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GO! Automation with LOGO! and SIMATIC S7-1200 Number 1 | April 2014 | siemens.com/go Small, powerful, and easy to use! Interview with Josef Ploch and Helmut Schindler about the new LOGO! 8 GO! 1/2014 | Contents 2 Small, powerful, and easy to use! 4 Special vehicle construction 16 The good witch Wehner Motors GmbH & Co. KG, Kalbach-Uttrichshausen, Germany Industrial communication 19 Increased flexibility and performance Industrial remote communication Locking system 22 Under lock and key Leukhardt Schaltanlagen Systemtechnik GmbH, Schwerin, Germany Gripping technology 24 Safely gripping concrete sleepers HSE Jürgen Schäfer, Alfdorf-Pfahlbronn, Germany Products 26 Ideal for beginners Communication module RF120C Editorial 3 Generation change Cover 4 Small, powerful, and easy to use! New LOGO! 8 logic module device generation Agriculture 8 Fresh milk from a vending machine HSE Jürgen Schäfer, Alfdorf-Pfahlbronn, Germany 20 Sweet gold in the spin cycle Harzer Antriebstechnik GmbH, Bad Lauterberg, Germany Raw material processing 10 From scrap to valuable material Metran Rohstoff-Aufbereitungs GmbH, Kematen an der Ybbs, Austria Pump technology 12 Charge the hose! Speck Pumpen Verkaufsgesellschaft GmbH, Neunkirchen am Sand, Germany Cover photo: Siemens AG/A. Kradisch S i e m e n s A G Editorial | GO! 1/2014 3 “I’m an automation specialist.” This is something being said by more and more people with electrical expertise – people for whom automation was previously beyond their abilities. The key to this change lies in the simplic- ity and attractive price/performance ratio of modern microcontrollers. With the LOGO! line, Siemens has been paving the way for this shift for many years. The company’s products have often been copied but never equaled. Now the next innovation is coming along with LOGO! 8, which we are in- troducing in this issue of our magazine. If the previous versions set the standards for usability and functionality for controllers in the lowest performance range, this applies even more to LOGO! 8. The built-in web server, which allows the creation of web pages for monitoring and controlling the logic module via the Internet (remote control) with no special programming skills, and the built-in Ethernet inter- face are exceptional features in this device class. New communication mod- ules open up new system-compliant communication options and expand the field of application of these nano-PLCs. The creation of switching pro- grams is also made easier with the innovative LOGO! Soft Comfort V8 soft- ware. Again and again, the reliability of our automation systems is the focus of interest. Controlling a locking system with Simatic S7-1200 in the security- sensitive area of a correctional facility is a great example. For worldwide sales of machinery and equipment such as honey extractors, the reliability of our systems is also a prerequisite for successful use. We are not running out of unconventional ideas for microautomation applications, as is demonstrated by the example of the Oil Slick Witch, which is on the road with the Simatic S7-1200 on board, or the LOGO!-controlled milk vending machine as a niche product in agriculture. I hope that with this issue of our magazine we can again shed some light on the possibilities that are hidden away in our smallest automation systems and are just waiting to be discovered and used. Warm regards, Heinz Eisenbeiss Head of Marketing and Promotion, Industrial Automation Systems Generation change S i e m e n s A G / A . K r a d i s c h 4 GO! 1/2014 | Cover S i e m e n s A G / A . K r a d i s c h Small, powerful, and easy to use! With LOGO! 8, the successful Siemens logic module is entering the next generation. The new module satisfies almost all customer requirements, with simplified handling and full communication capabilities over Ethernet, reduced space requirements compared to LOGO! 7, and an easy-to-use web server application. New LOGO! 8 logic module device generation 5 Cover | GO! 1/2014 L OGO! has long been firmly established as an in- telligent logic module for switching and control solutions in small automation projects. The module’s simple assembly, minimal wiring require- ments, and easy programming using LOGO! Soft Comfort allow the quick implementation of many solutions for simple machines and installations, as well as for building automation and a variety of ap- plications in private spaces. Marketing manager Josef Ploch and product manager Helmut Schindler explain what the new LOGO! 8 has to offer. Mr. Ploch, you have known LOGO! virtually since its initial launch. You know how LOGO! has evolved from generation to generation. What is new in LOGO! 8? Josef Ploch: In principle, we have made the two pre- vious LOGO! versions, 6 and 7, into one. A device, that once again has the size of the LOGO! 6, with a width of 72 mm (module width 4 TE), provides an Ethernet interface and an integrated web server for all basic units, and offers a much-improved display. The new LOGO! 8 series comprises eight basic units, seven digital modules, and three analog mod- ules. The digital outputs were increased to 20, and the analog outputs were increased to 8. Due to the built-in Ethernet interface, additional programming or LOGO! TD cables are not necessary; standard Ethernet cables are sufficient. Helmut Schindler: The maximum number of func- tion blocks and shift registers is retained as in the LOGO! 7. However, there are now 64 digital and an- alog flags each, and 50 message texts can display much more meaningful messages. For data logging, there is space for up to 20,000 data records on the standard microSD card. All voltage variations and functions can be combined. Four of the new LOGO! 8 basic units for the different voltage types have the new, six-line display with 16 characters per line and three controllable background colors. And if a TDE text display is to be connected, it now also saves space in the subdistribution board because the connection is via Ethernet and two additional TEs module width are not needed as for the previous TD cable. The LOGO! TDE with two Ethernet interfaces has the same dimensions as before. Are there any additional components for the LOGO! 8? Helmut Schindler: In addition to the previously mentioned TD text display and digital and ana log modules, there is also the LOGO! CSM module, which can be used as an Ethernet four-port switch for expan sion of the Ethernet interfaces for cost- effective implementation of small, local Ethernet networks. There are also a variety of LOGO! power modules available for supplying power. The new LOGO! CMR2020 module can be used for SMS com- munication for alerting and remote control via cell phone or for position determination using GPS. The module offers the option of automatic time synchro- nization on cellular networks as well as via GPS. Josef Ploch: These are functions that did not previ- ously exist and that users will appreciate for solu- tions such as break signals or actuation of church bells. Using GPS, it is now possible with this module S i e m e n s A G Highlights of LOGO! 8 The new LOGO! 8 has eight basic modules with Ethernet connectivity, which allows them to communicate with each other and with all Simatic S7 systems via Ethernet. Due to the greatly improved display, message texts and status information can be displayed much more clearly. In addition, the integrated web server enables even more cost-effective monitoring and control. The innovative LOGO! Soft Comfort V8 software makes it quicker and easier to create programs and implement communication functions. And, finally, alerting and remote control via cell phone, automatic time synchronization, and position determination are all possible with the additional CMR2020 module. 