Modular plugging, flexible testingPlug-in test system for the protection of equipment in high- and medium-voltage systems

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Weidmüller Information & News | No. 12

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Extensive safety monitoring for biogas treatment based on membranes

Surge protection concepts with an edge for roof-mounted photovoltaic systemsWIN !More best connections inside. Let's connect.

Dear readers,

“Coming together is a beginning; keeping together is progress; working together is success,” said Henry Ford. We too believe that working together will, in the long term, be the basis for our success, the world over. It is our declared aim to maintain close proximity with our customers and partners around the globe and to continuously engage them in dialogue. This is the only way in which we can learn from one another and meet the needs and special requirements, in a practical and realistic manner, of every sector and every region.

With this in mind, last year in 2012 we concentrated our efforts on increasing our commitment in international markets. For example, we opened offices in Hong Kong and Finland. Towards the end of the year we signed a joint venture agreement with our Slovenian partner Iskra and we have just started 2013 by founding a sales office in Denmark. Our approach of using long-term joint ventures and partnerships to extend our global position was demonstrated by the number of anniversaries we celebrated in 2012, including 45 years of Weidmüller in Austria, 40 years in Australia and 30 years in Singapore. We have also been operational in Portugal, Hungary and the Czech Republic for 20 years now.

Our reward for these long-standing links is satisfied customers, impressed by our solutions. Operators of power stations and grids, for example, are able to benefit from our capability to continually address the requirements of their sector through measures such as innovation workshops. In return, the knowledge this gives us is seamlessly incorporated in new product developments, such as our all-purpose WIPRO test terminal strip, currently being used by grid operator TEN Thüringer Energienetze (p. 8-9). Solutions

of this kind clearly show what distinguishes our innovations: their unique proximity to our customers.

This edition of WIN! also includes other interesting customer projects from around the world,

and background articles on product innovations and technologies. I hope you find this issue stimulating and enjoy reading it.

With kind regards,

Volpert BrielSales and Marketing Director

»We believe in working together in the long term – the world over.«

2 | Editorial

ImprintThe next edition of WIN! will appear in April 2013, as a special edition for the Hannover Messe.

Editor:Weidmüller Interface GmbH & Co. KGGlobal Market CommunicationKlingenbergstraße 1632758 Detmold Germany

Editorial office:Julia BusseContact:win@weidmueller.com

Realisation: M.P. Media-PrintInformationstechnologie GmbH

Pictures: Weidmüller, shutterstock/Igor Bulgarin (p. 6), iStockphoto/TommL (p. 12+13), Bombar-dier (p. 14+15), iStockphoto/IgorIvanov (p. 17), fotolia/Andrei Merkulov (p. 22)

© 2013 by Weidmüller Interface GmbH & Co. KG. Reproduction and publication,in full or in part, only allowedwith express permission bythe Editor.

In Brief 4 Company news

New sales office in Denmark – German-Slovenian joint venture between Weidmüller and Iskra – 60 years of training at headquarters in Detmold – Combining marking with progress: the new PrintJet ADVANCED – Insight into the world of an orchestra: third Weidmüller talk with Christian Gansch

In Focus 8 Modular plugging, flexible testing

The all-purpose Weidmüller WIPRO test plug-in system supports all test scenarios that arise in a distributor system of TEN Thüringer Energienetze

In Action 10 Extensive safety monitoring

To ensure round-the-clock availability for the BORSIG biogas treatment systems, the intrinsically safe ACT20X signal converters support extensive safety monitoring

12 Plant-wide safety with the SIL-3 relaySIL-3 relays from Weidmüller underpin the functional safety of the several thousand safety switching circuits in a DCS system from ABB

14 A relaxed approach in the countrysideA surge protection solution from Weidmüller ensures a reliable warning of approaching trains in the innovative EBI Gate 200 level crossing from Bombardier, in all weathers

16 Surge protection with one eye on the futureWeidmüller’s product range includes surge protection concepts that meet the very latest standards governing the specific requirements of photovoltaic systems on the roofs of industrial buildings

In Detail 7 UL-certified crimp connection

With UL certification for its crimped insulated wire-end ferrules, Weidmüller opens up an infinite number of possible applications around the globe

18 Practical shieldingThorsten Ortjohann, product expert in earthing and shielding at Weidmüller, talks about the latest developments, the basics of shielding and the solutions of tomorrow

20 Compactness is the name of the gameWeidmüller’s practical connection solutions aid the manufacturers of industrial controllers at all performance standards of automation and systems engineering

22 Permanently supplied – part 1Weidmüller’s industry-specific solution concepts enable a high-availability, redundant power supply to be established

10 Extensive safety monitoringfor biogas treatment based on membranes

16 Surge protection concepts with an edge for roof-mounted photovoltaic systems

8 Modular plugging, flexible testing - test plug-in system for protection and secondary technology

3Contents |

Companies

Long-term link for new impetus in overvoltage protectionGerman-Slovenian joint venture between Weidmüller and Iskra

Weidmüller and Iskra Zaščite, the Slovenian experts in surge protection, signed a joint venture agreement in Ljubljana in November. The agreement includes the construction of a new production site in Brecise, Slovenia, as well as the development and production of innovative solutions for surge protection. The joint venture will trade under the name Weidmüller & IZ Surge Protection Products.

