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GO!Automation with LOGO! and SIMATIC S7‑1200
Number 1 | May 2015 | siemens.com/go
Safely distributedSimatic S7‑1200 controls modular pipe system
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Cover photo: Publicis Pixelpark, G. Fürstenberger
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Bakery equipment14 Sweet treats
Heim Gerätebau GmbH & Co. KG, Uelzen, Germany
Modular pipe system17 Safely distributed
Fr. Jacob Söhne GmbH & Co. KG – Jacob Rohrsysteme, Ingenieurbüro Güldenmeister
Observatory20 Always receiving
Technical Vocational School 1 (TBS 1) and IUZ Observatory, Bochum, Germany
Products22 SMS communication via LTE
LOGO! 8 communication module
Easy introduction to Safety IntegratedSimatic S7‑1200
23 Mobile monitoring and controllingSimatic S7 app
Dialogue
Editorial3 Recognized
Heating control system4 Heating with pizzazz
Elektro Ibel, Osterwaal, Germany
Building management systems6 The only limit is your imagination
Building automation in residential buildings
Exhaust systems8 A dusty affair
Munder Engineering GmbH & Co. KG, Stuttgart, Germany
Agriculture10 A faster route to beer
Elektro Ibel, Osterwaal, Germany
Air‑conditioning technology12 An excellent climate
Clim Cool Project GmbH, Renningen, Germany
GO! 1/2015 | Contents
Safely distributed
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Editorial | GO! 1/2015
In April, the LOGO! 8 Roadshow came to an end. The six‑month trip took our new logic module across Europe. The LOGO! truck stopped off in many places in Belgium, Denmark, Germany, Finland, France, Italy, the Netherlands, Austria, Poland, Switzerland, Sweden, and the Czech Republic, allowing numerous customers and interested parties to see in person how easy the new microcontroller is to operate. The combination of presentations and practical exercises in hands‑on workshops, in which experienced LOGO! users introduced newcomers to the world of the logic module, generated a great deal of enthusiasm. The wholesalers who hosted the events were very pleased with the response from their customers. We are sure that the fan base will grow as a result of the LOGO! 8 Hello World Tour because the new features and functions enable exciting ideas to be developed and implemented with LOGO! 8. We are pleased to again present some of these applications in this issue of GO!
The LOGO! 8 received an entirely different type of recognition with the prestigious iF Design Award 2015 in the product category. In the words of the jury, the system “features a new display integrated flush into the base module, giving the smallest of the Siemens automation systems a contem‑porary appearance. The light guide positioned across the edge allows the system status to be seen in various mounting positions.” The jury also praised the simplified operation and enhanced communications capabili‑ties via Ethernet. But the highest recognition we continue to desire is first and foremost your satisfaction as a user in the implementation of your proj‑ects, whether it be with LOGO!, Simatic S7‑1200, or any of the other com‑ponents in our portfolio of automation products.
I hope you enjoy reading this issue.
Heinz EisenbeissCEO, Marketing and Promotion, Industrial Automation Systems
Recognized
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GO! 1/2015 | Heating control system
Master electrician Christian Ibel is a resourceful man. With the LOGO! logic module, the native of Upper Bavaria has implemented control technology for many special projects, including the coal‑fired heating system of his home in Osterwaal, where he replaced the supplied controller with LOGO! 8.
The service technician, who also works part time in his own com‑pany as an electronics technician,
had good reason for the unusual choice of a coal‑fired heating system in 2013: “It doesn’t receive any subsidies, but it is much cheaper to purchase than com‑mon models using oil, pellets, or wood chips.” The coal‑fired boiler was deliv‑ered to him with a controller, but the controller did not satisfy the creative tinkerer. “I have now completely re‑placed it with my own solution using LOGO! 8,” he says. “This allowed me to integrate many useful functions – from
better combustion settings to being able to view faults over the Internet.”
Only lighting it is manual
In the heating system, a motorized auger feeds the coal from the storage container into the boiler as required. There, a blower provides combustion air or preservation of embers when no heating is occurring. The ash is dis‑charged into a special container. To pro‑tect the boiler, there is also a buffer tank for hot water, which is heated via a feed pump and then fed into the
underfloor heating circuits and radia‑tors.
A LOGO! 8, with a digital expansion module, an AM2 RTD module for the connection of PT1000 temperature sensors, a LOGO! Power supply unit, and an external text display, controls the firing and monitoring of the coal‑fired boiler as well as the feeder pump to the buffer tank. For preservation of embers, coal is added at certain inter‑vals and the blower switched on briefly. If the heating operation then starts be‑cause the heating water temperature in the buffer tank has fallen below a
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Heating with pizzazz
In the coal‑fired boiler, a blower provides combustion air, and a LOGO! 8 controls the firing
Elektro Ibel, Osterwaal, Germany
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Heating control system | GO! 1/2015
INFO AND CONTACT
siemens.com/[email protected]
certain value and therefore needs to be increased again, the blower runs continuously.
Monitoring via display and web server
The feeder pump to the buffer tank is turned on in the heating operation when the temperature in the boiler is 5°C higher than in the tank. If the boiler transitions from heating operation to preservation of embers, the residual heat is discharged into the tank to ensure maximum efficiency. Using a three‑way mixer, the LOGO! 8 controls the flow temperature for the underfloor heating in relation to the outdoor tem‑perature. Ash removal is also regulated using counters and timers: it only starts after repeated feeding of coal and has a programmed duration.
The new LOGO! 8 generation im‑
pressed Ibel in a number of ways: “First of all, in terms of price. And then it is also narrower, taking up even less con‑trol cabinet space than its predecessor. Thanks to the web server and app, I can also remotely monitor the boiler from a smartphone, tablet, or PC and access the controller and the program from anywhere.” The external text display of the LOGO! 8 also has clear advantages: “It provides more characters per line than before, so you can write out a slightly longer phrase, such as ‘ember preservation,’ for example, and it has different background colors. In normal operation, the background color in my solution is white; in case of a fault, it is red, and it turns orange in manual op‑eration. In manual operation you can run tests, for example, or you can con‑trol all outputs such as the pump, blower, and ash removal separately during cleaning.”
