INTERVIEW: USER-FRIENDLY MEASUREMENT TECHNOLOGY TO GO / Page 16

SHINING A LIGHT ON PROCESSES – REVEALING POTENTIALS / Page 12

SIX SIGMA: OPTIMIZATION COMES FROM THE BOX / Page 08

direct industryInformation for Electrical Engineering and Industrial Automation November 2015

Photo: ©iStockphoto.com/cherezoff

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Compact, Fast, Secure: Modern Automation with the PFC100 Page 04

“To Respond More Directly and Individually to Customer Requests” Page 07

Six Sigma: Optimization Comes from the Box Page 08

Shining a Light on Processes – Revealing Potentials Page 12Using Six Sigma to Attain (Virtually) Error-Free Operation Page 14“Reliable Data is the Key to Increasing Energy Efficiency” Page 15User-Friendly Measuring Technology To Go Page 16Transparency on Tour Page 18

Uncovering Potential for Improvement: Using the Mobile Measurement Kit Page 21

An Expanded Offering: The WAGO-I/O-SYSTEM 750 XTR Page 24

For All Essential Applications: The New EPSITRON® ECO Power Supplies Page 25

PFC200 Communicates via Mobile Network Page 25

Your Machine Needs a Business Card Page 26

Legal Information Page 28

CONTENTS

Dear Readers,

These two paths couldn’t be more different: While many companies are easily satisfied with the energy consumption information provided on supplier invoices, others have long recognized energy efficiency as a competitive advantage and have made it a key part of their stra-tegic goals. However, an amendment to the Energy Services Act has triggered an increased industrial focus on energy and system efficien-cies. Considering that there is the potential to save up to 70 percent through effectively managing energy consumption, these “motivations applied from above” should really not even be necessary.Transparent data form the foundation for any efficiency-driven ef-fort – whether it relates to energy or to system availability. Without solid data, it is impossible to determine potential and gauge im-provements. Fortunately, the first step does not necessarily require expensive technology – cost-effective counters and temporary con-sumption measurements are providing significant, and actionable, results. If sufficient potential is identified, then permanent solutions can be installed to make long-term improvements that are guided by benchmarks and comparable load histories.WAGO has specifically configured one of its Roadshows with a practical demonstration of energy measurement technology and sent it around Europe. The specially equipped Roadshow also

has information on what kind of legislative support is available for such initiatives. After the Roadshow’s eight-city tour, it became im-mediately clear that there is a tremendous amount of interest in innovative energy and measurement data solutions. The consensus appeared to be that energy flows alone are not sufficient for com-parisons between machines and systems. Therefore, more mean-ingful key figures are required, and these are formed in connection with production and machine data.In this issue of WAGOdirect industry, you will learn how our WAGO-I/O-SYSTEM 750 ensures transparency. Then you are wel-come to visit us to discuss this – or any other topic – at international tradeshows this coming year, such as the SPS IPC Drives in Nurem-berg, Germany.

We look forward to hearing from you!

Best regards,Lukas DökelMarket Management Industry & Process

EDITORIAL

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■ The demands placed on automation systems are virtually sky high. And what is clear is that there is no jack-of-all-trades device. How-ever, a system must satisfy multiple demands to be successful. And WAGO's PFC100 achieves this by uniting high performance and safety into one compact housing.

Compact, Fast, Secure: Modern Automation with the PFC100With a real-time-capable Linux® operating system and comprehensive security packages, the compact PFC100 is a decisive contribution to IT security.

In every automation application – whether in process technology, industry or in buildings – certain primary criteria selected during planning greatly influence decisions for or against a control system. Among these variables are the type of the protection class, number of interfaces, the required cycle times or simply the price. One char-acteristic alone is seldom so crucial that all others can be ignored. Instead, a ranking usually arises out of the decision process, and

A suitable variant for every demand: the PFC100 is available with or without a supply module, with DIP switches or serial interface, with or without an expanded temperature range of ‒20 °C to +60 °C.

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there is generally no compromise regarding the top criterion. While the size of many control cabinets and boxes is not literally calculat-ed down to the last centimeter, installation dimensions are actually the leading feature in an entire series of applications.

■ Installation Dimensions as the Deciding FactorMany sectors have applications in which an automation system’s dimensions, in conjunction with satisfactory performance, are more important than all other characteristics – primarily in traditional ma-chine and equipment engineering. The demands for constant opti-mization and a growing variety of functions continuously increases the complexity of modern equipment. Automation technology must evolve as these changes grow; however, the technology can’t claim additional installation space. These demands are the most apparent in the process technology and offshore industries.For example, in contrast to conventional and self-contained system architectures, “package units” are equipped with their own auton-omous intelligence. The process-related modules, which integrate an I/O level and their part of the automation, assume various basic tasks. Transportation and integration into a complete system must be flawless, and it must be performed by a particularly space-sav-ing automation system.A prime example of this is highlighted by the limited, and ex-tremely precious, physical space on drilling rigs and ships. Engine monitoring is a typical on-board control process. For example, constantly reading machine parameters for an electronic control unit (ECU) for a compressor or power supply unit, is critical to long-term, error-free operation. Supporting technological devic-

es simply can't interfere with these primary systems. In addition, weight plays an important role in determining whether the nec-essary automation technology can be accommodated in a small housing or in a control cabinet.

■ Security Comes StandardThe demand for high-performance automation systems that have a compact footprint remains extremely high. In 2013, WAGO launched the PFC200, creating a new performance category for DIN 35 rail-mount controllers. WAGO debuted the PFC100 in No-vember 2015, which places an even greater emphasis on compact dimensions, while retaining a high level of performance thanks to a Cortex A8 processor that delivers a powerful 600 MHz. The PFC100 is available in two variants – both are a mere 62 mm wide, yet house either two ETHERNET connections with DIP switch-es (750-8101), or a serial RS-232-/RS-485 interface (750-8102). Both of these variants have 12 MB of memory that automatically divides into program code and data. This is quite sufficient for most applications, particularly because even more memory can be pro-vided through the integrated microSD slot.For machines and systems with links to a higher-level control system or remote data connections, IT security is essential. As recently as 2014, the German Engineering Association (VDMA) issued a study showing that only 57 percent of companies surveyed recognized one of the established security standards. Shockingly, fewer than one-third actu-ally used them. In 29 percent of companies, security breaches have already caused losses in production.

