UPDATE - The innovation magazine from Phoenix Contact

UPDATE - The innovation magazine from Phoenix Contact | Phoenix Contact

The power of the elements How the sun, wind, and water move the world The sun is the universal source of energy. Heating and cooling cause the atmosphere to move, water to evaporate, and make rain possible. 2,245 megawatts – the largest solar park in the world. 57 square kilometers in Rajasthan in the north of India. The sun provides more energy in one hour than humankind consumes in a year. 41 g CO2/kWh are generated by a photovoltaic system after the manufacturing carbon emissions are amortized after approx. two to three years (coal, 820 g CO2/kWh). 11 % of Germany’s electricity demand could be covered if every roof had a photovoltaic system installed. 270 square miles of solar surface could cover the world’s electricity needs. That is around 378,000 soccer fields! x 378,000 18 % current average efficiency of the latest-generation photovoltaic panels. 1,198 ft 59.3% of the kinetic energy of the wind can theoretically be utilized by wind turbine generators. 656 ft i d n w d r a d n a t S n o i t a t s r e w o p i n o i t a t s r e w o p d n w e d u t i t l a - h g h u a k p h c S i i 1,207 ft 515 ft r e w o t V T n i l r e B l a r d e h t a C e n g o l o C The high-altitude wind power station in Schipkau/ Brandenburg (to be completed in 2026) will be the tallest wind power station in the world. 5.15 quadrillion tons – the weight of the entire mass of air on Earth. That is about one millionth of the Earth’s mass. 1 quart of water that is 100 meters high contains almost 1 kilojoule of potential energy. 90 % <2% current average efficiency of the latest-generation hydroelectric power plants. New turbine technology and so-called fish ladders reduce fish mortality to less than two percent and open up migration routes to spawning grounds. 236 ft Highest hydroelectric power plant capacity worldwide in megawatts. Ten years ago, Swiss engineer and pilot André Borschberg completed the longest non-stop flight of all time, lasting five days and nights, in a solar-powered aircraft. The wings of the solar-powered plane were studded with more than 17,000 solar cells. Weight: 2.3 t Average speed: 49 mph 0 0 5 , 2 2 0 0 0 , 4 1 0 0 0 , 6 1 Itaipú (Brazil/Paraguay) Baihetan (China) Three Gorges (China)

Davis Mathews CEO North America Phoenix Contact EDITORIAL The energy transition runs on partnership Dear readers, The energy transition is often framed as a race for better products – new technologies, smarter components, more innovation. Technology matters, but it’s not the hardest part. The real challenge is partnership. Today’s energy systems are more interconnected, data-driven, and time-sensitive than ever. No single company or utility can modernize the grid alone. Success depends on how well utilities, technology providers, integrators, and industry organizations work together to design systems that are reliable, secure, and built to evolve. The most effective solutions are co-created, not just dropped into place. They account for legacy infrastructure, regulatory realities, operational constraints, and long-term scalability. That requires trust, openness, and a willingness to collaborate beyond traditional vendor relationships. In this issue of our customer magazine, we highlight the possibilities, technologies, and approaches for making the energy transition a success. We hear from people who are part of this exciting journey into the future and what drives them. Partnerships, like those featured in this issue, drive the energy transition. By listening first, solving real problems, and committing to long-term success, we can build a grid that’s ready for what comes next – together. The Phoenix Contact innovation magazine 3

The Phoenix Contact innovation magazine Y G R E N E Generate This issue is the first in a series that focuses on the topic of energy – its generation, storage, distribution, and consumption. 4 The Phoenix Contact innovation magazine Committed to sustainability – Himmighausen is not only the ancestral seat of an age-old noble family. The generational mindset is also reflected in a state-of-the-art solar park. 06 Natural resources The sun is the main force behind all activity on our planet. Its energy can be used directly via solar panels. Or via the detour of wind power, which captures the movement of the atmosphere heated by the sun. On the other hand, the energy detour via the combustion of fossil fuels, which were created through the capture of solar energy by photosynthesis, is proving to be a mistake in the long term.

SIGNPOST Powering the future with safe, reliable, and economical electricity. 28 Vibrations reveal problems – on wind turbines as well. 24 Josef Ecker knows what solar park operators need. After all, the Phoenix Contact Solution Partner is one himself. 14 Energy on point – Synhelion bundles the power of the sun. 20 Canadians use heat, pressure, and a fabric duct to combat ice formation on wind turbine generators. 32 SOLUTION PARTNERS Sunny prospects DEVELOPMENT When a wave warns Josef Ecker comes from a family of farmers. But instead of grain, the enterprising entrepreneur now harvests energy from the field. | 14 The Wölfel company specializes in the detection and evaluation of vibrations. It also develops new solutions for wind turbine generators in collaboration with Phoenix Contact. | 24 ROTOR BLADE HEATERS Hot against ice Canadian and Finnish developers are using two very different methods to combat ice on rotor blades. | 32 FOCUS Energy in the spotlight It can get pretty hot in the blazing sun. Why is this exactly the right thing for a Swiss company? | 20 ENERGY Smart, sustainable production Through a trusting partnership, Phoenix Contact supports Schweitzer Engineering Labs with local manufacturing and new connector technologies. | 28 Editorial | 03 Behind the scenes | 38 Legal notice | 39 The Phoenix Contact innovation magazine 5

