04 Cover story UPDATE 4|17 The average temperature of the earth's surface has increased by 0.85°C from 1880 to 2012. The number of weather- related natural disasters has increased by 46% since 2000. the 1950s. Only focusing on one option means neglecting the others and ignoring the impact on other systems, people, and the environment. Aside from the nearly incalculable costs, in European cities at least it is not possible to intervene heavily in the existing infrastructure that has grown over centuries because of competing land use. So how can we transform cities so that they remain functional and livable in the future despite urbanization and climate change? Using data as a raw material Digitization appears to be the key to overcoming ecological, technical, and social challenges. The concept of an effi cient and sustainable smart city is designed to boost urban transformation processes and install new value added chains. However, the term smart city is not clearly defi ned: it consists of diff erent ideas, approaches, projects, and measures. But what unites all these factors is that data is the raw material for countless smart technologies and applications. Data generated by diff erent sources – such as cars, mobile networks, weather sensors, and electricity meters – can be aggregated, linked, evaluated, and used as the basis for innovative services or products. Overlaying large heterogeneous volumes of data makes it possible to analyze situations that have been impossible to calculate so far. Complex infrastructures and public utilities can be controlled immediately and effi ciently in this manner. Data from vehicles and transport infrastructure help to even out traffi c fl ows. Irregularly generated wind and solar power is turned into a key contributor to the energy revolution, thanks to data from countless sensors and using intelligent networks and storage technologies. People's digital movement patterns within cities make it possible to draw conclusions about safety and hazardous situations. Digitization therefore off ers tremendous technological possibilities. Creating powerful basic infrastructure Not everything that can be digitized does in fact have to be digitized. However, digitization delivers access to exciting opportunities to A vast amount of data is generated by cities and communities that can be used to develop solutions for the many challenges that arise Smart Cities
Smart Building Cost-eff ective building management for new buildings from Phoenix Contact Electronics Effi cient and sustainable IoT-based Emalytics building management system for resource-friendly operations management Who does not want to save the environment while also reducing costs – and in comfortable surroundings at that? These apparently contrasting objectives can in fact all be achieved simultaneously in the fi eld of commercial and residential buildings. However, this requires an intelligent ecosystem for energy and building management: Emalytics. The market for commercial and residential buildings is characterized by increasing energy costs and growing environmental awareness in addition to statutory requirements. Decentralized power generators, intelligent process monitoring, and changed usage behavior therefore make it possible to run properties in a manner that allows for optimized consumption. The structure of the building management system required for this calls for comprehensive planning, from the project analysis, to developing an overall concept and improving building operation, through to implementing energy effi ciency measures. Therefore, for example, the building technology supply systems – that is sanitation, heating, interior air, electricity, light, lightning protection, communication, information, and safety technology – should be networked better with each other to allow for the best possible operations management. The digitally collected, processed, and linked data must be automated in a holistic approach which includes a building technology supply that spans all facilities. This can only be realized with a modern, IoT-based building management system. Reducing engineering and wiring costs The Emalytics ecosystem therefore combines the management and operation of building supply technology, as well as power monitoring, in one platform. Data points are condensed across diff erent properties into meaningful information, enabling processes to be sustainably optimized and predictive maintenance and servicing concepts to be established. This means that technicians do not service devices regularly. Instead, the device reports when there are signs of wear. The Emalytics system receives the data generated at the fi eld level by way of the