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These reasons are precisely why WAGO’s PFC100 is equipped with everything to supply state-of-the-art security and encryption. Users can now upgrade their controllers to meet the requirements outlined in the White Paper issued by Germany’s highly regarded Federal Association of Energy and Water Industries (BDEW), or the securi-ty catalog published by the Federal Office for Information Security (BSI-IT). The PFC100, like the PFC200, supports IT security with its real-time-capable Linux® operating system. The Linux® environment enables implementation of encryption technology via TLS 1.2 (Trans-port Layer Security). This allows an IPsec or OpenVPN connection for sending encrypted data to be established directly from the con-troller. In addition, a standard firewall provides additional protection for the PFC100 from unauthorized access.

■ Smaller and Even More EconomicalIn addition applications throughout Europe and the Americas, coun-tries in the Middle East and Asia are have become particularly in-terested in the PFC100. In India, for example, the market demands robust, no-frills machines and systems. Grain winnowers, rice grind-ers and hammer mills don't need to be optimized any further; the technology is mature and “Made in Germany” suffices.To meet demands for an even smaller and more attractively priced solution, the PFC100 is available in an ECO version. With a 50 mm installation width, it is 12 mm slimmer than its two siblings because no separate supply module is required. The 24 V power supply is provided directly to the ECO controller. A total current of 700 mA is available for the stackable bus modules, which is sufficient for many smaller applications.

■ Easy to Operate and with Integrated Software EngineeringThe PFC100 is configured using the e!COCKPIT engineering software. The CODESYS-3-based development environment (IEC 61131) is fully equipped with functions that provide faster and eas-ier operation. The “ribbon” layout, for example, offers a clear and context-sensitive menu bar that has proven effective and successful in other modern software applications. Only the functions that are directly related to the current task are visible to users. End-to-end data storage, from initial planning up through configuration, helps accelerate the engineering process.The PFC100 can be used as a standalone controller or subordinate to a control system. This flexibility combined with its technical fea-tures makes it the perfect solution for supporting Industry 4.0.

Text: Jens Krake, WAGOPhoto: WAGO

The PFC100 is compact, reliable and equipped with comprehensive security packages.

The Linux® environment enables the implementation of encryption technology via TLS 1.2.

The PFC100 is configured using e!COCKPIT engineer-ing software that's based on CODESYS 3.

Fulfilling the demands for a high-performance automation system in a compact footprint: the PFC100 Cortex A8 processor delivers 600 MHz of processing capacity.

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■ Rainer Schmutte, former manager of the regional WAGO sales of-fice in Minden, has just accepted leadership of the newly created “Sales AUTOMATION Germany” division this year. He and his team are gearing up to oversee the automation customers for all business divisions. In an interview, the 41-year-old manager, who holds a master’s degree in engineering, discusses the reasons for the strate-gic expansion of sales activities and his future responsibilities.

■ At the start of January 2016, you became the head of “Sales AUTOMATION Germany." Why did WAGO create a new division?Schmutte: We plan on meeting sales expectations and growing the automation segment with new products and solutions that are under development. This will enable us to offer the expertise of our system advisors and specialists to customers across Germany.

“To Respond More Directly and Individually to Customer Requests”With Rainer Schmutte as the point man, WAGO established a new “Sales AUTOMATION” division in 2016.

■ What goals do you have for the near future?Schmutte: In the next few years, we are going to use our automa-tion portfolio to focus more specifically on defined target markets and on applications for our customers. With the newly created sales division, we will be able to respond more directly and individually to customer requests.

■ What specifically piques your interest in this new job?Schmutte: In this position, I have the chance to establish and devel-op a division from the ground up. This is a challenge that I accept enthusiastically. In addition, I will not be managing the entire port-folio, like before, but instead I can concentrate on the automation sector – a division that I have gained comprehensive knowledge of during my 14 years in sales at WAGO.

■ Thank you for the conversation.

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Six Sigma: Optimization Comes from the Box Exact measurement data for more efficient food production.

■ Thanks to WAGO's “Six Sigma data acquisition box,” Mondelēz International has fine-tuned their production and delivery chains. The specially developed box from Minden helped the world's leading snack company increase the global efficiency (GE) of its produc-tion lines.

Through hissing and clattering, after rolling, conching, molding and packaging, the end product appears – dozens of packages of chocolates that land in large shipping cartons. Several thou-sand of these cartons leave the production line in Bratislava, Slo-vakia every day. Soon, these will be joined by a few thousand

more. “We are currently in the process of increasing the global efficiency of our production lines,” states Werner Badtke, Senior Manager of Automation & Manufacturing Systems – Global Engi-neering at Mondelēz International.Mondelēz International was created in October 2012 when Kraft Foods was spun-off into two independent companies. Today, Mon-delēz International is the leading provider of chocolates, cook-ies, gum, candies and drink powders in more than 165 countries. Around the world, consumers enjoy products from their favorite brands, like Milka, Philadelphia, Cadbury, LU and Oreo. With around 100,000 employees, the company posted pro forma

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In order to increase global efficiency on its production lines, Mondelēz International needed valid, comprehensive operating data from their systems. Using customer specifi-cations, WAGO developed the 750 Series-equipped “Six Sigma data acquisition box” to reliably provide the desired information.

revenues of more than 30 billion U.S. dollars in 2014. From the corporate headquarters in the USA, CEO Irene Rosenfeld steers the company toward further growth. In order to succeed, the pro-duction and delivery chains required additional optimization to further increase the global efficiency of production.

■ Measure First, Then ImproveProducing more with existing systems – the first steps toward this ambitious goal have already been made for chocolate pro-duction in Bratislava. This location is one that has implemented the first phase of Mondelēz International’s new process man-agement system. It is called Six Sigma. By using Six Sigma pro-duction processes, product quality should be increased over multiple steps, leading to greater customer satisfaction global-ly. Another expectation is that their production lines worldwide will become more efficient thanks to Six Sigma. “Our systems already function at a high level. We were aiming for improve-ments ranging between one and five percent depending on the unique situation at each individual location,” explains Badtke. This would be initially be achieved by reducing idle times for the machines. And the first step necessary was the establishment of a company-wide definition of key performance indicators (KPI). That involved actual values from the respective facilities in or-der to determine the reasons behind long idle times for specific machines.