SOLAR POWER N oblesse oblige. Anyone like Georg von Puttkamer, centuries, is used to thinking in the long term. Of who was born into a family whose lineage goes back Making a virtue out of necessity But this railroad line proved to be a suitable building block for the solar park idea. As von Puttkamer became more aware of the issue of climate change and the need for responsible course, not everyone would rise to this challenge. But the son of this noble family, originally from Hinterpommern, follows personal action, he realized that the railway line, which he in the footsteps of his ancestors and is striving to keep the house, farm, and land together so that he can pass them on to future generations. And since von Puttkamer was not born yesterday and the yields from forestry and fields are not without risk due to climate change and the bark beetle, this forestry graduate and qualified tax consultant decided back in January 2020 to turn a low-yielding field into a large solar park. And a flagship park at that. This is because the solar park is within walking distance of the family’s home which, in fact, is the 300-year- old Himmighausen Castle with its adjoining estate and large landscaped park. A little less glamorous is the railroad line on which passenger and freight traffic runs from Hanover to the Ruhr region. The busy route runs just a few yards away from the had always seen as a burden, was about to prove its worth 130 years after its construction: Land along railroad lines can be used for concessioned construction projects such as solar parks. This means that there is no need for complex development plans and the resulting bureaucratic red tape to go through the approval process. So should four generations of railroad noise be good for something positive after all? Especially as the 1.76 million square feet of agricultural land on which the solar park was to be built was rich, but not making anyone rich. This is because the land was rich in stones. A country road runs along the other side of the long valley on which the site is located. Railroad line, monoculture, road – a solar park would be most welcome here. However, the landowner had not reckoned with bureau- cracy, environmental impact assessments, and concerned castle and divides the stately garden into two halves, as it citizens. There were a large number of objections and does the entire estate. complaints, and the park became a political issue. It took a good two years before the idea slowly became a project. The 1.76 million-square-foot solar park extends to the right and left of the railroad line in the Fischbach Valley, whose stream flows into the Emmer River in Himmighausen. 10 The Phoenix Contact innovation magazine

Jumping back in time to the construction phase: The solar panels are arranged in 684 strings connected to 57 inverters. The park feeds energy into the public grid via two grid connections, each with a power control unit. 12 25,650 GWh of power is generated by the park from the sun. That is enough for around 5,000 single-family homes. photovoltaic panels were elevated so that there is space between them for groves and wildlife. There are no projects without a project planner, and this role was filled by BLG Projekt from Wolfhagen. Phoenix Contact became the technical cooperation partner. The reason behind taking on this role was not completely endangered animal and plant species with power generation, but also to restore the original, small-scale cultural landscape with hedges and groves. Sowing native flowers and herbs between the rows of modules gives insects a rich menu and altruistic, because the solar park is not far from the company’s own All Electric Society Park and serves as an opportunity for visitors to see the practical implementation and expertise of prevents soil erosion at the same time. Birds and wild animals will also find this so interesting that they simply ignore the elevated power modules – and some even use them as cover. the Blomberg-based industry leader. Sheep are used as live lawnmowers to prevent the bushes from taking over the solar panels. The fence, which surrounds Diversity instead of monoculture the entire power plant for safety reasons, also plays a second The result is a very special solar park. It’s not just the role – one of animal welfare. performance data that is impressive, but also its integration What sounds like an idyll for nature lovers also delights into the landscape. Instead of continuing to eke out a rather dull existence as a monoculture sprayed with artificial fertilizers and pesticides, hedges and native fruit trees will in the future divide the 1.7 million-square-feet power field into small plots. The idea was not only to combine a habitat for the investors. The power yield is so high that the revenue yield of the former farmland is 25 times higher than before. Not without pride, von Puttkamer calculates that the entire park will be carbon neutral after around two and a half years, including all the CO2 emitted during the construction phase → The Phoenix Contact innovation magazine 11

SOLAR POWER and that emitted through the manufacture of the technologies access the park and stabilize the grid frequency and voltage. used. Stress for the grid It is time for a change of scenery. Georg von Puttkamer leads In addition, the electricity generated can be sold by direct marketers on the electricity exchange.” The journey from the first idea to a functioning solar park was not an easy one. However, the organizational and us from the castle to the solar park. Here, we meet Burkhard technical hurdles have now been overcome. The sun is Dittmann. He knows the system and details inside out, because the Phoenix Contact sales team expert was involved in the planning and installation of the system from the very shining, the inverters are humming, and the park is making every effort to repay the investment made with renewable and clean energy. This not only pleases its owner, but also beginning. As he opens the gate, Von Puttkamer tells us that “the output of 12 GWh from the 25,650 elevated photovoltaic panels covers the needs of around 5,000 single-family homes.” This means that Himmighausen, with its 450 inhabitants, will become a net exporter of electricity. Burkhard Dittmann adds, “The only catch is that the power generated here far exceeds the power required on site – that is, if you look at the solar power generated during the day. At night, however, the ratio is reversed. Because there isn’t any power available from the sun at night, the local loads must be supplied by the public power grid. Without suitable control mechanisms, this will quickly push the power grid to the limits of its capability.” It is clear that the family entrepreneur has also become an expert in solar parks. “Since 2019, there has been a binding application rule that states that the active and reactive power fed in by generation plants such as our solar park can be influenced via the grid operator’s remote control technology. This ‘remote control’ function enables the grid operator to lays the foundations for future generations. And far beyond the boundaries of their own farm. (lo) “The idea was and is to combine a habitat for endangered animal and plant species with power generation.” Johann Georg von Puttkamer It also has to pay off! The landed gentry of East Westphalia think in practical, traditional terms and – as in the case of von Puttkamer – also as visionaries. 12 The Phoenix Contact innovation magazine

The sun controller Accessing the public power grid is the task of the power control unit (EZA-Regler). It acquires the system data and communicates it to the grid operator. At the same time, it enables secure remote access. Burkhard Dittmann explains how the control system works. “The programming language Matlab Simulink was used to train the PLCnext Control, the core of the power control unit, in its control and access functions. These functions are certified. Freely programmed functions can also be used. The yields from the individual components of the system in Himmighausen are recorded. The power control unit also processes data from a weather station.” Dittmann pats “his” control cabinet almost lovingly. “But the components alone are not enough. We had to go through a component certification process for our solution. The manufacturers of generators, such as inverters, must obtain unit certification for their components. And on top of all that, the operator also needs a system certificate. The operator is only entitled to the full feed-in tariff once the system has been certified as a complete system. Burkhard Dittmann not only knows the Himmighausen Solar Park inside out: the Phoenix Contact engineer is also an expert on power control units. 431.5 TWh of electricity were fed into the German power grid in 2024. (Statista 2025) Controller, network modules, independent power supply, I/O links, and energy measuring devices are components of the power control unit. The Phoenix Contact innovation magazine 1313

