Focusing on the future for the power supply of tomorrow

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Weidmüller Information & News | No. 13

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Energy efficiency embodied in Weidmüller's production process

The key factor functional reliability in traffic engineeringWIN !More best connections inside Let’s connect.

Dear readers,

T he demand for power continues to grow. Experts predict an increase in global power consumption of around 60 percent by 2030. Industrialisation in the emerging markets and changes to power concepts

in industrialised nations involving an increased amount of renewable energies form the background to the paradigm shift: smart processes and new technologies for generation, distribution and consumption are gaining in importance. Added to this are changes in the power plant landscape, the integration of renewable energies, the expansion of networks and the development of power storage solutions. New power concepts like these represent both an opportunity and a challenge for the entire industry.

As an international partner in industrial connectivity, we provide the energy industry with a wide range of powerful modules and components developed especially for these requirements. Our products help to ensure improved efficiency and simplify the commissioning and maintenance processes. Benefiting from these factors are companies such as British Solar Renewables, where our connection and monitoring solutions can be very smoothly integrated into sustainably designed photovoltaic systems (page 12 – 13). A look behind the scenes of our application centre for photovoltaic solutions provides an insight into how we manage to precisely satisfy changing practical requirements time and again (page 14 – 15). We also help to shape trends for the various energy technology segments from the outset: in dialogue with policy and partners in the field (page 4 – 5).

We’re focusing on the future for the power supply of tomorrow. At the same time, we’re an expert partner for a wealth of other industry segments. Why not find out about some of them in this edition of “WIN!”? I hope you find this issue stimulating and enjoy reading it. With kind regards,

Volpert BrielSales and Marketing Director

»As an international partner in industrial connectivity, we support the energy industry with a wide range of powerful modules and components developed especially for these requirements.«

2 | Editorial

ImprintThe next edition of WIN! will be published in November 2013 as a special edition on SPS/IPC/DRIVES.

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

Editorial office:Julia BusseContact:win@weidmueller.comRealisation: M.P. Media-PrintInformationstechnologie GmbH

Pictures: Weidmüller, shutterstock/Dabarti CGI (S. 1 + 3 + 10), iStockphoto/Freezingtime (S. 4), gettyimages/Monty Rakusen, (S. 7), British Solar Renewables (S. 12 + 13),

shutterstock/Pavel L Photo and Video (S. 16 + 17), iStockphoto (S. 18), HANNING & KAHL (S. 3 + 21), gettyimages/Baran Özdemir (S. 22), iStockphoto/urbancow (S. 23)

© 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

Industry meeting for protection technology experts – European Business Summit: Commitment to project implementation essential – Awarded with the “Top 100” seal of innovation – In dialogue with partners from the wind industry – Crimping: a permanent connection

In Focus 8 Binding sustainability –

embodied energy efficiencyWeidmüller has been handling energy and resources responsibly for many decades. A current prime example is a new production hall featuring an innovative heat recovery system and energy monitoring

10 Focusing on the future for the power supply of tomorrowWith a global focus and local sales teams, Weidmüller is making sure its products and services meet the needs of energy industries around the world. Application-specific solutions and services form an integral part of this

In Action 12 Flexible connection systems for

harmoniously integrated photovoltaic systemsJust as British Solar Renewables’ photovoltaic systems blend harmoniously into the British landscape, so the connection and monitoring solutions from Weidmüller integrate harmoniously into the relevant system structure

16 Smooth aluminium production thanks to precise signalsWhile modernising their control cabinets at an aluminium production facility, the Brazilian engineering and assembly company EBM faced leakage currents and a lack of space. The solution: the TERMSERIES relay with multi-voltage input

18 Safe flow of traffic even during thunder and lightningA Peter Meister AG control system is set to ensure that traffic flows smoothly at Switzerland’s Brüttisellen junction. Surge protectors in the VARITECTOR PU series ensure the sustainable reliability of the control system

20 Make way for deployment in traffic engineeringFor its system solutions in the rail and local transport industries, HANNING & KAHL relies on technology that the company believes will stand the test of time – such as electronic solutions from Weidmüller

In Detail 7 Clever power distribution in sets –

saving up to 50 % spaceIf you want to save space and costs with control cabinet layout and value clearly organised cabling, you are sure to be impressed by the new WDK 10 feed-in and distribution terminals

14 How is a generator junction box actually made? A look behind the scenes provides insights into the Weidmüller application centre for photovoltaic solutions

22 Safe bypasses with buffer modulesPart 3 of the “Permanently supplied” series explains how brief interruptions and dips in supply are reliably bridged with zero-maintenance buffer modules

10 Focusing on the future for the power supply of tomorrow

20 The key factor – functional reliability in traffic engineering

8 Energy efficiency embodied in Weidmüller

3Content |

Industry meeting for protection technology expertsRenowned companies and speak­ers came together to exchange ideas with Weidmüller in Vienna

Protective equipment in high- and me-dium-voltage switchgears monitors the

power system for overloads as well as earth faults and short-circuits, safeguard-ing the security of the power supply. At the end of February, Weidmüller invited representatives from network operators, energy suppliers and engineering offices to exchange ideas on this segment’s spe-cial requirements at a meeting in Vienna. Specialist contributions were made by experts from Siemens, Omicron and KoCoS Messtechnik, a supplier of testing and diagnostic solutions for electrical power supply. The topics addressed included current protection systems and testing solutions for protection and measuring technology, as well as power supply quality against the backdrop of the energy turnaround.

