CHINA’S RACE TO THE TOP / Page 14

direct processInformation for Power and Process Technology, October 2015

EXCELLENT! — DIMA PREVAILS / Page 10

STRONGMAN ON THE HIGH SEAS / Page 26

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Dear Readers,

China is often described as a country that poses many challenges. Despite this, China generally rewards those who work hard with tremendous opportunities. Twenty years ago, I told our Ger-man CEO that you can cover your eyes, point anywhere on a map of China and start a business wherever your finger landed. You will always find opportunities. Today, of course, we choose our markets more carefully before we invest in them. In China, for example, we decided to focus on the petrochemical and marine sectors. Between 2003 and 2013, the petrochemical sector averaged 25 % growth over the previous year, and it continues to increase faster than GDP. Initiatives that promote exports and the modern-ization of Chinese industry, like “One Belt, One Road” or “Made in China 2025,” combined with reduced coal usage, guarantee constant growth for equipment manufacturers — particularly in offshore projects. With a global market share of 50 %, the Chinese shipbuilding sector is the glob-al market leader; after enduring some difficult years, it is enjoying increased attention from the central government. As a direct result, maritime equipment sales have grown by 11.8 % in 2014 to almost 100 billion RMB (15 billion Euro). To further propel growth, the shipbuilding sector was selected on May 19, 2015 as one of the ten focal points for the “Made in China 2025” initiative. Reliability, quality and usability are deciding factors in selecting equipment for use in the petro-chemical and maritime sectors. WAGO components equipped with CAGE CLAMP® connection technology prove their value every day under the harshest conditions. WAGO components also come with an extensive list of vital approvals, including installation in hazardous environments or offshore areas. WAGO automation technology power supplies, current transformers, signal con-ditioners and terminal blocks, represent a comprehensive product portfolio of electrical equipment used in the petrochemical and marine industries. Globally, we have teams of localized application and software engineers who will support you during each step of your project, helping transform your individual challenge into a magnificent opportunity.

Volker Palm

General ManagerWAGO ELECTRONIC (TIANJIN) CO., LTD.

EDITORIAL

On Board and Under Control Page 04

DIMA — Foundation for Intelligently Networked Systems Page 06

Decentralized Intelligence — New Paths in Process Automation Page 07

“Modular System Design Reveals a Future Trend!” Page 08

Excellent! — DIMA Prevails Page 10

An Exapnded Offering: The WAGO-I/O-SYSTEM 750 XTR Page 11

A Weather Eye on Reliability: Every Ship. Every System. Any Weather. Page 12

CONTENTS

East

Asia

China’s Race to the Top Page 14“Safety is Our Highest Priority” Page 16Manufacturing Depth is Increasing in East Asian Shipbuilding Page 19Asia — Shipbuilding Hotspot Page 20Asia’s Importance Grows in the Design of Large Refineries Page 22WAGO in East Asia Page 24

Strongman on the High Seas Page 26

Special Challenges Deserve Specialized Solutions Page 28

Clever Terminal Blocks – Perfect Process Page 30

Prevent Complaints by Providing Top Quality Page 32

For Use Around the Globe: WAGO Telecontrollers Speak DNP3 Page 35

Legal Information Page 36

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■ The number of intelligent components is increasing aboard ships. To logically use all of the information collected from various points to control basic functions, Beijing-based MAPPS-SERI developed an intelligent platform management system.

When it comes to using automation technology, integrating informa-tion and withstanding extreme environmental conditions, the require-ments of modern ships have undoubtedly reached a new high. The trend toward increasingly intelligent ships has placed a great deal of demand on information management and control systems. After all, they have to record, process and visualize the bulk of the data. With the development of a proprietary integrated platform management system (IPMS), the Chinese company MAPPS-SERI Technology Co. Ltd, headquartered in Beijing, has established a true benchmark in this area.MAPPS-SERI specializes in maritime information and control systems. Their systems are primarily used on naval vessels, training ships and foreign merchant craft. Using MAPPS-SERI’s integrated platform man-agement system, ships can amass sensors, control system, network communication, intelligent data processing and other information

technology into one system. They rely on digital and automated com-ponents for the ship’s equipment, and use the network as a connecting link to smoothly integrate the multiplicity of information, which is re-corded, controlled and managed on board, into one platform.

■ Full Speed Ahead due to Innovative TechnologyIn order to manage the diverse signals found on different ships, the IPMS uses a flexible and modular approach: it operates RTUs (Re-mote Terminal Units) that serve as interfaces to a large spectrum of sensors and actuators. These interfaces can be directly wired to ETHERNET using serial connections. This, however, requires the use of electronic components that command a higher-level system via an open architecture. And analog I/O modules from the 750 and 753 Series WAGO-I/O-SYSTEM can readily meet this challenge. They can be easily integrated into both signal conditioning and process-ing functions; they also provide galvanic isolation. The RTUs also enable data recording, perform plausibility checks (audits), check or scale measured values, transmit necessary data to other IPMS subsystems, process automated control sequences, output control signals to actuators and execute integrated online and offline tests.

On Board and Under Control Clearly bundling ship information and control signals

The entire system has a greater tolerance for errors thanks to de-centralized data processing and the control of subsystems. This factor and the definition of standard RTUs in specified sizes en-able MAPPS-SERI to reuse previous control cabinet designs in subsequent projects. This expedited engineering greatly benefits customers.

■ All from One Source Based on drawings provided by MAPPS-SERI, WAGO’s Chinese production facility in Tianjin equips complete RTU control cabinets with WAGO-I/O-SYSTEM and WAGO terminal blocks, as well as additional equipment from trusted third-party sources. Using the WAGO-I/O-SYSTEM 750, MAPPS-SERI can individually configure each node to meet customer-specific requirements. The multi-chan-nel, digital I/O modules can be freely combined and enable a high degree of granularity and flexibility. This finely modular structure enables the design of extremely compact, space-saving units. Collaborating with WAGO provides MAPPS-SERI with decisive ad-vantages in connection technology as well. WAGO terminal blocks have maintenance-free CAGE CLAMP® spring pressure connection technology — connection quality no longer depends on careful, la-bor-intensive installations by the electrician. Spring pressure clamp-ing technology enables not only fast and easy connections, but also increases connection reliability, especially when used in envi-ronments that test resistance to vibration, impacts and corrosion. If terminal blocks with screw connections are used aboard ships, the screws can easily back out and loosen the connections. Therefore, they routinely require labor- and cost-intensive maintenance. Using WAGO’s spring clamp technology eliminates this problem to en-sure safe, reliable and uninterrupted operation. “We trust the products from WAGO,” states Yuming Liu, manager at MAPPS-SERI. “Yet we remain vigilant about standardizing com-ponents. Therefore, efficient management and the approvals of all components by classification societies are very important to us.”

For the employees of WAGO China, who deliver not only com-ponents, but complete control cabinets to MAPPS-SERI, this means they must be mindful of the quality of their own components. They also need to monitor the source materials that are used to construct the cabinets. In addition, they subject each individual control cabi-net to quality assurance tests, from visual inspection to mechanical and electrical testing, to ensure that the control cabinets satisfy re-quired safety levels.

■ Efficient Team Work“We are different, because we can provide not only highly reli-able products, but also complete solutions that satisfy customers’ demands,” explains Yuming. For him, the service connected to WAGO products is vital to their collaboration: at the beginning of the project, MAPPS-SERI was faced with a very narrow timeframe for providing the RTU control cabinets. WAGO China was able to quickly react to customer requirements and delivered on time. “We would like to establish a long-term partnership with WAGO. We are planning on using other innovative products and services from WAGO, which in turn allows us to continue improving our products and services.”

Text: Qingchuan Wang, WAGO ChinaPhoto: WAGO China

• The open architecture of the WAGO-I/O-SYSTEM 750 allows a direct link to ETHERNET.

• The WAGO-I/O-SYSTEM enables customer-specif-ic configuration of each individual node.

• The definition of standard RTUs ensures the reus-ability of the entire system.

Won over by WAGO components: Yuming Liu, manager at MAPPS-SERI, desires a long-term collaboration that will yield tremendous innovation.

In Tianjin, WAGO China builds complete, prefabricated RTU control cabinets.

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■ At the NAMUR China Conference 2015 in Shanghai, WAGO will present modular solutions for the process industry that will provide system operators with greater flexibility and reduce their automation costs.

