depending on the 

application. Oil-cooled starters are more 

compact and more economical than air-cooled 

devices. The oil is used here solely as a heat 

store. The large thermal time constants and the 

resulting long cooling periods only make them 

suitable for use in applications with a low 

number of startup operations per hour. For 

applications with a large number of startup 

operations per hour, the use of air-cooled 

starting resistors with shorter cooling periods is 

more economical. The size of the starter 

depends on the oil volume and the required 

thermal capacity. The operations per hour can 

be determined by the size of the tank surface: 

ribs and radiators can quadruple the number of 

operations possible. Classical applications for oil 

starters are machines that require a high 

starting torque such as all types of mills and 

crushers. Even today, there are no other 

economical alternatives for oil-cooled starters. 

A special case involves degrees of protection 

higher than IP23, where the heat is dissipated 

by means of heat exchangers. 

THE COMPANY 

GINO GmbH Elektrotechnische Fabrik 

is based in Bonn and Eisenach, and 

began life as a foundry at the beginning 

of the last century under the name Carl 

Wiemann GmbH. The product range 

includes air and oil-cooled starting 

resistors, pre-wired power, braking, 

filter and grounding resistors for 

applications in industry, and in drive, 

power station and traffic technology. 

Contact: www.gino.de 

Control under extreme conditions 

GINO accordingly places high demands on the 

communication modules for control, operation 

and visualization. Devices of the easy series and 

MFD-Titan have become first choice for these 

tasks: The easy series provides modules for data 

and signal exchange with a control station via 

Profibus, DeviceNet or CANopen. In this way, 

the machine is monitored for blocking via the 

counter input of an easy800. 

With the simple and easy-to-handle control 

relay, customer requirements can be 

implemented swiftly using state-of-the-art 

technology, such as the acquisition of external 

signals, visualization, logging and 

communication. The brush lifting device of the 

slip-ring motors is also controlled via easy. 

Compared to other control and operating 

solutions, easy is highly cost efficient. The 

modular series offers all the required 

enhancement options required including the 

frequency counter input. 

Visualization with MFD-Titan 

If necessary, an MFD-Titan display can be used 

for defining parameters and for logging. 

MFD-Titan is designed as an industrial device 

for rugged operating conditions in machines or 

systems. The operating temperature range is 

thus from -25 to +55 °C. Furthermore, all 

connections are provided with maintenance 

free and vibration-resistant spring-loaded 

terminals. The full-featured graphic display 

(IP65 protection) with 132 x 64 pixels also 

comes with a backlight that can be switched on 

as required. The operator keypad can also be 

configured to individual requirements. 

Oil starter types vary in their number of startup 

stages as well as in the various monitoring 

parameters such as oil temperature or 

switching state. The optional OPC server is 

available for easy800 for simpler remote 

visualization and operation. Together with the 

easy Ethernet module and the visualization 

written in C#, the different oil starter types can 

now be configured individually from the PC. All 

relevant parameters of the startup operation 

are clearly displayed, and the operator can 

make interventions if necessary. The OPC client 

also enables users to implement their own 

control station. 

Contactors 


GINO also prefers Moeller products when it 

comes to contactors. These are selected on the 

basis of criteria determined and tested in the 

laboratory. GINO places special importance on 

the switching of resistive loads and the currents 

and voltages present during starting. As the 

frequency of the currents and voltages becomes 

close to DC current as the synchronous speed is 

approached, contactors must also be able to 

carry out these difficult switching operations 

properly. The values of Moeller's contactors are 

ideal for this. 

CONCLUSION 

Dipl.Ing. Chr. Schink, from GINO R&D had 

this to say: “Our maintenance free 

starters are renowned for their highly 

rugged design. For this to continue, we 

ensure that the elements used for 

control, operation and visualization also 

meet the most stringent requirements. 

The user-friendly modules of the easy 

series and MFD-Titan are exactly the right 

choice for us. Thanks to their simple 

expandability, they can be adapted 

flexibly to the requirements at hand. Our 

customers just pay for what they actually 

require, whilst still maintaining the 

possibility of all options in the future. The 

short delivery times and Moeller's 

competent services were also important 

factors in choosing easy.” 



21

22 

Field Service – 

Active Round the World 

Our customers worldwide value Moeller’s Field Service 

because they know they can always rely on its varied 

support system. 

Operation in 

St. Petersburg 

The situation: 

Russians also enjoy waffle pastries, and fully 

automated waffle production plants are 

installed in St. Petersburg in Russia. The waffle 

mix at the ZAO “Zolotoj Kljutschik” pastry 

plant is automatically stirred, baked and 

produced in different types of flat waffle with 

fine, medium or deep squares. Imprints with 

company logos, special engravings, fillings 

with cream, caramel, chocolate or jam provide 

for a wide range of tastes. 

