Solar Power Stations

8/8/2019 Solar Power Stations

1/32

CUSTOMER MAGAZINE EATON ELECTRICAL SECTOR EMEA

[email protected] www.moeller.net

SOLUTIONS22

P. 22

Eaton Power ManagementEnsures Process Safety

Solar power stations: Parabolic trough solar collector uses air as heat transfer mediumP. 10|Pack it:

Smart-Wire-DT controls packaging machines P. 12|Photovoltaic roos:Always tracking and facing the

sun P. 16|State o the art: Motor and pump test bench with SmartWire-DT P. 20|


2/322 SolutionS 22

ContentImprint

Solutions is the customer

publication of Eatons Moeller

business

Published:

Eaton Electrical Sector EMEA

Eaton Industries GmbHHein-Moeller-Strae 7-11

53115 Bonn

Tel.: +49 228 602-0

Fax : +49 228 602-62275

E-Mail: [email protected]

www.moeller.net/solutions

Editors:

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

Christian Bcker

Integral Dr. Schumacher

Authors:Marco Bellotti, Christian Bcker,

Willi Fries, Paul Knodel,Wolfram Kber, Peter KruseErnesto Mitruccio, Anita Putkinen,Dr. Monika Schumacher,Bernhard Teepe

No. o copies: 16,000

This customer publication isprotected by copyright, applicableto all articles, diagrams and photos.Eaton reserves all rights.

KM0213-4316EN

Article No. 150411

Layout: buntebrause agenturPrinted in Germany (11/10)

Translator: Terry Osborn

TRANSTech Translations

News... 4-8

Training pact... 9Gstrow Vocational College Uses SmartWire-DT Model Installation

Solar Power Stations... 10-11Parabolic Trough Solar Collector Uses Airas Heat Transfer Medium

Pack It... 12-13SmartWire-DT Controls Packaging Machines

Mediterranean Liestyle... 14-15 SmartWire-DT Automates Italian Grape Pressing System

Photovoltaic Roos... 16-17Always Tracking and Facing the Sun

Pico Breweries... 18-19Brewing Beer Yourself

State o the Art... 20-21Motor and Pump Test Bench with SmartWire-DT

Mnsterland Brewery... 22-23xEnergy Ensures Optimum Availability

Ground freezing Plant... 24-25Eaton After Sales Service Operation in Russia

Oasis o the Seas... 26-27

Eaton UPS on board

E-Mobility... 28-2950 Million Kilometers with Eaton Hybrid Drives

Inoboard... 30-31

P. 18P. 10

P. 20 P. 12


3/323SolutionS 22

THE COMPANY

SmartWire-DT has been available on the market for well overa year. What conclusions can you now draw and what hasbeen the response of the market to the new technology?

K.H. Arndt: The sales figures are surprisingly positive. In the firstnine months alone, customers have implemented around 25,000connections. This does not include the North American marketsince we will not approach this market until the SmartWire-DTsystem has UL/CSA approval. We are planning the market launchin North America for the beginning of 2011.

At the start of the launch you offered both the switching andprotective devices as well as the pilot devices all equippedwith the communication system. What does the time scalelook like for future product groups?

K.H. Arndt: We are making rapid progress. This year we havefitted part of the circuit-breaker series and the PKE electronicmotor protection from 12A to 32A with SmartWire-DT. The PKErange up to 65A will be completed in the coming year. We willalso include the DS7 soft starter in the SmartWire-DT system in2011.

In order to get a better picture and perspective, whatpercentage of switching devices, protective devices and pilotdevices sold today are networked via SmartWire-DT?

Dr. M.U. Scheter: Our expectations are realistic. The percentageis currently in single figures but this is increasing strongly.

In order to make SmartWire-DT broadly available on themarket, you announced last year the wish to form strategicpartnerships with well-known companies. How far have thesetalks developed?

Dr. M.U. Scheter: We are currently in discussions with severalpartners. We are offering a SmartWire-DT development kit in2011, enabling 3rd party users to integrate SmartWire-DT intotheir products.

SmartWire-DT eliminates the need for the I/O level on thecentral controller so this benefit was already announced tousers. Does this visionary goal still stand and when do youthink it will become reality.

K.H. Arndt: SmartWire-DT was designed in this way fromthe start, and this benefit is a key element of our technology.All applications already implemented to date have shownemphatically that the I/O level is no longer needed. In order tofurther advance this vision, we will be expanding the 2011 productrange by providing the control relays (easy), CoDeSys-based PLCsand HMIs with integrated SmartWire-DT. This is interesting forsmall to medium-sized applications as the user no longer needs agateway.

When will your frequency inverters have the interface?

Dr. M.U. Scheter: We will also be fitting our M-Max and H-Maxfrequency inverters with a SmartWire-DT interface within thenext 18 months. It is not our aim to replace established fieldbussystems with SmartWire-DT. We will continue to offer switchgearwith fieldbus interfaces such as Profibus-DP, CANopen Ourpriorities are the reduction in wiring and design engineering onthe one hand and cost-effective diagnostics on the other. Thisparticularly applies to the control circuit devices and the motor

starters that do not have any fieldbus interface and require a lotof wiring.

Karl-Heinz ArndtDr. Martin U. Scheter

With its official presentation of SmartWire-DT at the Hannover

Fair 2009 Eaton set the most important milestone in themarket launch of the product. The Solutions editor spoke

to Karl-Heinz Arndt, head of SmartWire-DT development

at Eaton, and Dr. Martin U. Schefter, Business Unit Manager

for Industrial Automation and General Manager of Eaton

Industries Holding GmbH, about customers experiences

with SmartWire-DT and further development steps in the

technology.

SmartWire-DT in Practice


4/324 SolutionS 22News

NEWS +++ NEWS +++ NEWS

Automation Award

The Automation Award is the most important prize in theautomation sector. At the 2009 SPS/IPC/Drives fair in Nuremburg,the technical publication elektro Automation of the Konradinmedia group held the Automation Award competition for particularlyinnovative products. All exhibitors at the fair were able to competewith their innovative new products. A jury made up of the VDMA,ZVEI (German Electrical and Electronic Manufacturers Association)and the editor team of elektro Automation nominated the Top10products for the Automation Award 2009 from the 78 productssubmitted. The nominated products were then exhibited at thestand of the Konradin media group over the course of the SPS/IPC/Drives fair. Visitors were then able to vote for their personalfavorites from these Top10 products. After the participation ofaround 2200 visitors at the SPS/IPC/Drives fair, the result of theAutomation Award 2009 was as follows: The winner was EatonMoeller with SmartWire-DT and 21.5 percent of the votes.

TR Award

At this years Hannover Fair, Orhan Erenberk, general managerof Thomas Industrial Media GmbH, Hattingen, presented the TRAward (www.technische-revue.eu) for a particularly innovativeproduct to Dr. Martin U. Schefter, Business Unit ManagerIndustrial Automation and managing director of Eaton IndustriesHolding GmbH and Karl-Heinz Arndt, SmartWire-DT developmentmanager at Eaton Automation.

Presentation of the TR Award 2010 to Eaton Industries for SmartWire-DT.TR editor Jrgen Wirtz, Karl-Heinz Arndt, SmartWire-DT developmentmanager at the Industrial Automation Business Unit of Eaton, Dr. MartinU. Schefter, Business Unit Manager Industrial Automation and generalmanager of Eaton Industries Holding GmbH, and Orhan Erenberk, generalmanager of Thomas Industrial Media. (from left to right)

Four Awards for SmartWire-DT From

Eatons Moeller Business

The innovative SmartWire-DT connection

and communication system for switching

devices has already been awarded four

times in one year by the European trade

press. It has received the Automation Award,

the TR Award, the Industry Prize 2010

and the ITVA Award 2010.


5/32SolutionS 22 News


Industry Prize 2010

SmartWire-DT was also awarded the INDUSTRY PRIZE 2010 atthis years Hannover Fair. For the past five years, the Karlsruhe-based publishers Huber Verlag fr Neue Medien has awardedthe INDUSTRY PRIZE for the best solutions developed byGerman industry. Highly innovative product developments andnew products are selected from companies in the industrial,supplier or service sectors. From over 400 entries in 2010, anexpert jury consisting of professors, scientists, trade journalists,sector and industry experts, assessed all the products enteredaccording to specific criteria: Innovation, effect on increasingefficiency, as well as suitability for small and medium-sizedenterprises. What was particularly outstanding was the fact thatEaton Moeller was awarded both the overall winner title as wellas the category winner for the electrical engineering sector.

The idea of SmartWire-DT has been around since the nineties.However, the technological requirements for the implementationin a compact space and at acceptable costs were not availableuntil recent years. Today, the use of SmartWire-DT by customerscouldnt be easier. My team and I are naturally very pleased thatwe have once more gained a high reputation with SmartWire-DT,Karl-Heinz Arndt explained.

