Automation with LOGO! and SIMATIC S7-1200
Transcription
Automation with LOGO! and SIMATIC S7-1200
GO! Automation with LOGO! and SIMATIC S7-1200 1/2016 siemens.com/go GO! 1/2016 Two become one 3 4LOGO! 8 and KNX module for lighting control Hand in hand for smart solutions Automation technology for buildings On the safe side 6KNX module enables pump control at a shopping center in Basel Five-star automation for guests and staff 8Building automation with LOGO! 8 at a luxury hotel in Greece More comfort in church 4 Kaeser 10LOGO! 8 makes lighting and heating control simple in a church in Töpen, Germany Know-how 13LOGO! 8 to KNX: Just try it Dust hazards safely eliminated 17LOGO! 8 ensures safe decontamination of asbestos Fully automated weighing and feeding 22Simatic S7-1200 ensures reliable processing of the smallest items 19 Always optimally aligned to the sun Siemens AG/W. Geyer The balloon in the bottle 24 Innovative beverage bottling with Simatic S7-1200 Product news 26Failsafe CPU, Energy Meter module, and firmware update 19Higher power yields at a solar power plant thanks to a micro-PLC Cover photo: Kaeser 2 GO! 1/2016 Automation technology for buildings Hand in hand for smart solutions “Home automation,” “smart home,” and similar terms are commonly heard buzzwords in the modern world, which is one of the reasons why smart system solutions are the focus of this year’s Light + Building show, under the slogan “digital – individual – connected.” installation in terms of comfort, aesthetic appeal, and expandability are met without going over budget. The expert tip on pages 13–16 describes how to get started connecting LOGO! to KNX. The articles on pages 4–7 provide more detail on applications of the KNX module in public and commercial buildings. The application range of the S7-1200 Basic controller is also being expanded with a number of new features. The new Energy Meter module, for example, provides energy management in the lower power range. And a new failsafe CPU will also expand the range of applications. A few of these appli cations are presented on pages 19–25. Siemens offers flexible automation solutions for residential and commercial buildings Publicis Pixelpark Siemens is providing the necessary solu tions and technologies to make buildings more efficient and enhance user comfort – because today’s developers are of course looking for energy-saving installation solutions offering maximum comfort and the widest range of safety and security functions. In the private residential building sector, however, the new-build phase especially entails a great deal of additional investment, and so there is rarely any spare cash for complete building automation. In combination with the new CMK 2000 communi cation module, selected KNX devices, and a well-planned infrastructure, LOGO! 8 can be deployed to handle building automation tasks. In this way, the demands of a modern 3 GO! 1/2016 Kaeser Kompressoren SE, Coburg, Germany Kaeser Two become one A global leader in the manufacture of compressed air systems based in Coburg in the Upper Franconia region of Germany deploys LOGO! in conjunction with the KNX fieldbus in many areas of the building control and utility supply systems for its factories. Thanks to the easy migration of an energy-saving lighting control to the high-performance latest-generation LOGO!, in one of the production facilities the number of base units has now been halved from two to just one using a KNX module. Founded in 1919, Kaeser Kompressoren SE today employs more than 5,000 people worldwide – with just under 2,000 of them in Germany. The company’s product portfolio covers the full spectrum of compressed air generation, conditioning, and distribution. The growing familyowned business successfully markets its highly reliable, economical, and energy-efficient products and related services through branch offices and exclusive partners in more than 100 4 countries. Production facilities are in Germany, at sites in Coburg and Gera. Two new production buildings and an additional administration building are currently under construction at the company’s headquarters location in Coburg. The company has a long-standing system partnership with Siemens. “We particularly like the standardization, compatibility, and almost unlimited combinability of the solutions. We use a wide variety of Siemens products in our utility supply and building control systems, from transformers to KNX modules,” explains Stefan Gruber, head of Kaeser’s electrical infrastructure and systems technology department. He cites further benefits: “We can obtain all the electrical components we need from a single source; we can rely on expert advice and sup port in all areas; and long-term worldwide availability of replacement parts for the products is assured.” GO! 1/2016 Lighting as and when needed Gruber operates about 100 LOGO! units in his department alone, mostly in combination with KNX, as a flexible and convenient bridge, as it were, bet ween the KNX world and the conventional world. “It is something that has developed over many years,” reports KNX Manager, Christian Pohley, who programmed his first LOGO! way back in 1999, in the second year of his apprenticeship at Kaeser. “Back then it was used to switch the lights on and off in different factory areas, as well as providing a central switch-off function, controlled by buttons on a panel. Today, our lighting control with LOGO! is more diversified, and we use it in multiple buildings.” In the distribution center, for example, until recently two Logo! 0BA7 units connected to a KNX module switched the fluorescent ceiling lighting – grouped by area – in three separate phases: “Brightness sensors detect how much light is falling from the outside onto specific points in the logistics center precalculated by us,” says Gruber. “The light strips beneath the ceiling are divided into thirds, and if more light comes in from outside LOGO! switches off one-third of the »The LOGO! and KNX module no longer have to be installed in the same place, because the new module has network capability and is a stand-alone unit.« Christian Pohley, Kaeser Kompressoren overhead lights in the area concerned, then a second third in the next phase. With this solution we save around 25% on our electricity bill for lighting. With KNX alone, that could only have been done at much greater expense and effort.” The final third of the light strips provide the basic lighting that always stays on. Migration in two hours The migration to the new LOGO! 8 with the new LOGO! CMK 2000 KNX module took Pohley just two hours. “Of course, my many years of experience helped,” he says. “Drag-and-drop programming is very easy and has not changed essentially since the early days. But the best thing is that I now need only one unit instead of two. The reduction was possible because with the new KNX module I am able to configure the 50 communication objects via KNX, freely and indepen- dent of the analog and digital inputs and outputs – even with a maximum number of LOGO! hardware modules.” Another benefit: “The LOGO! and KNX module no longer have to be installed in the same place, because the new module has network capability and is a stand-alone unit. And that adds flexibility too: I can deploy the module where it’s most useful at any given time.” Based on this positive experience, Pohley will also be controlling the lighting in the two new production buildings in Coburg with the LOGO! 8. And he is also looking to install the likewise energy-saving ventilation and shading control