The fault: 

The waffles of the St. Petersburg production 

plant did not have the same degree of 

browning after the baking process. This was 

really puzzling since the state-of-the-art 

production system from Germany, provided 

with innovative Moeller technology, had 

passed all final checks before shipment. There 

were also no indications of potential faults 

after commissioning. 

The supplier of the flat and hollow waffles 

systems, Herbenstreit from Mörfelden- 

Walldorf, travelled to the site with the Moeller 

Field Service and located the fault 

systematically. The oven heating elements 

were controlled by a Moeller XC200 and 

Moeller DM4 soft starter. The network analysis 

indicated an asymmetrical current depending 

on the reference value set. The soft starter was 

then run with a setpoint potentiometer, which 

also showed imbalanced output currents. A 

phase exchange and the halving of the 

electrical heating output didn't give any 

further clues. Only after the currents and 

voltages were measured thoroughly with an 

oscilloscope through the entire setting range 

was it clear that a break in the supply voltage 

was causing premature voltage zeros, so that 

the thyristors were firing too early. 

The cause: 

The voltage breaks were due to uk values 

(relative short-circuit voltage 6.5 and 9 

percent) of the supply transformers being too 

high. This resulted in voltage drops when a 

corresponding current load was present. 

The solution: 

A protective circuit for the thyristors, new 

choke dimensions and the installation of a 

suction filter rectified the problem. Zolotoj 

Kljutschik now produces evenly browned 

waffles. 


Operation 

in Minneapolis 


Siyeza Creative Foods, LLC is a company based 

in Minneapolis, USA, that produces all types of 

pasta for deep frozen products. A Moeller 

touch display-PLC (HMI-PLC) controls the 

production machine. All signals are passed to 

the HMI-PLC via a XI/ON remote I/O with a 

Profibus gateway. Other Moeller components 

include five frequency inverters as well as 

RMQ control circuit devices. 

The fault: 

Normally the machine is switched on and 

started up around 7.00 am every morning. The 

screen, however, stayed dark several times, 

and the touch display PLC only booted up 

after the third or fourth power up attempted. 

Even after the devices were replaced and the 

Cable Train Operation 

at Airport Toronto 


The new passenger transit system at Toronto 

Airport in Canada links the new main terminal 

MTB1 and terminal 3 with a parking lot 

situated outside. Up to 2150 passengers can 

be transferred in one hour in each direction. 

The mass transit system consists of two railbased 

shuttle trains that are driven via a wire 

cable. The wire cable is driven continuously at 

one point and run over the entire section, 

similar to the principle used with a cable car. 

The shuttles are rigidly connected to the wire 

cable and do not have their own drive or 

braking equipment. Acceleration, braking and 

stopping are carried out exclusively via the 

wire cable. All Cable Liner Shuttles are fully 

automated and do not require a driver or 

escort personnel. The 1.5 km long section 

between the end stations is covered by the 

shuttles in 3.5 minutes. 

power supply checked, the same problem 

occurred every morning. 

At 6.15 am in the morning the Moeller Field 

Service once more confirmed the fault 

described. The tracing of the power supply 

and the Profibus signals did not produce any 

more findings as to the cause of the fault. 

Initial suspicions arose after asking employees 

when and how the equipment was cleaned. 

Answer: An intensive high-pressure cleaning 

of factory hall floors, walls and all machines 

was carried out every night after production 

had ended. 

The cause: 

The next day, another test was carried out at 

5.15 am. It was then that the cause was 

found. The inside of the control cabinet doors 

showed considerable signs of wetness and the 

devices were consequently soaked in moisture. 

The humidity on the PCBs caused creepage 

currents that produced the undefined device 

behaviour. In short, the touch display PLC was 

being operated outside of the specifications. 


The Cable Liner Shuttle technology from DDC 

(Doppelmayr Cable Car, Wolfurt, Austria) is 

designed for harsh climatic conditions. Thanks 

to the wire cable drive system, snow and ice 

have no effect on the traction between the 

wheel and the rail. This concept also stands 

out on account of its very low noise, without 

any rotating wheels. 

The operation: 

The power supply for this shuttle is 

implemented with Moeller NZM circuitbreakers. 

UL approval, a high switching 

capacity and total reliability were the principal 

reasons why these devices were chosen. The 

Moeller Field Service commissioned the 

system together with a local panel builder 

after the cable train had been assembled and 

installed. This was because of the tight time 

schedule involved. It took only one day to 

install the NZM2 circuit-breakers and carry out 

all the necessary settings. The cable train now 

operates as if driven by a ghost, and even a 

hotel close to the railway does not experience 

any disturbance. 