6 GO! 1/2014 | Cover S i e m e n s A G / A . K r a d i s c h to retrieve the current position and time worldwide and thus synchronize the clock in the LOGO! 8 fully automatically – with no additional GSM provider costs. But the CMR2020 also offers other important high- lights: since it is easily connected with the LOGO! 8 through the Ethernet interface, it can exchange da - ta with the LOGO! 8 in accordance with the signal situation, send out SMS messages autonomously, or read control commands from an SMS and pass them on to the LOGO! 8. When connected to GPS, it pro- vides a cost-effective method for container tracking, for example. For this application, position data can be requested at regular intervals via SMS and then also sent via SMS to the headquarters by the CMR2020. In the new generation, the display has also been greatly improved. Helmut Schindler: Yes, that’s right. We have really made a qualitative leap with the display. Six lines with 16 characters each now offer twice as many characters per message. There are also the three background colors of white, orange, and red – which increase usability enormously. The TDE external text display can even show as many as 20 characters per line. The user information is clearly structured, there are fewer abbreviations, and the message texts and status information are more visible and readable than before. For users, the compatibility of a new device or software version with previous versions is an important factor in the decision to upgrade. Is the LOGO! 8 compatible with all previous versions? Josef Ploch: The LOGO! 8 is compatible with all pre- vious versions in terms of its connections. The same also applies to all programs. Only when a text display is used is it necessary to enter an Ethernet address. Message texts are retained and can now be extended in terms of the number of characters for the new dis- play of the 8 series. But that’s not all! If the LOGO! 8 is connected to an access point, the web server can be easily activated in the message block, making it possible to access the LOGO! 8 with a smartphone. What is the new software like? Helmut Schindler: The new LOGO! Soft Comfort V8 has been completely revised in terms of its design. It is easy to operate and provides intuitive support to the user in stand-alone or network mode for pro- gram creation and in the configuration of the many functions. The menu structure and input windows have been optimized. Functions are interconnected as usual with the click of a mouse, and the new soft- ware is even quicker and easier to use in some respects. Programs from previous versions can be copied to it. The properties of the text messages are adapted to the new display and can be extended accordingly, including the addition of symbols for user-defined messages. Parameters are referenced graphically and clearly shown in the program. In network mode, viewing for up to 16 participants is possible. Up to three programs can be displayed side by side, and signals from one program can be dragged and dropped into another program. The communication is automatically configured and shown in the net- work view, and the network inputs and outputs are inserted into the individual programs. Josef Ploch: Configuration of the web server is now quite simple – requiring little more than a few mouse clicks. The user doesn’t need HTML programming “ We have really made a qualitative leap with the display. It offers not only more characters per line but also the three background colors of white, orange, and red – which increase usability enormously.” Helmut Schindler, LOGO! Product Manager 7 Cover | GO! 1/2014 INFO AND CONTACT siemens.com/logo [email protected] LOGO! CMR2020 • Supports remote communication via cellular network with the new LOGO! 8 logic modules • Enables remote monitoring and control of systems with LOGO! 8 via SMS • Position recognition via GPS signal • Querying via SMS • Time synchronization via NTP server, GPRS, or GPS • Easy configuration via web interface • Quick and meaningful analysis of the module status • Stand-alone operation possible through integrated inputs and outputs “ Configuration of the web server is now quite simple – requiring little more than a few mouse clicks. The user doesn’t need HTML programming skills.” Josef Ploch, LOGO! Marketing Manager skills, but instead simply chooses one of the two rep- resentations offered on his or her terminal equip- ment. This is how it works: If a message text is pro- grammed for LOGO! 8 or for a TD, then the text re- lease is for the LOGO! 8 display, the LOGO! 8 TD, or both. After that, a checkmark is set for the web server and you can begin operating the LOGO! 8 using a smartphone, tablet, or PC – and it appears in the view as if the user were standing in front of the LOGO! or text display. This requires that the LOGO 8! be connected to a router, of course. And LOGO! Soft Comfort V8 also conveniently supports the many functions of the LOGO! 8. Mr. Ploch, Mr. Schindler, thank you for the interview. S i e m e n s A G / A . K r a d i s c h S i e m e n s A G GO! 1/2014 | Agriculture 8 HSE Jürgen Schäfer, Alfdorf-Pfahlbronn, Germany J ürgen Schäfer is a textbook Swabian tinkerer. The trained electrician and programmer went into business for himself in 1994 with hardware and software solutions for mechanical en- gineering – ranging from planning to control cabinet design and installation to commissioning. “I specialize in smaller systems and special solutions that are not worth the effort for the large sup- pliers,” he says. To survive in a competitive market among the big players, an independent company needs to look for niches that will allow it to fulfill specific needs and demonstrate creativity. With his milk vending machine, Jürgen Schäfer from Alfdorf, Germany, shows how it’s done. As a flexible microcontroller, LOGO! opens up many options for him. Fresh milk from a vending machine developed a milk vending machine for him. We got into a conversation, and I ended up being brought on board to provide the control system.” The proto- type offered in a trade journal then aroused such interest that Schäfer saw an opportunity and took advantage of it: building milk vending machines, which he has successfully marketed since 2010 under the company name “millymat.” Based on standard refrigerators, they D u d a r e v M i k h a i l - F o t o l i a The 2008 financial crisis was also very much felt by Schäfer, forcing him to look for new areas of development. By chance he found a promising field of activity in agriculture. He explains: “I was acquainted with a farmer who was suffering from the low milk price and who wanted to meet the grow ing demand for regionally produced foods. For this reason, he sought new ways of direct marketing, and his broth er Agriculture | GO! 1/2014 9 are far more cost-effective than com- petitive products. Milk from the farmer without the need for personnel The principle is as follows: The nutri- tion-conscious customer puts coins into the machine slot, depending on the desired amount of milk; places a container under the dispensing tube; and starts the output at the push of a button. The built-in pump then sucks up the milk, which flows into the con- tainer. If the customer releases the but- ton, the milk output is interrupted, al- lowing him or her to replace the filled milk bottle with an empty one, for ex- ample. There are two main types of “millymat”: a version that is suitable for direct mounting on the farmer’s milk tank and one with its own milk tank, which may also be positioned in a sep- arate building, such as a farm shop. Schäfer quickly moved on from his simple prototype, whose automation system was based on a coin checking device, a flow sensor, and a counter mo- dule. He began to use the LOGO! OBA6 microcontroller with expansion mod- ules and an additional external text dis- play. “For professional marketing, it is important to have such features as speed control for the pump so that the milk does not foam up, defrosting and cleaning programs, and monitoring and diagnostic capabilities,” the entre- preneur and craftsman explains. LOGO!, supplied by the electrical whole saler Emil Löffelhardt GmbH & Co. KG from Fellbach, Germany, had already impressed him in other applications due to its 12-V power supply and pro- cessing of analog values. “In addition,” he says, “every electrician is familiar with it and can help with problems on-site. It is easy to handle and cost- effective.” Automatic defrosting and cleaning system LOGO! makes it easier for Schäfer and his customers to set the number of pulses depending on the temperature and adjust the fat content of the milk so that after the insertion of coins, the re- quested volume is accurately dispensed. Using the time switch of the controller, the resourceful electrician programmed the external text display. For example, he assigned the push buttons of the text display twice and set the controller to store information such as the display of the price per liter, the deposited sum of money, the flow quantity in tenths of a liter, and the hours of operation. If no milk is flowing, the farmer receives error messages that indicate the possi- ble causes, such as an empty tank, a faulty sensor, or a defective pump. He can shut down the vending machine at the push of a button. “To be on the safe side, the push buttons respond only when they are pressed and held down for a certain amount of time,” says Schäfer. “That was also easily pro- grammed with the LOGO! Soft Comfort software.” On the integrated display, parameters can be set, such as the volume of milk per inserted sum of money. It is also possible to narrow down and accurately diagnose errors based on the status parameters. Schäfer’s ambition is to offer the right solution for every need. Therefore, he also offers cashless variants of the “millymat,” which he intends to convert from the