Werner Badtke, Senior Manager of Automation & Manufacturing Systems – Global Engineering at Mondelēz International, “For many of our production systems, the cost advantage of the ‘Six Sigma data acquisition box’ is immense when compared to reprogramming. On top of everything, the WAGO product exceeds our expectations and was available to us very quickly.”

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Mondelēz International has 168 facilities and around 1,000 production lines. With the aid of the “Six Sigma data acquisition box” from WAGO, their efficiency will increase by one to five percent depending on the location.

It sounds simple; however, this type of data collection is difficult to obtain during day-to-day operation. There are hardly any hurdles with newer machines because they already provide a great deal of information regarding numbers of cycles, interruptions or idle times; if not, their controllers can be easily reprogrammed for this. With older machines, however, reprogramming the controllers can require extreme expenditures – if it is even possible because some systems simply don’t allow it. “It was obvious that WAGO would be an appropriate partner for solving this problem,” states Badt-ke. “The question was: how much time and cost would it take for WAGO to implement our requests.”

■ Fast, Cost-Effective and Highly FlexibleUtilizing WAGO’s 750-880 Controller, the German company de-veloped a product within a few months that not only satisfied Mon-delēz International’s exact specifications for data collection, but was also flexible enough to be used on any production line. This new product was dubbed the “Six Sigma data acquisition box.” “The ‘Six Sigma data acquisition box’ was designed to use opto-couplers for data collection. This way, we could record electroni-cally isolated signals at any system part, completely independent

from the machine controller,” explains Nils Otterpohl, Global Key Account Manager for “Food” at WAGO. Interfering signals are also guided directly to the box. Badtke expresses his satisfaction, “The solution is ideal for obtaining the desired data in real-time and doing it economically.” Another great advantage: the “Six Sigma data acquisition box” can be installed on site and config-ured in one day.At the end of 2013, the first version of the “Six Sigma data acqui-sition box” went into operation on the chocolate production lines in Bratislava. After some minor fine-tuning, the box was ready for series production at the end of 2014. Compared to the initial models, which merely processed the eight signals included in the initial customer request, the finalized product is equipped with two additional digital input modules and can record 40 signals. Thanks to the optocouplers, the box can also determine differ-ences between input and output counters to identify incorrectly produced products. Manual inputs are conveniently possible via a WAGO touchscreen. This allows systems operators to input times for cleaning or for machine conversion during a produc-tion changeover. And what's important here is that the operating interface’s language can be set to that of the operators.

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Mondelēz International optimizes the global efficiency of its production lines using the “Six Sigma data acquisition box.”

The “Six Sigma data acquisition box” provides Mondelēz with the operating data necessary for optimization.

The “Six Sigma data acquisition box” can be flexibly used on any production line.

Mondelēz International treats the world with Milka Choc-olates, Jacobs Coffee and Oreo Cookies. Werner Badtke, Senior Manager of Automation & Manufacturing Systems – Global Engineering, ensures that the existing production systems produce even more of these treats. And WAGO helps him do this with the “Six Sigma data acquisition box.”

■ Minimizing Idle TimesManagement can retrieve reasons for disruptions and other infor-mation via the box; to facilitate an overview, a list of the top five reasons for disruptions is provided. “Site managers are obtaining valid information about interruptions and their frequency from the ‘Six Sigma data acquisition box.’” They can now systematically reduce idle times based on the data,” confirms Badtke. An integral component of each “Six Sigma data acquisition box” is WAGO’s 750-880 Controller, which includes a Webserver (CODESYS OPC Server) that forwards data to higher-level IT systems at Mon-delēz International. In addition, the data is stored on an integrat-ed SD memory card in a CSV format. It is also possible to access the data using an app for mobile devices.

Because the “Six Sigma data acquisition box” is an autonomous and universal solution, it can be used at all Mondelēz International facilities globally. And this has sparked tremendous interest in the box. While the “Six Sigma data acquisition box” will not be used on all production lines, Badtke explains that, “Everywhere that re-programming is relatively expensive, difficult or not possible, the box is the best solution.” In chocolate production in Bratislava, the “Six Sigma data acquisition box” smoothes the path to higher efficiency.

Text: Nils Otterpohl, WAGOPhoto: ©studio2013/Fotolia.com, Mondelēz International,

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Shining a Light on Processes – Revealing PotentialsSpecial attention should be placed on energy efficiency and system effectiveness within industrial production.

■ Naturally, this depends on the system; however, control and monitoring of industrial production is fairly data intensive. For high-quality products to emerge from a complex production line, a great variety of sensors and actuators are required to ensure that all control values lie in the green zone. Previously, the necessary field devices had to be individually wired; to-day, I/O systems are used. When looking at energy efficiency and system effectiveness, modern automation technology can indeed provide much more than the operators have been get-

ting from their machines. This needs to change, and automation is often the best way to achieve it.

Automation technology feeds on data: sensors detect physical variables, convert them into electric signals and forward them to the controller. The controller decides which mechanical actions should be triggered by which actuators. This type of data commu-nication is commonplace in industrial automation. However, data is most often tracked “only” to achieve guaranteed production.

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While energy efficiency and system effectiveness may play a role, they are capable of much more. In addition to purely ethical and eco-nomical factors, the Energy Services Act has increased pressure com-ing from the federal government. All companies, that were no longer counted among the small or medium-sized enterprises (SME) due to their size, faced a Dec. 5, 2015 legal deadline. Prior to this date, they were required to perform an energy audit that adhered to DIN EN 16247-1, or enact an energy management system per DIN EN ISO 50001.