SOLAR POWER renewable power generation scene. Anyone who has J osef Ecker has become a well-known face on the the pleasure of visiting the enterprising entrepreneur at his company headquarters near Landshut is first greeted by an idyllic Franconian setting. In the middle of cornfields lies what at first glance appears to be a typical Bavarian farm. Lots of light-colored wood, a long main house, barns, and agricultural machinery. Solar panels sparkle on the roofs – everyday life in any rural area. Farming for electricity the beginning it was a one-man show together with a few students, and we worked exclusively in the solar sector right from the start. But I’m not an ecowarrior at all,” laughs Josef Eckert. “I trained as a farmer and an electrician, which are both full-fledged apprenticeships. The real driving force behind the switch to electrical operations at that time was the lack of prospects in agriculture. We gave up the dairy farm in 1990 and the last animals left the farm in 1998. But the symbiosis of agriculture and photovoltaics was ideal, because we had the large buildings and areas that we needed for installing the systems. I had the connection But anyone who pulls into the farmyard is greeted by the energy transition. Dozens of heavyweight transformers are waiting to be installed in their respective secondary substations, and behind the open barn doors, large switching and speak the language of agriculture. Even today, around 50 percent of our customers are farmers.” Josef Ecker now employs a good 60 people to take care of the planning, construction, and operation of solar parks, from devices are waiting to be prepared for use. Josef Ecker and small to large. Ecker is primarily active in Bavaria (“where his team plan, develop, install, and operate solar parks far people speak and understand our language”). Elektro Ecker beyond the borders of Bavaria. is also his own customer, as it also operates its own solar “A bit of farming, a bit of electrician work – that is enough parks. However, the main focus is on building solar parks for for a lifetime.” Josef Eckert has to smile to himself when customers. These customers no longer just come from the he talks about the beginnings of his business. “But now agricultural sector. “Today, business operators are also a I no longer have time for farming.” The busy farmer’s son started his “sideline” electrical business back in 2008. “In major target group, because they want to move away from high electricity prices.” Everything from solar panels to heavy transformers can be found on the former farm. 16 The Phoenix Contact innovation magazine

As a Solution Partner, Elektro Ecker fully relies on Phoenix Contact. 874 electricity grid operators are active throughout Germany. 4 transmission system operators secure the transregional power supply. Own assembly lines: If you want solar, you can get everything from a single source here, right up to the grid connection in your own concrete house. Lightning bolts and control For a long time now, Josef Ecker and his team have been known far beyond the borders of Bavaria. And that has Things didn’t stop at the control cabinet. “We purchased an initial batch of prefabricated concrete sheds and then installed our switching devices and measuring panels in them. We then went to the Intersolar 2019 trade fair with these complete solutions – with a very rudimentary booth and, initially, little attention. But we sold our first systems. That was inspiration enough to develop the topic further.” something to do with their typical Bavarian stubbornness. Ecker founded the company Trafomacher. “This allowed “And with our thriftiness,” adds Helmut Schratzenstaller with us to install our control and measuring systems in third-party a grin. The electrician has delved deep into the world of IT solar parks without the name Elektro Ecker evoking too much and control systems and is one of the experts when it comes of a feeling of competition,” says Josef Ecker, describing the to programming Ecker’s systems. background to his two companies under one roof. One day, a violent line of thunderstorms stretching across almost all of Bavaria knocked out solar parks one When it is tight at the front after the other. “We were able to detect this via our remote The overall concept for the switching devices includes a maintenance systems,” explains Josef Ecker, “but then suitable controller at the feeding point. This is where the a specialist with the appropriate authorization to switch respective grid operator accesses the system to regulate it medium voltage gear had to check all the systems and so that the power grid remains stable and the unavoidable reconnect them to the grid. If there was a fault in the system, fluctuations in renewable energy do not cause any damage the circuit breaker would trip again, and the technician would have to go back into the system. Nobody really knew why this was happening. That cost us time and money. So we dealt to the grid. “But we wanted to understand what this power control unit can actually do. At first, it was just a black box that we paid for. As project developers, we had no insight into with the issues of controllers and control cabinet building in- what the power grid operators ultimately regulate or do after house and quickly developed our own solution." our systems have been connected.” → The Phoenix Contact innovation magazine 17

Helmut Schratzenstaller adds, “The more you get into the control side of photovoltaics, the more complex things become. This also sets us apart from our competitors. Most concentrate on individual areas, such as regulators, controllers, or connections. We supply the entire bandwidth, from A to Z. Therefore, we can also influence a whole range of parameters. If something is tight at the front, we know where we can tweak something at the back to make it fit. This makes us fast and capable of acting, and therefore independent." David and Goliath Josef Ecker proudly adds, “To simplify the operation of the system, we are in the process of programming our own operating and configuration interface. We can now communicate with the experts from Phoenix Contact on an equal footing.” Marina Friedberger smiles. “Sometimes we are already a step ahead.” The graduate engineer has been part of the Elektro Ecker team for three years. Before that, she worked in automotive engineering. “We are practical people who are very close to the actual operators. This gives us a head start, even over large companies such as Phoenix Contact,” she explains. Elektro Ecker has been one of the Solution Partners in the Phoenix Contact network for a long time. The issues that the team tackles go far beyond simply connecting solar parks. The expert goes into detail. “Between 80 and 90 percent of solar parks are built on 800 volts on the low voltage side. These power grids may not have a ground connection from the transformer neutral point and must have insulation monitoring. This is why inverter manufacturers are now demanding IT systems everywhere, which they use to provide monitoring right down to module Josef Ecker talking shop with Phoenix Contact expert Jörg Hildebrand. For the self-confident entrepreneur, this was unthinkable. “So we set up our first in-house controller, directly on the PLCnext platform from Phoenix Contact. With the help of the PLCnext libraries and the expertise of my employees, we have continued to adapt this controller to meet the various standards and requirements. Today we are using the certified power control unit from Phoenix Contact. And we not only connect PV systems directly to the medium-voltage grid, but also sell the connections to other PV system manufacturers. Between 80 and 90 percent of the stations on our farm go to other system manufacturers.” “If something is tight at the front, we know where we can tweak something at the back to make it fit.” Helmut Schratzenstaller The amount of copper alone makes it clear that large projects are also being done here. 18 The Phoenix Contact innovation magazine

