Power management

Control system for photovoltaic current feedingNew products

Simatic S7-1200 with fi rmware V2

GO!Automation with LOGO! and SIMATIC S7-1200

LOGO! optimizes the control of hydraulic drilling systems

Flexible and Customized

15th Issue 2/2011

GO!Automation with LOGO! and SIMATIC S7-1200

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Cover photoFlexible and customized: LOGO! optimizes the control and monitoring of hydraulic drilling systems

Behind the steering wheel in a wheelchair: LOGO!

controls a device to help people in wheelchairs get

into a pickup truck

2018More efficient cutting: An innovative high-pressure

unit for cooling lubricants reduces production costs by

up to a five-figure amount

An exciting project: Rehabilitants build a

Simatic S7-1200-controlled production line

3 Editorial

4 An exciting projectRehabilitants build a Simatic S7-1200-controlled production line

6 Well temperedAn innovative masterpiece combines requirement-based cooling and heating functions for babies‘ bottles

8 Smaller, easier, betterLOGO! replaces complex system for level measurement and documentation at the Maschsee lake

10 Flexible and customizedLOGO! optimizes the control and monitoring of hydraulic drilling systems

14 To new horizonsSimatic S7-1200 with firmware V2

16 Self-suppliersSimatic S7-1200 and umes Energy-Manager make households more independent of the public electricity grid

18 More efficient cuttingAn innovative high-pressure unit for cooling lubricants reduces production costs by up to a five-figure amount

20 Behind the steering wheel in a wheelchairLOGO! controls a device to help people in wheelchairs get into a pickup truck

22 Walk right inTIA Portal for Simatic S7-1200

24 Service and dialogue

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Heinz EisenbeissCEO Marketing and Promotion Siemens Automation and Drives, Industrial Automation Systems, Sales and Marketing

Editorial

Dear Readers:

SPS/IPC/Drives is the most important trade fair for automation

and control technology in the German-speaking part of the

world. I look forward to presenting all the innovations to our

Simatic S7-1200 microcontroller and our LOGO! logic modules to

the trade visitors here again. The addition to our LOGO! portfolio

with the 0BA7 series, which has been available since last spring,

sets a new market benchmark with its extended communication

capability. With the integrated Industrial Ethernet interface, up to

eight devices of the 0BA7 series can be networked so that their

application possibilities are considerably extended – at an

extremely favorable price. The new interfaces allow communication

with controllers of the S7 family and, in connection with Simatic HMI panels,

provide particularly efficient HMI possibilities for your LOGO! applications, with

convenient graphic and touch functionality.

Users of our smallest Simatic controller, the S7-1200, also get what they want, of

course. Apart from all the new additions to the Simatic S7-1200 hardware and

software range, this issue of GO! also presents interesting new applications such

as the Energy-Manager – a topic of keen current interest. With the introduction of

the S7-1200 to our new TIA Portal engineering framework, S7-1200 users now

have maximum ease of operation and state-of-the-art engineering – once more,

Siemens sets the market benchmark here. To make the introduction and

changeover as easy as possible for you, I would like to draw your attention to our

training offer, about which you will find information on page 22 of this issue.

I hope that we have again given you interesting ideas for your daily activities with

this issue of GO! and wish you enjoyable reading.

GO! 2/2011 3

4 GO! 2/2011

Training

Eduard Korn shows trainees Jochen Koch and Alexander Baal (from the left) their new workstations

The elomech training company of the Nuremberg Vocational Training Institute teaches technical qualifications based on typical production processes and relies on Siemens control systems in matters of automation. Trainee mechatronic technicians are now also learning the advantages of the Simatic S7-1200 in their project work and making these an integral part of their training.

The exciting project idea of training location coordinator Peter Hartig and rehab trainer Eduard Korn: In the middle of the room a training island,

with an automated production process raised at its center, and around it eight lab workstations for the budding mechatronic technicians. As a result, the newly outfitted automation room would offer the automation and visualization of a complete transfer line in addition to the use of bus systems, the speed control of motors, the pneumatic activation of cylin-ders, and programing possibilities on various systems.

Rehabilitants build a Simatic S7-1200-controlled production line

An Exciting Project

BETWEEN LOGO! AND SIMATIC S7-300

No sooner said than done. “After clarifying what the island should look like with our draftsman in March last year, the next decision was what to buy,” Korn explains. “Just at that time, Siemens launched the Simatic S7-1200 controller, and we had already worked with LOGO! and Simatic S7-300 but also with Simatic S5 and other Siemens products such as frequency converters with good results before.” The new controller then also convinced the electrician

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The Nuremberg Vocational Training Institute and elomech

The Nuremberg Vocational Training Institute is a

nonprofit retraining facility offering adult

training. The prime goal is the integration of

participants into the employment market.

Qualifications and partial qualifications in more

than 25 vocations, most of them with the

Chamber of Commerce final examination

certificate, are offered at the head office in

Nuremberg. Training as a mechatronic technician,

for example, lasts two years.

The elomech technical training company, with its

Departments Automation, Sample Construction,

Service, and Installation was founded in 2008 to

create a practical working environment on-site.

The process steps are selected according to the

vocational profiles or the specific requirements of

the area of activity.

Training location coordinator and professional educator Peter Hartig (left) and electrician and rehabilitant trainer Eduard Korn have relied on Siemens controllers for many years

at a training event. “After all, it can already be used to perform more complex tasks and train in han-dling the touchpanels that are widely in use today.” Other advantages: “Siemens also supplies training literature that we are expressly allowed to copy for our purposes,” says Korn. “The support is simply excellent when you do not understand things immediately. And we are relying on the market leader, whose control systems many of our retrainees will encounter in their future careers.”

WORKSTATIONS WITH SIGNAL LAMP

In the first part of the project, 20 rehabilitants – in addition to other training activities – assembled, set up, and wired the workstations under supervision by Korn between July 2010 and August 2011. To save resources, they processed sheet-metal plates that had already been used elsewhere in their training and then mounted a Simatic S7-1200 controller, on the left a touchpanel, on the right a signal lamp as an actuator, and on the rear a switch and the cables on each. They painted the plates and fixed them to benches, on each of which a note-book with Simatic Step 7 software now stands. Only the rough structural or graduation system was given; the budding mechatronic technicians had to do the detailed planning and implementation largely by themselves.