UPDATE 4|17 Technology 07 IoT-based ILC 2050 BI type controllers. The Inline controller combines classic sensor technology and actuator technology by way of protocols such as Modbus/RTU, LON, KNX, M-Bus, DALI, and EnOcean which are specific to the particular facility. Corresponding communication modules from the Inline portfolio are added to the controller for this purpose. New IP-based smart devices can also be integrated easily into the ILC 2050 BI. The Inline controller then sends all data to the ecosystem in a standardized format. Thanks to the protocol-neutral integration of the field devices into the IoT-based controller, the engineering and wiring time is reduced considerably. Optimizing supply processes Creating plant engineering designs including all data point lists incurs high costs. In Emalytics, the recorded and normalized data points of the building technology supply system are defined once and are then available to the entire system. The data points turn into a data information object which can be called up from anywhere: from the controller, the server, the display, or other devices. The preprogrammed assembly libraries for the building infrastructure minimize engineering costs. Blocks for simple programming of peak load and load management are already integrated, for example. The ecosystem contains libraries with common heating, air conditioning, and ventilation technology functions, including compliant system symbols for constructing the display. Linking the data points with the system parameters significantly accelerates commissioning of the system. Thanks to the support of web technologies, users can adapt the Emalytics operating concept to their particular needs – no matter whether they access the system by way of a notebook, touch panel/tablet PC, or their smartphone. The different properties can also be controlled and monitored from any location with the building management system. Integrating existing buildings into the solution is easy too. This provides numerous benefits for operators who can now compare locations with one another or establish a communication platform for all properties. It is possible to improve the supply processes for all buildings based on the existing data. If, for example, waste heat from the production building and the power generated by the solar panel system on the roof are used to heat an office complex, the corresponding costs are reduced considerably. An important contribution to environmental protection The operating costs decrease over the property's lifetime, since Phoenix Contact combines a holistic building system design with intelligent data usage concepts and modern automation technology. Lower energy IoT-based ILC 2050 BI type controller in use consumption also protects the environment. And people feel comfortable in the buildings since, for example, they can adjust the air conditioning and blinds to their individual needs. Farina Georgi Phoenix Contact Deutschland GmbH
08 On site UPDATE 4|17 A true win-win situation Building IoT in practice in production and logistics Since space had become scarce at the Nowy Tomyśl production site, Phoenix Contact erected two new buildings. The company's own IoT-based management platform Emalytics and the ILC 2050 BI controllers designed for the facility area ensure energy-effi cient operation in a pleasant working environment. weeks for the engineering and commissioning of the two buildings. Due to the standardization of the data generated, engineering time was reduced by over 50 percent in comparison to conventional systems. Needs-based air conditioning Due to the ongoing growth of Phoenix Contact, the fi ve production buildings in Nowy Tomyśl, Poland, were no longer enough. That is why the Executive Board decided in 2016 to construct two more buildings. There are now 5,000 additional square meters available in the logistics area, with an injection molding section, the tool store, and the metalworking shop being housed in the 13,000 square meters of the seventh building. A team of two employees only needed ten Thanks to the integral building planning as well as the intelligent networking of technical building equipment and energy supply, the two new halls can be operated energy-effi ciently. The Emalytics building management system allows for protocol-neutral integration of the nearly 10,500 data points by way of the IoT- based ILC 2050 BI controllers. The collected data is standardized and then transferred to the superordinate management and operation The IoT-based ILC 2050 BI controllers transfer all data of the facilities to the Emalytics building management system r e l g e i Z j e z r d n A : e c r u o S
UPDATE 4|17 On site 09 facilities. The various building infrastructures are linked together here to improve the individual processes from an energy point of view. Thanks to the use of a preprogrammed library from Phoenix Contact for integrating common HVAC applications, the engineering of the building infrastructure can be designed easily and quickly. The data center of the Polish subsidiary, for example, is air conditioned depending on temperature and load. This takes into account the optimal efficiency of the two cooling units, which are components of the cold water system along with the three adiabatic recirculating coolers. The cooling units as well as the compressor for supplying the production area are connected via BACnet IP to the automation solution. This simplifies