SOLUTIONS - Moeller Electric Parts

N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E WMoeller Safety Manual:The way to the safe machine compliant with EN ISO 13849-1and EN IEC 62061Moeller has published the “Safety Manual”for machine and system builders, trainersand trainees and all those wishing to cometo grips with the subject of “machine andsystem safety”. Like Moeller‘s Wiring Manualwhich has been an established publication fordecades, this new technical guide providesan easy entry level to all the issues involved insafety technology.The CE compulsory marking, stipulated inthe current Machinery Directive 2006/42/EGand in force since the beginning of 1995,has provided the basis for implementing thesafety requirements of a machine. It laysdown the basic requirements for the safety ofmachines which must be observed by machineand system builders in the European singlemarket.The use of harmonised standards forfunctional safety listed in the EU OfficialJournal, such as EN ISO 13849-1 or IEC 62061,is recommended in order to satisfy verificationin accordance with the requirements of theMachinery Directive. Only if the standardswere observed in the design of functionalsafety, can it be presumed in the event of anaccident involving personal injury that theoperator and machine builder has fulfilled allmachine safety requirements.The “Safety Manual” offers a systematicapproach to machine and system safety:Starting with definitions, it categorizes theaspects of the safety system in logical stages,and covers the range from risk assessmentto the selection of safety-related parts ofcontrol systems to the determination of thesafety integrity level. A large number ofcircuit examples with the associated safetyparameters provide further clarification.“Stopping in an emergency (Emergencystopdisconnection)”, “Monitoring ofmovable guards, and open hazardousareas”, “Safe operation and setting” andmuch more. Both the use of conventionalsafety relays and the new easySafety safetycontrol relay are described systematicallyin individual chapters. The easySafety inparticular offers the user versatile solutionsfor several safety requirements, thanks tothe ready-to-use safety function blockswhich simplify compliance with the relevantstandards. In addition to the safety circuitdiagram containing the safety configuration,easySafety also has a standard circuit diagramfor non-safety-related functions, thusproviding an optimum integration of standardand safety functions.Quicklink ID:MS1804Connecting Instead of WiringMoeller SmartWire Gateway for ModbusThe gateway for Modbus RTU (RTU =Remote Terminal Unit) expands Moeller‘srange of fieldbus couplers for theSmartWire connection system. In additionto the SmartWire gateways for Profibus-DP,CANopen/easyNet that are already in therange, it is now possible to connect up to 16contactors, motor starter combinations orSmartWire I/O modules to the Modbus RTUfieldbus. Moeller‘s Modbus gateway roundsoff the gateway series in terms of bothdesign and functionality. All the benefitsof the SmartWire system are retainedwithout restriction, such as error-free andfast control wiring, simple configuration ofthe SmartWire system and the reduction ofinput and output channels in the PLC.The management of SmartWire data as wellas the operation of the SmartWire system issimple, transparent and reliable. The datafrom the SmartWire slaves are providedboth in compressed and expanded datawidth (up to 8 bytes per slave). This allowsmore efficient data transfer and optimumadaption to the performance of the PLC.The fieldbus interface of the gatewayallows both point-to-point communicationvia RS232 as well as the integration of theSmartWire system in an existing Modbusnetwork via RS485.The Modbus gateway (SWIRE-GW-MB)supports data rates of 9.6 Kbit/s, 19.2Kbit/s, 38.4 Kbit/s and 57.6 Kbit/s, andcan be connected to virtually any freelyconfigurable serial interface. The gatewaythus offers a perfect solution for a widerange of small-scale or large-scale machineand system building applications.Quicklink ID:MS18056For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W S + + + N E W SDeep WaterMoeller Field Service ensures correct controlresponse in deep wellWithout water, life is not possible. As groundwater onlyrarely contains any material concentrations that are harmfulto health, it is of particular importance for the drinkingwater supply. Air pollutants released into the ground or theexcessive spreading of fertilisers and pesticides, as well asharmful substances from contaminated sites can severelyreduce groundwater quality and can only be removed fromthe water with great difficulty. Preventative groundwaterprotection is therefore essential and is a key requirement formaintaining high quality potable water. Municipalities aretherefore specifically defining water protection areas withextensive protection requirements.The water supply department for theMontabaur collective municipality operatesa number of well systems in the south of theWesterwald. A new well system was put intooperation in the Montabaur water protectionarea of Höhe in 1991. A complete overhaulof the electrical installation was carried outin 2008. Up to 200,000 m 2 of potable wateris conveyed annually from a depth of 102 m,stored temporarily in a high-level tank, treatedand fed into the water supply network.Moeller supplied the entire control systemfor the water well system. A DF51-340-7K5frequency inverter controls the speed of thepump and thus regulates the water flow rate.The DF51 frequency inverter comes with anintegrated keypad with a four-digit 7-segmentdisplay, a serial interface and with digital andanalog inputs/outputs. Integrated electronicmotor protection, manual restart, DC braking,PID controller and PLC functions are alsoprovided. The actual value required for thecontrol system is received by the PID controllerfrom a flow meter.During the commissioning of the pump controlsystem, a satisfactory control response couldnot be achieved, even by changing severalcontrol parameters. According to the localelectrical fitter, the drive was “oscillating”between the minimum (20Hz) and themaximum (50Hz) frequency. The MoellerField Service was called upon to analysethe problem and rectify the fault. With itsspecialists, Moeller is always able to offer helpwhen system faults have to be examined andrectified. Alternatively, customers can carry outinteractive troubleshooting via the Internetor can access Moeller‘s Field Service databasedirectly.In the case of the pump control system,Moeller Field Service specialists werecalled to the installation. It wasn‘t clearwhether the cause of the fault was dueto an insufficiently parameterised PIDcontroller or was in the measuring systemfor the controlled variable. In the firststep the parameters of the PID controllerwere assigned very slow response settings.This allowed stable states to be achievedalthough the control system becameunstable as soon as flow disturbanceproduced by eddies in the pipe of the flowmeter could be heard. This added to thesuspicion that the actual value measuringwas possibly being corrupted by air presentin the pipe, thus causing an unstable PIDcontroller response. In the second step thecontrol system was examined more closely.The well is located at the highest point inthe entire system, consisting of the well, thepipe and the high-level tank. The high-leveltank, which serves as a storage for potablewater, is located at a lower point than thewell. This difference in height caused air inthe pipe system and therefore corrupted theflow rate readings.To rectify the error, the entry of air intothe flow rate measuring area had to beprevented. A fast solution that could beimplemented easily was found: Reduce thepipe cross section enough so that no aircould enter the section between the pumpand flow meter and thus corrupt the flowrate reading. In order to limit the flowrate to 25 m 2 per hour, the pipe valve wasclosed accordingly. The drive was also runat maximum speed for the first one to twominutes in order to remove any residual airfrom the measuring area. The result wasimpressive since now the control behaviouris continuously stable.Quicklink ID:MS1809For Moeller Electric Sales and Support call KMparts.com (866) 595-96169

Hard to PortContactors set transverse thrusters in motionOnly large ships like mega yachts or container ships with a transverse thruster are allowed to enterharbours on their own, thus enabling them to manoeuver in the harbour basin without the needfor expensive tugs. Transverse thrusters are also called bow or aft thrusters, depending on wherethey are mounted. The manoeuvering system consists of a tube running through the body of the shipacross the direction of motion and a propeller mounted in the centre of the tube, which, dependingon the rotation direction, causes the ship to move to port or starboard by the force of the flowingwater. The well-established Hamburg-based company Jastram offers different manoeuvering systemsand has primarily specialised in transverse thruster systems in the range from 50 kW to 1650 kW. Therheostats for controlling the slip ring motors are switched using reliable and durable Moeller DILMcontactors with vacuum technology.THE COMPANY10The shipbuilding supplier Jastram GmbH& Co KG was founded in Hamburg1889 and is today run by the fourthgeneration of the family. Jastram hasoperations worldwide and specialises inmanoeuvering systems such as rudderpropellers, finned rudders, rudder motorsand bow thrusters for commercial vessels,container ships and mega yachts. Thehigh quality, reliability and long service lifeof its products, as well as its customerorientedservice are the features thatmake Jastram renowned with shippingcompanies and shipyards all over theglobe. (www.jastram-group.com)For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18Bow thruster BU90F, with a tube diameter of 1600mm and a drive output 700 kW, generates a thrust of96 kN at 1770 rpm.Jastram supplies transverse thrusters fornew ships and conversions for older ships.The sailing school ship of the German Navy,the “Gorch