At this year’s NAMUR China Conference in November, WAGO is presenting solutions for the process industry, including DIMA (De-centralized Intelligence for Modular Applications). The DIMA meth-od was developed in response to NAMUR’s 2013 NE 148 rec-ommendation regarding automation solutions for modular process systems. This requirement stems from the needs of process system operators, who must respond faster to changes driven by new cus-tomer requirements, markets or production conditions.Unlike conventional and closed system architectures that have tra-ditional visualization and process control systems with I/O and control levels, DIMA focuses on equipping self-contained modules with their own intelligence. For this purpose, the system architecture is divided into two areas: the management level (“only” assumes

DIMA — Foundation for Intelli-gently Networked SystemsA Revolutionary Automation Solution for the Process Industry

complete process monitoring and procedure control) and the indi-vidual process modules (incorporating an I/O level and their part of the automation). Cross-system functions, e.g., recipe management, are performed by higher-level automation; the automation within the modules handles all base functions.

■ Centerpiece of DIMA — the Module Type PackageModule Type Packages (MTP) describe the modules. The MTPs contain information on process control integration, operating and monitoring functions, as well as batch functions. The module suppli-er configures the module, the system operator uses the appropriate MTP in integration engineering and then configures the overall sys-tem. Communication between management level and a module is service-oriented (SOA, Service-Oriented Architecture).With DIMA, automation modules can be equipped with their own intelligence and, just like modular LEGO® building bricks, are eas-ily integrated into systems and flexibly replaced later. This gener-ates a manufacturing process that is networked to a high degree,

WAGO is hosting the NAMUR China Conference, which will occur on November 18–19, 2015, in Shanghai. NAMUR is an inter-national association of leading users of automation technology. NAMUR adds value to companies because it unites the skills of automation technology users in the process industry with the goal of building and operating efficient, sustainable and safe process systems. The theme of the seventh NAMUR China Conference is “Decentral-

ized Intelligence — New Paths in Process Automation.” WAGO will address this topic by introducing modular automation solutions for process systems.Guest speakers at the NAMUR China Conference include Andreas Schadt, CEO of SpiraTec AG. SpiraTec is a solution and services provider for automation technology and IT in the process and man-ufacturing industries. You will find an interview with Andreas Schadt on page 8 of this issue of WAGOdirect process.

is exceedingly flexible and is incredibly customizable. This means system operators can become significantly more flexible over the entire lifecycle of their systems — they’ll be able to quickly react to changing market demands and can offer customer-specific products at competitive prices.The DIMA approach stands ready to satisfy one of the essential driv-ers of Industry 4.0: the digitalization of the value-added chain.

WAGO sponsors the seventh NAMUR China Conference in Shanghai

Decentralized Intelligence — New Paths in Process Automation

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■ In order to meet the urgent demands of the market for faster, more flexible and more economical production processing, systems must be highly modular. These types of systems can significantly reduce manufacturing time, enable flexible changes to the system architec-ture — even during manufacturing and operation — and accelerate new product launches. In order to learn the current status of modular system design in the process industry, we’re offering industry insight from Andreas Schadt, CEO of SpiraTec AG.

■ What is the status of modular system design in the process indus-try?

“Modular System Design Reveals a Future Trend!” Andreas Schadt, CEO of SpiraTec AG, regarding modular system design in the process industry and WAGO’s DIMA concept

Schadt: Modular concepts and advancements in system construc-tion have been long-established in the process industry. However, only recently has a new stage of process technology modularization become evident, noticeable even. Accordingly, we find ourselves in a transitional period to this new stage. Let me elaborate a little:For decades, “Package Units” (prefabricated, processing units) have been incorporated into system design within the various industrial sectors. However, this integration was often only for auxiliary and supply systems, which are commonly referred to as utility systems. The actual production process for the product was often a unique system — it was constructed as a fully set-up system corresponding to

the method, volume and local conditions. The important difference is that now the primary processes are also modularly constructed much faster and more flexibly using Package Units and Container Solutions, which is where I see the (actual) leap in development.

■ In your opinion, will this spread to the other industrial branches in the future?Schadt: The sectors each face different demands and thus have dif-ferent reasons for designing in more, or less, modular ways. Just as the expression “time to market” is viewed differently in the various branches, fast and flexible system construction is achieved with dif-ferent levels of importance depending on the sector. Additionally, the criteria differs for defining the future degree of modularization in systems. Global repeatability of production systems or subsys-tems, scalability of equipment for a process step and the existence/availability of prefabricated, tested modules all play an important role here. The latter is becoming increasingly important. This also includes a variation of the “LEGO® Approach,” in which ever more complex production systems are being built in a modular fashion. In summary, I believe that modular system design has not proliferated equally among all the sectors; however, future trends are indicative that it will.

■ Presumably, what you are saying applies to the German market first — do you see Germany as a pioneer in modular system design? And, how do you assess the international markets? Can you identify regional differences, preferences or even negative biases in system design?Schadt: Fundamentally, you have to understand that compared to German-speaking areas, there are places around the world with substantially more investments in greenfield projects. Germany is not a pioneer in the implementation of modular system design. The topic is not related to specific countries, but instead — as already mentioned — is sector-specific. There are different international sys-tem construction companies that are already serving the various sectors globally. In particular, the engineering, procurement and construction companies, have their own methods and have already developed different modular concepts. However, there is currently no internationally established standard for the interconnection of modules — neither in process technology or in the requisite process automation.

■ At the moment, several NAMUR working groups are developing an automation technology standard based on the DIMA concept introduced by WAGO. As a system designer, what is your great-est desire that you see stemming from this work and any future NAMUR recommendation?

Schadt: SpiraTec AG is active as an inter-disciplinary engineering firm in system design for several different sectors. When considering automation tech-nology and industrial IT solutions, integrating controllers and the data connections between the modules is the greatest challenge. At this point, let us consider the procurement of pro-

cess delivery units (modules) for a new production system as an example: in this case, the respective units are ordered from several different vendors. Correspondingly, one can already surmise how many variants will have to eventually be coupled or integrated with one another. Every time we build a project- or customer-specific in-terface standardization, we do it from scratch. Therefore, my great-est wish would be to develop a global standard using the NAMUR recommendation that can be used by Package Unit manufacturers, system designers, control system vendors and solution providers. The flexible integration of process modules and their decentralized con-trollers would thus be standardized. At the same time, this would result in a giant step forward in developing Plug-&-Produce modules according to Industry 4.0.

■ Finally, look into the future: what expectations do you have for process control system manufacturers when the DIMA specification is completed? Schadt: In order to satisfy the new standards, PCS manufacturers will have to make larger system developments. This is because the engineering systems for the smaller controllers (usually PLCs) that are used by Package Unit vendors and module producers, as well as the engineering systems for the larger process control systems, will have to be adapted. In addition, further development in higher-level systems, like Batch and MES, will be required. My expectation — relative to my desire — is that the process control system producers will make the necessary investments to “bring the standard to life” in the industry. Charles Darwin once said, “It is not the strongest of the species that survives, nor the most intelligent that survives. It is the one that is most adaptable to change.” This perfectly summarizes my opinion of the upcoming trends in industrial production.

■ Thank you for the conversation.

Andreas Schadt, SpiraTec AG

Photo: SpiraTec

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■ At Achema, the leading international tradeshow for the process industry, two prestigious awards were bestowed upon WAGO’s new DIMA method. The concept for Decentralized Intelligence for Mo- dular Applications (DIMA) recieved an award from the distinguished German trade journal atp edition and the Achema Innovation Award 2015.

■ atp AwardGerman trade journal atp edition traditionally awards the Youth Development Award at the GMA Automation Congress in Baden-Baden, Germany. The award honors young scientists for their pub-lications in atp edition. In the “Industry” category, the atp award 2015 was presented to the team of authors who introduced the DIMA method. The text, “Decentralized Intelligence for Modular Automation — Approach Solutions for Realizing Modular Systems” was written by Thomas Holm, Helmut-Schmidt-University, Hamburg; Michael Obst, Dresden University of Technology; Prof. Dr.-Ing. Alexander Fay, Helmut-Schmidt-University; Prof. Dr.-Ing. Leon Urbas, Dresden University of Technology; and Dr. Thomas Albers, Dr.-Ing. Sven Kreft, and Ulrich Hempen from WAGO.