“Network protection technology in high and medium-voltage switchgears places particular requirements on net-work operators, as systems’ protective functions have to be checked regularly – and not just before initial commis-sioning, but also regularly during opera-tion,” explains Rötger Sander, Energy Technology Expert at Weidmüller. “Our latest development, the WIPRO test plug system for protection and second-ary technology, generated a great deal of interest. Indeed, KoCoS Messtechnik AG immediately integrated our system in their solution portfolio as a result of the meeting in Vienna. In collaboration with us, the testing systems and meas-uring technology manufacturer wants to pass the benefits of simplified check-ing and testing for protection relays on to its customers, thereby increasing the efficiency of the checking process.”

In discussion with partners from wind energyTogether with Dirk Bauer­kämper, Industry Manager for Renewable Energies, Weidmüller is being repre­sented on the Management Board of the VDMA’s (German Mechanical Engineering In­dustry) Wind Power Working Group

Taller, able to deliver greater performance, primarily zero-maintenance, suitable for all climate zones and both onshore and offshore installations – these are some of the requirements for wind turbines of the future. But wind turbine manufactur-ers have to do more than merely overcome the associated chal-lenges. Indeed, there is a wide supplier industry with products and services specifically designed to satisfy the requirements of the wind industry.

In Germany, the VDMA’s Wind Industry Working Group is bundling together the technical competen-cies and perspectives available. The working group was re-positioned at the start of 2013 in Frankfurt at a meeting of members involving 65 sector representatives, and has elected five parties to its Board of Management. Topic areas, from mechanics and automation, to original equipment manufacturing (OEM) are covered, thanks to wind turbine manufacturer GE Wind, Winergy, a company specialising in gearboxes and couplings for wind turbines, Gräpel, a system supplier for sheet metal products, Argo-Hytos, a component supplier for hy-draulics and fluid technology, and Weidmüller. Following the portfolio split at the end of August, the working group will focus on market analyses that consider trends in energy turnaround and public rela-tions. “As a newly elected Mem-ber of the Board, I look forward to contributing to the success of energy transition, in dialogue with our partners in the wind industry,” states Dirk Bauerkämper.

The various issues for considera-tion discussed in the presentations and experience reports resulted in animated exchange between participants

Speaking in Brussels about the future duties of European industry: Markus Beyrer, Director General of BUSINESSEUROPE, Prince Philippe of Belgium, Jürgen Thumann, President of BUSINESSEUROPE, Dr. Peter Köhler, Weidmüller Spokesperson of the Board and Chairman of BUSINESSEUROPE’s Industrial Affairs Policy Committee, Leif Johansson, President of the ERT (European Round Table of Industrialists) and David Thomlinson, Chief Geographic Strategy & Operations Officer.

European Business Summit: Commitment to project implementation essential

As Chairman of the Industrial Affairs Committee, Weidmüller Board Spokesman Dr. Peter Köhler is encouraging greater commit-ment when implementing market-ready technologiesNew energy industry trends and op-portunities to drive growth in European industry were topics of the 2013 European Business Summit, which took place at the start of June in Brussels. In his capacity as Chairman of the Industrial Affairs Committee in the BUSINESSEUROPE employers’ associ-ation, Weidmüller Board Spokesman Dr. Peter Köhler explained what he thought of the future duties and oppor-tunities in European industry as part of a discussion round.

The leading individuals involved in the round all agreed that opportunities for the sector have been taken, but that the framework conditions have to be improved at a political level. Everyone considered the prompt implementati-on of specific projects with a view to maintaining competitiveness as being a matter of urgency. “In parts of Europe, youth unemployment is more than 50 %,” Mr Köhler reminded the parti-cipants. “I am of the opinion that this cannot continue and that we should take suitable measures to boost Euro-pean business. High expenses, such as energy costs, are like a niggling stone

in the economy’s shoe.”

Megatrends of the future identified Innovations suitable for everyday use provide relief in this respect: “The industry has identified the major trends of the future and has been intensively working to provide customised solu-tions for years.” He then went on to add that the Electra Report was a good example of this. It specifies (among other things) how the EU Commission wants to create sustainable growth by creating corresponding framework conditions, such as by promoting research and development. In addition to energy generation and security of supply, this also touches on the topics of climate change and providing energy at competitive prices: “The technology for efficient energy generation, distri-bution and use has been on the market for a long time now,” Mr Köhler reminded his audience. In spite of this, too few specific projects have been implemented: "Now, we have to enter the implementation phase as quickly as possible. Only in this way can we exploit the benefit of being the first asso-ciation to implement specific measures, thus maintaining our level of competitiveness.”

Awarded with the “Top 100” seal of innovationWeidmüller is classed among the most innovative German SMEs

In July, Weidmüller was crowned one of the most innovative German SMEs. In the “Top 100” analysis, Weidmüller delivered an especially impressive performance with its innovation marketing. “Together with sales and industry management, innovation market-ing takes over the idea creation process and evaluates just how relevant planned innovations are to the market and to customers. But it also provides direction and sup-port for each individual product development stage, right up to field tests with key customers and market communication that focus-es on the target group,” as the jury explains in its statement. “The mul-titude of national and international patents that the SME, founded in 1850, holds is testament to how successful this process is.” An academic corporate analysis un-dertaken by the Vienna University of Economics and Business forms the basis of the award. This year, the innovation experts examined a total of 245 companies.

Dr. Sascha Nolte (left) and Dr. Jan Stefan Michels of Weidmüller accepted the award in Berlin from science journalist, physicist and presenter Rangar Yogeshwar

5In Brief |

Crimping: a permanent connectionA new crimping tool for hard-to-reach places is added to the Weidmüller practical and profes-sional tools portfolio

The quality of a crimp connection calls for more than just manual skills; indeed, professional tools and high-quality materials are also crucial factors. Crimp connection requirements are specified in international standards and regula-tions, such as DIN EN 60352-2. Essen-tial quality criteria include the tensile strength the connection achieves and avoiding typical crimp defects. Care should especially be taken when choos-ing components. After all, not every conductor fits every contact, and one tool isn’t suitable for all crimping tasks.