electronic key to RFID soon. They will of course also be controlled with LOGO! an automatic defrost cycle. At a fixed time in the evening, the controller dis- connects the socket outlet of the refri- gerator from the power by relay and switches the machine to power-saving standby mode. The backlit external text display built into the control cabinet is blank or shows “No dispensing pos- sible.” Money inserted is no longer ac- cepted, but is instead returned to the customer. Only the power supply unit and LOGO! continue to be powered. Useful information and error messages The cleaning was also automated in a clever manner, minimizing the ef fort re- quired. “In the switched-off milk vend- ing machine, the farmer only needs to pull out the hose and put it on the drain. This creates a circuit for rinsing,” Schäfer explains. When the milk driver arrives, pumps out the remaining milk in the tank, and starts the rinse cycle, the connected vending machine is auto- matically also rinsed using an inte- grat ed remote control switch. With the “millymat 100 standalone” with its own milk tank, an agitator is also controlled by LOGO!, preventing the cream from settling. There is a temperature mea- surement option as well, with a corre- sponding sensor. Schäfer also makes extensive use of the possibilities of the LC display and INFO AND CONTACT siemens.com/logo [email protected] P u b l i c i s , G . F ü r s t e n b e r g e r Impressed by LOGO!: electrician and programmer Jürgen Schäfer (right) with Michael Rapp from Emil Löffelhardt GmbH & Co. KG 10 M e t r a n The shredded material consisting of rubber, plastics, and metal is mixed in the turbidity tank with magnetite and water in order to subsequently separate the individual materials based on density N ature knows no waste – and we don’t either! That is the philosophy of the Müller-Gutten- brunn Group (MGG), an international holding company that combines a number of internationally active recycling companies and has its headquarters in Austria. Every year, MGG handles approximately 850,000 t of material, processing waste industrially with the aim of gaining scrap, metals, plastic, and paper that can be used as secondary raw materials. Within MGG, Metran Rohstoff-Aufbereitungs GmbH in Kematen an der Ybbs is responsible for processing nonferrous shredder residue, mixed metals, and metal-containing slag into unmixed fractions for smelters. The name Metran is a shortened form of the German word for metal separation plant. Individ- ual materials from electronic scrap and car shredding are separated through the elaborate application of physical laws so that reuse can take place. The in- house “recycling kitchen” continuously further de- velops the sorting methods. Separation methods include dry and wet processes; crushing, shaking, and sieving equipment; and magnetic methods as well as sensor technology. From e-waste to plastic As with junked cars, e-waste is also shredded in a shredder and separated into ferrous and nonfer- rous components. While the iron is smelted in steel mills, nonferrous metals, rubber, and plastics are fur ther separated from the e-waste and from junked cars by Metran. To this end, the material is first ground again in a scrap mill and separated into parts larger and smaller than 12 mm using screens. The coarser fraction then goes into a sink-float sep- aration plant. In the sink-float separation process, metals are separated from other materials such as rubber or plastics on the basis of their different densities. The material is placed in the turbidity tank with water and granular magnetite. Magnetite increases the density, and lighter components such as rubber or plastics float to the top. In this way, various ma- terials can be separated depending on the setting. The mixture is controlled by a density measurement. The density, of 1.4 to 1.8 g/dm 3 , is determined by a load cell. The signal of the transmitter is monitored on a 4–20-mA analog input of the LOGO! module. Depending on the nature of the supplied raw ma- terial, the density is brought to the desired set- point value through the introduction of mag net ite or control of the valve for supplying water. The Scrap, especially electronic scrap, often contains valuable metals or plastics. Sophisticated sorting and processing methods make these materials available for reuse. The sink-float separation process at an Austrian recycling center was partially automated with LOGO! Metran Rohstoff-Aufbereitungs GmbH, Kematen an der Ybbs, Austria From scrap to valuable material GO! 1/2014 | Raw material processing 11 Raw material processing | GO! 1/2014 INFO AND CONTACT siemens.com/logo siemens.com/multiranger [email protected] [email protected] module via Ethernet. Automatic, manual, and service mode are available for selection. The operator uses the touchpanel to specify the set-point values for density and water level, and the actual values are displayed both graphically and in plain text. The high-quality 5.7” touchscreen provides a clear, user- friendly overall view of the system according to the selected operating mode. Another advantage of the operating unit is the display of any fault or alarm messages, color-coded according to message class and quickly and clearly identifiable visually. Metran has put its trust in products and solutions from Siemens for years. The company is very satis- fied with the support and service provided by the Industry Automation Division of Siemens in Vienna. Metran was able to achieve significant quality improvements in production and plant optimization by using a wide variety of Siemens automation, drive technology, and process-monitoring compo- nents. Due to previous experience with Siemens, which was consistently positive, the staff would like to continue the successful collaboration in the future as well. level in the turbidity tank is monitored by the Siemens MultiRanger transmitter and by an ultra- sonic sensor. Automatic density measurement with LOGO! Until a year and a half ago, the water and magnetite supplies were still being controlled by hand. This led to a lack of precision, and the machine frequently had to stop, wasting valuable time. Together with Siemens, Metran implemented an automated density- measurement system. After technical consultations, Metran opted for LOGO! 0BA7. Metran production manager Anton Pils and Rainer Göbel, a consultant from Siemens Austria, collaborated closely to create the LOGO! switching program and the visualization interface of the Simatic HMI touchpanels, as well as commissioning and fine-tuning the system. The team of electricians from Metran handled the instal- lation and connection of the new components and the necessary circuitry changes in the existing con- trol cabinet. A LOGO! 0BA7 logic module now automatically mo- nitors and controls the water valve and the supply of magnetite, based on the fineness of the material in- troduced. The results are impressive: separation is more precise, manual control is eliminated, and a great deal of time is saved. Simple and clear operation using a touchpanel The system is operated using the Simatic HMI KTP600 Basic color PN, which communicates with the logic • Fully automatic control results in significant time savings and greatly increased quality. • A clear, user-friendly operator interface is provided by the Simatic HMI KTP600 Basic color PN connected to the LOGO! 0BA7. • LOGO! and the operating unit can be reached from any point in the network and can be easily monitored or programmed with new switching programs or user interfaces. • Variable values are transferred via Ethernet to a higher-level Simatic S7-300 controller, which controls and monitors the other parts of the system. LOGO! 0BA7 highlights M e t r a n 12 GO! 1/2014 | Pump technology F or Speck Pumpen Verkaufsgesell- schaft GmbH, which has been head quartered in the German town of Neunkirchen am Sand since 2005, tradition and innovation go hand in hand. In 1959, the company emerged from the Nuremberg family business Speck Pumpen Daniel Speck & Söhne. Since 1999, Speck has been manufac- turing pumps to supply firefighting water – with increasing success. New regulations in Germany’s drinking water ordinance and the DIN 14462 standard for the hygienic separation of the po- table water network from the firefight- ing water system made it necessary to supply fire hydrants using pressure- boosting systems with storage tanks P u b l i c i s , G . F ü r s t e n b e r g e r Charge the hose! With new standards, the requirements for supplying firefighting water in buildings have become more complex. The focus is now on their control systems. For use in pressure-boosting systems with attached storage tanks, LOGO! impressed the German pump manufacturer Speck. Speck Pumpen Verkaufsgesellschaft GmbH, Neunkirchen am Sand, Germany LOGO! provides