Bronze at 18th ITVA Award or SmartWire-DT Thats Lie

The film SmartWire-DT Thats Life was chosen for this yearsITVA Award for exemplary audio-visual communication solutionsin the sales promotion/marketing category and was awardedthe Bronze Pyramid. The presentation ceremony took place onSeptember 24 2010 during a gala event at the Photokina trade fairin Cologne. The jury praised the clear comparison of the old, verywork intensive switch panel technology and the new SmartWire-DT technology, as well as the attractive and new interpretation ofthe evolutionary concept. The film takes up a quotation of CharlesDarwin which states that it is not the strongest that survives,but the one who is flexible and can adapt to change both inprofessional and in private life. This year over 100 companiescompeted for the much sought after Pyramid awards. The ITVAAward is presented each year by the largest association of audiovisual communication, the ITVA, and is one of the most importantmedia prizes in Germany. The 3:25 minute long film was producedfor Eaton Industries by LAKRITZ.Film GmbH in Leonberg, andfilming was carried out in Cologne and at Eaton in Bonn.

ITVA Integrated TV & Video Association e.V., Frankfurt/Main,(www.itva.eu)

5

Quicklink ID: ES2200

Karl-Heinz Arndt and Dr. Martin U. Schefter (both from Eaton Industries)receive the Industry Prize 2010.

At the Photokina 2010 the jury presentedthe IVTA Award for the film SmartWire-DT Thats Life. Bernd Crten andWolfgang Bison from Eaton Industries,Nathalie and Lambert Straub from LakritzFilm and festival manager Dr. GerhardDotzler (from left to right.)


6/32SolutionS 22News


6

XC202 with Variable IP Addresses

Highspeed PLC


Low-cost visualization with twice the performance

and an enhanced range of functions

MFD-CP10

multi-function display

Open and closed-loop control, display and operation in a compactformat: Eaton has added two new CPU modules with a 24 V DCpower supply to its MFD-Titan range. They can be fitted directlyon the MFD-80 (IP65) display units in the usual manner andfastened via two standard 22.5 mm drill holes plug & and workat its simplest. Like the tried and tested MFD-CP8.., the new CPUmodules are available as a version with easyNet (MFD-CP10-NT)or as a stand alone version (MFD-CP10-ME). Compared to theirpredecessors, which are still available, the new MFD devices havetwice the program and graphical screen memory and twice theprocessing speed. As well as a faster performance, Eaton offersthe user a host of options for more powerful programming andprogram expansion, as well as a larger number of function blocksand screen elements in a program. All MFD components can becombined flexibly with each other, thus always offering the idealsolution for the tasks at hand.

The following functions expand the range for the new membersof the MFD-Titan series: A multiplexer function block from theeasy800 series, simple scanning of the currently displayed screen,

simple language selection during operation (such as German /English) and double the number of retentive markers.

The associated EASY-M-512K memory card is designed forthe external storing of a program, such as for transporting it ortransferring to other CPU modules.

The MFD-Titan multi-function display with CPU and powersupply unit can be expanded by users with inputs and outputsin order to produce a compact HMI device. It therefore offersthe performance range of an easy800 together with powerfulvisualization features. The MFD-Titan can be connected to standardbus systems via easyNet. The customized labeling of the display

using the Label-Editor software enables the unit to be given acustomized appearance, for example with laser inscribed logotypesor affixed logos.

Eatons XC-CPU202-EC4M-XV rounds offthe high end of its XCcontroller series. TheXC202 is designed asa high performancePLC: A high-speed RSCprocessor (532 MHz)

and a larger memory (4 MB) provide considerably greaterresources for communication tasks. Compared to an XC-CPU201,the XC-CPU202 thus offers around a six to eight times fasterprocessing speed.

The high performance controller is now available and featuresan integrated Ethernet interface for programming access and

data exchange in the network. The special feature of the newcontroller is the fact that users can access it via differentIP addresses. For example, one can be configured as aprogramming port whilst another is provided solely as a datainterface. A special function allows both the IP address and thesubnet address of the controller to be defined individually. Thisenables the controller to be integrated simply in an existingcorporate network.

The XC202 fits seamlessly into Eatons existing XC range. Userscan thus utilize all the input/output modules, communicationmodules and accessories available. Either MMC/SD memory

cards or USB sticks can be used as the memory medium for data.The required operating system update (Windows CE 6.0) can becarried out via the Ethernet interface as well as via these memorymedia.

Besides the Ethernet and combined CAN/easyNet interface,the XC202 also features a serial interface. This is designed forprogramming but also as a transparent interface for connectingbarcode readers, printers or other devices. The interface can beprogrammed easily by means of a browser command for therequired mode.

The controller also comes with a web server which enablesit to be accessed via the Internet. Users can easily call up allvisualization pages created with the CoDeSys programming

software using of a web browser. This type of web visualization isalso ideal for remote maintenance tasks.

As well as the Ethernet interface (with a display of the Link/communication status) and the CANopen/easyNet interface (witha switchable bus terminating resistor), a 29-bit CAN identifier anda USB interface (2.0 Host), the high performance PLC comes witheight digital inputs and six digital outputs on board.



7/32

Unlike PKZM4 motor-protective circuit-breakers,the PKZM4-..-CB circuit-breakers are provided withlarge creepage and clearancedistances at the incomingand outgoing main currentterminals. The new deviceheight is therefore 165 mm.These changes and extensivetesting have made it possiblefor the switches to be approvedas fully-fledged circuit-breakersto UL 489 / CSA C22.2-5.09.On the PKZM4-..-CB, thecurrent flow direction can beset as required as is the casewith the entire Eaton range ofcircuit-breakers.

The circuit-breakers canbe used as branch circuit

protective devices (BCPD) in feeder and branch circuits. Theswitches can also be used for protecting non-motor loads. In orderto use the PKZM4-CB, contactors and frequency inverters must beapproved for protection by circuit-breakers. Motors will continueto be switched and protected by the Type E and Type F motorstarters based on UL 508.

Three types are on offer: Firstly PKZM4-16-CB (adjustable10 - 16 A), secondly PKZM4-25-CB (adjustable 18 - 25 A) and thirdlyPKZM4-32-CB (adjustable 24 - 32 A).

The SCCR (short-circuit current rating) of the circuit-breakers is65 kA for 480Y/277 V and 22 kA for 600Y/347 V, and they have adevice width of only 55 mm. They are consequently turning intogenuine problem solvers thanks to the high SCCR and suitabilityfor 600Y/347 V.

LOREM IPSUM DOLORNEWS +++ NEWS +++ NEWS

7SolutionS 22News

New High-End XV150 Touch Display Series

from Eaton with an Aluminum Front

Developed for the North American MarketCircuit-Breakers for Rated Currents up to 32 A


As one of the leading manufacturers of components and systemsfor electrical engineering and automation, Eatons has added 5.7",8.4" and 10.4" devices to its HMI and HMI/PLC series: The newXV150 devices with resistive touch technology and color TFTdisplay offer an optimum solution especially for the price sensitivesector and stand out for their high quality aluminum fronts withprotection to IP65, robust metal housings and an especially flatdesign.

Even basic version devices come with an Ethernet and RS232interface as well as two USB interfaces for a wide range ofautomation tasks. The 400 MHz RISC processor can optimallyhandle even demanding PLC applications in addition to HMI tasks.

The 128 MB onboard memory can be expanded if required withan SD memory card. Depending on the version, an RS485 and aCAN/MPI or Profibus DP interface are provided in addition to thestandard interfaces.

Like all visualization devices of the xSystem product groups, theXV150 can be programmed as a PLC to IEC61131-3 with theGalileo visualization software or CoDeSys visualization softwareand with the CoDeSys-based xSoft-Codesys-2 programmingsystem. Thanks to its small mounting depth, the panels can alsobe installed where users find space restricted. All display frontscan be inscribed with customer labels. The Eaton XV100 andXV150 touch displays and touch display/PLCs provide the userwith a broadly based product range for price sensitive industrial

applications. From 3.5", 5.7" and 7" devices in a light and robustplastic housing up to the high-end XV150 in a metal housing(5.7", 8.4" and 10.4") with elegant aluminum front. Furthermore,the standard, long-standing and well-tried hardware platformoffers maximum reliability and long-term available. All XV150devices are compatible with the XV400 devices of the next higherperformance class. The standard project design and programmingtool for the XV series also supports the requirements for amodular machine design.


XV-150


8/328 SolutionS 22News


SOL30-SAFETY PV Firemans SwitchThe SOL30-Safety is a DC switch-disconnector (32 A) in anIP65 enclosure. This is installed in direct proximity to the PVmodules and inserted in the DC cable to the power inverter. ThePV firemans switch has two switch positions. In the POWERposition the current is fed through from the PV modules to thepower inverter. In the SAFETY switch position, both DC cablesare interrupted the switch is also lockable, as is necessaryfor maintenance work in large solar installations. The integratedundervoltage release also enables the switch to be actuatedremotely using a PV emergency-stop pushbutton actuator. If inthe event of a fire, the fire brigade isolates the entire house fromthe grid, this automatically causes the tripping of the PV firemansswitch and thus also the isolation of the PV cables. Any dangerto rescue personnel from live DC cables in the event of a fire isthus totally removed. Eaton designed its firemans switch bothfor solar power systems in private homes, as well as for large PVinstallations on the roofs of public buildings or in agriculture.