That’s why there are different crimp-ing tools for wire-end ferrules, for other contacts such as cable-lug sleeves and cable lug connectors with pre-rolled crimp claws, for PVC, PC and polyamide-insulated connec-tors, for non-insulated cable lugs and connectors, for fibre-optic cables, for coaxial connectors such as BNC, TNC and N plugs, or for SUB-D contacts. Weidmüller’s range includes profes-sional tools for all of these areas of application that users can deploy to achieve precise results – fast.

With the new PZ 6 Roto L, Weidmüller is once again launching a crimping tool on the market that adapts practically to its users’ requirements. Thanks to its rotatable crimp insert, the PZ 6 Roto L can be used as space conditions per-mit. As an optional feature, cables and wire-end ferrules can be integrated in the tool from the front or side.

Continue reading online for answers to the following questions and others: What pitfalls does crimping with wire-end ferrules in-volve? And what should you observe in the case of international deployment?▶ http://www.weidmueller.com/Expert_Paper_Crimping

Let’s connect.

UL approved crimp connectionThe UL certification for our crimped, insulated wire-end ferrules means that Weidmüller has opened up an amazing number of possible applications for use around the world. Wire-end ferrules, manual tools and crimping machines from Weidmüller, as an overall system, are approved. In other words:

Weidmüller tool + Weidmüller wire-end ferrule = UL-approved crimp connection Let’s connect.

6 | In Brief

C oncatenated, modular control cabinets, as commonly encountered in production lines, should be as compact as

possible to facilitate integration into the machine environment. Well structured cabling is also required so that you know at a glance, which cable is going where, when troubleshooting.

“Power distribution with conventional circuit terminals used to take up lots of space in this application, because you had to allow two bridged modular terminals per potential, which made handling more difficult and cabling confusing due to crossing lines. A configuration like this can always be a source of faults with unnecessary follow-up costs,” explains Product Engineer Martin Adamczyk from Weidmüller. “Our double-level WDK 10 terminals for power supply

and distribution now enable users to save up to 50 % space compared with solutions that were previously commonplace.”

Compact power distribution – clearly structured concatenation

With the screw connection terminals, connecting two conductors to one terminal point is now an option and complies completely with standards for cabling the neutral and phase distribution. By implementing PEN functionalities with standard cross-connections, TN-C networks can also be transformed very simply into TN-C-S networks. This means that efficient solutions are now available for all your power supply and distribution needs.

“Supplying our power distribution solution in complete sets makes for easy customer installation and reduced overall costs,” comments Martin Adamczyk on the advantages of the solution package. “Especially compact and clear concatenation can be achieved in applications such as modular control cabinets.”

If you want to save space and costs with control cabinet layout and value clearly organised cabling, you are sure to be impressed by the new WDK 10 feed-in and distribution terminals.

Especially compact and clear concatenation can be achieved with the WDK 10 in applications such as modular control cabinets

A clever solution for a transparent control cabinet structure without crossing lines: The WDK 10 extension allows you to save up to 50 % space compared with conventional WDU terminals – and to noticeably minimise costs

Smart power distribution with sets Up to 50 % space saving

7In Detail |

the production hall supplies the neighbouring administrative building with heat during the transitional period and is thereby drastically cutting its heating requirement.

Prime example: Energy-saving production hall

“The necessary heat is collected by the production machines and cross-section technology, such as compressed air systems, refrigeration machines and the like, and is distributed to consumers

via a low-temperature network heated up to 40 °C,” explains Weidmüller’s Head of Energy Management, Helene Derksen-Riesen. “All of the connected power consumers are designed for this low temperature level. These include, for example, wall air heaters, ventilation systems, office heating appliances and ramp heating. We supply the corresponding consumption points with waste heat from around 70 °C to 75 °C in another distribution network. The power of this high-temperature network is around 150 kW.”

»The hall at the Detmold site manages without its own heating system and requires 95 % less energy.«

Binding sustainability Embodied energy efficiency

Weidmüller has been handling energy and resources responsibly for many decades. This commitment was recognised 25 years ago with the Environment Award from ASU (the Institute for Occupational Medicine, Social Medicine and Environment). In 2007, we were awarded dena’s (the German Energy Agency) first ever Energy Efficiency Award for exemplary energy efficiency projects. In 2013, Federal Minister Philipp Rösler recognised Weidmüller as a climate protection company for “outstanding innovativation in climate protection”. A current prime example for the steps that led to this recognition is a new production hall featuring an innovative heat recovery system and energy monitoring.

W eidmüller installed the initial heat recovery systems to reduce its natural gas consumption

for ambient and process heat back in the 1990s. Together with numerous other measures in building services and mechanical engineering, the

company was, for instance, able to reduce the heating system’s output by 50 %. Another step was the installation of a network control unit for compressed air stations. Electronic pre-switching

devices have been a standard feature at Weidmüller since 2001. The best current example of Weidmüller’s efficient energy management is a production hall inaugurated in 2011, which incorporates the knowledge and experience acquired over the last

few years. The hall at the Detmold site operates without its own heating system and requires 95 % less energy than specified in the 2007 Energy Saving Ordinance (EnEV) valid at the time of construction. In addition,

The numerous automatic injection-moulding machines with their high compressed air requirement are one example of how heat generated in the Weidmüller production hall can be used for heating purposes in another location

8 | In Focus

Turkish Energy Forum are beneficial to both states. I’m delighted that we’ve been able to apply our expertise as a manufacturer and an expert in the sector,” enthused Weidmüller CFO Harald Vogelsang, taking stock after the trip. Weidmüller introduced the Turkish delegation to the benefits of “energy

efficient networks” as the forum’s first active contribution.