“We are pleased to have found our new partner Iskra, whose core competence

Dr. Peter Köhler, CEO of Weidmüller (right) and Dr. Otmar Zorn, owner of Iskra Zaščite (left), seal the deal on the joint venture between Weidmüller & IZ Surge Protection Products in Ljubljana.

in surge protection helps us tap into new markets,” enthuses Dr. Peter Köhler, CEO of Weidmüller. He was full of praise for the partnership, in which “Iskra will concentrate on developing and producing components, while Weidmüller focuses on a closely meshed sales network,” he continued. “Fusing such promise in the framework

of a joint venture will benefit both partners greatly.” Under the terms of the collaboration, Weidmüller will define the technical specifications for new solutions and the requirements of surge protection, whereas Iskra will be responsible for the development and production of products and their components.

Companies

New sales office in DenmarkBy founding an independent Danish sales office, based in Copenhagen, on 1 January 2013 Weidmüller took the next step in its strategic expansion of the Scandinavian market. “The Danish market is characterised by wind-based energy generation, the process industry and machine construction, which is increasingly demanding

application-specific solutions,” explains Weidmüller CEO Dr. Peter Köhler. “By founding Weidmüller Denmark, we are intensifying links with our Danish customers and partners and will be able to offer even faster solutions for tailored application-specific requirements.”

Weidmüller products and solutions have been used in Denmark for more than 50 years and until now have been sold by sales partner Wexoe. “Thanks to our wide and high-quality range, we have already managed to gain a foothold in the Danish market,” says Weidmüller Sales Director Volpert Briel, who believes that restructuring to

provide direct sales is both a sensible and an essential step. “To set

additional and new trends in the provision of new technologies and outstanding services, we now require our own sales team.”

4 | In Brief

Products

Combining marking with progress: the new PrintJet ADVANCEDThe new industrial printer, with built-in enhancements, is designed to meet the most exacting requirements of progressive automation.

6,000 markers in 45 minutes – the sensational result of a further development to the successful PrintJet range from Weidmüller. Regardless of the industrial surroundings, the PrintJet ADVANCED can be used as a stand-alone solution anywhere, at any time and without delay. If necessary, 24-hour operation is possible without the print process having to be monitored. Metal marker printing is available as standard and opens up

additional possibilities. Thanks to the integrated industrial PC, spontaneous orders can also be implemented at speed: the software components needed and all common standard layouts are pre-installed. Maximum system transparency and intuitive operation are provided by the pivoting touch panel. If you consider consumption, emissions and efficiency, the PrintJet ADVANCED is the cost-effective, state-of-the-art solution that combines marking with progress.

Companies

Commitment to training as an investment in the futureWeidmüller celebrates 60 years of training at the Detmold head office

When Roland Strötker arrived for his first day of work 60 years ago, he was one of a kind – the first apprentice at Weidmüller. Nowadays, the family-owned company helps around 200 junior employees enter professional life all over the world. Weidmüller celebrated “60 years of successful training” in November together with partners and other

interested parties at its Visitors’ Centre in Detmold – and Roland Strötker was among them. “As a technology venture our success is based on innovative capacity – time and again, qualified and creative junior employees provide a key impetus

for successful development,” affirms CEO Dr. Peter Köhler. But training also sees the company taking on social responsibility: “Demographic change, a lack of skilled workers – as a family-owned company, we believe it is our social obligation to help meet these challenges.”

Quite a lot has changed in 60 years: Sina Frings (1st from right), trainee cutting

machine operator, and Roland Strötker (3rd from right),

Weidmüller’s first trainee, explain the differences to CEO Dr. Peter Köhler (centre) and

Dr. Eberhard Niggemann (left), head of the academy, while

standing over a punch for metal parts

5In Brief |

Companies

Hitting the right note togetherThird Weidmüller talk with guest speaker Christian Gansch

Just before Christmas, over 200 invited guests enjoyed a new insight into the world of the orchestra during the third Weidmüller talk with conductor and producer Christian Gansch.

Afterwards, it was clear to everyone that, as in a company, harmonious interaction is key to the success of an orchestra. The audience discovered an astounding number of parallels between management processes in companies and orchestras.

What appears to be the effortless teamwork of an orchestra is shaped by complex mechanisms and clear processes. The balanced mix of independence and team spirit is all-important. Guest speaker Gansch has conducted the Deutsches Symphonieorchester Berlin and the BBC Symphony Orchestra, amongst others. “Every musician in an orchestra not only needs to master his or her own instrument, but also the art of playing together with others,” said Christian Gansch in his presentation. “The overall result doesn’t stem from prescribed harmony, but respect for other experts: listening to one another and working together is the recipe for success.” In the podium discussion that followed, Weidmüller CEO Dr. Peter Köhler agreed: “As a technology company, diversity is important to us for a thriving culture of innovation – sometimes that also means constructive friction.”At the same time, values such as respect, tolerance and also

modesty are of great importance to a family-owned company like Weidmüller: “That’s why we believe in interdisciplinary teams and open communication, even across company hierarchies,” explained Köhler. In his book “Vom Solo zur Sinfonie – Was Unternehmen von Orchestern lernen können” (“From solo performances to symphonies - what companies can learn from orchestras”), which was published in 2006, Christian Gansch explains the need for knowledge transfer within orchestras and how it relates to companies in the German-speaking world. He enjoyed international acclaim as a conductor and producer and is now a sought-after speaker and coach. The Weidmüller talks take place three times a year. “It is important to us that we give our staff and partners food for thought and promote active discussions on topics such as sustainability, values and leadership,” says Köhler, explaining the reasons behind the series of events.

6 | In Brief

7In Detail |

in the NAFTA area covering North America, Canada and Mexico, for example, the UL certificate signals an end to the trade and import restrictions of the past.”

