Document Sample
Automation Solutions for Machine and System Building | 6th Edition

Human Machine Interface with PLC on board



Contents Imprint News

Page 2 Page 3-5

Packed reliably MEURER HMI-PLC: Scalability and flexibility

Page 6–7

Textile production controlled with MFD-Titan

It depends on the mixture IBN / SCHRÖDER KOMBINATOR Modular systems with flexible automation

Page 8–9

Fixing with convenience MEYER New operating and control concept for textile machines with MFD-Titan

Page 10–11

The alternative to micro and compact PLCs KSD / FRIZ / WEMA-PROBST / LA PARMIGIANA HMI-CONTROL for new operating and control concepts

Page 12–13

Oven fresh thanks to Moeller technology

Decentralised conveying GILGEN LOGISTIK Efficient maintenance – remote starting

Page 14–15

Page 16–17 Efficient baking HEUFT Energy rationalisation in the baking process thanks to HMI-PLC

Reliabable power and data transfer MERCK Intelligent control modules integrated in the process control

Page 18–19

Moeller products control pharmaceutical production systems

Closed-loop control at your command BAYER / AGU Controlling the HVAC system of the parenteral products plant at Bayer HealthCare

Page 20–21

Safe harbour manoeuvres HDW HAGENUK DILM 1000 vacuum contactors for precise ship manoeuvring

Page 22–23

Published: Moeller GmbH Division Industrieautomation 53115 Bonn

Editors: Dirk Wunder (v.i.S.d.P.) Frank Spelter INTEGRAL Dr. Schumacher ® Authors: Ulrich Kanngießer Dietmar Kneisel Stephan Linke Dr. Monika Schumacher Frank Spelter Burkhard Staudacker

Contact: E-Mail: Internet: Copyright 2003 by Moeller GmbH

Layout: eye-eye Raum für Werbung, Cologne Printed in the Federal Republic of Germany (11/03) KM 0213-4244 GB Article No.: 272345




Operation in Frankfurt's Main Tower:

Moeller FIELD SERVICE Professional Round the Clock

Stopping in an emergency with XStart motor starters:

Safety at its Best

Saturday, 31 August just before midnight: the red lights are lit in the Frankfurt Main Tower. Reason: A circuit-breaker has tripped and is signalling a fault in the cooling water supply of the district-heating power station. Consequence: In the event of a failure, around 2,500 employees will not be able to take up their work – a potential financial loss of around 175,000 euros in personnel costs plus turnover per day. One call to Moeller Field Service is all that's needed: Moeller produced the parts required in the factory on the Sunday. On Sunday night the spare parts had already arrived in Frankfurt where they were installed by a Moeller team. By seven o'clock on Monday morning the Main Tower was fully operational once more.

The hard facts of a streamlined plan of action … … demonstrating: professionalism round the clock. For Moeller's Field Service actually nothing special. After all, the wishes of their individual customers have absolute priority. “At any time – at any place – worldwide”. Moeller's versatile and reliable range of services can always show their worth, particularly in “emergencies”. With state-ofthe-art software tools such as CRM (Customer Relation Management) the Moeller Field Service can access its customer data efficiently to find solutions as quickly as possible. Backed up by the short and yet powerful principle of the Field Service: “The success of our customers is also our success.”

The XI/ON XStart power modules apply the benefits of the remote I/O concept to industrial motor starters. They can be fitted for both DOL and reversing starters. Different fieldbus systems can be connected using the XI/ION gateway. The XI/ON XStart motor starter not only provides motor protection, but offers reliable disconnection, even with high short-circuit currents. XStart meets the requirements of type "1" coordination in accordance with EN 60947-4-1, so that persons and systems are not endangered in the event of a fault. Emergency-stop disconnections (Emergency-Stop disconnection to Category 2 of EN 954-1) require designs with positively driven auxiliary contacts that must also be connected to an external safety relay. For further information on the categories refer to the Moeller Safety Manual.

In accordance with the relevant standards, emergencystop functions are used when • an immediate disconnection of the power supply does not lead to hazardous states (uncontrolled stopping – STOP category 0 in accordance with EN 60 204-1), • hazards to operator and machine may arise, • or the emergency-stop device (emergency-stop pushbutton actuator) and its power supply are exposed to a particular hazard.

Communication made simple:

New Profibus-DPV1 Interface for Moeller Circuit-Breakers
The new NZM 2 to 4 electronic circuitbreakers from Moeller can also communicate with the outside world. They do this simply and effectively with the new NZM-XDMIDPV1 Profibus module. When used in conjunction with the Data Management Interface (DMI), NZM can thus be monitored and controlled remotely. Cyclical data polling enables the switch position (On/Off/Tripped) to be queried or checked quickly for the presence of load warnings. Load management functions can be implemented using the actual current values. The remote operator of the circuitbreaker is used for this. Users enter parameters to ensure optimum adaption to the load. The DMI enables the users to switch the motor feeders or change the rotation direction of a reversing starter. Every data point can be addressed individually as an IEC 61131 variable using the DPV1 commands, and can be processed

further in a Class 1 or Class 2 master. Cumbersome function blocks and data type conversions in the PLC are thus a thing of the past.



The Low-Cost PLC for medium-complexity machine and system building:

XC100 Even Faster and Smaller
Moeller's XC101 modular PLC now comes with new functions: four of the inputs provided on the CPU can be used as direct Interrupt inputs. This ensures a simple and immediate response to events, independently of the cycle time. If required, the XC-100 can also be programmed via the integrated CANopen fieldbus network, making it available for use in decentralised applications. Operation and programming of the entire system is thus possible from a central point, and of course, over large distances. The new high density I/O modules allow users to connect up to 32 I/O points in an extremely compact space, thanks to the 30 millimetre mounting width and 100 millimetre height. This further step in the reduction of device volume helps to meet the growing demand for more compact machines with less space available for the control electronics. The I/O signals are wired up using preassembled cables, thus saving valuable time. With the XC100/200 PLCs, users can create expansions for up to 494 digital signals with a mounting width of only 510 millimetres.