The SOL30-Safety PV firemans switch with a 230 V, 50 Hzundervoltage release is available from Eaton in three versions,depending on the connection type required: MC3, MC4 andmetric screw coupling. The switch is tested in accordance withIEC/EN 60947-3 and is suitable for ambient temperatures up to60 C. The maximum operating voltage Ue is 1000 V DC, themaximum operating current Ie is 32 A.

New materials and technological processes allow the developmentof new and attractive solutions. This fact is also the case atEaton: The contactors for 90 kW, 110 kW and 160 kW representthe start of the new designs making them smaller, lighter andcheaper. Eaton is offering DILM185A, DILM225A and DILM300Atype contactors with an inexpensive electronic coil actuation andcompact dimensions. The contactors can be used in applicationssuch as the switching of motors to utilization categories AC-3 andAC-4 and for switching resistive and capacitive loads.

The DILM185A and DILM225A contactors have the same basearea and the same hole pattern as their predecessors. This makesit possible for all users to replace them easily. The depth, which

has been considerably reduced by 28 millimeters, results in asignificant weight reduction of over 70 percent. The new coilelectronics reduces the power consumption in sealing 30 percent.

The DILM300A contactor has a considerably smaller width, heightand depth, thus saving space in the control panel and simplifyingmounting. In addition to a smaller base area and mounting depththan before, as well as a reduced weight, the reduced powerconsumption is also a financial benefit. The contactors cannaturally control operating voltages up to 1000 V.

The design, shape and color of the new DILM185A, DILM225A

and DILM300A contactors fit seamlessly into Eatons entirecontactor range. The accessories required, such as cable terminalblock, covers and motor protective relays have been adapted byEaton to match the new designs. Naturally, the associated Z5overload relays for direct mounting or for separate mounting arestill available for these contactors. Matching covers ensure thatfinger and back of hand protection is provided.

New Contactors for 90 kW, 110 kW

and 160 kW

Smaller, lighter, cheaper and more energy efficient

Safety has top priority




9/32SolutionS 22 9

In order ensure the long-term

competitiveness of Germany as a

place to do business, it is important

to work at the base, i.e. ensure that

a high standard of education is in

place. What, however, makes up a

good education? Mechatronics trainees at the Gstrow

vocational college HIS (Mecklenburg-Vorpommern)

define good education as follows: A good education isbased in practice, combining theoretical knowledge with

practical application and giving trainees a wide range of

skills and abilities.

In the automation department, trainees were recently able to puta SmartWire-DT (SW-DT) model installation into operation. Forthis, Eaton Industries in Bonn provided the HIS Gstrow vocationalcollege with all the components required. In the course sectionNetworking automation systems the SW-DT system had to beused as an example of a passive Profibus slave with a gatewayfunction.

Together with a few trainees, Peter Kruse, specialist trainer forautomation, completed the installation: The simple demonstrationof a new technology only brings a few benefits. Product videosonly provide trainees with information but do not give them anylasting specialist expertise. After receiving my inquiry, Dipl. Ing.Heribert Einwag, the engineer responsible for SmartWire-DT atthe Electrical Sector EMEA of Eaton Industries, was immediatelywilling to provide a model installation free of charge. I thendeveloped an experimenter board with which our trainees couldcreate a training installation simply and clearly.

The experimenter board is designed so that the overview circuitwith all bus stations is shown on the front. All the devices areclearly fitted on the back. A complete covering of the rear was notregarded as practical since it is required that the trainees are ableto fit on the Profibus connection cable and also actuate the rearconfiguration button.

Thanks to the prepared experimenter board, the trainees can betrusted to carry out different experiments. The commissioningof the bus system is the first task. For this the trainees receive aworksheet with a system overview. Peter Kruse used the viewof the SW-DT-Assistant software which is ideally suited for thispurpose. The necessary steps in the Simatic Step 7 hardwareconfiguration program are also guided. By working carefully,trainees can thus create a functional installation rapidly. Accordingto Peter Kruse, trainees often unfortunately make mistakes inselecting the bus stations. The troubleshooting process should

then allow trainees to rectify the incorrect component selection asindependently as possible.

Only when the bus connection is fully set up can the trainees startto configure simple switch operations, such as implementing theswitching of lights and contactors. In later training steps they use

the feedback function of thecontactors to activate controlsignal lamps via SmartWire-

DT. This training step is usedto demonstrate the scanningof contactor states and allowscomparisons of the actual andtarget configuration.

In further training steps, thetrainees learn how to activate apneumatic cylinder. A contactorswitches the solenoid of thevalve which moves the cylinderin and out. The end positionsensors can be connected tothe IO module and thus usedin the program. For safetyreasons, electric motors cannotbe switched via the contactor,since there is no three-phasesupply available in the collegeslaboratory.

The last task, the integrationof an emergency-stopcontrol system, is implemented so that the NC contacts of theemergency-stop switch open the enable inputs of the contactors.The switching information can also be passed on to the programvia the bus. In this way, the trainees can work out the benefits ofwiring the emergency-stop circuit quickly. At the same time, theycan trip the necessary switching operations in the program withoutany further cabling required. The Safe Stop operating mode canbe indicated via the lights of the experimenter board and a signaltower.

Peter Kruse is impressed: The tasks can be increased or reducedaccording to the capabilities of the trainee. This allows virtually alltrainees to achieve success. SmartWire-DT makes this possiblewith simple handling. Course lecturer Kruse adds: Workingwith the experimenter board has proved worthwhile. The traineeshave to become acquainted with a new system and commissionthe installation on their own. SmartWire-DT is particularly suitablefor this since only a few steps are needed to set up the busconnection. The extensive preinstallation on the experimenterboard allows the users to come to successful results quickly.In this way, the practical training promotes the gathering of

experience and the development of specialist expertise trainingat its best. Thanks to the kind support of Eaton Industries we havebeen able to integrate a valuable module in our training syllabus.

Gstrow Vocational College Uses

SmartWire-DT Model Installation

SmartWire-DT


APPLICATION


10/32SolutionS 2210

Solar Power StationsPrototype of a Parabolic Trough Solar CollectorUses Air as Heat Transfer Medium

Todays parabolic trough power plants use either steam,

thermal oil or liquid salt as a circulating heat transfer

medium. However, these types of media have the

disadvantage that they circulate in the solar field at high

pressure. In the event of a leak therefore both persons

and the environment are at risk. For example, around

one million liters of thermal oil are used for a 50 MW

power stat ion.The Swiss company Airlight Energy Manufacturing SA based inBiasca designed quite a revolutionary concept for how electricalenergy can be generated from the sun in future using parabolictrough power plants in an environmentally safe way and witha high level of personal safety. Based on current calculations,

an area of 600 x 600 km would be enough to cover the totalworlds energy requirement. Large desert regions in northern andsouthern Africa, in Mexico, the Arabian Peninsula, as well as someregions of India and Australia would be suitable for locating largepower stations.

Airlight Energy chose air as the absorber medium and can thusmake use of two particular benefits: Air enables temperaturesof over 600 C to be reached, and also the use of air as the

heat transfer medium provides the option of storing the energyrecovered in a store filled with pebbles. At night the flow directionis thus simply reversed and the stored heat is taken from thepebbles. In this way, solar energy can be generated as needed.

With this development, Airlight Energy is working to achievetechnological simplicity, reduced costs and to increase the overall

APPLICATION


11/32SolutionS 22 11

efficiency of the parabolic trough power plants. Andrea Pedretti,head of technological development at Airlight Energy, explainedthat the basic idea arose in a phone call from a student inAustralia, who asked how it might be possible to use membranesfor solar collectors.

Virtually perect parabola

The suggestion proposed in the form of a question gave theinitial spark: A parabolic reflector could be built from a coated,expandable membrane made from Mylar film. This enables

solar energy to be produced reliably and cost-effectively inpower stations. The basic concept included the simple ideaof using air pressure to shape a foil fixed at both ends into aperfect curvature. However, the air pressure applied to thereflector foil required an enclosed space, i.e. a cover foil thatspanned over the collector. The pressure chamber thus formedis pressurized to a few millibars using a variable speed fan.The cover foil is made from a transparent, low refractive ETFE(ethylene tetrafluoroethylene) material offering high light and UVpermeability as well as a low tare weight. A silicon fiber glassfabric is tensioned onto the base structure to thus produce a2-volume-pillow system. Thanks to further innovations fromAirlight Energy it was possible to achieve an almost perfectparabolic curve that ensures a high radiation concentration ontothe receiver.

High innovation partnered by specialists

As an additional step, Airlight Energy developed its own supportingstructure: The use of light precast concrete elements on sitesignificantly eliminated the maintenance work required. This allowsthe supporting structures to be rotated on the foundation withvery little energy required. The mirror can track the position of thesun precisely at any time thus ensuring optimum use of the sunsradiation. Data from NASA as well as from meteorological stationsis used and evaluated in the main computers in order to calculatethe optimum inclination of the collector. At wind speeds over25 m/s, the collector is moved into the safe horizontal position.

The R & D work is partnered by specialists from the SUPSItechnical university in Tessin, the Swiss Federal Institute ofTechnology Zurich (ETHZ), as well as the Paul Scherrer Institute.The project is also supported by the Swiss Federal Office of Energy.