The professional electrician was able to program detailed message texts for the current operating status and nu‑merous fault messages, which were not previously available and which he can also view on his office computer via the Internet, thanks to the embedded web server of the LOGO! 8. The LOGO! app allows the messages to be viewed on a smartphone as well. For example, if there has been no temperature in‑crease in the boiler within half an hour after the start of the heating operation, the LOGO! 8 goes into fault mode with the message “No flame.” If the system pressure decreases below 1.2 bar, a fault is also indicated, thanks to the built‑in pressure switch. The boiler then switches over to ember preserva‑tion. If the temperature in the boiler ex‑ceeds 100°C, a safety temperature lim‑iter interrupts the power supply of the control system and switches on the feeder pump to the buffer tank. Thanks to the corresponding sensor technol‑ogy, the system also indicates when the ash container is full, when the coal bunker is nearly empty, or when the ash removal system is not functioning properly, for example.
Efficient processes
The operating hours can now also be read in order to check the correct func‑tioning of the coal‑fired boiler. The var‑ious capabilities of LOGO! 8 allowed Ibel to make further improvements in the control system of the processes himself. Because the heap of embers steadily de‑creases in size during the preservation of embers, during the transition to the heating operation, the LOGO! 8 feeds more coal in proportion to the duration of ember preservation, ensuring that there is always enough coal for full heating output in the boiler. Protection of the control system completes Ibel’s convenient and efficient solution. To ensure that the LOGO! 8 does not ex‑ceed the allowable operating tempera‑ture in the control cabinet above the boiler, at 55°C it switches on a fan that cools the control cabinet. The solution has been successful in every respect.
For normal operation, Christian Ibel chose white as the back‑ground color for the external text display
In manual operation – identified by the orange background – all outputs can be separately controlled
The LOGO! 8 solution allowed the electrical technician to program many significant fault messages
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GO! 1/2015 | Building management systems
When Heiko Katheder built a house last year in Fürth, Ger‑many, he asked himself how
he could increase comfort through automation, make the building more attractive to demanding tenants, and increase its value over the long term. The Siemens salesman initially thought about convenient controls for electric blinds and lighting, as well as auto‑matic irrigation of the garden, but he also wanted an upgradable solution. In addition, he wanted to be involved in the implementation in order to “get a feel once again for the technology in practice.”
A strong team
“I was aware that LOGO! now has many functions that private individuals can also use very easily,” says Katheder. “It opens up fantastic opportunities, and as a user you are only limited by your own imagination.” He also knew that the LOGO! 0BA7 series had a CM EIB/KNX communication module with KNX components that is easily networked.
“This gateway made the many physical inputs and outputs of a mere LOGO! solution unnecessary, thus saving a great deal of hardware and space. As an alternative, a complete KNX solution would also have been possible. But I
quickly realized that this would be much more expensive. I wanted to use KNX where it would make sense.” Kath‑eder thus chose a combination of LOGO! and KNX. He designed the solution and created the program for the logic module in his spare time, and an electrician installed and wired the hardware on‑site.
In the central distribution board in the basement, there is now a LOGO! 8, which controls the lighting on the stairs, in the technical rooms, and in the outdoor areas, as well as watering in the garden. There are two LOGO! 0BA7 units each in the distribution boxes of the ground floor and first floor, and another in the attic, each equipped with digital expansion modules and the CM EIB/KNX communication module and networked with CSM switch mod‑ules via Industrial Ethernet.
The communication modules com‑municate via KNX, using multiple sen‑sors in the bedrooms, the living room, and the kitchen. This set‑up offers many advantages, as Katheder ex‑plains: “For installation, only one cable is needed, despite a six‑ or eight‑way panel, and 24 volts are sufficient for operation. In addition, the KNX push buttons require less space than conven‑tional switches, and they can be flexi‑bly assigned: I can assign the individual
push buttons at any time to different functions when I need to do so, with‑out having to change anything in the wiring.”
Convenient functions freely programmed
Katheder wanted to make the building management system as user‑friendly as possible for his tenants, so the electric blinds can be operated both individu‑ally and as a group. “LOGO! also al‑lowed many convenient functions to be freely programmable,” he says. “For example, double‑clicking any of the push buttons allows all the blinds on the floor to go up or down. And in the living room and by the exit there are push buttons to raise or lower the blinds.” Even when residents leave the house, forgetting to turn off certain lights is a thing of the past, as the light‑ing can be switched off with a single click. Likewise, presence simulation can be switched on in order to deter bur‑glars by turning on lighting and raising or lowering blinds at random times.
Thanks to the time switch, the LOGO! can also define switching times for the blinds and watering, so that the garden does not dry up in the summer. The LOGO! annual time switch disables this automatic operation from November to
The only limit is your imaginationWhether the task involves increasing comfort in residential buildings or monitoring basements for water and intrusions, LOGO! offers many opportunities to add value to buildings and make them safer through automation – for example, in combination with KNX components or a communication module for alarm signaling via SMS.
Building automation in residential buildings
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March so that the pipes do not burst in case of frost. “The tenants can adapt the switching times on the text display of the LOGO! to their needs and switch them on or off,” says Katheder. Another function relates to the stairwell light‑ing: “Children in particular sometimes forget to turn these lights off again.” For this reason, LOGO! automatically turns the lights off after two minutes – unless the user holds down the push button for a second. Then the light stays on so the stairs can be cleaned, for example.
Monitoring the basement with SMS alarms
Katheder already has other functions in mind that he could implement with the hardware that is already in the building, to make the house safer, for example. Sharing experiences with colleagues is extremely helpful. One colleague, Jochen Messingschlager, has already taken advantage of the fact that the CMR2020 communication module for LOGO! 8 can be easily connected to the base module via Industrial Ethernet in‑terface and integrated into the GSM system with a SIM card. “As a member of the volunteer fire department,” he
says, “I’ve been involved in several de‑ployments due to basement flooding. I want to be prepared in the worst‑case scenario and receive alerts if I’m not at home.”