More Approvals and Certificates for the ZEV Electronic Motor-Protective Relay
ZEV is an innovative motor- protective system for motor currents from 1 to 820 A. All motorprotective relays provide the standard protective functions in the event of phase failure, overload or current imbalance. However, ZEV can also achieve a lot more. It has been drastically reduced in volume – by up to 58 times. Small, light current sensors with wide current ranges simplify selection and reduce inventory costs. Users just have to wrap small sensor belts around the cable and fix them with Velcro fasteners. The keypad and LCD simplify setting and controlling. The ZEV, including its current sensor system, has approvals for the following countries in addition to UL, CSA, PTB and ATEX 100: - China: CCC and CQC, - Poland: BBJ-SEP, - Ukraine: GOST. The way is clear for the almost worldwide use of the ZEV, so that its outstanding and versatile benefits are now available for even more customers around the globe. The extremely easy-to-fit Rogowski sensor (ZEV-XSW-820) is a typical example of the many benefits of the ZEV system: with a small installation volume and a wide current range (40 ... 820 A) it is already in great demand with our customers.

Software Update:

EASY-SOFT V5.10 [Pro]
Moeller is continuing the success story of EASY-SOFT with Version 5.10. Armed with new functions, improvements to the visualization and simulation features, as well as a regular update service, EASY-SOFT users can develop their automation solutions even faster and more effectively. The latest functions and improvements to the visualization and simulation tools are varied and appealing: • EASY-SOFT allows users to work on several projects simultaneously. • The mask editor offers new enhanced functions, for example, for aligning, grouping and moving graphical objects. • With new import and export functions in the mask overview of the visualization tool, users can now manage different language versions. The enhanced project printout function also outputs all the visualization data required in addition to the circuit diagram and its parameters. • The enhanced simulation tool is a highlight of the new version: in parallel with circuit diagram simulation, the tool can simulate the display of easy400/600, easy800 or MFDTitan devices without the need for an actual MFD device to be present. • The update process for EASYSOFT is also new. Users can always update their EASY-SOFT version directly from the program, thus eliminating the need for lengthy searches on the Moeller server.



XVC600, Box-PC and DVI Monitor
Moeller designed the touch display HMI-PLCs of the XVC600 Series for controlling, operating and monitoring machines and systems. The XVC600 Series brings Pentium power to the compact class of PC-based HMIPLCs. Tried and tested features of a device combining a graphical touch screen operator panel and a powerful compact PLC – fanfree and without any mechanical moving parts – have been enhanced by Moeller by adding essential features for today's market such as scalability and flexibility. All devices offer flexible mounting features, and can be configured as touch display HMI-PLCs for remote operation using a compact PC and DVI monitor. In this configuration, the computer (box PC) can then be installed up to 10 metres away from the display (DVI monitor) without any loss in quality thanks to the digital DVI standard. Users select between devices with infra-red touch or seamless resistive foil touch. The PLC is programmed in compliance with the IEC industrial standard. Graphical screen masks can be designed efficiently and simply using the EPAM visualization tool that runs as an Excel plug-in. Split screen technology thanks to Ethernet

DVI monitor 6.4 – 15 inch

and integrates third-party systems such as valve stations, I/Os or drives via standard fieldbus interfaces. An Ethernet interface is provided on board, and the high degree of protection (front IP65) and Compact Flash memory make all touch display HMI-PLCs suitable for use in harsh industrial environments.

Up to 10 metres

Split screen TV is well-known from Formula 1 racing. Moeller has now made this technology available for its customers on all touch display HMI-PLCs. Instead of advertising, customers can display in the local device the online screen contents of another HMI-PLC. All touch functions for the displayed screen content can then be used quickly and without any restriction. The split screen technology (VNC remote control) is primarily designed for telecontrol service applications: system states can be diagnosed remotely and users can carry out system functions via the telecontrol service. Split screen technology is also an effective tool for operating and monitoring production lines. The control concept of the touch display HMI-PLC series is open

Box PC

HMI-PLC 5.7–15 inch

Remote I/O – XI /ON:

New Technology Modules for XI /ON
Moeller has extended the range of the XI/ON modular remote I/O system with new modules: two serial interface modules and one XN-1SSI module. This now enables the system to also cover demanding technology functions. The two XN-1RS232 and XN-1RS485/422 serial interface slice modules can transfer serial data streams via the XI/ON system. This makes it possible to connect up a wide range of devices such as printers, scanners or barcode readers that are provided with an RS232, RS485 or RS422 serial interface. The XN-1SSI module is another new component in the XI/ON range. The technology module allows the connection of SSI encoders with a 24VDC (500mA) power supply, a word length of up to 32 bits and a transmission rate of 1 Mbit/s. Like all modules in the XI/ON series, the new technology modules can also be plugged or unplugged during operation without destroying the module electronics.


Packaging Machines Rubrik

HMI-PLC: Scalability and Interface Flexibility

Meurer was founded in 1969 in Fürstenau. Today the company manufactures film wrapping and case packing machines, conveyor and palletising systems. The company holding is divided into four business areas: Meurer Packaging Systems GmbH & Co. KG, Meurer Palletising and Conveying Technology GmbH with headquarters in Freren, Meurer Electrical and Control Engineering Technology GmbH & Co.KG, which is the international system supplier for automation and mechatronics, and supplies the required units of control, visualization and bus systems. Meurer Environmental Technology GmbH was set up in 1993 as an addition to the end-ofline packaging systems in order to work on the development of a high-level gasification reactor for utilising solid fuels.

Today’s machine builders can only improve their competitive strength and reduce costs at the same time by using a state-of-the-art automation system. As packaging machine builders, Meurer were faced with increasing demands in terms of the intelligence, operator guidance and diagnostics functions of their machines over all machine sizes and generations. Customer requirements also have to be fulfilled with the most cost-effective solution. Moeller’s scalable automation system with its flexible interface capability ensures that Meurer keeps its competitive edge: What was already developed on a small machine for Asia can be adapted to customer requirements for a larger line in Europe or North America.