Optimised energy consumption in machines and systems

Weidmüller is counted as a pioneer, committed to innovation in energy management. At the same time, in its role as an industrial connectivity partner, it offers the energy sector integrated solutions, including systems for smart grids or energy management.

“Energy-efficient networks” at the German-Turkish Energy Forum

Weidmüller recently applied its energy knowledge and experience in Ankara as part of the first German-Turkish Energy Forum with Federal Minister of Economics and Technology Dr. Philipp Rösler. Mr Rösler visited Turkey in April 2013 together with a delegation of entrepreneurs. The focal topics of the forum were renewable energies, energy efficiency, power plant and network expansion – all topics in which Weidmüller intensively invests. The Energy Forum, which was newly founded in 2012, offers German and Turkish players in the energy industry a platform for dialogue and co-operation.

“At first glance, Turkey’s positive growth is clear to see with its new houses, businesses and factories. Safe, affordable energy is becoming increasingly important to the Turkish population and economy. The measures resulting from the German-

The ”Power Monitor“ is one example of how Weidmüller supports its customers in optimising the energy consumption of its machines and systems. Used in all kinds of electrically supplied systems, the device very accurately measures and visualises the relevant characteristics. The “Power Monitor” is

thus laying a foundation for setting up efficient energy management in the industry – and at the same time is paving the way for further measures that Weidmüller will use to get its partners

involved in its energy management and controlling expertise.

Thomas Peter, Head of the Electronics Business Unit, discussing precise identification of electrical characteristics as the basis of efficient energy management▶ http://www.weidmueller.com/Power_Monitor

»Weidmüller is counted amongst the energy management pioneers thanks to its commitment.«

Thanks to efficient heat recovery, the company heats 11,000 m² with a tenth of the stipulated legal energy limit – one of many measures for which Philipp Rösler recognised Weidmüller as a climate protection company in March 2013

Left: Weidmüller CFO Harald Vogelsang (right) accompanied Federal Minister of Economics and Technology Philipp Rösler to the German-Turkish Energy Forum in Ankara in April 2013

Let’s connect.

9In Focus |

Interview

»Our goal is to optimise, monitor and sustainably ensure the continued supply of power.«

Focusing on the future for the power supply of tomorrowWith a global focus and local sales teams, Weidmüller has the energy industry’s global requirements in its sights and is gearing the products and services it offers towards these. Application-specific solutions and services that Weidmüller uses to precisely incorporate its performances into power supply processes form an integral part of this. Global Industry Manager Markus Schade outlines the range of solutions.

WIN! The world of power supply no longer calls for simple solutions. Traditional energy generation systems are competing with renewable technologies, competition is becoming tougher and requirements greater. How is Weidmüller supporting the energy industry in view of these challenges?

Schade: We’re at home in the world of energy suppliers, something that’s reflected, not least, in our global commitment. All over the world, our local sales teams are on hand to help those responsible for energy solutions in the industry. Sophisticated connection solutions, such as our SAK modular terminals for power plant technology, have been guaranteeing reliable processes in traditional power supply for decades. With specially designed products, nowadays we’re also optimising processes in segments such as photovoltaics and wind energy. Our test interfaces in energy networks are also making it easier to maintain transformer stations. With solutions like these, we’re making the connection to the energy security of the future. WIN! Every industry has its own requirements and not only needs standard products, but also, more and more frequently, individual solutions. What does Weidmüller offer the energy industry here?

Schade: As far as we’re concerned, the energy industry is one of our focus industries for which means we develop solutions tailored precisely to the relevant applications. To expand this range in line with demand, we’re continually picking up on our customers’ requirements wherever and whenever they occur: directly in the markets, this means we can optimally respond to regional requirements. In Germany, for instance, local energy suppliers are specifying the technical connection conditions (TCCs) for low-voltage distributors in both the industrial and private sectors. TCCs define how terminal strips are designed in the main distribution board and what the installer has to precisely comply with

when incorporating counters and safety equipment. We completely approve this structure for our customers. We offer ready-built, marked and tested terminal strips according to the TCCs, under a single order number. In the same way, we provide our customers with complete enclosure solutions. We offer plastic and metal enclosures in a variety of sizes and featuring needs-based hole patterns, assembling them with terminal strips or electronic devices – even from third-party suppliers – as classic distributor enclosures. We design the entire internal and external labelling according to the customer’s planning, for example, using standardised marking in accordance with the Reference Designation System for Power Plants (RDS-PP). The enclosure is equipped in our global application centres so we can precisely respond to specific requirements.

WIN! In which sectors are these enclosure solutions used?

Schade: Our Klippon® stainless steel enclosures are, for instance, used as decentralised switching units in large-scale power plant technology, such as directly in a gas turbine, where it would not be possible to install a standard cabinet. A considerable criterion here is our enclosure systems being approved for potentially explosive conditions, which they satisfy thanks to ATEX certification and the IECEx being the global approval framework for explosive risk zones. In addition to indoor areas, our robust enclosures are especially suitable for outdoor use, such as in the transformer station sector. We perform the necessary approval tests in our own, certified laboratory. Our range of testing services also includes individual simulations for customer requirements which extend beyond the standards.