Excellent! — DIMA Prevails DIMA was distinguished with the Achema Inno-vation Award 2015 and the atp Award

■ Achema Innovation Award 2015For the third time, the trade journals Process, Process Worldwide, Pharmatec and Laborpraxis from the Vogel publishing house have awarded the Innovation Award at the international Achema trade fair. In the category of Instrumentation, Control and Automation Technology/Process Automation, the award was presented to WAGO for the new DIMA method. With this award, the jury — which includes editors and experts in the user industries — honors the most innovative devices, systems and methods of the year. De-gree of innovation, quality, economic feasibility for the user, exist-ing applications/pilot projects and presentation are all evaluated.

■ In harsh environmental conditions, additional air conditioning systems and specially protected circuitry drive up automation tech-nology costs. This is not the case for the extremely robust WAGO-I/O-SYSTEM 750 XTR. With twelve new components, it is now even more versatile and can be used, for example, in systems for renewable energy, substations, shipbuilding or in railway applications.

■ PFC200 ControllerThe new products in the WAGO-I/O-SYSTEM 750 XTR line include the compact and powerful PFC200 with the real-time-capable Linux® operating system. The 750 XTR Series controller is available in two versions with different numbers of communication interfaces: either two ETHERNET connections and an RS-232/RS-485 interface or with two ETHERNET connections, RS-232/RS-485, CAN, CANopen and PROFIBUS-DP-Slave interfaces. With the PFC200, users have the option of planning their projects using the e!COCKPIT design software in a CODESYS 3 environment, as well as with WAGO-I/O-PRO within the CODESYS 2 environment.Both versions of the PFC200 are also available for the 750 XTR Series as telecontrollers that support DNP3 in addition to the IEC 60870-5-101, -103 and -104, IEC 61850, IEC 61400-25 tele-control protocols. Until now, planning with the telecontrol variants took place exclusively in CODESYS 2. The PFC200 Telecontrollers also command IPsec and OpenVPN to comply with the highest se-curity standards. Featuring SDHC memory, the fan- and battery-free PFC200 is maintenance-free and extremely robust.

■ 3-Phase Power Measurement ModulesIn addition to the new controllers, the 3-Phase Power Measurement Modules expand the application range of the WAGO-I/O-SYSTEM

An Exapnded Offering:The WAGO-I/O-SYSTEM 750 XTRMore performance, telecontrol technology and energy data recording: a total of twelve new components make the WAGO-I/O-SYSTEM 750 XTR even more versatile.

750 XTR. It is available for the 750 XTR Series in three versions: for measuring using current transducers at a maximum measuring current of 1 A or 5 A, as well as for measuring with Rogows-ki coils. All relevant measured values (e.g., reactive/apparent/effective power, energy consumption, power factor, phase angle, frequency, over-/undervoltage) are transmitted directly into the process image, without requiring high computing power from the controller. With this information and a harmonics analysis up to the 41st harmonic, the 3-phase power measurement module can provide comprehensive network analysis.In addition, WAGO has added other components to the WAGO-I/O-SYSTEM 750 XTR portfolio: two 2-channel digital input mod-ules for 60 V and 110 V, an 8-channel digital output module with 2-wire connection technology (filter 0.2 ms), a 2-channel analog input module for 4–20 mA and a separation module for visual demarcation of segments with different voltage ranges within a node.

■ The WAGO-I/O-SYSTEM 750 XTRThe WAGO-I/O-SYSTEM 750 XTR combines the benefits of the successful WAGO-I/O-SYSTEM 750 with key features for extraor-dinary dependability in tough environments: Extreme resistance to temperatures from -40 °C and +70 °C, immunity to interference up to 1 kV (< 60 V, Class VW1) and 5 kV (> =60 V, Class VW3), as well as vibration resistance up to 5 g. The system requires little space and is distinguished by low energy and maintenance costs. This, along with incredible system uptime, enhances productivity.

Accepting the Innovation Award for WAGO: Left to right: Ulrich Hempen and Wolfgang Laufmann, Market Management Industry and Process, WAGO, Thomas Holm University of the Federal Armed Forces in Hamburg and Dr. Thomas Albers, AUTOMATION Management, WAGO.

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Bundled expertise for ship automation

■ Cranes and anchor winches, separators and wastewater treatment plants — there are diverse installations aboard a vessel that must be equipped with intelligent controllers. The Chinese company, Luzhou Electrical, has specialized in developing and manufacturing maritime automation for 30 years, and they rely on WAGO components at their facility in Nanjing, China.

Modern marine control technology has set increasingly stringent standards for the components used in yachts, oil tankers, container ships and large cruise ships. With good reason: On the high seas, these components must defy environmental conditions that typically plague ordinary products from the electrical and electronics industries: water, salt air, extreme temperature cycling, vibrations and shock. Components that are used in maritime auto-mation must therefore be certified for use at sea — and for global applica-tions. Luzhou Electrical, headquartered in Nanjing, understands this well. Luzhou Electrical is a holding subsidiary of CSSC Luzhou Co., an affiliate of the China State Shipbuilding Corporation (CSSC). For 30 years, Luzhou Electrical has specialized in the development and production of electrical components for maritime automation. This includes areas like deck equip-ment, such as cranes, anchor winches, davits for lifeboats or steering gear,

as well as equipment for cabins, like separators, trash incinerators, ship wastewater treatment plants, oil/water separators or desalinization plants. Controlling these devices and systems, recording and processing of a large variety of field signals, exchanging information, as well as monitoring and determining operating states of the equipment all require excellent automa-tion technology. Luzhou Electrical receives this from WAGO.

■ Good Experiences“The use of WAGO products was explicitly required for many of the international projects that we received,” explains Xue Hong-wu, General Manager at Luzhou Electrical. “In the meantime, we find ourselves absolutely impressed with the quality and service from WAGO — both in China and abroad. WAGO is simply a pres-tigious brand and, due to their collaboration with first-class ship building companies, has become very experienced in the sector.” When it came time to select automation components from WAGO, the fact that the components are certified by several global agencies, such as GL, LR, DNV, BV, RINA, KR, NK, ABS and PRS was not the only deciding factor. The capability and reliability of WAGO employees shown in their collaboration was the tipping point. “Technical support

from WAGO is excellent,” states Dai Qiang, an electrical engineer who has been working for Luzhou Electrical for five years. “They are ready to answer questions and solve problems anytime and anywhere. Whenev-er we contact WAGO, their engineers provide the best solution for any application problem.” The foundation of this customer-focused offering is the WAGO-I/O-SYSTEM 750, which Luzhou Electrical integrates into its ship control technology. The WAGO-I/O-SYSTEM 750 offers a flexi-ble, modular and space-saving footprint: the variety of input, output and specialty modules, the potential for combining modules with 1, 2, 4, 8 and 16 channels in any way, and the combination of PLCs with analog, digital and specialty signals, are among the product highlights that inter-est the engineers at Luzhou Electrical.

■ Error-Free ConnectionsAnother substantial argument for WAGO products relates to how they are delivered: much of the shipboard automation is prefabricated and commissioned on-site in the ship. This makes CAGE CLAMP® connec-tion technology a favorite among the electrical technicians at Luzhou Electrical, like Chen Cheng. Spring pressure connection technology of-fers the advantage of being faster to install than screw connections. It is also resistant to vibration, is maintenance-free and allows people on site to implement necessary installation and wiring work — without previ-ous instruction. “The professional installation tools aid our wiring work immensely. WAGO’s tools that strip and crimp the wires increase our efficiency during installation by 30 % and prevent many problems from the outset,” reports Chen. “Ferrules and wires are connected so tightly with one another that the connection between conductors and WAGO-I/O-SYSTEM 750 modules is guaranteed.”

• Thanks to many specialty function modules, the WAGO-I/O-SYSTEM can be used flexibly.

• WAGO tools for stripping and crimping wires improve installation efficiency by 30 %.

• WAGO components are certified by many diverse agencies for the shipbuilding industry.

■ Exploiting Joint OpportunitiesGeneral Manager Xue is completely convinced by the smooth collabo-ration — both now and into the future. “I have seen that WAGO just in-troduced the PFC200 Controller, which provides excellent functionality and is particularly well-suited for shipbuilding,” he confides. “I believe that this will open new possibilities for us,” he adds. If it were up to him, Xue would bring WAGO into the value-added chain much earlier in the future, perhaps even during product design and development. “Particularly for increasing efficiency and reducing costs, the practical experience at WAGO could benefit us tremendously during the devel-opment of technologies and products.”