SOLAR POWER level via the inverters. This is not a problem in a new solar park. But retrofitting existing systems is a problem because the insulation material, which has been buried in the ground for years, ages and can become brittle. We therefore want to extend the substation’s monitoring relay so that we can keep 15 minutes. When the exchange prices are really good, the participating park operators can, for example, feed in fully for 15 minutes. However, if this reverses and prices fall, the order is given not to feed anything into the grid for 15 minutes, or to store the electricity in the battery storage system. Due to the track of this material’s condition and issue an early warning. often unsatisfactory internet coverage in Germany, though, In addition, when the miniature circuit breaker trips, we it can happen that the internet is completely disconnected want to be able to differentiate whether this was caused by for control commands and these control commands come a subordinate protection circuit tripping due to frequency or voltage or by an actual insulation event.” Transparent grid The self-confident industrialist is also passionate about another issue: the lack of transparency regarding the energy grid operators’ curtailment measures. “For the park operators, this means a loss of earnings of many thousands of euros, often even hundreds of thousands. The law stipulates that there is financial compensation for this. We now track the condition of the systems via VPN, record this in a database on our own portal, and document this for the operators. This gives us a very good overview of what is actually going on in the grid.” Marina Friedberger adds, “The aim is to record every five minutes whether the grid operator is regulating the connection. We want to export this data and make it available to the solar park operator. At the end of the day, they know what they really should have earned and are able to take this up with the grid operator. We developed the interface that we use for this based on the power control unit’s PLCnext Technology.” “This transparency was initially very surprising for the power providers,” Josef Ecker continues. This gives the residents of Landshut and their customers unprecedented insights into the architecture of the power supply, as Helmut Schratzenstaller confirms: “We repeatedly see that on a beautiful sunny day in Germany, around 30 to 40 percent of the systems are being derated. And this varies greatly from grid operator to grid operator.” Electricity as a commodity While the man from Landshut and his team are causing quite to nothing. This quickly leads to considerable contractual penalties, which can quickly run into five-figure sums. For 15 minutes of incorrect feeding! Of course, no park operator can risk that.” Josef Ecker, Marina Friedberger, and Helmut Schratzenstaller (from left). “We are working on solutions to equip the substations with Starlink modules from the start so that they are reliably real-time capable,” says Josef Ecker, outlining the next challenges. “Compared to the potential contractual penalties, the costs for the satellite network are peanuts.” a stir on the operator side, he is already devoting himself to completely new tasks: “Our next big topic is battery storage systems. Technically, they operate with a different control The solutions that Elektro Ecker is developing here on the basis of feed-in controllers from Phoenix Contact are of great interest for the entire German power grid. We can method based on the frequencies in the power grid. The operators of these utility-scale storage facilities have a very different view of power grids. This is where the direct marketers come in.” Helmut Schratzenstaller explains the new outlook: “The direct marketers, who are active on the electricity exchange, all regulate within a time window of look forward to the next news from the farm near Landshut. (lo) The Phoenix Contact innovation magazine 19

SOLAR POWER E verything is actually quite simple. After all, almost When a magnifying glass is held up to the sun, and its everyone knows the trick with the magnifying glass. focal point is focused on a sheet of paper, the paper starts to burn after a short time. The concentrated energy of the sun becomes so hot that the paper reaches its flash point. Solar tower power stations use this principle. They work with mirrors and a tower that is significantly higher than you can hold a magnifying glass. The mirrors, which can track The heliostats are aligned to a focal point and track the position of the sun. aligned so that they focus the reflected sun rays onto a spot at the top of the tower. This is where the receiver is installed, which converts the solar energy into high-temperature process heat. The solar energy that is concentrated in this way generates temperatures of more than 2,800°F. “This is actually an absolute world record,” explains Carmen Murer. She should know, because she is the press spokesperson for the Swiss company Synhelion. the sun, direct the reflected sun rays onto the tower. In Jülich, North Rhine-Westphalia, such a solar tower has been standing a good 65 feet high since June 2024. At its feet stand an armada of mirrors, so-called heliostats. They can be Federal solar pioneers Synhelion is a spin-off from the Swiss Federal Institute of Technology (ETH) in Zurich. As early as 2010, the synthesis of hydrocarbon molecules with concentrated solar power → The Phoenix Contact innovation magazine 21

In the modular Fischer-Tropsch plant, real solar fuel is produced from the syngas. The tower in which the receiver sits is a good 20 meters high. was successfully achieved in a laboratory application. innovative strength of the Swiss team. “The heliostats, the Kerosene was produced exclusively from the components CO2 and H2O in the laboratory for the first time in 2014. The two scientists, Dr. Gianluca Ambrosetti and Dr. Philipp Furler, then founded Synhelion SA in 2016, with the addition of “Solar Fuels.” Following successful open-field experiments, the construction of DAWN, the first solar tower power station for the industrial production of fuels, began in 2022. The Jülich site was chosen because Synhelion works closely with its colleagues at the German Aerospace Center (DLR). There is also a second solar tower at the site, unique in all of Northern Europe, which is used by DLR scientists for research purposes. The collected heat is fed into a thermochemical reactor. There, a syngas consisting of H2 and CO2 is produced from CO2, water, and methane. This hot syngas is liquefied in a “gas-to-liquid” process. The liquid solar crude oil is then further processed in a normal refinery. In addition to kerosene as the largest portion, gasoline and diesel can also be produced in this way. The energy that is not needed immediately is transferred solar receiver, the thermochemical reactor, and the thermal heat accumulator are all developments of ours.” The Swiss company has registered a total of 20 patent families to protect its inventions. "In the foreseeable future, we will continue to have situations where we have to burn fuel. In air traffic, for example, battery electric drives make no sense. With solar kerosene, we only release as much CO2 as we have previously extracted. There is no burden due to fossil fuels.” Millions of tons of kerosene Both DAWN and the RISE solar tower power station, whose construction in Spain began in 2025, are still relatively small systems. But Carmen Murer is certain: “We are breaking new ground with these systems and showing that the technology can be scaled up to almost any industrial level. However, we will do this step by step, as the systems would otherwise not be financially viable.” Synhelion expects to be able to produce around one million tons of kerosene in ten years. “Initially, we will also build and operate the systems ourselves.” Then, to an energy storage unit with a ceramic interior and is then the plan is for Synhelion to act just as a technology provider available when the sun has set. In this way, the Swiss start- up company can achieve continuous 24/7 production without interruption. According to Synhelion, it is also around ten times cheaper than a comparable battery-electric energy source. “Synhelion has created or further developed four fields of technology,” says Carmen Murer, describing the and for mineral oil companies to take over production. “The investment in the construction of these systems is very high. But the subsequent production costs are very low,” says Carmen Murer, describing the hurdles and opportunities for a rapid expansion of the technology. The products made of light and air are already in high demand. Swiss Air is just one of the Swiss innovator’s 22 The Phoenix Contact innovation magazine