Engineering costs continue to take up an even larger share of the overall costs of a project. Furthermore, the smaller the machines were, the more unfavourable this proportion normally was. Meurer therefore looked for an automation system that featured reusable software modules, offering scalability in terms of performance, and flexibility with regard to its communication functions. This last requirement is particularly important because of the wide range of fieldbus systems used around the world: “What we require from an automation system is a seamless software and flexible hardware platform – from the small operator terminal up to the largest touch display, including the electronic drive controls. A lowcost machine cannot be equipped with the same operating device that is used for a

complex line. Nevertheless, we don’t want to continually re-write new software modules for every machine size. We therefore looked for a system with which we could use the software cohesively in any machine size,” said Ludger Richter, sales and project manager for packaging systems at Meurer. The right solution was found with Moeller’s automation specialists in Bonn. Operating and monitoring Initially Meurer was only looking for an operator system. This was where one of the major time and blockage problems in machine engineering occurred. The idea of implementing one operator interface on many different devices without any modification



requirements offered the engineers the possibility of considerable savings. The integrative Moeller concept of a compact PLC with an integrated operator unit not only reduces the number of interfaces but also the time and costs required, particularly for programming and engineering. Meurer also looked for a suitable visualization system together with the operator unit. The performance range of conventional visualization systems was far too large for the requirements of operator interfaces on Meurer machines. The licenses are always for the entire package even though key functions of these kinds of packages were not required. Even here, Moeller could offer the right solution. The visualization integrated in the Moeller devices functions completely differently to conventional visualization systems. They are programmed in tabular form, in fact using Excel. Operator device functions can simply be transferred from one device to another one using the Copy & Paste functions in Excel. Meurer was also attracted to the integrated web server of the HPG series. The screen entry masks are configured with the Easy PageMachine (EPAM) visualization tool that runs in Excel. The size of the software objects can be configured as required. An integrated scroll bar allows a screen page of virtually any length to be created. In other words, page changing is no longer necessary. The size of the touch buttons can be adjusted as required. The user can also create reports without any problem and read them simply into Excel. The error diagnostics supports fast troubleshooting in the event of a malfunction. Moeller visualization created in EPAM running in Excel

Interfaces For Meurer, the standard integration of the Ethernet interface on the HPG 300 is an absolute necessity today. This allows remote maintenance functions to be integrated as required in the new machine generations without any difficulty. Service technicians can access an entire line via a teleservice system. The HPG series includes a CANopen interface as a standard feature, which is used by Meurer for controlling a number of small drives. Meurer machines often use an integrated Profibus interface on the I/O level. Whilst other automation suppliers only offer Profibus as a slave system, Moeller devices can integrate a Profibus master if required. This allows Meurer to save an additional component. Profibus integration on small PLCs is often a problem for many automation manufacturers. However, Moeller can cover this area as well. In their international business, the machine builders from Fürstenau also have to take into account the requirements of their customers with regard to interfaces. A machine’s communication must therefore be easy to replace when necessary. A multi-protocol board from Moeller supports all important interfaces, thus ensuring the necessary communication capabilities and the fast exchangeability of components.

PLC programming software The Moeller system allows the use of standard software modules regardless of device size and performance class. The user interface of the design software is also always the same for the developer, regardless of the target platform. The fact that Moeller used 3S programming software in its automation components was a great benefit to Meurer. The company had already been able to gain a lot of experience with the CoDeSys system before the partnership. A number of software modules were therefore already available that could be used in the new devices. Meurer suppliers also used the programming system, thus enabling a seamless integration. The scalable cycle times that the Moeller system provided were also a decisive factor in choosing the Moeller system.

The device concept of the HPG series offers a wide range of automation and networking options: PLC and HMI are combined together in one device. Both Thomas Tegethoff and Reinhard Meer, engineers at Meurer, agree: “Moeller’s HPG series allowed us to make considerable savings. In the construction of control cabinets alone we are able to make cost savings thanks to the new seamless system. In the software engineering we can also achieve a considerable value addition for the customer in the same amount of time.”

The HMI-PLC provides a scalable automation concept


Food Industry Rubrik

Modular Systems with flexible Automation

Ing.-Büro Niendorf
Automatisierungstechnik GmbH

The engineering consultants IBN are based in Niendorf an der Stecknitz, Schleswig Holstein. Their key area of competence is in process control for the food industry. With its PMS production management system, the company now already complies with EU Directive EG178/2002, that comes into force on 01.01.2005: IBN systems implement customised materials tracing solutions as specified in the EU Directive. IBN’s largest customer is Schröder GmbH & Co. KG, which was founded in Lübeck in 1928. Schröder Kombinator supplies worldwide processing plants, machines, and automation for the food industry.

Plants in the food industry need to have a modular structure. Each unit has to be integrated in a line that is configured for the particular product being processed. This requires the use of a scalable automation system. The operator level must have a standard design – from the text display for manual control, to a medium-sized graphic panel, right up to a production management system with data archiving for product tracing and the evaluation of tests in the laboratory. Moeller’s XSystem allows the machine builder to adapt the automation to the process engineering modules at hand – an invaluable benefit in terms of continuity and flexibility for visualization, HMI and control systems.

With Moeller’s XSystem, IBN could adapt to the automation to the process engineering modules at hand: each unit is equipped with its own PLC that can be networked via the fieldbus. Moeller’s compact MI4 text display (MI4-101-KC1), integrated in the stainless steel housing, can be plug connected by the customer to a unit for local operation. The systems can be equipped at a later date with

an HMI touch panel or a SCADA system. With Moeller’s MV4 touch panel, IBN was able to create the same operator interfaces as on the SCADA system. This is what Torsten Krüger, technical manager at IBN, had to say: “Our largest customer, Schröder Kombinator, standardises its systems using modular elements. With previous automation components, commercial



Production management system


infra-red touch panel

Ethernet PLC


such as process parameters. The process data is observed from the monitor, managed or assigned parameters. The operator controls the system and activates valves or motors via the monitor. The automation system consists of a combined IP54 control/load cabinet, an MV4 touch panel, several XC100 CPUs in a modular arrangement, as well as digital/analog I/O modules. Frequency inverters are designed for mounting to motors. The software solution consists of the following: - Motor control and monitoring for the final control elements contained, - Continuous closed-loop controllers for temperature, pressure, flow and speed controls, - Two-point controller for hot water heater, - Valve control and monitoring for valves with and without feedback. - Recipe management, - Automatic program for initial mixing, metering or production, - Test report generator for test evaluations.