“One female participant planned, constructed, commissioned, and documented a sample work-station within the scope of her so-called ‘company project’ for the Chamber of Commerce examina-tion,” Korn relates. “After configuring the Simatic S7-1200, she also had to write a test program for the visualization by the touchpanel as proof that she had done and wired everything correctly.” This test program is relatively simple. When you press red on the touchpanel, the lamp lights red, when you press yellow it lights yellow, and green, green – but it all has to work first. “When we had prob-lems with the programming, Siemens helped us immediately and unbureaucratically here on-site.”

CONTROL OF TRANSFER SYSTEMS

“Other rehabilitants created a kind of light circuit with time control as they had already done before with LOGO!” says Korn. Production is now con-tinuing, as Hartig explains: “We will invest in

transfer systems so that our trainees can create the production line according to their own ideas in a second project stage.” The result will be that they can access the production line with relocations, diversions, and high rack from the individual work-stations.

The decisive factors for the rehab trainer and training location coordinator: “Here, like everywhere else, our trainees work on models that correspond on a smaller scale to those that they will find in their later working lives – for example, in the food or packing industries,” Korn says. “Closeness to reality is very important for us and we have found the right partner in Siemens in this respect,” Hartig adds. Both men are very pleased with the project to date: “The project was a final highlight for our trainees in which they could show what they had learned and which at the same time prepared them for their later working lives.”

6 GO! 2/2011

Cooling Technology

The examination board was impressed: With his Bottle Master 2000 for cooling and heating babies' bottles, the Austrian master electrician

and prospective master for cooling technology Robert Vock has found a brilliant solution – some-thing we have never had before. The principle for generating cold in the Bottle Master is similar to a refrigerator except that the waste heat created by the cold compressor is used here to prepare hot water parallel to the cooling. The concept was only previously used in this form for banked blood, which is cooled for storage but has to be warmed up before giving people blood transfusions.

CONSTANT TEMPERATURES GUARANTEED

The Bottle Master prototype contains two water baths for two bottles each, which are cooled or heated to a constant temperature. To ensure even temperatures, the system is equipped with an additional evaporator and condenser by air exchange. In this way, the given temperatures – for example, 4°C and 38°C – can be constantly achieved independently of each other in the water baths.

With the produced amount of heat, one water tank is heated by a hot gas pipe. A built-in water pump produces an artificial surface increase in the tank.

The gaseous coolant is liquefied by the emission of heat. An air-exchange register (a bypass operation) can be switched over to by means of a solenoid valve and a temperature controller to dissipate unnecessary thermal energy. The coolant is passed on to a moisture and dirt filter via a compensation tank. This is followed by a sight glass with a mois-ture indicator, and the so-called liquid line flows further to the cooling tank. This is also variably controllable by solenoid valves. The coolant is expanded to the evaporation range by a throttle component as required. The drop in pressure causes the coolant to start evaporating, and it is sucked in through the suction pipe (evaporator output) and compressed by a piston compressor.

USER-FRIENDLY AUTOMATION OF PROCESSES

The complete circuit control and digital temperature control are handled by the LOGO! logic module. It gives the commands for cooling and heating, depending on the built-in PT100 temperature sen-sors in the water tanks. In addition to the basic unit (0BA6 series), there are two digital and two analog extension modules for measuring the temperatures in the water baths and an external text display. The user enters the set-point temperatures simply by pressing a button. When one of the water baths has

An innovative masterpiece combines requirement-based cooling and heating functions for babies' bottles

Well TemperedLaborious cooling of baby food in the refrigerator and heating up on the cooker or in the microwave could soon be a thing of the past in maternity wards and day-care centers. For his master examination in cooling technology, Robert Vock designed a device that combines both functions perfectly. The innovative Bottle Master 2000 is reliably controlled by LOGO!

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LOGO! turned out to be the ideal solution for the control

Robert Vock has created a brilliant masterpiece with the Bottle Master 2000 Ph

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reached its set-point temperature, the controller switches to the bypass mode to transfer surplus cold or heat to the ambient air until both nominal tem-peratures are reached. LOGO! also monitors the pressure of the cooling bath and queries the water level sensors every half hour. In case of evaporation losses in the hot water section, LOGO! automatically feeds more water via solenoid valves.

“You only have to set up the Bottle Master and connect it to the water mains,” Vock says, explaining the user-friendly operation. “You fill up the water tanks and then set the set-point temperatures – LOGO! does the rest.” What especially convinced him were the comparatively complex, and accurate to the micro-degree, programming possibilities with the text display. “With the help of Rainer Göbel, LOGO! promoter at Siemens Austria, I was even able, in addition to the fault messages, to have tips on how to remedy these faults programmed and displayed,” Vock explains. “The compact solution also saves space and reduces the wiring require-ments in comparison with a conventional control panel. On the easy-to-operate text display, the user sees everything the device is doing at a glance and can change set-point values and pressures at the push of a button.”

MORE LOGO! FOR COOLING TECHNOLOGY

Vock is currently working as a house technician at the Vienna Siemens City administration but in a few years will be taking over his father's company, Elektro-Kälte-Klimatechnik Vock in Raggendorf, Lower Austria, which has already been using Sie-mens control components for a long time. He wants to use LOGO! even more, especially in the cooling technology: “One big advantage, for example, is the free programmability so that the switching program can be adapted individually to the customer's system conditions. If I want to extend the system later, I can just add components to the program without too great an effort.”

There is also a clear cost advantage over conven-tional controllers: “I need at least two controllers to implement a cold/heat circuit,” Vock explains. “The LOGO! basic unit already has four switches for four devices. The four contactors that I would need for a conventional solution alone would cost me more than the LOGO! module, which also gives me its switching logic and controller functions.” Vock will very soon be able to exploit the experience with his masterpiece for other innovative and user-friendly control solutions with LOGO!

8 GO! 2/2011

Measuring Technology

Data collection made easy and convenient with the memory card Si

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The Maschsee is a 2.4 km long and up to 530 m wide artificial lake in Hannover. It covers an area of 78 hectares and has a volume of 1.6

million m3. The lake was built in the 1930s as a catchment for the spring floods of the Leine River and to allow more flexible use of the Leine valley. Today it is a popular leisure spot that attracts espe-cially people interested in water sports.