WIN! The significance of reduced-CO2 and zero-emission energy generation continues to grow. What special solutions and services does Weidmüller have for renewable energies?

Schade: We support both wind energy and photovoltaics with practical

packages of solutions featuring perfectly co-ordinated products. Our top priority here is to guarantee system availability through transmission security – at all times. Our special connection solutions for wind turbines are, for example, used in nacelle top boxes, hub pitch boxes or tower base bottom boxes. In photovoltaic systems, one of the things we use our generator junction boxes for is to enhance efficiency. Assembled between the solar modules and inverter, they serve as the ideal connection, protection and monitoring system for the energy generated. As is also the case with our stainless steel enclosures, we have already developed numerous standard configurations based on recurring customer requirements. These are specially tuned to the individual architecture of photovoltaic systems, but we also implement individual solutions in close co-ordination with the customer.

WIN! In conclusion, what goals has Weidmüller set for the new electricity age?

Schade: With our integrated connection solutions and services, we want to reliably support power supply in the future. We will do everything we can to support the goal of being able to optimally complement both renewable and conventional energies in intelligent electricity networks. With our solutions, we’re pursuing aspects such as communicative networking in a correspondingly intense fashion. Our goal is to optimise, monitor and sustainably ensure the continued supply of power.

Are you interested in our application-specific solutions and services for power supply? Then contact your local Weidmüller sales partner, who will be happy to help. Let’s connect.

11In Focus |

Flexible connection systems for seamless integration in photovoltaic plants

Today, combining renewable power with the protection of the environment and sustainable agriculture is the approach actively being pursued by British Solar Renewables. It is therefore not surprising that just as their photovoltaic systems need to blend harmoniously into the British landscape, so their connection and monitoring solutions need to seamlessly and appropriately integrate into their system structures.

“Solar power is predictable and quantifiable and is therefore ideal for use in the latest technology advancements such as those involving energy storage,” says Angus Macdonald, Managing Director from British Solar Renewables. “We are proud that we are able to influence and provide solutions that move our customers away from a dependence on fossil fuels. As a result of this, we have found that the number and variety of renewable energy projects we have been asked to undertake has increased dramatically.”

The role of British Solar Renewables is to install solar systems on agricultural land, whilst ensuring that it can continue to be used for productive farming purposes such as animal grazing or crop growth. The company’s specialists take great care to ensure that they produce the best solutions to ensure a biological balance

on the land used. Indeed, the number one priority for British Solar Renewables is for their photovoltaic systems to blend as harmoniously as possible into their surroundings. And naturally, they expect the connection and monitoring solutions in their systems to do likewise.

Efficient connections and consistent communications reliability

“We wanted connection solutions that can be adapted precisely to our system concept. Simply

The solar systems of British Solar Renewables share agricultural land with grazing animals

12 | In Action

»Weidmüller’s practical product range provided us with both the specific connection and monitoring solutions we were looking for.«Joe Wootton, Technical Manager at British Solar Renewables

using an inverter manufacturer's complete package of generator junction boxes and monitoring software pre-configured for standard applications was out of the question,” says Joe Wootton, Technical Manager, of the company’s requirements. “However, Weidmüller’s practical product range provided us with both the specific connection and monitoring solutions we were looking for and perfectly covered our explicit and individual requirements at various locations.”

Weidmüller mapped the requirements of British Solar Renewables and then developed specific junction boxes, as required, in its application centre for photovoltaic solutions (▶ See p. 14 – 15 for a glimpse behind the

scenes of how equipment junction boxes are developed). Components from its Industrial Ethernet range were used to ensure consistent communications reliability from the panel to the control room. In addition, Serial-Ethernet converters, switches and routers were employed to deliver quality and reliable data transparency. Continuous output monitoring was provided by Weidmüller's Transclinic xi+ system, which is linked up for optimal performance with the inverters used.

Saves time thanks to flexible labelling solution

“To round off our solution, we were able to provide British Solar

Renewables with customer-specific labelling in the form of our flexible marker range. Alongside our SFX markers for intelligent cable marking with cable tie bushings, the company also uses our ClipCard device markers, offering numerous formats and types of attachment as well as highly resistant labelling of a quality you usually only get with engraving,” says Stuart Roper from Weidmüller. “Consistent labelling noticeably saves British Solar Renewables significant time in identifying installed cables and device junction boxes – time that the company wishes to use for focusing on its core business of sustainably linking renewable power generation with agriculture.”

13In Action |

“We should give our customers high-quality solutions that they can rely on,” states Arnau Sumpsi, Global Product Manager for Photovoltaics, explaining his standard. “That’s why in all of the development phases, we ensure quality down to the smallest detail and don’t leave anything to chance.”

Construction

The design process for a generator junction box starts with the technical specifics of the photovoltaic system. Developers from the Weidmüller team ensure that the practical requirements are copied to highly detailed documentation pursuant to the international DIN EN 61439-2 standard. These then serve as a basis for further solution development.

G enerator junction boxes make up around 0.5 % of the initial investment when installing a photovoltaic system. But you shouldn’t underestimate their quality. Opting for a lower-

quality generator junction box may well bring savings from a short-term perspective, but this can also have devastating consequences in the medium to long-term: temporary failures, an unexpectedly lower level of system efficiency, a multitude of maintenance tasks and even fire in the generator junction box are all realistic consequences.

How is a generator junction box actually made? A look behind the scenesIn its application centre for photovoltaic solutions, Weidmüller develops generator junction boxes for the optimum connection between the solar modules and inverters. A look behind the scenes provides insights – from the construction to the approval process.