Unit 1

Unit 2

Unit 3


text operator panel


Frequency inverter

requirements only allowed us to implement this step with the software. This meant that when buying the first units, the customer had to know exactly how large the final extension of their system was going to be so that we could choose the most suitable automation device. Each extension therefore involved enormous additional costs. With the XSystem we are at last able to implement the modular system with the hardware as well.” Each unit is equipped with a compact XC100 with its own intelligence. Today’s IBN customers create one complex system from several units. An XC200 is used as a master controller for automatic mode. It is connected via RS232 or CAN bus to an MV4 touch panel for implementing small-scale solutions or as an operator unit at the machine. Large solutions can be implemented by linking the XC200 via Ethernet and OPC server to the IBN SCADA or PMS system. Thanks to the XSystem, IBN can offer its customers a scalable system. Customers can now adapt system expansions flexibly to the technical requirements at hand and the

financial resources available rather than being restricted by the capabilities of the automation selected. Expansion for recipe and automatic mode management IBN’s project at Schröder involved a solution for recipe and automatic mode management. The MV4 had been introduced at Schröder a year and a half before and is integrated in a tried and tested visualization concept (InTouch) which is to be retained as much as possible. However, with the technical features of the MV4, requirements increased in terms of the amount of process data to be handled. Furthermore, both visualization systems had to have standard user interfaces. The new Schröder Kombi-LOG system controls, regulates and monitors the system. A graphic operator panel ensures simple operation and process control. The system also handles the management of master data

The valves are equipped with pneumatic actuators, solenoid valves and indicators.

The operating personnel in the laboratory and in production have quickly become familiar with the MV4 touch panel and the SCADA system with their standard operator interfaces. A line can even be reconfigured by the company personnel for a new product, such as margarine, cooking fats, dressings, ketchup or bakery, fat or sugar products – without having to adapt the software. Other benefit: The laboratory systems can be networked with the SCADA systems. This facilitates an upscaling from the laboratory to the production system. This technological step alone reduces the costs of the electrical system for creating a plant control by 30 percent.


Textile Industry Rubrik

New Operating and Control Concept for Textile Machines with MFD-Titan

The continuous pressure to develop innovative products and reduce prices, as well as increased demands with regard to the operation and control of machines force textile machine manufacturers to be constantly on the lookout for new ideas. Maschinenfabrik Herbert Meyer GmbH, one of the leading manufacturers of textile machines, can now meet these challenges with Moeller’s new MFD-Titan multi-function display. MFD-Titan is a product of the next automation generation, that combines PLC and visualization functions in one device. Only one software is required for the control, visualization and networking functions, thus considerably reducing the time required for engineering and programming.

For over fifty years Messrs. Maschinenfabrik Herbert Meyer GmbH in Rötz/Oberpfalz has been producing machines for the clothing industry, for technical textiles and textiles for vehicle interiors. The company has operations worldwide. In addition to design, development and production, Meyer carries out the installation of its machines itself. The company earns its reputation on the basis of high standards in quality.

In order to satisfy customer requirements in the operation and control of the new generation of fusing machines, Maschinenfabrik Herbert Meyer GmbH decided to use the new MFD-Titan multi-function display from Moeller. A high level of operator friendliness can be provided for the machine thanks to the fully-fledged graphic display and a customized user interface design. Four controllers for two temperature controls, one pressure and one speed control, and an activation function for a frequency converter were also required. MFD-Titan can not only fully meet these requirements but can also master special closed-loop control functions without restriction, such as pulse width modulation for controlling heating circuits.

Customised marking The external marking of the display and operator unit can also be designed by customers themselves. In this way, a machine manufacturer can not only use a unique logo, but can also provide specific inscriptions for precise operator guidance: in addition to a company name or other identification mark, all the integrated buttons and the two status LEDs can be provided with markings for the device concerned.



Simple networking and expansion The compact MFD-Titan belongs to the easy800 series with which it can be combined and expanded without any problems. Users simply fit the easy modules on the side. MFDTitan can be remotely expanded via easyLink, and a complete network can be set up using easyNet. This therefore provides a wide range of expansion options: The MFD control concept includes interfaces for Profibus DP, CANopen or DeviceNet for communication with devices from other vendors. The machine controls can therefore be integrated in a suitable communication network as well as providing data exchange with a higher-level system.

MDF-Titan provides HMI and control functionality

One software is enough The easySoft-Pro software is a complete package: it enables users to create the control software, assign parameters to the function blocks used, configure the visualization interface, all masks and button functions and finally configure the entire project including the networking. As if that isn’t enough, the software also offers functions for simulating the control program, documenting the project, and also for establishing communication between the PC and the controller. The user therefore only requires one software package and one interface on the computer in order to cover all the functions required. If other control devices are connected to the easyNet, all devices can be addressed and loaded with programs as required from one device.

User-friendly visualization The visualization function allows users to create masks, for which the MFD provides a number of tools and display elements that can be assigned different attributes. Possible elements include static texts, message texts, graphics, numerical value or date displays in different formats, value inputs or bit displays. The variable attributes that can be assigned to an element range from “visible”, “invisible”, “flashing”, “static” to “inverse display”. The text management supports multi-lingual displays. The Mask Overview allows several language areas to be stored in which static texts and message texts can be entered and called. This form of language management is a mark of any fully developed visualization system. The capability of the Button Editor and Mask Control also reduces the configuration required for the automation task, since visualization and control are implemented on the same hardware and software platform. In this way, all the variables of the control device are directly available for visualization and can be used for controlling display elements, for outputs and for data inputs. Value input does not require the use of the integrated control device but uses configuration windows to set the step width and other attributes for data entry and value display.

Not programming but parameterisation The MFD-Titan multi-function display features an integrated easy control device called “easy-inside”. The core of this is an easy800 with an extended range of function blocks such as PID controllers, signal smoothing and pulse width modulation function blocks and many more. The processor allows 32-bit operations. The cycle time can be set to the shortest possible time, to fixed values between 1...1000 ms or by the software. A number of variables can be used as the cycle time setpoint. In this way, machine builders are armed with a wide range of solutions for complex closed-loop control tasks.

Meyer presented the new upgraded machine series on the market together with innovative fixing machines. A number of improvements could be implemented thanks to MFD-Titan. The new control concept not only increases reliability but also simplifies operation. All functions can be set intuitively at the same time and readjusted if required – on one ergonomically designed and generously sized operator interface.