A test programme is currently being completed at the installationsite of the 3rd prototype in Biasca, where the relevant data isalso being collected and the mathematical models validated. Allessential indicators such as temperatures in the collector andin the storage bed are recorded, documented and visualized onscreens in the control room.

Reliable miniature circuit-breakers andresidual current devices

Eatons Moeller business supplied miniature circuit-breakers andRCD devices (PLSM and PFIM), as well as EMR4 measuring andmonitoring relays and an NZM2 circuit-breaker which is used asa main switch. The main task of the products was to monitorthe cables and systems for overcurrents or short-circuits. AirlightEnergy awarded the contract to Eaton due to the impressivefeatures of the overall package: the high standard of finishing andmaterial quality of all products; the fast mounting of the miniaturecircuit-breakers and residual current devices in the control panel thanks to the busbar system for Xpole devices; their versatilerange of application options; their comprehensive range ofapprovals and in no small part the global service provided by Eaton.

INfO

The Company: www.airlightenergy.com

Products: PLSM miniature circuit-breakerPFIM residual current circuit-breaker

Quicklink ID: ES2208 [www.moeller.net]

Airlight Energy Holding SA andits subsidiary Airlight EnergyManufacturing SA, based inBiasca/Switzerland was foundedin January 2007 by five Swissprivate investors who financed theinitial development phase. Anotherinvestor joined the companyin May 2007. Airlight Energy

pursues the aim of finally beingable to create an environmentallyfriendly and economical systemof producing electricity from solarenergy. The project is supportedby the Swiss Federal Office ofEnergy.

PLSM miniature circuit-breaker

Features: Contact position indication, red - green,terminal aid, protective cover, three-position latching slide,rated currents up to 63 A

PfIM residual current circuit-breaker

Features: Complete type range of compact residual current circuit-breakersfor residual current and additional protection, large number of ratedcurrents available, real contact position indication


12/3212

SolutionS 22

SmartWire-DT Controls Packaging MachinesPack ItGillenkirch Packaging Systems is a family business based in Dinslaken that develops and produces sorting and

packaging plants and systems for the fruit and vegetable market worldwide, such as for the processing or freezing of

potatoes, onions, carrots, tomatoes, apples or citrus fruits. Gillenkirch machines and systems are offered as bespoke

customer solutions and meet rigorous requirements in terms of capacity and hygiene. Specially developed processes

ensure that products are handled quickly and gently and thus secure product quality during the entire

packaging process.

Optimally eicientswitchboard design:

All motor starters were snap fittedto the vertically installed busbarsystem using busbar adapters. Thecontrol system was implementedwith SmartWire-DT. The otherwisestandard terminal strip was notrequired since all motors wereconnected directly to the motorstarter.

APPLICATION


13/3213

INfO

The Company: www.gillenkirch.com

Products: SmartWire-DT, PKE motor-protective circuit-breakerMSC motor starter, XC200 modular PLCM-Max frequency inverter


The latest example is an installation designed as a completesolution for a Swiss customer. The potatoes supplied locally bythe growers are first tipped into a silo, from where conveyorbelts take them to a washer and move them finally to a polishingand drying system. Before the potatoes are stored in the silo,they are put through a quality control. The potatoes are takenfrom the different silos for particular varieties and fed to a scalesand packaging machine. The entire process is controlled andmonitored by a process control system.

The core of the control system is made up of an 8 meter wideswitchboard containing the following Eaton components: circuit-breakers and motor-protective circuit-breakers, contactors,

compact PLCs, the SmartWire-DT connection and communicationsystem as well as frequency inverters and soft starters.

The open-loop and closed-loop control of system sections isimplemented with the XC200 modular PLC which is connectedto the system via its integrated Ethernet and CANopen interface.The data is exchanged with the touch displays and the higher-level control system via Ethernet. The fieldbus level is addressedvia CANopen. As a special feature, all 270 contactor-controlleddrives use PKE/SmartWire-DT to provide current measuring forpreventative maintenance. In order to shorten installation times onsite, all motor feeders are fitted with plugs which can be pluggedonto the contactor directly without any intermediate terminal strip.

Gillenkirch developed a metal support especially designed forfastening the motor cables in the switchboard so that 60 motor

starters can be assembled compactlyin each section. The modular approachnot only reduces mounting times in theworkshop, but also simplifies the writing offuture quotations.

In order to work with as many identicalparts as possible when assembling theswitchboards, Eatons value added logisticsfitted the motor starters with a standardcontactor size on the busbar.

The exchangeable bimetal block of thePKE could be fitted at a later time after themotor list is approved by the end customer.This enables the drives to be pre-installed even without a knowledge of the exactcurrent values so that the system couldbe shipped quickly to the Swiss customer.

All controlled drives are implementedvia frequency inverters of the M-MAXseries, which are also connected to themodular PLC via CANopen. These havethe task of optimally adapting the conveyorspeeds and water volumes to the relevantproduction process.

The PKE enhanced with SmartWire-DTenables all switching states of thecontactors and motor-protective circuit-breakers to be signalled and shown in thehigher-level production control systemwithout the need for complex wiring. Pre-assembled cables/connectors are used for

the connection between motor starters and SmartWire-DT thuseliminating the need to use a screwdriver 3240 times, as requiredfor 270 drives using the conventional method.

The combined assembly of the control cables with the powersupply in the SmartWire-DT system also results in an increasedPerformance Level as the energy for the individual drive is isolatedtwice as it were in the event of an emergency-stop: A 65 Acontactor disconnects the supply conductor to the 400 V AC maindistribution busbar and the motor contactor is also switched offby disconnecting the power supply from the 24 V DC network ofSmartWire-DT.

Thanks to the high short-circuit rating of the PKE motor-protectivecircuit-breakers, an additional back-up fuse was unnecessary. Theconsistent use of the bus systems down to the field level andthe extensive modular design result in a significant reduction incosts equally in terms of design, mounting and quotations aswell as in terms of shorter delivery times.

CONCLUSION

Oscar Manteca, partner at Gillenkirch had this to say: Weset high standards in quality, reliability and service for allsystem sections. Innovations such as SmartWire-DT help usto continuously further develop our product range and keepit in line with the latest state-of-the-art. As we were ableto impressively reduce the installation times, it was evenpossible to supply the system described here before theagreed date. The integrated current measuring of all loadsenables the direct signalling of different load states on theprocess control system. The system operator carries out any

optimization online and thus avoids production downtimes.We are very satisfied with the new SmartWire-DT solution.

Gillenkirch Packaging SystemsGmbH is a family businessbased in Dinslaken (North Rhine-Westphalia). Since the seventiescomplete sorting and packagingsystems have been developedand manufactured for the fruitand vegetable industry, withapplications worldwide. Gillenkirch

is taking up the challengeof offering top products forworldwide use with customizedproducts and systems.

PKE motor-protective circuit-

breakers with SmartWire-DT

technologyMotor starter combinations with PKE together with SmartWire-

DT allow integration into the automation world: The modular

PKE-SWD-32 COM interface is used to implement differentsignalling functions such as diagnostics, status or overload signals,

as well as the actual current flow of the PKE. The data can be

transferred directly to the controller and is made available to the

entire installation. The data transparency thus created increases

the efficiency and operational reliability of the drives in the areaof the motor-protective circuit-breaker. PKEs integrated in the

SmartWire-DT system increase system availability by transferring

process data, reduce the wiring in the control circuit and save

time-consuming troubleshooting during commissioning andmaintenance.

SolutionS 22


14/32SolutionS 2214

Mediterranean Lifestyle

Eaton SmartWire-DT automates a grape pressing systemfor Italian wine production

Its a well-known fact that wine, bread and olive oil are some of the essential foods in southern countries like Italy

things that help to make up the Mediterranean lifestyle. Italy is one of the major wine producing countries in Europe,

with more than 60 million hectoliters of wine being produced in an area of over 908,000 hectares (as at 2000). The

Italian company Pimmel Automazioni uses Eaton automation technology to ensure the high level of quality in

wine production.

Pimmel S.r.l., an Italian company based in Gaiarine Treviso, startedin 1986 with heating control concepts for wine production and forthe production of sparkling wine in autoclaves. Control systemswere also developed for other phases of the wine making processsuch as feeding, grape pressing, the filtering and stabilizing ofproduction processes. The company now primarily develops

highly specialized electrical systems and automation solutionsfor industrial and building applications. Nowadays, Pimmel meetsevery customer need, from the traditional electrical system up tothe management of electrical systems and machines equippedwith high-tech automation controllers and personal computers.

APPLICATION



Highly eicient processing

The automation of a new grape press had to be implemented ina winery plant. This required the control of the grape washing

plant, the grape feeding system and the control of the valves fordistributing pressed wine. In addition to this, the end customersplaced considerable importance on the ability to monitor theentire system, to document all operating phases automatically, tomanage alarm messages and to archive process data. A furtherrequirement was the integration of the automation solution in thecustomers own IT infrastructure, in order to ensure a seamlessdata flow from the process level right up to management level.

Outstanding automation solution

The automation system consists of three units an operatorpanel, a main panel and three secondary panels. The core of thisautomation solution is made up of PLCs, touch panels with agraphical user interface, as well as Windows-compatible software.Thanks to the special software solutions developed by Pimmel,the customer can monitor the entire installation, track all operatingphases precisely, manage alarm messages and archive dataprocesses. The operator panel consists of a field of pushbuttonactuators, an IPC with a 17" screen for monitoring the system anda 3.5" XV-102 touch panel.