Fock” and the “Bodo Supplier”,which were converted to a cable repairand maintenance ship are examples ofvessels that were retrofitted with Jastramtransverse thruster systems. On mega yachtssuch as “Al Mirqab” (Kusch yacht building),Jastram transverse thrusters are used withnoise reduction. The technology and thedimensioning of transverse thrusters areanything but simple, even the mountinginvolves precision work.Structure of a bow thruster systemA bow thruster system basically integratesa drive and gear unit as well as a propeller.Diesel, hydraulic or electric motors are usedas drives.When mounted, the bevel gears of thecyclo palloid gear and the propellers areexpanded hydraulically and adapted to thegear shaft. For this oil press fit, the contactpattern or contact surface is examinedclosely to ensure a 100 percent fit.Transverse thrusters have either a variableor fixed pitch propeller. Variable pitchpropellers are run at a constant speedand the thrust is controlled by changingthe pitch of the propeller blades. Fixedpropellers are driven with slip ring motorsand rheostats as well as frequencycontrolled systems. The circuit of theresistors in the rotor circuit controls thespeed over three to seven stages, and threestagetransverse thrusters are mostly used.Each bow thruster and all individualcomponents are tested and approvedby classification societies such as Lloyd’sRegister (LR), Germanischer Lloyd (GL), DetNorske Veritas (DNV), Bureau Veritas (BV)and American Bureau of Shipping (ABS) etc.DIL - rugged, reliable and durableJastram drives switch ratings of up to 1650kW, which means that conventional barmountedcontactors or motor-operatedcircuit-breakers and switch-disconnectorswith remote operators are used. Transversethruster systems are designed for anaverage ship lifetime of 25 years, and sothe corresponding switchgear assembliesmust be dimensioned accordingly. With3000 to 4000 switch operations a year,this amounts to around 75,000 to 100,000operations after 25 years. For these kinds ofapplications, a 1600A switch-disconnectoris unsuitable since it is only designed foraround 2000 switch operations in AC-3 applications. On the other hand, theDILM 1600 A contactor with vacuumtechnology in AC-3 operation (starting/stopping, squirrel-cage motors) at 100percent of the rated current Ie has a devicelifetime verified at around 250,000 switchoperations. The vacuum tubes on the DILMare ideal for switching high voltages as arcsare not produced and no escaping gasesoccur during switching. As the switchingof a slip ring motor can only be assigned toutilisation category AC-2, the DILM offerssufficient reserve for zero maintenanceoperation with a ship lifetime of 25 years.The propeller speed can be varied on a3-stage rudder system by shorting theresistors in the rotor circuit in stages of 70,85 and 100 percent of the rated speed.The shorting of the resistors is handledby maintenance-free DILM 400/ 300contactors. The rotation direction of thepropeller and thus the starboard or portthrust is implemented with a reversingcontactor circuit consisting of two DILM1600 contactors.CONCLUSIONTorsten Jensen, responsible at Jastramfor the electrical design of the bowthrusters, had this to say about the useof Moeller components: “We only knowa few other suppliers on the marketwith products that can switch currentsup to 2000 A with the required 4000switch operations per year, and whichalso have all the relevant shippingapprovals. Our suppliers must have aworldwide logistics network so that wecan ensure the procurement of spareparts at any time. A comprehensive,partner-based support is equallyimportant to us. This is why we rely onMoeller technology.”Switchgear for a 700 kW bow thruster system, consisting of two DILM 1600 contactors for controlling thepropeller rotation direction and DILM 400/ 300 for the speed control by bridging the resistors in the rotorcircuit.Quicklink ID:MS1810For Moeller Electric Sales and Support call KMparts.com (866) 595-961611

PlasticSmartWire use in recyclingplants made in ItalyExtruders are primarily used for recycling plastics and all extruders basically have the same design.This therefore consists of the screw shaft that is located in the screw cylinder. The nominal diameterand outer diameter of this screw bore are the same. The shaping outlet opening (nozzle) of the screwcylinder is located at the front, whilst the drive at the back, usually consisting of an electric motorwith a gear unit (extruder gears), provides for the rotation of the screw. The materials to be processedare normally fed from the top into the screw via a funnel. The specific know-how is integrated in thedesign of the system and the technology used. That is why the latest extruders of the Italian companyCDM Engineering / OMP Prealpina use innovative Moeller technology and components.CDM Engineering / OMP Prealpina is acompany that supplies extruders with screwdiameters of 30 / 60 / 80 / 105 / 130 / 180 mmand venting extruders with diameters of160 / 220 / 250 mm. The output ranges from20 to 1300 kg / h depending on whether theextruder is to be used solely for recycling orfor compounding. The machines are availablefor single and dual venting. If necessary,extruders can be installed as tandem systemsso that severely contaminated or moistmaterials can also be processed withoutany problems. CDM extruders process awide range of different materials such aspolyethylene, polystyrole, polypropylene,polyamide or polycarbonate. CMD extrudersalso convert plastics into compounds inaddition to recycling. The plastics aremixed with additional filling or (glassfibre) reinforcement materials as wellas other (mineral) additives. In thecompounding process, at least twohighly compatible (plastic) materialsare physically compounded andtherefore reformed for special applications.The compounds then have other propertiesthan the individual source materials. Forexample, if two polymers are compounded,such as PA (polyamide) with ABS (acrylonitrilebutadiene styrene) this produces a so-calledpolyblend. Compounding requires preciseand reproducible metering of the individualmaterials as well as the precise application ofheat.Innovative Moeller technologyAll CDM machines are fitted out with ahost of Moeller components. A MoellerXC100 / 200 PLC with a CANopen network isimplemented for system control. This is linkedto an infra-red touch display which offersthe operator intuitive operation and alsosimple parameter entry when required. Theequipment also includes different pushbuttonactuators from the RMQ-Titan series such asemergency-stop buttons or pushbuttons forthe simple selection of machine operatingmodes during the different process steps.Added to this are Moeller circuit-breakersand motor-protective circuit-breakers forAC and DC motors.12For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18Connecting instead of wiring withSmartWireThe CDM machines are equipped withSmartWire as a technological highlight.SmartWire enables conventional xStart motorstarters to be connected to a PLC withoutany complex and error-prone control wiringrequired. This is because SmartWire replacesthe control wiring between control systemand switching devices with pluggable, preassembledconnecting cables. Whetherduring installation, commissioning and in anytroubleshooting in later operation, SmartWirereduces time and costs significantly. Aspecial benefit for customers: SmartWire isan addition to the well-established range ofMoeller switching devices and is designed asan accessory for the standard devices.SmartWire can be used with motor starters ofMoeller‘s xStart series. The two componentsof this range, the motor contactor and themotor-protective circuit-breaker, are bothconnected with a contact module withoutany cables. In order to make a motor starterSmartWire-compatible, the user simply plugsan additional SmartWire module onto thecontactor. This module provides a six-poleplug-in connector that replaces the controlcircuit connection.The SmartWire connection provides thecontactor actuation and indicates theswitch position of the contactor and themotor-protective circuit-breaker. Up to 16The extruder plant is controlled by a combination oftouch panel and RMQ control circuit devicesSmartWire-enabled motor starters can beconnected with a gateway. For systemswith more than 16 starters users can simplycombine several gateways. The connectionuses a six-pole SmartWire cable withplug connectors. The control voltage forcontactors is fed centrally on the gateway.The emergency-stop disconnection of thecontrol voltage that includes the entire motorstarter group is also implemented centrally onthe gateway.The main circuit wiring on the supply sideis implemented with a busbar system withsnap-fitted device adapters.THE COMPANYBoth companies CDM Engineering / OMPPrealpina are committed to the designand construction of machines. Thecompany based in Busto Arsizio near Milanproduces highly reliable plants for plasticrecycling and compounding in a 3500 sq mproduction area. CDM engineeringwas founded over 30 years ago, andacquired OMP Prealpina, a well-knowncompany that primarily produces plasticextruders. Quality, efficiency in service andtechnological innovation are key prioritiesin order to maintain a presence on theworld market in addition to operations inItaly. (www.cdmengineering.it)All drives of the extruder plant are controlledby SmartWire. SmartWire replaces both theconventional control circuit wiring as well as the PLCI/O modules.A CANopen gateway is used to connectthe motor starters to the XC100/200modular PLC.If required a Profibus DP connection is alsopossible. Additional I / O elements can beadded to SmartWire for more complex tasks.The slice design modules can be used flexiblyas required: For example, they can also beused to connect up motor starters withratings higher than 15 kW, to monitor anNZM incoming circuit-breaker or to integratecomponents from other manufacturersinto the system. This last application doeshowever require some additional wiring.CONCLUSIONAll CDM plants can be equipped toindividual requirements on request, suchas with energy-saving motor drives orwith remote control systems for remotemaintenance. CMD machines of the 105,130 and 180 series currently have theSmartWire system as standard. At CDMEngineering / OMP Prealpina and alsowith customers, SmartWire is making agood impression in every respect, evenmore so when designing more complexmachines and systems.Quicklink ID:MS1811For Moeller Electric Sales and Support call KMparts.com (866) 595-961613