Weidmüller offers a comprehensive range of crimp connection products, comprising wire-end ferrules (compliant with DIN 46228 Parts 1 and 4) with and without plastic collars and available in nominal conductor cross-

F or a safe and permanent crimp connection, all the parts need to be perfectly matched. Conductor ends with custom-

fit, wire-end ferrules don’t break off in the event of vibration loads. Compared with bare ferrules, wire-end ferrules with plastic collars deliver improved electrical safety and mechanical stability. They make possible a totally gas-tight connection. If wire-end ferrules and tools from different providers are used, DIN EN 60352-2 for solder-free connections may not be satisfied. The wire-end ferrules could burst as they don’t fit properly or the wire extraction forces may be insufficient. Weidmüller therefore provides you with a perfectly tailored, complete system, comprising wire-end ferrules and tool.

Good quality workmanship, working practices conforming to standards, long-term process stability

“Our crimp connections have proven themselves in billions of connections over the years. We have had UL certification for our plastic insulation, for a long time,” reports Tobias Sondermann, a tool expert who represents Weidmüller in North America. “UL certification of our wire-end ferrule, manual tool and crimping machine as a complete system, offers our customers infinite possible uses and ultimately, market benefits around the globe. For exporting companies

UL-certified crimp connection for market benefits around the world

»Our crimp connections have proven themselves in billions of connections over the years.”«

With UL certification for its crimped insulated wire-end ferrules, Weidmüller opens up an infinite number of possible applications around the globe.

sections of 0.14 mm2 to 50 mm2. Crimp sets, special tools, stripping and crimping machines to wire-end ferrule boxes and empty boxes with colour markings are also included. Precisely matched to one another, as a system these components represent consistently good quality workmanship, with working practices conforming to standards and long-term process stability.

Quality tools from Weidmüller are synonymous with optimum electrical contact processing

»As well as its flexible, modular structure, we are also impressed by the fact that WIPRO embodies the connection system and marking benefits of a modular terminal.«

Modular plugging, flexible testingTest plug-in system for protection and secondary technologyThe all-purpose Weidmüller WIPRO test plug-in system supports all test scenarios that arise in a distributor system of TEN Thüringer Energienetze GmbH. It is because the parties worked as partners on product development, that practical requirements have been seamlessly incorporated in the product solution.

M ains protection technology in high- and medium-voltage switchgear places

particular demands on power utility companies. The facility’s protective function needs checking, not just once before starting up for the first time, but

regularly during operation. As an industrial connectivity partner, Weidmüller has, for decades, supplied practical products for testing protective equipment: test disconnect terminals with various connection technologies have proven themselves on the market over many years. With its finger always on the pulse, Weidmüller has specifically developed and optimised this concept over time, in close collaboration with customers from the energy sector. This has resulted in the modular WIPRO (Weidmüller Interface for Protection Relays) test terminal strip.

The need for consistent standard system is satisfied

“By working closely with power plant and grid operators, we are continually learning their everyday requirements and incorporate this knowledge in our new product developments. And that’s exactly what happened with TEN Thüringer Energienetze, an ➜

8 | In Focus

E.ON Thüringer AG company,” reports Rötger Sander, an expert in energy technology at Weidmüller. “Test units from another provider had produced a circuit arrangement with little modularity in the solution used previously. It became obvious that a consistent standard system, that can be adapted for good flexibility, was needed. We were happy to meet this need on the basis of the solutions we had already produced.”

The new WIPRO test terminal strip, with variants covering all test circuits, thanks to a modular design of up to 22 connection points, came into being at an innovation workshop where Weidmüller was able to fully grasp what TEN was looking for. Regular meetings during the development phase helped practical requirements to be seamlessly incorporated within the product solution. The result has convinced the TEN development team: Besides the flexible, modular structure, they are also impressed by the fact that WIPRO embodies the connection system and marking benefits of a modular terminal. They also like the way it can be fitted either on the mounting rail or in the switch cabinet front. TEN opted for frontal installation so that they can undertake tests whenever they want during operation and the cabinet remains reliably sealed.

The service technicians use coding elements to assign the test adapters to the various circuits. They then simply connect the appropriate plug and test device already connected to the base unit and can therefore immediately run tests. Once plugged in, the automatic interlock in the base unit prevents the test plug from coming loose during protective relay testing. Impermissible or incorrect wiring on the test terminal strip is immediately indicated by the integrated connection protection with lead sealing. Functions such as automatic short-circuiting or lengthwise disconnection are

already included in the innovative interface system. With three advanced contacting stages, the WIPRO is always one step ahead: certain tripping paths can be deactivated before the current transformer short-circuits and the voltage transformer isolates.

“With this solution, we supported TEN through the entire test phase and start-up of their distributor system in Pausa, Vogtland,” reports Sander. “Since the grid operator also uses our connection technology and the Weidmüller marking system, TEN benefits from having one contact who is aware of all their requirements and who is highly commited to serving them.”

Consult our online catalogue for details of WIPRO, our test interface for relay protection and automation equipment▶ http://catalog.weidmueller.com/

catalog/Start.do?localeId=en_EN&ObjectID=group2488287590869

Let’s connect.

The WIPRO test terminal strip for protective relays turns regular testing in high- and medium-voltage facilities into a simple, routine task

9In Focus |

A t present, the gas produced by most biogas plants is used locally in a combined heat and power plant.