Top left: During construction, a photovoltaic system’s technical data is precisely taken into considerationLeft and top: Individual customer requirements are incorporated into the development process to create a prototype generator junction box

14 | In Detail

Prototype development

If a suitable standard design has not yet been developed to satisfy the requirements of a photovoltaic project, the team firstly starts by developing a prototype. The responsible design developer ensures that everything can run smoothly during the subsequent mass production process. Upon request, clients have the opportunity of firstly testing the prototypes in their real application and providing feedback. The Weidmüller team is on-hand to provide help in any way it can during tests of this kind.

Checking

For certification pursuant to DIN EN 61439-2, Weidmüller performs the following checks with its generator junction boxes: corrosion resistance, UV resistance, impact resistance, protection degree, clearance and creepage distance, dielectric strength, impulse withstand voltage, heating test, electromagnetic compatibility – and much more upon request.

Production

From the tool, to the processes, to the individual employees; all elements of the production process are checked on a regular basis. In this way, Weidmüller ensures that the production of the generator junction boxes completely satisfies the practical standards. As soon as a generator

junction box has undergone the mechanical processing, assembly, cabling and marking phases, it is handed over to another team for checking.

Routine verification

Weidmüller individually checks every generator junction box produced for potential deviations and production defects.

The check includes the following tests (among others): protection degree check (IP), clearance and creepage distance, protection against electric shock, mechanical operation, dielectric strength, cabling, operational performance and function. Once the tests have been

successfully completed, a test report is signed. Weidmüller then delivers this to the customer with each individual generator junction box.

Acceptance sampling

Within the context of ISO 9001 and to satisfy the quality standards that Weidmüller applies to itself as a manufacturer of high-quality generator junction boxes, a random sample check is performed from every production batch before shipment. This closes any “quality loopholes” and allows Weidmüller to continually improve its development and production processes.

»In all of the development phases, we ensure quality down to the smallest detail and don’t leave anything to chance.«Arnau Sumpsi, Global Product Manager for Photovoltaic

Left: Here, a heating test pursuant to DIN EN 61439-2 is being performedTop: Within the context of routine verification, the dielectric strength is tested pursuant to DIN EN 61439-2

15In Detail |

»Set between the regulation equipment and the controls, our relays have proven to be the ideal interface in this application.«Fernando Montanho, Application Engineer

Seamless aluminium production thanks to precise signalsWhile modernising their control cabinets at an aluminium production facility, the Brazilian engineering and assembly company EBM faced leakage current and a lack of space. The solution: TERMSERIES relays. With multi-voltage input the signals are now always ideally suited to the automation – and the aluminium powder flows continuously to the more than 160 ovens.

The Brazilian engineering and assembly company EBM (Empresa Brasileira de Montagens) based in São Paulo specialises in the manufacturing of control panels. A large high-grade

aluminium manufacturing plant has recently placed an order with the company to equip it with control cabinets for the motors running the materials handling equipment transporting aluminium powder to the ovens. Each oven has been assigned two separate control cabinets: one with electromagnetic relays to drive the motors and one with the relevant control. EBM was asked not to change the existing controls. However, the electromechanical relays were to be replaced with more efficient electronic components to better safeguard the processes against failure in the future. The engineering specialist was tasked with creating a harmonious interface between the existing and the modernised control cabinet for each oven. ➜

16 | In Action

Constant signals even during voltage fluctuations

“Modernisation projects like this one by EBM are regularly carried out in the area of plant and process automation to increase performance and security. One of the challenges faced is that the measurement and control equipment works with voltage levels subject to fluctuation in some cases,” explained Frank Polley, a product manager at Weidmüller. The control used in the control panels for aluminium production features 220 V AC outputs, where leakage current had previously been diminishing performance and causing irregular control voltages in the direction of the motor control cabinets. In addition to this challenge, the available space for equipping the control cabinets was remarkably limited. Given these circumstances, a number of options had already been tested, but none of them met the application standards – until EBM heard about the TERMSERIES relays, which seamlessly integrate multi-voltage inputs and changing input voltages in one product.

Extra room for planning the switch cabinet

“Set between the regulation equipment and the controls, our relays have proven to be the ideal interface in this application. A row of them is only 6.4 mm wide, which is unique for components with multi-voltage input. Compared to standard solutions, these products save valuable space on the mounting rail and provide extra space for planning the switch cabinet,”

reported Fernando Montanhano, Weidmüller Engineer, who is supporting EBM on site. “As a universal coupling level to the field that processes signals from 24 V to 230 V UC with only one version, our TERMSERIES handles every voltage fluctuation – so it trumps conventional relays with an upper switch limit of only a few volts.”

EBM generally prefers partnerships that allow the company to modify its system completely to fit the needs of each project – a successful maxim in this case.

Your requirements are our benchmark. Experience the practical details of our TERMSERIES: ▶ http://www.weidmueller.com/TERMSERIES

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Despite the limited space in the motor control cabinets, EBM could schedule the narrow TERM-SERIES relays without any problems

17In Action |

Safe flow of traffic even during thunder and lightning

E xperiencing heavy traffic of 130,000 vehicles on average per day, the Brüttisellen junction in the Zurich-North metropolitan area is a real bottleneck. This key hub is where the A1 and A53 come

together and merge traffic arriving from Zurich, eastern Switzerland, the Zurich Oberland and the Zurich Unterland.

Despite being regularly maintained, the four bridge structures that traffic travels across on the A1 have dropped below the permissible limits over the last few years. For this reason, extensive renovation work is currently being performed. In this context, Peter Meister AG, the control switchgear expert, has been commissioned with a new control system for the section of road near Brüttisellen.

