Advance 2014 3 en

Number 3 | November 2014 | siemens.
com/advance
advance
The magazine for Totally Integrated Automation
The road to the

digital enterprise
Focus on digitalization at
SPS IPC Drives 2014
20
Editorial
Drive technology
04 Making things right
16 Energy-saving glass pressing

The Waltec company migrates to more compact, more
flexible, and more efficient servo-pump technology
Focus
06 The road to the digital enterprise
Siemens demonstrated advances in digitalization
ofmanufacturing at SPS IPC Drives 2014
18 Dancing screens
Sinamics S120 converters provide for spectacular stage
design at the Chinese Spring Festival Gala
08 Energy management pays off

The Siemens Amberg plant successfully uses modern
switching and protection technology
20 Conveying expert
Sinamics G110M distributed inverter for logistics
applications without a higher-level PLC
Automation technology
Integrated Drive Systems
10 Wireless flexibility
Frieters Innovativ's switches now feature a wireless
connection to the Simatic controller
22 Perfectly optimized logistics

High consistency at Liebherr in Biberach thanks to a
fully automated warehouse with conveyor technology
11 Perfection in measuring technology

Simatic S7-1500 ensures that the measured results
areprocessed quickly at Wisatec
14 Perfect modernization
CP Kelco in Finland has upgraded to the control
systems of the Simatic S71500 and S7-1200 series
2
24 From product to system

Integrated Drive Systems create the best conditions
foroptimum energy efficiency in the drivetrain
Cover photo: Siemens AG
Andreas Messner
11
Siemens AG / W. Geyer
advance 3/2014 | Contents
08
38
Siemens AG
32
Siemens AG
Energy management
pays off
Training
Power supplies
27 Fit for the mining industry

Siemens trains employees of Poltave Ore Mining
andProcessing Enterprise on-site in the Ukraine
36 Well-designed power supply

The new and reliable SitopPSU8600 power supply
system can be configured in TIA Portal
Safety technology
Industrial controls
28 Design, testing, documentation

Safety-relevant components of a machine control
system must be validated
38 Standards-compliant control cabinet design

Changes affecting how low-voltage switchgear is used
and control cabinets are built
31 Safety training for industry automation

Controlling and commissioning fail-safe Simatic
controllers in the TIA Safety course
Services
32 Safe control of large forces

SAG automates its track moving machine with
a fail-safe Simatic controller
Industrial identification
40 Global network of experts

Siemens works in close collaboration with specialized
external partners all over the world
Dialogue
42 LOGO! 8 / Library / Newsletters
34 Clear tool identification

Tool manufacturer MAPAL uses a Siemens RFID
transponder for its Tooltronic actuating tool
advance 3/2014 | Editorial
Karlheinz Kaul
The entire value chain of the

manufacturing process of a Sirius
contactor shows just how much
improvement can be achieved by
using automation software in
plants.
Making things right
Siemens AG
Editorial | advance 3/2014
The same trend that has been developing in the private sector can be seen
in industry as well: increasing digitalization. For us, this means that our
product development and manufacturing processes are being digitalized.
Industrial software for plant automation will play an increasingly important
role throughout the entire lifecycle of plants.
This year at the SPS IPC Drives fair, we showed the improvement potential
that this digitalization trend entails. At the center of our booth in Hall 11
you could see the entire value chain of the manufacturing process of a
Sirius contactor, from design and planning to engineering and production
to service.
Energy efficiency is another very important factor for optimized manu
facturing. Economy and ecology go hand in hand here. By using less energy,
companies aim to reduce costs and protect resources at the same time.
Drives account for about 70 percent of energy consumption in the manu
facturing industry. With the new IE3 motors, which will be compulsory as
of January 1, 2015, a great deal of energy can be saved. These savings can
be further increased by using frequency converters and modern industrial
switching technology. The industrial switching devices of the innovated
Sirius modular system have low internal power loss and are designed
toperfectly complement the energy-efficient IE3 motors (read more on
page 38).
In addition, many of our switching, protection, and control devices
already feature measuring functions that make it possible to record and
evaluate energy data (read more on page 8). These innovations are already
being used in our plant in Amberg and demonstrate how efficiency can be
increased in a sustainable manner throughout the entire manufacturing
process.
Let the many examples presented in this issue of advance inspire you.
I hope you enjoy reading this issue.
Yours,
Karlheinz Kaul
Head of Digital Factory Control Products
Siemens AG
advance 3/2014 | Fokus
SPS IPC Drives 2014
Siemens AG
The road to the

digital enterprise
Prof. Dr. Dieter Wegener,
Head of office
Industrie 4.0
software solutions. Digitalization ranges from product design and production planning to production
engineering and production execution. In the future,
software will play a significant role in every aspect
of plant automation for evaluating data in the plant,
explains Heinz Eisenbeiss, head of marketing at
Factory Automation.
This is already the case, as the automation specialist impressively demonstrated at this years SPS IPC
Drives. The showcase and at the same time the
highlight of the Siemens booth in Hall 11 demonstrated the entire value chain using the example
of one of the companys own production processes
he challenges posed by global competition in the production of a contactor from the Sirius
the manufacturing industry lead to the ques- line.
tion: How can things be produced even better
in a more productive, more efficient, more flexible, From design to production planning
and especially more competitively viable way? One
answer is digitalization. It is the essential element It all starts with the first phase: designing a product
that brings all the phases of product development with the necessary CAD/CAE data. The machine deand manufacturing together, as it provides for the sign is based on these data determining how the
seamless integration of all phases of production, contactor must be assembled and what functional
from design, planning, and engineering to execution units are needed to do so. This is where the NX
and services.
integrated software solution for CAD, CAE, and CAM
But how? This approach requires partners that are comes into play. With this software, products such
already providing their customers with the right as the Sirius contactor showcased at the trade fair
products and solutions so they can be globally com- can be digitally designed, simulated, and virtually aspetitive today and tomorrow. Siemens is such a part- sembled over the entire assembly line before the proner and is thus focusing on developing its industry totype is made. Especially in the area of mechanical
With the slogan Making Things Right