■ High Savings Potential for IndustryThis topic is critical to industrial operations, which consume approx-imately 45 percent of Germany’s electrical energy and are respon-sible for one-third of that nation’s greenhouse gas emissions. These statistics make it clear: successfully transitioning to greater energy efficiency depends heavily on industry. The Federal Environmental Agency estimates that there is the potential to trim electrical con-sumption by nearly 20 percent.Those who optimize their compressed air, pump and ventilation sys-tems have the best chances for savings; approximately 70 percent of industrial electrical use goes to electrical drives and connected equipment. According to a study by Germany’s IFEU Institute in Hei-delberg and Fraunhofer ISI in Karlsruhe, potential savings are tied to improving individual components, such as the electromotor of a processing machine. Better component tuning or the implementation of needs-based control and regulation were also identified as key solutions. Pumps and ventilation systems can yield particularly large savings through the introduction of variable speed drives. Put very simply: even a more precise layout of the system to fit the actual re-quirements will achieve potential savings.

■ Best Practices: BASFBASF SE in Ludwigshafen, Germany demonstrates how this type of optimization initiative can look. The company's property on the Rhine, which encompasses around ten square kilometers, is the larg-est integrated chemical complex in the world. The annual energy consumption alone is 6.2 terawatt hours (TWh), and the annual con-sumption of process steam is measured at 18.7 million tonnes. In order to cover their needs, the company operates three CHP plants of its own that include both gas and steam turbines. In light of these numbers, it is understandable why BASF began working on an en-ergy management system that complies with ISO 50001 in 2011. It took almost two years to achieve certification for all energy use at the Ludwigshafen location.The energy management system is currently the foundation on which the chemical company bases its energy-savings potentials. Steam, which one operation releases as “waste,” is now used as energy by another operation; the educts from one manufacturing process can serve as pre-cursor products for a chemical reaction in another process. These con-cepts are not new; however, the notion of an entire facility as a network and central control level – as required by ISO 50001 – meant there was potential for even greater synergies.

■ Linking Energy Efficiency and System EffectivenessEnergy efficiency is one thing, system effectiveness is another: using systematic recording and evaluating select machine and operating data, planning maintenance – among other things – may be much more precise. Continued on page 19...

Using Six Sigma to Attain (Virtually) Error-Free OperationSix Sigma is a systematic approach to process improvement; it is based on statistical and analytical methods and corrects errors in multiple steps. To accomplish this, Six Sigma relies on the statistical method of Gauss’ standard distribution, which describes errors or deviations. In this case, Sigma represents a standard deviation; Six Sigma describes the smallest deviation. Thus, if Six Sigma is achieved, then a process is virtually free of errors. The path to Six Sigma leads the phases Define, Measure, Analyze, Improve and Control. Six Sigma was developed at the end of the ’80s by Motorola. The impetus was the Japanese lean man-agement model. By the mid-1990s, the concept found global acceptance after General Electric celebrated its success. Today, Six Sigma is used by numerous manufacturing firms and service providers.

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Modernized operations within the food sector are paying increas-ingly close attention to energy efficiency. Filling and packaging are the last steps in the production chain. This is executed on complex, interlinked manufacturing lines consisting of up to 20 individual ma-chines and more than 100 drive motors for transporting containers. Energy sources are primarily composed of electrical energy (power) and mechanical energy (electrically generated compressed air).We in the department of Food Packaging Technology support the food and beverage industry with competitive research projects. We employ methods and tools that enable the rating of present energy consumption and facilitate the development of strategies aimed at increasing energy efficiency. In a joint effort with the department of the German Engineering Association that’s focused on food and packaging machines, as well as numerous mechanical engineering firms, we are working on standardizing specifications and mea-surements. These figures will focus on the energy and media con-sumption of filling and packaging machines. Our goal is enabling uniform record consumption to make it comparable.In the scope of my doctoral thesis, I developed a simulation that predicts the electrical energy consumption of packaging machines, such as in an interlinked beverage filling system. The thesis also in-cluded studies regarding increased energy efficiencies in container transport. The prediction is performed as a function of the respective operating states of individual machines within the production line, thus mapping real system behavior. To validate the models, mea-surement data from actual industrial systems was indispensable. For the current project, all relevant individual consumers on two bever-age filling lines were equipped with permanent and mobile sensors to record electrical active power, creating a reliable database.

“Reliable Data is the Key to Increasing Energy Efficiency”

Isabel Osterroth, Research Assistant in the Department for Food Packaging Technology at the Technical University in Munich.

With the aid of this comprehensive measurement data, the models could be validated and improved. These models are now available for developing user-specific energy optimization strategies.

Isabel Osterroth, Dipl.-Ing.

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User-Friendly Measuring Technology To GoOSRAM energy experts, Andreas Heyde and Frank Blase, talk about the inherent challenges of data collection within industrial production.

■ The prevailing mindset within industrial manufacturing is that sys-tems will run at full speed with virtually no interruptions, even though the process itself demands a significantly lower level of energy. Cor-rectly controlling partial load and stand-by consumption remains one of the greatest challenges when increasing the energy efficien-cy within production. In addition, Andreas Heyde and Frank Blase from the Equipment Engineering department at OSRAM explain the advantages of considering the total efficiency of one machine. In the interview, the Project Coordinator and the Measurement Tech-nology Expert spoke about new tasks for skilled electricians, condi-tion-based repair and the importance of having the entire crew on board with the project.

■ Several years ago, you developed a mobile measurement kit that you sold to an OSRAM subsidiary. Why has it been so well received?Blase: Because it is so user-friendly. An example: 80 to 90 percent of the tasks are already prepared as pre-analyses in the software. This reduces internal roadblocks and can set skilled electricians loose to perform the measurements and analyses.

Heyde: We are testing methods for breaking down the technical and engineering aspects for skilled workers – for example, with-in the scope of motor efficiency analyses of large drives. This ad-dresses the issue about where the switch to the next efficiency class provides the best results. For decisions like this, you also have to economically justify investments using key ROI figures.

■ What is the reason for bringing energy measurement data collec-tion, including analysis, to skilled electricians?Heyde: If we present measurement technology to the world as an easy-to-use measurement kit, then we will generate greater accep-tance about the entire project – even abroad. By acceptance, we mean that a firm’s skilled electrician performs all of the production analyses – not some stranger in a white coat from some remote research department.Blase: When we reach the point where machine operators know how the measurements function and what the values mean, then the enthusiasm for optimization develops on its own.

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■ Up until now, have process optimizations played a subordinate role at the machine level?Heyde: No, not at all. However, optimizations have previously had the goal of making processes faster and smoother with higher qual-ity. Aspects like energy efficiency or resource conservation have not played as large of a role in this.