Text: Tommy Shan, WAGO ChinaPhoto: WAGO China

General Manager Xue Hongwu would like to collaborate with WAGO in the future for product design and development.

Luzhou Electrical pre-assembles several control cabinets that only require on-site connection and commissioning aboard the ship to be operational.

A Weather Eye on Reliability: Every Ship. Every System. Any Weather.

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China’s Race to the Top“Made in China 2025” actually made by “the Rest of the World?”■ In Asia, particularly China, the demand for automation technology will rise meteorically in the coming years. This offers foreign technology suppliers enormous potential; however, this is also linked to risks that are just as large. Anyone wanting to play a long-term role in the Chinese market must emphasize the correct features for their particular sectors.

China — contract manufacturer for the world? That was yesterday! Today, the Chinese state that they will implement Industry 5.0 directly in China, and appear quite intent on making this a reality. And, they’re ready to jump over several steps: it is no longer enough for the Chinese to follow the market, they want to lead. This corresponds with the line taken by Chinese lead-ership. In May, the government adopted a strategy to advance China to the position of leading industrial power in the world: the “Made in China 2025” strategy. By 2049, the 100th anniversary of the founding of the People’s Republic of China, the strategy will have been implemented in three large stages. At that point — based on the Chinese government plan’s — “Made in China 2025” will no longer stand for cheap, mass-produced goods, but for innovation, quality and efficiency.

■ “Made in China 2025”“Made in China 2025” is very reminiscent — as far as the content re-lates to the strategy — of Germany’s Industry 4.0 concept, or America’s notion of the “Internet of Things.” And this is because each has the same basis: the digitalization of modern, value-added chains. The Chinese government has correspondingly pledged to support nine broadly de-fined tasks: improving manufacturing innovation, integrating technology and industry, strengthening the industrial base, fostering Chinese brands, enforcing green manufacturing, promoting breakthroughs in ten key sec-tors, advancing restructuring of the manufacturing sector, promoting service-oriented manufacturing and manufacturing-related service indus-tries, as well as internationalizing manufacturing. The Chinese regime has ten key areas for implementing their “Made in China 2025” strategy. Sectors that are undergoing a boom worldwide:

1. New information technology2. High-end numerically controlled machine tools and robots3. Aerospace equipment4. Ocean engineering equipment and high-end vessels5. High-end rail transportation equipment6. Efficient vehicles and alternative powertrains7. Electrical equipment8. Farming machines9. New materials, such as polymers10. Bio-medicine and high-end medical equipmentContinued on page 18...

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“Safety is Our Highest Priority”

■ Lower oil prices are creating a strong economic headwinds for the offshore industry — particularly in Europe and North America. The U.S. market is taking advantage of the reduced utilization of their per-sonnel and resources by investing in new technologies and reducing production costs by replacing obsolete machines and systems. Looking across the globe, Daryl Goh, Regional Sales Manager for WAGO Singapore, describes the challenges and opportunities for the Southeast Asian market that are resulting from this trend.

of this include the maintenance-free CAGE CLAMP® Terminal Blocks, flexible I/O products and the precision of our JUMPFLEX® Signal Conditioners. Our new EPISTRON® CLASSIC Power Supplies with DNV and GL approvals, signal transducers with Ex approval, XTR and many oth-er products have created new opportunities. Because our customers have had more downtime, due to this recession, we have been able to conduct more meetings with them. It makes a lot of sense to talk with our customers more during this time because they have more time to spare.John D. Rockefeller once said, “I always tried to turn every disaster into an opportunity.”

■ What trends are you seeing within Asian shipbuilding? And how are these affecting WAGO?Goh: I believe that the marine construction sector will keep evolving during the next 10–15 years as urbanization in the developing coun-tries of Southeast Asia continues growing. And this will spur an increas-ing need from these countries for trade and transport activities. Additionally, our interconnect and automation technologies have prov-en themselves over years within shipbuilding. And we are continuing to expand our business in this sector by introducing new products that exceed the demands of the market.

■ How has this change impacted your business? What role do you see for WAGO in the future?Goh: I would have to say that the drop in oil prices has undoubtedly slowed the shipbuilding and process industries. However, even though we are experiencing slower growth this year, we still see opportuni-ties in every setback. In today’s fast-paced and fiercely competitive market, mechanical engineering and manufacturing companies are under constant pressure to develop new and innovative products with-in increasingly shorter periods and do so while minimizing costs and maximizing quality. In this competitive environment, WAGO continues to stand out. We are making concerted efforts to expand our business, restructure our processes and invite more experts to join our WAGO family.

■ Aside from the oil and gas industry, what other sectors of the pro-cess industry are you active in, and why?Goh: In addition to oil and gas, we are active in the chemical, phar-maceutical and water treatment industries. The potential for growth in these areas is practically invaluable. The large and growing middle class demands higher crop yields, more consumer goods, and better water processing, which in turn necessitates more modern and inex-pensive automation systems. In water treatment, reliability and safe system operation are the highest priorities. Using WAGO’s hardware

■ Mr. Goh, how does the situation in the offshore industry play out in Southeast Asian markets? Goh: Actually, we can’t escape from the recessionary trend impact-ing both the marine and offshore industries. In our region, we have just recorded a 30 % reduction in business with existing customers. However, we still believe that opportunities are present in every crisis. The products in our portfolio, which help our customers reduce overall ownership costs, open up these opportunities for us. Prime examples

or software, programming expenses can be reduced and system op-eration can be simplified. The modular, fieldbus-independent WAGO-I/O-SYSTEM 750 is the ideal solution for supporting applications from simple regulated measurements on up to automating entire wastewa-ter treatment systems.

■ Malaysia, for example, acts as the technological transfer hub along the entire Pacific Rim. What sales channels does WAGO use here?Goh: As one of the fastest-growing economic regions in the pan-Pa-cific area, Malaysia’s flourishing oil and gas sectors offer solid mar-ket opportunities for companies in both upstream and downstream technologies. Its geographic location and large oil and gas reserves make Malaysia an ideal base for expanding into the Asian oil and gas markets. WAGO also has a large number of helpful customers in the shipbuilding and process industries who support us in convincing new clients to try WAGO products. We use distributors, system partners and wholesalers to access this region.

■ Reliability and system uptime are both important factors in effective production. What can WAGO offer to the process industry, in your opinion, that would guarantee this?Goh: These factors directly correspond with WAGO’s corporate phi-losophy, because “safety” is our highest priority. We diligently main-tain this safety philosophy — from development to delivery. As a result, our maintenance-free and reliable products permit us to invest more time in the actual demands of process technology systems. This also applies to our offshore systems.

■ At the annual NAMUR General meeting, WAGO introduced a pi-oneering solution for decentralized, modular automation of process systems: DIMA (Decentralized Intelligence for Modular Applications). What is DIMA and what advantages does this method offer the pro-cess industry?Goh: Using DIMA, automation modules can be equipped with their own intelligence and — similar to a notebook on a docking station — are easily integrated into systems and can be readily exchanged later. Systems operators will be significantly more flexible over the entire life-cycle of a system because of this. At the same time, automation costs will be reduced, because the solutions required to automate individual modules within a modular process system are significantly less than those of a conventional self-contained system within a large process control system. DIMA enables a significantly more adaptive system de-sign (scale up by numbering up); in this context, the integration of auto-mation can begin to parallel that of modular manufacturing. This saves time and enables earlier commissioning of new production systems.

■ Thank you for the conversation.