that is already in use at the Gera plant. “There the LOGO! operates as a timer – again at an unb eatably low cost,” he says. “It receives the DCF [German longwave time signal] from the weather station on the roof via KNX, and I have programmed it so that, depending on the season, it opens and closes the blinds and the windows at specific times of day.” siemens.com/logo josef.ploch@siemens.com From fault signaling to gate control Kaeser Kompressoren uses low-cost, user-friendly, spacesaving LOGO! solutions in many other areas – with and without KNX. signal the fill levels of tank installations, as well as on numerous models, such as one for a turnstile gate (see photo below) in the company’s own training workshop. Applications include signaling for nonsafety and systemrelated faults, such as in heating and ventilation. They are logged by LOGO! for maintenance purposes and sent via KNX to the home server, which then in turn sends e-mail or SMS text messages to the appropriate personnel. Kaeser also uses LOGO! for intelligent c ontrol of the two pumps in an effluent pumping station and to monitor and Kaeser To enable the security officer at the main site to open and close the entry and exit gates of the remote location known as the Mobilair works from a KNX panel, Pohley installed a LOGO! 0BA7 unit at each location and connected them over the company’s Ethernet network. 5 GO! 1/2016 Schroer Elektronik, Steinen, Germany On the safe side The vacuum unit in the power substation of a retail and business park must meet stringent requirements, including trouble-free operation, easy operator control, and a secure KNX connection between the distributed controls and the central master control system. LOGO! 8 and the new CMK 2000 KNX module meet every requirement. The Stücki Shopping Center in Basel, Switzerland, which also incorporates a hotel and business park, is located on the site of a former dye works. At the heart of the complex is the power center, featuring an absorption refrigeration unit that generates both heat and cold utilizing the heat discharged from a special waste incinerator and a sewage treatment plant. This recovery of waste heat allows the buildings to be heated without using fossil fuel. The liquid separator separates the air/water mixture and removes the air from the plant water 6 Publicis Pixelpark/J. Koch As the water is routed from the heat exchanger to the refrigeration unit, the design results in air collecting in the pipes. A vacuum system from Busch AG has been installed to continuously suction off the air. If the refrigeration unit were to draw in air, it would malfunction. The machine would be blocked and would come to a stop. The two pumps in the vacuum unit are connected to a Busch liquid separator, which separates the air/water mixture and removes the air from the plant’s water. As the water collects in the bottom section of the separator, the air rises into the top section. Once the bottom chamber is full, the float switch sends a signal to the LOGO! 8–based vacuum unit controller. The logic module opens the valve, and the tank is emptied. LOGO! 8 as an intelligent controller in the KNX system Electronics company Schroer Elektronik, located in Steinen in the southern German state of Baden-Württemberg, has been manufacturing control cabinets and systems since 1991. Its services include the creation of automation solutions for pump systems, and it was the pump manufacturer GO! 1/2016 The second component of the project for Schroer was to connect the vacuum unit control to the central control system of IWB, the regional utility company in the Swiss canton of Basel-Stadt and energy supplier for heating and cooling operations of the Stücki power center. The new LOGO! CMK 2000 communication module provided the automation expert with the ideal solution for deploying the logic module with the KNX module as an intelligent controller within the KNX system as the foundation for the retail and business park’s building management systems. LOGO! 8 connects the KNX module via Ethernet. This means all the input/output addresses are left free for digital and analog signals. The operating states of the vacuum unit are transmitted directly over the KNX bus to the central control system and enable the plant operator’s building services to monitor operations from the technical services center. Professional backup from Siemens support Schroer has been using products from the LOGO! system line to execute a wide variety of automation tasks for years. “Reliability is one of the key benefits,” he says. “We have never had a faulty LOGO! back from a customer.” And when the new KNX module was launched, the automation and PLC expert quickly recognized its benefits too. “Thanks to the KNX interface, IWB’s service department is able to access the LOGO! directly from the control center and retrieve information on the operating states of the vacuum unit. The customer controls the systems in the power center but at the same time can monitor states centrally and intervene as necessary,” Schroer explains. The plant states are indicated on the LOGO! display as well as on a remote HMI. And the same information can be viewed on a monitor in the control center. Publicis Pixelpark/J. Koch that contracted company owner Bernd Schroer to design and implement the controls for the vacuum system in the power center of the Stücki Shopping Center. The PLC specialist chose to automate the plant with a LOGO! 8 12/24 RCE logic module. Experts who appreciate the LOGO! solution: Bernd Schroer, owner of Schroer Elektronik (left), and IWB systems engineer Roger Hafner Configuration made simple Schroer and his staff configured the control set-up for the vacuum system using the LOGO! Soft Comfort V8 software, which enables programs to be written and implemented quickly and easily. Communication functions are programmed by drag and drop. Individual program segments can be simulated, optimized, and merged into the overall functionality. “The functionality is rounded off by tools for compiling the documentation, with a switch ing program, comments, and parameter settings,” says Schroer. The operator control software offers different user interface languages and can be programmed accord ing to specific requirements. Processes and errors are visualized on the HMI. When LOGO! reports an error to the system, the service engineer can click on a button to view the details of the operating state. Publicis Pixelpark/J. Koch Schroer is full of praise for the professional backup provided by the Siemens support staff: “Service backup is always accessible, and they always respond without delay. Our questions regarding the KNX interface were answered expertly.” The success of the shopping mall project has given Schroer plenty of optimism for the future. “We have high demands in terms of the functionality and u ser-friendliness of our solutions. In Siemens we have a reliable, expert partner for all aspects of automation.” Vacuum unit control with LOGO! 8, the CMK 2000 communication module, and the CSM 12/24 switch module siemens.com/logo josef.ploch@siemens.com 7 Princess Andriana Resort & Spa GO! 1/2016 Pantelis Katsidonis & SIA EE, Rhodes, Greece Five-star automation for guests and staff In the Princess Andriana Hotel & Spa in the former fishing village of Kiotari on Rhodes, electrical, instrumentation, and control design specialist Pantelis Katsidonis & SIA EE developed and implemented a cost-effective solution for the monitoring and control of building functions. The state-of-the-art room electronics concealed from the guests’ view feature LOGO! microcontrollers. 