■ When did rethinking this begin?Heyde: For us, a lot changed with the introduction of the energy management system per ISO 50001 – of course, it was initially met by several with a great deal of skepticism.

■ Why is that?Heyde: Simply from the fear that the energy manager would come down and set the adjusting wheels, without our input, to ensure that the manufacturing processes saved energy at the expense of quality.

■ Do you have a specific example in mind?Blase: Let’s take vacuum pumps, which generally run at 100 per-cent. Manufacturing experience says that it has to be this way so that the lines don’t get contaminated – even on weekends. We scru-tinized this and considered what would happen if we switched the vacuum off during production interruptions, or reduced the power for smaller lamps, because there is not as much to remove from the smaller glass bodies. There was a lot of asking, “Why?”

■ And how could you convince them?Heyde: By not just considering the energy savings; we looked at the total machine efficiency. For the vacuum pump, a lower speed means a longer lifespan for all of its seals, which in turn extends the maintenance intervals. These results motivated everyone, because it yielded benefits for everyone.

■ However, this meant that you had to strategically include your col-leagues; doesn’t it?Heyde: Absolutely; nothing functions on the machines without our skilled workers. Afterall, they are the ones who know the production processes the best. We sought to use their experience and expertise in the process as resources to improve efficiency and build connections in the software tools. This only works as a mutual project.

■ Reduced wear, longer lifespans: can targeted measurements be used for preventive maintenance as well?Blase: Yes, very much so, which is why we at OSRAM talk about condition-based maintenance. We want to know, through target-ed measurements, when maintenance is necessary. Thus, we are exchanging previously calculated maintenance intervals for those based on actual values. With the measurement kit, we can quickly determine whether such data can be measured at all; if so, at which points using what sensors. We therefore prevent the blind, and ex-pensive, collection of all data from everywhere.

■ What type of applications have been implemented at OSRAM?Blase: We can draw conclusions, based on the motor current mea-sured in a glass processing machine, with regard to how much the quartz fumes have contaminated the mechanical parts. Sluggish-ness in this case is comparable to sand in the gears. In the mean-time, things have progressed far enough that measurement devices have their own IP addresses and are part of our network.

■ That means that you can access them from anywhere, right?Heyde: Yes, that is correct. Condition-based maintenance has very strong, relevant ties to the Industry 4.0 concept thanks to its multiple integration opportunities. On the horizon, we see connections to manu-facturing execution systems at an operation’s command level – in other words: big data. WAGO's controllers are ideal for this thanks to their variety of interfaces and free programmability.

■ Thank you for the conversation.

Andreas Heyde, Equipment Engineering at OSRAM

Frank Blase, Equipment Engineering at OSRAM

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“We may be a small company, but we con-sult for several large industrial firms that need solutions for their measurement and control technologies. In order to do justice to energy efficiency, we would also like to offer a mobile measurement solution. Therefore, it is import-ant for us to know which products and solu-tions WAGO has for collecting energy values and processing these datasets. However, in addition to technical solutions, we also need expertise in knowing which legal standards to apply.”Werner and Peter Igel, INTECH Industrietechnik GmbH

“We are learning about energy measurement and management because, in our community, a large community center is about to be com-pletely renovated. When this happens, we would like to be qualified to speak with the architects about our concepts and wishes.”Karl-Heinz Flögel and Jacqueline Totzauer, Mainhausen municipality, Construction

“While I have known about DIN EN ISO 50001 for quite some time, I only recently learned that it can also apply to service pro-viders. This made WAGO’s information ses-sion the perfect opportunity to become more informed about the differences between audits and energy management systems – without being completely immersed in technical text. Here I can learn straight from the experts what is important. In addition, I also get to know what products WAGO offers for energy mea-surement, so that I can create new ideas for services.”Marko Medvesek, Bilfinger Maintenance GmbH

The WAGO Roadshow brought information to eight German cities about energy measurement and management.■ The new Energy Services Act has added energy efficiency to the agenda of every company. It no longer matters if customers are from process technology, mechanical engineering, from the automotive sector, planning offices or retailers — sooner or later, all operations will have to deal with this topic. Large enterprises had to sprint in order to meet the legal deadline, which called for an audit or certification by Dec. 5, 2015. A good reason for WAGO to devote an entire Roadshow to the topic. And a good time for planners, designers and energy managers to get informed.From the beginning of October through the middle of November 2015, the WAGO Roadshow visited eight cities across Germany to provide information about the legal requirements and techni-

cal solutions for operational energy management. The speakers at the informational events were noted experts with hands-on expe-rience, including the Federal Union of Energy Consumers (VEA), various energy consultants and providers of software solutions for measurement data visualization. In addition, a variety of WAGO customers spoke about how such optimization approaches could look in practice while they shared their own experiences and best practices.And the information was incredibly well received; in fact, the kick-off event in Seligenstadt near Frankfurt am Main was completely booked with more than 60 guests. Five of the guests shared why they took the time attend.

Transparency on Tour

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Continued from page 14...Increased vibrations, for example, provide information that some-thing is not running correctly somewhere; increased current values are a prominent indication for contaminant accumulations. Devia-tions in the temperature curves point, in turn, to worn components. Companies would do well to capture their energy data to bring transparency to the processes. This energy data could then be sensi-bly combined with other media consumption values to paint a bigger picture.Transparency is an essential key to success, but it is not the only one. Even if quality measurement data is available, the decisions re-garding how the data is used are critical. Likewise, both appropriate visualization and a logical interpretation are also essential. Suitable measures for energy savings can only be determined after examin-ing measurement data in the appropriate context and using different methods for analysis. Energy management systems that comply with ISO 50001 function based on methods and key figures – the lat-ter permits comparisons to be made between what is expected and what is measured.