Alongside this direct approach to producing electricity, supplying the biomethane contained in the biogas to the gas grid is another efficient

way of using this renewable source of energy and a method with impressive flexibility which can be used anywhere. To achieve the gas quality and methane purity needed for the grid, the raw

biogas has to enriched. One system concept for treating biogas using a membrane process is provided by international company BORSIG Membrane Technology GmbH, a member of the BORSIG Group. “Compared with conventional treatment processes for separating

CO2, membrane technology offers a number of technical benefits,” reports project manager Achim Depner. “Gas separation using membranes is a continuous, purely pressure-

driven gas separation process. The membrane process requires no additional equipment, and no laborious regeneration or treatment of other media is needed. This flexible process setup allows us to tailor our modular concepts accurately to the needs of each location.”

Round-the-clock availability needed

Through its comprehensive services, BORSIG hopes to provide its customers with outstanding reliability and operating safety. For this promise to cover all elements of the system, the company attaches great importance to high-quality systems engineering and components that have been proven several times over in industrial applications. “Any failure or downtime is associated with high costs, and in the worst case scenario, supply bottlenecks,” explains Depner. “Our biogas treatment systems should run

without any interruption – 24 hours a day, 365 days a year. Short interruptions are only planned for maintenance or regular service work.”This round-the-clock availability,

»Our biogas treatment systems should run without any interruption – 24 hours a day, 365 days a year.«Achim Depner, BORSIG

Extensive safety monitoring for biogas treatment based on membranes

The system concepts of BORSIG Membrane Technology GmbH provide efficient process solutions for biogas treatment based on membrane processes. To ensure round-the-clock availability, the intrinsically safe ACT20X signal converters from Weidmüller support extensive safety monitoring.

In continuous use, thanks to extensive safety monitoring: the membrane modules in BORSIG’s process solution

10 | In Action

standardised signal values. With the BORSIG systems, all signals from the transmitters and the approx. 50 sensors and 30 to 40 actuators are sent to the ACT20X modules.

“One of the requirements of BORSIG was that the PT100 resistance thermometer can be connected to the signal converter itself. Extensive certification for the separation of the explosive risk zone was also important to them,” reports Gustav Lage, project planning and planning manager at Bormann und Reinhold. “As well as satisfying these requirements, we were impressed by the way that Weidmüller’s signal converters could be accurately adjusted in many different ways using the WI-Manager software.”

coupled with the necessary safety, requires a lot of monitoring. The system therefore has several points at which samples of the gas mix can be tested. The temperature, pressure and oxygen levels are thoroughly tested in the Ex zone. Gas sensors for CO2 and methane emit alarms if a potentially flammable gas mix results from leaks. Since lean gas combustion involves an exothermic reaction with a naked flame, the concentration of methane is also monitored very closely.

Reliable, standardised signal values

A key role in this safety monitoring process is played by the ACT20X signal converter from Weidmüller, which switching system manufacturer Bormann und Reinhold included specifically, in view of the stringent safety conditions. With their intrinsically safe inputs for standard DC, temperature and resistance signals, they reliably separate the zone at risk of explosion from the safe zone. Used near sensors, the ACT20X modules are perfectly suited to galvanically decoupling the control level from the sensor level and generating reliable,

The performance features of the ACT20X ensure that temperature fluctuations, electromagnetic interference, vibration, corrosion and atmospheres at risk of explosion don’t affect the accuracy of signal transmission and conversion in any way. The biogas treatment system customers benefit from accurately calculated measurements which can be transferred as stable 4 to 20 mA signals over long distances. The extensive monitoring and alarm functions of the signal converters also offer increased safety. The integrated programmable relay output issues an alert in the event of malfunctions; this makes troubleshooting faster and easier and also reduces facility downtimes.

»Extensive certification for the separation of the explosive risk zone was important to BORSIG.«Gustav Lage, Bormann und Reinhold

The ACT20X has proved to be the optimum signal converter solution for the system concepts used by BORSIG for biogas treatment

Happy with the joint solution: Torsten Söder from Weidmüller with Gustav Lage and Heinz Berg von Bormann und Reinhold (from left to right)

Gas separation with membranes is a continuous, purely pressure-driven gas separation process

11In Action |

Facility-wide safety Reliable emergency shutdown with SIL 3 relays

The quality of DCS systems significantly influences the productivity and safety of processing plants. Weidmüller supports partners like ABB with solutions that allow efficient and reliable system shutdown. In the case of a current expansion project for a petrochemical plant in Korea, SIL 3 relays from Weidmüller support the functional safety of several thousand safety circuits.

I ncreased demands on the safety of processing plants and the development of increasingly efficient

technologies in the field of process engineering have caused a trend in which chemical plants worldwide have invested millions in upgrade and expansion projects. This development creates extensive projects for the various systems suppliers. In the case of one such expansion project, ABB has successfully upgraded the DCS system of a large petrochemical

plant in Korea. As a long-time partner, Weidmüller has in this case supported the electrical engineering company with solutions that are precisely tailored for use in safety systems.

Perfectly tailored for use in security systemsFunctional safety played a crucial role in this project. According to EN/IEC 61508 standards, this state is achieved when potential risks are reduced to a tolerable level by safety systems and organisational regulations. "In this context, a measure that ABB has taken in the current Korea project is to use our SIL 3 relays for emergency shutdown and for permanent control of safety-related processes," informs Sang Hyun An, who accompanied ABB, on behalf of Weidmüller, on location in Korea.