analysis, repair, and maintenance. Individually adjustable lighting The lighting of the production building is likewise also regulated as needed according to a schedule. In the production areas as well as in the offices, lighting is based on working hours and shift schedules. Additionally, energy-saving LED lamps are installed in the new buildings. Thanks to their DALI functionality, these lamps can be dimmed depending on the brightness of their environment. The offices are also equipped with EnOcean presence detectors with brightness sensors. This ensures that only so much energy is consumed as is actually necessary. Lighting is controlled via the DALI protocol as well as the EnOcean button. In this manner, every member of staff can adjust the lighting conditions to their specific requirements at their workstation. The ILC 2050 BI controller makes it much easier to commission the lighting, because the DALI lamps and EnOcean buttons can be configured directly from the Workspace or read in respectively. The window blinds are operated automatically based on the weather forecast and the position of the sun, and can also be controlled directly from the workstation. Touch panel PCs are mounted in the production building which can be used to control all the lighting in the production area directly and query information about the climatic conditions. r e l g e i Z j e z r d n A : e c r u o S The cooling units as well as the compressor for supplying the production areas are connected to the automation solution to simplify analysis, repair, and maintenance The production employees are also able to adjust the lighting individually. Intelligent networking The building management of the Polish subsidiary is connected to the Emalytics system in Blomberg via a superordinate server structure. Facility Management staff at headquarters thus have access to the management and operation facilities of the buildings in Nowy Tomyśl. Due to the consistent networking of the locations, individual applications can also be programmed by other subsidiaries and the locations can provide support for each other. The building IoT solution therefore also allows for building and energy management that spans locations. The high degree of data transparency and the simple engineering make it possible to network the building infrastructures and properties intelligently and sustainably, thus ensuring that buildings are operated efficiently. Christoph Wermter Phoenix Contact GmbH & Co. KG phoenixcontact.com
10 On site UPDATE 4|17 EVCC Professional is the core element for charging station communication and control Making electromobility affordable Charging stations provide power generated from renewable sources from battery storage systems In the future, it should be possible to charge electric vehicles as quickly as cars with a combustion engine can be refueled. This requires lots of energy. If, for example, four charging points with an output of 350 kW each are installed, 1.4 MW of power can be drawn if they are all used at the same time. Since this connected load does not exist everywhere, it has to be retrofitted at very high cost. It should be noted that the power is only required for around 15 minutes and does not have to be available 100 percent of the time. The simultaneity factor of the load is 80 percent for each charging station. A medium-voltage control cabinet costs around 300,000 euros. You also need a charging station with two charging points and a distribution cabinet for approximately 200,000 euros. Given maintenance costs of around 10,000 euros per year and an amortization period of five years, you need to invest and finance a total of 550,000 euros to use each station. Due to the relatively high cost of electricity, as well as estimated earnings of 9 cents/kWh, 35 to 70 charges would have to be performed at the station every day for a period of five years. This is a considerable number by today's standards. However, if the idea of an emission- free future is going to be more than just lip service, there will be no way to avoid expanding electromobility combined with the use of energy generated from renewable sources. Providing the connected load in a more cost-effective way The costs associated with providing the requisite connected load must be brought down in order to make the charging infrastructure affordable to develop. Batteries can be used as energy storage for this purpose. Battery storage is primarily used for providing alternating current and also supplies the charging stations with direct current on the secondary side. Therefore, the storage provides the power required for charging and is recharged up to full capacity with a low primary output. The advantage of battery storage over a control gear lies in the ongoing electricity costs. A higher base price has to be paid for the high connected load of the control gear, while the price per kWh is low. For the lower connected load required by battery storage, the base rate is cheaper but the costs per kWh are higher. Nevertheless, the storage version is more efficient to run even with the same investment costs, since higher amounts can be achieved to pay off any financing. Using the battery together with an existing solar plant or wind turbine has an even more positive effect on running costs. Intelligently controlling the charging process A charging infrastructure with high amounts of energy can be managed in a number of ways. Each charging point can be controlled in such a manner that the available energy is divided according to the connected load. If the four charging points in the example cited above are in use, the connected load is limited to 1.12 MW by the simultaneity factor. This means that