8 At the five-star Princess Andriana resort, state-of-the-art management systems implement the buildings’ comfort and safety functions, all controlled in an energy-efficient manner by LOGO! in conjunction with a Siemens building automation system. The resort offers a total of 481 guest rooms spread over a main building and several bungalow complexes. There are single, double, and family rooms, with balcony, terrace, or access to a private pool. The main building houses a lobby, a reception desk, an Internet lounge, restaurants, and coffee bars, as well as a spa area and fitness room. Illuminated, music-activated water fountains provide breathtaking visual effects in the evening hours. The contracting team from Pantelis Katsidonis & SIA EE has specialized in electrical installations and energy management system design since 1992. Timed for the start of the 2015 season, the electrical, instrumentation, and control design experts upgraded the Princess Andriana’s power switchboard, which now incorporates KNX building automation modules. Six LOGO! 8 units with expansion modules and analog outputs were installed in the remodeled switchboard. GO! 1/2016 Princess Andriana Resort & Spa Illuminated, music-activated water fountains provide breathtaking visual effects in the evening hours The logic modules control functions such as the ventila tion systems in the hotel complex’s lobby area, supplied by 10 single-phase inverters. tion. The rooms’ air-conditioning and lighting are controlled according to whether there are guests present. A master button centrally switches all assigned functions on and off. Remote support via VPN To ensure smooth operation of the systems, the hotel’s building services manager presets the set-point values, which are then automatically executed by the program written using LOGO! Soft Comfort. One logic module serves as the master, transmitting the control commands to all the subordinate modules. One benefit of the new version of LOGO! is remote technical support via a closed communi cations network known as a virtual private network (VPN). From the LOGO! master unit, the engineer controls devices including the inverters through a web browser and is able to intervene in processes via the browser in the event of any errors. LOGO! also activates a welcome message and the room lighting when guests insert their room card in the slot on the door. When the guests enter their room, the TV turns on, showing a message such as “Welcome Mr./Ms. Smith,” followed by a promotional film about the hotel. Guests are able to operate all the in-room electrical systems with switches from the Siemens Delta switch range, as well as controlling the lighting, the blinds, and the air-conditioning system. When the card is removed when the guests leave the room, all electrical devices are automatically turned off. This saves energy The Greek electrical, instrumentation, and control design specialist has also implemented another hotel project based on LOGO! 8. In an expansion project at the five-star Atlantica Imperial Resort & Spa on Rhodes, the logic module was deployed for functional control covering 28 luxury apartments. The intelligent control system implemented by LOGO! 8 significantly reduces the hotel’s energy consump- Flexible automation of functions • Automatic dimming of exterior and pool lighting • Activation of reception lighting according to external light conditions • Motion-sensitive dimming of corridor lighting with presence detectors • Centralized and individual room temperature control • Control of room lighting, blinds, and drapes based on presets • Automatic operation of water fountains based on predetermined choreography Optimally coordinated systems To ensure that all technical processes run smoothly, safely, and energy efficiently, the building automation and the heating, ventilation, and air-conditioning (HVAC) solutions were implemented using the KNX communications standard. The Gamma building control has proved to be extremely efficient, offering high levels of comfort for guests, including optimal coordination of the lighting, sun protection, and in-room air-conditioning functions. These functions adapt to changing requirements in the course of the day, providing a highly energy-efficient solution. Each lighting and HVAC function can be centrally monitored and controlled, including monitoring for any malfunctions. The building automation solution comprising LOGO! and a KNX bus system was chosen because of its flexibility and expandability. The electrical, instrumentation, and control design team also established the technical preconditions to control every room’s functions – whether lighting, air- conditioning, or blinds – from reception. The programming of the room controls worked very well, and the team met the deadline for implementing the project by the start of the season. There will be more automation projects featuring LOGO! – everyone involved is sure of that. siemens.com/logo christos.tsatsaronis@siemens.com 9 GO! 1/2016 Elektro Richter KG, Naila-Lippertsgrün, Germany In the church of the small Lutheran parish of Töpen in the Upper Franconia region of Germany, state-of-the-art control technology keeps everyone warm during services. Last December, the church’s heating and lighting systems were upgraded with two LOGO! 8 units with a Comfort Panel and remote communication capability. 10 Publicis Pixelpark/G. Fürstenberger More comfort in church St. Martin’s church in the 1,000-person parish of Töpen has a welcomingly bright, friendly interior enhanced by decorative floral paintwork on the gallery walls, ceiling, and pews. Concealed among the images are infrared heat emitters, which ensure comfortable temperatures during church services, funerals, and other events, even on the coldest winter days. Richter, son of the company owner and head of the technical department, says: “The firsttime use of a Siemens Comfort Panel made the solution in Töpen very u ser-friendly. We chose Siemens and LOGO! 8 mainly because the two LOGO! basic modules are so easy to connect in the maximum configuration and are also easy to connect to the panel via a switch module.“ As part of restoration work on the church building, electrical contractor Elektro Richter KG from nearby Naila-Lippertsgrün was engaged to update and simplify the instal led systems. Established 75 years ago and now operating throughout Europe, Richter employs 50 people and runs a lighting shop in Köditz. The company had in fact already performed similar work in other churches, in some cases using LOGO! Electrician Daniel More compact, easier to use Previously, the lights and heating were controlled by a console with many buttons soldered together by a member of the church community in his spare time. “By dismantling it and replacing it with the Comfort Panel, we made space in the equipment room,“ says Richter. “We were able to reduce the energy consumption of the heating system, but above all we made the Publicis Pixelpark/G. Fürstenberger GO! 1/2016 system easier to control. The CMR 2020 module supplied as a free extra synchronizes the time, meaning services always begin punctually, and also enables ope rators to switch the heating on or off as required by sending a text message from a cell phone.” The modification, programming, and testing were completed in about two weeks, just in time for Christmas. A LOGO! 8 logic module with two DM16 24R digital expansion modules controls the lighting. Lamps, spotlights, and chandeliers can be