Overall, ABB has constructed thousands of safety circuits within the framework of the upgrade project. Devices that are used

here must always meet special requirements. Few companies, however, offer the security of appropriate certification by an independent body. Weidmüller is responding to this with its SAFESERIES safety relay. It is certified by TÜV NORD according to EN/IEC 61508 standards for safety integrity level SIL 3, and meets low as well as high demand rates, which appealed greatly to ABB. ➜

12 | In Action

»Functional safety played a crucial role in this project.«

A solution for low as well as high demand ratesThe process of emergency shutdown is not permanent, but should only be activated in emergency situations. Obviously, it only needs to operate at a low demand rate in so-called Low-Demand Mode. The High-Demand Mode, with a higher rate of demand, has, however, also played a central role in establishing functional safety in relation to large projects. Therefore Weidmüller SIL relays are also used in ABB systems in controlling permanent processes such as controlling valves, motors, fill levels, flow and pressure within the petrochemical plant.

“The features of the relay cover both low and high demand rates and the comprehensive certification allows use in worldwide operations,” summarises Sang Hyun An. “In addition, the safety relay stands out with its special switching capacity in the input circuit. It makes the module immune to test impulses that are typically used by DCS systems to monitor the status of signal circuits. These advantages make our SIL 3 relay the perfect product solution for the establishment of emergency shutdown systems in the process industry.”

Reliably shutting down during an emergency, safe application in corrosive atmospheres and furnace control in thermo-process facilities - read our series on “SIL in practice” online:▶ http://www.weidmueller.com/

en/sil_article

IN FOCUS Full compatibilityA key criteria for ABB in the selection of SIL 3 relays was their compatibility with the 800xA-Hi control. This high level of compatibility is also reflected in active industrial Ethernet components from Weidmüller. With the granting of the "Industrial IT Enabled" certificate, Weidmüller’s managed and unmanaged switches belong to a portfolio of industrial IT products which ABB engineers can use for real-time automation and information management solutions. Extensive tests have proven that these switches are totally compatible with ABB’s 800xA automation architecture. These control components are essentially used within process automation, but also in other industrial segments. The goal of the Industrial IT initiative is to set a standard for productivity and benefit. For this purpose, the various products, hardware and services from the ABB Group and strategic partners such as Weidmüller are tested to see if they comply with industrial IT standards defined by ABB. This then provides ABB customers with a guarantee that such certified products can be used optimally in conjunction with other industrial IT products.

Let’s connect.

13In Action |

as either a fully ‘on-demand’ system, or a ‘fully automatic’ system offering complete flexibility to the local railway authority.

When configured in the ‘on-demand’ setting, the user is required to press the prominent crossing request button. Once the button has been pressed the system will validate the status of the railway and will provide the user with a green or red light signal. If the red light signal is displayed to the crossing user this will be accompanied by an audible warning, alerting them to the imminent arrival of a train.

“After analysing the application and environment where EBI Gate 200 is deployed, we recommended to

A safe feeling in the countryside Level crossing warns users in all weathers

EBI Gate 200 is a level crossing system designed for railway applications and has been engineered specifically to improve the safety for user-worked crossings on railway networks. The primary implementation of EBI Gate 200 is public footpaths, farm crossings, bridleways and user-worked crossings. It can be fitted with an optional renewable energy system which is designed to reduce its environmental impact. The installation of EBI Gate 200 into brownfield sites is more cost effective than traditional level crossings

due to the fact that testing is conducted within the production factory prior to installation and commissioning, this minimises the need for on-site testing and shortens the installation time.

Suited to every outdoor situation

EBI Gate 200 is designed as a total overlay system and therefore it is totally independent of the existing railway infrastructure. In addition to this EBI Gate 200 can be configured

Bombardier’s Rail Control Solutions division have developed EBI* Gate 200, a new level crossing system. EBI Gate 200 is intended to alert people to oncoming trains when crossing tracks in rural areas. A solution from Weidmüller ensures overvoltage protection in all weathers.

EBI Gate 200 is the first crossing of its kind designed to harness renewable energy.

* Trademark(s) of Bombardier Inc. or its subsidiaries.

14 | In Action

Bombardier they should use our overvoltage protection devices from our new VARITECTOR PU series to give a maximum surge current of 40 kA,” reports Nigel Young who, as Weidmüller's Industry Manager for Infrastructure, supported Bombardier on site. ”Our solution enabled us to perfectly meet the technical requirements of Bombardier. Successful testing in a prototype unit also confirmed this.”

A safe feeling

As the overvoltage protection devices used came from the new VARITECTOR PU series, Bombardier is already using lightning and overvoltage protection that meets

future standards. The devices already satisfy the requirements of the global IEC/EN 61643-11 standard just introduced. This permits the worldwide use of the system. The overvoltage protection solution provides additional safety in the form of its guaranteed resistance to vibration, which can be decisive when installed in the control cabinet next to the level crossing.

“The fact that you can hear and feel the arrestor engaging in the base gives users a safe feeling,” states Young. “One can reliably check the protection function locally, simply by glancing

»Our solution enabled us to perfectly meet the technical requirements of Bombardier.«

Once the button has been pressed the system will validate the status of the railway and will

provide the user with a green or red light signal.

at the large centred status window. The remote signalling contact also

keeps people responsible updated on the protection

system’s status at all times.”

The fact that you can hear and feel the arrestor engaging in the base gives users a safe feeling.

15In Action |

distinction is made between installing photovoltaic modules on the roof of a public building already equipped with lightning protection and installing on a building without such protection, say a warehouse. If external lightning protection is in place, the photovoltaic modules should preferably be considered as isolated units on the roof. Installing the photovoltaic system does not represent any additional risk of lightning discharge. The system should however be set up in the protective zone so that it doesn’t produce any adverse effect. Compliance with the separation distance required in IEC 62305-3 (VDE 0185-305-3 Supplement 5) is essential. If this is not possible, partial lightning currents should be taken into account by, for example, using shielded

mains generator cables to reduce induced surge voltages. With a sufficient cross-section of at least 16 mm², the cable shield can also be used to control the partial lightning currents. Alternatively, type I lightning

protection components can be used at the entry point into the building to provide protection for the transition between lightning protection zones 0 and 1.