Chill FactorTHE COMPANYFrigel AG has its headquarters inZuzwil, Switzerland, and was founded1994. The company operates in the fieldof commercial-industrial refrigerationand air conditioning technology andhas grown continuously since itsfounding. Frigel only builds energyefficientsystems, which are plannedand built in Zuzwil. The company‘sown employees install the systems andprovide long-term customer support.Frigel has different service locations inSwitzerland. (www.frigel.ch)Moeller technology controlsrefrigeration systems in SwitzerlandThe quality of foodstuffs doesn‘t just depend on the propertiesof the primary products but also on how they are transportedand stored. Consequently, it is important that foodstuffs incatering establishments, sales outlets and production areas arestored at the correct temperature. The Swiss company Frigel AGis a specialist in refrigeration technology and air conditioning. Itsupplies refrigeration systems for food outlets, petrol station shops,supermarkets, for vegetable production, fruit storage, dairy productionand also for cooling operating rooms. Frigel uses Moeller technology exclusively for electricalcontrol and switching devices.14For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18Less is moreCooling requires energy. Efficient coldproduction is vital for economicalrefrigeration. Furthermore an optimiseduse of energy also ensures a low emission ofenvironmentally harmful CO 2 . Frigel buildsenergy-efficient compression refrigerationsystems and also designs all its componentsincluding the control concept so thatresources are used economically duringoperation. The refrigeration systems alsohave to be robust and reliable. This is becausecustomers are also considering costs notonly in terms of acquisition costs but alsoparticularly in terms of running costs overthe lifetime of the system. The electricalcontrol and switching devices are exclusivelyfrom Moeller. Frigel values the ruggednessand reliability of the device, and Moellerwas chosen particularly on account of theprice/performance ratio of its products and itsoutstanding service.Regulated coolant circulationDepending on the refrigeration outputrequired, Frigel offers systems with one tofour cooling compressors which ensure thecontinuous circulation of the refrigerant.The most frequent systems used have twocompressors.After the system is started, the firstcompressor is started via a DS6 soft starter.Ensuring continuous cold production: Two coldcompressors with control cabinet and operator unit,emergency-stop actuator and main switch.The special starting method (asymmetricaltrigger control) for the soft starter functionprevents DC components that normallyoccur with a two-phase controlled starter.This guarantees a smooth motor startup.Ramp times and start voltage can be setby means of potentiometers. Suddenpressure fluctuations in the circulation of therefrigerant are thus prevented and protect allcomponents in the cooling circuit. To adjustthe refrigeration output to requirements, thesecond compressor is controlled via a DV6vector frequency inverter according to thespeed. This ensures optimum smooth runningcharacteristics for the motor and is ideallysuited to highly dynamic drives.With more than 200 percentstarting torque and virtuallyfull standstill torque, the DV6is one of the most powerfulvector frequency invertersin its class. Extensiveprotective functionsensure safe operation aswell as the protection offrequency inverter andmotor from overload,overtemperature,overvoltage and undervoltage aswell as phase loss.easy controlledThe refrigeration system is controlled byeasyControl (EC4P). This compact PLC withthe easy design combines the well-triedand simple easy concept with the benefitsof programming to IEC/ EN 61131-3.Furthermore, the CoDeSys programmingsystem and its functionality go far beyondthe standard requirements of EN 61131-3.The freely-graphical CFC (ContinuousFunction Chart) offers an additionalprogramming language. Options forsimulating the user program, the integratedfieldbus configurator, the powerful testand commissioning functions, as well as theintegrated visualization tool ensure thatapplication requirements can be implementedrapidly and simply.The EC4P comes with a 256 KB programmemory and 224 KB for data as well as 12digital and 8 transistor or 6 relay outputs.The combination of the EC4P PLC and theremote MFD-Titan display (IP65) mountedin the control cabinet door allow fastand simple visualization and operationof the refrigeration system, even in harshambient conditions, such as in dirty orhumid environments. Information such asthe operating mode of the system, alarmmessages and actual temperatures aredisplayed in plain text. The keypad of thedisplay allows the operating parameters tobe set according to the refrigeration systemto be controlled. All basic visualizationfunctions can be programmed easily usingthe function blocks of easySoft-CoDeSys.The communication connection is set upautomatically and therefore requires noadditional effort. And unlike foodstuffs,the easyControl stays fresh over a widetemperature range from -25 to +55 °C.A PID controller ensures constant climatic conditionseven when disturbance factors are present.The multi-function display visualizes all relevantoperating data.Quicklink ID:MS1812CONCLUSIONSepp Hersche, responsible for the systemconcept and the programming of therefrigeration control at Frigel explains:“We are impressed by the easyControland easySoft-CoDeSys automationsolution. Our service technicians setthe parameters individually via theMFD-Titan multi-function display andadapt it to suit the system at hand.In this way we can now control alltypes of refrigeration systems with asingle standard program. This savesus considerable work in programmingand maintaining the software. Ourrefrigeration system must be designedwith a high degree of reliability. Toensure this we also use Moeller productsfor the switching devices.”For Moeller Electric Sales and Support call KMparts.com (866) 595-961615

Safety PackageeasySafety inpackaging technologyIn order to transport products, theyare normally packed appropriatelyin accordance with regulations. In thefood and non-food sectors carton and/or bagsare used for this purpose. Packaging lines themselvesconsist of several subsections such as filling stations with dosingand weighing systems, cartoning machines, packing stationsand palletisers. Q-bag, a subsidiary of Optima PackagingGroup, offers tailored customer applications with its highperformancecartoning machines and tray packers. The entireautomation technology is provided by APA-Tec. The guaranteeof the machine‘s functional safety requires the compulsoryobservance of the Machinery Directive and the relevant safetystandards. Moeller‘s easySafety also provides outstanding,perfectly matched and cost-effective safety-related functions forpackaging machines.THE COMPANIESQ-bag packaging machinery GmbH& Co. KG has its headquarters inSchwaikheim, near Stuttgart and hasrecently become a subsidiary of theOptima Packaging Group. Q-bag isa household name in the sector asa manufacturer of future-orientedpackaging machines and systems.The company is ideally set up withinnovative, high quality products aswell as a worldwide service.(www.optima-packaging-group.de)APA-Tec GmbH is based in Böbingen,near Schwäbisch Gmünd, and wasfounded at the beginning of 2004.Its main activities focus on the designand implementation of automationsolutions for general machine buildingand packaging. Even modernisationtasks, i.e. the so-called retrofittingof packaging systems, has a separatecompetence area. APA-Tec suppliesmachine control units as well therelevant services from planning,commissioning up to after-salessupport. (www.apa-tec.de)16Products are packaged in many ways on theirway from the manufacturer to the user. Retailpackaging, for example, has to meet differentrequirements than transport packaging.Powdery, free flowing and chunky products areprimarily packed in bags and then placed incartons. Cartoning machines from Q-bag offer anoutstanding degree of flexibility as well as a largesize range with a high performance. A typicalexample is the packaging of wheat semolina.The filling of semolina in bags is controlledby dosing and weighing units. The cartoningmachine prepares the folding cartons. Thecartoning machine then places the filled bagsas bag-in-box items in the cartons provided andthe cartons are closed. Up to 220 cartons withfill weights of 250g are packed every minute.The individual packages are provided with thecurrent batch data in a printer station, are thenpassed to the tray packer where packaging unitsconsisting of 10 cartons each are made up. Thesepackages are conveyed to the palletiser with anintegrated wrapper, where they are stacked fortransport on pallets and then wrapped againand sealed in a stable protective film. The entireprocess runs fully automatically, and all processdata is recorded and archived.High speed and flexibilityThe servo-controlled application describedhere involves 19 servo axes in all, whichcontrol the required folding, dosing andtransport operations in the cartoningmachine and in the tray packer. Themachines are equipped with Elau MotionControl Systems with an integrated PLCfunctionality. The programming is carriedout on the largely known CoDeSys IEC61131-3-compliant programming platform.Touch panels installed close to the machineare used for the visualization of the system.They are used to operate and configurethe entire system (including processparameters, speeds, dosing quantities,format management for the packaging).In the event of a fault, a history