The main control panel manages the entire power section forthe stemmer-crusher machines and those for stalk and vinasseextraction. The three secondary panels house remote I/Ostations which control the electropneumatic valves of the productsorting section and the mashing and sanitization section. Thecommunication between the main panel and the three peripheralpanels is implemented via CANopen.

Pimmel has already been relying on the automation devices ofMoeller and Micro Innovation for several years. Both companiesnow belong to Eaton, a leading global power managementcompany worldwide. Pimmel uses the remote I/Os of the XI/ON series, HMI/PLCs of the XV series, as well as low-voltageswitchgear such as circuit-breakers and motor starters.

Inside the main panel, a XION remote I/O station is used for theacquisition and management of all the signals coming from theprocess. The higher rated motors above 7.5 kW are fed from SLXfrequency inverters, while M-MAX frequency inverters and DS4soft starters are used for all the other smaller motors.

Pimmel also chose Eatons SmartWire-DT intelligentcommunication system for switchgear and control circuit devices.All motors and the pushbutton actuator field on the operatorpanel are controlled via SmartWire-DT, since the key benefitof SmartWire-DT results from the elimination of control circuitwiring and simpler commissioning and engineering. Several

price evaluations verify SmartWire-DT as a significant meansof reducing the otherwise usual assembly and wiring costs by more than 60 percent. This also reduces the high projectengineering requirements for the PLC I/O modules. SmartWire-DTalso enables a more compact panel design.

Users are impressed by the very simple SmartWire-DTtechnology: Without any additional and special automation know-how, every slave on the SmartWire-DT line can be automaticallyassigned an address on the gateway at the push of a button, inthe order of the slaves connected. The individual slaves, such ascontactors or indicator lights are not activated until the addressis called. The maximum length of the SmartWire-DT bus is 600meters inside or outside of the switching cabinet, connectingup to 99 slaves. Pimmel was also able to considerably simplifyall wiring and testing processes for the automation of its grapepress plant thanks to the flexible and easy-to-use SmartWire-DT communication system. This includes clear status LEDs thatare integrated in all connected SmartWire-DT slaves. Pimmelcustomers, whether from Italy, Europe or overseas, gave an

extremely positive response to the use of SmartWire-DT.

INfO

The Company: www.pimmel.it

Products: SmartWire-DT,HMI/PLC XV-102,SLX and M-Max frequency inverters


Pimmel S.r.l., an Italian companybased in Gaiarine Treviso, wasfounded in 1987 and primarilyoperates in the field of highlyspecialized electrical systemsand automation solutions. Thecompany covers here both theindustrial and the building sector.With its extensive know-howPimmel offers fully developedsolutions on the market that

meet virtually every requirement

in the production process. Thecompany guarantees top productquality standards through heavyinvestments in new productiontechnologies. It also offersexcellent pre-sales and post-salesservices. Moreover, Pimmelfosters an optimum workingenvironment for its keen andconscientious employees as wellas the further development of a

quality culture.


16/3216

Photovoltaic RoofsAlways Tracking and Facing the Sun

Farmbau Fertigsysteme is a company that has now developed the Vario Sun House,

a house with an adjustable photovoltaic roof, having already developed the rotatable

photovoltaic Sun House that fully follows the position of the sun. The Vario Sun

House follows the course of the sun on two axes the inclination and the cardinal

direction. Unlike the rotatable Sun House, the building stays in the same position

and only the roof changes its angle. The Vario Sun House is either supplied asa bungalow with a flat roof and roof garden or with a second penthouse floor

and roof garden area that is easier to integrate. For all its control components and

corresponding automation software Farmbau relies on top quality and cost-efficient

technologies from Eaton.

APPLICATION



Photovoltaic systems use virtually every ray of the sun to turnits energy to electricity and thus to financial benefit. Buildingswith a monopitch roof construction produce a large usable areafor installing modules. The autotracking of the photovoltaicarea will then obviously produce a higher yield. With Farmhausprefabricated systems, owners themselves decide whether theroof is to be fitted with standard, high performance or partiallytransparent glass modules, thus determining the possible financialyield. Farmhaus offers the Vario Sun House in a range of sizes andwith different features.

The entire roof area of the Vario roof is moved hydraulically usingfour cylinders. A lattice girder system transfers the static forcesinto the four fulcrums. Two cylinders are moved in on eachfulcrum and stabilize the system. The other two cylinders tilt theroof according to the position of the sun, following the cardinaldirection in three stages, east, south and west.

The building envelope is state-of-the-art: effective thermalinsulation, modern heating systems, unrestricted scope for designand a square ground plan for optimum room utilization with smallexterior wall areas. The photovoltaic roof above the building alsoprotects the roof garden and creates additional usable space.

High perormance designed cost-eectively

The precise control of the entire roof area according to the courseof the sun is implemented with a compactly designed HMI-PLC the XV100 (XV-102-D6-57TVR-10-PLC) Micro Panel. The high-performance PLC integrated in the XV100 touch panel handles thenecessary complex calculations of the suns position, and guidesthe Vario roof from east to west following the sun. The proveneasy800 modules are used as cost-effective I/O.

With the XV100 (5.7 inch widescreen TFT color display withresistive touch technology) deployed here, Farmhaus is usingthe Compact class offering maximum performance in a smallformat. With its robust design, the XV100 not only offers a fully

developed operating unit but also a high performance: a powerful400MHz RISC processor, onboard memory of 128MB, expandableas required with an SD card, a small mounting depth, Ethernetinterface onboard, also CAN, Profibus, RS232 or RS485 as anoption and also a USB Host interface (from 5.7" display size).

Users value the tried and trusted easy800 I/O modules dueto their simple networking capability: This allows up to sevenmodules to be connected on the XV panel via the easyNet, thuscreating up to 280 I/Os. Their small standard front dimensionsenable them to be mounted in subdistribution systems. They areavailable in AC and DC versions that can also be used together.The maximum expansion in the easyNet is up to 1000 meters.

Visualization with Galileo

Galileo is an easy-to-learn, and nevertheless powerful andcomprehensive project design environment, ideally suited forall machine and process-oriented applications in system andmachine building. With its non-sector specific design, Galileooffers seamless project design for all graphical operator unitsfrom the Eaton HMI product range as well as for PC single-usersolutions. Galileo always provides the project designer withthe full functionality without any graduated restrictions on tags(variables) or screens, according to the performance specificationsof the panel used.

Galileo can be connected simply and safely to both the controllevel or the office world. With this full range of functions it ispossible to fulfill virtually any wish: Drag & drop positioning(wysiwyg) of the objects, simple object parameterization,enhanced password handling with complex password and agingfunction, comprehensive recipe handling, alarm handling (withtime stamp, history and diagnostics support with picture display),convenient series assignment of texts and pictures to variables,many graphical objects (such as bar graph, slide adjuster, graphplotter, curve chart, camera etc.), dynamic switching of units ofmeasure, direct printing on the panel (reports, forms), import of15 different picture formats, simple import of PLC tags, onlinelanguage change, Unicode support (also Asian character sets), textimport/export in XML format (e.g. Excel).

CONCLUSION

Christian Vetter is the owner of Vetter-Steuerungstechnik, anew company based in Pfinztal-Sllingen that has establisheditself on the market in the field of controllers, visualization,PLC programming and consulting for special machinebuilding. He had the following to say: We have handledand programmed the project. The XV100 touch panel andlikewise the products of the easy series are ideal for theVario Sun House from Farmbau. The automation offers highperformance and is exactly dimensioned. With easySoft forrelays and easySoft-CoDeSys as a runtime environment,we have two powerful programming interfaces with manyready-to-use function blocks. They simplify our programmingrequirement and thus reduce development costs.www.vetter-steuerungstechnik.de

INfO

The Company: www.farmbau.eu

Products: Touch display PLCeasy800 control relayXV100 visualization, Galileo


Farmbau Fertigsysteme GmbHis based in Langenburg and wasfounded in 1997 by WolfgangMaier. Success started with roundreinforced concrete tanks, forwhich an infinitely variable roundshell was developed. Farm shedbuildings made from thermallyinsulated concrete sandwich panelstructures represent anothersource of business. These were

gradually optimized and also

adapted for office buildings, hallsand private homes. Today theSun House and the Vario SunHouse now represent milestones.Farmbau places importance on itsown know-how, ranging from thepre-assembly plant in Insingen,the planning office, the staticsdepartment, right through to thecompetent team, that offers thestate-of-the-art building.


18/32SolutionS 2218

Beer is a drink enjoyed all over the world. It has a tradition that goes back centuries. In Germany, the use of pure

ingredients for top quality brewing was ensured very early on with the Bavarian Purity Law of 1516, which stipulated

that only water, hops and the malt produced from barley could be used in the process. Whilst beer is currently

enjoying an increase in demand, it is nevertheless produced as a bulk product. However, many beer lovers appreciate

a more individual taste. This is why Pico brewing systems allow you to brew virtually any beer yourself using the same

methods as the small craft breweries. Highly reliable Eaton components are used for the visualization, operation and

control of the Pico brewing systems.