“To enable our customers to set up their photovoltaic systems that are fit for the future, our solutions always satisfy the very latest application and product standards. Our entire range of surge protection devices already meets the current standard EN 50539-11:2012 which stipulates how surge protection in photovoltaic systems has to be designed on the DC voltage side,” explains Ralf Güthoff, a specialist in lightning and surge protection at Weidmüller. “While using surge protection devices on the AC side of low-voltage systems is currently seen as standard, several things still need taking into account for DC voltage applications. The challenge here is to design surge protection devices both for the photovoltaic modules’ maximum off-load voltage and for maximum system availability and safety.”

W hether it be their exposed location or the large area covered by photovoltaic systems and the associated buildings – they are

always at risk of lightning discharges. Resulting damage can affect individual components or take down the entire system. Lightning currents and surge voltages are often responsible for damage to inverters and photovoltaic modules. Not only does this damage represent huge repair costs for operators, it also has a major impact on the economic viability of the entire facility. Weidmüller provides integral solutions which conform to all relevant standards, thereby preventing such dire consequences, whilst ensuring reliable integration within current lightning protection regulations.

Application and legislative requirements at a glance

The specific requirements of surge protection depend on the application itself. In terms of building installations, a basic

Surge protection with one eye on the future Roof-mounted photovoltaic systems with an edge

»To enable our customers to set up their photovoltaic systems fit for the future, our solutions always satisfy the very latest requirements.«

Weidmüller’s product range includes surge protection that meets the very latest standards governing the specific requirements of photovoltaic systems on the roofs of industrial buildings – on request, they can be individually configured and integrated, ready-to-wire, in a housing. With such equipment, system operators can count on their anticipated returns.

Installation on buildings with external lightning protection – spacing is the key here

16 | In Action

Effectively preventing worst-case scenarios

The most suitable location for surge protection devices in a photovoltaic system depends on the type of system, the system design and the distance. In the case of a small building with external lightning protection and a photovoltaic system fitted on the roof, it is usual to only protect the inverter’s DC input as the cable lengths are short. If fitted on larger industrial buildings, such as warehouses or production plants, the cables between the photovoltaic module and inverter may be more than 10 metres in length. Surge protection devices should then be installed close to the photovoltaic module and inverter.

Originally surge protection devices were designed only for normal grid AC voltages. The introduction of photovoltaics brought with it applications where products have to withstand high DC voltages. One potential consequence of using inappropriate solutions is that insulation errors can arise on the module after years of use. This results in all the photovoltaic module’s voltage being applied to the operational pole in the surge protection device which is then overloaded. If surge protection devices based on metal oxide varistors are permanently loaded due to excess continuous voltages, this may result in the cut-off mechanism being destroyed or tripped. In photovoltaic systems with high system voltages, the worst-case scenario is that activation of the cut-off mechanism triggers a fire, as a result of the switch arc produced. Using fuses as upstream overcurrent protection mechanisms do not solve this problem because the photovoltaic module’s short-circuit current is only slightly higher than that of the rated current.

“Our new VARITECTOR PU surge protection range features a practical solution which conforms to the very

latest standards. The devices are designed especially for photovoltaic applications and effectively prevent the undesired activation of cut-off mechanisms,” says Güthoff. “The worst-case scenario of a fire is therefore effectively prevented.”

Simple system integration of surge protection is through installation in pre-wired generator junction boxes. In response to regular customer requests, Weidmüller has developed numerous standard configurations of generator junction boxes as a system for optimum connection but also protection and monitoring, but is also happy to produce custom solutions on request – for concepts fit for the future with a real edge.

When installing photovoltaic systems on the roofs of industrial facilities, specific requirements must be observed

Weidmüller provides practical configurations of generator junction boxes not only as a system for optimum connection but also for protection and monitoring.

Practical shieldingin widespread and compact applicationsIncreasingly complex systems are making it harder to guarantee trouble-free operation. Thorsten Ortjohann, product expert in earthing and shielding at Weidmüller, talks about the latest developments, the basics of shielding and the solutions of tomorrow..

WIN! What trends have you noticed in earthing and shielding?

Ortjohann: Most people are aware of the issue of earthing, thanks to our current mains system types. Earthing is usually understood to mean protective earthing to protect

life and limb. But there is also functional earthing, a term that very few people have heard of, which relates to protecting electrical equipment. For a visual distinction, functional earthing must be produced in a different colour. We provide white PE terminals for this purpose. The protective earthing must be green and yellow. In terms of shielding, the number of data cables, processors and frequency converters used in

industrial systems is growing all the time. Troubleshooting in the event of an EMC fault is therefore becoming increasingly complicated and any problems that arise are tackled through changes on a trial-and-error basis. Against this backdrop, issues such as cable routing, potential compensation and shielding will become greater in importance and in the medium term, be just as important as functional solutions. ➜

»Extensive systems such as large container ships are a particular challenge.«

18 | In Detail

WIN! In which specific industrial sectors are you already witnessing major challenges?