The lake was not connected directly to the Leine because this would have soon caused a sludging problem. It is purposely above the water level of the river and is supplied with water from the nearby Ricklinger gravel pits by a pump station. Here, three pumps pump about 100,000 m3 of water a month into the lake from March through October and therefore keep a constant water level, which would otherwise drop up to 2 cm a day due to the contin-uous evaporation and seepage.

SIMPLE TASK, COMPLEX SOLUTION

The actual pumping process is controlled manually and depends on the current water levels in the gravel pits and in the Maschsee. In addition, the water authorities' approval demands proof of the amount of water taken from the groundwater. The City of Hannover has installed a small measuring station to measure the daily amount of extracted groundwater and the current water levels.

The measuring station collects all the data required for the documentation of the pumping process. Two level meters provide information about the current water level of the two bodies of water. An inductive flow-meter in each of the three pumps supplies counting pulses that record the pumped amounts of water.

These values used to flow into a PLC, where they were time stamped and converted into digital form. The

LOGO! replaces a complex system for level measurement and documentation at the Maschsee lake

Smaller, Easier, BetterWhat previously demanded complex programmable logic controller (PLC) solutions can now often be achieved with a simple, small controller. This is demonstrated by an example at the Maschsee lake in Hannover. Here, a fairly complex combination of PLC, PC, and special software was quite easily replaced by a Siemens LOGO! logic module.

GO! 2/2011 9

Maik-Ulrich Schmidtmann, S&A Schaltanlagenbau (left), and Berno Jünemann, City of Hannover, in front of the new space-saving solution with LOGO! in the measuring station

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actual documentation then took place in a notebook in which a specially developed program was running to collect and prepare the data and save it in Excel table form. A city clerk used the notebook at regular intervals and saved the table to a disk so that the recorded values could be included in a report for proof to the responsible authorities.

EASIER IS BETTER AND LESS EXPENSIVE

At the beginning of 2011, the time came to change the notebook. “But that was easier said than done,” says Berno Jünemann of the City of Hannover Civil Engineering Department. “The application on the notebook was still running with Windows NT, an operating system that is no longer sold. The soft-ware would not run on a new notebook with Win-dows 7 and would therefore have had to have been completely rewritten.”

They therefore contacted S&A Schaltanlagenbau in Garbsen, where they spoke to Maik-Ulrich Schmidt-mann. S&A was founded in 1992 and has since established itself extremely successfully in the instrumentation, control, and automation market. One aspect of this is water treatment, in which S&A is today considered an expert partner for communi-ties and interest groups. Schmidtmann remembers: “My first impression was that a relatively simple problem was being solved with rather complex technology at the Maschsee. There just had to be a better way.”

The solution came from Siemens and consisted of an intelligent logic module from the LOGO! series. These modules provide a cost-effective solution for simpler automation tasks, in many cases eliminating the need for a complex PLC with its programming and implementation expenses. The LOGO! module of the 0BA7 series used at the Maschsee offers a choice of 43 integrated logic functions that can be linked with up to 400 blocks. A simple programming system makes the programming very fast. There are several function keys and a display that can show fours lines of 32 characters each for local operation.

In order to document the groundwater extracted for the Maschsee, a single LOGO! module is sufficient to replace the existing system of a PLC and note-book with evaluation software. “Replacing the notebook and writing new software would have

cost about 5,000 euros. The LOGO! solution only cost 200 euros,” Schmidtmann points out. He con-tinues: “Such a logic module can also be pro-grammed in no time and supplies exactly the infor-mation we need for this application.”

The integrated memory card slot of the logic module was particularly interesting here. The col-lected data are simply written as a CSV file on a Secure Digital (SD) card from which the necessary Excel table can easily be created.

The LOGO! logic module looks a little lost in the large measuring station control cabinet. The steel box that used to house the notebook is now empty. But the new solution is not only a lot cheaper. It is also easier to handle: “With the low data volume concerned, it is enough for an employee to stop by once a month and simply change the memory card,” Jünemann confirms.

WHERE SIMPLE IS SIMPLY BETTER

The City of Hannover is in the same situation as many other communities and interest groups. There are a number of applications in which something has to be monitored, recorded, or controlled. The sites concerned are often far away from any com-munication infrastructure but the tasks to be solved are really quite simple. Data transmission or tele-control are usually too expensive and a full-fledged control system too complex.

This is where the small controllers from the LOGO! series come in. They have a modular structure and are inexpensive, even though they are capable of performing greater tasks. The City of Hannover Civil Engineering Department is therefore already consid-ering how the experience gained from the Maschsee project can be applied to other projects. Sometimes “Think small” is exactly the right solu-tion.

10 GO! 2/2011

Mechanical Engineering

AGBO GmbH uses LOGO! for the automation of its drilling rigs. The rigs meet the customers' many different requirements cost-effectively and reliably.

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LOGO! optimizes the control and monitoring of hydraulic drilling systems

Flexible and Customized

GO! 2/2011 11

Long decades of experience have made AGBO GmbH one of the leading manufacturers of mobile near-surface drilling gear. In addition to

the hydraulic drilling rigs, the company based in Wathlingen, Lower Saxony, Germany offers drill rods and components such as roller bits, hammer drills, and drill heads. The rigs are designed for various processes such as jetting, suction, hammer, core, and anchor bores and are suitable for using at depths of up to 2,000 m. They are used worldwide for providing drinking water and reducing the groundwater level but also for building ground analysis, seismographic investigations, exploration drilling, and explosive ordnance detection.

Owing to its great depth of production, the com-pany’s design department is well able to produce the different customized rigs. The drilling gear is completed by hydraulic units and controllers as well as electric cables and switch cabinets, mounted on truck chassis or caterpillar tracks and delivered. In addition to water suppliers and drink manufacturers, customers include companies in the fields of ground surveying and geothermal projects.

Until approximately a year ago, the machine manu-facturer used conventional switching technology in its drilling rig controllers. “A greater model variety with increasingly shorter order cycles and higher safety demands forced us to look for a more efficient solution,” Christian Price, production man-ager and assistant to the AGBO executive, explains. Probitron GmbH in Bielefeld has been AGBO’s

partner for the electronic part for many years. Probitron’s CEO Patrick Oliver Battré suggested using the LOGO! logic module from Siemens as an alternative for drilling rig control and monitoring.