standards- compliant monitoring for wire breaks and short circuits with fault diagnos - tics. Product manager Dieter Schäfczuk and master electrician Christian Callian, both of Speck Pumpen Verkaufsgesellschaft GmbH, and Alen Bajric, Siemens, (right to left) are satisfied 13 Pump technology | GO! 1/2014 “ The LOGO! Soft Comfort software is user-friendly and intuitive, with the application examples on the Internet also being quite helpful.” Christian Callian, master electrician, Speck Pumpen for firefighting water in structures such as industrial buildings, hospitals, schools, apartment buildings, high-rise buildings, and underground parking ga- rages. With the Feuercell and Multicell series, Speck offers its customers com- plete solutions with one or two pumps, depending on the require- ments. The high-rise direc- tive, for example, calls for redundancy in buildings more than 23 m in height. The storage tanks have the conformity mark of the German Technical and Sci- entific Association for Gas and Water (Deutscher Ve r- ein des Gas- und Wasser- faches e. V., DVGW), and the entire system is tested and certified by DEKRA. Firefighting water for fire hydrants The fully automatic operation of such pressure-boosting systems in case of fire is simple. If someone opens the valve after opening the wall hydrant cabinet and pulling out the hose, the firefighting water flows. This causes the pressure to fall. Sensors detect this pressure drop, causing the control sys- tem to start the pump of the pres- sure-boosting system. Because flow sensors also monitor the flow pressure, the system pumps continuously while the firefighting water flows. In order to replenish the firefighting water, which is separated from the potable water by a feed tank using motor ball valves with electromotive actuators, sensors also monitor the water level in this tank. If the water drops below a certain level, the control system sends a command to open the valve. Once the level rises to a certain height, the valve is closed again. s h u t t e r s t o c k Standards-compliant monitoring for wire breaks and short circuits with fault diagnostics places special demands on the control system, which requires that 4–20-mA standard current signals be processed. “This was much easier to implement with LOGO! than with the control system we used before,” says master elec- trician Christian Callian. “We didn’t have to rein- vent the wheel but could instead convert the pro- grams with support from Siemens.” And the electri- cians could deal with many other tasks optimally as well, thanks to the tailored solution com prising the LOGO! 0BA7 basic unit with integrated text dis- play, two analog modules, a digital module, and a remote text dis- play in the control cabinet door. Messages on the text displays Callian was able to program approxi- mately 20 full-text messages with date and time, making operation and main- tenance much easier. 14 GO! 1/2014 | Pump technology Wire-break monitoring with LOGO! If an analog sensor outputs a value of 0 to the controller, it is not clear whether the value is actually 0 or the sensor is defective. In such cases, sensors can be used that normally output a current signal of between 4 mA and 20 mA. If the controller detects a signal on the analog input that is significantly smaller than 4 mA, it is safe to assume that the sensor or the sensor cable of the controller is defective. + Use of an AM2 expansion module for evaluation of signals in the range of 0 to 10 V and/or 0/4 to 20 mA + In the analog function block, 4–20 mA is selected as the sensor + Insertion of an analog threshold switch that either triggers an alarm message in case of signals less than 4 mA or controls a desired behavior of the system, such as disabling the defective area, alerting the operator, or sending an SMS to the service technician Example: The pressure of a water supply system is to be kept constant with a variable-speed pump. Implementation: LOGO! 12/24 RC as a basic unit with an AM2 expansion module with AI3 and AI4 analog inputs. PI controller in the LOGO! program, pressure sensor for 0–4 bar, provides values 4–20 mA. Nominal pressure: 2 bar. The system is designed to detect a wire break of the sensor and issue an alarm signal and display a fault message in this case. If no firefighting water were to flow and the pumps were in danger of run- ning dry, the corresponding message would appear on both text displays and be provided to the control room, if present, for evaluation. While the text display on the cabinet door provides quick information, the user can also in- tervene in the program on the text dis- play of the base unit. This is password protected to prevent abuse. “For us, the password protection was another major plus point for LOGO!” explains Speck product manager Dieter Schäfczuk. Automated weekly test runs also serve to replace the potable water in the feed pipe to the tank in accordance with the standard. This is controlled by LOGO! with a timer function. Schäfczuk calculates in advance how long the motor ball valve must remain open so that enough water is flushed through the pipe into the tank and on into the conduit by overflow. In addition, there is a one-minute weekly test run of the pump. The LOGO! solution allows sensor-based dry-run protection of the pump to be realized as easily as runtime and temperature-monitoring functions. Ready for the future Many other Siemens products are in- stalled in the pressure-boosting system as well. “We know from years of ex - pe rience that we can always expect time ly and good advice from Siemens and that spare parts are immediately available,” says Schäfczuk. Callian adds, “The LOGO! Soft Comfort software is user-friendly and intuitive, with the ap- plication examples on the Internet also being quite helpful.” With LOGO!, Speck is also well equip- ped for the future – whether for pres- sure-boosting systems for the firefight- ing water supply or perhaps soon also for the potable water supply. Thanks to the networking over Ethernet, the logic module also enables a redundant de- sign in the control system, as may soon be required, and the system can be eas- ily extended and refined at any time. INFO AND CONTACT siemens.com/logo [email protected] K N O W - H O W 15 Pump technology | GO! 1/2014 3. Wire-break monitoring with alarm message + Insertion of an additional analog threshold switch followed by alarm output and alarm message text + Sensor: 0–20 mA, in order to be able to evaluate values below 4 mA (range 0–4 mA corresponds to input units 0–200 – that is, input signals in this range must not occur when the sensor is operating properly) + Starting value 0 and switch-off value 200 + Switching of output 4 upon wire break, activation of an alarm message with the date and time of the fault Tip: If you activate the ticker text for lines 3 and 4 as “line by line,” a service telephone number is displayed on an alternating basis with the date and time as additional information on lines 3 and 4 of the message text. 1. Programming the controller + Switch between manual and controller operation with input I1 + Sensor: 4–20 mA, scaling 0–4,000 with three decimal places (this generates values of 0–4 bar on the display in the message text) + Set-point value: 2,000, corresponds to 2 bar + Pump in manual mode with a fixed value of 100 (this corresponds to 10% of the maximum value = 1 V) Note: No wire break can be generated in the simulation. 4. Constant activation of the background lighting of the display For better readability of the messages, starting with LOGO! 0BA6, the background lighting of the display can be switched with the M25 flag or enabled at all times in the basic settings on the device. With LOGO! 0BA7, the display of the integrated LOGO! display can also be observed in the online test. Note: When the alarm message is output, the acknowl- edgment function is activated – that is, after rectification, of the fault this needs to be acknowledged with the “OK” button. S i e m e n s A G S i e m e n s A G S i e m e n s A G 2. Constant display of basic values on the display A message text with the set point and actual value of the pressure and the actual value for controlling the pump is displayed at all times. The actual values are displayed as values and as a bar graph. S i e m e n s A G 16 GO! 1/2014 | Special vehicle construction W e h n e r M o t o r s The good witch A German towing and metal construction company developed a vehicle that makes oil on roadways disappear as if by magic and gave it the fitting name of Oil Slick Witch (Ölspurhexe®). Since 2011, the vehicle has been controlled in an effective and user-friendly manner by a Simatic S7-1200 controller with a Simatic TP1500 basic touchpanel. Wehner Motors GmbH & Co. KG, Kalbach-Uttrichshausen, Germany W e h n e r M o t o r s 17 Special vehicle construction | GO! 