1|16 The customer magazine from Phoenix Contact | April 2016 Maintenance in transition Planning service calls better and avoiding downtimes Status: OK
02 Editorial UPDATE 1|16 Dr. Frank Possel-Dölken Director of Manufacturing Systems Maintenance needs data Dear readers, Imagine you are responsible for a major production line. What would you give to know exactly which critical component, like a conveyor belt motor for example, will breakdown next and bring production to a halt? Including all that aggravation and overtime for you and your people. To prevent this, the usual strategy would be to replace it on spec or according to schedule. Your experienced fitter could also run the critical equipment and place a hand or ear on the housing and note any unusual vibrations or noise. Would it not be better to have sensors attached directly to your imaginary motor to regularly measure the voltage, temperature or vibration values and write the analyzed patterns to databases in order to forecast any failure in a timely manner? This requires reliable and precise signal acquisition. In cases like these, Phoenix Contact is available as your partner. Together we can analyze how your process and operating data reaches your diagnostic systems and tailor a specific and practical solution for your measurement and control technology. Whether it be wired or wireless communication, measurement conversion in a potentially explosive environment or connection technology in extreme weather conditions – we will ensure a continuous data stream for your processes. This provides you with the optimum prerequisites for building up your own process-relevant knowledge in order to better plan your maintenance work and identify any failures early. Editorial 02 Dr. Frank Possel-Dölken Interview 03 Günter Seel, Smartblue AG, Munich Cover story Maintenance in transition 04 A combination of strategies will lead to success Technology Marking 06 Portable printing systems for industrial marking Surge protection Fully automatic electrical testing of surge protective devices Monitoring Safe plant access from the cloud 14 16 On site Monitoring 08 Photovoltaic park operator 12 18 21 21 21 21 uses a monitoring solution from Phoenix Contact Signaling Field bus functionality for signal lights on the Kiel Canal IT security Secure remote service solution for rotary transfer machines New products Ethernet extender system Photovoltaic panel switch-off High-current feed-through terminal blocks Software for application parameterization News 22 Phoenix Contact named best employer three times 22 Expertise bolstered in the areas of operation, monitoring and cyber security 23 US trade journal honors Phoenix Contact phoenixcontact.de phoenixcontact.com
UPDATE 1|16 Interview 03 Ideal addition Monitoring hardware from Phoenix Contact has proven to be successful with photovoltaic plant data loggers Smartblue AG develops and operates Internet- based software and processes for technical management of solar parks. The company prefers solutions from Phoenix Contact for recording, storing and transferring energy data to the remote control stations (see p. 8). The editors of UPDATE spoke to its founder and CEO Günter Seel about the background reasons for the collaboration. UPDATE: Mr. Seel, why you recommend Phoenix Contact' solutions for data logging in your customers' photovoltaic systems? Günter Seel: That's because your and our product and service portfolios complement each other almost perfectly. Phoenix Contact delivers concentrate on analyzing the values and their graphical representation. Another important aspect: when it comes to photovoltaic equipment, we're talking about capital goods with an approximate life expectancy of 40 years. So we need to take a longer-term view. Phoenix Contact delivers standardized industrial components and the supply of spare hardware parts is ensured for a long time. Long-term aspects are also of primary importance when it comes to developing software like PC Worx. This monitoring solution can be extended and modified with little effort. That's an important point to consider since the requirements and regulations are constantly changing, especially in the photovoltaic sector. Günter Seel, Smartblue AG, Munich UPDATE: How did the collaboration start and how did it evolve? Günter Seel: In 2011, we were looking for a technology partner for a research project. With Phoenix Contact we found a partner who firstly had a good overview of the technical requirements, but who also showed technical sophistication during consultations and ultimately the patience needed to stay with this longer- term development project. Our customers subsequently asked us to offer them the appropriate hardware as standard. We first started by introducing monitoring hardware onto the market for photovoltaic monitoring with remote maintenance and complemented that with functions for park control and for direct marketing. So, we now have the whole range of monitoring hardware available in our portfolio. “Photovoltaic equipment has an approximate life expectancy of 40 years. So we need to take a longer-term view.” UPDATE: Thank you very much for talking to us. the components and software modules for the plant. These provide the data which we then evaluate and visualize accordingly on our Smart Control portal using intelligent algorithms. UPDATE: What makes Phoenix Contact's product portfolio so special for the solar energy industry compared to competing products? Günter Seel: The difference is in the standardized software libraries and drivers for example. This means we no longer have to worry about any proprietary protocols for communicating with the inverters. We can fully