FUNCTION INTEGRATION PROTECTS AGAINST WIRING ERRORS

In the opinion of the probitron CEO, the controller offers a number of alternatives. “LOGO!’s functional variety makes it ideal for implementing reliable automation solutions. All settings are made on the PC and transferred to the system. The logic module enables a simple and space-saving installation, short installation time, and fast programming, and it protects against wiringerrors by the function integration. It also saves the parameterization of conventional components such as timers, relays, diodes, counters, and contactors,” Battré explains.

Price points out that AGBO does not produce in series but makes customized drilling rigs from standard components according to the modular principle. Every system consisting of motors, gears, pumps, winches, rotary heads, drilling towers, and chassis is practically a prototype. The junction boxes also vary from model to model because different customers always ask for different sys-tems. “If functions need to be adapted or extended, this entails great effort with wired logic. In the worst case, the existing junction boxes must be replaced by bigger ones because they are too small. By comparison, program logic can be changed with a few mouse clicks,” says Battré.

“The implementation of the switching and control technology is now much easier. After the installation in the junction box and loading of the programs, the logic module is immediately ready to work,” say Christian Price (left), assistant to the AGBO executive, and Probitron CEO Patrick Oliver Battré.

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Mechanical Engineering

» Our experiences with LOGO! are all positive.«Christian Price, Production Manager, AGBO

Four of the eight digital inputs that are available on the hardware side can be used as analog inputs and four as fast counting inputs. With program memory for 400 function blocks, the logic modules in 12/24 V-DC technology offer sufficient capacity for indi-vidual applications. Up to 50 four-line message texts, which show all relevant machine parameters clearly, ensure convenient, practical operation. The device has an Industrial Ethernet interface, which serves as a programming interface and for commu-nication with other controllers. It is also equipped with a slot at the front for inserting SD memory cards.

CONTINUING TO WORK IN THE USUAL CONFIGURATION ENVIRONMENT

Extension modules make it possible to extend the devices to 24 digital inputs, 16 digital outputs, 8 analog inputs, and 2 analog outputs and to plug them to the LOGO! without additional wiring. In combination with the LOGO! Soft Comfort program, the programming, simulation, and documentation can be performed by drag and drop. Changes to the process parameters can be made directly in the display of the logic module. The performance range with regard to the number of I/Os and the program capacity can be extended by networking so that users can continue to work in the usual configura-tion environment without changing over to more complex controllers.

LOGO! Soft Comfort allows the drawing of contact and function plans by selecting practical function blocks and connecting them by drag and drop. No programming language has to be learned for this. The programs can be simulated and tested offline on the PC. The software also supports the docu-

mentation with switching programs, comments, and parameter settings. Macros can be used and libraries created and reused for recurrent program sequences. Individual function blocks can also be exchanged without having to draw new connec-tions.

“Customers want more and more functionality in the drilling rig systems, which makes conventional switching systems more complex. This produces a greater volume and often also a greater weight. The space and loading capacity on the vehicles is lim-ited, however. The compactness and function integration of the logic module are therefore very welcome,” Price explains. “The controller is configu-rable for additional tasks at any time. The plug-and-play mode also allows a later performance upgrade at any time within a few minutes.”

DRILL PIPE SCREWED WITHOUT STRESSING THE THREAD

LOGO! performs the control and monitoring and detects the statuses of the drilling gear by proximity switches. For example, the mast head of the drilling rig must be folded down first when relocating. The mast is retracted and placed on a vehicle carrier. The controller detects faults in the processes and reports them immediately with an alarm signal. Another function controls the rope laying mecha-nism installed for working with the drilling tools. A hydraulic cylinder in which proximity switches are installed is fixed to the top end of the mast for this. They control the valves and ensure that the cylinder moves in and out in rapid sequence.

Functions such as “screw pipe” and “loosen pipe” are also triggered by buttons and controlled by LOGO!

GO! 2/2011 13

The “screw pipe” function ensures that the rotary head turns slowly in aclockwise direction at a defined speed and the drill pipe screws with the preset thrust without stressing the thread. In the “release pipe” function, the rotary head turns in the opposite direction and the thrust acts upward. A lower or higher pressure of the drilling gear is also necessary depending on the nature of the ground. The respective setting is made with the “contact pressure control” function.

If a drill pipe has a total weight of 20 t but a drilling head may only move down with a pressure load of 1 t to avoid damage to the pipe, operation takes place with a counteraction of 19 t. In this case, LOGO! controls the hydraulic valves and ensures constant load compensation. Checking of the fan for the gear oil cooling is also the job of the logic module and is controlled by thermal switches.

RELIABLE, TROUBLE-FREE USE

Despite the high mechanical loads and difficult ambient conditions to which the drilling rigs are

sometimes exposed in operation, the logic modules operate very reliably and trouble-free. If conventional technology were used, all the electrical components would have to be mea-sured in a service case. This could make the localization of the error source very time-inten-sive. With LOGO!, the central control unit is simply changed, loaded with the existing pro-grams, and restarted.

“Our experiences with LOGO! are all positive. The operation of the drilling gear has not changed. The implementation of the switching and control technology has been considerably simplified, however, which in turn has an effect on the work time and costs. The savings on material and weight with the changeover from wire to software logic are also tremendous,” AGBO's Price sums up. Probitron CEO Battré underlines the uncompli-cated commissioning: “The device is unpacked, mounted on the DIN rail, and connected to the power supply. The device is fully functional after wiring the inputs and outputs and loading the programs.”

The settings of the logic module ensure that the rotary head screws the drill pipe with the preset thrust without stressing the thread

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New Products

The micro-PLC features extensive communication possibilities

Simatic S7-1200 with firmware V2

To New HorizonsThe new firmware V2 lends the innovative Simatic S7-1200 system a functionality that could previously be found only in higher-performance-class controllers. But it is still inexpensive, simple, modularly structured, and very compact.