turned on and off zonally as before. New features in this application are the status indicator on the Comfort Panel and the centralized on/off function. Energy-saving fine adjustment The heating posed much greater challenges. For the regular Sunday services, Richter pro- grammed a three-hour preheating mode, which now no longer needs to be started manually but runs automatically at an individually specifiable time. Depending on the temperature measured by the temperature sensor inside the church, the heating starts up three hours or – after appropriate pauses – two hours or one hour before the service. Since 1789, St. Martin’s Based on predetermined heat-up times, the LOGO! calculates the required preheating time to reach the target temperature. If a freely programmable maximum temperature is reached or exceeded inside the church, the heating remains completely off. “This graduated operation saves energy, because previously the heating was running continuously every three hours, even when we set the system for shorter heating cycle times,” says Richter. He further improved the cycle stretches back to the 14th church has been delighting parishioners and visitors to the village of Töpen, Germany, with its bright interior and decorative floral paint- work. The history of the Lutheran parish church century. At that time, a smaller chapel stood on the same site 11 GO! 1/2016 Publicis Pixelpark/G. Fürstenberger Publicis Pixelpark/G. Fürstenberger »The operating mode of the heating system can be quickly identified by the background color of the new LOGO! display: red means the heating is on; white means it is paused.« Color-coded graphical views of the church’s nave on the Comfort Panel indicate to the operator which pews and/or galleries are currently being heated control: “Now the pastor can set the thresh ld temperature for cyclic operation of o the heating. When the next temperature set point is reached, the heating system halves the cycle time.” A user-friendly special feature in the Töpen church remains, in that the cycle itself can also be individ ually programmed. One heating period always lasts 30 seconds, but it can be split into two manually as required, such as 15 seconds heating and 15 seconds pause, 10 seconds heating and 20 seconds pause, and so on. A further comfort bonus: the cycle can be set separately for each heating circuit, comprising three pew heaters, by means of touch sliders on the Comfort Panel. A second timer in the LOGO! handles services or other events outside the normal service schedule based on the same heating principle, with heating start times freely selectable by day and minute. There are also two external timers: one programmed by Richter each December with a calendar function to provide automatic heating for “one-off” services during the year (such as at Easter or on Whit Sunday), and one with which the pastor can switch the heating on and off manually at any time, such as to protect against freezing. Perfect interaction The operator can see the heating status by the background color of the new LOGO! display: white means the heating is on but 12 Daniel Richter, Head of Technical Department, Elektro Richter is paused; red means the heating is running. Color-coded graphical views of the church’s nave on the Comfort Panel additionally indicate to the operator which pews and/or galleries are currently being heated. Along with the easy connectivity by drag and drop, Richter likes the flexible modular expandability of LOGO!: “Including the Comfort Panel, I get practically all the elements of the solution from a single source, from one point of contact, and they all work perfectly together. And when I did have a question – specifically about the Comfort Panel, which I was using for the first time – I got help immediately.” The high maintenance required by the previous control console was cut virtually to zero by the state-of-the-art technology: “LOGO! is a standard product that I can reorder at any time. If I needed to replace something, all I would need to do is reload the existing program,” Richter concludes, looking ahead. “Also, if the requirements for any of our future church upgrade projects are similar, I can reuse this pro gram, and I will just have to adjust minor details.” siemens.com/logo matthias.witschel@siemens.com KNOW-HOW Siemens AG Expert tips: Connecting LOGO! 8 to KNX LOGO! 8 to KNX: Just try it Together with the new CMK 2000 module for connection to KNX and selected KNX devices, LOGO! 8 offers a highly flexible automation solution that provides customers with a wide range of benefits and ease of operation at an affordable cost and can be updated to accommodate changing room usage at any time in the future. The following briefly describes how LOGO! 8 can exchange data with other KNX devices. There are many vendors of KNX devices, so only the basic configuration of LOGO! 8 on the KNX is outlined here. 13 GO! 1/2016 What do you need to get started? – LOGO! Soft Comfort demo version + – ETS5 demo version • 50 freely configurable communi cation objects Both are available to download free from the Internet (see link listing at end). • Maximum usable LOGO! capacity Screenshots property of Siemens AG To check out the programming requirements, all you need initially are two things: The LOGO! 8 base unit and the CMK 2000 KNX module communicate via Ethernet. This delivers significant advantages over previous versions: Figure 1 • Ability to use logic operations and time and analog functions within the LOGO! program as well We assume you are already familiar with LOGO! programming, and so we will focus on connecting to KNX: 1. Transmitting a binary signal from LOGO! 8 to a KNX device 2. Transmitting a binary signal from a KNX device to LOGO! 8 and integrating into the LOGO! program For example, a fan is controlled by an on/off delay (Figure 1). In LOGO! Soft Comfort there is initially no indication as to whether a KNX module is connected or not. Figure 2 Depending on the application, a telegram can be sent to KNX either directly from the input (without even needing to use the input in the LOGO! program) or from the output (if there are multiple links, also by way of a flag in the program). The best view for beginners after opening the ETS software to create a new project is “Devices.” Insert the LOGO! device into the initially empty project with the CMK 2000 (Figure 2). Figure 3 To be able to use the CMK 2000 in ETS, first import the matching product database. You will find this knxprod file ready to download at siemens.de/gamma-td?te2=CMK2000 Figure 4 14 Take care: there are various previous versions. It is the file displayed here that must be imported. GO! 1/2016 After the database has been imported, the CMK 2000 module is displayed in the product catalog and is available for further use in the project. Now add the CMK 2000 module to the project by choosing “Add device.” It is then displayed in the device list (Figure 3). Figure 5 When you select the module from the list and then open the “Parameter” tab at the bottom of the screen, you first see the basic settings for the CMK 2000 module (Figure 4). It is important to enter the IP addresses of the LOGO! base unit and the CMK 2000. In the example, the default addresses have been retained. The other settings are irrelevant for the time being. Figure 6 Now specify a communication object for data exchange, such as for channel 1. When you select channel 1 and specify the direction of transfer from LOGO! to KNX, you see a list of data types to choose from. In our example, digital