memoryand extensive Help functions provide theoperator with the necessary information andensure a high level of plant availability.easySafety controllers can implement allsafety-related functions, such as Emergencystopcircuits or guard circuit monitoringwith a setting function. Together with thecontact-free disconnection of the outputstage of the Elau servo they achieve thehighest level of plant safety. The easySafetycontrollers are linked into the Profibusnetwork of the systems with the easy204-DP interface. This is used to transfer faultor status messages from the safety systemto the machine control where they areevaluated and displayed.easySafety for operating and plant safetyPackaging lines are normally large in areaand involve several potentially hazardouspositioning sequences which have to besafeguarded by technical means. A largenumber of Emergency-Stop actuators,guard doors and operating elements forsafe setting operation have to be controlledand monitored, whilst the plant has to beswitched to the safe operating state inthe event of an emergency. Traditionallythese functions are implemented with acomplex system of hardware components.easySafety reduces this hardware complexity,For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18easySafety monitors all door and emergency-stop circuits, and communicates with the motor control system via Profibus DP.which is restricted to the sensor / actuatorlevel. This device enables applications tobe implemented that comply with thehighest safety requirements: The safetyrelatedcontrol relay complies with category4 in accordance with EN 954-1, PL e inaccordance with EN ISO 13849-1, SILCL 3in accordance with EN IEC 62061 as well asSIL 3 in accordance with EN IEC 61508. Inthis respect the date 30.11.2009 is of specialsignificance for panel builders. After thisdate, only EN ISO 13849-1 and EN IEC 62061shall apply to new machines, and the “old”EN 954-1 shall no longer apply. easySafety istherefore designed to be future-proof andcan be optimally combined with Moeller DILand PKZ switching and protective devices aswell as RMQ control circuit devices.The devices of the easySafety series comeas standard with a host of conventionalsafety relays in the form of safety functionblocks, such as Emergency-stop, guard doormonitoring optionally with the monitoringof guard locking, light curtain with andwithout muting, two-hand control button,safety switch mat, enable switch, safety footswitch, operating mode selector switch, zerospeed and overspeed monitoring, externaldevice monitoring, safety timing relays andsafety markers. easySafety devices comewith 14 safety inputs and have either fourrelay outputs or one redundant relay plusfour redundant transistor outputs. Thesafety function blocks of easySafety caneither be configured from a PC or directly onthe device. Thanks to the easySoft-Safety PCconfiguration software with an integratedsimulation function, users can save the timerequired for project design and alreadyeliminate any faults before commissioning.easySafety offers more than a stand-alonesafety control relay. In addition to the safetycircuit diagram contained in the safetyconfiguration, the safety control relay alsoprocesses a standard circuit diagram. Thiscan be used for standard tasks such asthe processing of diagnostics messages orgeneral control tasks for a machine. If theinputs or outputs are insufficient for solvingthe standard task, standard expansionmodules of the easyRelay series can beconnected with the easySafety device.CONCLUSIONeasySafety supports machine and systembuilders in a wide range of safety-relatedtasks. Eberhard Vaas, owner of APA-Tecexplains: “easySafety provides us witha high level of flexibility during thedevelopment, design and commissioningphase and reduces the need forexpensive hardware. Added to this isthe fact that we can use easySafety forboth safety-related and also for standardtasks. The connection to a fieldbus orPLC is also ensured: Whether Profibus-DP,CANopen or DeviceNet – the easy familyalready offers coupling modules that canbe used by easySafety devices.”Quicklink ID:MS1813For Moeller Electric Sales and Support call KMparts.com (866) 595-961617

Nowadays, plastics technology increasingly uses high end hygroscopic plastics such as nylon,polycarbonates and polyester which require a steady and constant drying temperature with 0.1to 0.02 percent residual moisture, and in some cases well below 0.01 percent. Only in this waycan the required physical properties and desired surface finish be achieved. Insulation propertiesthat improve products, as well as the prevention of material shrinkage, streaking and sink marksreinforce the need for using high quality drying systems. The entire KTX50 to KTX1200 drier seriesfrom Simar uses the Moeller easy device family because its versatility, scalability and networkingcapability allow coverage of a wide application range.Dust DryScalable multilingual automationsolutionsControl with only one easy MFD-TitanThe conventional driers were equipped witha PLC as well as separate closed-loop controlmodules and time switches. The aim of the newdevelopment was to reduce costs and expandfunctionality at the same time. After an intensivesearch, the Swabian company Simar decided toopt for the easy MFD-Titan control relay. MFD-Titan integrates different individual componentsin a single controller unit. Ease of operation wasalso considerably increased since the entire displayand operation functions were implemented inone display unit. The customised labelling optionfor buttons and LEDs means that operation of theMFD-Titan is largely self-explanatory.The operating principleThe driers of the KTX series operate withtwo generously dimensioned desiccantcartridges that are fed alternately withthe air to be dried. Switching betweenadsorption and regeneration is controlledby the time or dewpoint together witha dewpoint indicator control. The driersoperate at a dew point temperaturebetween -30°C and -50°C.18For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS17SOLUTIONS18An exactly defined volume of dryair is passed through the plastic granulesto be dried, so that this adsorbs the moisture fromthe granulate over the set period of time.In order to dehumidify the air, this is passedthrough a molecular sieve consisting of zeloithewith a high capacity to adsorb watervapour. Once the saturation point of themolecular sieve is reached, it is heated up to 250°C according to a fixed temperature curve and thusregenerated.THE COMPANYSIMAR GmbH, with headquarters inVaihingen/Enz, was founded in 1977. Thecompany has grown and evolved on thebasis of innovative and pioneering bulkmaterials technology. Close cooperationwith customers has led to the developmentof systems for conveying, drying andblending an extremely wide range ofbulk materials. Not just for the plasticsindustry, but also for use with foodstuffs,pharmaceuticals and chemicals. Nomatter whether you work with granularor powder bulk materials, Simar alwaysoffers sensible alternatives to conventionalsolutions. Simar has branches or sales andservice partners in over 30 countries.( www.simar-int.com )Scalability of the easy familyAn MFD-Titan device with a double relayexpansion is already enough for the smallestdrier type. If several drying silos are used, theMFD-Titan is simply expanded with an easy800device linked via easyNet. In this way, up to fivedrying silos can be connected up without anyproblem. The drier version with automatic loadadaption is a special highlight. Depending on thesupply and the return temperature, motorisedflaps are controlled and visualized with theMFD-Titan. For this Simar uses the easyControlcompact controller, which can be networkedeasily via easyNet with the controllers already inplace. In this way, any requirement can be metquickly and cost-effectively. With programmingin compliance with IEC61131-3 easyControloffers a highly flexible program structure usingeasySoft-CoDeSys. The function blocks providedin the standard library and the easyControlclosed-loop control library can be combinedsimply with user-defined POUs.The PID controllersThe core of the program is made up by the PIcontrollers. A PI controller with a downstreamPWM function block is used for controlling theregeneration and adsorbtion heating. Dependingon drier type, up to seven PI controllers arerequired. The control loop of the adsorbtionheating presents a particular challenge. Asthe control circuit responds extremely quickly,there is a risk that the granulate may overheat.However, this problem can be solved simply witheasy closed-loop controller function blocks. Thetemperature setpoint and drying time are setvia the MFD-Titan according to the material. Ifnecessary, users can also store the closed-loopcontroller parameters in password-protectedmenus. The process air heaters are controlled bysemiconductor relays.Online language selectionIn an initial step the application was createdin four languages (German, English, Frenchand Spanish), which can be selected duringoperation. Other languages (Polish, Czech,Rumanian, Hungarian, Russian, Bulgarian, Dutch,Portuguese) were added at the customer‘srequest. All languages are stored in an easyprogram and are thus easy to maintain. Whenthe program is loaded, the user selects whichlanguage group of four languages each areto be assigned to the MFD-Titan. Germanand English are obligatory in every languagepackage.Connection to bus systemsThe Moeller easyControl also features anEthernet interface in addition to the busmodules for Profibus-DP, CANopen, AS-Interface,DeviceNet. This allows the KTX driers to beconnected easily to a higher-level PLC or a hostcomputer. Different accessories of the KTX driersallow adaption to customer requirements.Quicklink ID:MS1814CONCLUSIONHarald Weinert, technical manager atSimar GmbH explained:“The minimum space requirement,the high degree of flexibility and theprice /performance ratio reinforced ourdecision to use the easy device familiesfor the implementation of a new controlgeneration. A customer-friendly menuguidance with multi-lingual plain textdisplay, the remote diagnostics andteleservice features, as well as theflexibility provided for future systemexpansions were important criteria for usduring the development phase. Thanksto the easy family we were able tocombine a host of customer and processrequirements in a single control system.”Vetter-Steuerungstechnik is a newowner-operated company based inPfinztal which has established itselfon the market in the field of specialmachine programming. As ChristianVetter explained, “Products of theeasy family are ideal for Simar KTXdriers. Their modular design allows usto fit different drier sizes with exactlythe right control system. easySoft andeasySoft-CoDeSys offer us two powerfulprogramming user interfaces with a hostof ready-to-use function blocks. Theysimplify our programming requirementand thus reduce development costs.”(www.vetter-steuerungstechnik.de)For Moeller Electric Sales and Support call KMparts.com (866) 595-961619