One of the great advantages of the new firmware is the total integration in Totally Integrated Automation (TIA). TIA significantly

simplifies the engineering. The TIA Portal software, as a central engineering framework, covers the entire lifecycle of the machine or plant: from the planning and design phase through configuration and programming to commissioning, operation, and upgrading. With its emphasis on integration and adapted interfaces, the software enables a uniform data storage process throughout the entire engi-neering process. Control technicians and program-mers now also have standardized engineering tools for all automation systems and applications at their disposal in the field of microautomation. This reduces training expenses, supports the development and application of engineering expertise, and contributes to faster and safer engineering processes.

DISTRIBUTED ARCHITECTURES AND MASTER COMMUNICATION

With the new firmware, the controllers can now be used as Profinet RT Masters with full Profinet func-tionality. This includes wireless Industrial Ethernet communication, time and event-controlled archiving, and web server access. The Simatic S7-1200 also has unrestricted Profibus DP Master capabilities for

connecting to distrib-uted I/O systems such as Simatic ET 200 and other distributed com-ponents and enables device diagnostics via the Profibus network. The micro-PLC can be used accordingly as a

low-cost controller for distributed architectures in machines and plants.

One new feature is the integration of the AS-Inter-face into the TIA Portal environment. The integra-tion of the Simatic S7-1200 into AS-Interface networks is enabled by an AS-i communication component. In this way, simple point-level archi-tectures such as lamp columns and push-button stations become part of TIA.

TELEMONITORING, TELECONTROL, TELEMAINTENANCE

Typical applications of simple automation systems are, for example, lifting systems. The systems are usually far-ranging and have no fixed connection to the plant operator’s control center. Thanks to the new GPRS module, the Simatic S7-1200 can commu-nicate with master systems via public networks, which also enables telecontrol and telemainte-nance. The controller can be programmed so that operators can be alerted to critical conditions or failures by short text messages. If the service pro-vider allows fixed IP addresses in the network, the Simatic S7-1200 can also provide machine-machine or system-system communication via GPRS. But the machine-machine control can also be provided without fixed IP addresses if the telecontrol server is set up as an exchange server that exchanges control commands in both directions. In any case, suitable protective measures such as IT security, for example, 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 www.siemens.com/industrialsecurity).

GO! 2/2011 15

The new Simatic S7-1200 offers more functions and applications – and yet it still remains an economical, compact and modular micro-SPS

The CP1242-7 extension module enables the sending of alarm signals via public mobile radio networks

S7-1200 withCP1242-7

S7-1200 withCP1242-7

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TYPICAL TASKS PERFORMED EASILY

The upgrade also improves the user-friendliness and the technical possibilities when the controller is used together with HMI and SCADA systems. The micro-PLC has a new communication channel for HMI systems. Symbolic addressing enables real-time data access and a panel download is no longer necessary after changes to the PLC data structure. The system also offers simple time synchronization for the Com-fort Panel and the Simatic S7-1200 controller and supports the system diagnostics. The programming performance is considerably improved and applica-tions can be implemented with the aid of high-level programming languages such as SCL and extensions. Another advantage is in the easier exchange of the program code between all controllers of the Simatic family, including PC-supported systems. This creates additional synergies and scaling capabilities both in the engineering and in the operation.

MOTION CONTROL AND PROCESS CONTROL

More convenient operation was also one of the key aims in the improvement of the motion control. A Motion Wizard offers integrated technology func-tions for the operation of stepper motors and servo-motors with pulse interfaces. The wizard offers tools for configuration, commissioning, and diagnostics in the Step 7 Basic engineering system for the “axes” technology object. The motion control commands in the user program are based on PLCopen, an interna-tionally recognized standard for motion control. The axes and drive functions can be checked or the axis moved manually with the control panel. Status bits serve for monitoring the status and error messages of the axis and the motion status for monitoring the motion commands of the axis.

The micro-PLC is equipped with an easy-to-operate PID wizard for simple control tasks. In addition to a two-step controller, a three-step PID (proportional-integral-derivative) controller is available in the Simatic S7-1200. This enables a basic overview of tendencies to display process data such as nominal and actual values. The tools for configuration and commissioning are provided by Step 7 Basic for the technology object “PID controller.” PID commands are provided in the user program for configuration of the PID controllers for manual control and also with self-optimization functions.

With its comprehensive properties and functions, the Simatic S7-1200 can take on tasks that were not previously possible in microautomation. Thanks to its modularity, the system can easily be adapted to the requirements and requires little space in the switch cabinet. The Simatic S7-1200 can be expanded into an extremely powerful control system that offers the unlimited scalability and interoperability of modern automation systems but at the same time can still be used at an extremely attractive price as a very simple controller for very simple applications.

16 GO! 2/2011

Self-Suppliers

Inventive minds: Thanks to the Umes Energy-Manager, Udo Mürle (left, with his partner Martin Jaiser) can use up to 85 percent of the electricity generated by the photovoltaic system installed on his garage roof himself

1) Umes® is a registered trademark of Umes Independent and Mobile Energy Systems, Pforzheim

The idea is as obvious as its implementation is ingenious: If I do not want the energy generat-ed by my photovoltaic system to be fed into

the electricity grid but want to use it myself, which makes me more independent of electricity from the grid, I need meters, storage batteries, inverters, and a control system. “Our Umes1 Energy-Manager mea-sures the total electricity generated by the photo-voltaic system just as accurately as the electricity consumption in the building,” explains electrical en-gineer Martin Jaiser, who designed and developed the innovative device together with his colleague Udo Mürle in Pforzheim over many years. “If the photovoltaic system generates more electricity than the household can use, the device taps the surplus electricity from the central electricity distributor in

real time and saves the difference in storage batter-ies via the inverter. If the house uses more electrici-ty than the photovoltaic system can provide, the Umes Energy-Manager feeds the exact difference back into the house network.” The inverter trans-forms the 48 V DC voltage of the storage batteries into the 230 V AC voltage of the electricity network and vice versa.

85 PERCENT OWN USE IN SUMMER

Feeding electricity into the grid and drawing elec-tricity from the public electricity network are re-duced as far as possible. This offers private house-holds very concrete financial advantages: They become more independent of their provider's elec-

Simatic S7-1200 and Umes Energy-Manager make households more independent of the public electricity grid

Self-SuppliersIn times of rising electricity prices it is becoming increasingly attractive to generate and use one's own electricity. In connection with a photovoltaic system installed on the roof, the Energy-Manager from Umes Independent and Mobile Energy Systems can considerably increase the amount of self-generated electricity for home use. The processes are controlled by the Simatic S7-1200.