As a technician, he mounted a water sensor on the input of a LOGO! 8. If the sensor comes in contact with water, it transmits the signal to the logic mod‑ule, which then sends an alarm SMS to the stored mobile numbers via the CMR2020 communication module. In the same way, Messingschlager allows sensors on all window contacts on the ground floor to be monitored, issuing an alarm in case of burglary. He also wants to integrate special smoke detec‑
Communication modules distributed throughout the building communicate via KNX, with multiple sensors in the rooms of each home
INFO AND CONTACT
siemens.com/[email protected]
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tors into the system and the children’s rooms upstairs. “Since LOGO! 8 can eas‑ily network the various stories of the building, I only need the CMR2020 in the basement. Programming the data exchange between the LOGO! 8 units is accomplished with LOGO! Soft Comfort V8 in network mode with drag and drop. There is really no easier way to communicate between devices!”
With the LOGO! in the central distribution board in the basement, lighting in various areas and garden watering can both be controlled
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GO! 1/2015 | Exhaust systems
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LOGO! 8 controls four cleaning programs with different types of filters
Excavators, dump trucks, loaders, bulldozers, and trucks need clean air for the combustion of fuel and smooth operation, but these vehicles are
often used where a great deal of dust is stirred up – in quarries; in gravel, cement, and concrete plants; and in mining. As a result, the air drawn in by the en‑gine is heavily loaded with dirt and dust particles. If this dust is not filtered out, it acts like sandpaper in the engine and quickly leads to wear of mechanical components as well as total failure of the engines.
Munder Engineering GmbH & Co. KG, based in Stuttgart, has for the last two decades been a lead‑ing provider of innovative cleaning solutions such as exhaust systems for dedusting filter cartridges, air‑shower booths for blowing off dusty work clothes, and clean‑room personnel locks where loose parti‑cles adhering to work clothes are removed. “The de‑mand is especially great for highly flexible exhaust systems in which a variety of filter cartridges can be cleaned with short changeover times. They present an economical alternative to expensive new procure‑ment. The service life of the filter cartridges is sig‑nificantly increased, and the protection of the ma‑chines is safely guaranteed,” says CEO Lothar Munder, describing the benefits of his systems.
Teach‑in with LOGO! 8
To ensure that the systems are easy to use, Munder relies on automation technology from Siemens. For operation, switch boxes are mounted on the exhaust systems that include LOGO! 8 logic modules for mon‑itoring and control of cleaning processes as well as Sitop power supply units, Sirius safety relays for
Filter cartridges in vehicles and suction systems quickly become filled with dust and must be replaced. A sophisticated exhaust procedure, semiautomated with LOGO! 8, enables their cost‑effective reuse.
Munder Engineering GmbH & Co. KG, Stuttgart, Germany
A dusty affair
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Exhaust systems | GO! 1/2015
INFO AND CONTACT
siemens.com/[email protected]
protective door monitoring, and other electronic components. To display the cleaning programs, the logic module is connected via the Ethernet interface with a LOGO! 8 TDE via the side surface of the switch box. The display shows six rows with 20 characters per line. It has different background colors for visual accentuation and four freely assignable function keys for the various cleaning programs.
HG Elektrotechnik of Notzingen assumed respon‑sibility for the planning and implementation of the electrical components. To reduce the effort involved in setting up the machine and automating the man‑ual monitoring of the filter levels, Munder decided to use logic modules. LOGO! 8 is set up for teach mode. During the teaching of the microcontroller, the worker moves across the upper and lower height of the filter cartridge with the exhaust nozzle, thus cap‑turing the coordinates. These steps are repeated for each filter cartridge, and the created programs are stored. The logic module stores four cleaning pro‑grams with different filter types that can be easily re‑trieved and run by the operator using the control buttons. The user can create additional programs at any time for filter cartridges with different heights and internal dimensions.
After the dirty filter cartridge is positioned on the grating of the system and the front door is locked, the cleaning program starts. The exhaust nozzle is inserted into the filter cartridge, starts to rotate, and blows the dust particles to the outside at a pressure of 6 bar. The dust falls through the grating into a col‑lection container. After the nozzle has reached the lower operating point, it reverses and moves back up to the upper end of the filter cartridge. After the cleaning cycles, which last between 3 and 10 min‑utes depending on the dust level, the lift cylinder re‑turns to its original position. LOGO! 8 turns off the exhaust, and the worker can remove the cleaned fil‑ter cartridge.
Reducing costs with compressed air
Cleaning the filter cartridges with an exhaust system is significantly cheaper than regular replacement and new procurement. Even if they start out extremely dirty, the filters are nearly as clean as new at the end of the process, and they achieve a service life of sev‑eral hundred hours with continuous cleaning in ac‑cordance with the manufacturer’s specifications. “If a company invests some €100,000 per year in re‑placement filters, the managers quickly recognize the cost‑effectiveness of filter cleaning. The cost of replacing the dedusting filters can quickly be re‑duced to 25%,” says the equipment manufacturer.
Filters for suspended particles need to withstand mechanical loads over a long period of time. Under the extreme operating conditions in quarries, min‑ing, and construction sites, this presents a challenge,
where the performance limit can be reached in some cases after just 10 hours of operation. Gentle clean‑ing of the filter cartridges using exhaust systems is an efficient alternative. For plant operators, this re‑sults in significant savings because it requires fewer costly replacement filters. In addition, the industrial environment is safer and less dusty for both man and machine.
“ The logic module is the
ideal solution for ease of
use of the systems. It
leaves nothing to be
desired when it comes to
reliably controlling and
optimizing cleaning
operations.”
Lothar Munder,
Munder Engineering GmbH & Co. KG
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GO! 1/2015 | Agriculture
hops are still wet in the top layer, I can run the fan at full capacity and thus ac‑celerate the drying,” he explains. “When the hops become lighter, the fan is turned down accordingly. In this way we save around half an hour per cycle, resulting in 30 minutes less oil consumption.”