cooperation partners. There are concrete purchase agreements already in place with the Swiss aircraft manufacturer, Pilatus. In addition, the solar diesel is to help a Swiss operator of historic steamboats move forward. Pure thermal process energy is also inspiring new ideas – cement manufacturer Cemex has already conducted successful trials with solar cement. But first and foremost, the Swiss are interested in the dream of flying – with light and air. (lo) synhelion.com “DAWN mirrors the entire technology chain, from sunlight through to fuel, on an industrial scale.” Carmen Murer, Head of Communications, Synhelion Receiver ② Steam (~500°C) to the receiver Steam (~1,000°C) to the reactor Reactor ⑤ Heat storage unit Supply of CO2, H2O, CH4 ③ ④ Syngas H2 + CO2 n d i a ti o o l a r r a S ① Mirror field ① The solar radiation is reflected by a mirror field (heliostats) and focused onto the receiver. ② The receiver converts the solar power into high-temperature process heat. ③ The generated heat is fed into the thermochemical reactor, which converts CO2, water and methane into syngas, a mixture of H2 and CO2. ④ The syngas is then ⑤ To enable continuous processed into fuels such as gasoline, kerosene, and diesel via the “gas- to-liquid” process. operation of the system, part of the heat generated is stored in a thermal energy storage unit. The Phoenix Contact innovation magazine 23

Dream team on the tower – the joint solution from Wölfel and Phoenix Contact has no equal anywhere in the world. Nils Lesmann and Philipp Dauer from Phoenix Contact had to take an involuntary break. weak points and negative influences. Phoenix Contact contributes the appropriate hardware and expertise for the sensor technology and automation. T he clouds pile up on the horizon. The first gusts of wind whip across the land. A thunderstorm is approaching. Nils Lesmann and Philipp Dauer are unaware. This is because they are active in the base of a blade on a wind turbine generator. Together with experts from Wölfel Vibrations make you smart Engineering, they are testing a sensor update and setting up a wireless connection for transmitting data into the nacelle. To reach the Bluetooth module in the 187-foot-long blade, Lesmann climbs a good 30 feet into the narrow space. It is already the second of the three blades that are on schedule today. Suddenly the command comes: “Get out of the blade, get off of the turbine.” The thunderstorm has come dangerously close. On their way down, the engineers can already see the first sparks of the electrostatic charge on the weather station. It crackles Today, the thunderstorm has won, and the team heads back to the office. Sebastian Obermeier is an expert in developing algorithms for wind turbine generators at Wölfel and explains the effects of vibrations on wind towers. “You can think of it like a musical instrument, the rotor blade vibrates at its very own frequencies but not audibly to the human ear. However, these vibrations reveal a lot about the structure, potential ice coating, and any damage that may have occurred. We differentiate between the natural frequencies of the rotor blades themselves and vibrations induced by external audibly. But the safety engineer, who maintains contact with influences or operating loads.” them from below, ordered their retreat in good time. If you want to catch the wind, you have to withstand it. And moving air can be very moody. Sometimes a gentle breeze blows around the rotor blades, sometimes violent gusts batter the tower. Sometimes mechanical wear puts a strain on the system. Plus, it is not uncommon for freezing water to cause unwanted imbalances. For more than 50 years, the engineering company based in Höchberg, in Lower Franconia region of Germany, has been addressing the issues of vibrations and acoustics. Founded by Professor Dr. Horst Peter Wölfel in 1971, the company now has around 170 employees at five locations that develop solutions for earthquake engineering, vibration protection, noise emission control, vibration reduction, and the structural All these influences reduce the service life and yield health monitoring of wind turbine generators. The facility in of wind turbine generators, sometimes drastically. It Hamburg is the center for all wind power-related topics. therefore makes sense to keep an eye on the condition of the Sebastian Obermeier explains the contribution that asparagus-shaped power generators – the more precisely, the better. This is exactly where a dream team has joined forces. Wölfel specializes in detecting structural changes continuous vibration monitoring can make to wind turbine generators: “Undetected cracks, material fatigue, and build- ups of ice – all of these can become noticeable through and using sophisticated data analysis to track down potential changes in vibration patterns. If you listen at an early 26 The Phoenix Contact innovation magazine

WIND POWER stage, you can avoid damage and significantly increase the availability of the system. Continuous vibration monitoring, especially of the rotor blades, therefore makes operations more efficient and safer.” Nothing works without practice Nils Lesmann, one of the experts in the Phoenix Contact wind team, describes the collaboration between the two companies: “We have been developing state-of-the-art condition monitoring systems together for several years. It is not just about being able to measure precisely. It is important that we can integrate the data into the control systems of wind turbine generators. This is why the structural health monitoring (SHM.Blade) and ice detection (IDD. Blade) systems developed by Wölfel have also found their place on the open platform of PLCnext Technology from Phoenix Contact and are integrated into the complete Blade Intelligence rotor blade monitoring system.” But what previously worked smoothly in the laboratory and on the computer is pushed to the limits of functionality in the field, or even beyond them. The devil is often in the details. Do metal components in the nacelle shield the wireless transmission? How are sensors attached to reliably report data to the control system for years? How is the necessary data transferred from the sensor to the controller? “Ultimately, a malfunction only becomes apparent when a system is back in operation after installation. This means that in the event of error messages, the wind turbine generator must be stopped again. This can be expensive, because downtimes have to be paid for, of course,” says Sebastian Obermeier. “That is why developments for the offshore ensure that the tight development budgets are not exceeded. The years of collaboration are paying off for both companies, as Nils Lesmann explains: “The result is a powerful plug-and-play solution: the sensor data flows directly into the open control platform – for maximum transparency, flexibility, and connectivity in the park network or towards the cloud. Wölfel’s monitoring and analysis expertise is ideally complemented by Phoenix Contact’s connection technology and control expertise. This collaboration enables us to provide a modular structure for monitoring wind turbine generators that is unique in the entire wind energy sector.” (lo) “Wind turbine generators are like musical instruments that vibrate at their own unique frequencies.” sector, for example, are so complex and costly. You can’t just Sebastian Obermeier, Wölfel drive up in a van and climb the tower.” Precise planning, in- depth specialist knowledge, and a great deal of experience to The hollow tower of a windmill is a large resonating body. 27