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The simple installation is one of the Umes Energy-Manager's greatest strengths

tricity prices and receive – for systems up to 500 kWp – a self-sufficiency payment from the net-work operators according to the German Renewable Energy Sources Act (EEG): “Together with the saved network electricity, the self-sufficiency payment adds up to a savings of four to eight cents per kilo-watt hour depending on whether the household us-es up to 30 percent or more than 30 percent of the generated electricity itself,” says Jaiser. “He is better off than when feeding in in any case.“ But the 30 percent can only be “cracked” with a power stor-age unit. “With my own Umes Energy-Manager I use 85 percent of the generated electricity myself in summer,“ says Mürle, putting a figure to the impres-sive result. “Five to 10 euros electricity costs per month – that's not easy to beat.”

One great practical advantage of the Umes Energy-Manager is the simple installation, which makes ret-rofits easy. A main line only has to be laid from the meter cabinet to the subdistribution board of the device, plus the connection of inverter, lead-acid batteries, and noncontact power sensors. “It is also quite easy to change over from a single-phase sys-tem to a two- or three-phase system ‒ you only need additional inverters,” says Mürle. Multiphase systems are of interest where there is an increased power requirement, for example, in schools and consumer markets, or if total independence is to be achieved.

INTEGRATED WEB SERVER IS VERY WELCOME

The decision for the Simatic S7-1200 in the choice of control system was driven by the good Siemens sup-port, the good price performance ratio, and above all the sophisticated Step 7 Basic configuration soft-ware in addition to the reliability of the PLC: “I was able to generate the three-phase Umes Energy-Manager from the single-phase one in a very short time, for example, because I was able to use all the previously created basic components thanks to the

uniform library concept,” says Jaiser gives. He adds a second example: “The calibration of the power sensors to the controller is also very convenient. I can start the calibration project and the target software for the PLC simultaneously on my PC and copy the generated calibration coefficients to it without intermediate steps.”

The Umes Energy-Manager incorporates a Simatic S7-1200 with CPU 1212C plus and RS 232 serial interface for communication with the inverter and the signal extension module with additional an-alog inputs for measuring the total of six power sen-sors. Touchpanels such as the Simatic Basic Panel KTP600 or KTP400 can be connected optionally but, according to Jaiser, private customers prefer to use the web server integrated into the new CPU firm-ware Version 2.0. This enables information about the CPU and the current control data (currents) to be called up on a computer with a web browser via the Ethernet cable. The safety contactors for the line contactor and the surface-mounted distributor boxes are also from Siemens.

THE RIGHT PRODUCT AT THE RIGHT TIME

The first systems, which went into operation in May, are running absolutely reliably. “We have the right product at the right time,” Jaiser say. He is accord-ingly optimistic that he will sell several hundred sys-tems in the coming year.

And the development is not over: “We are currently testing alternative battery technologies, for exam-ple, with lithium iron phosphate and want to consid-erably expand the web server with design assistance from Siemens,” says Jaiser. “Some of our customers also want us ‒ as the real measuring intelligence in the system ‒ to take over the data entry and ar-chiving of their photovoltaic systems,” his partner Mürle adds. And both these inventive minds can en-visage cooperation with Siemens very well here.

18 GO! 2/2011

Mechanical Engineering

The inner values integrated compactly: combiloop CL3

The combiloop high-pressure units for cooling lubricants increase production efficiency and the quality of the output for turning, milling, and drilling processes. With the combiloop CL3 the hydraulics specialist Müller Hydraulik now sets new standards in design, performance, efficiency, and sustainability. A Simatic S7-1200 micro-PLC is the brains of the innovative high-pressure system.

The appearance and space-saving structure of the combiloop CL3 high-pressure unit for cooling lubricants already mark it as a miracle

of efficiency that can be perfectly integrated into any production system as an add-on unit. The functional components – including a self-cleaning automatic filter and a 130-liter clean liquid tank – are housed in a modern chassis and are integrated extremely compactly. Thanks to the automatic filter technology, filter units up to 30 µm and integrated substream filtration of the machine tank are no longer a problem. The innovative controlled pump generation offers up to 15 °C less heat input in comparison with conventional high-pressure pumps. And with very high pressures up

An innovative high-pressure unit for cooling lubricants reduces production costs by up to a five-figure amount

More Efficient Cutting

to 300 bar, even the smallest boreholes can now be projected in the cutting process.

HIGHER CUTTING SPEED, LONGER SERVICE LIFE

The principle: A transfer pump feeds the medium from the machine tool tank through the self-cleaning automatic filter into the clean liquid tank, where it is stored. Once the clean liquid tank is full, valves automatically switch the system over to bypass filtration and the cleaned medium is fed back into the machine tank. The clean cooling lubricant is fed from the clean liquid tank through up to 10 switchable outlets in solenoid valve tech-nology and via high-pressure lines directly to the

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Müller Hydraulik GmbH

For almost 20 years, Müller Hydraulik GmbH in

Villingendorf, Germany, has combined classic

plant and assembly construction with reliable and

professional services. Today, with a staff of 16

people, the company continues to build up and

expand its expertise in the project business in

control technology and in the development and

production of innovative system solutions. Both in

special assemblies and system solutions and in the

repair and maintenance of hydraulic systems –

customers throughout Europe benefit from the

company's capabilities in all things hydraulic.

internally cooled tools of the machine, revolver, or spindle, wherever the high pressure is currently needed. Chips are therefore broken off and rinsed away at the tool blade and there is no need for time-consuming clearing.

The high-pressure processing is the big advantage of the add-on unit: “Such high-pressure systems are mainly used in large series production with auto-matic longitudinal lathes and fine cutting,” says Martin Müller, one of the managing directors at Müller Hydraulik GmbH responsible for sales and marketing. “Where intricate parts are produced, for example, for the watchmaking and medical industry, for titanium, very hard alloys, or deep boreholes in one action, there is no way to do without them.” They increase the step speeds in cut-ting, productivity, and tool service lives, among other things, the latter up to 15 times, which may mean a five-figure cost saving in the production process. And they increase the surface quality and thus the quality of the output “in passing.”