The fan speed is controlled by a LOGO! logic module using an air mass sensor and a defined time. To evaluate the air mass sensor’s data, Ibel uses the 0–10–V analog input of the base mod‑ule, and to control the frequency con‑verter he uses a 0–10– V analog output of the AM2 AQ expansion module. “These inputs and outputs were a deci‑sive factor when choosing LOGO!,” he says. While the air mass flowing
In the middle of the Hallertau, one of the most important hop‑growing re‑gions in Germany, lies the farm
owned by Christian Ibel’s parents. Pro‑ficient with LOGO! and convinced of its benefits (see article on page 4), Ibel de‑cided to automate his parents’ hops kiln, where the hops are gradually dried by hot air to between around 10% to 11% water content.
On the floor of the towerlike build‑ing is a large oil burner with a fan motor that heats the air and forces it upward. Three layers are separated by grids. The fresh hops arrive on the top level and remain there for five hours. Then they are shifted manually to the next layer, where they continue to dry for three hours. For the final drying,
they are moved down to the lowest layer in a sliding drawer, which can then be easily pulled out. When the hops are moved down a layer, fresh hops immediately replace them so that all layers are being used.
Fan speed adjusted as needed
Before the automation, the kiln always used consistently low fan power. This prevented the hops when they were dry and therefore lighter, from blowing around and leaving holes in the top‑most layer, hindering the drying pro‑cess. In 2012, Ibel therefore installed a frequency converter to regulate the fan speed and increase the efficiency of the hops kiln. “At the beginning, when the
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Before brewers can process hops, the hops must be dried in a kiln. Master electrician Christian Ibel demonstrates how the drying time and the oil consumption of a kiln can be significantly reduced through automation with a frequency converter and LOGO!
Elektro Ibel, Osterwaal, Germany
A faster route to beer
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Agriculture | GO! 1/2015
The separate text display allows operation from an easily accessible locationThe hop cones are dried here
through provides information about the dryness of the hops, the speed must be reduced by 20% after half an hour of drying. Manual mode is also possible.
If the mass airflow exceeds a certain limit value, a hole has likely been blown out, which must be filled again. At this point the system goes into the “fault” operating state, and the logic module regulates the fan speed down to the lowest value.
When a certain moisture level has been reached, the hops must be brought to the adjacent conditioning plant within a few minutes. LOGO! recognizes this thanks to a moisture sensor with a frequency output. The frequency, which decreases as the hops become drier, is monitored with the “threshold switch” function. The control system reduces the speed of the fan enough that the hops do not dry out. At the same time, it triggers an optical
INFO AND CONTACT
siemens.com/[email protected]
warning signal – an easily visible light outside the building – as well as an acoustic telephone signal via a “make contact” element.
Conditioning with analog value comparisons
In the conditioning plant, the fan of an air‑circulation system standardizes the moisture content of the cones to a cer‑tain percentage value by remoistening them a bit or drying them slightly fur‑ther. The logic module also controls this process. It compares the tempera‑ture and humidity of the air outside and inside the kiln with the values of the hops in the conditioning plant. De‑pending on the requirements, servo‑motors open a multileaf damper either toward the outside, to moisten the hops with the humid outside air, or to‑ward the kiln, in order to allow the hops to be dried a bit more with hot air. “Be‑
cause post‑drying is difficult, we prefer to dry the hops in the kiln a little more than desired at the end and then re‑moisten them in the conditioning plant,” explains Ibel.
In addition to the price/performance ratio, Ibel appreciates LOGO!’s integrated text display, which shows all the im‑portant operating states, data, and faults directly in the control cabinet, in‑cluding the current percentage values, the operating time, faults, or manual mode. This helps optimize the opera‑tion of the system. The system will soon be upgraded to LOGO! 8 so it can also be operated from a smartphone via the web server.
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GO! 1/2015 | Air‑conditioning technology
Live TV broadcasts offer broadcasters in the highly competitive media market the opportu‑nity to score points with real‑time reporting on
current events. At sporting events or entertainment shows, broadcast vans transmit the sound and image recordings directly to the broadcast center, where the station integrates them into the current program. Flawless delivery of the live broadcast signals re‑quires enormous technical effort and expense, and the broadcast van must transport extensive studio equipment to the location where the recording will take place: cameras, tripods, cables, mixers, and transmission equipment. Optimally cooling all the
transmission technology in the vehicles represents a particular challenge.
Clim Cool Project GmbH (CCP) in Renningen, Ger‑many, specializes in air‑conditioning and refrigera‑tion installations, including both building and indus‑trial equipment as well as projects in special vehicles. The latter include broadcast vans of radio and televi‑sion stations, for which CCP develops customized solutions. “Having dependable cooling systems in the vehicles is essential for reliable use of broadcast‑ing technology. These systems enable both the equipment and the staff to work efficiently when it gets warm in the vehicle,” says Ralf Elsasser, who is responsible for electrical engineering and automa‑tion at CCP.
Air‑conditioning systems operate constantly
To ensure that employees feel comfortable in the broadcast vans and that the equipment operates smoothly, CCP equips the vehicles with systems for room and equipment cooling designed for use in am‑bient conditions of ‑25°C to +40°C. While employees adjust the temperature in their workplaces manually, the ambient temperature of the electronic devices is automatically maintained at a constant level using a
An excellent climateHigh‑performance air conditioners in broadcast vans ensure that sensitive equipment performs reliably and that the staff can work efficiently even in high ambient temperatures. Simatic S7‑1200 Basic Controllers control the cooling systems in vans equipped by Clim Cool Project.
Clim Cool Project GmbH, Renningen, Germany
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Air‑conditioning technology | GO! 1/2015
A fully air‑conditioned Bavarian Radio broadcast van is packed with sensitive technology
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INFO AND CONTACT
siemens.com/S7‑[email protected]
The air‑conditioning system can be easily operated using a Simatic touchpanel
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PLC. “We tested various offerings to find out which control system would be best for our tasks and could be programmed most easily. The decision was unan‑imously in favor of the Simatic S7‑1200,” reports Elsasser.
Once the vehicle is at the transmission location, all the transmission technology runs continuously in standby mode because it would be too time‑ consuming to power down the devices in the eve‑ning and boot them up again the next morning. However, this means that the air‑conditioning systems must operate continually.