input I1 is to be used (Figure 5). As in the LOGO! program, input I1 is selected. The default data type matches the signal (Figure 6). Figure 8 Figure 7 Next, assign the communication object now shown for channel 1 to a group address. To do this, click on the row of the communication object in the “Group address” box, choose “Link with,” and assign a new group address with an appropriate name (Figures 7 and 8). Later, the signal in the group address will be linked to the communication object of an actuator on KNX. Figure 9 To process a switching signal from a KNX device in the LOGO! base unit, select the opposite direction for the communication (Figure 9). Here, flag 10 in the LOGO! device is controlled over channel 2. The program in the LOGO! device is then as shown in Figure 10. Figure 10 This corresponds to the program from before, except that the input has been replaced by the flag configured in the ETS. 15 GO! 1/2016 Analog signals are handled similarly. This topic is not discussed in detail in this article, which just presents the most basic scenario where the analog input does not need to be used in the LOGO! program. Only the transfer of the value at the terminal of the analog input to KNX is enabled (Figure 11). The transfer from KNX to LOGO! 8 is shown in Figure 12. Figure 11 Here, the value must be included via an analog flag for further processing in the program (Figure 13). In the example, the heating is switched on at low temperatures, and off above 200 (here an unscaled value; LOGO! works with analog values from 0 to 1,000). For a detailed description, refer to the application examples on the LOGO! pages. siemens.de/logo-anwendungsbeispiele Figure 12 LOGO! Soft Comfort V8: siemens.de/logo-demosoftware ETS5 demo version: my.knx.org (free registration required for download) Figure 14 LINK:_KNX Downloads_ siemens.de/gamma-td?te2=CMK2000 Figure 13 siemens.com/logo josef.ploch@siemens.com Figure 14 16 GO! 1/2016 deconta GmbH, Isselburg, Germany Asbestos is a natural mineral fiber that does not burn, decay, or rust and that acts as an insulator against cold and noise. Thanks to its durability, asbestos was widely used in the past to make corrugated roofing boards and as insulating material. It has in modern times been declared a harmful pollutant, and its use is banned by law. Even the minutest quantities of fibers entering a person’s airways can cause incurable bronchial and lung disease. However, asbestos residues are often still found in industrial plants and residential buildings, so major efforts must be made to clear the properties affected. These clearing operations can be quite complex, depending on the type of asbestos-contaminated material installed, because no fibers can be allowed to be released; they must be captured in their entirety and disposed of in such a way as to eliminate any risk to human health or the environment. deconta, based in Isselburg in the Lower Rhine region of Germany, specializes in helping companies clear asbestos residues. One of the technologies the company develops and manufactures is mobile air locks through which personnel enter and exit contaminated zones. The air locks comprise multiple chambers, depending on the standard to which the clearance work is being carried out, divided into so-called black and white zones. Exiting from the contaminated environment, a worker enters the first air lock chamber in the black zone. After a precleaning stage, the worker showers in a special room. Publicis Pixelpark/J. Koch deconta develops and manufactures high- end decontamination systems based on both existing and new technologies to prevent asbestos residues such as those found in industrial plants and residential buildings from being transported into the environment, either by way of uncontrolled air exchange or by adhering to work clothing. The systems are automated with LOGO! 8. Photograph courtesy of the U.S. Geological Survey Dust hazards safely eliminated »Our plan to make tried and proven systems even safer and more efficient with LOGO! has been an unqualified success.« Christian Krolle, CEO, deconta 17 GO! 1/2016 Interface to remote monitor As part of a comprehensive upgrade to deconta’s tried and proven “deco mobil” mobile air lock, the existing manualswitch-based control system was replaced by the LOGO! 8 12/24 RCE logic module, installed in the air lock system’s control cabinet together with the DM8 12/24R and AM2 digital and analog expansion modules. This solution enables even complex standards to be met, and sensors can be installed to make operations even safer. To visualize the air lock functions, LOGO! is connected to the KTP 400 Basic color touchscreen display via the Profinet interface. The interface is also used to program the micro-PLC with LOGO! Soft Comfort. Another benefit of using the KTP 400 is the ability to customize the input screens via an intuitive menu structure, as well as multilingual user guidance on the HMI. This means deconta’s customers are able to easily configure the deco mobil to meet specific on-site requirements and can monitor the system to ensure safe, trouble-free operation. Operating states are continuously displayed, enabling timely intervention – such as filter replacement, for example – to maintain safe operation. deconta engineer Martin Hemming (right) explains his app to Siemens sales executive Björn Muthmann To make controlling the mobile air locks as user-friendly as possible, deconta engineer Martin Hemming has developed a smartphone app. He explains: “LOGO! sends an SMS text message to a smartphone, which translates the commands into understandable graphics. Users can see at a glance which air lock functions are active. Data displays include the water and diesel tank fill levels, the water and heating temperatures, the pump mode, and the lighting status.” The smartphone app can also be used to control all LOGO! functions remotely. At the click of a button in the user’s smartphone app, a text message is automatically sent to the communication module, which immediately returns a confirmation. “Our plan to make tried and proven systems even safer and more efficient with LOGO! has been an unqualified success,” reports deconta CEO Christian Krolle. “We can now put together complex sequences that were not previously feasible. Functions that we previously had to set manually are now controlled by the logic module. It activates the complete system on a timer basis, for instance, and ensures that the air locks are preset to the right temperature and ready for operation at the start of each shift. That provides enormous improvements in energy efficiency.” In some cases, for example, the law requires that the vacuum unit be kept running for a certain time after a decontamination cycle, a job that Krolle believes LOGO! handles very well. Once a week the LOGO! timer activates the water heating in the airlock tank to prevent the growth of legionella bacteria. Krolle concludes: “The automation makes the decontami nation work much safer and minimizes the health risks of workers in the decontamination area.” deconta deconta’s engineers enhanced the LOGO! solution to work with mobile communications using the CMR 2020 commu nication module. It is designed to work with the LTE (Long Term Evolution), UMTS (Universal Mobile Telecommunications System), and GSM (Global System for Mobile Communications) standards. deconta uses the communication module for remote monitoring, alarm signaling, and control of the mobile air lock systems. It also allows users to track a mobile air lock by GPS