WIND POWER centers, artificial D ata the electrification of everything: These technologies drive innovation and economic growth and make intelligence, our lives easier. At the same time, they are pushing the electric power grid to its limits. “As a country and as a world, we are consuming more power than ever before,” said Ryan Bradetich, senior vice president of research and development at Schweitzer Engineering Laboratories (SEL). To meet this demand, more energy is being generated through renewable sources, like wind and solar, and nuclear is also poised to make a comeback. This challenges utilities and private companies to ensure that electricity is always reliable, safe, and affordable. Joshua Hughes, engineering manager at SEL, explained, “Stitching all of those together into a reliable power source is a real challenge for the industry. With new energy sources, you need new solutions to control and manage them. That is what is driving a lot of the new product development and features within SEL products.” Partners with common values SEL invents, designs, and builds digital products and systems that protect, automate, and control critical infrastructure around the world. This technology prevents blackouts and enables customers to improve power system reliability, Schweitzer Engineering Laboratories invents, designs, and builds products and systems that protect, automate, and control electric power systems. Its mission is to make electric power safer, more reliable, and more economical. The company manufactures in five U.S. locations, including its headquarters in Pullman, Washington. safety, and cost. “Our founder, Dr. Schweitzer, uses a phrase that summarizes our value statements: We do business the way our mothers would want us to,” said Kelly Van Nuland, supply chain director at SEL. Phoenix Contact and SEL have a long-term relationship, and the companies share similar values. “Like SEL, Phoenix Contact has a long history in the electric power industry,” said Heinrich Dyck, vertical market manager for electric power at Phoenix Contact USA. “Our strategy in the electric power industry is centered around the seamless integration of electrification, networking, and automation. We aim to create a more efficient and reliable power infrastructure through cutting-edge technologies and solutions. At the core of our partnership lies a shared commitment to innovation and connectivity in the electric power industry. Together, we envision a future where sustainable energy solutions empower communities, drive economic growth, and create a cleaner, more connected world for future generations.” 30 The Phoenix Contact innovation magazine Continuous innovation drives the electric power industry In 1982, SEL founder Dr. Edmund O. Schweitzer, III, invented the first microprocessor-based digital protective relay. The protective relay detects when a fault occurs on a power system. If there is, it needs to open or reclose a breaker to isolate the current from going to that fault. “To improve grid safety, when there’s an incident, we turn the power off,” said Hughes. “And then to increase reliability, we’re going to turn it back on as quickly as we can. Damage reduces the power system’s reliability, so we are also limiting damage to the equipment.” “After the protection happens, an automation system like Fault Location Isolation Services Restoration (FLISR) analyzes the fault location and the electric circuit configuration to determine the best new configuration to restore power to as many users as possible while keeping the electrical fault isolated and safe,” Bradetich explained. →

“Traditional methods detect a fault by monitoring the electrical current. These methods must wait for fault current before they can open breakers. Ed went back to first principles and asked, “How can we do it faster?” He realized that a fault generates a traveling wave, and if our relays sampled enough data fast enough, they could detect the fault much faster.” Today, SEL relays can collect a million samples per second, enabling them to detect faults eight times faster than traditional relays. This means they no longer have to wait for the current to go into the fault. About 15 years ago, SEL began putting Ethernet ports on its protective relays. Dr. Schweitzer challenged his team to ensure the communication is suitable for protection. That led to SEL’s efforts in Software-Defined Networking (SDN). SEL’s OT SDN is a networking solution engineered to meet the specific demands of IEC 61850 and cyber-sensitive facility- related control systems. “I’m excited to work with Phoenix Contact, as they bring components previously built overseas back to the United States.” Angelica Salazar, Purchasing Manager at SEL “We want to ensure our engineers have the products needed to build prototypes and pilot runs,” said Angelica Salazar, purchasing manager at SEL. “Sourcing those components close to our manufacturing sites helps us establish a reliable supply chain with long-term support for As technology changes, such as higher use of renewable those products.” energy sources, the characteristics of the power system change. “The dynamics are becoming faster, so we needed to invent new algorithms that adapt to the power system,” Bradetich stated. “Renewables like solar and other technologies don’t have a rotating mass behind them, so the algorithms we typically use to detect faults don’t work. We’re extending the capabilities of the existing power system by being able to While Phoenix Contact is based in Germany, the company has invested significantly in American manufacturing over the past 20 years. In 2022, Phoenix Contact was expanding the capabilities of its manufacturing plant near Harrisburg, Pa. Plans included the addition of an injection molding machine. Chris Beevers, director of the electronic channel at Phoenix Contact, recalled, “When we told SEL about our strategy of moving more production to Harrisburg, they said, detect faults and trip faster.” “Wow, we love that. We have the same strategy.” High demand requires reliable suppliers to where we are in North America. There’s a lot more barriers Hughes stated, “Most connector companies are not close While connectors are small, they play an important part in the reliability of SEL”s equipment. “Every time our industrial product line does a project, we use Phoenix Contact terminal blocks,” said Hughes. “Their dependability, professionalism, and the quality of the components stand out. They”re a modern solution and scalable to our product needs” (Figure 3). Most of SEL’s terminal blocks and connectors are customized, such as different materials, platings, and mounting options. For example, SEL typically mounts connectors through a panel, rather than connector-to- connector. “The two sides of the connector are separated by the panel. Because of that, we need a modified offset between the two sides of the connector,” Hughes stated. “For engineers, working with a partner who is willing to customize components is very valuable, because we are not limited to off-the-shelf solutions.” Strengthening the supply chain Phoenix Contact and SEL have worked together for decades, but during the COVID-19 pandemic, SEL faced a new challenge: supply chain issues. to collaborating and working together, and I really value being able to do that. We’ve been depending on Phoenix Contact practically my entire career, and I feel like that trust has been rewarded.” (lo) Phoenix Contact and SEL have a long-time partnership, and Phoenix Contact has created numerous custom solutions and unique configurations for different SEL projects. The Phoenix Contact innovation magazine 31