EASY OPERATION, HIGH FLEXIBILITY

All processes are controlled by an enclosed Simatic S7-1200 with CPU 1212C, supplemented by two digital signal modules and combined with a Simatic Basic Panel KTP400 integrated into the chassis. Constantly in connection with the machine con-troller as a standard interface or with a machine-specific interface, it monitors the filling level in the clean liquid tank and switches on the high-pressure outlets sequentially or simultaneously as required. It checks the feed pump that sucks in the soiled medium, gives the command for automatic cleaning of the filter, and communicates the operating state of the device.

“The controller convinced us with its price perfor-mance ratio, the much simpler parameterization and operability with the touchpanel, and finally with the flexibility that it offers via the link to the machine tool,” Müller explains. In this way, pressure stages can be programmed for the individual out-lets, which can then be called on the touchpanel display. With a suitable machine tool, the customer can conveniently enter in the machine program which cutting type or which processing step he or she wants to use with which pressure.

“Another advantage is the visualization,” Müller points out. “For example, alarm messages can be displayed much better and are very easy to acknowl-edge. The pressure can also very easily be measured and adjusted intermediately on the touchpanel. We were therefore able to omit an additional pressure gauge.” The new solution also has advantages for the manufacturer Müller Hydraulik itself: “We can start and run our test programs very easily with the touchpanel prior to delivering the systems,” says Müller.

POSITIVE EXPERIENCE, GOOD SUPPORT

Müller Hydraulik has already had positive experi-ence with the Simatic S7-1200 in the combistream, an integrated combination of high-pressure unit and chip conveyor, in which even more complex auto-mation tasks had to be performed. “After that, the decision to also use the controller for our best combiloop was obvious, especially as the support from Siemens is also excellent and the components are available worldwide,” Müller explains.

The delivered systems are running perfectly. “The controller leaves us possibilities to extend the functionality of the combiloop, for example, in the area of the sensor technology, and to visualize it with the touchpanel,” says the managing director, taking a look into the future. His company is now planning to equip other system series with fre-quency converters from Siemens.

20 GO! 2/2011

Waiting for its driver: GMC Sierra pickup truck converted for drivers in wheelschairs

he wrote an e-mail to Kraig Schlosser, a good friend and mechanic: “If we can get a wheelchair behind the steering wheel of a pickup truck or an SUV we will have a huge success.” But it turned out to be harder than he thought. Pickup trucks and SUVs do not really have the space or the technical prerequi-sites to be converted for people in wheelchairs. But that did not stop Kitchin and Schlosser from trying out various possibilities. The two of them began studying the offers of local dealers for unusual vehi-cle features. “Instead of looking at the outside or in-side of trucks, we were crawling underneath them to measure the chassis,” Kitchin explained with a laugh. They came across two models, the Chevrolet Silverado and GMC Sierra Extended Cab 4×4, which were built in Fort Wayne.

A DREAM COMES TRUE

Kitchin exploited his friend's car-building talent and began converting his fi rst pickup for wheelchairs in

LOGO! controls a device to help people in wheelchairs get into a pickup truck

Behind the Steering Wheel in a Wheelchair

In 1999, the life of 33-year-old advertising manag-er Steve Kitchin changed dramatically. He was sit-ting in the back seat of a customer's car on a busi-

ness trip when the car swerved off a bend on a winding road in North Carolina and hit a tree. He had spent his whole life in Fort Wayne, Indiana, played semi-pro softball, and loved sport – karate, basketball, boating, skiing, and working out in the gym. “After the accident I was totally dependent on friends and relatives from one second to the next,” Kitchin said about the diffi culties in the early days of his paraplegia.

THE CHALLENGE OF MOBILITY

One of the problems he had to deal with: He could not get behind the wheel of his car without help. “In the fi rst six months, friends helped me and put me in the driver's seat so that I could move about,” said Kitchin. For the next nine years, a minivan then played the main role in keeping Kitchin mobile and allowing him to continue working in the adver-tising profession. “In 2009, the car was fi nished but I didn't want another minivan,” Kitchin continues. So

Pickups converted by GoShichi for drivers in wheelchairs are giving disabled drivers in the United States new mobility. The device for helping them get in is controlled by LOGO!.

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Steve Kitchin shows how it works A look into the cockpit The control center of the wheelchair lift

Vehicle Construction

a workshop. “We cut into the vehicle, two welders fabricated parts, and a couple of months later we had a truck I could drive in a wheelchair,” Kitchin said. “When I fi rst got into the truck, I just couldn’t stop smiling. My dream had come true. I knew right then we had to build a bunch of them to help other disabled drivers experience the same freedom.”

Kitchin and Schlosser were in business with their company GoShichi, named after their softball jersey numbers and karate class nicknames. The new assembly line ran into an early setback when the imported 12 V programmable logic controller (PLC) running the critical pickup truck door and wheelchair lift operation was suddenly unavail-able. “We had built 20 pickup trucks that were sitting here without control systems,” Kitchin ex-plained. Then things suddenly came to a standstill. “We adapted quickly and found a replacement, but we needed a converter and more moving parts,” he continued.

RELIABLE CONTROL OF THE DOOR LIFT APPLICATION

GoShichi was committed to developing a highly re-liable automatic system for pickup trucks und SUVs with which people in wheelchairs could get into their vehicles. They required a reliable controller for this. The 12 V LOGO! logic module with built-in HMI now controls and monitors GoShichi's complex door lift application with a new level of reliability. “The Siemens team helped us with the program-ming of LOGO!, which is smaller and better than the previous solution and fl exible enough for future developments,” Todd Brown, electrical engineer at GoShichi, explained. “Service, support, and the in-novative solutions of Siemens are unique,” Kitchin added. His company is now preparing to meet the demand in North America and beyond. “Siemens'

automation and control platform has a good reputa-tion all over the world. It helps to give us credibility and worldwide acceptance and grants us the reli-ability that we need to expand our business to new regions,” Kitchin explained. He has already shown groups from the Middle East, including Israel and Abu Dhabi, around the plant. “We will be shipping accessible pickup trucks to the Middle East and the Siemens control solution is enabling us to expand with peace of mind.”