UPDATE 4|17 Smart Energy 280 kW can be drawn from every charging point. If two charging points should now be used by conventional CCS2 and the two other charging points by fast-charging CCS2-HPC electric vehicles, the load is discharged unevenly. While conventional electric vehicles are charged at a maximum of 50 kW and do not use 230 kW, the fast-charging cars need an additional 70 kW per charging point. In this case, scalable power electronics off er a solution consisting of multiple modules – such as 15 units delivering 75 kW each. One 75 kW module is then assigned to each of the two charging points with the CCS2 vehicles, so that the remaining 13 modules can be used for the fast-charging vehicles. An intelligent matrix assigns six to one charging point and the remaining seven modules to the other charging point. Communication in line with requirements This type of energy allocation requires intelligent communication elements such as the EVCC Professional DC charging controller. This module charges the electric vehicle by way of Power Line. Relevant data can be exchanged directly with the matrix of the power electronics by means of CAN or Modbus/TCP. Energy measurement devices or RFID card readers can be linked via Modbus RTU/ TCP. Solar plants or wind turbines are integrated through the EVCC Professional interfaces. A touch panel indicates the current status of the on-site charging process. The charging controller can be used with battery storage with a capacity of either 100 to 200 kWh. The maximum load that can be drawn is 320 kW, for example, which is why the CCS2-HPC vehicles are fully charged in around 18 minutes. In reality, the vehicles often only consume 50 to 80 percent of the battery capacity, which means that up to three electric cars can be charged with a simultaneity factor. The battery can then be recharged in an acceptable time with a variable feed-in power of 20 to 150 kW. Dirk Vogel Phoenix Contact E-Mobility GmbH phoenixcontact.com Modularly structured and intelligently linked power electronics designed for small spaces, yet delivering the highest possible performance, supply and distribute energy
14 On site UPDATE 4|17 Traffi c jams don't stand a chance Managed Switches in tunnel traffi c control Nobody likes being stuck in traffi c. That is why traffi c signals provide for a smooth and safe fl ow of traffi c. This also goes for the Cholfi rst tunnel in Schaffh ausen, Switzerland. Managed Switches from Phoenix Contact ensure that data is transferred reliably between the traffi c systems and control engineering. The Swiss A4 highway is an important transit route for North-South traffi c. Every day, over 25,000 vehicles use its northern section, which also serves as the Schaffh ausen expressway and includes multiple tunnels. The operating and safety equipment installed in the tunnels guarantees a smooth fl ow of traffi c. For this purpose, the equipment is divided into diff erent sections – such as energy supply, lighting, ventilation, or traffi c control – which each have their own control technology. Since the section of the A4 highway close to Schaffh ausen was opened way back in 1996, some of the technology was no longer up to current standards. For this reason, the Federal Roads Offi ce (FEDRO) commissioned Ticos Engineering & Software AG with the renovation as well as the renewal of the operating and safety equipment of the Cholfi rst, Fäsenstaub, and Schönenberg tunnels. The control engineering of the Cholfi rst tunnel was modernized for the traffi c control section. Ticos replaced the system control as well as multiple local controllers for this purpose. The allocated control cabinets are located in the engineering rooms or sub-distributions of the two tunnel portals. All existing and many new street signals are connected to the traffi c control engineering here. The Ticos employees transferred the signals from the previous to the new controller step by The sign gantry at the entrance to the Cholfi rst tunnel is equipped with dynamic traffi c control Smart Traffi c