The PLC sends an alarm message to a cell phone
Temperature sensors and set‑point adjusters for the cooling stations are connected to the analog inputs
of the PLC; their values control the systems. The last employee to leave the vehicle after the end of the program activates a monitoring function. If a sensor detects a temperature limit value, the control system sends an alarm signal to the cell phone of the staff member on call. Ten minutes later the PLC switches off all power for safety reasons.
Step 7 is the common platform used for engineer‑ing the Simatic S7‑1200 and Simatic HMI Basic Pan‑els. The high‑resolution 15‑inch displays with touch operation can be optimally adapted to CCP’s applica‑tions so that the air‑conditioning systems in the ve‑hicle can be graphically monitored and controlled. Before Elsasser loads the software onto the control‑ler, he performs functional program tests. The simu‑lation reduces commissioning time and lowers costs. In the event of later program changes, such as cus‑tomization of limit values, he transfers the modified programs into the control system using a laptop or sends them by e‑mail to customers, who import the programs into the controller using Simatic Download Manager.
Straightforward and integrated operating concept
For comprehensive sales and service activities, Siemens collaborates closely with distribution part‑ners, all of which are very familiar with the local con‑ditions and requirements on the customer side. One of these partners is Löffelhardt GmbH in Fellbach, Germany. According to Elsasser, “Löffelhardt has the appropriate expertise in automation and responds flexibly to our special requirements.” The air‑ conditioning expert emphasizes that although elec‑trical wholesalers supply CCP, he has always found an open ear at Siemens for the clarification of technical issues.
“Another deciding feature for us was the TIA Portal engineering framework, with its straightforward and integrated operating concept,” says the automation engineer. He is especially impressed by the program‑ming of the HMI touchpanel with WinCC flexible, the TIA Portal HMI engineering software: “The software is user‑friendly, self‑explanatory, and intuitive to operate. The individual objects can be placed on the touchpanel using drag and drop. You assign them to events – for example, what action to take when trig‑gered – and select the appropriate variable.” Step 7 and WinCC flexible are linked together and share a uniform operating interface. Elsasser says: “I have al‑ready tested several solutions, but the HMI program‑ming with WinCC flexible is unbeatable.”
14
Glazed or unglazed jelly doughnuts or crullers – with or without jam, chocolate, or vanilla cream filling – are particularly popular on New
Year’s Eve or during Mardi Gras. These deep‑fried pastries are extremely popular internationally in many variations throughout the year. The sweet treats are made in large deep‑frying devices with electric heating elements at the bottom that heat the frying grease to between 140°C and 180°C.
Heim Gerätebau GmbH specializes in the develop‑
ment and manufacture of deep‑frying and baking equipment. Under the Jufeba brand, the company based in the Lower Saxon town of Uelzen manufac‑tures table and floor models, computer‑controlled compact and continuous systems, and grease filters and pastry fillers. The equipment manufacturer’s flagship is the new generation of automated contin‑uous doughnut‑frying systems with which both small pastries such as mini French crullers and large pastries such as jelly doughnuts are made.
Bakeries around the world make daily use of doughnut fryers from Heim Gerätebau. Quality craftsmanship and the reliability of the systems, as well as their automation with Simatic S7‑1200, ensure consistent results.
Heim Gerätebau GmbH & Co. KG, Uelzen, Germany
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Bakery equipment | GO! 1/2015
“We started with the automation of our plants ap‑proximately seven years ago,” says Thomas Hoff‑mann, who is responsible for electrical engineering and programming at Heim Gerätebau. “First we used LOGO! logic modules from the 0BA6 series, followed by models from the 0BA7 series. But we equip the new continuous doughnut‑frying systems with Simatic S7‑1200 controllers to map the various fry‑ing processes with a PLC. In addition, we wanted to facilitate operation of the systems with large touch‑panels. When we changed over to the Simatic S7‑1200, LOGO! did not support external screens,” says the automation specialist. “After all, we wanted to use just one configuration interface to avoid having to continuously switch between systems. The service and warehousing were also optimized through the standardization.”
Engineering system for easy creation and customization of applications
“The Simatic S7‑1200 controller seemed ideally suited to meeting the increased requirements,” says Chris‑topher Zaleski, head of assembly and production at Heim Gerätebau. “The modular design of the control system opened the possibility of equipping the dif‑ferent devices with a PLC model.” In order to quickly obtain the necessary expertise, Hoffmann ordered a Simatic S7‑1200 Starter Kit. “According to the ‘un‑pack, plug in, start’ method, the starter package with
a CPU, touchpanel, input simulator, Ethernet cable connected to the programming device, and access to the Step 7 Basic configuration interface offered us a good method for practicing programming, operat‑ing, and commissioning the PLC in a manner that was quite practical,” says Hoffmann.
“Today we have a software package that is the same in its basic functions for all systems and that we can fully customize for each individual customer,” adds Hoffmann. Integration of the control system into the Totally Integrated Automation (TIA) concept enables access to the Step 7 Basic programming soft‑ware. TIA Portal provides the tools that make it pos‑sible to create and adapt automation applications as required. The library is particularly useful. It facili‑tates and accelerates the implementation of various automation tasks, as the function blocks of the li‑brary can be directly integrated into the programs.
During the introduction of the S7, Hoffmann at‑tended a three‑day Siemens Sitrain training course, where he familiarized himself with the variety of functions as well as the operation and programming of the micro‑PLC. In addition, he learned how to use the Simatic Step 7 Basic engineering system. The course enabled him to deepen his theoretical knowl‑edge and complement it with practical exercises with the automation components. “The course showed participants how to use the PLC more effec‑tively and to put the programs into operation more quickly,” Hoffmann says.
With the Simatic S7‑1200 controller, frying processes of the automated continuous doughnut frying systems are displayed on the PLC
Electrical heating elements integrated into the bottom of the unit heat the grease to between 140°C and 180°C
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GO! 1/2015 | Bakery equipment
Control system monitors frying operations and ensures optimal results
“The frying programs, in which parameters such as temperature and frying time are stored according to the type of pastry, can be accessed via the system’s touchpanel,” says Zaleski. “The baker chooses the product, such as jelly doughnuts, quark balls, or reg‑ular doughnuts. He puts the dough into the cradle of the fryer and lowers it so that the dough pieces float on the surface of the hot grease. The cover of the grease pan closes, and the program is started.” For example, when the jelly doughnuts have reached the desired level of browning on the bottom side, they are automatically rotated and cooked on the other side. After the frying time has elapsed, the system raises them from the hot grease and places them on a baking sheet.