1/2014 W ehner Motors GmbH & Co. KG in Kalbach-Uttrichshausen, Ger- many, is praised by custo mers as a “manufactory” due to its custom- ized solutions, made almost entirely in- house, in special vehicle construction. With the Oil Slick Witch, Wehner Motors GmbH has secured market leadership in the elimination of traces of oil, fuel, grease, and other contaminants on road surfaces, interlocking paving, or indoor floors. Sixteen of these vehicles have been sold to towing services and fire departments. Launched in its initial version in 2004, the Oil Slick Witch can now be pur- chased in four variants. The most elab- orate version, an 18-t truck, is equipped with an additional sweeper for pretreat- ment in case of extreme soiling. The central component of all the vari- ants is a patented flexible suspended swivel system with two or three surface cleaners. Water is sprayed through rotating nozzles onto the surface to be cleaned at high pressure (between 180 and 275 bar) and at temperatures of up to 95°C. In this way, the contaminants are released from the pores and form an emulsion that is sucked up by means of a high-performance vacuum system in the same operation. The design in- cludes the tanks necessary for fresh water and wastewater as well as for cleaning additives and antifreeze, the suction fan, and a hydrostatic operat- ing mechanism for the cleaning drive. A camera system monitors all processes during operation. Complete step sequences at the press of a button Since 2011, the cleaning has been controlled with a Simatic S7-1200 with CPU 1214C and operated and moni- tored by the driver using a Simatic TP1500 basic. “Compared with the conventional so lu tion, this solution enabled automated step sequences, provided expanded and improved dis- plays, and resulted in much easier work for the user overall,” says Steffen Wehner, a certified electrical engineer who is responsible for the electronics of the Oil Slick Witch. “In addition, the modular control system saves us space in the control cabinet and re- duces wiring requirements.” The cleaning components are much easier to make frost-proof. To blow out the lines with air and then rinse them with antifreeze, all the user needs to do is press the “Frost-proof” function on the panel. Then all the necessary processes are triggered, each with its own duration stored in the system – both for the pre-spray system on the surface cleaners and for the surface cleaners themselves. Prior to the auto- mation of the cleaning processes, the driver had to carry out an entire series of operating steps and insert a secur- ing bolt in order to move the three sur- face cleaners into the transport posi- tion and safely raise them for the trip to and from the accident site. Today he or she remains in the vehicle and presses the “Transport Position” hard- ware button followed by “Raise.” Once the front attachment is in the raised position, it is automatically bolted with a safety pawl. Speedometer and operating-hour meter The important functions of the Simatic S7-1200 also include variable adjust- ment of the water pressure depending on the level of soiling and the substrate. Among the technology functions in- tegrated into the PLC, particular use is made of the counter. Because the truck speedometer only begins to move at speeds above approximately 5 km/h, the CPU counts pulses detected by a sensor on the cardan shaft over time and in this way calculates the speed of the vehicle during the cleaning drive. This is then displayed on the panel in increments of 0.2 km/h. In hydrostatic auxiliary drive, the PLC controls the power supply and takes over the safety circuit for the joystick, which controls the speed. Operating-hour counters are pro- grammed for functions including the high-pressure pumps, and a reset is possible for wear parts. A timer pro- tects the current value displayed on the touchpanel so that the reset function cannot reset the counter until the but- ton is pressed and held down for sev- eral seconds. Even safety-relevant vehicle signals are processed. Because the reverse gear should not be engaged during the clean- ing drive, a corresponding warning appears on the touchpanel in this case. Finally, the PLC functions also include control of the indicator lights and sig- nal tones when the vehicle is started; all are briefly triggered. Efficient engineering in TIA Portal and service quality The cleaning time remaining is calcu- lated based on the pressure and water level and displayed on the touchpanel. For such complex calculations, there is the “Calculate Box” block in the Simatic Step 7 Basic software, which allows di- rect input of formulas. “A huge advantage is the full integra- tion of this engineering software with the Simatic WinCC Basic HMI software in TIA Portal,” emphasizes Wehner. “Thanks to TIA Portal, step sequences can be efficiently programmed, and variables can be easily integrated into the panel.” A Siplus Upmitter for the special requirements of vehicle con- struction protects the control system. It stabilizes the voltage range of the alternator to the required 24-V direct voltage. • Clarity: On the 15” display, all values such as pressure, temperature, and fluid levels can be controlled and ope rated at a glance • Graphical display of the fluid levels allows for quick understanding of service functions • Color display enables error messages in red • Full-text error messages such as “Caution: Joystick to center position” or “Caution: Disengage reverse gear” facilitate operation Simatic HMI Panel 18 GO! 1/2014 | Special vehicle construction INFO AND CONTACT siemens.com/s7-1200 siemens.com/tia-portal [email protected] Service has always been important at Wehner Motors. The company trains its customers, has a service vehicle avail- able, and manufactures many spare parts itself. A new level of service is now being provided by remote mainte- nance via GSM teleservice module with a SIM card provided by the customer and a GSM antenna. “I dial into the ve- hicle system with my laptop and can observe the program and diagnose er- rors as if I were sitting right in front of the truck,” says Wehner. In this way, un- productive downtime can be avoided in most cases or at least reduced. Modularity for customized solutions “Another strength of the solution is its modularity and expandability,” the elec trical engineer continues. “We can flexibly tailor the control system to custo mer requirements.” For example, the professional fire department of Wiesbaden, Germany, wanted function and orientation lighting for each of the push buttons of the switch panel. For this reason, the Oil Slick Witch was equipped with a touchpanel as well as two Simatic HMI KP8 PN key panels, in- stead of a conventional switch panel; five LEDs of various colors enable visual feedback. Other benefits include re- duced wiring requi rements due to the Profinet interface to the PLC and fewer input/output modules, saving space in the control cabinet. A Simatic HMI Basic Panel KTP400 Mono installed on the rear is used for additional display of the levels of fresh water and wastewater. And as for expandability? To include the sweeper in the automation, and to be able to switch the necessary pneumatic and hydraulic valves on the hardware side, it was only necessary to install two input/output modules in addition to the standard five – no sor cery required! W e h n e r M o t o r s W e h n e r M o t o r s For the transport position of the swivel system of the Oil Slick Witch with three surface cleaners, a safety pawl is automatically bolted “ A huge advantage is the full integration of this engineering software with the Simatic WinCC Basic HMI software in TIA Portal.” Steffen Wehner, electrical engineer, Wehner Motors GmbH & Co. KG The driver operates and monitors the cleaning and vehicle functions from his or her cab using a Simatic TP1500 basic 19 Industrial communication | GO! 1/2014 With its products for industrial remote communication, Siemens offers a comprehensive portfolio of solutions for telecontrol and teleservice applications. For additional applications such as video transmission, smart grid applications, and condition monitoring, various industrial modems and routers are available. Increased flexibility and performance Industrial remote communication W ith telecontrol, automated systems can be monitored and controlled from a central control room. To this end, remote terminal units (RTUs) are used in geographically distributed process stations – in sewage and water treatment plants, district heating networks, and pumping sta- tions, as well as in oil and gas supply, power distri- bution, and traffic engineering, for example. The new CP 1243-1, CP 1243-1 DNP3, and CP 1243-1 IEC communications processors open up many new possibilities for the realization of highly flexible and cost-effective RTUs based