■ EnPI, KPI, OEE: Making Measurement Data ComparableAn important measurement is the energy performance indicator (EnPI), which is used to evaluate energy-related outputs. The key performance indicator (KPI) is similar, it is a key figure that shows the degree to which an organization has reached an important goal based on factors critical to success. The overall equipment effective-ness (OEE) is a typical KPI substitute, it is used to examine the actual utilization of a machine comparted to what is theoretically possible. Consequently, in addition to pure production speed, idle times for repairs and maintenance also impact manufacturing automation.The energy efficiency experts at OSRAM in Berlin are increasing-ly ignoring pure productivity figures, like KPI, in order to expand energy efficiency. Using EnPI, they can see how much energy was purchased and how many widgets were sold. Previously, OSRAM focused on machine investment values, like the number of units, re-jects and quality; however, since introducing the energy manage-ment system, more attention has been paid to energy consumption per number of units.

■ Subsidies from the Federal GovernmentThe importance of industrial energy efficiency is made clear with a quick glance at the information on subsidies provided by the Federal Ministry for Economic Affairs and Energy (BMWi). In 2014, just un-der 35 million euros flowed into research projects for increasing en-ergy efficiency in industry, the trades, commerce and services. And new proposals for 40.4 million euros of subsidies were approved.

With a focus on energy-intensive sectors, the BMWi is primarily sup-porting projects related to energy optimization of individual process steps, the development and introduction of new technologies and system components. It is also focusing on the development of com-plex supply concepts and waste heat utilization systems. In addition, the subsidized projects refine cross-sectional technologies which can be used across industrial sectors. These include heating and cooling technologies, miniaturization and separation methods, and measure-ment and control technologies.The federal government is encouraging not only research projects, but also specific measures for increasing energy efficiency. Com-panies can obtain financial support to introduce an energy man-agement system or energy management software from the Federal Office of Economics and Export Control (BAFA). There are grants for external consultants, employee training and the acquisition of measurement technology. Additionally, replacing individual systems or aggregates with highly effective alternatives and systematically optimizing technical systems are subsidized in many cross-sectional technologies.

■ Poor Performance Despite High PriorityIn spite of the federal support, German industrial corporations have struggled to invest in appropriate savings measures. Obstacles in-clude high demands for profitability, which are reflected in demands for short payback periods. These expectations must also compete with measures for increasing sales or improving product quality. De-pending on the size of the company, other reasons include lack of personnel or a low level of importance.A June 2015 survey fielded by the University of Stuttgart revealed that currently, German enterprises are not expecting to increase ef-forts to improve efficiency. An investigation by the International En-ergy Agency (IEA) mirrored the university’s findings. The IEA noted that industrial efficiency in Germany lags behind Japan, the USA and other European nations. This remains the case, despite the top-ic’s relevance and the implications it holds for both the environment and maintaining the competitiveness of German corporations. Best practices, like those at BASF and OSRAM, demonstrate that things could be different.

Text: Lukas Dökel and Julia Ockenga, WAGOPhoto: ©iStockphoto.com/cherezoff, Munich Sedcard, WAGO

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Measurement components, control technology, visualization unit: WAGO's hand-luggage-size measurement kit contains everything you need to detect a wide varie-ty of data – from energy up to media consumption values.

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Uncovering Potential for Improvement: Using the Mobile Measurement KitFor data collection in their mobile measurement kits and control cabinets, OSRAM relies on the WAGO-I/O-SYSTEM 750.

■ Whether the project involves condition-based maintenance or an energy management system that adheres to ISO 50001, transparent data forms the foundation for any type of optimization. Before per-manently installing automation technology in the control cabinet, it pays to analyze all of the possibilities first. In the mobile mea-surement kit, OSRAM developed a clever solution for temporarily collecting and evaluating energy data and media consumption. Measurement technology and the WAGO-I/O-SYSTEM ensure the necessary flexibility.

When Andreas Heyde and Frank Blase go on business trips, there are often long discussions at security check points. In addition to briefcases and suitcases, the pair usually has another piece of lug-gage – one that the security personnel working the scanners cannot make heads or tails of. When Heyde, a 50-year-old Berliner, and Blase, a 43-year-old from Siegerland on the Rhine, talk about their mobile measurement kit, you can see the enthusiasm they have for

the project they developed two years ago for OSRAM. The Project Coordinator and the Measurement Technology Expert have been working for the lighting manufacturer for a combined four decades at the Berlin facility.

■ Saving Energy, Optimizing MaintenanceTogether with colleagues from the Equipment Engineering department, the duo works to drive OSRAM technologically and economically. To meet their goals, they develop and implement new systems, provide support for production and processes and track everything that has anything to do with project and risk management. The mobile mea-surement kit is a result of this drive, created from the “Energy Efficiency Initiative” that OSRAM founded in 2012. Since then, more than 21 gigawatt hours (GWh) of electricity and 10 GWh of gas have been conserved – as much as a small German city uses in a year. Increasing energy costs and ISO 50001, published in 2011, were decisive in convincing the firm to increase its efforts in this area.

Before and after the potential analysis: previously, the production control of the 25 annealing furnaces was performed by hand with an information chart; now maintenance technicians have an overview of every furnace via the WebVisu app.

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Switch, split core current transformer, power supply, rail-mounted terminal blocks, I/O-System: WAGO's electrical connection and automation technology constitutes a large portion of the measurement kit.

OSRAM was ahead of its time, the European Energy Efficiency Directive 2012/27/EU mandated the implementation of regular energy audits or an energy management system at large German enterprises by December 2015. The goal is a common framework for promoting energy efficiency in the European Union. And OS-RAM has satisfied the legal requirements of ISO 50001 for more than a year. “The mobile measurement kit contributed substantially to this success,” explains Heyde, the project coordinator. “It is our first course of action when we need to initially identify potential energy savings.”

■ Recognizing Potentials, Deconstructing InhibitionsCleverly packaged measurement components, control technology and a visualization unit are hidden in the hard case, which is about the size of a carry-on bag. “In 53 x 35 x 22 cm, we accommodated everything necessary for collecting the most varied data; it has a modular design and can be used directly via plug and play,” explains Blase, the expert in measurement technology. This gives OSRAM valuable insight into energy consumption, as well as additional information about the status of a system or manufacturing line. The data could be relevant for con-dition monitoring, such as compressed air, vibrations, temperature and other digital and analog values. The concept behind the case is simple: shed light on the darkness and reveal potential savings. By using retrofittable technology, like split core current transformers and Rogowski coils, the installation and dismantling are swift and rarely interrupt production. Access to machine controllers or electronics is usually not necessary. Only after the newly obtained data validates improved energy efficiency or process sequencing, will the automation technology be perma-nently installed in a control cabinet. Heyde sees yet another advan-

tage, “the limited timeframe required to use the kit and the evidence it produces, which demonstrates whether to engage in a production system or a facility’s technical systems or not, reduces anxiety for the authorized personnel. These are the individuals who feel they simply must do something.”