UPDATE 4|17 On site 15 step. Ethernet-based communication was also realized at the field and control level as part of the modernization of control engineering. Redundant Ethernet ring using fiberglass technology A redundant Ethernet ring using single mode fiberglass technology is used to cover large distances and to also ensure high availability. Ticos selected Managed Ethernet Switches from Phoenix Contact as infrastructure components. A major reason for this decision was the easy handling of the devices, which can be set up in a redundant ring topology without any other configuration. The 2206-2FX-SM switches have two fiberglass interfaces in a single mode version with SC Duplex connectors, as well as six twisted pair copper interfaces with RJ45 connectors. The single mode ports are connected to the fiberglass installation by way of FO patch fields. The fiberglass cables run through a service duct between the tunnel portals. The switches mounted in the cross section control boxes are coupled to the fiberglass ring in this duct. The main and local controllers of the substations located in the engineering rooms are connected by way of RJ45 ports. Switches with single mode uplinks are extended in the substations by versions with eight twisted pair ports to integrate additional devices into the network. Central configuration and diagnostics from the engineering room The traffic control section includes the lighting of static signals, blinkers, and traffic lights, as well as lane and switching signals. The field of action of this section's control engineering includes the tunnels, the entrances to the tunnels, and the assigned open sections of highway. A variable direction sign system is operated in the project section of the A4 highway to redirect traffic when the tunnel is closed. Prism variable direction signs, which had been connected to the control engineering in parallel until now, show the alternative routes. With the new solution, it is now possible to couple to the switches directly or by way of serial/Ethernet converters. While the switches installed in the engineering rooms can be accessed easily, the devices installed in the service duct, entrance areas, and on the open sections of highway The control technology installed in the substation is connected to the fiberglass ring by way of the FL Switch 2206-2FX-SM are difficult to reach. For this reason, the Ticos employees can assign the devices an IP address by way of the network with the Network Manager startup tool. All switches can be configured and diagnosed from the engineering room should any further settings be required. Future expansion to other projects So far, Ticos has had very positive experiences with the FL Switch 2200. “We particularly like the simple handling of the components,” says Armin Spiess, Division Manager at Ticos. “That's why we are also going to expand this networking concept to other tunnel sections, as well as to other possible follow-up projects after approval from the client.” Uwe Nolte Phoenix Contact Electronics GmbH Web code: #1551
The two screw feeders in the intake pumping station extract up to 846 m3 per hour Smart Water The more effi cient, the better Renewing automation technology at the Monsheim wastewater treatment plant The modernization of water management systems usually only aff ects the individual process steps. This is entirely diff erent at the Monsheim wastewater treatment plant, which is undergoing a full overhaul. The new concept mainly aims to achieve a more process-oriented way of working, as well as to reduce energy consumption, which should be 100 percent self- generated in the future. The Monsheim wastewater treatment plant has a treatment capacity of 46,500 population equivalents, although this number can rise to 120,000 during the grape harvest in Rhineland- Palatinate from September to December. This means that lots of energy is required to clean the water. Those in charge therefore expect that, by renewing the automation technology, not only will technical processes be improved, but energy utilization will also be optimized. This called for modular and powerful control technology as a basis to easily connect the fi eld devices to the control system. After the retrofi t, ten Axioline controllers spread over the entire system will control all processes that take place at the sewage treatment plant. From the intake to the exhaust fans through to the cogeneration unit, the measurement values are recorded via analog and digital interfaces and processed in the distributed controllers so that they are also available for energy analysis later on. To achieve a high degree of effi ciency, a redundant FO- based network ring was built throughout the entire plant with intelligent Factoryline switches. Network and transmission errors therefore cause a process to fail far less often than in the past. All processes constantly in view Operating panels installed throughout the plant show the status of the individual processes and components to employees based on the powerful network. Employees can now manually intervene in the respective process, if required. Thanks to the coupling of the uninterruptible power supplies (UPS) to the control system, important operating states of the battery – such as the current state of the power supply – can be read out. Furthermore, the UPS provides information on the charging state, as well as the remaining runtime of its energy storage, and warns about failures early on.