Purest WaterAutomated filling station witheasyHMI and easyRelayThe Bremen-based company AcmosChemie develops and produces barrierlayerproducts which prevent or minimisecontact between two materials. Thewater required for manufacturing theproduct must be treated, conveyedand dosed via filling stations. ElgaBerkefeld, a company based inCelle near Hannover, implementeda tailored solution for the fillingstations at Acmos Chemie usingMoeller automation components.THE COMPANIESElga Berkefeld GmbH has had itsheadquarters in Celle near Hannover forover 110 years, and since 2004 has beenpart of Veolia, or more precisely VeoliaWater Solutions & Technologies, a leadingcompany worldwide in water treatment.The company‘s core areas of competenceare the planning, engineering andrealisation of comprehensive plantsfor potable water and process watertreatment. Furthermore, the companyoffers standard and tailored watertreatment systems for house equipmentand building technology, installationsfor the petrochemical industry, powergeneration, shipping and offshoreplatforms, as well as mobile plants foremergency equipment.(www.elga-berkefeld.de)Acmos Chemie KG, Bremen, developsand manufactures barrier-layer productssuch as release agents, lubricants, anticorrosiveagents, metalworking fluidsand high temperature resistant coatingsfor the wood, glass and plastics industry.The origins of Acmos Chemie go backto 1909, and the company now sells itsrange of over 1000 products worldwide.(www.acmos.com)20Acmos requires highly purified water for themanufacture of its chemical products. Thetreatment plant installed by Elga Berkefeldsupplies this highly purified water byhardening and reverse osmosis, and thenfeeds it into a storage tank. A ring mainwas installed so that the highly purifiedwater can be transported into the differentproduction areas. This currently reaches fivefilling stations via a pressure booster station.A solely manual and mechanical operationof the filling stations, however, wouldrestrict the operating personnel during thefilling process and make it more difficultto maintain constantly precise dosing.Furthermore, the simultaneous drawingof water from several stations could causean uncontrollable supply shortage whichwould take the capacity of the plant to itslimits. The precise observance of mixingratios is also vital in order to maintainthe constant high quality of the chemicalproducts. The decision to use an automatedand programmable solution for the fillingprocess was therefore a logical step. Thetailored automation concept had to befuture-proof and therefore provide spacefor later optimizations.Automated solutionThe requirements for the plannedautomation solution were far greaterthan those stipulated by the standards.The actual states / values of the sensors,such as flow speed and storage tank levelhad to be measured in order to controlthe actuators such as pumps and valvesso that the setpoint states/values definedRemote filling station consisting of easy800 controlrelay and MFD4 touch display.by the operator could be reached. Thiskind of automation task was one that ElgaBerkefeld had implemented as a standardsolution for several hundred similarapplications – using Moeller‘s easyRelayprogrammable compact controllers. Theadditional challenge of the Acmos solutionarose from the fact that different setpointswere required for virtually every fillingoperation due to the different chemicalproducts involved. With the new solution,the operating personnel should be able toset product parameters at all filling stationssimply and with a few operations at anytime. In addition to this, it must be possibleto monitor warning and fault messages, aswell as relevant actual values, setpoints andlimit values at a glance.MFD4 with touch technologyThe requirements placed on HMI devicesin the chemical engineering industry arehigh. However, a programmable, fullgraphics colour display with robust touchtechnology meets these requirementsideally. Moeller‘s metallic MFD4 multi-For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18The multi-function display is used to startautomated dosing and display the available volumeof purified water.function display was therefore chosen forthe visualization of the filling stations. Itcomes standard with a special polyesterfoil which is highly resistant to solvents.The rugged MFD4 (protection class IP65)is provided with an absolutely flat, fullgraphics 5.7 inch TFT display with 32,000colours and resistive touch technology. Thedevice, with a bevelled front frame andsmall mounting depth, is also suitable foruse in dust environments in accordance withthe ATEX Directive 94 / 9 / EC Zone 22 Cat3D and is also approved for use on ships.The Windows CE-based MFD4 comes asstandard with an integrated 64 MB SRAM,4 MB Flash for data / program memory,6 MB for the visualization and a batterybackedreal-time clock. Users can utilisethe integrated PLC functionality or usethe standard CANopen/easyNet, Ethernetand RS232 interfaces for data exchangewith different controllers. The devices alsocome standard with a slot for an onboardMMC card. Only the easySoft-CoDeSys (IEC61131-3) software is required for the boththe visualization and the PLC application.This provides the programmer with all thefunctions for creating screens, password andalarm management or trend and bargraphdisplay. The web server provided onboardallows created screens to be accessed viathe Internet or an Intranet.Intuitive operating conceptAcmos had already created a user-friendlyoperating concept for its filling stations,thus allowing intuitive operation. Thisincludes graphic elements such as bargraphdisplays for filling levels and filling progress,as well as meters for flow speed, colourbasedstatus changes and function settingssuch as supply measurements or pressureboosting, and last but not least warningmessages. Setpoints are entered via atemporary numerical keypad. In addition tothe actual filling operation, general screensare provided such as the deactivationfunction for cleaning the display, the systemparameters or password protection menu.Intelligent I / OThe Elga Berkefeld implementation used aneasy800 which is connected to the MFD4 viathe CANopen / easyNet interface and whichallows the connection of digital and analoginputs and outputs. The programmableeasy800 processes the signals in advancethanks to the easySoft software and itswide range of function blocks integratedin the device. For example, the high-speedcounter function block can calculate thewater volume from the pulses received fromthe flow meter, and the frequency counterfunction block can calculate the flow speedin liter per minute from the same pulses.The level in the supply tank is output as ananalog value via a pressure transmitter andscaled to a liter value using the value scalingfunction block. This therefore allows theMFD4 to receive absolute actual values fromthe easyRelay and use the released CPUresources for other tasks.CONCLUSIONPUMPSTATIONINTERMEDIATETANK STORAGEWATERTREATMENTHartmut Sonder, project manager atElga Berkefeld, explained as follows:“Moeller‘s MFD4 allows us to provideoutstanding solutions to all ourcustomer requirements. The opencommunication interfaces enablehardware and software to be usedanywhere, and the system offers anoutstanding price/performance ratio.We chose easy800 for intelligent I/Oprocessing since the devices of the easyfamily have been serving our customersreliably for years.”DOSINGSTATIONDOSINGSTATIONDOSINGSTATIONDOSINGSTATIONDOSINGSTATIONQuicklink ID:MS1815For Moeller Electric Sales and Support call KMparts.com (866) 595-961621

Energy RichNZM circuit-breakers protect hydrogen generatorsRapidly increasing energy costs and the limited resources of fossilfuels such as coal, oil and gas are forcing both the use and thedevelopment of renewable energy sources. While solar plants andwind turbines are becoming increasingly more economical forpower generation, the question of an efficient energy storage isat present still largely unanswered. An environmentally friendlyand emission free energy storage can be provided by convertingelectrical energy into hydrogen, a potential energy carrier of thefuture. Moeller circuit-breakers and contactors are in operationwith the HySTAT-A onsite hydrogen generators manufactured byHydrogenics Europe NV, the Belgian branch of the Canadian basedHydrogenics Corporation.Hydrogen can reduce the dependency on oiland gas imports and reduce CO 2 emissions atthe same time, especially in countries whereraw materials are scarce. The combustionof hydrogen only releases heat and watervapour. On an industrial scale, hydrogenis mainly produced from natural gas andother fossil fuels since it is present there ina bound form. However, hydrogen can alsobe produced from water in an electrolysisprocess using electrical DC current. Asearly as 1800, the German chemist JohannWilhelm Ritter used electrolysis to splitthe chemical compound of water into itselements of hydrogen and oxygen. Fromtoday‘s perspective, the special advantageof this process is that neither electrolysis northe reverse process, power generation usingfuel cells or combustion, produce harmfulgreenhouse gases such as CO 2 .The IMET electrolysis cells produce up to 60 m 2 hydrogen per hour.22For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18Hydrogenics is a leading manufacturer inthe field of hydrogen generators and fuelcells. The Hydrogenics HySTAT-A hydrogengenerator station is a so-called IMEThydrogen generator using the process ofalkaline electrolysis.TapOxygenTapHydrogenThe “Inorganic Membrane ElectrolysisTechnology”, or IMET for short, offers apressure of up to 25 bar and a hydrogenproduction volume of up to 60 Nm 3 / h perstation. The hydrogen is generated usinginorganic membranes with a very highefficiency. The operation of the hydrogengenerator requires a water and an electricalconnection (380-600V three-phase AC). Thepower consumption is approx. 