Daryl Goh, Regional Sales Manager of WAGO Singapore

Daryl Goh, Regional Sales Manager for WAGO Singapore, Offshore and Maritime Construction Industries in Southeast Asia

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■ From Follower to LeaderImplementing the “Made in China 2025” strategy is supposed to en-able China to lead other industrialized nations — it will connect China to the world in a way that catapults it to the top. This is surely not only for an improved image, but because there is an imperative need for action: China’s days as the land of low wages are numbered, economic growth is sinking just at the time when wages are starting to rise. The number of workers is dropping as a result of demographic changes. Outlying markets, which were a previous target of the export strategy, are demanding increasingly higher quality. On top of this, the need to protect resources keeps growing. China has been forced to step away from cheaply produced mass goods and toward quality and innova-tion. And like any investement, the “Made in China 2025” strategy will cost the Chinese central government. Official government promotion of “Made in China 2025” is much more extensive than the promotion of Industry 4.0 in Germany. However, China is at a significantly lower technological starting point for initiating the “Made in China 2025” strategy than Germany was for Industry 4.0. There is no doubt that a significantly higher degree of automation and intelligent, networked production designs will ultimately prove key to their success. It is not by chance that Chinese firms are actively seeking to collaborate with Ger-man companies, and that the Chinese government invited prominent German politician Sigmar Gabriel to lecture on Industry 4.0. The Chi-nese are basing their “Made in China 2025” strategy on Germany’s Industry 4.0 movement — and for the further automation of their entire industrial base. As in the past, the first stage presumably includes learning as much as possible from other nations, but only with the ultimate goal of stepping quickly out of the shadows of their “teachers” to surpass them. The path from follower to innovator and leader has already led to remarkable success for other Eastern Asian countries. Consider the industry based on home electronics: Japanese and South Korean companies copied many products from Europe and America. Japanese companies close-ly emulated German and American products (with South Korean firms then copying their Japanese counterparts) before marching to the front of international competition. Now the Chinese are learning from the rest, and this will eventually lead to the stage where innovations are generated. This strategy has worked well in the past with easy-to-make products; why won’t it work just as well in revolutionizing existing pro-duction processes?

■ Winning or Losing?Will western vendors of automation technology ultimately be the winners here? Certainly in the short- and medium term. For the next few years, the “cake” that China is dividing up is so large that additional foreign com-panies — along with Chinese enterprises — can claim a respectably large slice.This is due to the fact that the degree of automation in China is

currently at an extremely low state, according to a study by the consult-ing firm, Stieler Technologie-& Marketing-Beratung. The proportion of tool and die machines with NC controllers in China is, for example, simi-lar to that of Japan at the end of the ’70s. Correspondingly, the Chinese automation sector will grow in the coming years: experts calculate an

East Asian countries lead the world in ship construction — both in the numbers of ships built and in the tonnage that these ships represent. Chi-na alone fulfills more than 40 % of orders within the maritime construc-tion industry; South Korea supplies more than 30 %. The two countries obviously lead when it comes to international shipbuilding. Following a few difficult years, the Chinese marine industry is undergoing a consoli-dation — and this is not just because the ship construction industry is one of the ten sectors that the Chinese central government selected as focal points for their “Made in China 2025” initiative. As a direct response, the regime is backing a few viable shipyards that have the potential

With vertical manufacturing for ship construction increasing in East Asia, WAGO provides support with an intuitive engineering design tool.

to build and develop more complex ships; these shipyards could also handle more complicated engineering tasks. Shipyards that prove inca-pable are deliberately cut off and will eventually fail. China is no longer interested in building simple ships — the construction costs associated with them are too high, due to quickly increasing labor expenses, and the demand is too low. Instead, there is a plan to reduce the construction costs by enabling local manufacturing and engineering firms to now oversee tasks that were previously completed by foreign companies. This is already significantly apparent in switchgear production: where control cabinets that were once supplied as complete units from Europe, they are now constructed in Asia. Next, they will be designed there as well. This trend is also apparent in marine construction. China was once previously limited to building hulls and propulsion systems. Now with instrumentation, control and automation technology and control func-tionalities installed as completed units from abroad — Chinese compa-nies are now increasingly seeking their own, homegrown ICA solutions. During the most recent industry tradeshow, Marintec, there was already a greater demand for software and controllers from local companies. If more complex engineering work shifts to China, then suppliers must offer solutions that support and facilitate the design process. WAGO offers, for example, the new engineering and design tool e!COCKPIT. This software provides a design environment based on CODESYS 3, which supports everything from hardware configuration, programming, simulation, and visualization, up to commissioning.

average 15 % for all of industrial automation within the next five years. While expanding during this first state, China will undoubtedly be advised by foreign companies with a wealth of experience. In East Asia, particulalry China, the need for automation is quick-ly gaining ground, along with demands for automation solutions. Domestic automation components cannot yet hold a candle to those from Europe and the USA, particularly with regard to precision, reliabil-ity, intuitive operation and speed.

■ Emphasizing Features — Exploiting StrengthsWestern companies will be able to record significant success in the short- and medium-term with automation components or solutions that are reliable, high quality and — above all — easy to use. And this is spe-cifically for those sectors, which are directly influenced by increasing automation, such as the energy industry. Continued on page 23...

Source: Study of Industrial Automation in China;STM — Stieler Technologie & Marketing-Beratung

Developing market share for both local and foreign compa-nies involved in China’s industrial automation sector

Total:336.8

Total:169.8

Total:93.5

–Total growth Chinese firms

2010-2015 +104 %

Total growth Chinese firms 2015‒2020

+133 %

Total growth foreign firms 2010‒2015

+67 %

Total growth foreign firms 2015‒2020

+71 %

Chinese firms 40 %

Chinese firms 45 %

Chinese

Foreign

Chinese firms

2010 2015E 2020E

177.0

159.8

76.1

93.6

37.3

56.2

Mar

ket s

ize

(Bn

RMB)

400

350

300

250

200

150

100

50

0

Source: Study of Industrial Automation in China;STM — Stieler Technologie & Marketing-Beratung

Market for industrial automation in China — 2010‒2015‒2020

Total growth

2015‒2020 +98 %

Total growth 2010‒2015

+82 %

Total: 336.8

Total: 93.5

Total: 169.8

Mar

ket s

ize

(Bn

RMB)

400

350

300

250

200

150

100

50

02010 2015E 2020E

Source: SEA Europe, based on IHS Fairplay

Europe

Japan

South Korea

China

RoW

1990 2000 2013

Composition of shipbuilding capacities

Technology Technological gaps

Smal

l

Med

ium

Larg

e

Sensors •

Industrial software •

Robotics •

RFID •

Cloud •

Source: China Monitor Number 23;merics Mercator Institute for China Studies

Chinese technological levels in core technologies for Industry 4.0.

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■ East Asian countries lead the world in shipbuilding — both in the numbers of ships and in the tonnage that the ships represent. China alone fulfills more than 40 % of orders within the maritime construc-tion industry; South Korea supplies more than 30 %. The two coun-tries obviously lead when it comes to international shipbuilding.

Asia — Shipbuilding Hotspot WAGO at Marintec and Kormarine

Based on these statistics, it’s only fitting that Asia’s two most prom-inent marine tradeshows, Marintec and Kormarine, take place in China and Korea respectively. Working and merchant vessels will be the focus for both shows.

After Seoul, Busan is the second-largest city in South Korea. In 2015, it will host the Kormarine Trade Show.

The container harbor in Shanghai — the site for Marintec — is the largest in the world.

■ KormarineSince 1978, Kormarine has been one of the most important maritime Asian tradeshows — this year, the focus has expanded to include the oil and gas industry. At this year’s show, which will occur in Busan, South Korea, they ex-pect 40 international exhibitors from 15 nations, and 40,000 visitors from 80 different countries. Busan has the second most important shipyards in South Korea, eclipsed only by Ulsan’s. WAGO is participating in Kormarine with its own booth for the first time since founding a South Korean subsidiary. “For this tradeshow, our goal is establishing the types of connections that we have with European customers in Asia,” strategizes Norman Süde-kum, Market Management Industry & Process, Head of Marine & Offshore at WAGO. “Beyond that, we have hired a new Bu-san-based sales professional who is specifically devoted to the marine industry. This will gain a foothold for our subsidiary,” he adds. WAGO will also present products at Kormarine that are related to automation and network technology and carry marine approvals.WAGO at Kormarine: 4W24, Hall 4

■ MarintecFor the fifth consectuive time, Shanghai will be hosting Marin-tec. The city commands the largest container harbor in the world with 35.3 million TEU (Twenty-foot Equivalent Unit, a measurement of capacity for container ships and harbor transshipment volumes). The last Marintec in 2013 welcomed 1,700 exhibitors and 57,900 visitors. WAGO will host its own booth at Marintec to demonstrate its com-mitment to China with sales, support and manufacturing. “Especially for products that require explanation and training, which includes our automation products, the customers want to know that we can readily provide on-site support,” explains Südekum. “Because the value-added depth in China is going to increase, we are also expect-ed to support European marine shipbuilders during the migration to Chinese control cabinet manufacturers,” he explains. The focus of WAGO’s presentation will be on the automation portfolio that WAGO offers for the marine and offshore sectors. WAGO at Marintec: Hall N2, booth D31-08 (within the German Pavilion)