on Simatic S7-1200. All the variants of the CP 1243-1 provide cyclic and event-controlled transmission of measured and set-point values and alarms to the control station without complex programming. The control room is connected via various public or private networks (remote networks) using exter- nal modems or routers, such as Scalance M, which are connected to the Industrial Ethernet interface of the communications processor. The CP 1243-1 DNP3 and the CP 1243-1 IEC ex- pand the TeleControl Professional portfolio to in clude support for the standardized DNP3 and IEC 60870 telecontrol protocols. Different types of networks, such as mobile networks (GSM/GPRS/ UMTS), Internet via DSL, dedicated lines, and so on, are supported through the selection of appropriate industrial modems and routers, such as Scalance M. The CP 1243-1 expands the capabilities of the S7-1200 in the TeleControl Basic system to allow for control room connection through the use of Inter- net via DSL. For Simatic S7-1200 stations, the CP 1243-1 enables the system to be secured against unauthorized access through the integrated fire- wall and virtual private network (VPN) security functions. INFO AND CONTACT siemens.com/industrial-remote-communication [email protected] Note on industrial security: Suitable protective measures (including industrial security, e.g., network segmentation) must be taken to ensure safe operation of the system. Further information on the topic of industrial security can be found on the Internet at siemens.com/industrialsecurity. ... Control center DNP3 DSL modem DSL modem VPN tunnel GPRS S7-1200 S7-300 S7-300 Industrial Ethernet Security Module Scalance S Security Module Scalance S TIM 3V-IE DNP3 Station TIM 3V-IE DNP3 CP 1243-1 DNP3 Scalance M874-2 Station Station Simatic PCS 7 The extensive portfolio of telecontrol and teleservice components enables secure monitoring and control of automated plants via public or private networks 20 GO! 1/2014 | Agriculture g e r t r u d d a - F o t o l i a H arzer Antriebstechnik GmbH, based in Bad Lau- terberg in the German state of Lower Saxony, specializes in the design and construction of sophisticated automation solutions with a focus on drive technology. The team led by company founder Marcus Warlich has experience in a variety of indus- tries, such as mechanical engineering, plant construc- tion, and special machinery as well as the process industry. For the past year, Harzer Antriebstechnik has been mass-producing honey extractors as a sub- contractor to the company CFM Steuereinheiten. A honey extractor consists of a cylindrical stainless steel vessel in which a honeycomb basket is mounted with a swivelling axis that is connected to the drive below the vessel. Depending on the extractor size, the honeycomb basket contains 4 to 16 honeycomb pockets into which honeycombs are inserted. Once the lid is locked and the spin cycle is selected, the drive actuates rotation of the honeycomb basket. The honey is thrown against the inner wall of the ves- sel by centrifugal force, and from there it flows down and accumulates on the bottom. To fling the honey out on both sides of the honeycomb, the honeycomb pockets are turned by reversing the direction of mo - tor rotation. To complete the process, the honey is fed through a discharge valve into a collecting tank. Streamlining and simplifying the processes Until the introduction of the new control units, CFM worked with conventionally produced controllers. Honey extraction required experience and intuition to consistently find the right parameters. The new control units needed to be more compact and sim- pler to operate, and their functions needed to be self-explanatory. After a thorough examination of the options available on the market, the pro ject team led by Warlich chose Simatic technology and the Sinamics G110 compact frequency inverter as the variable-speed drive. A mo tor connected with the frequency inverter is controlled using the CM1241 (RS485) communication module of the The seamless interplay of the control system, operator panel, and drive system in an innovative automation solution for the operation of honey extractors meets the high requirements of beekeepers and makes the solution uniquely efficient. Harzer Antriebstechnik GmbH, Bad Lauterberg, Germany Sweet gold in the spin cycle 21 Agriculture | GO! 1/2014 INFO AND CONTACT siemens.com/S7-1200 [email protected] Simatic S7-1200. Depending on the extractor type and drive, the 1212C or 1214C CPU models are used. Communication is carried out via the USS drive protocol. The single-phase motors, with outputs from 0.37 to 2.2 kW, are supplied with 230-V AC. For the combined push-button and touch operation, the Simatic HMI Basic KTP400 compact 3.8” display is used on the front of the controller, which pro- vides enough space for visualization of the self- explanatory operator display. The beekeeper acknowledges the spin program and configuration using push buttons. He or she monitors the process and can modify the specified motor speed individually. Thanks to the ability to change languages on the fly, the operator panel is ready for international use. With the old control boxes, the control knobs and switches always got sticky with honey. Now the user can simply ex- change cover sheets on the operator panel that are optionally available for purchase. Engineering software minimizes configuration effort For the engineering, Warlich uses TIA Portal with the Simatic Step 7 Basic software. The Simatic operator panels are configured with WinCC Basic. Thanks to its integration in TIA Portal, Simatic Step 7 Basic pro- vides opportunities for online diagnosis and the addition of technology objects. Libraries and time- saving reusability of data, intuitive editors, and drag-and-drop functions enable fast and easy engi- neering. The controller, frequency inverter, and operator panel are contained in a metal housing, which is mounted on a wall or freestanding on a rack, for op- eration. A CB1241 RS485 communication board han- dles the serial data exchange. The parameters of the CB1241 are also assigned with Simatic Step 7 Basic. The board is designed for the connection of USS pro- tocol drives, enabling access via the serial RS485 bus, which is used to control the drives and read and write parameters. Standardization and high-quality results The use of standardized components ensures high availability. All the honey extractors operate uni- formly with a single control model. The production conditions of the different types of honey are deter- mined only by selecting the spin program and the drive parameters. In this way, the beekeepers achieve consistently high-quality results in natural honey extraction. Due to the quality of the Siemens products, there are virtually no maintenance costs. If service is required, it is only necessary to discon- nect the network and machine connections and send in the controller. In recent months, Harzer Antriebstechnik has equipped more than 150 honey extractors with the new automation solution. Warlich sums up: “From the controller to the frequency inverter to the operator panel, we rely on Siemens technol o- gy in this system and have had good experiences with it. The high reliability and optimal cost bene- fit ratio of the components, as well as the innova- tive engineering software, contributed to the suc- cessful outcome.” Modern technology for a sweet treat: honey extractors from CFM with Simatic controllers C F M 22 GO! 1/2014 | Locking system j u s t i z . n i e d e r s a c h s e n . d e T he Sehnde Correctional Facility, an institution of the German state of Lower Saxony, is one of the largest and most modern correctional facilities in the country. Five Y-shaped prison buildings are de- signed to house up to 514 prisoners. Workshops and a medical center are located immediately adjacent to them. The entire complex is situated on a 15.4-ha site surrounded by a 6.5-m-high wall. The inmates are distributed across 29 stations, which are in turn assigned to nine correctional de- partments. Each correctional department is respon- sible for the safety of two corridors, which can be viewed and monitored from the station office. The locking system is of particular importance, of course. Long gone are the days when prison officers locked and unlocked the cells individually with a thick ring of keys. Today the massive locking systems are equipped with electronic locking mechanisms that can be operated both remotely and manually. Com- prehensive sensor technology monitors the locking state and detects suspicious tampering. Replacement during normal prison operation After encountering problems with the original lock- ing system, the Sehnde Correctional Facility decided to replace the entire system. Leukhardt Schaltanlagen Where could the requirements of a locking system be