QUALITY AS A DRIVER OF SUCCESS

“As it turns out, there are a lot of disabled drivers searching for alternatives to the traditional accessi-ble minivans that have their shortcomings,” said Kitchin, pointing out one of his parking pet peeves. “Many of the older vehicle lift systems require at least eight feet of clearance. If other cars park too close, you can actually be blocked in or out of your own vehicle.”

“The reliability of LOGO! has exceeded our expecta-tions,” said Brown, claiming the company has yet to encounter problems with the controller. “Much of our business is driven by word of mouth, and Sie-mens' quality has proven to be a real driver behind our success,” added Kitchin. “Once the door is shut, you would never know the truck is designed for a disabled driver. It’s that seamless,” said David. “GoS-hichi and Siemens have developed a solution that gives disabled drivers an alternative to conventional systems and gives them more freedom.” “Necessity is the mother of invention,” said Kitchin, who also wants to offer the Chevy Suburban SUV with GoShi-chi as soon as possible. “As we add new trucks and SUVs to our lineup of accessible vehicles, it’s great to know we have the control system in place to meet our future needs and the demands of disabled drivers everywhere.”

22 GO! 2/2011

Further Training

The Totally Integrated Automation (TIA) Portal for Simatic S7-1200 forms the working environment for standardized engineering with Simatic Step 7 Basic and Simatic WinCC Basic. Sitrain, the Training for Industry, offers two courses to help users learn about the installation and assembly, programming, and diagnostics of the Simatic S7-1200 controllers in this new environment.

TIA Portal for Simatic S7-1200

Walk Right In

Siemens Totally Integrated Automation Portal

Totally Integrated Automation PortalSTEP 7 V11 WinCC V11 StartDrive V11

SIMATIC Controller SIMATIC HMI SINAMICS

GO! 2/2011 23

Contents of the Simatic S7-1200 basic course

p Overview and essential features of the SIMATIC S7-1200 system family

p Components of TIA Portal: SIMATIC STEP 7 Basic and WinCC Basic

p Program processing in the automation system

p Binary and digital operations in function plan (FUP)

p Installation and assembly of the SIMATIC S7-1200 automation system

p Addressing and wiring of the signal modules

p Commissioning of the hardware and software of the SIMATIC S7-1200 with TIA Portal

p SIMATIC S7-1200 hardware configuration and parameterization

p Presentation of the touchpanel

p Saving and documentation of executed program changes with TIA Portal

Contents of the Simatic S7-1200 advanced course

p Hardware diagnostic functions of TIA Portal in the SIMATIC S7-1200 automation system

p Software diagnostic functions of TIA Portal in the SIMATIC S7-1200 automation system

p Application possibilities of different component types (FC, FB, OB, DB)

p Presentation of the SCL programming language

p Commissioning of the distributed I/O devices on Profinet IO

p Commissioning of a WinCC project

p In-depth study of the contents by practical exercises on the TIA system model

p Technology functions, PID controllers, and drive functions

The Simatic S7-1200 basic and advanced courses teach practical know-how

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Both courses are held as blended learning courses, that is the courses combine training on the Internet with a three-day attendance

course. The course participants receive web-based training to prepare for the attendance course and increase their learning from the attendance course. The theoretical knowledge learned in the courses is intensified by numerous practical exercises on a TIA system model so that optimum learning is guaran-teed. And prospective participants can test whether they are satisfied with their state of knowledge in these courses in an online beginners' test before applying.

THE SIMATIC S7-1200 BASIC COURSE

In the “Simatic S7-1200 Basic Course” (short title: TIA-MICRO1 intensification of the contents by practical exercises on the TIA system model) the handling of TIA Portal is taught as well as basic knowledge of the structure of the Simatic S7-1200 automation system, the configuration and parame-terization of the hardware, and the basics of pro-gramming. The course participants create, change, and extend small Simatic Step 7 programs in order to be able to reduce downtime in the future. An overview of the HMI rounds off the course.

THE SIMATIC S7-1200 ADVANCED COURSE

The “Simatic S7-1200 Advanced Course” (short title: TIA-MICRO2) deals with programming in SCL, linking of drives, use of the TIA Portal diagnostic tools, and Profinet IO. In addition, the course partic-ipants are introduced to technology functions of the Simatic S7-1200 system, for example, PID controllers and drive functions.

24 GO! 1/2011

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Publisher: Siemens AG, Sector Industry, Industry Automation, Automation Systems, Sales and Marketing, Gleiwitzer Str. 555, 90475 Nuremberg, Germany Tel.: +49 (911) 8 95-48 11, Fax: +49 (911) 8 95-27 86 Editorial Responsibility: Heinz Eisenbeiss, I IA AS S MP In-house editorial staff: Eva-Maria Blockus Publishing House: Publicis Publishing, Erlangen, Germany Editorial staff: Robert Engelhardt Layout: Kerstin Rosenow Copy editor: Marion Schwab DTP: Mario Willms Printed by: Wünsch, Neumarkt, Germany GO! appears twice a year ©2011 by Siemens Aktiengesellschaft Berlin and Munich. All rights reserved. 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 upon in the terms of contract. S7-300, S7-1200, Siemens LOGO!, SIMATIC, SIMOTICS, STEP, TIA Portal, WinCC are registered trademarks of Siemens AG. If trademarks, technical solutions, or similar products are not listed, this does not imply that they are not registered. All other products and system names may be trademarks of their respective owners and must be treated accordingly.

SPS/IPC/DRIVES

You have questions ‒ we have the answers!

In 2011 Siemens is again inviting you to come and see new products, systems, and solution concepts at SPS/IPC/Drives. At the Siemens booth in Hall 2 we will be

showing you how we can make automation and drive technology easier and more efficient, increase the productivity of your plants, and sustainably improve your competitiveness. With TIA Portal, the innovative engineering framework, we signpost the way to the future of modern engineering for all automation tasks. With Simotics, the range of Siemens electric motors is given a name that stands for maximum reliability and efficiency. Energy-efficient production is at the same time a challenge and an opportunity. We show you the right products with which you can save energy and reduce costs. A new distributed I/O system and new possibilities for industrial communication are further highlights at this year's fair.

At www.siemens.com/sps-fair

you can also find out about the highlights and trends directly from the fair and take part in all the activities at our booth online.

Live or at our web sites: You are very welcome.