4.2 kWh perNm 3 / h of hydrogen.Platinum electrode(Anode)Sulphuric acidPlatinum electrode(Cathode)Hydrogenic supplies mobile or stationary hydrogengenerators worldwide.Optimum safety and reliabilityIn order to ensure optimum plant safety andreliability, Hydrogenics chose circuit-breakers,contactors and miniature circuit-breakersfrom Moeller. The electric power is fed viaone or several 250A NZM2 compact circuitbreakers.DILM contactors are used on theprimary side for the supply of the threephasetransformer. A three-phase rectifier onthe secondary side provides the DC voltageto the electrolysis cells so that the electrolysiscan begin.NZM circuit-breakers reliably protect allcables and conductors in the plant fromoverload and short-circuit currents. Themicroprocessor controlled digital electronicsin the circuit-breaker continuously measuresthe operating current r.m.s. values of theelectrolyzer. Unlike analog electronics, anyharmonics in the network are evaluatedcorrectly and do not produce any nuisancetripping. In the event of a fault, the cause oftripping such as phase imbalance is loggedin an internal memory. Ten events are storedin the history together with detailed factsenabling the fault source to be identifiedrapidly if necessary. The information ispresented clearly in the field with the NZM-XPC-SOFT software, and the software itself iseven available in nine languages. All the datacan be stored, printed out and distributed forlater troubleshooting tasks.Powerful, robust and long service lifeWhilst circuit-breakers primarily protecthydrogen generators from short-circuitand overload, DILM contactors are usedfor the actual on and off switching of theelectrolysis cells concerned. The largest plant,HyStat-A 1000Q-60-10 runs up to four cellstacks in parallel. They are switched on oroff according to the hydrogen requirement.However, DILM contactors not only offeran optimum lifespan in standard AC-3Aoperation, but are also ideal for switchingtransformers in AC-6A operation. Naturallythese devices also have the specifications foractive safety such as interlocked opposingcontacts, safe isolation or contact protection.All DILM contactors up to 170 A are providedThe circuit-breakers protect the electrolyzer fromoverloads or short-circuits and document the causeof tripping in the event of a fault.with box terminals with two terminalchambers. This enables users to also wiredifferent conductor cross sections safely,reliably and error-free.THE COMPANYHydrogenics GmbH (Gladbeck,Germany) and Hydrogenics EuropeN.V. (Oevel, Belgium) are the Europeansubsidiaries of the HydrogenicsCorporation with headquarters inMississauga (Ontario, Canada). Thecompany is quoted on the stockexchange (NASDAQ: HYGS / TSX: HYG)and is a leading company worldwidein the development of clean energysolutions, with branches in NorthAmerica and Asia as well as in Europe.Hydrogenics promotes the hydrogeneconomy by commercially developinghydrogen and fuel cell products. Thethree core business fields in Europeare organised as follows: HydrogenicsGmbH in Gladbeck produces fuelcells with a focus on complete energymodules and electrical hybrid systems.Hydrogenics Europe N.V. in Belgiumsupplies stationary hydrogen generationand fueling systems.(www.hydrogenics.com)Quicklink ID:MS1816For Moeller Electric Sales and Support call KMparts.com (866) 595-961623

Hot StoneNZM protects and monitors pizza ovensFreiberger Lebensmittel is a company that operates two electrical stone ovens for its pizza production atits Berlin plant. The essential components of these ovens are NZM series circuit-breakers from Moeller.These are intelligent switching devices that integrate a wide range of electronic components and arecommunication enabled via the Data Management Interface (DMI). Thanks to the DMI, NZM circuitbreakerscan be parameterised, switched and monitored remotely. The diagnostics information simplifiespreventative maintenance and allows faster troubleshooting in the event of a fault.24Electrically heated continuous feed ovensnaturally have a high current requirementand with the pizza ovens used at Freibergerthis is P = 450 kW. This corresponds to themotor rating of a V12 combustion engine withover 600 HP. The power is supplied from two1250 kVA low-voltage transformers that areconnected in parallel and have a short-circuitlevel of approx. 60 kA. Two NZM3 630A circuitbreakerswith a 150 kA short-circuit breakingcapacity are used for switching off this kind ofpower rating safely in the event of a fault. Themaximum rated current must be set exactly sothat immediate disconnection is possible in theevent of an overload caused by a fault, in orderto ensure optimum protection of the operatingpersonnel and the ovens.The rated current of the oven primarily dependson the amount of dough mix to be heated, i.e.the number of pizzas in the oven, as well asthe required feeding speed and the number ofbaking shelves. In the event of a short-circuit, thecircuit-breaker must be able to disconnect thepizza oven in 0.04 s.Configurable protective functionThe circuit-breakers of Moeller‘s new NZMseries guide the power to the connected loadsand disconnect them reliably in the event ofoverloads or short-circuits. They can be used forsystem and cable protection, motor protection,or selective and generator protection. The releaseelectronics unit forms the core of every NZM,and is used to not only detect the actual currentsquickly but also to evaluate them at the sametime. The circuit-breakers disconnect reliably ifthe adjustable release thresholds are exceeded.This prevents damage to machines or plants. Inpower distribution systems, incoming circuitbreakersand several outgoer circuit-breakersare arranged hierarchically and their parametersmatched up selectively so that unaffected sectionsof the system can continue to operate withoutany interruption. Circuit-breaker parameters canbe shown graphically in the form of trippingcharacteristics for optimum setting, thussimplifying commissioning.Preventing downtimes and managing powerefficientlyThe release electronics unit derives importantoperating and diagnostics data from the actualFor Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18THE COMPANYFreiberger Lebensmittel GmbH & Co.Produktions- und Vertriebs KG was foundedin Berlin in 1976 and is now Europe‘s largestcompany in the production of deep-frozenpizzas with an annual production of 450million. Important steps towards this werethe invention of stone oven pizzas and theintroduction of the “Alberto” brand. Since1998 Freiberger has been 100 % subsidiaryof the Südzucker AG and has productionfacilities at five locations in Europe.(www.freiberger.de)currents measured. Load warnings and overloadsare detected, thus enabling measures to be takenearly before a system shutdown is necessary.However, in the event of a disconnection, thecause of tripping and the previous events canbe read from the electronics unit, such as shortcircuit,load warning, affected phase, imbalancedphase load.With this important information it is possibleto rectify faults rapidly. The current andstatus monitoring, the remote switchingof the circuit-breakers and, if necessary,all connected motor starters also providethe basis for tariff optimised load andenergy management. Freiberger also usesa Data Management Interface (DMI) fromMoeller. This not only provides the foodmanufacturers with the functions alreadydescribed but also enables them to transferthe data remotely via Profibus DP. Byexporting and logging the current data inMicrosoft Excel the used energy (work) canbe displayed on an operator panel. Thiscreates greater transparency and generatesvital data for further budget planning.Simple system integrationAn FDT-compatible control system allowsremote diagnostics, current monitoring,remote parameter setting and remotecontrol via one operating software, withoutany additional engineering required. Forthis Freiberger uses the Factory Suiteprocess control system. The standard FDTinterface (Field Device Tool) ensures thata Moeller DTM (Device Type Manager)can communicate with a human machineinterface (HMI) software such as supplied byWonderware. Device integration thus simplyinvolves installing the appropriate DTM. Thecontrol system establishes communicationwith the device for this purpose, forexample, via Profibus-DPV1 or Ethernet/Profibus gateways.Overview at a glanceThe remote monitoring, maintenance andservicing of the power distribution systemare usually carried out by specially trainedpersonnel using autonomous service stations.The FDT-Navigator in combination withthe NZM-DTM is one such service station.This virtually turnkey combination enablesnetworked circuit-breakers to be read insimply with a fieldbus scan and displayedgraphically in a topology. In this way, a fastoverview can be obtained of any faultspresent and their location, as well as the typeof fault involved. In many cases, the softwarepackage thus replaces a visualizationsystem with its additional requirements forcreating pictures or the tedious allocationof communication variables. The FDTinterface also makes the system open forthe integration of other devices for powerdistribution and automation.The Data Management Interface the diagnosticsand operating data of the circuit-breaker to bescanned.Quicklink ID:MS1817CONCLUSIONHans-Georg Müller, head of electricalengineering at the Freibergerheadquarters in Berlin, explains:“Installing the NZM software wassurprisingly trouble-free and fast. Todaythe software simplifies work whenmonitoring electric ovens. As we placeconsiderable importance in a constantlyhigh standard of quality, the NZMcircuit-breakers now also ensure thatthis is possible. We are technically wellequipped for the future.”For Moeller Electric Sales and Support call KMparts.com (866) 595-961625