higher than in a correctional facility? In Sehnde in Lower Saxony, an automation system with Simatic S7 controllers watches over several hundred doors and ensures that the security center has everything under control. Leukhardt Schaltanlagen Systemtechnik GmbH, Schwerin, Germany Under lock and key Bird’s-eye view of the Sehnde Correctional Facility building complex 23 INFO AND CONTACT siemens.de/lorem [email protected] Locking system | GO! 1/2014 INFO AND CONTACT siemens.com/S7-1200 [email protected] Systemtechnik GmbH from Schwerin in northern Germany offered a compelling solution based on the Simatic S7 automation system. Siemens partner Leukhardt specializes in the de- sign and construction of low-voltage switchgear and in the automation of machinery, industrial plants, and buildings. A locking system of the highest safety category was not an everyday challenge. Leukhardt opted for a distributed solution with Simatic S7-1200 controllers and Simatic ET 200S bus couplers. “The sophisticated building structure of the institution made it possible to limit work within the stations, with the associated security precautions,” says Frank Tappendorf, head of automation at Leukhardt. In the prison buildings, the pipes and wires of the sanitary and electrical systems run in supply shafts that extend from the ground floor to the attic. They are accessible only through security doors. A shaft is located between every pair of prison cells, resulting in a compact building management system. The cables of the prison area locking systems are also accessible from this shaft. Because the locking system needed to be in- stalled during normal prison operation, Leukhardt opted for a central communications infrastructure. This had the advantage that only the locking sys- tems of the cell doors and the main entrances needed to be connected to the Simatic ET 200S bus coupler. All other work could be performed outside the secured area. Each door fully under control At the head of each floor and at the intersection of two corridors is a station office with visibility of the entire station. Simply structured control panels on the Simatic HMI KTP600 color touchpanel allow all doors to be locked or unlocked individually or to- gether. Red and green color coding indicates the locking state of a door. Each prisoner should be able to open and close his cell door himself during the period in which the sta- tion is open; therefore, during this time the cell doors open from the inside by means of a push button and can be locked from the outside with a key. This is mainly for protection from theft among the prison- ers when every door in the locking system is in the open state during the station’s open period. The individual locking systems within a building are linked via bus couplers with Simatic S7-1200 using the User Datagram Protocol (UDP) network protocol. The touchpanels in the stations communi- cate directly with the controllers via Profinet. The individual Simatic S7-1200 units in turn com- municate via DeviceNet with a higher-level Simatic S7-300 master CPU in the security control center of the correctional facility. Using a touchpanel, facility personnel can control higher-level locking functions and overwrite local settings. The system also allows unrestricted viewing of the operating state of each sensor and actuator of a door. In addition, more than 220 passage doors can be controlled within the cor- rectional facility. Transparent overall system Each locking mechanism offers a series of integrated monitoring functions, which are categorized based on importance. If there is a security-related malfunc- tion somewhere in the facility, a detailed status re- port appears on the touchpanel in the security cen- ter. This allows the prison staff to respond promptly. In addition, the service technician is informed of the exact nature of the malfunction from the beginning and can proceed through the many locks and doors in a targeted manner with the necessary tools and spare parts. “The system is running great,” says the deputy head of the construction department of the Sehnde Cor- rectional Facility, Piel. “You can see each locking con- tact and instantly recognize when a contact is not there. This makes the locking system transparent and enables rapid and targeted elimination of faults.” j u s t i z . n i e d e r s a c h s e n . d e Up to 514 prisoners can serve time at the Sehnde Correctional Facility H S E J ü r g e n S c h ä f e r 24 GO! 1/2014 | Gripping technology HSE Jürgen Schäfer, Alfdorf-Pfahlbronn, Germany W hether the task is sorting, as- sembling, processing, clean- ing, packaging, or labeling, when it comes to flexible hardware and software engineering of unconven - tio nal machines and devices, HSE Jürgen Schäfer from Alfdorf in southern Ger- many is a reliable and creative partner. For example, the world’s most success- ful provider of handling systems for building materials, Probst Greiftechnik Verlegesysteme GmbH, with its main plant in Erdmannhausen, likes to work with the resourceful electrician and programmer. Among the jointly developed special solutions is a threshold gripper com- missioned by a leading manufacturer of concrete sleepers for rail-based long- distance and local transport. The rail- way sleepers, which are 2.20 to 3.80 m wide and weigh 80 kg or more, support the rails and fix their position. The steel and sheet-metal sleeper gripper built by Probst, which is 7 m long, or 9 m with the extension, is sus- pended from a gantry crane and used in the customer’s concrete plant to stack and transfer 25 to 30 railway sleepers at a time onto trucks or freight cars. It needs to grip five sleeper types of different widths in a manner that ensures that they do not fall. Fully automatic and self-monitoring The customer’s previous sleeper grip- pers were operated entirely by the Safely gripping concrete sleepers Due to its compact, scalable, and flexible design, the Simatic S7-1200 is suitable for a wide range of automation tasks. For electrician and programmer Jürgen Schäfer, there was never a doubt that this controller could also be used to control and monitor a railway sleeper gripper. 25 Gripping technology | GO! 1/2014 INFO AND CONTACT siemens.com/s7-1200 [email protected] H S E J ü r g e n S c h ä f e r crane operator and could only open and close. The new gripper was to be completely automatic and able to mon- itor its travel as well as the clamping hydraulics itself for safety reasons. It needed to be compatible with the ex- isting grippers and use conventional wired communication systems. This was a challenging task made for the passionate inventor Schäfer, who as usual took responsibility for all the electronics and programming, includ- ing safety engineering. “I needed to recognize all error contingencies and have these queried by the control sys- tem,” he stresses. Compact control system and intuitive programming in TIA Portal It was clear that contactors and relays would not be enough for such a task. “However, I had little space for the con- trol cabinet, which I needed to place di- rectly on the gripper. This is just one of the reasons the Simatic S7-1200 com- pact controller with CPU 1214C and three input and output modules, com- bined with a Sitop power supply unit, Sirius switchgear, and fuses from Siemens, was perfect for the job.” He purchased all the products through the electrical wholesaler Emil Löffel- hardt GmbH & Co. KG. Schäfer had already used the Simatic S7-1200 in several projects and was highly satis- fied: “It is reasonably priced, can be in- tuitively programmed using TIA Portal, and is easy to operate. I needed no training and was able to get started right away.” On a type-selector switch, the cra ne op e rator selects the appropriate sleep er width, and the signal is transmitted conventionally to the control cabinet over wires. Controlled by the Simatic S7-1200, the gripper automatically opens far enough that it can grip. Then the crane operator uses the two joy- sticks to move the device mechanically into the right position and presses the start button for “Clamp” or “Close.” The gripper then grips the sleepers fully automatically, with both the travel and pressure being monitored by the Simatic S7-1200, based on the preset format and the flow rate, fill level, and temperature of the hydraulic oil. “After all, the gripper really needs to have a tight grip to avoid having the sleepers fall during lifting,” says Schäfer. Visual fault signals If the values programmed for each of the five types of sleepers are reached, the green light on the control cabinet of the gripper comes on, and the crane operator knows that he or she can now lift the sleepers. Opening the gripper is then also controlled and monitored by the Simatic S7-1200 until the pressure is off and the specified travel has been traversed. Then