Heim Gerätebau provides the baker with an intro‑duction to the operating procedures of the system on‑site. Zaleski continues: “We show him how he can achieve optimal results through the appropriate set‑tings. The control system monitors the frying proce‑dures and provides information regarding the pro‑duction quantity and the end of the frying time. It counts the pastries and controls the heating, trans‑port, and turning devices.” The PLC is set as required and password protected so that only the production
INFO AND CONTACT
Training options:siemens.com/sitrain Information regarding the S7‑1200 and Starter Kits:siemens.com/S7‑1200 [email protected]
manager can change the values. Because bakery equipment manufactured by Heim Gerätebau is in‑stalled worldwide, fast and reliable service is critical. The technicians use the Internet to access the sys‑tems for maintenance, for example. This saves time and makes most on‑site visits unnecessary. If a bak‑ery wants recipes to be adjusted, Hoffmann con‑nects with a remote device and makes the changes.
“I’m impressed by the performance of the Simatic S7‑1200 controller in the automation of our systems,” says Hoffmann. For him, the Simatic control system is perfectly tailored to the machines’ requirements and very flexible in the networking of controllers, HMI panels, and engineering components. In addi‑tion to the online help, the various Internet forums are very useful: “You quickly find the right answers to all questions concerning the control system and programming software there.”
The individual frying programs can be called up using the touchpanels on the systems
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The company Jacob presented the new swivel‑pipe switch for the first time at POWTECH 2014 in Nuremberg
Safely distributed
Fr. Jacob Söhne GmbH & Co. KG – Jacob Rohrsysteme, Ingenieurbüro Güldenmeister
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GO! 1/2015 | Modular pipe system
are also metal detectable. If sealing parts enter the production process for any reason whatsoever, they can be completely removed using metal detectors. In this way, foods such as milk powder – and ultimately the end user – are optimally protected against con‑tamination when bulk material is passed through the telescopic pipe of the distributor into different silos as needed.
Encoders and high‑speed counters ensure precision
The food‑grade multiway distributors represent a qualitative leap in terms of the control system, which can optionally be used in conjunction with a variety of sensor and measurement instruments, including pressure, temperature, and humidity sensors; level indicators; and flowmeters. The previous conven‑tional contactor and relay control with mechanical limit switches was replaced by a Simatic S7‑1200 controller.
Thanks to the PLC’s high‑speed counter, the posi‑tion of the telescopic pipe can be queried from the connected incremental encoders without contact. The Simatic S7‑1200 controller controls a Sinamics V20 1 AC 230‑V inverter, which gently starts and brakes the motor and allows the telescopic pipe to go to the predetermined set‑point value in order to con‑nect it to the outlet in a pneumatically precise man‑ner. At the same time, the other unused outlets are capped with dustproof seals to prevent contamina‑tion. While the pipe moves, pinch valves or ball valves seal the outlets in the event of a backlog. This means that only the outlet that is currently in use is open.
Food safety is a top priority. The new Food Grade Line, a modular pipe system from Jacob Rohrsysteme, meets both the stringent European and American requirements for the first time in its market segment. With the Simatic S7‑1200, the turn‑head distributors also achieved a qualitative leap toward greater efficiency and flexibility in terms of the control system.
Fr. Jacob Söhne GmbH & Co. KG, based in Porta Westfalica, Germany, with 40 sales representa‑tives, 450 employees, and more than 5,000
products, is the global leader in modular pipe sys‑tems for dust removal, ventilation equipment, and overflow pipe systems for handling bulk material. The multiway distributor for the chemical and food processing industries can distribute bulk material to different silos as needed for up to 2 × 20 different outlets.
The new food‑grade turn‑head distributor of high‑quality stainless steel, which is also available in ATEX design, meets both the strict European regula‑tion EC 1935/2004 and the American FDA Food Pol‑icy for contact with food – the first product line to do so. All seals, such as shaped seals and ring seals,
Interior monitoring via the Simatic
HMI TP1900 Comfort Panel
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Modular pipe system | GO! 1/2015
Greater productivity on all sides
The new solution has many advantages: “The cost of implementation is far less, and efficiency and ulti‑mately productivity are higher,” says Stefan Gülden‑meister of Ingenieurbüro Güldenmeister, who was responsible for the engineering of the new control system. “Previously, you had up to 40 limit switches that needed to be mounted, electrically wired, and adjusted and tested individually.” To ensure that no food gets into the distributor and spoils, the distribu‑tion pipe must form a complete seal, precise to the millimeter, with the outlet. Over time, this precision could suffer due to wear of the mechanical limit switches, which must be prevented by timely main‑tenance. The PLC and rotary encoder, however, en‑sure maintenance‑free high precision over many years.
“In addition, it is now possible to move the pipe counterclockwise,” adds Patrick Jacob, managing partner at the company Jacob. “If the outlet to the right of the occupied path can be accessed via the shortest path during silo or product changes, this brings productivity gains for the customer.” Jacob, and thus the end customer, saves money and space for limit switches, contactors, and relays.
Always comprehensively informed
The measurement and sensor technology were sig‑nificantly expanded and brought up to date. The Simatic S7‑1200 evaluates the operating data re‑corded and displays them on the web server, which is integrated as standard. On the TP1900 Comfort Panel, the swivel‑pipe switch is visualized in real time as a photo‑realistic 3‑D film in sync with its actual
INFO AND CONTACT
siemens.com/S7‑[email protected]
movement. In addition to control using the Comfort Panel, the swivel‑pipe switch can be controlled and monitored via smartphone or PC with a web browser. Using the Scalance W761 access point, the customer can log in directly to the website of the swivel‑pipe switch via Wi‑Fi. On the display and website, opera‑tional, maintenance, and fault messages are dis‑played, along with measured values and the camera image. As an alternative to the TP1900 Comfort Panel, the KTP400 Basic Panel can be offered for sim‑pler applications.