Future-proof surge protection for greater planning security

“An absolutely reliable traffic control system is essential at the extremely busy Brüttisellen junction, as the only way to create a safe flow of traffic here is to use dynamic displays that automatically adapt to the vehicle flow,” explains Fabio D’Ottaviano of Peter Meister AG. “One of the main requirements we were tasked with fulfilling was to appropriately install a system that runs perfectly both day and night, and in all weather conditions. We satisfied this standard with a high-quality lightning and surge protection concept, among other things.”

A Peter Meister AG control system will ensure, in the future, that traffic flows smoothly at Switzerland’s Brüttisellen junction. Future-proof surge protectors in the VARITECTOR PU series ensure the long-term reliability of the control system even in adverse weather conditions.

18 | In Action

A lightning strike involves a voltage discharge of several hundred kilovolts. In an extremely short time, there can be currents between 50 and 200,000 amps. Electronic components, in particular, are generally not able to withstand this massive voltage surge. To prevent downtimes, Peter Meister AG is relying on surge protectors in Weidmüller’s VARITECTOR PU series. These not only offer reliable protection, but also long-term planning security.

“Only Weidmüller was able to offer us surge protectors that already satisfy the IEC/EN 61643-11:2012 standard valid since September 2012,” states Mr D’Ottaviano. “As we’re already working for our clients with the latest technology, we’re saving them the necessary adaptations when the three-year transitional period of the EN standard becomes a national one. Especially in an extensive construction project like this one, we’re playing it safe and are able to save planning costs.”

Protection against storm-related damage and downtimes is becoming more significant

With its tightened criteria, the newly introduced IEC/EN 61643-11:2012 standard takes the growing significance of reliable surge protection into consideration. The number of heavy thunderstorms the world over has increased significantly over the last few years and the World Meteorological Organization (WMO) anticipates that, given globally increasing average temperatures, the number of heavy thunderstorms will continue to increase further. “Compared to the impacts of a lightning strike on people and material, the costs for a modern surge protection system are quite low. Also, the longer a system is operational, the more likely it will suffer surge damage,” explains David Schütz, Industry Manager at Weidmüller. “I therefore clearly advised Peter Meister AG to protect the entire system with surge protectors featuring the latest technology.”

The VARITECTOR PU lightning and surge protectors work with combined Varistor gas discharge tube technology. The rapid status report in particular was a decisive criterion for Peter Meister AG. The remote signalling contact with “PUSH IN” socket can be

connected in a flash and enables permanent monitoring of the surge protector’s status. Also, the large status window offers the best product overview, as the functional status of the surge protectors in the cabinet can be seen at a glance. With these product features, VARITECTOR PU will help to ensure a smooth flow of traffic at the Brüttisellen junction once the renovation work is finished. Indeed, it is already doing so today thanks to the sophisticated planning security. 

David Schütz (left) identifies the optimum surge protectors for the road construction project together with Fabio D’Ottaviano of Peter Meister AG

»Only Weidmüller was able to offer us surge protectors that already satisfy the IEC/EN 61643-11:2012 standard valid since September 2012.«Fabio D’Ottaviano, Peter Meister AG

VARITECTOR PU surge protectors work with combined Varistor gas discharge tube technology

19In Action |

Make way for deployment in traffic engineeringThe key factor – functional reliability

“We really don’t make product and series releases easy for ourselves. Before we use a component in our systems, we first of all have to be completely convinced by it,” sums up Kay Klöcker, Product Centre Manager for Signal Engineering, discussing what HANNING & KAHL expects of all its system parts. The specialist for control and safety technology, such as signalling systems, point controls or level crossings for track-guided rail traffic, knows how essential reliability is in traffic engineering: “Controls and points have to fully satisfy their safety requirements at all times.” New products are accordingly put through their paces before they are used. The innovative medium-sized company generates benefits

from partnerships with companies that – when it comes to their components – have equally high longevity, availability and technical performance standards. The collaboration with Weidmüller is correspondingly valuable for HANNING & KAHL.

Quality portfolio for traffic engineering

As a member of the German Railway Industry Association and the railway team of the German Electrical and Electronic Manufacturers’ Association, Weidmüller is extremely familiar with the requirements placed on modern traffic systems and offers a range of solutions geared towards the needs encountered in the railway industry. “The components we use in traffic engineering are constantly exposed to extreme influences. Correspondingly, every product is subject to strict quality management and satisfies the necessary international railway regulations and standards,” reports Industry Manager Detmar Saalmann. ”Even under adverse conditions, our solutions guarantee excellent functional reliability – in all climate zones around the globe.” HANNING & KAHL proves this quality promise in its internal product release procedure. “The trust we place in Weidmüller and the high value that the robust components radiate, even at first glance, mean that the initial assessment is a positive one – as was recently the case with the newly used Industrial Ethernet converter for integrating serial communication devices into Ethernet networks,” explains Kay Klöcker.

Pushing to the extreme

To ensure that the electronics used are directly operational in all situations, following the initial evaluation, HANNING & KAHL makes sure it is confident by performing some stress tests. Among other things, these tests push the environmental conditions in traffic engineering to the extreme. The Weidmüller converters therefore had to prove that they would remain functionally reliable in icy areas of use, in Scandinavia for instance, by triggering a cold start when frozen. For smooth use in hot regions such as Australia, where there sometimes are not any cool breezes whatsoever, the electronics module also had to withstand a 72-hour fire test in the furnace. The device was even able to satisfy all aspects of the electrical isolation “killer criterion”.