Ortjohann: Facilities covering large areas such as refineries, power plants, sewage plants and rail infrastructure are a particular challenge. One good example in transport engineering is large container ships, where the length of a section of cable, from say a bridge to the engine room, may be 100 metres or more depending on how it is routed. The large distances and the associated transition resistances mean differences in potential of up to several volts between the distant points. Because of the compensating current, the cable has a capacitance that satisfies no function whatsoever, consumes energy and also produces its own electric field. Even sharing a reference to ground to the ship structure doesn’t eliminate this problem.

WIN! What can be done in such cases?

Ortjohann: Today we still resolve this issue with one-sided shielding to eliminate the constant compensating current and therefore the capacitance. In such cases, it is absolutely essential that the shield connection has a reliable contact. Since the low-impedance transfer must be via the cable shield for the system to function perfectly, shielding on both sides would be the preferred option. We have worked hard to address this problem and will soon have a practical solution that allows the shield to be applied on both sides, even in extensive applications – for greater safety, reduced transfer impedance and no undesired capacitance whatsoever.

WIN! Besides the problems you mention in large facilities, do you see any specific requirements for compact applications?

Ortjohann: Of course. One good example is frequency converters which usually operate in a frequency range of 4 to 8 kHz. Rapid acceleration and deceleration of drives, combined with

alternating frequencies and currents, illustrate the high perturbation potential of this equipment. The objective is to dissipate the high-frequency interference currents on the motor line shield. But the signal lines also have to be shielded to ensure good system safety and stability. If the shielding isn’t carried out properly at this point, in

the worst case scenario, interference levels in high double digits result in transmitter signals being manipulated and cause unintended responses on the controlled machines. To effectively prevent coupling from signal lines, the shield should be applied on both sides such that the entire line shield area, i.e. as large an area as possible, makes contact. This kind of secure shielding is needed, even in the smallest space.

WIN! What are Weidmüller’s latest solutions for shielding in compact environments?

Ortjohann: Traditional shields are often tall add-ons, e.g. because they need mounting rails. With the KLHA shield clamp holder we recently launched, users can connect shields compactly and anywhere they like. Thanks to this direct contact to the shield, the holder replaces the need

for a 10 x 3 mm rail. It has room for up to seven shield clamps and is provided in two different heights. Our new SH-4C holder also carries the 10 x 3 mm busbar at a height of just 19 mm. These solutions give our customers much lower shielding than was previously the case, as well as a proven and robust installation. We are therefore extending our extensive range of shield clamps and accessories in response to real-life demands.

WIN! What basic principles would you recommend for safe plant operations?

Ortjohann: Alongside the obvious one of the shield contact, the length of the non-shielded strands at the final connection points is also important. The shield should always be positioned close to the connection point. If this is well inside the interior of the cabinet, I would recommend shielding as close as possible to the point of entry into the cabinet and again on the equipment itself. Only this will prevent coupling on neighbouring lines. For me, the basic principles of ensuring trouble-free operation also include the following basic rules. Always route energy and signal lines separately. With compact machines and systems, apply the shield on both side. With facilities covering large areas, continue to shield on one side to prevent the compensating current and therefore the unwanted capacitance. In the future, this last point will be superseded by a new “rule”. Then the new Weidmüller solution can be used for shielding on both sides in applications covering large areas!

The new SH 4C busbar holder has an impressively low height because it is screwed onto the mounting plate directly, without a mounting rail

What is the significance of functional earth in terms of shielding and earthing? Weidmüller has the answers:▶ www.weidmueller.com/int/

Functional_Earthing

Let’s connect.

19In Detail |

Compactness is the name of the gameForward-looking technology for industrial controllersWeidmüller’s practical connection solutions aid the manufacturers of industrial controllers in all performance standards of automation and systems engineering. Excellence in compact solutions really is the name of the game.

“Semiconductor engineering for industrial automation has made great strides in recent years. On the one hand, it allows us to produce controllers that are increasingly sophisticated. Cost pressure and requirements relating to facility safety and compliance with industry-wide standards are increasing at the same time,” explains product manager Gerd Richter. “We have been following this trend closely and our product range has often been one step ahead of

it. For example, we optimised our male connectors for the automatic assembly process and reflow soldering procedure very early on. We are responding to the trend for ever increasing numbers of sensors for monitoring purposes with an all-purpose choice of compact connection solutions.”

Precise signal processing in tiny spaces

High-precision signal processing is needed for safe system operation with increasingly complex automation – in as compact a space as possible. Weidmüller’s answer is a product range tailored perfectly to the requirements of sensor signals. For example, our 30-pole BL-I/O connection

impressive introduction to our products can be experienced in advance through our configurator, which allows customers to design their own individual connection solutions online. Our unique 72-hour sample service enables development engineers to test their chosen solution as a sample in their device design, no more than three days after they have put it together. Just like our comprehensive design-in advice, we guarantee this service worldwide.”

OMNIMATE SignalDiscover our full range of device connectors for industrial automation applications in this video: ▶ http://www.youtube.com/watch?feature=player_

embedded&v=XFg7utch3Go

Let’s connect.

level is currently the most compact 3.50 mm version plug-in solution for connectors with three wires. Even if the controller isn’t switched on, the signal display shows the correct sensor wiring. The associated electrical distribution supplies eight sensors with the voltage required. Solid “PUSH IN” wire connectors also guarantee that the sensors run continuously and safely.

Additional 3.50, 3.81 and 5.00/5.08 mm plug-in compact solutions offer virtually unlimited design options at the connectivity level. Our wide range of male connectors means the assembly components can be produced cost effectively and are equipped for the automated SMT process. PCB terminals with “PUSH IN” connectors offer a cost-effective alternative to plug-in solutions. They can be processed in both the wave soldering and reflow process – without any compromise in SMD or SMT assembly.