The optional camera can monitor the interior for contamination. In case of a fault, the camera can also provide support in troubleshooting if the turn‑head distributor is mounted in an area that is difficult to reach. The control cabinet, display, measurement system, and camera may optionally be delivered with ATEX (explosion protection) and EHEDG (hygiene) approvals.
Options for every requirement
“Perhaps the greatest advantage of the new solution is its flexibility, as it can be customized to meet prac‑tically any customer need,” says Jacob. The Simatic S7‑1200 communicates in industrial environments via Profinet, Profibus, and Wi‑Fi. Control via the digital in‑puts of the S7‑1200 in BCD code is also available as an alternative. The control system can be easily integrated into higher‑level production processes.
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The swivel‑turn switch can be remotely controlled and monitored via smartphone
Patrick Jacob (left), managing partner of Fr. Jacob Söhne GmbH & Co. KG, with Jörg Schlamilch (center), promoter at Siemens, and Stefan Güldenmeister of Ingenieurbüro Güldenmeister
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GO! 1/2015 | Observatory
On the extensive grounds of the observatory, where the dome of the radome is the most striking
feature, there is also a 12‑m‑high tower, on which an aerial system was recently mounted. As if by magic, the 1.5‑m‑ diameter parabolic mirror follows the polar‑orbiting satellites. Invisible to the eye, the satellites move above the ground at an altitude of 800 to 1,000 km and usually disappear behind the horizon after a few minutes. In tracking the satellites, the two gear motors of the antenna’s rotary frame continuously move the parabolic mirror into the precise position that permits the antenna the best reception of data and signals – especially of weather im‑ages. These data provide valuable in‑formation in the study of the environ‑ment and climate change.
Tracking control in real time
Since the retrofit of the antenna system, this challenging task has been reliably performed by a Simatic S7‑1200 with CPU 1214C, a digital input module, a digital output module, an analog out‑put module, CM 1241 RS232 communi‑cation modules, a CM 1243‑5 Profibus DP master, and a Sitop PSU 100L power supply unit. Once the system has been calibrated to a geostationary satellite, the PLC receives the movement data of the respective polar‑orbiting satellite via TC/IP from a higher‑level path server, including the exact time, and then tracks it permanently and continuously. “The real‑time capability of the Simatic S7‑1200 is a great plus here,” says Thilo Elsner, head of the IUZ Bochum Obser‑vatory. “Previously, even the sequence
control presented us with enormous programming problems.”
A data block in the PLC converts the data from the higher‑level server so that it can be processed, and the PLC provides the speed controllers of the two drives for the astronomical coordi‑nates of the azimuth (horizontal orien‑tation) and elevation (vertical angle between the horizon and antenna direction) with the required voltage and thus the speed and direction of rotation. The transistor speed controller then controls the 0‑ to 24‑V DC power supply based on the input voltage of 0 to 10 V DC, which is specified to it by the PLC via its PID controller and the an‑alog outputs.
Two absolute encoders report the ap‑proached position to the Simatic S7‑1200 via Profibus DP and allow read‑
Always receiving
The Bochum Observatory, with its Institut für Umwelt‑ und Zukunftsforschung (IUZ, Institute for Environment and Future Research), is an important research and training institution in North Rhine–Westphalia and is also in demand internationally as a partner of the American space agency NASA. In the reconstruction of a satellite receiving station, a Simatic S7‑1200 proved to be the perfect solution for the control system.
Technical Vocational School 1 (TBS 1) and IUZ Observatory, Bochum, Germany
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Observatory | GO! 1/2015
justment if the specified position has not yet been reached. Meanwhile, the control system calls up the next posi‑tion and gives the command that this position must be taken at the pre‑scribed time. A portable hand control is also available for assembly and service work. “The team created a system that can serve as a reference for us for fu‑ture projects,” says Elsner.
Interesting training project
The innovative solution can be at‑tributed to collaboration between the educational partners IUZ and the Tech‑nischen Beruflichen Schule 1 (TBS 1, Technical Vocational School 1) of the city of Bochum. The unusual project supported by Siemens was developed and implemented by five aspiring state‑certified electrical engineering technicians, all of whom already have initial training behind them and are employed.
“We first put the satellite receiving station into operation in 2001,” says Elsner. “After its total failure, caused by corrosion and consequent damage, we decided to rebuild it last year.” It quickly
became clear that the former stand‑alone solution with PCB controller and incremental encoders should not be restored. “It was prone to failure and was neither weatherproof nor stress‑ resis tant over the long term. That’s why we wanted to adapt the system to current industrial standards – with a compact PLC from market leader Siemens. This would also mean that we would no longer have problems with maintenance and spare parts.”
For the skilled workers who were al‑ready somewhat familiar with Siemens and PLCs, the project was a welcome challenge. “For me the attraction was that it has to do with space technology and is not just a day‑to‑day task,” says Patrick Hoffmann, a trained energy electronics technician specializing in industrial engineering. And for Chris‑tian Ullrich and Christian Czoske, who had the same initial training, it was clear from the outset that the project needed to have a Simatic S7: “We were able to not only plan the automation but also implement it.” Their teacher and head of the college of technology at TBS 1, Wolfgang Rode, says: “The project documentation is now also an
Rightly proud of the successful retrofit: the prospective certified technicians in electrical engineering (from left to right) Thomas Glowin, Christian Czoske, and Salih Laluti
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excellent calling card for future em‑ployers.”
Straightforward engineering
In addition to the Simatic S7‑1200 functionalities that were important for the solution, such as the self‑ optimizing PID controller, the Profibus communi‑cation, and the programmable web server, the team learned to appreciate the easy engineering with TIA Portal during the project, which lasted from February to June last year. “Although we had not yet worked with it, we needed no training, since we were al‑ready familiar with the Step 7 world,” says Czoske. “After we connected the absolute encoder to the PLC, we only had to enter the GSD file of the manu‑facturer into TIA Portal and the control system already knew what it had to do. That saved a lot of time and stress!”