Control Engineering

MFD-Titan: HMI-CONTROL for New Operating and Control Concept

The continuous pressure to develop innovative products and reduce prices, together with increased demands with regard to machine operation and control, characterise the market of future machine generations. This trend is being developed with a new generation of control relays and multifunction displays which are increasingly competing with micro and compact PLCs. Featuring short program cycles, a wide range of function and arithmetic blocks, as well as optional fieldbus networking capabilities, these kinds of devices are removing the traditional image of a control relay. They are advancing to become compact visualization devices with integrated operation and full-featured control functions.

Moeller developed the new MFD-Titan multifunction display as a device of the new automation generation, combining control and visualization functions in one device. With this the Bonn-based automation specialist is offering a genuine alternative to existing PLC solutions for small to medium-sized machine building applications. The robust display of the MFD-Titan offers a quality design and outstanding flexibility in operation and parameter setting. The fullyfledged graphical display with 132 x 64 pixels offers a switchable backlight and meets the high industrial protection requirements of IP 65. Two freely configurable status LEDs indicate additional operating states and signal alarms. The permissible operating temperature range is from –25 to +55°C and therefore allows the control electronics to be used in machines or systems. Control engineering for a crane system MFD-Titan takes over the function of the operator interface at the control station: in addition to the central visualization of fault messages from individual network stations, the display also shows the operating states. Menus are provided to graphically display speeds, limit switch positions, operating hours, maintenance intervals. MFD-Titan – networked with the easy control relay – handles the following tasks and functions with a high degree of reliability: double and single hoist mode, synchrocontrol with high control quality, hoist interruption, selective load measurement, linear field weakening, dynamically adapted control response, soft starting / delay, load-dependent motion response, programmable setpoint channels.



Recipes for the pasta machine MFD-Titan ensures the “right mixture”. La Parmigiana produces different types of pasta machines in different sizes for the production of a wide range of pasta products: this ranges from the simple spaghetti to filled ravioli. The user-friendly systems allow the new machines to work with a high degree of precision and meter the required raw materials automatically. The MFD-Titan control system ensures the trouble-free and automatic control of the basic parameters such as pressure, temperature, speed, absorption and delivery volume.

Modular control concept for profiling systems Wema Probst, a machine building company, uses the power of MFD-Titan and easy800 for the control of its new profiling system. The new multi-function display provides networking already on board, from which not only the machine builders, but also their end customers can benefit. Wema Probst machines and systems have been particularly successful in the field of small timber processing. The Wema Probst concept: first of all, every system section should be equipped with its own autonomous control system. When supplying a complete system, the individual control systems are networked to control the entire system. The system is then to be operated and monitored from a central control desk.

Features of the MFD-Titan
• Networkable via Easy-Net with up to 8 stations, 320 I/Os and 1000 m, • Optional fieldbus coupling (Profibus, Device-Net, CANopen, AS-Interface), • Three products in one: - operator unit with display and keypad, - control unit with high-speed CPU (Easy inside), comes with 10 menu languages as standard, - analog and digital I/Os with cage clamp terminals, • Attractive industrial design, • Customised laser inscription of front plate, • Parameter assignment instead of programming, one software for control, visualization and networking functions. Temperature control of profile wrapping machines For over fifty years, Friz has been active in the construction of membrane presses. A major specialisation has been profile wrapping machines, i.e. machines for surface coating linear profiles on wood materials, plastics or metals with decorative papers, veneers, laminated materials or thermoplastic foils. Friz integrated the complete temperature control in the MFD and easy800. The external temperature controller that was previously used has been completely removed. This saves costs and creates more space in the control cabinet. The metering control was also integrated in the MFD and now controls the metering volume of the glue via the analog output – according to roll width, discharge speed and selected application quantity.


Materials Handling

Efficient Maintenance – Remote Starting

Materials handling projects have to be implemented within increasingly faster time frames. Rapid Link – the remote switching and installation system – is ideal for roller conveyors, buffer roller conveyors, belt conveyors, monorail and overhead conveying systems or skid conveyors and saves valuable time during installation, commissioning and maintenance. At the Coop's distribution centre in Wangen near Olten, Switzerland, automation components are used in the reusable container circulation system (roller containers and reusable containers). The buffered roller containers wait in the top floor for distribution in the individual conveying sections.
When the project was tendered for 5000 roller containers per day, Coop gave clear specifications as to the circulation capacity required. The roller container system has been successfully tried and tested in all branches so that hand-pallet trucks are no longer necessary. The engineering for the Coop project was carried out by Hayek Engineering. Gilgen Logistics was awarded the tender to supply the reusable container circulation system. As Dipl. Ing. Othmar Neuhaus, manager of control engineering at Gilgen Logistics, said: “With this system we had to take some new approaches, and we were also under time pressure. AS-Interface, Rapid Link's data bus, considerably reduces the time required for engineering. What is more, the system can be commissioned in stages. This is a significant advantage since it means that every individual module of the conveyor section can be tested beforehand. We used over 100 motors in total. The drives for the lifts, turntables, shuttle cars were controlled separately, whilst all belt conveyors of the horizontal sections were controlled by Rapid Link. All system sections are virtually tailor-made.” Another clear advantage is explained by Dipl. Ing. Andreas Köstinger, responsible for hardware planning in control engineering at Gilgen Logistics: “The problem with conventional systems was that the control cabinet could not be planned until the drive solution had been clarified. With Rapid Link, however, we don't have to worry about this any more. Furthermore, thanks to the adjustable current range between 0.6 and 5 A, we could use the same motor starters everywhere. The entire sensor system is also connected to the motor starter. Additional slaves to process the sensor signals are no longer necessary.” The conveying system uses optical sensors to detect whether reusable containers are required or whether roller containers are being transported full or empty. Optimised utilisation of the buffer space was of key importance. This required the type of unit to be detected correctly: The decision which type of unit was to be sent on which section is made in the shuttle car. It has to be ensured that both types are available at the right time. If conveyed goods get jammed, this generates a timeout in the control system. It is now only a matter of disconnecting the appropriate conveyor section and rectifying the cause of the fault. Service technicians set

Gilgen Logistics Systems AG from Oberwangen, Switzerland, started up in 1967 as a supplier of part systems and components. In 1993 Gilgen Fördersysteme AG was founded and is still today a division belonging to Gilgen AG. Gilgen Logistics Holding AG was founded six years later. With the integration of the automation and IT division, Gilgen Logistics now offer total solutions for logistics applications, with activities in European and overseas markets. The Gilgen range covers all projects for conveying and storage systems, loading and special systems. Consulting, planning, engineering, development, construction, control, software, installation and training are some of the services available.