04 Cover story UPDATE 1|16 Equipment using wireless communication is becoming more and more popular for maintenance tasks Maintenance in transition A combination of strategies will lead to success Maintenance has evolved from a necessary evil to a productivity factor that businesses approach with a variety of strategies. Products and solutions from Phoenix Contact help to implement the most suitable maintenance concept. Every production line operator – big or small – is interested in having it run as smoothly and efficiently as possible. The larger the system, the more serious is any component failure. If this happens during continuous production, as in a chemical plant, a power station or a petrochemical plant, then every minute of a standstill leads to high losses. It is not surprising therefore that the process industry in particular has long been optimizing the maintenance of its equipment. Asset management, or the management of equipment, are the buzzwords here. Major industry players take a systematic approach: an analysis of the causes of failures in the production process of a large chemical company revealed that over 50 to 60 percent of its plant failures could be traced back to rotating components, i.e. pumps, compressors and other units. To avoid these kinds of failures or detect them in advance, operators apply different strategies that can also be cumulative. The ideal outcome is production with virtually no downtimes. Maintenance inspections with support The simplest method is for the maintenance engineer to replace critical components to a specified schedule before they operate at risk. Although not every component does the maintenance engineer the favor of perishing to schedule. The method of choice is the traditional periodical maintenance inspection, during which an employee follows a prescribed route to check all the equipment for unusual vibrations or noises. But the worker's task can be supported by technology. Errors will be avoided as a result. Phoenix Contact offers RFID tags, for example, and the necessary printers and readers that can be connected via Wi-Fi. The maintenance personnel is guided through the system by RFID readers and all inspections are tracked and recorded electronically. There is direct online and mobile access to information about the equipment to be serviced, with guidelines and visual support from the maintenance center.
UPDATE 1|16 Cover story 05 Communication in the field is becoming ever more important Condition-based maintenance requires sophisticated condition monitoring. Any replacement is decided based on the current degree of wear. The recorded measurement data must reach the evaluation logic as unaltered as possible. Adverse ambient field conditions should also not play a role. At the same time, devices are becoming more and more communicative as shown by the example of the Mini Analog Pro series of signal conditioners. These devices offer several monitoring options that simplify system maintenance. The use of tablets in industrial applications is growing rapidly, resulting in an ever-increasing demand for solutions for wireless communication with these devices. The user can query and optimize any values from the system quickly and easily via Bluetooth. In addition, current process values can also be read by a PC via a Bluetooth adapter or by a smartphone via Bluetooth. All status and error displays are always clearly visible directly on the control cabinet and provide a quick overview. Devices that recognize themselves The use of components that can diagnose themselves is becoming increasingly important for condition-based maintenance strategies. This is the case with the Plugtrab PT-IQ surge protection and the Quint UPS-IQ uninterruptible power supply units, for example. These devices independently monitor their functional efficiency and remind you when they need to be serviced or replaced. Speaking of intelligence: the motor manager Contactron can even use its smart performance measurement to determine the precise operating point of drives and thus detect any wear, dry running and other load without the need for additional sensors. This too is an important component in maintenance strategy. Standardized open protocols are used which facilitate data processing and integration into superordinate maintenance systems. Security solutions with industry-proven firewalls guarantee secure communications. Christoph Manegold phoenixcontact.com Smart uninterruptible power supply (UPS) with IQ technology IQ technology in the Quint UPS-IQ uninterruptible power supply units ensures a reliable power supply to a system at all times. It constantly supplies information to the user on the state of charge as well as the remaining runtime and service life of the power storage device. This prevents gaps in the supply and early shutdown of industrial PCs. Maintenance work can be better planned. The power storage device is only exchanged if it is necessary, because the remaining life expectancy is reported directly to the higher-level controller. Products and solutions from Phoenix LEDs and floating relay contacts provide function monitoring. Contact connect remote outstations or remote plant components with the control center. Conventional telephone lines, fiber optic connections or wireless solutions can be used. The wired contacts are used to report whether the load is buffered, whether the power storage device is charged, or whether an alarm is pending.