and view its current location on Google Maps. Publicis Pixelpark/J. Koch This process ensures that workers do not come into con tact with the hazardous asbestos fibers, and the worker can then safely get dressed in the white zone. Negative pressure prevails throughout the system, and there is also a guided airflow. Asbestos fibers must be prevented from escaping from the work area into other rooms or the out side environment, either through openings or by adhering to clothing. Illustration of the deco mobil mobile air lock system 18 siemens.com/logo bjoern.muthmann@siemens.com GO! 1/2016 Since the installation of 229 solar modules that auto matically track the movement of the sun, the Bindlacher Berg solar power plant has been producing almost a third more yield. The tracker units are controlled by an integrated solution based on Simatic S7-1200 controllers and the Solar Tracking Toolbox. Bindlacher Berg solar power plant: 229 dual-axis sun trackers deliver approximately 2.4 MWp of power The investors in the Bindlacher Berg solar power plant near Bayreuth, Germany, have good reason to be pleased. The 229 solar modules on the 7.3-ha former military barracks site can now – either individually or collectively – be automatically aligned exactly to the sun on two axes, and this yields over 30% more power compared to fixed installations. Each tracker has a power output of 11 kWp; the total of approximately 2.4 MWp can power as many as 1,000 households. Automation tried and proven in industry The solution was implemented by Gerlitz elektro-gmbh based in Bayreuth. The project team, headed by engineer Matthias Pellert, implemented an automation solution based on modular, expandable Simatic S7-1200 Basic controllers and the modular Solar Tracking Toolbox, in which Siemens has bundled various largely preas Bindlacher Berg solar power plant, Bindlach, and Gerlitz elektro-gmbh, Bayreuth, Germany Siemens AG/W. Geyer Always optimally aligned to the sun 19 GO! 1/2016 Siemens AG/W. Geyer Gerlitz elektro-gmbh project manager Matthias Pellert (left) and Tobias Ködel from Siemens appreciate the fact that the system can be controlled and monitored both locally and remotely sembled and tested functions, applications, and concepts for special tracking tasks as well as viable, modifiable sample projects. The control system, tried and proven in industrial applications, is rated for operating temperatures from -20°C to +60°C, which means it can be operated in the on-site switchboxes on the trackers all year round. The selected CPU 1212C is also powerful enough to handle online tracking computation based on the high-precision Solar Position Algorithm created by the US National Renewable Energy Laboratory (NREL), which Siemens has implemented in a licensed base module for its control system. The algorithm is able to determine the position of the sun depending on the time of day to an accuracy of 0.0003° for the next 6,000 years. Distributed control system The CPU computation offers the advantage that the trackers operate with no higher-level control and can work autonomously. The control systems also have enough resources for all other tasks, including commu nications (also via web server) and sensor and actuator monitoring. With robust absolute value encoders, which are connected in a simple and failsafe manner to the S7-1200 by a CM 1241 communication module via an RS485 interface and using the Modbus protocol, every controller knows the position of “its” tracker even after a power 20 failure, and on resuming is able to move it rapidly to the correct position. To avoid unnecessarily high network loads, not all 229 trackers are moved simultaneously. Instead, they are moved in groups at offset times. This function, too, is parameterizable from the free Toolbox. Integrated to create a modular solution The Simatic S7-1200 can be easily configured and programmed via TIA Portal, as can the Simatic HMI Comfort Panel for monitoring and control of the solar power plant in the central control station. For monitoring and control, systems inte grator Gerlitz adapted the precompiled sample applic ation for the Simatic WinCC visualization system and generated its own user interface by which all 458 tracker axes are monitored and controlled. Another basic function of the Solar Tracking Toolbox, so-called back tracking, has also been implemented. This prevents solar modules from overshadowing each other when the sun is low in the sky. At high wind speeds the modules are likewise moved automatically to a safe storm position. Snow can also be tipped off the modules in winter by setting them at a greater tilt angle. Remote access via VPN, tablet, or smartphone A Simatic IPC 427C industrial PC (Microbox PC) acts as the master computer for the entire solar park. The Microbox runs a standardized communication algorithm; detects the tracker controllers in turn over multiple channels via an Ethernet connection; and visualizes their operating state, current positions, error messages, and other operational data. A specially developed data concentrator optimizes commu nications. Error messages can be sent by e-mail and text message (SMS) to freely definable recipients. Operators can also log in to the system from home via a VPN (virtual private network) using the Sm@rt Server WinCC option. Remote access is even possible with a tablet or smartphone, using Siemens’ specially developed Sm@rtClient app. Generally, authorized users are able to access the plant remotely to control and monitor it without any engineering system. This is most easily done using the web server built in to every tracker controller, which provides precompiled customer-specific HTML pages containing relevant data for down loading. siemens.com/s7-1200 tobias.koedel@siemens.com GO! 1/2016 The technology dictates the yield Thanks to its relatively high peak power output, the Bindlacher Berg solar power plant is ranked third among all tracking photovoltaic plants in Germany. We asked Michael Krokauer, chief executive and technical manager and member of the plant’s investor group, about his experience. Mr. Krokauer, the Bindlacher Berg solar power plant has been running the tracking system since mid-2014. How is the system meeting your expectations under what are, after all, the often gray skies of the Upper Franconia region? The plant has been much more stable and reliable since the system was commissioned. Above all, however, we are well on our way to achieving the theoretically possible yields in practice, both when the sun is shining and on cloudy days. Our yield is currently at least 30% higher than that of fixed installations, with still more potential to improve. We are thoroughly satisfied with every sunbeam that we are able to optimally convert into electrical power, which is then fed into the public grid in accordance with Germany’s Renewable Energy Act (EEG). What were the key factors in that success? The special functions of the Siemens control systems, including the back tracking function and optimized tracking control, enable us to achieve more than ever before, even when confronted with unfavorable situations. The technology dictates the yield. »Our yield is currently at least 30 percent higher than the yield of fixed installations.