Solution – astonishingly simple: 

The Moeller Field Service recommended that 

the customer used a control cabinet with 

protection to IP 66 which should not be 

positioned directly at the machine. 

MS1313 


23

24 

Around 1000 Circuit-Breakers 

with 1000V Operating Voltage 

for the AVE Madrid-Lleida 

Moeller has collaborated with Cobra Instalaciones y Servicios in the 

development of the Sistema de Detección II project involving the supply of electrical 

equipment for the AVE high-speed rail section between Madrid and Puigvert in Lleida. The AVE 

now completes the section from Madrid to Lleida in approximately one hour less than before. The 

train reaches a speed of over 300 km/h for about 100 kilometres of the 530 kilometre section. The 

project used 730 NZM2 1000V circuit-breakers and 230 NZM10 1000V circuit-breakers of which all 

were equipped with motor operators. 

The Spanish railway company RENFE are the operators of 

the AVE. The Sistema de Detección II project consists of a 

power supply network provided with sensors along the 

section concerned. Twelve different types of sensors are 

used for the following functions: detection of objects 

falling on the rails in front of tunnels and overpasses, fire 

detection in tunnels, wind detection and hot box 

detectors. These sensors monitor all safety levels during 

operation according to the railway regulations for high 

speed travel. The network provides a constant power 

supply to the system, which integrates a number of its 

own substations, transformers or generators. 


AVE 102 built by Bombardier

The entire power supply network is controlled 

from a central control station (CRC) in 

Saragossa via fibre optic cables (FOCs). 

Altogether 241 sections were installed along 

the line. These consist of so-called consumer 

panels for supplying the different sensors as 

well as supplier panels that guarantee the 

constancy of the power supply. 

The entire line is fed with a 750V AC singlephase 

voltage which is transformed in each 

section to 230V AC. All elements are remotely 

controlled with 24V DC and 125 V DC. 

The consumer and supplier sections handle the 

following functions 

Consumer sections: 

• Feeding the single-phase current at 750 V 

AC from Lleida and Madrid. 

• Voltage transformation from 750 V AC to 

230 V AC. 

• Voltage supply of 230 V AC to the electronic 

equipment (sensors). 

• Remote control via fibre optic cable from a 

central control station. 

Supplier sections: 

• Voltage supply of 750 V AC and distribution 

in Lleida and/or Madrid. 


230 V AC. 


750 V AC. 

Moeller industrial switchgear for the 

harshest operating conditions 

Railways have some demanding requirements, 

and this especially applies to high-speed rail. 

The operating conditions are extremely harsh, 

and components must be particularly rugged in 

order to ensure reliable and safe service over a 

long lifespan. This is particularly the case since 

railways are considered to be the safest and 

most reliable form of transport. These 

demanding requirements are reflected in the 

special regulations and specifications applicable 

to railways. The relevant standards in Europe 

refer to other general standards that stipulate 

the requirements of ambient conditions, such 

as shock and vibration, an extended 

temperature range, humidity, salt mist or 

voltage variances. Operational reliability has to 

be ensured for very long periods. 

AVE (Alta Velocidad Española) 

The AVE (Alta Velocidad Española) is the 

Spanish high-speed rail system based on 

the French TGV. Three connections are as 

yet designed and completed for use by 

high-speed trains in Spain: Madrid - 

Toledo (since 2005), Madrid-Lleida (since 

2003) and Madrid-Seville (since 1992). 

The 2005 Madrid - Barcelona section has 

been under construction since the 

beginning of 2005. The sections were 

constructed for European standard gauge 

systems instead of the standard wide 

gauge used in Spain. The reason for this 

change was to later enable connection to 

the high-speed rail network in France. 

The normal track width in Spain is 

otherwise 1,668 mm, compared to the 

standard 1,435 mm used in most parts of 

Europe. The Spanish railway company, 

RENFE, is the owner of the AVE, and 

bought the train protection system and 

the overhead contact line of the 

completed sections from German 

suppliers. Moeller components, 

particularly circuit-breakers NZM 2 to 4 

for 1000 V, provide the reliable power 

supply for the Madrid – Lleida section. 



Moeller supplied different products for the 

AVE, such as the NZM circuit-breakers up to 

1 600 A, Xpole modular rail-mounted devices, 

DIL contactors from the xStart series and easy 

control relays. 

The NZM circuit-breakers are designed with 

an operating voltage of 690 V AC for switch 

operations in two-phase systems. 

Around 1000 NZM circuit-breakers are used 

for an operating voltage of 1000 V and 

different current ratings from 20 A. All the 

circuit-breakers are remotely controlled and 

are fed with a 24 V DC auxiliary voltage. 

Around 1000 Xpole protective switches are 

used with different current ratings for various 

applications. Each protective switch is 

remotely controlled with a 24V DC supply and 

control voltage. 