06 UPDATE 1|16 Professional mobile marking is essential for advanced maintenance concepts Mobile markers Portable printing systems for industrial marking The continuous and permanent marking of equipment is an essential requirement for efficient maintenance concepts. The mobile Thermomark Prime printing system allows the user to have all options of a stationary device in the field for the first time. Those who want to be productive require organization and an overview. Therefore, it is becoming increasingly common in industrial companies to provide all components, devices and systems with a unique and comprehensive marking. This allows companies to not only formally meet the legal specifications or requirements from quality management systems, but also assist the user in obtaining an overview. Continuous marking enables neat, uniform documentation of all equipment, making it possible to simplify its maintenance. Depending on the operational classification, this forms the foundation for the automation of maintenance processes. Establishing and retaining this type of standard requires considerable effort. In particular, the trend toward decentralized production facilities increases the need for flexible models when marking. To be as time and resource-efficient as possible, marking required for large-scale projects is planned in detail in advance. However, the practitioner is aware that during decentralized processing of markings short-term changes occur that require a spontaneous response. Mobile solution without comprom ises The Thermomark Prime thermal transfer printer has been developed exactly for this requirements profile: It is compatible with the Clip Project planning and marking software and can be used for comprehensive configuration and assembly in stationary operation. Simultaneously, it is equipped with completely integrated marking software and high-performance rechargeable batteries so that markings can be created on site. An intuitive, easy-to-use touch display is used to input the data quickly and in an uncomplicated manner. The printer detects the material automatically and also queries the magazine and ink ribbon. This eliminates misprints almost completely. The device processes over 600 different types of material in card and sheet format for marking terminal blocks, conductors, cables, devices and systems. Particularly in the event of maintenance and servicing, time and costs can be saved, as
UPDATE 1|16 Technology 07 markings can be added, changed or renewed immediately and right on site. It is thus not necessary to create these markings at a central location. Even more flexible with Thermofox The mobile Thermofox handheld printer is used to make this work considerably more efficient. The data is entered in an uncomplicated manner using the printer's clearly arranged control panel. The manageable, battery-powered device prints plates, labels and shrink sleeves in rolls immediately on site. These are available in combined material ribbon cartridges, which can be replaced easily in only a few seconds. The Thermofox uses a USB interface to connect to the Thermomark Prime. Its touch display is also used to process complex projects conveniently. Their compact dimensions and low weight allow the devices to be transported conveniently. This is facilitated using suitable transport accessories. Jennifer Achilles phoenixcontact.com Continuous printing with barcodes eases mobile maintenance RDS-PP – Further development of the KKS to an international standard Systems, technical devices and equipment have been marked in accordance with the Identification System for Power Stations (KKS) since the beginning of the 1970s. The adoption of different European standards, however, resulted in a portion of the code letters used in the KKS that no longer correspond to the valid international standards. Therefore, VGB PowerTech e. V. overhauled the KKS in accordance with current rules and regulations with the goal of establishing international standard conformity for manufacturers and providing power stations with a uniform marking. The Reference Designation System for Power Plants, abbreviated RDS-PP, was developed in 2008 as a steady ongoing development of the existing system. This system corresponds to the international standards, but, at the same time, adopts the existing code letters of the KKS function key up to 90 percent. The KKS is expanded in the RDS-PP by the marking blocks "Common assignment" for locations and "Functional assignment" for marking dynamic processes. The RDS-PP meets the requirements for use worldwide through the compliance with international standards of IEC and ISO.
08 On site UPDATE 1|16 Output in real time Photovoltaic park installer Envalue GmbH uses a monitoring solution from Phoenix Contact Solar energy park installer Envalue's system data is permanently accessible using the data acquisition and transfer solution from Phoenix Contact. The industrial quality of its components ensures maximum reliability and profitable maintenance in the event of a system failure. built the parks in abandoned gravel pits or on landfill sites. The company specializes in erecting and operating solar energy parks for investors and can provide numerous references in Germany and Europe. One of these is the solar energy park Gleaming in a shiny blue, one photovoltaic park follows the next in the Lusatian Lake District, about 25 kilometers south of Cottbus. Project leader Rüdiger Haslinger knows them like his own backyard. His employer, Envalue GmbH, Kieswerk near Freienhufen with a total capacity of approximately 3.1 MWp, which went into operation in 2015. In the park, around 13,000 crystalline modules are fixed-tilt and combined into 528 strings. The solar park, encompassing an area of approximately 52 hectares, is divided into The photovoltaic park Kieswerk near Freienhufen with an output of 3.1 MWp