Drive concept with Rapid Link
Feeder circuitbreaker Speed controller Manual local operation

Head end

Head end

Feeder circuitbreaker

Motor starter

Programmable function unit

A power bus system based either on a flexible busbar or round cable design is used to feed all the modules. The profiled cable (7 x 2.5 mm) supplies the 400V AC voltage and the 24V DC control voltage. Load junction sockets can be installed at any point on a flexible busbar, and fault-free load junctions can be created using insulation displacement termination. The modules use IP65 plug connectors to ensure rapid module connection and exchange.

The Rapid Link series Rapid Link is used in small and large materials handling systems, particularly in distribution and production logistics. It offers all the necessary functions (IP65) for switching and protecting spatially distributed drives remotely via Profibus-DP and AS-Interface. The Rapid Link system requires few spare parts, is quick to install and easy to commission – around 50 drives per day are normally possible. The modular Rapid Link system includes a wide range of functionally tested units that are ready to connect: • Head end (Interface Control Unit, interface to the open fieldbus), • Feeder circuit-breaker (lockable with three padlocks, protected against overloads and short-circuits), • Motor starter 3-phase electronic motor protection (value range from 0.12 to 3 kW), • Speed controller (frequency inverter controls AC motors up to 3 kW, four fixed speeds and two directions of rotation), • Manual local operation of material handling units and • A programmable function unit (intelligent slave for stand-alone I/O processing).

the priorities but don't interfere in the program structure: for example, this kind of program intervention allows the buffer area to be emptied immediately if required. The operators can disable certain areas or fill individual sections more than others using the appropriate operator units. “Rapid Link meets our requirements for plug and play functionality to a very high degree,” says Othmar Neuhaus. “That's also the reason why we based the system on the AS-i bus, since it is suitable for a wide range of sensors and actuators available on the market. We can also cover virtually the entire conveyor section with only two cables – one power cable and one data cable. Installation requirements are considerably reduced. The individual conveyor section modules are compact, both in terms of their mechanical design and the electrical system, and can be connected up together without any problems.”

Whilst the Coop previously processed 28 to 29 railway wagons a day with 14 to 15 employees, it now manages at least the same volume with only nine to ten. The new reusable container circulation system operates without any problems. Rapid Link ensures flexibility for the user. The system uses the AS-Interface, and is open for all standard fieldbus systems: With the Interface Unit providing the gateway solution, higher-level networks such as Profibus DP, Interbus, CANopen or DeviceNet can be installed using standard hardware. Apart from the gateway function, the Interface Control Unit also provides the AS-i power supply. RAPID LINK is thus a sound financial investment offering security for the future.


Food Industry

Energy Rationalisation in the Baking Process Thanks to HMI-PLC

Karl Heuft GmbH is a family run company situated in Bell in the Eifel and has been existence for over 160 years. For years it has enjoyed continuous growth in the field of baking ovens and baking systems. The production of bakery products is one of the most energy-consuming manufacturing processes. Heuft offers the technical possibilities to increase the capability of companies, through improved oven design, optimised oven conveying or measures for heat recycling. A new heat combination system was recently developed that uses the waste thermal energy of the baking ovens and reduces the heat required for production.

The craft of baking has considerably changed in recent years. The development of increasingly larger baking plants and the growth of branches have led to increased competition in the sector. Only by means of rationalisation, automation and technology is it possible for small and medium-sized companies to optimise processes and make use of potential savings. A key aspect of this is the efficient use of energy in the baking process – a so-called heat combination system. The Moeller XVC-100 HMI-PLC and the XI/ON remote I/O system not only ensure efficient energy utilisation but also enable the thermal energy to be available outside of the baking time.

A baking oven takes up forty to sixty percent of the energy consumption in a bakery. It is therefore only logical to take steps here to reduce energy costs. After all, heat is removed from every oven by the actual baking process, by the finished products and the radiation of heat into the environment. In addition to this, a considerable proportion of the heat is emitted into the flue in the form of fumes and flue gas. The production of baking products requires a comparatively small amount of the energy used.

Every baker therefore asks the question: Which thermal currents that leave the oven can be used, for example, for heating service water or for heating the building? What technology is required for this? What are the costs of a suitable solution? The considerable amount of residual heat produced by the ovens and radiated into the environment during the daily baking process can be transferred to a thermal buffer store using a thermal oil/water heat exchanger. The heat carried by the flue gas of the burner can also be transferred to heating or ser-



vice water systems using a flue gas heat exchanger. In an oven with a separate discharge of flue gas and fumes, such as a thermal oil baking oven, 33 percent of the energy supplied can be recycled during the baking process.

Web visualisation Remote programming Ethernet
Heat combination system Text display PLC

Baking oven 1 Touch HMI-PLC

Baking oven 2

Baking oven 3

Heat combination system for more efficiency A Moeller XVC-100 HMI-PLC and the highly granular XI/ON remote I/O system are used for the heat combination system. The HMIPLC continuously monitors and controls the temperatures in all system components and, if necessary, switches in the thermal oil boiler, even outside of the baking period. The plant can be customised to the specific environmental conditions of the plant and operator requirements if necessary: this applies both to the plant parameters, the setpoints as well as actual day data and switch times. PLC interfaces enable all plant components to be networked and expanded to form an intelligent energy management system. Individual components such as fume condenser, flue gas heat exchanger and buffer store are combined to form the heat combination system for the customer’s specific needs.