C hunks of ice can fly almost half a mile if they break away from a large wind turbine generator with a hub height of 485 feet and a rotor diameter of 492 feet, such as a Vestas V150. The chunks that are hurled through the air can weigh several kilograms. No wonder that systems that are at risk of icing are shut down as a precaution if they are not protected against such an occurrence. However, accidents involving personal injury are extremely rare. But the trouble with ice starts much earlier. Just a few millimeters of ice on the rotor blades cause the aerodynamic flow to stall. The ice changes the shape and surface of the carefully optimized surfaces. This reduces lift and increases drag. As a result, the blades rotate more slowly, the system works much less efficiently and generates significantly less electricity. Needless to say, rotor blades that run out of balance put stress on the entire structure of a wind turbine generator. The resulting imbalances accelerate material fatigue in all areas, from the tower to the bearings in the hub to the blades themselves. The only measure if ice is detected or suspected is to shut the system down. But such forced downtimes come at a cost. On average, a good 15 percent of annual electricity generation is lost when wind turbines have to come to a standstill due to icing. As this affects not just one wind turbine, but usually an entire park, even small parks can quickly add up to six-figure sums. Therefore, a well-functioning ice detection system is well worth it for operators and investors. This means that the system is only switched off if freezing water actually adheres to the blades. The only alternative is an estimate based on weather data, which is of course less accurate than the detection of actual ice formation. Northbound The further north the wind farm locations move or the higher the turbines themselves touch the clouds, the more pressing the issue of icing becomes. If you can turn on the heating after detecting ice, you are in a good position. On the following pages, we present two very different solutions that were developed in collaboration with Phoenix Contact. (lo) → Regions at risk of icing throughout the world 7 to 14 days average time per year that a wind turbine generator in northern Germany ices up; at higher altitudes this can reach more than 30 days. Ice throw and ice falls 32° to -4°F temperature range in which clear ice, rough ice, or frost forms. Seifert formula Hub height = 393.7 ft Rotor diameter = 458.3 ft (Hub height + rotor diameter) x 1.5 = maximum ice-throw distance (393.7 ft + 458.3 ft) x 1.5 = 1278 Maximum ice-throw distan c e fo r a r u n n i n g s y s t e m I c e f a l l Ice fall = Pieces of ice falling from a stationary wind turbine generator (partly influenced by winds). 1278 ft The Phoenix Contact innovation magazine 33

WIND POWER Canadian hot air Heat right to the tip about icing on wind turbine generators, she practically I t can’t be that difficult. When Daniela Roeper first heard immediately decided to solve the problem. A few years, several patents, and a company foundation later, we asked: Has the Canadian got ice formation on blades under control? → Daniela, how does a young woman come to be involved in ice formation on wind turbine generators? I studied machine building and worked for companies in the Canadian wind power sector during the semester breaks. That is how I became aware of the issue. With a bit of courage and the support of a government-funded program for startups, I got started after finishing my studies in 2016. → And then success came almost by itself? (laughs) That would have been nice. Surprisingly, the technical implementation was the minor problem. We had an initial solution ready by 2017. Our aim was to develop a system that could be retrofitted in existing windmills as easily as possible without having to remove the blade. And this retrofit should not take more than a week. Heater Blade hub installed and ready for operation, was not operational. You only notice this when the system is in operation. →How do you get hold of systems on which you can carry out the necessary tests? → What distinguishes the Borealis solution from other blade heaters? That is indeed a major challenge. Everything soon ran The trick is the air flow. Normally, the centrifugal forces in the smoothly in the lab at the university. Distributing the heat blade would simply push the cold air, which is heavier than output across a rotor blade is no trivial matter and requires a great deal of expertise. We developed simulation processes that can map the thermal and flow conditions in the rotor the warm air, into the tip of the blade. The tip of the blade can reach speeds of up to 248.5 miles per hour, where enormous centrifugal forces are at work. We have developed very blade. But the real challenge was to install such systems complex flow models to guide the air in the direction we want on site and make them durable enough to function for a it to go. Our system actually works mechanically because we long time. Details such as attaching the solution to the blades were difficult. The conditions inside a rotor blade under the harsh environmental conditions of the far north are extremely challenging. For example, the centrifugal forces in the damp and cold environment are so great that the connectors in our blow warm air into the blades and let it work for us there. To achieve this, we laminate tubular fabric channels in the rotor blades. We then use fans attached to the base of the blade to blow warm air through these channels into the tips of the rotor blades. The heater itself is located centrally in the base of the blade. Due to the rotation, the warm air is systems sometimes simply came unplugged during operation. then distributed throughout the blade, especially at the This meant that the heating system, although correctly leading edges, where ice formation from the outside is 34 The Phoenix Contact innovation magazine

Fabric duct Blade tip “The problem is always the tips. That is where ice is most likely to form.” Daniela Roeper, CEO Borealis Wind most problematic. The fans are very powerful and generate a relatively high pressure to circulate the air. This is also the difference compared to other similar systems that work with significantly less power. Our approach enables us to exchange air and deliver the warm air to where ice is most likely to form. The problem is always the tips. This is because these are precisely the spots that pass through the upper layers of air and capture the crystals. When the wind turbine rotates, there is about twenty times the pressure on our fabric channels. The material has to withstand the vibrations. It must be fire-retardant. We had to find out whether the fabric absorbs moisture and how much, because this changes its weight and thus the forces acting on it. Initially, we supported the fabric channels with fiberglass poles, similar to a tent. The disadvantage was that they were relatively heavy. At the beginning of 2024, we developed a new system in which we install a bracket in the tip of the blade and tension the heating system like a rope. This is lighter and much easier to install. The rotation forces press the glued-in holding point, where the rope is tensioned into the tip, and fixes the system in place. The current system consists only of fabric, which weighs around ten kilograms. (lo) Powerful fans blow warm air into the blades through ducts. → The Phoenix Contact innovation magazine 35