UPDATE 1|16 On site 09 three sections, each allocated to one inverter respectively. These convert the DC voltage into AC voltage and then feed a transformer which converts it to 20 kV. The generated AC voltage is then transmitted by underground cables to the grid connection point approximately five kilometers away. Good monitoring is mandatory Even large solar parks or park networks are not generally equipped with a continuously manned control room on site. At the same time, the operator and the investors involved have the system's maximum return on investment in mind. That's why the operating conditions such as currents, voltages, direct sunlight and many others must be continuously ensured in order to react quickly to any malfunctions. This opens up a business segment for innovative software developers and new service providers in the solar sector. Smartblue from Munich has proven to be successful in this field. It develops evaluation software and data logger solutions for photovoltaic parks and has already monitored many of Envalue's solar systems on behalf of the operators. Phoenix Contact's data logger This is also the case in the Lusatian solar energy parks. A Phoenix Contact system solution is used here to record the park's data. The measuring chain starts with the strings: either 16 or 24 strings are merged depending on the version and individually protected by fuses in the string combiner box (SCB). One double string each is routed through one of the Solarcheck module
10 On site UPDATE 1|16 openings in order to record the string currents. Likewise, the voltage and ambient temperature can also be recorded with the Solarcheck measurement module. The analog data is processed in a measuring module, digitized and then sent on via Modbus protocol. Valvetrab surge protection for the DC area and Plugtrab for securing the communication line, a Uno power supply and connection technology from Phoenix Contact round out the range of SCB equipment used. The collected DC current is transmitted to the inverter via an isolator. The data from all SCBs, the inverters and data from the substation's network connection point converge in the data logger cabinet. Installed there as a core component is an ILC 191 Inline controller, which is used to run the photovoltaic management application that was programmed from the Solarworx library's function blocks. Rüdiger Haslinger explains: "The function blocks from the Solarworx library let you read the data from all commercially available inverters, which has simplified our programming. You also receive good support from the team at Phoenix Contact when it comes to the connection." The connection to the direct marketers' control system has increasingly become a particular challenge. But this function too is possible without much programming effort, so that the system output can be managed in line with market requirements. A Smartblue perspective The complete system overview, which comprises regularly updated current and voltage values for the double-strings, inverter data and ambient park conditions, such as temperature, solar radiation intensity and many other things, is collected in 1 to 5 minute intervals and typically sent every 15 minutes to the Smartblue server in Munich via the Internet. Here, valuable information is created from the bare numerical sequences in csv* format. Günter Seel, CEO of Smartblue, explains it this way: "We try to automate the technical management of a solar energy park as much as possible. To do this, * csv: comma-separated values, a text file for saving or ex- changing simply-structured data A malfunction, like the failure of a string, can be detected and fixed quickly on the Smartblue portal
UPDATE 1|16 On site 11 we employ intelligent algorithms to assist us in evaluating the measurement data." Special software routines have been developed to quickly filter out the relevant information. Error messages with the same cause are summarized in a single message, for instance. Recurring error messages generate a so-called stacking fault that is displayed only once on the control station. For example, in practice this means that a defective module, a blown fuse in the SCB or a loose connector in a string is quickly detected. The operator can immediately instruct a repair and so minimize losses. Both the operator and the investor have around the clock access to all the system's data upon request. To do so, they only need to log into a website with their password to receive visual yield reports processed from the data. Industrial quality makes the difference When asked what sets Phoenix Contact apart from other solutions in the photovoltaic sector, Rüdiger Haslinger didn't take long to respond: "The difference lies in Phoenix Contact's robust Each string is protected individually industrial quality. In contrast to our competitors' measurement boards, where the strings are connected directly, the Solarcheck measurement module, for example, does not generate heat since measurements are contactless." Christoph Manegold phoenixcontact.com Intelligent monitoring of photovoltaic systems with Smartblue Smartblue AG develops and operates soft- ware and processes for monitoring and opti- mizing photovoltaic systems. Its customers are photovoltaic system operators who require an industry-wide software service that combines maintenance, lifecycle management, yield prediction and remote control on a single portal. "We use the latest Big Data technology to promote automation of the operational processes," explains Günter Seel, CEO and founder of Smartblue AG. To do this, Smart Control has developed a configurable automated control station for professional use in the field of operational management and energy supply. The web- based portal service can work in conjunction with all major manufacturers of inverters and data loggers. Using the proprietary software interface layer developed by Smartblue, all common communication protocols and data formats can be included in a unified data sys- tem. Smart Control's intelligent, automated error algorithms thereby continually analyze the incoming technical measurement data and report any malfunctions and reductions in yield. Upon request, customers will also receive a data logger solution that is adapted to the respective system. To ensure maximum reliability and long-term availability of the components, Phoenix Contact's industrial quality automation components are used in preference.