XI/ON remote I/O

XVC-100 HMI-PLC saves significant costs The eight-line text display shows all temperatures and operating states, and a membrane keyboard is provided for operator entries. Password-protected operator levels are available for the service technician, as well as day or 7-day time switches and manual or automatic modes. The entire temperature control of the thermal buffer and the activation of the thermal oil boiler outside of baking periods are controlled by the Moeller HMI-PLC. Other features include the activation of the hot water circulation pump by time switch

and temperature, and up to five outdoor temperature-controlled heating circuits with night reduction and holiday function. By selecting different heating curves, the heat combination system can be adapted to any existing or planned heating system. The CANopen interface of the XVC-100 is used to network the HPG-230 touch PLCs. The outstanding features of XVC-100 text display PLCs (compliant with IEC 61131-3) include their small mounting depth, integrated digital or analog I/Os, counters, interrupt and encoder inputs. With a 192 KB program and data memory, 56 KB data, 8 KB retentive data and CANopen on board, the HMI-PLC offers a cost-effective solution. A slot for Compact Flash memory cards up to 16 MB can be used for storing data, recipes or a program.

Automation concept of the thermal-oil baking oven

A heat combination system enables an average thermal oil baking oven in single shift operation with a 12 square metre baking area to save thousands of euros in annual energy costs – a considerable saving. Around forty percent of the energy supplied to the baking process can be recycled and saved at other locations or returned to the energy circuit. Without intelligent technology, resources of this kind can no longer be implemented. The costs used for this pay for themselves within a short time – an investment that quickly brings a payback also in terms of the reliability and precision of the system.

XI/ON: regulates and controls the baking process


Pharmaceutical Industry

Intelligent Control Modules Integrated in the Process Control

At its plant in Gernsheim, Merck KGaA produces effect pigments that are sold under the brand name Iriodin. In order to meet growing demand, Merck built a new processing plant. A facility of this kind required fast planning, maximum flexibility and the possibility for later plant expansions. For this reason, Merck decided to use future-proof standards, and chose PROFIBUS DP and AS-Interface for the field level. Moeller's MODAN® modular power distribution system and compact motor control centre (MCC) are used as standard system units to complete the redundant high-availability control system.

As a group of companies with operations worldwide, Merck kGaA specialises in pharmaceuticals and chemicals, as well as in laboratory products and laboratory distribution. It has a major focus on innovations in pharmaceuticals and chemicals, with which Merck continues a three hundred year old company tradition. At its 92 hectare plant at Gernsheim, products such as fine chemicals, pigments and reagents are manufactured and stored.

When implementing a new production plant, switchboards usually have to be continuously modified and expanded during commissioning and in subsequent operation. The plant users normally carry out expansions of this kind during operation, mainly under live conditions with the bus fully operational. The MODAN® modular power distribution and motor control centre with removable compartments was therefore the ideal choice for this application. MODAN® is a Moeller product that can also be networked via PROFIBUS and AS-I without any problems. The key benefit of a networked system is the flexible exchangeability of the removable elements. These units, which include the motor control module, can even be exchanged under live conditions. Moeller's compact motor control centres (MCCs) contain all the necessary units for short-circuit protection (PKZ), motor switching (DIL) and the PROFIMOD ZWK intelligent motor control module.



Power and data – transferred safely and reliably Autonomous motor control The PROFIMOD ZWK intelligent motor control module collects the relevant data about the motor to be controlled: the information is made available to the higher-level control system immediately or processed in advance. In this design, the conventional control circuit wiring on the plug-in module with contactor relays is no longer necessary. DOL starters, reversing starters, star-delta starters, Dahlander circuits and even soft starter control can be implemented by simply assigning parameters and connections. The entire, autonomous motor control system is handled by PROFIMOD ZWK. The motor control housed in the switchboard allows the motors to be commissioned in stages – without the connection of the higher-level control system. The motor controls initially just pass on the motor's operational, fault and warning signals to the control system via PROFIBUS DP. The new pigment production plant has a total of six main power distribution switchboards, each assigned to a particular process section and installed at different locations in the building. The six switchboards consist of 150 cubicles of which half of them are removable compartment sections. These removable compartment sections switch and monitor over 200 drives (between 5.5 and 75 kW) – with removable compartments and PROFIMOD ZWK intelligent motor control modules. Two fibre optic cables were installed in order to exchange all data with the control system reliably and quickly. Each fibre optic cable has a separate connection in the ring in order to ensure availability if there is a cable break. Both fibre optic runs are connected to all the cubicles in the building, in this case 150 of them. Inside the individual cubicles, the bus lines (PROFIBUS DP) are routed to the individual motor control centres via standard interfaces. The fibre optic coupler and Y coupler are located in the bottom of the cubicle: the fibre optic couplers convert the signal from

the fibre optic cable, whilst the Y couplers are used for connecting the redundant control system. All the elements in the panel are thus easily accessible for operating personnel. This simplifies the handling, troubleshooting and commissioning of the entire system. An EMC tested spur-line distributor was used in the switchboard for connecting the PROFIMOD ZWK devices, in accordance with the NAMUR NE 21 recommendation. The required transmission speed of 1.5 Mbaud could be implemented without any problems.

A final report written by Merck KGaA on the production of Iriodin‚ confirmed that the control of the switchboard system via PROFIBUS DP immediately brought with it a multitude of benefits. Networked with Moeller's intelligent motor control modules, the system design reduced the costs required for planning, installation and service. Two-wire cables have replaced thick cable bundles in the switchboard. Field device diagnostics and configuration are carried out from a control room that is connected with the periphery via bus systems. The field devices are equipped with a precise self-monitoring system supplying unambiguous status information.


Pharmaceutical Industry

Controlling the HVAC System of the Parenteral Products Plant at Bayer HealthCare

For safety reasons, the closed-loop control system of the parenteral products plant at Bayer HealthCare had previously been automated with primarily conventional switching devices. Detailed and expensively engraved mimic diagrams with LEDs were used for localising fault messages. A lot of space was required in the control cabinets and the number of components and distributor boxes used required a great deal of knowledge about the individual system components. The decision to modernise the system was therefore inevitable. A large number of Moeller products based on current standards are integrated with Profibus-DP in the HVAC system and increase the availability of the system.

The companies
Bayer HealthCare, Leverkusen, is a company with operations worldwide. With its Pharmaceuticals, Diagnostics, Biological Products, Consumer Care and Animal Health divisions, it combines the group's entire worldwide operations in the health sector. Bayer is present on all five continents with major bases in Europe, North America and the Far East. AGU, also based in Leverkusen, has been working in system planning engineering since 1992 for industrial IT applications, process control and automation, as well as in system and building planning. Its range of services covers all phases of planning, and AGU also supplies and installs industrial systems including the process control and plant management level.