Foto: iStock.com/TanawatPontchour Foto iStock.com/silkwayrain

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In the long-term, however, those companies will be better situated to succeed by protecting the expertise they import to China. They will also benefit by emphasizing features in these sectors that will, in the future, be more strictly regulated or become increasingly complex. This will in turn place higher demands on vendors and producers than, for exam-ple, consumer goods or textiles. WAGO views these parameters as givens, primarily in the petrochemi-cal and shipbuilding industries. This is primarily because WAGO solutions for these two industries play to our specific strengths, and could even serve as stimuli — one of which would be DIMA. DIMA is a pioneering method for automating process systems, which WAGO presented in the Fall of 2014 in Germany, and will introduce to China in November 2015. DIMA simplifies system en-gineering and enables subsequent changes in system architecture due to its modular automation structure. On the component level, WAGO’s I/O-SYSTEM 750 consists of more than 500 modules and is modular-ly designed, enabling custom configurations. WAGO components also come with numerous approvals, including installation in hazardous envi-ronments or offshore areas. WAGO automation components, power sup-ply units, current transformers, signal conditioners and terminal blocks, constitute a complete product portfolio for the electrical equipment used in the petrochemical and marine industries. WAGO can thus accommo-date firms wishing to obtain solutions from a single source, which dramat-ically expedites project commissioning. Regarding usability, WAGO’s spring clamp technology is incredibly important because connections can be made significantly faster than with screw connections.CAGE CLAMP® connection technology is maintenance-free and mini-mizes wiring errors. It has also proven itself under extreme conditions, such as salt fogs and humid heat and extreme temperature cycling, as well as shocks and vibrations. WAGO’s existing product portfolio currently satisfies the demands that

The petrochemical industry in China has grown an average of 25 % between 2003 and 2013. While it is still growing faster than the gross national product, growth has slowed significant-ly since then; this is primarily due to saturation of the market. In

Asia’s Importance Grows in the Development and Design of Large Process Systems and Refineries

the East Asian countries place on automation technology: the compo-nents are high quality and reliable, easy to handle and safe. They are also modular and can be flexibly incorporated; they are approved for diverse applications, and well-suited to the prevailing environmental con-ditions in Asia. Last, but not least, they reduce the total cost of ownership over the entire lifecycle of a system. Perhaps more important, however, than satisfying the current demands of the Asian market, is it that WAGO can spur stimulus for the future development of the automation industry in Asia through a methodology like DIMA. This this demonstrates the innovation that the domestic Chinese market will not be able to meet in the medium- or long term.

■ Remaining One Step AheadChinese companies are currently pursuing their American and German competition in terms of reliable, precise and high-quality automation solutions. German companies in particular offer the most unique appli-cation potentials. The timeframe is, however, limited. In the coming years, Chinese firms will increasingly catch up. In those circumstances, one can assume that foreign companies will be displaced from the Chinese mar-ket. The drivers of change will be private companies. They are, in general, faster and more nimble than state-operated entities. Even if they currently lack commitment from the Chinese regime, it still remains easier for state-owned companies to gain access to credit than private enterprises. How-ever, this is presumably not enough to curtail the spirit of optimism, joy in innovation and the dynamics of private companies, which is comparable to the spirit found in German corporations in the ’50s and ’60s. These Chinese companies are ready to forge new paths that lead to the top. The success that foreign companies will enjoy in a future China will de-pend on their ability to protect their expertise and continuously innovate in order to remain one step ahead.

Text: Volker Palm, Norman Südekum, Benjamin Böhm, WAGO

To supply traditional energy sources, like coal, oil and gas, floating process systems (FPSO — Floating Production Storage and Offload-ing Units), tankers and drilling and production platforms are needed.

In addition, Asia is becoming more important for the development and design of large process systems and refineries; it’s gaining each year on previous leaders, Europe and North America. In all of these cases, WAGO has solutions available for the decentralized auto-

spite of this, the process industry in China continues to grow at a disproportionate rate, in particular when compared with Amer-ica and Europe. Increases in population and automation usage are also continuously driving up demand for energy as well.

Due to state subsidies, increasing demand for “clean energy” has simultaneously led to a greater demand for automation solutions for photovoltaic systems and wind farms.

mation of modular systems and can spur future development of the East Asian chemical industry with the DIMA concept (Decentralized Intelligence for Modular Applications).

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WAGO in East Asia China

WAGO ELECTRONIC (TIANJIN) Co. LTDTel. +86 22 59677688info-cn@wago.comwww.wago.com.cn

Japan

WAGO Co. of JAPAN Ltd.Tel. +81 3 5627 2050info-jp@wago.comwww.global.wago.com/jp

Korea

WAGO Korea Co., Ltd.Tel. +82 314219500info.korea@wago.comwww.wago.co.kr

Taiwan R.O.C.

WAGO Contact, LtdTel. +886 2 22250123info.taiwan@wago.com www.wago.com.tw

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■ Salt in the air, vibrations, shocks and extreme temperature cycling dictate product usage on the high seas. These are incredibly extreme conditions — for humans, as well as for machines and systems. In Ul-san, South Korea’s largest floating crane was built, and despite these severe conditions boasts trouble-free operation — thanks in part to products from WAGO.

South Korean maritime engineers are internationally recognized for their technologies and abilities in building civilian and military ves-sels. It is no accident that Korean shipyards are increasingly tasked with building specialized ships — this extends from specialized freighters, for example for gas, as well as to offshore power plants. Currently, there is increasing demand for large floating cranes from Korean shipyards. Floating cranes are used whenever tankers, off-shore power plants or floating oil refineries have to be equipped at sea. This is usually due to insufficient depth at the existing quay facilities or because the rail-mounted cranes on the quay lack suffi-cient mobility. Floating cranes transport heavy components on the high seas and load them directly on site. Until now, South Korea’s largest crane had a lifting capacity of 8,000 tonnes. This record will soon be broken by a floating crane being construected in Ulsan that is reported to have a lifting capacity of 10,000 tonnes. This ship-yard decided to focus on particularly large and specialized floating cranes because of the prevailing geographical conditions.

■ Minimizing Cabling Expenses and ErrorsThe shipyard that was tasked with constructing the 10,000 t floating crane contracted with G.S.I. — a company specializing in crane con-trol systems — to design the drive control system.Although G.S.I. had previously used products from a competitor for installing electronic units, like terminal blocks, in this case, they con-ducted a test. WAGO products were compared with the existing products, and the performance of WAGO products won over the G.S.I. technology design team. Components from the TOPJOB® S rail-mounted terminal system were used for interface signals and for distribution in the AC and DC networks. A decisive factor for G.S.I. was the marking strips from WAGO, which were printed prior to installation with terminal block number and information. This signifi-cantly minimized the risk of errors.

■ Saving Space in the Control CabinetG.S.I. also decided to use a WAGO solution for the central control of the mooring winches used by the floating crane. Because space was extremely limited for the small scale control cabinet, the mooring winches were equipped with the 750 Series. G.S.I. has no doubt that the system can brave the rough conditions on the high seas, since it has a broad array of marine approvals. For G.S.I., the largest floating crane in South Korea became a true showcase, which will surely give the company a leg up on the com-

Strongman on the High Seas 10,000 tonnes of lifting capacity — the largest floating crane in South Korea

petition when bidding for future projects. And there would appear to be some in the pipeline, as other shipyards in South Korea are already contemplating the construction of new floating cranes.

Text: Haeyong Kim, WAGO KoreaPhoto: WAGO Korea

• TOPJOB S distributes power in the AC and DC networks for the drive control system.

• Pre-printed marking strips for rail-mounted TOPJOB S terminal blocks minimize cabling errors.

• The compact WAGO-I/O-SYSTEM 750 fits perfectly in the small scale control cabinet.

The largest floating crane in South Korea has a lifting capacity of 10,000 tonnes. It transports components for tankers, offshore power plants or floating oil platforms at sea and loads them there, on site.

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Special Challenges Deserve Specialized SolutionsAbsolutely maintenance-free: WAGO spring pressure connection technology■ Electrical conductors and the quality of their connections deter-mine machine and system uptime — regardless of the complexity of the system’s automation structure or its functions. Electrical con-nection technology must elevate feature one above all the others: reliability. And it must maintain this under all conditions and over the complete lifecycle of the system.