12 On site UPDATE 1|16 Communicative lights Field bus enabled signal lights facilitate navigation on the Kiel Canal The locks, which compensate the difference in altitude between the two seas, play a central role in the smooth operation of the Kiel Canal. Lock maintenance is simplified by LED signal lights from Phoenix Contact, because their operational data can be read at anytime. The Kiel Canal connects the mouth of the Elbe to the Kiel Fjord and, depending on their destination, saves ships a detour of up to 460 kilometers. The 100 kilometer long waterway runs through Schleswig-Holstein from Brunsbüttel to Kiel-Holtenau. It is one of the most traveled artificial navigable waterways in the world. The service technician can also retrieve all of the LED light's operational data via mobile phone The lock gates in Holtenau were fitted with a new signaling system as part of modernization efforts. The lights are installed on masts and use red, green and white signals to notify any approaching vessels whether or not the lock entrance is free. The signal lights are subjected to harsh weather conditions. These include high winds, salt water or even direct sunlight. In the lock, two new masts were each equipped with 18 LED lights that are required to withstand these conditions. Phoenix Contact's 300 signal light was deployed here. It supports maintenance personnel with status and diagnostic information. Industrial communication technology facilitates maintenance Carsten Klöhn, from the Communications Engineering section, is responsible for new installations and conversions as well as the control technology for the signal lights in the Kiel-Holtenau lock group. To him, it is crucial that "we are constantly informed about the status of the signaling lights. To accomplish this, the lights have to exchange lots of data with the higher-level controller." This is made possible through the use of industrial communications technology that extends to the light itself. The lights are connected using prefabricated cables and M17 hybrid plug-in connectors from Phoenix Contact. The hybrid plug simultaneously connects the power supply and the data line to the light. Any mix up is excluded. Lights with memory The maintenance department wants simple installation without having to set addresses or user IDs. This is particularly important when lights have to be replaced for maintenance. This is where the benefits of an electronic nameplate that can be read via the communication link come into play. This way, the control unit can detect whether or not the correct lamp is connected. The color, size and beam angle are transmitted, for
UPDATE 1|16 example. In the event of faulty installation or replacement, the control unit sends an alarm signal and prevents the light from turning itself on. In addition, Carsten Klöhn and his colleagues are supported by built-in recording of operating hours. The light's operating hours and the those of the individual LEDs are recorded separately and stored cyclically in the light. "When the light is replaced, the data migrates with the light so that the current operating hours can always be read," says Klöhn. LED technology with many benefits The LED technology in the light translates into energy savings and greater availability compared to the technology used so far. The LED's high availability not only comes from its longer service life compared to conventional light sources, but also from the light's special circuitry. When one LED fails, this is detected by a current and voltage monitor and reported back to the higher level system. According to the instructions from the control system, the other LEDs can be readjusted in order to achieve the same light output. In addition to the LED monitor, two scattered light sensors were installed in the signal light. These sensors detect whether the LEDs are emitting any light and how intensely they illuminate. The temperature of the light is also recorded in order to ensure operational reliability of the signal in all instances. Light output is reduced when the light's temperature increases to the point where it departs from the acceptable operating range. This happens, for example, when the lamp becomes enveloped in a ship's stream of exhaust gases. If the temperature increases further to a point where the light could be damaged, it is switched off. This function is supported by notification and alarm messages. When the temperature drops again, the light will resume operation after the message has been acknowledged. Werner Pollmann phoenixcontact.com Safe signals: Reliable signaling is essential for risk-free entry into the lock
14 Technology UPDATE 1|16 Checkmaster 2 is a complete test lab for surge protection devices in one case Pit stop for surge protection Fully automatic electrical testing of pluggable surge protective devices In order to reliably determine whether a surge protection device is still functional, it must be electrically tested. Only in this way is standard-compliant documentation of the test results possible. With Checkmaster 2, Phoenix Contact has developed a lightweight, robust and intelligent device for high-voltage testing of surge protective devices in these kinds of applications. To achieve high availability, operators must inspect and maintain their electrical system on a regular basis. This includes the regular inspection and maintenance of lightning protection systems. Specialist knowledge is required in order to carry out proper testing. That is why DIN EN 62305-3 requires that this test is performed by a so-called lightning protection specialist. Surge protective devices must also be tested. The installations should be electrically tested on a regular basis. For systems with high security requirements, for example, the legislator may dictate that a comprehensive test be performed if lightning strikes have occurred within a certain radius around the respective system. Electrical testing is necessary Regular maintenance of lightning protection systems is intended to ensure that the characteristics of a lightning protection system do not worsen over time. The components of an internal lightning protection system should as far as possible be subjected to a visual inspection. To make a reliable statement about the condition of surge protective devices, an electrical test is required whereby all the relevant components of the devices are tested. With this electrical test - the so-called high- voltage test - the test voltage is selected so that the tested surge protective device becomes conductive. The measurement results obtained during the test are then compared with the reference values and evaluated. Safe testing at more than 1000 volts DC The so-called response voltage should be determined for surge protection components with a switching characteristic, such as spark gaps and gas-filled surge protective devices.