Air-FreeSwitching wind turbines in a vacuumThe shortage of fossil resources means that the generation of electric power fromwind is nowadays more necessary than ever before. Woodward SEG from Kempenon the Lower Rhine has been a constant presence on the market for frequencyinverters for wind turbine generators (WTG) for over ten years. The experiencegained in power distribution and closed loop control engineering over this timeis fed continuously into the development of new products and technologies.State-of-the-art frequency inverters for wind turbine generators must meetthe most stringent requirements with regard to switching frequenciesand suitability for a wide range of supply grids. An optimised switchgearcombination based on Moeller products was therefore developed for thenew Concycle Wind frequency inverter generation.26The NZMH4 800 A compact circuit-breaker protectsthe generator reliably from overloads in the eventof a short-circuit. The contactor with vacuumtechnology handles the normal connection anddisconnection of the wind turbine generator. Thecombination can be used without any derating atambient temperatures up to 50° C.Merging experience and new ideasThe development of state-of-the-artfrequency inverters involves the bringingtogether of diverse objectives that aremostly contradictory. Experience in the windpower sector shows that inexpensive highquality components mostly have to offera lifespan of 20 years. The production andthe service of frequency inverters also hasto have a modular design, must be efficientand require little effort. After all, a windturbine generator is subject to a wide rangeof influences in various locations, such asextreme cold and heat, humidity, dust orsand, calm periods and storms. For thisreason, the selection and arrangement ofcomponents and their use in the harshestenvironmental conditions involves a greatdeal of technical know-how.The new frequency inverter generation ofWoodward SEG has to meet as a wide rangeof requirements as possible:• In spite of the high degree ofstandardisation, a modular switchboarddesign is nevertheless needed in order tomeet customer requirements. Tried andtested assemblies are therefore producedand tested in standardised productionprocesses.• Climatic requirements are fulfilled withtype-tested panel units with optional unitsfor heating and cooling – simulated inextensive test cycles, as well as in climaticcontainers.• Network operators are changing theirrequirements worldwide towards the activeand intelligent support of the electricitygrids by means of wind turbine generators.The simulations and software functionsneeded for this are developed and testedin the company‘s own test bay. In this way,the latest standards can be implementedwithin a short time.• Developments are controlled with thelatest Product Lifecycle Management (PLM)methods.• The different locations of wind turbinegenerators also require a wide rangeof wind profiles and therefore differentelectrical and mechanical load capacities. Afrequency inverter can thus connect to thegrid up to 2000 times a year.Operating principleThe generator for Concycle Wind frequencyinverter consists of a doubly fed slip-ringasynchronous generator. The frequencyFor Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS17SOLUTIONS18THE COMPANYWoodward SEG GmbH & Co. KG isbased in Kempen on the Lower Rhineand supplied its first frequency inverterfor a wind turbine generator at theend of 1996, at that time under theSEG logo. As SEG, the company hasalmost 40 years of experience in thepower distribution and protectiontechnology. Frequency inverter seriesproduction for the German market wasdeveloped rapidly from smaller pilotseries and also for the US market since2000. The “saturation” of the Germanwind power market from 2002/ 2003led frequency inverters from Kempenworldwide into other growing windpower markets: In countries such asFrance, Spain, Great Britain, as well asJapan, China and Australia they areconverting wind power into electricitytogether with the generator - on landand sea. Up to now more than 5000inverters have been installed for systemcapacities between 600kW to 5MWand also for larger capacities in future.(www.woodward-seg.com).inverter is switched into the rotor circuitof the asynchronous generator in order toregulate the system output according to therotor speed. IGBTs (insulated-gate bipolartransistor) generate a voltage with a variablefrequency and amplitude from a DC linkcircuit. The frequency in the rotor circuitis set according to the speed of the WTG,which depends on the wind. The stator of theasynchronous generator is connected to themedium voltage network via a circuit-breakerand transformer.Alternative connection to the gridThe speed range of wind turbine generatorsis more often in the lower range than inthe rated range. This means that circuitbreakershave to be switched on and offvery frequently. Added to this are the safetyrequirements which must be observed in theconnection to an industrial network withshort-circuit currents of up to 50 kA. Reducingthe number of switching operations reducesmaintenance costs as well as downtimes. Ifoperating currents of present day WTGs areto be controlled between 2000…3000A andswitched in the event of a fault, series circuitsconsisting of circuit-breakers and contactorsoffer a very good technical and yet veryexpensive solution. However, these kinds ofsystems are primarily considered from thepoint of view of costs, and so a cost-optimisedcircuit should also be used not least for thesereasons.There is, however, another solution. A“smaller” bypass consisting of an NZM (-Q2)circuit-breaker and (K2) contactor for the“main switch Q1” can handle the connectionto the grid in the partial load range. Even highshort-circuit currents with grid transients arecontrolled by the combination of softwarebasedcurrent monitoring and vacuum tubetechnology offered the DILM contactor. Theshort-circuit protection of the bypass circuit isimplemented with an NZMH4 circuit-breaker.Practical experience with this circuit to datehas shown that the switching operations ofthe main switch can be reduced with a bypass.An experienced team, consisting of specialistsfrom Woodward SEG and Moeller testedthe use, dimensioning and function of thecircuit and assessed the risk in the form of afailure mode and effects analysis (FMEA). Theresults of the analysis were impressive in everyrespect.Highly efficient switching up to 2200A with Moeller DILH contactors. The vacuum technology preventsexposed arcing and allows a considerably longer electrical lifespan compared to air contactors. The 2500 Arating class will be added to the series in futureA bypass to the main switch consisting of compactcircuit-breaker and vacuum contactor handles theconnection to the grid in the partial load range.CONCLUSION“Our customers have trust in ourtechnical solutions. We are continuouslyoptimising our frequency invertersand thus also reducing the life cyclecosts of the WTGs. In this respect weconsider ourselves at Woodward SEG astechnical partners of our customers,”team leader Eric Harmann explainedabout the use of Moeller components.“We are very happy with Moeller‘stechnical support. The understandingof a system for wind power technologycan only be achieved on the basis ofcontinuous cooperation. In my opinion,our strengths are in the search forcommon and well-founded solutions.”Quicklink ID:MS1818For Moeller Electric Sales and Support call KMparts.com (866) 595-961627

FlattenedxEnergy supplies South Americanchipboard plantTHE COMPANIESVSK-Technik Kübler GmbH, Worms,operates in the following businessareas: project management, planning,maintenance and commissioning for allaspects of electrical engineering anddrives, automation and mechanics. Thisranges from medium to low-voltagetechnology, from complete to partialsolutions for industrial electrical systems.(www.vsk.de).Dieffenbacher GmbH + Co. KG is aninternationally active group of companiesbased in Eppingen that develops andmanufactures press systems and completeproduction systems for the wood panelindustry, the automotive and componentsindustries. (www.dieffenbacher.de)The Eppinger-based international company Dieffenbacher is building a complete chipboard plantin the Bolivian Republic of Venezuela. The “Bariven” project covers the complete medium andlow-voltage power distribution in addition to the machine parts and the building complex.Moeller system partner VSK-Technik Kübler, based in Worms, built it on site using xEnergy.28For Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18Moeller System PartnerMoeller provides panel builders with a comprehensive range of enclosures anddistribution boards for power distribution systems up to 4000 A based on typetested function modules in compliance with IEC 60439-1. xEnergy, XVTL, CS orCI are examples of a complete power distribution system solutionthat consists of switchingand protective devices, the mounting technology, switch cabinets and the planning andcalculation tools, as well as giving due consideration to local installation practices (DIN, VDE,CEI, NF, UNE*).The Moeller system partners scheme for switchboards is an offer for panel builders thatprovides a range of different training courses on products and directives, as well as support foradvertising measures etc.The specifications for the South Americanchipboard plant are similar to those forthe power supply of a small town: Thepower is fed via two 115 kV / 13.8 kV highvoltage transformers with an output of 30MVA each, as well as a medium-voltagedistribution board and ten 13.8 kV / 0.44 kVtransformers with a