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GO! 1/2015 | Products
For the first time, the Simatic S7‑1200 Basic Controller can now also perform failsafe tasks. With the failsafe 1214FC and 1215FC CPUs and the corresponding failsafe
I/O modules, an integrated safety solution is now available for the first time for Simatic controllers in the low power range. Consistent engineering in TIA Portal makes it possi‑ble to easily port failsafe programs from a Simatic S7‑1200 to a Simatic S7‑1500. The new Simatic S7‑1200 V4.1 has been enhanced with additional functions. Like the Simatic S7‑1500, the Simatic S7‑1200 now also features option handling in its central configuration, enabling flexible machine de‑signs. In series manufacturing, for example, this enables sav‑
Simatic S7‑1200
Easy introduction to Safety Integrated
The new LOGO! CMR2040 communi‑cation module supports remote communication via cellular network
with the new LOGO! 8 logic modules. This capability allows distributed sys‑tems to be monitored and controlled, or alarm messages to be sent, using SMS messages. With the LOGO! CMR2040, LOGO! 8 uses the latest wireless stan‑dard, fourth‑generation LTE (Long Term Evolution). The LOGO! CMR2040 offers the same functions as the LOGO! CMR2020 but enables use in regions in which only the LTE wireless standard is accessible. A fallback function enables the additional use of the module for the UMTS and GPSR wireless standards via GSM. Typical applications for stations with the LOGO! communication module include the following:
LOGO! 8 communication module
SMS communication via LTE
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ings during planning, commissioning, and documentation. The new PID Temp technology object provides perfect sup‑port for temperature control, and the CPU backup ensures easy restoration of the machine status. Controlled drives can be implemented with the Closed Loop PTO function, which is necessary to integrate Profinet drives. The integration of S7‑1200 communications processors (CPs) into the Simatic S7‑1200 was also improved. Users can now access the CPU web server and open user communication via S7‑1200 CPs.
siemens.com/S7‑1200
• Monitoring, sending alarms, and controlling distributed systems, such as level monitoring of a container, via SMS
• Control of blinds, lights, and power in buildings or control of garden irrigation via SMS
• Control of church steeple or school clocks, with regular time synchronization
• Container tracking (querying position and additional data such as current temperature values in a container with the LOGO! station via SMS and transmitting the data using the LOGO! communication module)
For use of the LOGO! CMR2020 and CMR2040 communication modules,
country‑specific cellular approvals must be strictly observed. Seesiemens.de/mobilfunkzulassungen.
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Magazines
Our technical magazines are a real added value for your busi‑ness. Whether you choose process news, motion world, or ad-vance, in each of our technical magazines covering the various areas of automation and drive technology, the information and technology are interestingly presented, well researched and up‑to‑date, and described with application examples.
As a plant operator or machine manufacturer, you are always well informed – with information specially adapted to your industry.
siemens.com/industry‑magazines
Current newsletter
Siemens offers electronic newsletters on various topics for sub‑scription. For example, with the Totally Integrated Automation newsletter you will be informed by e‑mail about new hardware and software, services, application examples, and important dates and events relating to Totally Integrated Automation – electronically and always right up‑to‑date. Simply register with your e‑mail address.
siemens.com/industry‑newsletter
Publisher: Siemens AGDigital Factory DivisionFactory AutomationGleiwitzer Straße 55590475 NurembergGERMANYsiemens.com/gosiemens.com/S7‑1200
Responsible for technical content:Heinz Eisenbeiss
Editorial chair:Josef Ploch
Publishing house: Publicis Pixelpark PublishingPostfach 32 40, 91050 Erlangen, Germanymagazines‑[email protected]
Editors: Dorit Gunia, Robert Engelhardt, Marion Schwab GO! is published twice a yearVolume 19
© 2015 by Siemens AktiengesellschaftMunich and Berlin.All rights reserved.
The following products are registered trademarks of Siemens AG:ET 200, S7‑1200, S7‑1500, SCALANCE, Siemens LOGO!, SIMATIC, SIMATIC Safety Integrated, SINAMICS, SIRIUS, SITOP, SITRAIN, STEP, TIA Portal, Totally Integrated Automation (TIA), WinCC
If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.
The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed in the terms of contract.
GO! 1/15
In late April 2015, a new version of the Simatic S7 app appeared with new features, a new design, and a new operator interface.
Mobile monitoring and controlling
Simatic S7 app
Note on industrial security: Suitable protective measures (including industrial security, e.g., network segmentation) must be taken to ensure safe operation of the system. Further information on the topic of industrial security can be found at siemens.com/industrialsecurity.
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INFO siemens.com/simatic2go siemens.com/S7‑1200
The app allows the identification and control of up to 50 network CPUs. In addition to the Simatic S7‑1200, the
app now also addresses the Simatic S7‑1500 and Simatic ET 200SP. Variables in trend charts and lists can be displayed and changed. Diagnostic data can be sent by e‑mail. CPUs can also be placed into start and stop operating modes from the mobile device. The app runs on Apple (iOS 5) and Android devices.
ANZEIGE FOLGT
A new design, new hardware, new software: The perfectintelligent logic module for switching and control tasks insmall-scale automation projects has launched the nextgeneration! With LOGO! 8, it is even faster, easier, andmore convenient to implement automation solutions forsimple machines or systems, in building automation, andfor applications in the private sector. This new LOGO! gen-eration accommodates virtually every demand of custom-ers with simplified handling. Impressive features include:• Innovative LOGO! display: twice as many characters per
message for clear formulation of message texts andwith selectable backlighting, such as red, to opticallyemphasize the current alarm status
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• Integrated Ethernet interface for the entire LOGO! 8product family: communication and networking areeasier than ever before
• Remote communication via cellular phone network:text message communications for easy alerts andremote control
• New external text display: more than twice as manycharacters as before and more options thanks to twoEthernet interfaces
• New backward-compatible software in a new design:ingeniously simple operation, configuration, and pro-gramming in single and network mode
LOGO! 8 Simply ingenious. Simply more.The logic module
Answers for industry.
E20001-F2290-P271-X-7600_AZ_LOGO8_Classic_210x280_EN.indd 1 17.10.14 13:40
