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 using<strong>Moeller</strong> 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 <strong>Moeller</strong>‘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. <strong>Moeller</strong>‘s metallic MFD4 multi-For <strong>Moeller</strong> <strong>Electric</strong> Sales and Support call KMparts.com (866) 595-9616
<strong>SOLUTIONS</strong>18The 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:“<strong>Moeller</strong>‘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 <strong>Moeller</strong> <strong>Electric</strong> Sales and Support call KMparts.com (866) 595-961621