The ProDesign consultant engineers based in Tuttlingen specialize

in the design and development of machines, special machinesand complete production systems, as well as in the developmentof compact brewing systems for the catering sector. Two homebrewing systems are currently available the Pico 50 and Pico150.The two sizes differ primarily in the yield per brewing process:The Pico 50 EP offers customers 50 liters of yield per brew, whilstthe Pico 150 EP offers 150 liters.

Stylish high-end compact brewing system

The Pico compact brewing system is a dual component brewingsystem in a stainless steel frame, consisting of two partiallyintegrated stainless steel containers which serve as a brew kettleand straining vat. The visible area of both containers is lined incopper. Their removable lids are designed as wrought coppercovers, one of which is provided with a small double-door opening.

All horizontal surfaces are made from 20 mm granite blocks. Thefront of the system is made from 1.0 mm copper plate (partiallyreinforced), whilst the sides of the system are made from 1.5 mmstainless steel. The frame is fitted on four heavy duty castors(two fitted with a brake). The system is provided with outgoingconnections, one for the electric current and one for filling thewater tank. The internal piping is made from stainless steeland food-safe flexible steel tubing. Both Pico systems comewith an integrated automatic mash and boiler unit which can beprogrammed with a touch panel.

High perormance HMI-PLC

Pico brewing systems rely completely on the products of Eaton foropen-loop and closed-loop control. A high performance HMI-PLCXV100 is used, either with a 5.7 or 7 inch widescreen TFT colordisplay with resistive touch technology (front protection to IP65).An XV400 with a stainless steel front (IP69k) could also be used ifrequired.

This HMI-PLC of the XV series forms the core of each Picobrewing system. The controller integrated in the panel (400 MHzRISC processor) runs on the easySoft-CoDeSys programmingsystem. CoDeSys Target Visu is used for the visualization.easySoft-CoDeSys combines open-loop/closed-loop control and

visualization in one software system. The Eaton XV panels usedin Pico brewing systems support CoDeSys Target Visu and Galileo(optional CoDeSys Web-Visu) visualizations.

Pico Breweries

Brewing Beer Yourself

APPLICATION



Visualization combinable as required

Galileo: Eatons interactive visualization tool is an easy-to-learnand nevertheless powerful and comprehensive project designenvironment. With its non-sector specific design, Galileo offersseamless project design for all graphical operator units from theEaton HMI product range as well as for PC single-user solutions.Galileo always provides the project designer with the full

functionality without any graduated restrictions on tags (variables)or screens, according to the performance specifications of thepanel used.

CoDeSys Target visualization: For the visualization objects ofa project the CoDeSys programming system creates ST code(structured text) which can be loaded onto the controller togetherwith other program blocks. If the functions are supportedcorrectly, the visualization can be started directly on the controller.

CoDeSys web visualization: This enables the visualization objectsof a project to be processed so that they can be loaded onto thecontroller in XML format. An integrated web server processes thecontroller data likewise in XML format and continuously refreshesthe visualization displayed. Any other computer with an Internetconnection can then access the visualization via a web browserregardless of the platform, for example for remote maintenancetasks.

easy800 or the I/O level

An easy800 can be connected simply and conveniently to thepanels of the XV series via easyNet. The CAN-based protocolis event-triggered and also offers a very high transfer speedeven with low baud rates. On the face of it, the idea of usingan easy800 for the I/O level of the Pico brewing systemsseems somewhat unconventional, since the easy800 itself is

an intelligent control relay. However, the easy800 offers someimpressive benefits: An excellent price/performance ratio, 12inputs (of which four can be used as analog inputs), 8 outputs(of which one can be used as an optional analog output), high-speed inputs up to 5 KHz (high-speed counters, frequencymeasuring, incremental encoders) and last but not least intelligentpreprocessing.

CONCLUSION

The general manager of the ProDesign GmbH engineeringconsultants in Tuttlingen, Dipl. Ing. (FH) Markus Salvermosersums up: We wanted a controller for our Pico brewingsystems that offered simple and clear operation, visualizationand control in equal measure. After all, our customers arebeer enthusiasts and not control engineers. Furthermore,we wanted highly reliable components to ensure long-term satisfaction for our customers. All Eaton components,whether they are XV panels with easySoft-CoDeSys oreasy800, meet these requirements at attractive prices.Eaton employees gave us expert support with our projects,

including the first test systems. Eaton products have nowbeen successfully used in series production with flyingcolors.

INfO

The Company: www.picobier.de

Products: Touch display PLC XV100xSoft CoDeSys


The Tuttlingen-based engineeringoffice ProDesign GmbH wasfounded in 2007 and designsand develops (special) machinesas well as complete productionsystems, particularly in the foodand medical technology sectors.Its development, design andproduction know-how are based onthe many years of experience of

its employees. The construction ofcompact brewing systems for thecatering sector was an additional,and yet important and constantlygrowing area of the company.


20/32SolutionS 2220

State of the ArtMotor and Pump Test Bench with SmartWire-DT

The company Dipl.-Ing. Kgel & Ernst & Co. GmbH

based in Sinzheim is fitting Eatons SmartWire-DT in its

own motor and pump test benches which it uses forin-house requirements. The SmartWire-DT connection

and communication system is used for controlling the

test bench. In addition to the basic functions, the test

bench is said to also serve as a showcase installation of

the in-house panel building department. The test bench

can thus also be presented to potential customers as an

example of state of the art efficient panel building. At

present SmartWire-DT is already being used to evaluate

analog values (currents and load) in the PLC from NZM2

circuit-breakers and PKE electronic motor-protect ive

circuit-breakers.

Kgel & Ernst operates in the field of repair and maintenance ofelectric motors, generators, servo drives, lifting equipment, pumps(drives) as well as in the construction of transformer stationsand industrial controls (energy / automation technology). Themotor and pump test bench designed as a showcase installationsuccessfully handled a wide range of test tasks. Different rotaryconverter sets and a rotary transformer are switched alternativelyto a test outlet. The voltage, current and frequency are measuredat the test outlet itself. Flow and pressure are additionallymeasured on the pump test bench at six different measuringsections. The pump test bench is designed for machines up to1200 kW.

The showcase installation has a decentralized structure. Thecontrol panel with the SmartWire-DT components is thus locateddirectly at the converter sets on the upper floor, thus allowingshort power connections between these and the control panel.

The control is implemented via SmartWire-DT with a Profibusinterface to the central PLC, and a touch panel is connectedvia Ethernet. The test stations are located in a hall on theground floor, the pump test bench is located in the coveredcourtyard area.

APPLICATION



The test bay is controlled by means of a mobile touch panel withfunctions for: selecting the test station, switching on the requiredrotary converter set, increasing the voltage as required, displayingthe required measured values, writing the required measuredvalues (e.g. voltage/current over time or pressure over flow rate)and documenting the test results in a database.

SmartWire-DT simple and cost-eective

Kgel & Ernst chooses its main suppliers carefully and negotiatestrusted and long-standing collaborations as well as a continuoustransfer of know-how regarding technical developments. Thefitting of SmartWire-DT in its motor and pump test bench wastherefore a logical step for Kgel & Ernst. For this variousDILM contactors, NZM circuit-breakers and PKE electronicmotor-protective circuit-breakers were used. These all have aSmartWire-DT connection.

As the example for connecting a motor starter combinationwith the PKE electronic wide-range overload protection shows,Eaton implements standards that were specially tailored forSmart-Wire-DT: The PKE-SWD-32 function element enables usersto integrate MSC-DEA motor starter combinations up to 32 A /15 kW in the SmartWire-DT system. As well as activating themotor starter combination via SmartWire-DT, the function elementtransfers all relevant information about the motor branch circuit,such as motor current, thermal motor load, switching states, tripindications (e.g. overload, short-circuit, phase loss) and muchmore.

The PKE-SWD-32 function element therefore replaces the controlwiring with the integrated control of the motor starter combinationand detects the switching states of contactor and motor-protective circuit-breaker alike. In this way, additional auxiliarycontacts are not required. The PKE-SWD-32 also eliminates theneed for external current transformers. Process failures can alsobe detected early thanks to the motor load data transferred. Inall users are provided with an optimum overview of the motorbranch circuit since all parameters set are transferred, such as Irvalue, tripping class (CLASS) or type of PKE trip block.

The integrated manual/auto switch enables either the manualor automatic control of the motor starter. The selectable ZMRoverload relay function (automated off and on switching ofthe contactor in the event of an overload) is used for the fastrestarting of the motor after overloads.

SmartWire-DT can also communicate directly with compactcircuit-breakers as well as control circuit devices and motorstarters. For this the NZM XSWD-704 module is used. Controlcircuit devices with 1-bit data can be controlled in exactly thesame way as circuit-breakers with 32-byte data. All NZM 2/3/4

circuit-breakers with an electronic release can be connecteddirectly to SmartWire-DT via the NZM module. Power distributioncurrents up to 1600 A are thus within the access range ofSmartWire-DT.