« Our replacement parts supplies are now also assured for many years, and the breadth of the Siemens product portfolio offers alternatives if new weaknesses are revealed in the original equipment. So our investment is secure for the future. That’s right. That is also what I meant by reliability. And the industrial automation technology provides a guarantee in that respect. With regard to malfunctions or failures, we and our partner Gerlitz have a range of options for secure remote access to the plant via the central master computer. The tracker controllers automatically report errors via SMS and e-mail, and we are able to see what is wrong and what needs to be done to remedy the situation, wherever we may be. That reduces downtime, eliminates unnecessary travel, and thus cuts costs. Siemens AG/W. Geyer Other essential factors in achieving sufficiently high margins are keeping maintenance costs within manageable limits and quickly detecting and eliminating failures, correct? Michael Krokauer Chief Executive and Technical Manager, Bindlacher Berg Solar Power Plant 21 Siemens AG/HL Studios GO! 1/2016 The K&K weighfeeder features two weighing lines and has a resolution of 0.002 g K&K Wiege- und Dosiertechnik GmbH, Fernwald, and Rohrbach Elektrotechnik GmbH, Butzbach, Germany Fully automated weighing and feeding Automatic weighfeeders must operate precisely, quickly, absolutely reliably, and (as far as possible) around the clock – also without operating personnel. This is what wholesale, retail, and industrial customers expect. A solution comprising the Simatic S7-1200 controller and the ET 200AL distributed I/O system optimally meets these requirements. K&K Wiege- und Dosiertechnik, based in Fernwald in the German state of Hesse, has been designing and manufacturing automatic weighers, counters, and feeders as well as complete packing lines for more than 25 years. CEO Egbert Ruß is focused on top product quality and reliability and always employs state-of-the-art technology. That was also the case when he developed and successfully commissioned a fully automated weighfeeder for an electrical engineering company in partnership with contractor Rohrbach Elektrotechnik from Butzbach, Germany. 22 Maximum precision for the smallest items Siemens Solution Partner Holger Rohrbach is a specialist in applications of the Simatic S7-1200 Basic controller, which was the microcontroller he used to automate the weighfeeder. The weighfeeder collates tiny items with single weights of 0.07 g to create packaging units of an exact quantity. The quantity is determined by weight. The weighfeeder has a resolution of 0.002 g, with a tolerance of one item above the specified quantity. The controller rules out the possibility of one item being omitted. GO! 1/2016 »Customers are often surprised at what can be done with the Simatic S7-1200, especially on smaller plant units. And if it is not quite adequate, we can easily transfer a project to the Simatic S7-1500.« Siemens AG/HL Studios Holger Rohrbach, K&K Wiegetechnik If two or more items above the specified quantity fall on the scale, the batch is rejected and the items are fed back in. The packaging process also runs fully automatically overnight, outside shift operations; all the personnel need to do is fill up the container in the evening. The weighfeeder operates with two weighing lines of differing widths. The items are fed in by vibrating conveyor channels. The wider channel delivers 90% to 95% of the target weight. Single items are then fed in via the narrow channel until the desired total weight is reached. The weights are measured by two Siwarex weighing modules. Wiring minimized To enhance reliability, K&K and Rohrbach eliminated vir tually all wiring, because “80% of all malfunctions in such systems result from wire breaks,” Ruß asserts. So all the inputs and outputs – the digital ones for the valves and limit switches and the analog inputs for the ultrasonic fill level sensors on the vibrator – are connected by way of the new compact ET 200AL distributed I/O system with IP65/67 protection. Ruß adds: “Having the distributed I/O directly in the plant on Profinet is in our view a major improvement in terms of the quality of our systems. The possibility to use much smaller switchboxes thanks to the relocated peripherals will also pay off in the future.” He agrees with Rohrbach that they have found a standard solution with which additional markets can also be opened up. “We believe a system of this kind will be highly attractive wherever goods are currently still weighed manually, because a rapid amortization period of two years is realistic.” TIA Portal. As a result, different target weights can be achieved with high accuracy even at the bulk feed stage. Then only a small quantity must be fed in to provide fine adjustment in the final stage. All this takes place with extremely high levels of user-friendliness. The operator just needs to enter the target weight, and the control optimizes itself. siemens.com/s7-1200 tina-maren.weith@siemens.com The Simatic ET 200AL I/O system directly on the machine integrates the sensors and actuators by M8 connectivity and communicates with the controller via Profinet Siemens AG/HL Studios Self-optimizing control A major highlight of the solution is the volume flow control accuracy on the vibrating conveyor channels. Because the bulk product can be distributed differently when fed in, the speed and frequency of the vibrator must be adapted depending on the fill level. The more effectively that is done, the faster the plant can run. Rohrbach programmed the controller with Structured Control Language (SCL) for Simatic S7-1200 integrated into 23 Siemens AG/W. Geyer GO! 1/2016 Leibinger GmbH, Teningen, Germany The balloon in the bottle The filling machines from Leibinger GmbH in southern Germany might soon see the climate killer CO2 disappearing from the beverage industry. The company’s revolutionary “Balloon-Style” technology is not only environmentally friendly and resource efficient; it is also the fastest filling method in the world. The machines are controlled and monitored by Simatic S7-1200 Basic controllers. 24 Making beverage bottling machines without CO2: CEO Benedikt Leibinger (right) and his automation specialist, Christoph Mutschler To preserve the taste, appearance, and shelf life of beer, wine, sparkling wine, and soft drinks, the beverages must not come into contact with oxygen during the bottling process. This is why the beverage industry has always flushed oxygen out of bottles beforehand with carbon dioxide (CO2) – a complex, costly, and environmentally unfriendly method. “Especially for smaller producers, who are our customer base and who often look to gain a competitive edge through ecologically sustainable production, that is uneconomical and bad for their image,” explains Benedikt Leibinger, whose Leibinger GmbH company specializes in bottle-filling machines. To address these issues, he got together with his designers to devise a method that eliminates the need for CO2 altogether. Award-winning method Leibinger’s now patented solution, Balloon-Style, removes the oxygen with the aid of a vacuum. A tube made of the recyclable plastic TPE, which needs to be changed only once a day, is fed into the empty bottle and inflated to create a balloon. Due to the internal pressure, it presses completely against the inside wall of the bottle, pushing the oxygen out. The beverage deflates the balloon again as it is poured in, and the balloon is removed from the bottle. As well as eliminating the need for CO2, GO! 1/2016 the main benefit of the method is that it prevents swirling and foaming. As a result, it now takes just one second to fill a half-liter bottle, compared to five seconds previously. That saves customers time and money. Leibinger’s method so impressed the industry as a whole