Mechanical engineers and system designers must offer their clients solu-tions that guarantee a high level of system uptime and reduce the total cost of ownership over the system’s entire lifecycle. This places a tremen-dous amount of pressure on those providing sys-tems to the chemical and process industries, as well as shipbuilding. The components used here must brave some of the roughest en-vironmental conditions and must perform flawlessly, until they are replaced during scheduled maintenance. This is why the importance of the connection technol-ogy for all types of electrical connec-tions should not be underestimated in mechanical and systems engineering. Ultimately, using safe and maintenance-free connection technology can provide significant

levels of investment protection during a sys-tem’s lifecycle. From the view of a system engineer or operator, usabil-ity should not come at the cost of safe and maintenance-free electrical connections. From both aspects — the connection quality and usability — the type of connection technology is the deciding factor.

■ Connections that are as Light as a Feather Allowances must be made for copper, which has unique flowing characteristics that can be impaired if a screw connection is too tight. Even if correctly installed, these connections become loose and contact resistance increases. Shocks, vibrations and tempera-ture fluctuations can impair the contact quality of a screw connec-tion. Shocks and vibrations occur commonly in marine applications; temperature fluctuation demands of -40 °C to +70 °C can occur in control cabinets that are installed in open-air sites located in areas with extreme climates. Conductor specifications, such as stripped

copper conductors, or conductors with lamellar or woven structures, also influence contact quali-

ty. For instance, conductors formed from a mesh of thin, individual wires are

quickly destroyed by screw connec-

tions. In contrast to screw c o n n e c -t i o n s , WAGO’s s p r i n g

c l a m p t e c hno logy

provides safe and mainte-nance-free connections for

electrical conductors — and has proven itself for decades.

They first demonstrate their advantages during installation and later during use: correctly connected from the start, the spring clamp technology endures even the harshest circumstances. Because the contact pressure that embeds the conductor into the current bar is determined by the spring, basically making it “pre-pro-

grammed,” it always functions optimally. The quality of the clamp-ing point remains consistent, despite shocks and vibrations, because the spring automatically compensates for these to maintain connec-tion integrity.

■ Correct Choice for Demanding ApplicationsBecause the CAGE CLAMP® connection has a gas-tight clamping unit, WAGO’s spring clamp technology ideal for challenging environments. These include applications in chemical or process technologies, or aboard ships and oil platforms, where aggressive, corrosive or oily sub-stances are used. WAGO also offers terminal blocks for use in hazardous areas. And, because the standard TOPJOB®S terminal block carries all of the necessary approvals for these hazardous locations, system engi-neers do not need to have an extensive inventory. Within measurement technology, WAGO terminal blocks represent an inexpensive alternative to specialized, usually more expensive, I/O modules for thermocouples. And finally, spring clamp technology has proven itself under the most ex-treme conditions, such as salt fogs, which are an everyday occurrence in marine settings or along coastal regions. They’ve also proven their abili-ty to withstand humid heat and shock loads up to 500 g. The maritime construction industry is increasingly relying on modular designs for their engineering and switching systems; for these systems, large portions are pre-assembled and wired using pre-installed cables. The advantages aris-ing from this — mainly quick and precise wiring without specialized instruc-tions — are only gained if clamping units and individual wires are correctly and clearly labeled. WAGO offers continuous marking strips, which can be printed with up to three lines of information, to ensure accuracy. This makes it possible for clear module marking that matches connection termi-nals to their respective system parts. Beyond accuracy, this increases wir-ing safety. With their combination of clear marking and supreme usability, CAGE CLAMP® connection technology streamlines wiring — particularly for difficult-to-access applications, such as offshore platforms.CAGE CLAMP® spring clamp technology is suitable for all types of con-ductors: solid, stranded and fine-stranded conductors. It is also compat-ible with ferruled, fine-stranded conductors, pin terminals and compact stranded conductors. This flexibility pays off, especially if system designers do not know what conductor types they will find while commissioning a switchboard on site. Because the spring’s clamping force withstands reuse, CAGE CLAMP® offers additional safety when used in systems that have long lifecycles and will eventually require some retrofits or upgrades. The enormous range of cross sections accommodated by WAGO’s spring technology clearly demonstrates its versatility and power: conductor siz-es from 0.08 mm² are safely and quickly secured via CAGE CLAMP®; POWER CAGE CLAMP connects conductors up to 185 mm². Addition-ally, WAGO offers spring clamp technology across its entire range of automation components.

CAGE CLAMP® has a gas-tight clamping unit: The spring clamp presses the connected conductor against the current bar within a defined contact zone. This action embeds the conductor into a soft tin layer with high contact pressure, securing it against corrosive infiltration.

In order to test and prove the long-term dependability of the clamping unit, corrosive atmospheres that could degrade contact quality are simulat-ed in climatic chambers.

■ Support from Project Planning to CommissioningWAGO supports the entire planning process of connection technolo-gy and automation with the smartDESIGNER online configurator. It has interfaces for EPLAN and WSCAD, among others. This enables bidirectional communication with the CAE system and ensures the integrity of the parts list. As an online application, the software is extremely usable and does not require integration by an IT depart-ment. This saves both time and money because outsourcing to an external service provider is not required, and there are no invoices for new installations or software updates. If any WAGO electrome-chanical components and automation systems are used in the switch-gear, the designer can conveniently use smartDESIGNER’s direct link to WAGO’s eShop. This location holds technical specifications, data sheets and downloads that can be directly accessed without advertising. Once the carrier rail has been configured, it can be au-dited by the tool, displayed in 3D and documented. It is also possi-ble to output marking for the WAGO components directly using the WAGO smartDESIGNER. Using project-specific approvals, a simple comparison can be executed by both the system designer and by the switchgear manufacturer using the same database. This enables documentation of every step. Which in turn generates transparency and reduces expenses.

The questions that you should ask in order to find the correct terminal blocks for perfectly supporting your process can be found on pages 30 and 31.

Text: Burkhard Niemann and Kay Miller, WAGOPhoto: WAGO

1

2

3

4 5

7

6

3030 31direct process

Clever Terminal Blocks – Perfect Process

Whether you are connecting a motor, diodes or LEDs, or whether you need disconnect terminal blocks, TOPJOB®S rail-mounted termi-nal blocks can satisfy virtually any need. They are proven for measurement applications with a cross-section range from 0.14 mm² to 2.5 mm², and from 4 mm² to 25 mm² in a direct power supply. In addition, the product family includes through-, double- and triple-deck terminal blocks Your advantage: you only need one portfolio of rail-mounted terminal blocks for all applications.

From the field level’s smallest measure-ment signal to a load of 90 A within a power stack, to securing connections with different nominal cross-sections — TOPJOB®S rail-mounted terminal blocks exceed expectations. The rail-mounted terminal blocks can be wired using unprepared solid, multi-strand and fine-stranded conductors that are one size greater than their rated cross-sec-tion. Your advantage: Save up to 25 % more wiring space and money

With Push-in CAGE CLAMP®, the TOPJOB® S rail-mounted terminal

block offers universal connection for all conductor types. Solid or

multi-stranded conductors, fine-strand-ed conductors with or without ferrules

— TOPJOB® S guarantees safe con-nections. Your advantage: You can directly connect fine-stranded con-

ductors without ferrules, saving time and money.

TOPJOB® S rail-mounted terminal blocks can be quickly and clear-ly labeled using continuous marking strips. Because the strips can be printed with three lines of information, there is space to designate each module and its function. Your advantage: With just the wave of a hand, you can ensure wiring accuracy and also save up to 75 % of your valuable time.

You can directly connect solid, multi-stranded and ferruled, fine-strand-

ed conductors with the TOPJOB® S rail-mounted terminal block. For all

other conductor types, simply use an operating tool that remains in the

operating slot to mark the opened clamping unit. Your advantage: Direct push-in termination reduces assembly

time and frees both hands when using the operating tool.

A flexible jumper portfolio is avail-able for TOPJOB® S: step-down,

standard, continuous jumpers and colored jumpers. This even includes

specialty solutions, like space-saving potential blocks, individual wire

jumpers and push-in taps — every-thing in one rail-mounted terminal block program. Your advantage:

Streamline your inventory thanks to a universal portfolio.

Where do I use these terminal blocks?

What function must the termi-nal block have?

How will I connect the conductors?

What is the current that I need to place on the terminal block?

How do I mark the terminal block?