Bayer commissioned AGU to work out a new system concept and plan the implementation work. For pharmaceutical production, the system had to undergo a technical inspection with qualification measures in compliance with the requirements of the American Food and Drug Administration.

another project requirement. The Moeller S40 programming system (compliant with IEC 1131) can now provide a clear user program structure based on function blocks: individually tested standard function blocks for qualification tasks were saved in a library (Library Manager) where they cannot be changed and where they can be reproduced at any time. The total periphery involved the following signals: 175 analog inputs and 60 analog outputs, 126 digital inputs and 144 outputs.

Modernised closed-loop control system The task of the HVAC system for the parenteral products plant was to maintain a fivefold pressure cascade of the cleanliness classes. Even a short shutdown of the ventilation system interrupts production in the entire plant. Not only the costs of a production failure but also the costs for requalification and disinfection measures are enormous and that's why the system had high requirements in terms of system availability. The replacement of the 45 discrete closedloop control and limit value calculation systems with an automation device was



SMS alarm messages in the event of faults

Supervisory control room

PS416 modular PLC

XI/ON remote I/O

MV4 touch panel

XI/ON remote I/O

XI/ON remote I/O

XI/ON remote I/O

XI/ON remote I/O

FESTO valve station

FESTO valve station

FESTO valve station

FESTO valve station

E+H MemoGraph

Part of the automation concept

Safe and reliable standards Bayer used Moeller's modular remote I/O system XI/ON for controlling the signals on the field level. There were several reasons for choosing these components for the project: Module changes during operation were possible without any parameter setting requirements and whilst retaining the existing wiring. • In the event of a bus failure, the “Retain actual value” response could be configured. • Users could directly utilise the base terminals of the electronic modules without the need for cross connections. • The decentralised structure of the I/O system saves mounting and material costs. • A wire break or an out-of-range value can be localised without any problem. A safety setpoint can be defined via the user program. • XI/ON offers flexible expansion at any time.

Thanks to its processing capabilities, Moeller's PS416 PLC could be used as the CPU unit to process the 249 measuring points of the system. The multi-processor operation of the PLC supports fast analog value processing and dynamic closed-loop control. Bayer uses Moeller's MV4 infra-red touch panel for HMI tasks. Two terminals are required due to the separation of cleanliness classes involved. The user program monitors the functions of the terminals. A malfunction in the plant's bus system can be handled manually via the enabled fail-safe function. Effective and fast interventions are possible thanks to detailed fault messages in the alarm list of the touch panel.

Bayer HealthCare systems depend on safe and reliable standards. This is because of the high costs involved in the event of a production failure, the stringent requirements of health authorities and the tough competition worldwide. The cycle time is approximately 170 milliseconds, in spite of the 6,358 function blocks of the user program and a number of automation components linked on the Profibus line. The PS416 central control unit is linked to a central signalling system. Critical fault messages are indicated in the supervisory control room and sent if necessary directly by SMS from the PLC.


Marine Engineering

DILM1000 Vacuum Contactors for Precise Ship Manoeuvring

Modern ships are fascinating, especially as they are high-tech products. Development engineers at HDW-Hagenuk are integrating innovations from IT directly in products and systems for marine electronics/electrical engineering. In addition to technical expertise, the integration of technologies requires a high degree of flexibility as well as an exact knowledge of the market and customer requirements. Bow thrusters represent a new field of business. Being the only supplier of compactly designed AC-3 contactors for motor ratings above 820 A, Moeller in Bonn was commissioned to equip the HDW-Hagenuk systems.

New business field: bow thrusters As a supplier for Jastram GmbH & Co KG, HDW-Hagenuk built the control panels for bow thrusters. Bow thrusters are used on ships for manoeuvring, for example, in harbours. HDW-Hagenuk marine engineering developed the electrical equipment for bow thrusters using 500 kW slip ring motors. The rated current of the motor is 875 A at 400 V. The bow thruster is used for manoeuvres to port and to starboard and requires a reversing contactor circuit for two motor directions. The bow thruster also had to operate in three output stages: 70, 85 and 100 percent. Operation under partial load uses resistance steps on the slip rings. Other resistance steps are used to run up the motor so that up to five resistance steps are switched. Moeller contactors were used in the system equipment as they were the only ones available in a compact design for motor loads in AC-3 operation with a rated current above 820 A. HDW-Hagenuk used two electrically interlocked DILM1000/22 vacuum contactors for the reversing circuit. DILM1000/22 contactors are suitable for switching motors up to a rated current of 1000 A. The resistance steps are switched with five additional contactors of type DIL4M115 to DILM500.

HDW-Hagenuk has been building ships for over 25 years and the company has been fitting ships with electrical equipment for nearly as long. Today the company is a subsidiary of HDW the largest shipbuilding company in Germany and is one of the leading system suppliers worldwide with its own manufacturing facilities. HDW-Hagenuk offers complete system solutions for merchant and marine shipping. The strength of HDWHagenuk’s marine engineering is the wide range covered by its two leading divisions for marine electronics and marine electrical engineering. Service and system expertise is ensured in all areas from development, design and engineering, to supply, commissioning, and service right up to after-salessupport.



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Please send me Moeller Solution regularly Please send us information on the following topics: 2004 Product overview Automation DILM und DILH high-capacity contactors ZEV motor protection

MFD-Titan® multi-function display EASY control relay XI/ON remote I/O XI/ON-XStart Fuseless motor-starter RAPID LINK decentralised drive control NZM circuit-breakers

Field Service onsite service MODAN ® power distribution system

PROFIMOD ZWK motor control and signalling system Electronic catalogue

The requirements of practical applications often give rise to new ideas which HDW-Hagenuk implements in marketable results, such as the ECDIS electronic sea map or the design of a ship’s bridge with state-of-the-art flat screens. Two congenial partners were found for the design of electrical equipment for bow thruster. Moeller emphasised its traditional expertise in the construction of switching and protective devices with the extension of its product range – right up to the highest motor ratings.

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