A system involving easy800 control relays is 

used for the selective tripping of circuitbreakers 

that protect and co-ordinate the 

750V AC power supply (operation at normal 

and maximum load), and where the specified 

current rating must be observed precisely. 

CONCLUSION 

RENFE, the Spanish railway company, had 

decided on a further development of the 

TGV Atlantique for its new normal gauge 

sections in Spain. Thanks to German 

suppliers, the AVE is a derivative of the 

TGV with the German LZB linear train 

control system. During test runs on the 

Madrid - Seville section the AVE set 15 

reached speeds of 356.8 km/h, a Spanish 

record. 



25

26 

NZM Circuit-Breaker Series 

Now with New Device 

Versions and Accessories 

Moeller has considerably expanded its NZM series of compact circuit-breakers with efficient device 

versions and accessories. This includes, for example, a new molded case switch with integrated 

short-circuit protection, which enables the switch to be used irrespective of the type of protective 

device used upstream. 

It now meets both the requirements of 

IEC/EN60947-2 Annex L, as well as being 

compliant with North American UL489 and 

CSA-C22.2 No.5-02 regulations. In this way, it 

can be used as the main switch for machines 

and is particularly suitable for exports to 

North America. 

A complete device series consisting of circuitbreakers 

and switch-disconnectors for an 

operating voltage of 1000V 50/60Hz is also 

new. The switches are derived from the 

standard circuit-breakers with an operating 

voltage of 400V, cover rated currents from 20 

to 1600A, and are designed with compact 

dimensions and cost efficiency in mind. The 

short-circuit breaking capacity of up to 20 kA 

enables devices to be used in applications 

such as in wind turbines, tunnels or mines. 

A mechanical locking feature will soon be 

available for circuit-breakers with a remote 

operator. Bowden cables enable switches of 

different sizes to be combined and arranged 

in different control panel sections. 

For the compact 630A NZM3 circuit-breaker, 

Moeller is offering terminal expansions that 

enable the connection of up to six cables 

with 240mm 2 per phase, as well as terminal 

bars of up to 80 mm in width. 

Moeller has also enhanced the residual 

current protection for circuit-breakers: 

residual current trip blocks with response 

values of 30...3000mA are now available for 

the smallest 160A circuit-breakers from the 

new series. The block can be fitted at the side 

or underneath the NZM1 circuit-breaker, 

depending on the installation requirements. 

An early-warning LED function indicates 

supply leakage currents already before 

tripping. Two auxiliary contacts are used in 

automated systems for remote fault 

indication. 

Fieldbus communication for all circuitbreakers 

with electronic releases has been 

extended with interfaces for CANopen and 

DeviceNet in addition to the Profibus 

interface already available. This enables users 

to implement the polling of diagnostics and 

operating data, the logging of current values, 

the parameter definition and control of the 

circuit-breakers as well as serving as a motor 

start function. In addition to detailed remote 

diagnostics, such as the transfer of warning 

and trip indications, and the display of load 


currents, the fieldbus allows the circuitbreakers 

to also be operated remotely and 

automatically via their relay outputs, with no 

additional cost. 

Moeller also added a 1600A version for the 

space-saving side wall operation of circuitbreakers 

and switch-disconnectors. The 

rotary handle can either be fitted on the 

front or side wall of the switch or on the side 

wall or mounting plate of the switching 

cabinet. Moeller's range of mounting kits for 

all main switch applications in machine 

controls is now covered up to a rated current 

of 1600A. 


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on the following topics 

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Industrial switchgear 2006 product overview 

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Electronic Catalogue 


SOLUTIONS13

Full Power 

in the Compact Class: 

easy Control 

s 

Automation products, 

system solutions and services 

all around the PLC and 

visualization, enhancing the 

performance of machines 

and systems. 

——— PC based HMI-PLC 

und PLC 

——— Embedded 

HMI-PLC 

——— Modular PLC 

——— Compact PLC 

——— HMI 

——— Remote I/O 

——— Operating and 

control relays 

The new easy Control compact controller allows you 

to move conveniently in the PLC world and access 

the large range of easy accessories on offer. 

4 

015081 065417 

Moeller Electric GmbH 

Fax (0228) 602-2275 · 

info@moeller.net 


The new easy Control compact controller demonstrates 

how Moeller has consistently advanced the success story 

of its easy control relay. 

easy Control rounds off the high end of the existing 

easy performance range and closes the gap between 

the easy control relay and the PLC. 

• Programming with easy Soft CoDeSys 

to IEC 61131-3 

• Large 256 K program/data memory 

• High processing speed of 0.3 μs per instruction 

• Versatile networking: 

Ethernet, CANopen, Easy-NET, RS232 


A06/08A

SOLUTIONS 13 - Moeller Electric Parts

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