Time-savings

Easy-to-use

Time-savings

Easy-to-use

Time-savings

Easy-to-use

Time-savings

Cost-effective

Easy-to-use

Time-savings

Cost-effective

Safety

Easy-to-use

Cost-effective

Time-savings

Easy-to-use

Cost-effective

Whether subjected to a compressor’s continual vibrations, salt fogs aboard a ship, oily air on an offshore platform or hazardous atmospheres in the chemical industry, TOPJOB® S rail-mounted terminal blocks have proven themselves in every field — even under the most extreme condi-tions. Your advantage: You have a safe connection in every environment, reducing your inventory and related expenses.

How do I make common-ing as fast and flexible as

possible?

What conductor types will be connected?

Time-savings

Cost-effective

Safety

Seven steps to the right terminal block.■ Environmental conditions exist in the process industry that place extremely high demands on electrical connections. The questions you should ask when selecting rail-mounted ter-minal blocks and the answers you need about TOPJOB® S can be found here:

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Havyard Group

■ Their technology is used on more than 450 ships worldwide. This means that sending maintenance personnel to deal with manufactur-ing errors represents a significant cost that the Norwegian company XTronica AS would rather avoid. The solution: simply deliver the highest quality. Consequently, their own employees and suppliers must satisfy these exacting demands. And WAGO is a trusted partner that easily meets this requirement.

XTronica is a supplier of maritime instruments that are focused on re-cording and visualizing tank fill levels and volume measurements, in-cluding the sensor systems. The Norwegian company delivers systems for monitoring tank fill levels aboard all types of ships, as well as other systems. “Our stand-alone systems include the requisite components from sensors to a human-machine interface (HMI),” explains Ingemar Strøm, Technical Manager at XTronica.

■ Excellent Quality for Gauging Tank Fill Level MeasurementsXTronica has demonstrated expertise in this area — and chose WAGO and the I/O-SYSTEM 750 when selecting partners. The measurement method when detecting fill level is determined by the demands of the shipping company or shipyard, as well as by the shape of the tanks. This can mean various pressure measurements, employing ultrasonic or radar measuring principles. The target is the development of us-er-friendly solutions with good functionality, excellent accessibility and low maintenance costs. This combination is particularly important to the end user. “In case of a production error or a component failure, the costs can accumulate quickly,” states Strøm. “Therefore, we place a lot of value on quality when selecting our suppliers. It is probably just a coinci-dence, but, generally speaking, we select German companies as our vendors. We took a long time to evaluate the different manufacturers, from sensor systems, through communications, on up to the HMI. We fundamentally examined every aspect of the entire value-added chain. Since we are a small and specialized company, we selected partners who were not only leaders in their markets, but play in the highest leagues when it comes to quality.”

Prevent Complaints by Providing Top QualityNorwegian firm XTronica AS relies on the WAGO-I/O-SYSTEM 750 for their systems for monitoring fill levels in tanks.

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The WAGO-I/O-SYSTEM 750 Telecontrollers now communicate in Distributed Network Protocol (DNP3). This telecontrol protocol, which is used for data exchange between I&C systems and distributed sub-stations, is established worldwide with primary usage in the USA, Asia and parts of Europe. Employing communication via DNP3, WAGO has readied its telecontrollers for worldwide telecontrol applications, such as monitoring distribution grids or far-flung production locations.“The fact that our telecontrollers can now communicate in DNP3, in addition to IEC 60870-5-101, -103 and -104, IEC 61850, and IEC 61400-25, is not only significant for us, but provies a number of ben-efits for our customers who export. Producers of wind turbine farms, for example, or transformers now have a universal telecontrol solution that is no longer restricted to specific regions,” explains Martin Paulick, WAGO AUTOMATION Product Manager. WAGO’s Telecontrollers are used as DNP3 substations to set up a reliable link to the power provider’s SCADA system. DNP3 compatibility corresponds to Level 2 and communication is performed either serial or via ETHERNET (TCP and UDP).Using DNP3 is particularly easy, thanks to a dedicated configura-tor integrated into the WAGO-I/O-PRO development environment. WAGO Telecontrollers include the following models: 750-872, 750-880/025-001 and -002, 750-880/040-001, 750-8202/025-001 and -002, as well as 750-8206/025-001.

FOR USE AROUND THE GLOBE: WAGO TELECONTROLLERS SPEAK DNP3Technology tuned for communication: WAGO’s Telecontrollers now commu-nicate in DNP3, as well as support IEC telecontrol protocols.

WAGO’s Telecontrollers are compliant with all relevant transmission protocols, making them ideal for use around the globe. A dedicated configurator in WAGO-I/O-PRO simplifies DNP3 parameterization.

• WAGO satisfies the high demands for quality that XTronica places on its partners.

• The WAGO-I/O-SYSTEM performs tank fill level measurements.

• Mixed operation of Ex and Non-Ex modules ensures a compact installation.

Rudolf Stoum, Manager of Support at XTronica in Norway

XTronica is a supplier of ship instrumentation systems. The company supplies, among others, systems for monitoring tank fill levels.

XTronica uses the WAGO-I/O-SYSTEM 750 to process Ex and Non-Ex signals in one system.

■ Upgrades Occur DailyRight after founding XTronica, talks were held with a series of differ-ent suppliers.“ According to our evaluations, WAGO satisfied our expectations regarding quality and functionality. In addition, WAGO offered their products at a competitive price, making it an easy deci-sion. As with our other preferred suppliers, the collaboration has de-veloped positively,” explains Rudolf Stoum, responsible for Support at XTronica. “We rely on programmable logic controllers, terminal blocks and other installation components from the WAGO product portfolio. Technology develops rapidly, and we have to keep up. This applies to new solutions, as well as existing installations.” In recent years, XTron-ica used modules with intrinsic Ex-barriers in addition to standard I/O modules to transmit Ex-i signals directly to controllers. This makes wir-ing even more compact.Eventually, all ships need upgrades to their technical systems in order to maintain functions or provide new and improved ones. When there are new problems to solve, the Support Division at WAGO has proven itself to be an excellent partner. “In our experience, they react quickly to all requests. There was already an operating situation that the leg-acy equipment could not handle; we had to find new solutions. It was good that WAGO had expert employees in Norway, as well as at their German headquarters,” recounts Stoum.

■ Expertise from 450 Ships under SailBased on a fleet of more than 450 operational ships that XTronica has equipped with systems, they have developed a broad portfolio of solutions. These solutions are in turn adapted to different ship types, including supply vessels, tankers, drilling rigs and cruise ships. The in-stallations are often made in shipyards in Turkey, China or Indonesia. In addition to individual systems, cultural differences and prevailing conditions must also be considered.“No matter where in the world our systems are installed, the quality must remain the same,” Strøm adds. “This position has already proven to be an excellent corporate strategy. The higher production costs are compensated for by a significant reduction in complaints by custom-ers.” The past proves XTronica to be correct: the company has not dispatched personnel to fix design faults. Additionally, the solutions from Norway function without the need for other control or monitoring systems.

■ Tailored Solutions with a High Degree of AccuracyFunctionality is one thing, accuracy another. In accordance with com-pany principles, the equipment used must have an extremely low level of measurement inaccuracy. After calibration of the sensors, they have an inaccuracy of only 0.1 percent, with 0.3 percent allowed for the entire measurement system. Since they only use robust, high-quality components, the completed installations do not require calibration af-ter installation. This has significantly reduced operating costs.“We rely on the possibility of standardized solutions, however, we adapt the end product to the specific demands of the customer when necessary,” states Strøm. In order to calculate different tank shapes, XTronica relies on software support. The company receives the tech-nical data regarding tank shape, usually in tabulated form. The pro-grammers develop algorithms from this in order to determine the fill level in the tanks. These types of systems can be quite complex: at, for example, 100 tanks per ship and 250 measurement points per tank, a large amount of data must be managed and evaluated. In order to obtain the most exact description of actual conditions, the calcula-

tions include interpolations. In addition, they have to consider the trim of the ship. This combination of expertise in measuring technol-ogy, software programming and experience is unique to XTronica.

Text: WAGO NorwayPhoto: WAGO Norway

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WAGOdirect process, October 2015

Editor: Eva Banholzer (responsible editor)

Phone: (0571) 887-418 Fax: (0571) 887-8418

Free reuse of this content is possible following approval and with appropriate citation. Contact: Eva Banholzer, WAGO. We assume no liability for unsolicited manuscripts and photos that are submitted. WAGOdirect process is published periodically throughout the year.

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