the light turns red. If there is anything wrong or the pro- grammed pressure, fill level, or tem- perature limit values are exceeded or not reached, the system shuts down and the light on the control cabinet shows a flashing or orange fault signal. In addition, for more precise error di- agnostics without a panel, Schäfer placed limit switches set for the differ- ent formats on the free outputs of the controller. The automated sleeper gripper is now being used successfully by the cus- tomer, and Schäfer can hope for repeat business. It is clear that he will then use the Simatic S7-1200 again: “It can do a great deal more, of course. In this un- usual application, it was the sufficient number of inputs and outputs for the five different gripping processes that was particularly important.” It is not difficult for him to name other advantages: “The customer has Simatic controllers in use elsewhere and em- ployees who are familiar with them. Spare parts can be quickly obtained anywhere and anytime, which is a great advantage for maintenance. And should such a device need to be used under more severe ambient conditions – in the tropics, for example – this can be easily accomplished thanks to the Siplus products from Siemens, without me having to change anything in the engineering.” Thanks to sophisticated self-monitoring, the sleeper gripper for five sleeper types is safe, despite the enormous load Space on the gripper was limited, but with the compact controller, the control cabinet could be kept small 26 GO! 1/2014 | Products S i e m e n s A G / W . G e y e r Comprehensive functions in TIA Portal support commissioning, diagnostics, and troubleshooting, saving time and money. The Simatic S7-1200 app also provides support during commissioning of an RFID application. The user can stand next to the plant with a smartphone, manually move a container with an RFID transponder, and immediately rec- ognize on the display whether the tran- sponder has been detected by the reader and the data read. Another aid for mechanical and electrical planning of a system is the full CAx data provided by Siemens Customer Support through the CAx Download Manager. Simatic S7-1200, the RF120C commu- nication module, and the RF200 Ident line represent a cost-effective identi- fication solution without expensive wiring of the bus connection and power supply to external communication mo dules. These connections are es- tablished through the controller. The single-channel design of the RF120C maximizes the performance of the Ident system. The RF120C communicates of the RF600 line requires several pa- rameters to be set. The control program is just as easily and intuitively created with TIA Portal, because all Ident functions are clearly shown in a library. The names of the new application blocks describe the functions to be executed. The address for the transponder needs to be de- fined on the block, and all the RFID- specific parameters are set. The opera- tion of the new blocks is identical to the other Simatic communication blocks. F or anyone familiar with Simatic S7- 1200 and TIA Portal but who has never programmed an application for industrial identification, program- ming the new RF120C module and per- forming the hardware configuration using drag and drop are as easy as with all S7-1200 modules. In the parameter assignment of the reader connected to the RF120C, all the selection options are also available as text. While a sim- ple reader of the RF200 line requires no further parameterization, a UHF reader The identification technology with RFID devices and code readers now forms a unit with the Simatic S7-1200 controller. Simatic RF120C is plugged directly into the controller and programmed via TIA Portal. Ideal for beginners Identification with Simatic S7-1200 • Low total cost of owner- ship with the RF120C and RF200 reader generation • Easy operation through full integration into TIA Portal • Future-proof solution thanks to support for all readers of the Ident RF200, RF300, RF600, MV400, and MOBY D/U lines • Universal application blocks both for the integrated solution with RF120C and for Profibus and Profinet Production control with RFID systems Communication module RF120C Magazines Our technical magazines represent real added value for your business. Whether you choose process news, motion world, or advance, the information and technology in our trade maga- zines for all areas of automation and drive technology are in- terestingly presented, well-researched, and described in appli- cation examples. As a plant operator or mechanical engineer, you are always well informed – in a manner that is tailored to your industry. Don’t miss another fascinating issue! Order a free subscription to your preferred technical magazine today. siemens.com/industry-magazines Current Newsletters Siemens offers subscriptions to electronic newsletters on a va- riety of topics – the Totally Integrated Automation Newsletter, for example. You can find the newsletter at industry.siemens. com/newsletter. You will be informed about hardware and software innovations, services, application examples, and im- portant dates and events relating to the topic of Totally Integrated Automation – making sure that you are always up to date. Simply register with your e-mail address. siemens.com/industry-newsletter INFO AND CONTACT siemens.com/ident siemens.com/s7-1200 [email protected] directly with the CPU of the controller using acyclic data sets. Ident profile for identification systems The Ident profile in TIA Portal from the identification library in the PIB_1200 program block guarantees high per- formance for different applications. For larger configurations with Profibus and Profinet, the RF180C (Profinet) and ASM 456 (Profibus) communication modules can be connected to the S7-1200 controller. No matter which of the communication modules are used (RF120C, RF180C, or ASM 456), the function blocks from the library remain the same. Control programs for identification written for S7-1200 in Structured Con- trol Language (SCL) can be used in the same way for S7-1500. The identi- fication application can thus be pro- grammed regardless of the control hardware, the communication module used, or the connected reader from the RF200, RF300, RF600, MOBY D/U, or MV400 product lines. The following example shows how easily this can work: An application in an industrial environment requires a system that reads the data matrix code (DMC) attached to an unfinished part and then writes the data to the RFID transponder of a system pallet. Previ- ously, only a simple identification ap- plication, such as a garage door con- troller, was programmed with S7-1200 and the RF200 ID system. For the new task, the existing program can be used and the read block can be linked with a Simatic MV420 code reader for read- ing the DMC codes. Then the RF120C communication module is configured with an RF200 reader. In the program, the RF200 reader and the write block are linked, followed by the linking of the data read from the read block of the MV420 to the write block of the RF200 – and the desired application is done. Published by: Siemens AG, Industry Sector, Communications Werner-von-Siemens-Str. 50, D-91052 Erlangen, Germany siemens.com/industry Editorial responsibility in accordance with the German press law: Heinz Eisenbeiss, I IA AS S MP Chief editor: Eva-Maria Blockus Publisher: Publicis Publishing P.O. Box 32 40, D-91050 Erlangen, Germany [email protected] Editorial staff: Dorit Gunia, Robert Engelhardt, Marion Schwab Copy editor: Susanne Wanke DTP: TV Satzstudio, Emskirchen Go! Appears twice a year; Volume 18 © 2014 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved. The following products are registered trademarks of Siemens AG: ET 200, PCS 7, S7-300, S7-1200, S7-1500, SCALANCE, Siemens LOGO!, SIMATIC, SINAMICS, SIPLUS, SIRIUS, SITOP, STEP, TIA Portal, Totally Integrated Automation (TIA), WinCC If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered. The information provided in this magazine contains merely general descriptions or characteristics of performance, which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. GO! 1/2014 Producte | GO! 1/2014 27 ANZEIGE FOLGT Answers for industry. siemens.com/ident Small readers – big value SIMATIC RF200: The compact and efficient RFID system conforming to ISO 15693 The SIMATIC RF200 may be small, but performance and economy are just as important as for any big device. As it is easy to install, it can be implemented in intralogistics applica- tions or small assembly lines quickly and cost-efficiently. What is more, you stay flexible. Because SIMATIC RF200 fits seamlessly into Totally Integrated Automation and is part of SIMATIC Ident, the comprehensive, integrated portfolio of industrial identification products from Siemens. (*) (*) Figure in original size