■ Compiled Individually, Used FlexiblyThis mission has already taken them around the world to China, Russia and America. In the meantime, interest has extended beyond OSRAM’s global facilities to other companies. In order to view the successes from this optimization in Germany, one does not have to travel far. At the OSRAM production halls located on Berlin's Non-nendammallee, the signs point to energy conservation and main-tenance optimization. By using the measurement kit, the potential can be determined, for example, for increasing the efficiency of a high-energy manufacturing step. In the past, a simple informational table with colored magnets to show orientation functioned as pro-duction control for a group of 25 annealing furnaces. Visualizing these load profiles exposed two major findings. On one hand, the available capacities were being insufficiently exploited; on the oth-er, idle times and necessary maintenance were recognized too late because there was no operating panel.In connection with the first analysis using the measurement kit, a WAGO PFC200 Controller was permanently installed to control the energy measurement modules. “We simply mapped the layout of the furnace group in WebVisu within the controller, and then ported all system conditions from the informational table on a one-to-one basis. The CODESYS platform fits extremely well in the total concept,” explains Blase. With a simple script, all energy consumption values are now transmitted to deZem, the company-wide energy management system.

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OSRAM relies on WAGO for mobile and permanently installed automation technology.

OSRAM technicians use the WAGO-I/O-SYSTEM as the central data collection point.

Standard with WAGO: 500 modules guarantee that virtually any signal can be detected.

Two years ago, these men created the measurement kit: Frank Blase (left) and Andreas Heyde (center), together with student Manuel Block, who supported the two during a recent round of software development.

“Because we can transmit current information about the systems to maintenance technicians at any time – as required in Industry 4.0 – maintenance is swiftly performed during the day shift. This minimized costly idle times,” summarizes Heyde.

■ Powerful Technology, Powerful Software ToolsOSRAM's technicians use the WAGO-I/O-SYSTEM 750 as the cen-tral data collection point. The more than 500 available I/O mod-ules guarantee that virtually any signal can be detected, according to the prevailing needs. Always included: WAGO's 3-Phase Power Measurement Module detects all relevant measurement variables from a three-phase supply network. The module directly processes these variables, including reactive, apparent, and effective power, energy consumption and power factor. According to Blase, “The features that we get standard from WAGO are sold by other manu-facturers as special features at increased prices.”To visualize the selected values, the users access the integrated tablet, which includes the WebVisu app, among others. This allows them to easily review and configure the WAGO components that are used. OSRAM developed their own WAGO plug-in for the mea-surement data collection software, called IPEmotion, as a sensible supplemental app. This enables the transmission of information, on an as-needed basis, to the deZem energy controller and energy management software. Combining Web Visualization, IPEmotion and deZem provides a powerful software tool for evaluating and processing the collected data.

Currently there are three measurement kits at the Berlin facility, while an additional eight have been delivered to international lo-cations. “At airports, we have gotten used to explaining what all the cables and technical components are used for. This is not re-ally necessary anymore when we talk to customers – it has gotten around just how effective the kit is. We have also recorded an ex-tensive e-learning tutorial on the integrated tablet, which answers many questions and explains a lot of basic information up front,” explains Heyde proudly. “While we do indeed find potentials for improvement during production, we are more than satisfied with our measurement kit at the moment.”

Text: Lukas Dökel, WAGOPhoto: WAGO

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■ In harsh environmental conditions, additional air-conditioning systems and specially protected circuitry drive up automation technology costs. This is not the case for the extremely robust WAGO-I/O-SYSTEM 750 XTR. Boasting twelve new components, the XTR Series is now even more versatile and ready for renewable energy systems, substations, shipbuilding or railway applications.

■ PFC200 ControllerNew products within the WAGO-I/O-SYSTEM 750 XTR Series include the compact and powerful PFC200 Controller with a real-time-capa-ble Linux® operating system. The new 750 XTR Series Controller is available in two versions with a different number of interfaces. The first features two ETHERNET connections and an RS-232/RS-485 interface. The other has two ETHERNET connections, RS-232/RS-485, CAN, CANopen and PROFIBUS DP-Slave interfaces. With the PFC200, users have the option of planning their projects using the e!COCKPIT design software in a CODESYS 3 environment or via WAGO-I/O-PRO in the CODESYS 2 environment.Both versions of the PFC200 are also available for the 750 XTR Series as telecontrollers that support DNP3 in addition to the IEC 60870-5-101, -103 and -104, IEC 61850, IEC 61400-25 telecontrol proto-cols. Until now, planning with the telecontrol variants took place ex-clusively in CODESYS 2. The PFC200 Telecontrollers also command IPsec and OpenVPN to comply with the highest security standards. Featuring SDHC memory, the fan- and battery-free PFC200 is mainte-nance-free and extremely robust.

An Expanded Offering: The WAGO-I/O-SYSTEM 750 XTRMore performance, telecontrol technology and energy data recording: twelve new components make the WAGO-I/O-SYSTEM 750 XTR even more versatile.

■ 3-Phase Power Measurement ModulesIn addition to the new controllers, additional 3-Phase Power Measure-ment Modules expand the application range of the WAGO-I/O-SYS-TEM 750 XTR. It is available for the 750 XTR Series in three versions: for measuring using current transducers at a maximum measuring cur-rent of 1 A or 5 A, as well as for measuring with Rogowski coils. All relevant measured values (e.g., reactive/apparent/effective power, energy consumption, power factor, phase angle, frequency, over-/un-dervoltage) are transmitted directly into the process image without re-quiring high computing power from the controller. With this information and a harmonics analysis up to the 41st harmonic, the 3-phase power measurement module provides comprehensive network analysis.In addition, WAGO has added other components to the WAGO-I/O-SYSTEM 750 XTR portfolio. These include: two 2-channel digital input modules for 60 V and 110 V, an 8-channel digital input mod-ule with 2-wire connection technology (filter 0.2 ms) and a 2-channel analog input module for 4–20 mA. Also new to the line is a separa-tion module for visual demarcation of segments with different voltage ranges within a node.The WAGO-I/O-SYSTEM 750 XTR combines the benefits of the suc-cessful WAGO-I/O-SYSTEM 750 with key features for extraordinary dependability in tough environments. These include extreme resistance to temperatures from -40 °C and +70 °C, immunity to interference up to 1 kV (< 60 V, Class VW1) and 5 kV (≥ 60 V, Class VW3), as well as vibration resistance up to 5g. The system requires minimal space and is distinguished by low energy and maintenance costs. These benefits, along with incredible system uptime, enhance productivity.