UPDATE 4|17 On site 19 Another objective of the modernization was to save costs during the engineering process. One option is to integrate the automation and visualization level. Employees at the wastewater treatment plants therefore use the Waterworx function block library for programming and creating the applications. The diff erent fi eld devices can be easily inserted into the application with the blocks. The integrated visualization interface allows for a fast connection of the process parameters to the control system. Consistent concept as an important foundation “By modernizing the individual treatment steps combined with the new automation technology and the intelligent fi eld devices, a consistent concept is now available to us which forms the foundation for operating our wastewater treatment plant effi ciently,” explains Ralf Schmidt, head of the Mittleres Pfrimmtal wastewater administration unit. A modern control system as well as reliable components are not enough to achieve the highest possible degree of effi ciency after the modernization. In fact, the focus needs to be on the solution as a whole. The coupling of complex fi eld devices to the control system often is often associated with considerable costs and a high degree of Waterworx function block library The Waterworx function block library ranges from basic functions for simple applications to complex drive, valve, and measurement blocks, as well as blocks for connection to a SCADA system. Existing and new fi eld devices can be integrated into the overall system easily by way of diff erent communication standards such as Profi bus, Profi net, and Modbus. Thanks to the continuous further development of Waterworx, the number of fi eld devices and possible connections is constantly growing. Axioline controller with mounted analog and digital modules susceptibility to faults. If the user employs the preconfi gured blocks tested by the manufacturer, it is easy for him to integrate the diff erent components and increase the availability of the application during operation. The information provided by the intelligent sensors and actuators is displayed in the control system and is therefore incorporated into the calculations regarding effi cient operation of the Monsheim wastewater treatment plant. Joel Stratemann Phoenix Contact Electronics GmbH
20 Technology UPDATE 4|17 Focusing on what matters most Outsourcing remote control technology to an external service provider Many cities and communities face similar challenges: everything needs to function reliably but the budget for the necessary employees and technical equipment is limited. Therefore, outsourcing makes sense in some areas – such as remote control technology. Water management companies now have to deal with IT security due to the introduction of Ethernet-based data transfer at the field level. In addition, the innovation and technology cycles are becoming shorter and shorter. This means that the automation components have to be replaced faster and employees have to be trained more frequently. This costs money that often is not available. To nevertheless keep up with the state of the art, remote control technology – and, as a first step, the control system – could be outsourced to an external service provider, for example. This scenario can be achieved with one of two approaches. In one instance, it could be feasible to have the computer hardware used to operate the control system provided by an external source – also called infrastructure as a service (IaaS). The responsibility for the software environment, including maintenance of updates and licensing costs that arise, then remains with the user of the remote system. Calculable payments instead of high initial investments Software as a service (SaaS) describes a situation where the entire control system, including the operating system and all licenses, is outsourced. This concept has prevailed as the more efficient solution in practice. This, for example, eliminates maintenance and servicing work and costs for the PC hardware. In addition, the service provider can work on the software by way of a web service. Furthermore, users do not need to block out any resources for updating the operating and control system, nor for communication interfaces or license costs. A service provider certified by the Federal Office for Information Security also ensures
22 News UPDATE 4|17 Direct to the control room Reliable signal transmission in confined spaces A lightning and surge protection concept is essential in large water and wastewater treatment systems. The Termitrab complete (TTC) surge protective devices from Phoenix Contact indicate an overload on the contactor module, Powerful protective devices for MCR technology and can be queried by the control center via the easily retrofitted field telecommunication function. Depending on his preference, the installer can choose between screw and Push-in connection technology for the product range. In this way, a surge protection concept can be implemented in the most confined spaces with protective devices featuring overall widths of only 3.5 mm and 6 mm. The Ex i certification of the TTC-Ex components permits their use in field distributors for Ex zones 1 or 2. Additional approvals attest to their suitability in accordance with Fisco (fieldbus intrinsically safe concept). Thanks to the multistage protective circuit, the three most important performance requirements – category D1, C2, and C1 – of the surge protection standard EN 61643-21  are fulfilled. Quickly connected Easy connection for energy storage Decentralized stationary battery storage systems that efficiently utilize renewable energies and stabilize the power grid in the process are key to the energy revolution. The hybrid connector system from Phoenix Contact for transferring data and energy offers fast and safe assembly of battery modules as well Modularly designed Variocon connection system as fast commissioning of the storage system, since the modules do not need to be cabled on site. Thus it is possible to design turnkey energy storage solutions of different capacities that are not tied to a particular power grid. The Variocon rectangular connector system is the foundation for the hybrid connector system. It is based on IP67, which makes it ideal for use in devices, as well as junction boxes and control cabinets in harsh industrial environments. It offers modular contact inserts with screw and PCB connection, as well as fixed contact inserts with crimp connection for turned and rolled contacts. The universal screw connections feature a high degree of reliability, low contact resistance, and a compact design. The contact insert modules are touch-proof throughout and can be coded to prevent incorrect connection.