WIND POWER Finnish mats Sauna for the blades the pleasure of talking to the experts from Wicetec A sunny disposition with cold feet – anyone who has cannot leave the conversation without smiling. However, the Finns’ mission is ice-cold and dangerous. How can ice formation on wind turbines be prevented? To stop this material-killing and life-threatening phenomenon, wind turbines without rotor blade heaters are slowed down as they rotate and generate energy. This, in turn, does not amuse the operators, as it also reduces their potential profits from electricity production. It also makes the installation of rotor blade heaters financially viable, whether retrofitted or fitted during the production of new systems. “We also for initially developed heating systems retrofitting,” says Tomas Wallenius, describing the beginnings of Wicetec. The 44-year-old engineer is an expert in thermodynamics and co-developed the patented heating system. Today, as CTO, he is one of the two General Managers of the Helsinki-based company. “We founded our company in 2014 as a spin-off from a state research institute, entirely without external investors and independent of the wind industry.” The Finns secured their first orders in 2016 in Canada, where a wind farm with 44 turbines was retrofitted with rotor blade heaters. More than 350 turbines, mainly in Canada and Sweden, now rotate with the retrofitted carbon fiber-reinforced heating mats from Wicetec. Today, however, the Finns are focusing primarily on integrating their systems as early as the rotor blade production stage. “Naturally, retrofitting is still an important part of our range. But it has become clear that a retrofit is disproportionately expensive and time-consuming. After all, the blades have to be dismantled and transported to a hall where we can install the carbon mats. Today, many investors are already demanding ice prevention systems from the start because the returns from more stable operations are naturally higher. In Quebec, for example, the authorities are Outside Normal blade coating Protective layer made of fiberglass-reinforced polymer Heater made of carbon-fiber reinforced polymer Blade envelope Inside 36 The Phoenix Contact innovation magazine

even making the heaters mandatory so that the windmills run more steadily and grid stability is not jeopardized.” Carbon heating mats are super-thin, with a thickness of just half a millimeter, including the coating. At the same time, they are extremely resilient and can withstand the constant vibrations of the blades for decades. The energy consumed by the heating mats themselves amounts to around 50 kilowatts in a 5-megawatt system. One technological highlight is the sensor that detects whether there is any ice on the blades – because it is virtual. “A physical sensor is very expensive and also difficult to install,” explains Wallenius. “Our virtual sensor is based on an algorithm that runs on a PLCnext Control from Phoenix Contact. The weather data measured by the sensor is fed into the control system and interpreted based on our decades of experience to produce a reliable ice forecast.” There are only a few competitors in the field of rotor blade heaters because “the business field is difficult, as you have to adapt each system precisely to the manufacturers and models. That requires a lot of expertise and specialized knowledge.” So, rosy conditions for the Finnish innovators? Tomas Wallenius has to smile. “The most astonishing thing for us is how slowly the issue of ice on wind turbine generators is gaining acceptance among operators, manufacturers, and investors. But we are on the right track.” (lo) “We have developed a virtual sensor based on PLCnext Technology.” Tomas Wallenius, CTO Wicetec The Phoenix Contact innovation magazine 37

BEHIND THE SCENES New Senior Vice President of Sales Phoenix Contact USA recently welcomed Vince Ridgell as the new Senior Vice President of Sales. He brings more than 20 years of leadership experience spanning sales, business development, and public-sector markets. Vince has held senior leadership positions at numerous industrial companies, where he led national sales strategies, drove public-sector initiatives, and consistently delivered growth across multiple business units. Recognized for his strategic vision and results-driven approach, Vince has built high-performing teams and successfully navigated complex regulatory landscapes throughout his career. and supported one another in solving complex problems. Phoenix Contact opens first phase of new production plant in Mexico Phoenix Contact has expanded its production footprint in the Americas to further develop its global production network, strengthen supply chains, and move closer to key markets. Production has begun in the first phase of construction at the company’s Querétaro site in Mexico. Davis Mathews and Kyle Bordner represented the U.S. at the grand opening in March. • Planned extension will increase total space to 215,000 square feet (20,000 m2) • Sample production for power Facts and figures: • First phase measures 135,000 square feet (12,500 m²) From the outset, the Querétaro site was shaped by international collaboration. Employees from the U.S., Germany, China, Spain, and Mexico brought diverse professional and cultural perspectives to the table supplies started earlier this year • Future production will include electrical and electronic components for control cabinet building • Future employment: Up to 700 employees by 2032 Technology Alliance Program (TAP) Phoenix Contact USA announced the official launch of its Technology Alliance Program (TAP). This global initiative expands the capabilities of Phoenix Contact’s EP Raptor Series of industrial network switches and the company’s broader computing ecosystem through validated, interoperable third- party applications. TAP is built on a simple principle: customers who rely on Phoenix Contact’s substation-grade hardware can choose the applications that best fit their operational and cybersecurity needs. The program accelerates the industry shift from multiple standalone appliances to converged, high-performance platforms capable of hosting cybersecurity, automation, and analytics applications directly on EP Raptor switches, Phoenix Contact industrial PCs, or within the PLCnext Technology ecosystem. Partners include: • Xona • Forescout • CyVault • EmberOT • SyskeyOT • Industrial Defender • JPEmbedded • PCItek • Radiflow 38 The Phoenix Contact innovation magazine

BEHIND THE SCENES Trade shows Phoenix Contact participates in many trade shows and smaller conferences throughout the year. These events are a great way to network with existing customers, meet others in the industry, and learn about technology trends. Check out some of the scenes from a few trade shows we’ve visited so far in 2026. Others coming up include: • Automate, June 22–25, in Chicago • IVT Expo, August 19–20, in Chicago • IMTS, September 14–19, in Chicago If you see Phoenix Contact at these or other industry events, stop by the booth to learn about our latest innovations and talk with our product experts Niagara Summit AHR Expo ARC Forum Legal notice Phoenix Contact GmbH & Co. KG Corporate Communications Lutz Odewald (Editor-in-Chief) Telephone: +49 5235 3-42153 Email: lodewald@phoenixcontact.com Design and implementation: Corporate Communications, Graphic Design Image credits: Cover image: © Shutterstock, fireFX © Shutterstock: 5, 12, 24/25, 28, 34, 37 Thomas Franz: 3 Andre Köller: 6 ff., 14ff., Lutz Odewald: 11, 37 Synhelion: 20 ff. Wölfel: 24 ff. Borealis Wind: 35 Wicetec: 39 Matt Austad and Brandon Sheaffer: 28ff; 38, 39 Copyright © 2026 Phoenix Contact All rights reserved. The Phoenix Contact innovation magazine 39 DTECH