INfO

The Company: www.koegel-ernst.de

Products: SmartWire-DT,HMI/PLC XV-102,SLX and M-Max frequency inverter


Lukas Kgel and WolfgangErnst founded the companyElektromaschinenbau Dipl.-Ing.Kgel & Ernst in Baden-Oos in1955. At the beginning of 1994,the founders handed over allcompany shares to Hannes Kgel,who assumes sole corporatemanagement. Kgel & Ernst,based in Sinzheim, has beenauthorized for a long time to

repair explosion proof machines.

The company has developed tobecome a competence centerin the central Baden area forcustomer-oriented solutions fordrive engineering with motors,pumps, system building, frequencyinverters, transformer stations andpanel building, control engineeringand automation.

CONCLUSION

Hannes Kgel, general manager of Dipl.-Ing. Kgel & Ernst &Co. GmbH summarizes: Our company has already wonseveral distinctions. Customer-oriented behavior, transparentworking procedures, and motivated, qualified personnelform the foundation of our success. We chose SmartWire-DTbecause we see ourselves as a competence center and rely

on innovative technology. The evaluation of the currentsand the thermal load from NZM2 and PKE is an extremelyinteresting feature for the control of our motor and pump testbench. The data can be evaluated in the PLC very easily andeconomically with SmartWire-DT.


22/32SolutionS 2222

Mnsterland BreweryxEnergy Ensures Optimum Availability

Since the founding of the brewery there have naturally beenseveral changes and new products, in addition to the main brandof smooth bitter Rolinck Pilsener, which is still on offer. Today the

traditional brewerys range now includes alcohol-free pilsner, AlexRolinck fine lager beer, a beer cola mix (Bastard) and the caloriereduced Rolinck Radler shandy beer. With these brands, thebrewery is able to meet the changing demands of its customersin terms of quality and taste. Rolinck has been part of theKrombacher brewery since 2007 and not only brews its regionalWestphalian regional beer. All Krombacher bottles destined forexport are bottled at Rolinck, and this includes the share of maltbeer which Krombacher sells in collaboration with other breweriesunder the brand name Vitamalz.

System installation with no delays

An extended product portfolio as well the increased productionvolume called for new concepts in the energy supply of the

production plant. Whilst the BBCpower distribution system in placeat the Rolinck plant in Burgsteinfurt

since 1974 still supplied powerfor the production machines, itwas increasingly more difficultto connect new consumers, letalone ensure the long-term 24h availability of the plant. Additionalproduction machines ultimately made it necessary to install a newpower distribution system. The old installation was designed asa TN-C system. Today many consumers in the production areahave a 5-pole connection. On the other hand, old machines(power outgoers) are still designed as four-pole systems with aconventional PEN conductor, Markus Wietkamp, head of electricalinstallations at Rolinck, explained. For this reason, the new xEnergysystem is designed as a TN-C-S system with a PEN and a PE rail.The aim is to achieve a gradual changeover to an EMC compliantinstallation in the TN-S system. For this purpose, the PEN bridgewas removed and the PEN labeled as a neutral rail.

The Rolinck brewery based in Steinfurt can look back on a long tradition: The clarinetist

Alexander Rolinck (1782-1849) was appointed to court musician and cup bearer of

Prince Ludwig of Bentheim-Steinfurt in 1800. From 1820 onwards, he dedicated his

life to his new passion the brewing of beer. In order to meet the requirements of the

continuously growing production process, a new and highly reliable energy distribution

system was critical. xEnergy was chosen with its high level of availability.

APPLICATION

Key eatures o the xEnergy main distribution system

5-polewithPENandPErail,

1000 A main busbar system

Incomersectionwith4size

2 low-voltage h.b.c. fuseswitch-disconnectors

1000Aincomersectionwith IZM drawout air circuit-breaker

Outgoingsectionwith

15 x Sz. 00, 1 x Sz. 2 low-voltage h.b.c. fuse switch-disconnectors

Outgoingsectionwith

20 x Sz. 00, 1 x Sz. 2 low-voltage h.b.c. fuse switch-disconnectors

Outgoingsectionwith5x Sz. 00, 4 x Sz. 1, 1 x Sz.

2 low-voltage h.b.c. fuseswitch-disconnectors

Reservespaces

Powerfactorcompensation



CONCLUSION

We are able to connect additional consumers withouthaving to isolate the system an outstanding benefit of thexEnergy system for us, Markus Wietkamp, head of electricalinstallations at Rolinck, explained. With our old system,we would have had to disconnect the entire panel and thenreconnect which meant in effect that we would have hadthe trouble of restarting the entire production process. Thisis why the xEnergy system was for us the only option,Wietkamp added.

INfO

The Companies: www.rolinck.dewww.uhlenbrock.org

Products: xEnergy low-voltage power distribution systemP switch-disconnector


In order to ensure as seamless a production flow aspossible, the conversion phase was completed quicklyand sufficient pre-production was carried out before theinterruption. Anton Uhlenbrock GmbH, a company with along-standing partnership with the Rolinck brewery, wasawarded the contract to install the system. The closecollaboration was focused on the refurbishment of electricmotors. This also however involved the electrical installation,the compressed air conditioning and the energy distribution.Thanks to xEnergys modular and flexible design, wewere able to install and commission the xEnergy systemat Rolinck in a very short time, Rolf Hundeler electricalinstallation foreman at Uhlenbrock explained.

xEnergy sae energy distribution up to 4000 A

xEnergy provides panel builders with a freely combinableproduct range for power distribution systems up to 4000 A.The system is a modular design and allows for a host ofintelligent combinations. Switching and protective devices,as well as the associated mounting system and enclosurecomponents are perfectly matched and form a technical andeconomical unit.

The system platform allows individual project design,maximum flexibility and fast assembly in the workshop.Expanding the modular system in order to meet growingrequirements is easy and quick, thus making it future-proof.The modular system integrates exactly tailored functionmodules that are type tested to IEC/ EN 60439, with Form1 to Form 4b internal partitioning, and complies with therequirements of European and local installation standards(DIN, VDE, CEI, NF, UNE). Panel builders are provided withefficient tools for all stages from planning, to quotations rightup to ordering. The documents and the switchboard frontview are printed out with the order. If required, Eaton cansupply the entire range packed in functional flat pack unitsor as a pre-assembled switching cabinet. Documents for the

installation also come with detailed assembly instructions.

Rolinck has been brewing pilsner inSteinfurt/Munsterland since 1875,and this is still the main brand ofthe brewery today. In January 2007,the A. Rolinck private brewerywas sold to Krombacher, one ofthe largest private breweries inGermany.

Anton Uhlenbrock GmbH basedin Steinfurt is a company servingthe industrial sector for industrialinstallations and machinebuilding. Uhlenbrock handles allproject phases such as planning,commissioning, maintenance andmodernization.


24/32SolutionS 2224

The Moscow-based Russian minerals and chemicals

company MCC EuroChem OJSC (EuroChem) gave Thyssen

Schachtbau GmbH the contract to sink the approx. 1,1180

deep production shaft of the Gremjatschinskij potash

deposit. The potash mine at the Gremjatschinskij

deposit is located in the Kotelnikovo district of RussiasVolgograd region, about 170 km south-west of Volgograd

and some 20 km to the north-east of the town of

Kotelnikovo.

The Russian mines are required in future to produce 2.3 milliontons of potassium chloride a year. Potash is a relatively strategicraw material for Russia since potassium salts are primarily usedfor fertilizers in agriculture, and demand for it will continue toincrease in future.

The geological and hydrological findings obtained from theexploration drilling programme indicated that the freeze methodwould be required for sinking the 1,180 m deep shaft. Much ofthe overburden in the target area was described as weak tomoderately stable and rated as water bearing.

When the ground freezes, the groundwater is kept below zero bythe cooling medium and is therefore frozen. With unstable rocklayers or subsoils this creates a stable watertight area around theshaft. The groundwater level and the groundwater are thus usuallyunaffected by this so that the process is environmentally friendly.The freeze pipe sunk in this case is around 520 meters.

The freeze plant uses ten 450 kW compressors which arecontrolled by Eaton DM4-340-315K soft starters. When thesystem was started, the circuit-breakers tripped for an unknownreason. A fairly typical case for the Eaton After Sales Service. Asthe hotline support could not come up with a solution, an on siteservice operation was necessary.

Once on site, it soon became clear to Bernhard Teepe from theEaton After Sales Service that connection faults in the compressormotors were the main cause of the systems malfunction. Thelabelling at the start and the end of the motor cable end had beenincorrectly reversed. Furthermore, a soft starter was not optimallyset, since Eatons DM4-340-315K Eaton soft starters can beconfigured for the more economical output level of 315 kW usingthe IN-DELTA circuit even though the motor has a 450 kW rating.With the IN-DELTA connection, the soft starter is installed inone of the delta windings of the motor and sized at a 58 percent(=1/3) smaller current rating. Bernhard Teepe then set all motor-protective circuit-breakers and timing relays and corrected thecircuit diagrams accordingly. After three days on site, the groundfreezing plant worked perfectly so that the schedule for sinkingthe shaft could still be kept.

Ground Freezing PlantEaton After Sales Service Operation in Russia

CONCLUSION

Erhard Berger, Thyssen Schachtbau GmbH project managerfor the ground freezing plant summed up as follows:Bernhard Teepe gave us fast and expert help. Thanks tohim the connection faults of the compressor supplier wereidentified and rectified so that the ground freezing plant couldbe put into operation on schedule.