Following these initial trials, a usage and handling test was conducted. Here, the media converter’s impressively comfortable, intuitive configuration was the element that stood out. The two Ethernet ports featuring a switch function, or even details such as the screw connection

In order for system solutions in the rail and local traffic industries to provide services almost unnoticed for years on end, there must be uncompromised availability. That’s why HANNING & KAHL relies on technology that the company believes will stand the test of time – such as electronic solutions from Weidmüller.

Kay Klöcker from HANNING & KAHL (left) informs Weidmüller’s Alexander Wiersbowsky about the positive experience with the product: The Industrial Ethernet converters could convince across the entire line

20 | In Action

for RJ-45 plug-in connectors, were very well-received. Furthermore, the internal listing of authorised IP addresses and the fact that simultaneous connections were supported to boost availability were also evaluated positively. The monitoring functions of the admin tools, meanwhile, were singled out as the perfect diagnostic feature. At the end and against this backdrop, the product and series release process was carried out on HANNING & KAHL’s premises.

Smooth track management

A typical application where Weidmüller converters are used nowadays is in modern, networked depots, where vehicle fleets are parked and maintained by workshops. To this end, HANNING & KAHL offers superior depot management systems, which also help to ensure that running-in processes and maintenance are optimally interlinked. Interrupted connections in communication are to be avoided here at all costs. If the tracks cannot engage or disengage on schedule

in the depot, there would be traffic chaos in city centres. The media converter from Weidmüller is therefore a critical module within the network for transferring process data from the various independent adjustment ranges. Central data availability ensures a transparent overview at all times.

HANNING & KAHL provides long-term guarantees for its systems. Even if the end customers in the private railway and public transport sector at best forget about the systems during this time thanks to their low-maintenance design, the system supplier is on hand around the clock to provide support services. “Here, too, it’s worthwhile having partners that deliver the same standard of service,” adds Kay Klöcker. “When we encounter challenges in the field, we can count on the fact that Weidmüller will provide us with prompt support.”

Depot management systems from HANNING & KAHL ensure that all running-in processes

and local rail transport maintenance tasks are optimally interlinked

»We really don’t make product and series releases easy for ourselves. Before we use a component in our systems, we first of all have to be completely convinced by it.«Kay Klöcker, Product Centre Manager for Signal Engineering

I f a car passes through a welding line, there’s hustle and bustle on all sides. Electric drives speed up and slow down the robots’ movements and thus re-position time and again. At the same time, the

robots’ claws set welding points at defined locations every few seconds. Heavy switched and alternating loads continually cause current peaks, which can easily result in short-term interruptions typically lasting around 200 milliseconds.

“A brief interruption like this seems harmless at first glance. But mains feedback within a fully automated welding line can cause extensive damage: from costly data losses, machine restarts and damaged product parts, to undefined system sta-tuses,” explains Klaus Schürmann, Product Manager for Power Supply at Weidmüller. “Our buffer modules are perfect for use in applications such as these that are affected by continually high pulses, which can cause faults in the plant network.”

Keeping functions up and running permanently

The high-availability 24V switched-mode power supply units of the PRO-M series, with their minimum mains failure bridg-ing time of 20 milliseconds, arrest very short interruptions and dips in supply voltage. The zero-maintenance Weidmüller buffer module, which bridges 20 amps in 260 milliseconds, is the ideal solution to reliably compensate for short-term

Be they switching operations in the company’s own network or weak low-voltage networks – the causes for short-term interruptions are diverse, and the effects always a nuisance. The zero-maintenance buffer modules from Weidmüller reliably bridge brief interruptions and dips in supply within the range of several 100 milliseconds.

Safe bypasses with buffer modulesPermanently supplied – part 3

22 | In Detail

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

Read the articles in the "Permanently supplied" series online:▶ http://www.weidmueller.com/Permanently_supplied

Let’s connect.

interruptions in the range of several 100 milliseconds. Two devices can also be switched in parallel to increase the current or buffer time. The modules can be easily looped into the cur-rent path between the switched-mode power supply unit and secure load, so they’re not just easy to plan, but can also be quickly retrofitted at any time.

Once it’s in use, system operators don’t really need to give the buffer module a second thought. Depending on the ap-plication, it has a service life of up to ten years. The “Ready” and “Fail” output signals are available for completely remote module monitoring. These can be tapped at any time on the clamping points provided. An LED provides the visual on-site display, while a relay contact is used for remote signalling. During this process, the “Ready” signal confirms that the buffer module’s internal capacitor battery is fully charged and thus ready for operation. The “Fail” signal is set immedi-ately if the input voltage fails.

In focus Buffers in weak low-voltage networks“Many of our customers supply machines in markets where weak low-voltage networks pose a challenge. Sample applications here include smaller machines for timber or metal processing in Eastern Europe,” explains Industry Manager Harald Winter. “As network fluctuations generally aren’t documented, machines may fail out of the blue. Here, buffer modules represent a practical way of being well-equipped for difficult network situations, especially in rural areas. As our module can be used without further rescheduling, our customers can respond flexibly to particular market requirements and successfully prevent problems.”

Additional challenges involve applications that are not only used as part of weak networks, but also outdoors, which is why Weidmüller buffer modules successfully ensure security of supply for agricultural machines in Australia. As the modules are suitable for ambient temperatures up to 70 °C, the heat in the Australian Outback doesn’t affect their functionality. In this application, too, they arrest brief dips in supply.

Current peaks in automated welding lines easily result in short-term interruptions

»Mains feedback within a fully automated welding line can cause extensive damage.«Klaus Schürmann, Product Manager for Power Supply

23In Detail |

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

Weidmüller – Your partner in Industrial Connectivity

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

Your local Weidmüller partner canbe found on our website:www.weidmueller.com/countries