that the company was awarded the German Innovation Prize for Climate and Environment, sponsored by the German Federal Environment Ministry. Tailored automation The Balloon-Style plants are automated by Simatic controllers and Comfort Panels, configured and programmed using the TIA Portal engineering framework. “The Basic controller, with its six integrated high-speed counters, fits optimally into our modular machine set-up,” reports Christoph Mutschler, Leibinger’s head of control and auto mation technology. Each S7-1200 CPU controls six fill valves on the Leibinger machines. Six magneto-inductive flowmeters measure the fill quantities. They are connected to the six count inputs of the PLC. To fill the exact quantity, the fill valve’s switching must be continually adapted to the postflow quantity. Mutschler explains: “Even minimal variations in the fill valve settings would be imme- diately noticeable by differing fill levels in the bottles. That is why we log the characteristic curves of every bottling operation and continually adapt the compensation.” The ser vice engineers are able to monitor the enormous volumes of data this creates on a PC via the integrated web server of the Simatic S7-1200 controllers. The S7-1200 controllers are connected as I-Devices to the filling machine’s central controller, a Simatic S7-1500, via a slip ring. At this point, a CPU 1511 is sufficient for integration of the drives and coordination of the sub ordinate Basic controllers. The central controller also communicates with a Simatic Comfort Panel for plant control and monitoring. High-efficiency engineering Mutschler greatly appreciates the controllers’ new trace function for fine adjustment of the fillers. “The flow rate and pressure must be kept absolutely constant. The trace enables us to remedy errors more quickly and drive improvements more efficiently.” For the Balloon-Style filler, Mutschler for the first time made productive use of the TIA Portal engineering platform. His appraisal: being able to program with Structured Control Language (SCL) throughout has greatly improved efficiency. “It allows programming independently of the filling points. The programs can be quickly and easily upgraded to include the required numbers of filling points. Changes are made just once and automatically applied to all filling points. The con sistently implemented symbolic access makes doing all that much more user-friendly.” High levels of user-friendliness Leibinger places great value on the high levels of user-friendliness of his filling machines: “Our customers expect that new technology can be applied by the master brewer without need for significant instruction. On the Simatic Comfort Panels, we are able to implement clearly structured, easily understood operator interfaces, as well as including additional guides – even in video form. If required, we can also log in to the customer’s plant remotely from here via Sm@rtServer to assist with diagnostics and maintenance after the sale has been completed.” siemens.com/s7-1200 tina-maren.weith@siemens.com How Leibinger Balloon-Style technology works The balloon is inflated with air or by vacuum. The balloon fully lines the inside of the bottle and the valve. The beverage is filled in a circular pattern, and the balloon is deflated. The fill valve is closed. The balloon is placed back on the guide tube. The bottle pressure is released. Leibinger GmbH The bottle is pressed against the fill valve and the balloon is inserted. 25 GO! 1/2016 SM1238 AI Energy Meter module Transparent energy flows for increased efficiency Exact measurement of energy flows is fundamental to any energy management system. The SM1238 AI Energy Meter module for Simatic S7-1200 is an ideal entry-level tool for machine- oriented energy management. It records the electrical parameters in the plant, such as overload, overvoltage or undervoltage, and load voltage. The measured values are processed directly in the CPU. The module is just 45 mm wide, making it extremely compact and space saving in the control cabinet. It also impresses with its low acquisition cost and large number of available measurements. The Energy Meter module enables energy management based on more than 40 energy measurement values. The module records electrical mea surements in single- and three-phase systems, and it can directly measure voltages up to 480 V AC without a transformer. Siemens AG Saving energy and optimizing its use are critical in the modern-day world. Energy management – based on know ing where, when, and why energy is consumed – plays a key role in enhancing the productivity of industrial plants. siemens.com/s7-1200 Simatic S7-1200 CPU 1212FC New safety CPU A new safety CPU will be available for the Simatic S7-1200 automation system with firmware Version 4.2. One of its advantages over conventional solutions is its reduced wiring. As no additional F-module is required, a slot is also freed up on the CPU 1212FC for expansions. The response time is improved because the CPU 1212FC is able to control the distributed I/O devices directly with Profisafe. Drives receive commands within microseconds. As another new feature, the emergency stop (E-Stop) functions on Simatic Comfort Panels can now also be connected with Profisafe. TIA Portal New firmware for Basic controller With TIA Portal V14, the firmware of the Simatic S7-1200 Basic controller is being updated to Version 4.2. The firmware update includes the following additional functionality: • Media Redundancy Protocol (MRP) for two-port CPUs 1215/17, providing more flexibility when constructing networks (e.g., flexible ring topology possible) and improved network availability Siemens AG siemens.com/s7-1200 • Backup/restore and automation unit copy with data remanence to protect against data loss (project data with actual values) siemens.com/tia-portal siemens.com/s7-1200 26 GO! 1/2016 siemens.com/magazine The Siemens Customer Magazine 2010 Future Publishing Find out about key trends in technologies, sectors, and markets – with views and insights from international experts and decision makers from industry, science, and the political sphere. In the Industry category you will find trends, facts, and solutions. Read industry-specific features and articles on the growth fields of electrification, automation, and digitalization. The Siemens Customer Magazine’s multimedia content embodies what drives Siemens: innovative strength and providing custom solutions that deliver a competitive edge. Keep your finger on the pulse of the modern age! Subscribe to our topic-focused newsletter and magazine now: siemens.com/magazine 27 Published by © Siemens AG 2016 Digital Factory Gleiwitzer Straße 555 90475 Nuremberg, Germany For further information please visit: siemens.com/s7-1200 siemens.com/logo Article No.: DFFA-B10142-00-7600 Printed in Germany Dispo 06307 17/78068 BR 0316 Subject to changes and errors. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described, or which may undergo modification in the course of further development of the products. The requested performance features are binding only when they are expressly agreed upon in the concluded contract. DELTA, ET 200, S7-1200, S7-1500, Siemens LOGO!, SIMATIC, SIWAREX, TIA Portal, and WinCC are registered trademarks of Siemens AG. Any unauthorized use is prohibited. All other designations in this document may represent trademarks whose use by third parties for their own purposes may violate the proprietary rights of the owner. Follow us: twitter.com/siemensindustry youtube.com/siemens