UPDATE 1|16 Technology 15 Usually the voltage drop or the residual voltage at a constant current of 1mA is determined for components with a continuous characteristic curve. Multistage surge protective devices with decoupling resistors must be constructed in such a way that the decoupling resistors can be tested simultaneously as well. DC voltages exceeding 1000 volts are sometimes used during the high-voltage test. A test device for surge protective devices should be constructed so that a safe high-voltage test of the protection devices can be conducted by technicians without specialist knowledge. The test device should be portable and robust so that it is suitable for on-site testing in electrical systems. Checkmaster 2 – the mobile test lab Checkmaster 2 is a lightweight, robust and intelligent test device for pluggable surge protective devices from Phoenix Contact. The device has a modular design and is safe to operate. It is equipped with a screen, a barcode scanner, a PLC and a remote controlled and current-limiting high-voltage power supply unit. Thanks to different test adapters, Checkmaster 2 can be conveniently adjusted for different surge protection devices. The test adapters are easy to swap without tools and without having to switch off the test device. A compartment for attaching another test adapter is located below the storage tray for the barcode scanner. A robust transport case is included for transporting and storing additional test adapters. In order to test a surge protective device using Checkmaster 2, a barcode scanner or the virtual keyboard is used to enter the surge protective device's order number. The corresponding test program is then loaded automatically. The test is completely automated, whereby the test results are evaluated with the help of a component database. Checkmaster 2 detects defective surge protective devices and pre-damaged devices whose electrical parameters are on the edge of the tolerance range. The test report with test results, installation locations and alphanumerics is stored safely against any mains failure. The data can also be written onto a USB stick. The results can be further processed with standard office software. Software updates available Software updates for testing surge protective devices are also available on USB stick. These are supplied free of charge for the database of the testable surge protective devices, the device firmware and the user interface. The user can select software from nine operating languages. Holger Heckler phoenixcontact.com Convenient replacement: the test adapter is replaced without tools in just a few steps
16 Technology UPDATE 1|16 Eaglei makes remote maintenance affordable for small maintenance groups Eagle eye is vigilant Safe system access from the cloud Large industrial systems are monitored and controlled using central control systems. These systems require not only large spaces but also trained personnel who man the control room around the clock. Moreover, the systems must be serviced and repaired on a regular basis. This is often not worthwhile for small functional units or largely autonomous systems. This is where the Eaglei ("eagle eye") cloud-based solution comes into play. Small remote assets, such as waterworks outstations, run the same work program almost 24 hours a day in most cases. A predefined process is then applied to the environmental variables, which change continuously. SCADA for the cloud Control Systems 21 was founded in 1999 in Dillsburg, Pennsylvania and is a renowned specialist for automation systems. Their software developers offer comprehensive solutions from design and installation through to initial startup. Their customers are mainly involved in the water, wastewater and oil and gas industries. With Eaglei, Control Systems 21 has developed a SCADA* solution that is only accessible via web browser. In the case of the elevated fresh water tank, this can now be automated according to customer specifications without requiring a central control system. This allows a program for an elevated fresh The client receives an IP address as well as a water tank to ensure it is filled according to demand and that the water pressure remains stable for the connected consumers. The process can be changed or stopped at any time. Further intervention or even permanent moni toring of all parameters is unnecessary. That's why monitoring by a centrally managed control system is overkill in cases like these. Control Systems 21 demonstrates how a remote asset can be monitored inexpensively with a cloud- based control system. user name and password. He can use it to access the maintenance group from anywhere, check the status and change parameters. At the same * SCADA: Supervisory Control and Data Acquisition, monitoring and controlling industrial processes using computers
UPDATE 1|16 Technology 17 To integrate remote stations into the Eaglei system, Control Systems 21 uses an FL WLAN 5101 WLAN access point. This was specifically designed for the North American market. Connection is secure Using the industrial router lets you exchange data with the virtual control system via a secure connection. This prevents any data manipulation and any unauthorized access from outside the network. The MGuard router also enables user- specific communication with the entire Eaglei solution. With its Eaglei cloud-based control system, Control Systems 21 offers an inexpensive and secure alternative to conventional control systems. Customers can monitor and control plant parts and remote stations from all over the world without having to worry about maintenance and repair work. Eike Wedekind phoenixcontact.com Mguard permits protected access to the maintenance group via a web connection time, the system can send alarms and messages via e-mail or SMS. Even existing systems can be connected in such a way that they can record and evaluate data. The solution connects to an existing process without influencing it. The data is subsequently collected and can be stored or transmitted to a control system. Concentrating on the customer's requirements Control Systems 21 opted for products made by Phoenix Contact when developing Eaglei. This lets the company purchase all the components from a single manufacturer, giving them more time to focus on actual customer requirements. The central unit of any Eaglei solution is a compact controller which is expanded with a secure MGuard industrial router. This router lets you connect the controller to the Internet via an existing DSL router. In most cases, however, the router has an integrated interface for mobile communication. Eaglei is then connected to the virtual control system via a private mobile network. Depending on the specific customer's application, the compact controller in use can be expanded with a different I/O modules. The incoming and outgoing signals are connected via relays from the PLC interface series, which require little space. Depending on the requirements, PSRmini safety relays are also used.