Safe connections for actuators

The actuators in a system need more than precise status information; in particular they need secure connections to reliably control relays, valves and motors. These connections should take up as little space as possible to avoid the need for larger connection cross-sections, cable lengths, switching voltage, and overall assemblies.

The Weidmüller B2CF compact plug connectors display a high connection density while also being very easy to use. Up to four levels of the 3.50 mm version can be set up to create a connection cross-section of no more than 1.5 mm². The actuator conductors can be quickly and safely connected using the “PUSH IN” spring force. The BLF 5.0x – which also features a “PUSH IN” connection – is also ideal for stringent connection cross-section requirements.

“The whole range is compact”

“Our product range allows manufacturers of industrial controllers to select the device connectors that are suited perfectly to their application. With this level of flexibility, there is one thing they can always rely on: the whole range being compact,” stresses Richter as the key benefit. “An

»Our complete range of device connectors for industrial controllers is compact.«

Try our unique 72-hour sample service:▶ www.weidmueller.com/de/Sample_Service

Let’s connect.

21In Detail |

I ncreasing production quality and plant availability are the drivers for continuously optimising production procedures. This is coupled with an increasing level of automation, which in turn brings with it

new challenges in ensuring a reliable 24 V DC power supply. As an industrial connectivity partner, Weidmüller provides versatile solutions which meet all the increases in requirements by interconnecting high-availability switched-mode power supply units with practical supplementary modules. One solution is the systematic establishment of a redundant supply.

Playing it safe, twice over

If a critical status occurs in traditional mechanical engineering – such as a blockage in materials handling or the failure of a robot – a safe status is usually reestablished by switching the system off. Things are different in the process industry, where mechanisms are used to, for example, prevent an explosion during chemical reactions. Fully shutting down the parts of the system in this case would be fatal. In these circumstances, process functionality must be maintained. Against this background, production processes in the process industry are set up with single or multiple redundancy. Requirements to this effect are therefore made of the electrical systems and not least, the AC power supply networks.

“For such cases, we offer two approaches to a redundant supply. Firstly plant developers can improve the availability of

Weidmüller’s industry-specific solution concepts enable a high-availability, redundant power supply to be established. High-performance components form the basis for a consistent supply that meets the most ambitious of industrial requirements.

Playing it safe, twice over, with redundancyPermanently supplied – part 1

In the process industry, process functionality must be maintained under all circumstances

Part 1: Playing it safe, twice over, with redundancyPart 2: Smooth operation thanks to uninterruptible power supplyPart 3: Safe bypasses with buffer modules

22 | In Detail

their plants by setting up redundant systems with our PRO-M power supply modules, with the addition of the associated diode modules. One advantage of this solution is that it is very compact. When the various PRO-M modules are fitted in the cabinet, they can be lined up, right next to one another, because there is no need to separate them for cooling reasons,” explains Klaus Schürmann, product manager for the power supply range. “The second solution is redundancy modules for our PRO-H family that we have developed especially for use in Ex zones and high-performance areas.”

Using redundancy modules allows two PRO-H power supplies with exactly the same distributed load to be operated in parallel (active current sharing). Should one device fail, the other takes on the full load, greatly reducing the probability of failure. Thanks to high MTBF (Mean Time Between Failures), values of up to 1.8 million hours and scope for installing in Zone 2, this solution is ideally suited to the process industry and energy technology.

High-availability power supply in shipbuilding and wind energy

Weidmüller also has redundant power supply solutions for the requirements of other industry sectors, where high-availability power supplies are needed. Rather than two AC grids, for example, one AC grid can be coupled to a bank of batteries. One solution is to combine a PRO-M switched-mode power unit with a diode module and the Weidmüller DC/DC converter. In ungrounded voltage systems, such as those in the emergency power battery system built into ships, the control voltage must be separated from the battery voltage. Class III protection, coupled with high efficiency, makes the compact DC/DC converter ideal for applications

of this kind. Another alternative is to use the PRO-M switched-mode power unit as the DC/DC converter and to couple it with a diode module and 110 or 220 V banks of batteries. Weidmüller also offers custom-fit solutions for comparable redundant concepts, such as those found in the electrical pitch systems of wind turbines. The switch-mode power supply, with a wide-ranging input from the PRO-M series, covers an input voltage range of 80 to 430 V DC and is ideal for such purposes.

“Redundant power supplies always offer twice the benefit: the failure of either a grid or a power supply will not result in the 24 V DC control voltage collapsing. Each redundant branch is independently able to supply the full output load,” says Schürmann, summing up the benefits of the solutions. “On the one hand, by using high-quality power supplies with high MTBF values and, on the other hand, by producing a redundant supply, machine and plant constructors in all industries achieve a significant improvement in application availability.”

»Redundant power supplies always offer twice the benefit.«

One way of building a redundant circuit to increase availability

With high-availability switched-mode power units and practical supplementary modules, Weidmüller has a power supply solution for every need

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Weidmüller Interface GmbH & Co. KGKlingenbergstraße 1632758 DetmoldT +49 5231 14-0F +49 5231 14-292083info@weidmueller.comwww.weidmueller.com

Weidmüller – Partner in Industrial Connectivity.

As experienced experts we support our customers and partners around the worldwith products, solutions and services in the industrial environment of power,signal and data. We are at home in their industries and markets and know thetechnological challenges of tomorrow. We are therefore continuously developinginnovative, sustainable and useful solutions for their individual needs. Together weset standards in Industrial Connectivity.