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■ WAGO's newest PFC200 Controller joins the WAGO-I/O-SYSTEM 750 equipped with a 3G modem with standard (mini) SIM card. This provides wireless GPRS Internet connectivity and allows convenient bidirectional communication via SMS. WAGO's PFC200 (750-8207) features two ETHERNET ports and an RS-232-/RS-485 interface for seamless network integra-tion. An integrated network switch enables easy line topology implementation. Additionally, the integrated Webserver pro-vides a user with online configuration options and status infor-mation anywhere he or she happens to be. Featuring a fan- and battery-free design with SDHC memory, the controller is mainte-nance-free and extremely robust.In addition to the standard version, WAGO's PFC200 is also available with either an extended temperature operating range from -20 °C to +60 °C (750-8207/025-000) or as a telecon-trol variant (750-8207/025-001). The telecontroller supports the following protocols: IEC 60870-5-101, -103 and -104, IEC 61850, IEC 61400-25, as well as DNP3. The PFC200 Telecon-

PFC200 Communicates via Mobile NetworkWirelessly control and monitor machines and systems over long distances.

trollers are also compatible with both IPsec and OpenVPN protocols for compliance with the highest security standards. Typical applica-tions for the PFC200 GSM-enabled controller include: infrastructure network monitoring (electricity, gas and water), decentralized data logging for machine and equipment monitoring, building automation and the processing industry.

Provides wireless Inter-net connectivity while sending and receiving SMS: WAGO's PFC200 (750-8207) with inte-grated 3G modem.

■ The economically priced and compact EPSITRON® ECO Power Supplies offer versatile DIN-35 rail and screw mounting options, making them easy to install in ultra-compact control cab-inets and devices. Each single-phase ECO Power Supply has a wide input range for AC voltages from 100–240 V and can be connected to utility grids worldwide. They provide 24 VDC nom-inal output voltages, and models are available from 1.25–10 A.Beyond control cabinets, the ECO Power Supplies are ready for a variety of consumer-oriented applications within the scope of the “household appliance standard” thanks to EN 60335 conformi-ty. This enables WAGO to economically bring trusted industrial technology to everyday applications, e.g., vending machines, slot machines, coffee machines, as well as heating controls and ventilation systems.

For All Essential Applications: The New EPSITRON® ECO Power SuppliesSlim, EN 60335-compliant and incredibly versatile: WAGO expands its range of EPSITRON® ECO Power Supplies with special models that have an even greater price/performance ratio.

Equipped with proven CAGE CLAMP® connec-tion technology, WAGO's 787-17x2 Switched-Mode Power Supplies can be easily installed in both control cabinets and everyday devices.

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DISPLAY

EASY TO USE – DIRECTLY ADJUST BRIGHT-NESS ON THE DISPLAY

ENERGY-SAVING SENSORS LIGHT THE WAY FOR SAFETY

e!DISPLAY is the high-performance HMI display with a resistive touch-screen for web-based visualization. On top of its technically advanced features, the Web Panel offers a sleek, user-focused design. The display has been optimized for the best performance – regardless of application type or system size – thanks to four available screen sizes (4.3” / 5.7” / 7.0” and 10.1”). UsabilitySensors can automatically adjust the brightness of e!DISPLAY based on a room’s ambient lighting conditions. Additionally, users can also easily and quickly readjust brightness levels to suit their needs. The display carries front-mounted screen setup buttons for exceptional usability.

Sensorse!DISPLAY features an energy-saving, stand-by function with a screen saver. Integrated sensors conveniently and automatically show the previous visualization as a user approaches the display. Operating conditions are recorded by a temperature sensor and can be used for reliable testing. Status LEDs indicate both operating status and operational feedback at all times. Mountinge!DISPLAY directly latches onto the control cabinet via mounting clips for quick and easy tool-free installation. Achieve IP65 levels of protection for the front of the display with additional clamping elements. This design flexibility makes e!DISPLAY extremely versatile and suitable for a wide variety of applications. The VESA mount al-lows universal mounting accessories to be conveniently used outside of the control panel.

The Web Panel 7300T

Your Machine Needs a Business Card

V2 V3

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UNMATCHED PERFORMANCE – BENEFIT FROM SINGLE-SOURCE COMPONENTS

INSTALLED IN A SNAP – A FLEXIBLE MOUNTING DESIGN

All from the Same SourceThe more harmonious the component integration is, the better the performance and reliability will be. e!DISPLAY provides high-quality visualizations via CODESYS 2 and WAGO’s e!COCKPIT engi-neering software (based on CODESYS 3). It also offers users new technologies, such as HTML5. High-performance solutions are yours when e!DISPLAY is combined with WAGO’s PFC200 and PFC100 Controllers. Please find additional information at www.wago.com/edisplay

Size Item Number

4.3” 762-3000

5.7” 762-3001

7.0” 762-3002

10.1” 762-3003

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LEGAL INFORMATION

WAGOdirect industry November 2015

Editor: Stefan Keggenhoff (responsible editor)

Phone: +49 571 887-9570 Fax: +49 571 887-89570

Free reuse of this content is possible following approval and with appropriate citation. Contact: Stefan Keggenhoff. We assume no liability for unsolicited manuscripts and photos that are submitted. WAGOdirect industry is published periodically through-out the year.

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CHWAGO CONTACT SARte. de l’Industrie 19Case Postale 1681564 DomdidierPhone: +41/26 676 75 86Phone: +41/26 676 75 01info.switzerland@wago.com