18 On site UPDATE 1|16 Productivity without breaks Secure remote service solution for rotary transfer machines with MGuard security routers Pfiffner's machining centers are connected to the manufacturer's support staff via the remote service system, which uses an internet connection. This means that customers receive support within a very short time when service is needed. This is all made possible by a remote maintenance solution based on MGuard technology from Phoenix Contact. The benefits of Internet-based remote access are obvious: to the service technician, the VPN (Virtual Private Network) behaves almost as if he were sitting directly in front of the system. This significantly shortens maintenance response times. Moreover, on-site deployments often become unnecessary, resulting in significant savings in maintenance costs. K.R. Pfiffner GmbH is a renowned manufacturer of rotary transfer machines for the mass production of precision parts. Many of the rotary transfer machines are delivered to the automotive supply industry, an industry subject to high price pressures, where the machines are forced to run day and night. That's why they are delivered with the option that Pfiffner's experts can connect directly to the system to diagnose faults and for maintenance work. "Initially, remote maintenance happened using analog modem connections. However, their performance no longer satisfied our requirements. We also experienced many connectivity problems," declares Tobias Halbritter. He supervises the remote maintenance system at Pfiffner and is largely responsible for implementing the structure based on secure VPN connections. The core element of the new remote maintenance concept is the FL MGuard RS4000 TX/TX VPN security router made by Phoenix The experts at Pfiffner will connect to your system via the Internet for fault diagnosis and maintenance assignments
UPDATE 1|16 On site 19 Contact, which is installed in the processing centers. "Since we already employ the MGuard technology with its integrated firewall in order to connect our systems to the customer's network, it was only logical that we use the device for secure remote access purposes as well," explains Halbritter. Control over network access Currently, 160 machines and more than 36 service technicians are integrated into the system. Whenever the user needs maintenance assistance, he activates a key switch and establishes the IPsec tunnel to the Pfiffner Remote Services Center. The service technician then has access to the system. The system operator thus maintains control over any access to the application, which increases acceptance of the technology. FL MGuard's optional external configuration memory is also helpful in this context. Since Pfiffner employees usually do not know the IP parameters of the customer network before machine delivery, the respective configuration can simply be transmitted via SD card later. The user's personnel does not require any special knowledge. The same applies to simple device replacement in the event of a fault. Restricting access to certain parts of the system The VPN hub is deliberately not integrated into the Pfiffner corporate network, but is operated as a portal system with its own Internet access. This enables Pfiffner to also permit external suppliers to safely access parts of the respective customer system. This connection does not need to be tunneled by its own communication network. The MGuard router's security function – especially the freely configurable firewall inside the VPN tunnel – makes it possible to restrict access to certain parts of the machining centers. The customer's systems are typically configured with identical address ranges for the network. The benefit of this feature is that individual system parts can always be reached using the same IP address. To ensure that no address conflict occurs whenever several rotary transfer machines are to be serviced at the same time, the addresses must be virtualized or depicted in separate address ranges. K.R. Pfiffner GmbH makes rotary transfer machines for the mass production of precision parts
20 On site UPDATE 1|16 The remote service box temporarily connects customer systems to the service center via VPN Exclusivity is thus guaranteed. This requirement is implemented in the MGuard routers by 1:1 NAT (Network Address Translation) in the VPN tunnel. Remote service box for temporary access Around 2,500 Pfiffner rotary transfer machines are in operation worldwide, whereby most systems are not yet permanently accessible via the network. The machine builder has developed a remote service box to also permit remote access to support the technician on site whenever servicing or retrofitting is required. The box also includes a FL WLAN 5100 wireless router in addition to the FL MGuard security router. The machine can thus be accessed on-site for a short time either via an Ethernet patch cable or a Wi-Fi network. After the service call is completed, the box is simply taken on to the next maintenance site. Michael Vetter phoenixcontact.com Unique mapping using 1:1 NAT NAT (Network Address Translation) is a router function that translates internal addresses into WAN IP address. The special type, 1:1 NAT, is used when several identical subnets are to be coupled to a higher-level network. Here, the subnets are depicted in unique, individual address areas of the factory network. This permits direct communication with the system's devices system without changing the controllers' IP addresses and defining additional routes. In FL MGuard, the 1:1 NAT function is also available within VPN connections. This means that plants can be equipped with identical IP addresses that are connected by tunnel connections to a central VPN router. This is particularly interesting for series machine production, where ideally systems are to be delivered that are configured identically.