rating of 1.6 MVA, aswell as a transformer for a 4.16 kV, 1 MVAmedium voltage drive.The low voltage power distributionsystem consists of 42 panels with six maindistribution systems with a rated current of2500 A, and a rated short-time withstandcurrent Icw of 50 kA. The power supply isimplemented via ten open IZMB2 circuitbreakerswith a rated current of 2500 A.Four coupling switches ensure emergencyoperation during maintenance or in theevent of a transformer failure. Both thetransformers and the incoming circuitbreakersare networked via Profibus, andsupply all operating data to the PLC formonitoring. A touch panel is used forcontrolling the power supply and visualizingthe system status.Modular xEnergy conceptVSK-Technik Kübler is an original MoellerxEnergy partner. xEnergy provides the Wormsbasedcompany with a freely combinableproduct range for power distribution systemsup to 4000 A. Operation is outstandinglysimple whatever the level of complexity.The system has a modular design and canbe arranged in intelligent combinations.Switching and protective devices, as wellas the associated mounting system andenclosures, form a technical and economicalunit. The system platform allows individualproject design, maximum flexibility and fastassembly in the workshop. This saves time,space and financial resources.The xEnergy modular system is futureproofand can be expanded exactly togrowing requirements. Its product rangecomprises incomer and coupling sectionsfor 4000 A circuit-breakers, individuallyconfigurable outgoer feeder sections withfixed compartment modules for switchingand protective devices up to 630 A, outgoingfeeder panels up to 630 A for switch-fusestrips, fuse rails and fuse switch-disconnectorswith different mounting depths, controland empty sections for optional equipment(such as with motor starters, PFC modules,frequency inverters, soft starters) as well ascarrier modules for modular rail-mounteddevices as service distribution boards.xEnergy consists of exactly tailoredfunction modules that are type tested withForm 1 to Form 4b internal separation inaccordance with IEC/ EN 60439, and givesdue consideration to European and localinstallation practices (DIN, VDE, CEI, NF,UNE*). As long as the panel builder followsthe Moeller assembly manual and installationinstructions, he can offer the system as atype-tested assembly (TTA) to his customerswithout any additional expenditure requiredfor testing.Panel builders are equipped with efficienttools for all stages from planning, toquotations right up to ordering. Thedocuments and the switchboard front vieware printed out with the order list. If required,Moeller can supply the entire range packedin functional flat pack units or as a preassembledswitching cabinet. Moeller alsooffers technical support and training courseson the construction of xEnergy. If required,the Moeller Field Service is also available foradvice and support.CONCLUSION“We have been official Moeller xEnergypartners since 2004 and have a verygood experience with xEnergy”, DieterRinghof explains. He is assistant tothe board of directors and has been atVSK-Technik Kübler for11 years. “ThexEnergy modular system allowed us tobid for the tender for Bariven project.Even for us, the planning, construction,testing and supply of 42 powerdistribution sections as TTAs within eightweeks was a real challenge. However,thanks to xEnergy were able to handlethis masterfully.”*IEC = IEC International ElectrotechnicalCommission = CEI Commission ElectrotechniqueInternationale; UNE Una Norma Española; NF Normefrançaise - Quality mark of the French standardsinstitute AFNORQuicklink ID:MS1819For Moeller Electric Sales and Support call KMparts.com (866) 595-961629

Moeller InfoboardMOELLER TRAININGOnline Training CenterThe Online Training Center providesapplication examples, tricks and tipson products, functions, applications foreasyRelay, easyControl, easyHMI and infuture also for easySafety devices. Thisalso contains the easy forum.Quicklink-ID: OTCTRAINING CENTERMatch schedule VfL GummersbachA strong team: VfL Gummersbach and Moeller.Professionalism, team spirit and lots of practical experience – qualities that both VfL Gummersbach andMoeller have in common. As well as being based in Gummersbach: The club town of these players in thenational handball league is also the site of the most important factory for Moeller contactors. Good enoughreason for us to actively support VfL Gummersbach as its main sponsor and provide fresh power on thehandball pitch.07.12.2008 15:00 p.m. TV Großwallstadt – VfL Gummersbach Großwallstadt09.12.2008 20:15 p.m. VfL Gummersbach – HSV Hamburg LANXESS arena, Cologne17.12.2008 17:00 p.m. TuS N-Lübbecke - VfL Gummersbach Kreissporthalle Lübbeck14.12.2008 17:00 p.m. Füchse Berlin – VfL Gummersbach Max-Schmeling-Halle, Berlin20.12.2008 15:00 p.m. VfL Gummersbach – TBV Lemgo LANXESS arena, Cologne27.12.2008 15:00 p.m. VfL Gummersbach – Frisch Auf! Göppingen LANXESS arena, CologneMOELLER TIPNew selector slide for dimensioningDOL and star-delta starters in ship buildingThe practical selector slide is also availablefor applications in ship building withmotor ratings of up to 500 kW. It enablesthe fast and clear selection of individualcomponents for the drive solution– without the need for a PC or other tool.The new slide shows you directly thecomponents for a complete drive trainsystem, from the mains supply up to themotor feeder. Once the required motorrating is set, the corresponding productsare shown immediately. The selector slidecan be ordered free of charge. If youprefer to use the selection aid online, thisis possible on the Internet at:www.moeller.net/selectMOELLER LIVEFairs and ExhibitionsGermany10.03. – 13.03.2009 | Anuga FoodTec, Cologne25.03. – 27.03.2009 | Eltefa, Stuttgart20.04. – 24.04.2009 | HANNOVER FAIR, Hannover02.09. – 05.09.2009 | Elektrotechnik, Dortmund14.09. – 19.09.2009 | DrinkTec, Munich24.11. – 26.11.2009 | SPS/IPC/Drives, NurembergEurope29.01. – 01.02.2009 | Häuslbauer fair, Graz19.02. – 22.02.2009 | Bauen und Energie fair, Vienna26.02. – 01.03.2009 | WIN Automation, Istanbul27.02. – 01.03.2009 | Welser Energiesparmesse fair, Wels24.03. – 27.03.2009 | MagyarRegula, Budapest31.03. – 03.04.2009 | AUTOMATICON, Warsaw31.03. – 02.04.2009 | Amper, Prague06.04. – 09.04.2009 | Elcom, Kiev12.05. – 16.05.2009 | Technical Fair, Belgrade01.09. – 04.09.2009 | go Automation, Basle01.09. – 04.09.2009 | Ineltec, Basle28.09. – 02.10.2009 | Elektrotechniek, Utrecht07.10. – 09.10.2009 | Smart Automation, Linz14.10. – 15.10.2009 | Mocon-Hydromech, GhentGet to know the Moeller automationworld: The Moeller training centres inNorth and South Germany offer you thechance to access, brush up and deepenyour knowledge of Moeller products.Seminars offered at EAZ-Aalen:Programmingwith CoDeSys |19.+20.01.2009 /14.+15.05.2009Basics of programming |21.-23.01.2009 / 25.-27.05.2009Intermediate programming |09.-11.03.2009 / 08.-10.06.2009EASY – (500/700) | 23.03.2009 /02.07.2009EASY – (800/MFD) | 12.+13.03.2009 /28.+29.05.2009Intermediate programming | 08.05.2009Seminars offered at bfe-Oldenburg::Programming to IEC61131-3 with CoDeSys(basics) |01.-03.12.2008EASY 500/700 |23.02.2009 / 02.11.2009EASY 800 | 24.02.2009 /03.11.2009MFD-Titan multi-function display |25.02.2009 / 4.11.2009Moeller MFD-Titan multi-function displayWorkshop | 26.02.2009 / 05.11.2009Programming with CoDeSys (basics)(Grundlagen) | 11.02.-13.02.2009 /18.11.-20.11.2009Programming with CoDeSys (intermediate)| 16.02.-18.02.2009 / 23.11.-25.11.2009Moeller frequency inverters and softstarters | 11.03.2009Design engineering with Moeller circuitbreakers| 06.05.-07.05.200930Quicklink-ID:EXPORTQuicklink-ID: FAIRSQuicklink-ID: TRAININGFor Moeller Electric Sales and Support call KMparts.com (866) 595-9616

SOLUTIONS18FAX Reply+49 (0)228 602-2275Please send me Moeller Solutions regularlyCompany:Name/First NameDepartment/FunctionStreet:Post code/Town:Country:Telephone:E-mail:Please include mein the distribution list for yourelectronic Moeller newsletter.QUICKLINKYour goal‘s just a click away.1. All texts are provided with a 6-digitQuicklink number.MS XXXX2. At www.moeller.net enter the requiredQuicklink number in the entry box at thetop right or enter a search term andconfirm.MS XXXXMOELLERINFO SERVICEFurther information:Up-to-date and fast.By fax, Internet, emailand for downloadFAX REPLY+49 (0)228 602-2275E-MAILinfo@moeller.netINTERNETwww.moeller.netNEWSLETTERinfo@moeller.netINFO REQUESTliterature.moeller.netELECTRONICCATALOGUEcatalogue.moeller.netPlease send me informationon the following topicsIndustrial Switchgear New Products Catalogue 2008Industrial Switchgear Product OverviewNew Features for NZM Circuit-BreakersProduct Information for SmartWire DarwieasyHMI MFD4 Multi-Function DisplayDarwin TechnologyNew Features for xStart ContactorsDIL H ContactorseasyRelay, easyControl, easySafetySwitchgear and Switchboards for the World MarketM-MAX frequency invertersMotor starter selector slidexEnergy Energy Distribution3. This takes you immediately to extensiveproduct information.For Moeller Electric Sales and Support call KMparts.com (866) 595-961631

www.moeller.netwww.moeller.netWith Moeller in control there‘s room for varietywithout compromising safety.Any deviations in the finishing of high quality wood and veneers are unacceptable – andthis also applies to safety. When sawing and pressing are involved, the protection ofpersonnel and plants has top priority. This is why our easySafety control relay combinesall conventional safety and control functions in one device. You can then adapt theapplication and configuration to suit your production requirements. This saves time andresources – whilst making no allowances for any safety tolerance. Like with all applicationsin which Moeller switches, protects, controls, monitors and drives.Also in your sector: www.moeller.net/safetyMoeller Electric GmbH · Info-Service · 53105 Bonn · Fax (0228) 602-227540 1 5 0 8 1 1 7 1 6 9 9For Moeller Electric Sales and Support call KMparts.com (866) 595-9616Moeller Electric GmbH · Fax (0228) 602 -2275 · info@moeller.net