The compressors for the freeze plant are housed in the containers

Erecting the drilling rigs for creating the freeze bore holes

APPLICATION



INfO

The Company: www.thyssen-schachtbau.de

Services/Products: After Sales Service,DM4 frequency inverter


Thyssen Schachtbau GmbH,Kh. Pimeno-Cherny Kotelnikovskymunicipal district, RUS VolgogradRegion


26/32SolutionS 2226

We supplied the cruise ship with more than 20 double-conversiononline UPSs, ranging from 1 kVA to 350 kVA. The UPS delivery iswithout doubt the largest in our 40-year history of providing themarine industry with uninterruptible power systems, says RauliLehtonen, Sales Manager at Eaton Power Quality.

The unparalleled size of the vessel and the variety of high-techapplications on board posed remarkable challenges in terms ofpower supply. One-hundred-percent reliable, continuous andclean power has to be guaranteed for the ships safety andcruising-related applications as well as commercial applicationsthat affect customer satisfaction the most. Our customer cannotrisk losing power in applications such as navigation equipmentand emergency power and lighting. A loss of load would result inhighly dangerous situations at sea, explains Lehtonen.

Reliable power leads to an enjoyable experience

Conditions on board a ship differ significantly from those onshore: the power distribution network is ungrounded, and theelectricity generated by the ships engines is not of uniformquality. That is why power needs to be double-converted for all

critical applications. Ship vibration, shocks, inclination, temperaturevariation and very limited space present further challenges for thesetup. In addition, every device securing safety and cruise-relatedsystems needs to meet the stringent requirements set by variousclassification organisations.

Eatons answer is double-conversion online topology. All ourmarine UPSs incorporate this; it can protect critical marineequipment from all types of power interruptions that may occur inthe ships supply network. To guarantee continuous, high qualitypower to the most critical loads, the UPSs can be configured toprovide parallel redundancy, Lehtonen says.

Every Eaton marine UPS also has a hardened mechanical design,shock absorbers and a drip-proof cover. Whats more, they alsoemploy the same global technical platform and the same corecomponents as our standard UPSs. This enables the use ofcommon spare parts and accessories and leads to effortlesssystem upgrading, maintenance and service.

On board Oasis of the Seas, Eatons UPS systems protect criticalapplications including emergency lighting, navigation equipment,ship automation and HVAC applications as well as casinos,theatres and other entertainment venues against disruptive powerinterruptions. The delivery consisted of a set of Eaton 9395, 9390,9355 and 9155 marine UPSs.

The project was a new milestone for us, as it saw the installationof the largest marine UPS we have ever delivered the 350 kVA

Eaton 9395 Marine UPS. The two 9395s on board Oasis of theSeas protect the most business-critical applications, includingcomputer systems and energy-intensive cash registers, Lehtonenexplains.

Oasis of the SeasSets sail with Eaton UPSs on board

Whats 361 metres long, 66 metres wide and attracts thousands of visitors every year? No, its not the Eiffel

Tower with a 40-metre extension placed horizontally its the worlds largest cruise vessel, Oasis of the Seas. This

giant cruise ship features 16 passenger decks, encompasses 225,000 gross registered tons, accommodates 6,360

passengers and 2,100 crew members, and towers 72 metres above sea level at its highest point. Oasis of the Seas

set sail on its maiden voyage on 5 December 2009, and as well as its massive physical size, the vessel has giant-sized demands in terms of power consumption: its total requirement for uninterruptible power can be as high as

2,000 kVA. The need for power protection devices is equally massive.

APPLICATION



Eaton also supplied UPS batteries and transformers as well as

PowerVision management software for system performancemonitoring.

Assembling a colossal puzzle

Oasis of the Seas is constructed of 181 grand blocks, eachweighing approximately 600 metric tons. Each block was firstfinished as far as possible, including the installation of electricaldevices, and then the blocks were brought together. This colossalconstruction puzzle took almost four years from contract todelivery.

One characteristic of marine projects is that the UPS systemscannot be installed as a whole in one go. Batteries have to be

delivered later, a few months before the ship delivery, otherwisethey would suffer during the long construction period in theshipyard, with all the dust and dirt. They would also be wornunnecessarily and their service life could not be guaranteed. In thecase of Oasis of the Seas, we supplied the UPSs in early 2008and the batteries in autumn 2009, explains Lehtonen.

Eaton has a long and trusted partnership with both the ownerand builder of Oasis of the Seas. We have worked with Eatonfor over 10 years in all of our most demanding cruise shipconstruction projects, says System Coordinator Ville Talsi ofshipbuilding group STX Europe, Turku, Finland. Their high qualityproducts and field services around the world have guaranteedan enjoyable cruise experience for passengers and uninterruptedworking for the sophisticated technology on board our ships.

Eatons power protection solutions are employed in five of theRoyal Caribbean International cruise lines Voyager-class ships(completed in 19992002), three of its Freedom-class ships(completed in 20062008) and in both of its Oasis-class ships.Oasis of the Seas sister ship, Allure of the Seas, is due to becompleted in late 2010.

INfO

The Company: www.eaton.com/powerquality/marine

Products: USV 9395, 9390, 9355, 9155


Giant of the seas in a nutshell Ordered in February 2006, maiden voyage 5 December 2009

Length 361 m, width 66 m, height 72 m above sea level(at highest point), gross tonnage 225,000

Capacity up to 6,360 guests and 2,100 crew members 16 passenger decks, 2,704 staterooms

Total power output 97,000 kW, power protection capacity2,000 kVA

First ship to feature the cruise lines neighbourhood concept ofseven distinct themed areas

Cruises the Caribbean from its home port in Fort Lauderdale,Florida, US

Sister ship Allure of the Seas due to be launched atthe end of 2010

Founded in 1968, Royal Caribbean International is a globalcruise brand with 21 ships currently in service and one underconstruction. The line also offers land-based cruise tour

packages in Alaska, Canada, Dubai, Europe, and Australia andNew Zealand.

Total power protection for theworlds largest cruise ship. Eatonsupplied more than 20 double-conversion online UPSs for thisgiant of the seas. The Oasisssister ship, Allure of the Seas, dueto be delivered by the end of 2010,

will also rely on Eatons expertiseto secure power distributionnetwork on board.


28/32SolutionS 2228

Battery

Hybrid Drive Unit

Eaton Hybrid System Controls

Supplier/OEM

Brakes(ABS)

Inverter/Controls

Motor/Generator

AutoClutch

Engine Transmission

Patented Hybrid System Software

HybridControl Module

E-Mobility Eatons Green Solutions

Over 50 Million Kilometers with Eaton Hybrid Drives

Since April 2008, Moeller has been a part of the Eaton

Electrical Sector of the Eaton Corporation. With Moeller,

Eaton has considerably expanded its product portfolio so

that almost half of the entire turnover was achieved in

the Electrical Sector with 5.9 billion US dollars in 2009.

51 percent of total turnover is generated in the Industrial

Sector with the Aerospace, Hydraulics and Vehicle

businesses. What might not be common knowledge

in Europe: Eaton is the only manufacturer in the world

to offer a complete range of hybrid systems for utility

vehicles and for buses.

Eaton started with the development of hybrid drive systemstwenty years ago, long before the hybrid drive system was acommonly established term. Today, the hybrid drive, as a genericterm for drive concepts with two different energy sources, is aleading technology for reducing the consumption and emissionvalues of automotive vehicles. The greatest saving potential is

achieved by vehicles that have to stop and start frequently, suchas city buses, refuse trucks, medium-sized delivery and off-roadvehicles, as well as other large vehicles. In order to develop anoptimum hybrid solution for these utility vehicles, developmentengineers at Eaton created exact motion profiles of customervehicles. Using this data it was possible for Eaton to developseveral different hybrid drive concepts: a hybrid electric, a plug-inhybrid electric, and a hybrid hydraulic drive.

Hybrid electric system

Hybrid electric drive systems have shown themselves tobe ideal for vehicles with superstructures such as a crane,which is normally driven by the idling combustion engine via a

hydraulic system. Switching off the engine when the vehicleis at a standstill is one of the best ways to reduce both fuelconsumption and system emissions equally. As soon as theauxiliary power is almost used up, the engine is automaticallyrestarted to recharge the system accumulators in less than fiveminutes.

APPLICATION



INfO

The Company: www.eaton.com/hybrid

Products: Eaton hybrid electric drive


Plug-in hybrid electric system

Whilst the system accumulators of hybrid electric systems canonly be charged using brake operations or via the diesel engine,the vehicles with a charging device the so-called plug-in hybridelectric system make it possible to charge the vehicle batteriesat a charging station (EV Quick Charger).

Hybrid hydraulic system

Eaton has developed hybrid hydraulic applications specially forfrequent starting and stopping in order to meet the requirementsof the different truck sectors. The system monitors and storesbrake energy of the vehicle and then use it for acceleration.

Eaton calls its hybrid hydraulic technology Hydraulic LaunchAssist or HLA, which consists of a parallel hybrid system asit supplements the conventional powertrain in order to reduce fuelconsumption. On a refuse truck, that stops