UPDATE 1|16 New products 21 Electrical safety in photovoltaic systems Photovoltaic rooftop systems generate DC voltages of up to 1000 volts and cannot be disconnected easily on the DC side. This becomes extremely dangerous when the system is damaged and staff are working on- site. The new intelligent Solarcheck RSD photovoltaic panel shutdown from Phoenix Contact independently places photovoltaic rooftop systems into a safe state. Personnel are protected from life-threatening electric shocks during installation and maintenance, or in dangerous situations. Intelligent Ethernet extender system The Ethernet extender system lets you connect managed and unmanaged extenders up to 20 kilometers for the fi rst time thanks to Plug and Play. This interaction lets you diagnose all devices and paths via IP and permits particularly cost-eff ective networking of expansive IP networks. The automatic topology and data rate detection saves time and money during commissioning. Another key advantage of this system is the fact that it can be easily extended without impacting ongoing operations. Besides point-to-point and line topologies, ring structures are also allowed. New high-current feed-through terminal block with T-LOX toggle lever connection Easy startup and parameterization The new TW 50 high-current feed-through terminal block is suitable for currents up to 150 A and voltages up to 1000 V. Thanks to its innovative toggle lever connection, conductors can be safely contacted with 16 to 50 mm² cross-sections. The conductor is inserted from above and the terminal point is swung shut with a traditional screwdriver. The terminal block can be fastened to the housing without tools using a wedge. A conductor connection for standard ring cable lugs is used as standard for wiring within the device. Connect+ is a freeware solution for the startup and application parameterization of all small-scale controllers from Phoenix Contact. The software is geared towards commissioning engineers who do not want to use the entire on-site programming environment. programming environment. The user can set the IP address and time of the target device and write project and parameter fi les on the controller. Connect+ thus protects know-how since the readable engineering project is not even included in delivery for the system. phoenixcontact.com
22 News UPDATE 1|16 A good place to work Phoenix Contact named best employer three times Prof. Dr. Gunther Olesch, Executive Vice President Phoenix Contact (left) and David Plink, CEO of the Top Employers Institute The Top Employers Institute honored Phoenix Contact as "Best Employer for Engineers 2016". The Center for Employer Attractiveness (zeag GmbH) in Constance, Germany nominated a total of 93 prizewinners. Phoenix Contact was certified nine times by the independent research institute in recent years and came in first place as early as 2012. Its HR strategy and employee orientation were highly rated. Steffen Neefe from the Top Employers Institute explains, “Our detailed investigation found that Phoenix Contact has created an excellent environment for employees while offering a broad range of creative initiatives." A special edition of Focus magazine took a closer look at German companies and their capacity as employers. Focus interviewed employees from more than 2,000 companies for its ranking. In the "Electronics, electrical engineering and medical equipment" sector, Phoenix Contact took second place and was beaten only by Festo. In addition, its facilities in Blomberg and Bad Pyrmont again received the "Great Place to Work" award. Well positioned in the digital future Areas of expertise bolstered for operation, monitoring and cyber security Operating and monitoring devices are the key interface between man and machine. They are regarded as a significant success factor for a successful digital transformation. That's Phoenix Contact HMI-IPC Technology develops human-machine interfaces why Sütron electronic GmbH was renamed Phoenix Contact HMI-IPC Technology GmbH on January 1, 2016. The company, based in Filderstadt, develops and produces operating and monitoring devices. It has already been a one hundred percent subsidiary of the Phoenix Contact Group since 2008. Data Processing Security, also called IT Security, is another prerequisite for the success of Industrie 4.0. To underscore this, Innominate Security Technologies received a new name on January 11, 2016 and now operates as Phoenix Contact Cyber Security AG. The company is being developed into a competence center for industrial cyber security within the Phoenix Contact Group.