Siemens demonstrated again at this
years SPS IPC Drives how the company
asa leading global technology
providercontinues to drive advances
inelectrification, automation, and
digitalization, with a focus on the
roadtothe digital enterprise with
theDigitalEnterprise Platform.
Focus | advance 3/2014
engineering, the NX Mechatronics Concept Designer Uncovering hidden potential

is used to design the machine. This comprehensive
solution for mechatronics design enables multidisci- The hidden and so far largely untapped potential
plinary synergies between mechanics, automation, of the continuously increasing quantities of data in
and electronics and thus revolutionizes the machine industrial production is huge. Plant Data Services
make it possible to use this potential intelligently by
design process.
The necessary production steps are automatically continuously capturing, filtering, structuring, and
derived from the engineering data, checked for fea- analyzing relevant data from various sources.
Whether energy consumption data, production figsibility, and simulated. This is possible thanks to the
excellent interplay of NX with Tecnomatix, Siemens ures, or diagnostic data, they are captured in TIA by
software solution for production planning. It not a large number of devices and transferred to the
only defines the individual production steps but also higher-level IT system. With the help of data-based
calculates the number and functions of the individ- services such as Asset Analytics or Energy Analytics,
experienced data experts can translate these data
ual automated handling modules.
Services
Siemens AG
Production
engineering
Production
planning
Production
execution
Product
design
Seamlessly integrated engineering

It is just a small step from production planning to engineering. This includes not only engineering automation tasks but also the planning and configuration
of the power supply, or, in other words, everything
that makes the production line work. Engineering
tools such as TIA Portal or tools to configure control
cabinet components are used in this phase. Here,
TIAPortal is key, as it integrates all the automation
software and hardware in a single engineering environment. The result: highly efficient project planning
and programming that is up to 30% faster.
Finally, the Sirius contactors are physically produced. The process also shows which data are generated and are available for tasks such as quality
management, energy monitoring, or service, which
is the last stage. This information is analyzed to find
out if and how the plant can be further optimized.
into specific recommended actions. This allows for

an increase not only in the energy efficiency of
machines and plants but in the overall plant efficiency, as well.
With these concepts, methods, and tools, Siemens
is taking specific and practical steps via the Digital
Enterprise Platform toward the digital enterprise.
Digitalization plays a decisive role in comprehensively optimizing all the value chains in the manu
facturing industry. The benefits: reduced time to
market, higher efficiency, more flexibility, and thus
increased competitive advantage.
INFO
siemens.com/sps-fair
advance 3/2014 | Focus
Siemens AG, Germany
Energy management
pays off
The Siemens plant Amberg in Germany impressively

demonstrates that energy management pays off. The key to
success includes switching, protection, and control devices with
integrated energy-measurement functions. The data acquired
inthis way can be fed into the appropriate evaluation programs
and can lead to a sustainable change in energy awareness.
During the implementation of an in

tegrated energy management system,
we benefitted from the fact that many
of our industrial switching, protection,
and control devices already automa
tically provide information such as current, voltage, and efficiency as standard, emphasizes Schmidt. Devices
with integrated, bus-compatible power
tilation and air-conditioning systems, electronics, such as the Sirius soft
media supply, compressed air, vacuum, starter and Simocode pro motor manand process cooling. Specific measures agement system, for instance, autoto improve energy efficiency 60 at the matically provide the measured values
plant in Amberg and 30 in Cham were needed for energy management. Distributed motor starters are equipped
defined during the first valuation run.
Energy management becomes

much easier with
integrated and
network-compatible
switching and
protection
technology.
Manfred Schmidt, Energy Manager,
Siemens plant Amberg
Siemens AG
nergy efficiency and sustainability

are the top priorities on the list of
challenges faced by todays manufacturing industry. Often, a few lowcost measures are enough to uncover
the most obvious energy savings potential. But what about potential savings that are less obvious? This is where
it is necessary to take a closer look.
First, it is important to understand
theenergy flows. Manfred Schmidt, energymanager at the Siemens plant in
A mberg, is aware of this. He is convinced that clear and reliable data are
crucial for successful energy management, as they lead to significant improvements in energy use. Once all the
facts are clear, we can discuss suggestions and measures for improvement
on a completely different level.
Accordingly, the company places high
importance on energy management.
Based on ISO standard 50001, the team
defined energy targets that are to be
met through comprehensive energy
management. The first phase was to
carefully and thoroughly examine all
processes and activities, including manufacturing plants, conveyor belts, ven-
Integrated measuring technology

for consistency
Focus | advance 3/2014
Energy management as a service

With Energy Analytics, even small and medium-sized plants and companies
are able to reach their energy targets more quickly than with an in-house
approach.
Siemens AG
Measured data are collected from field devices and transmitted to the
Siemens Service Center via an Energy Box. At the service center, the data
are processed, evaluated, and automatically made available to the
appropriate users based on their needs. The services offered range from
simple evaluations (transparency) to detailed analyses including savings
potential and benchmarks (analytics).
siemens.com/energyanalytics
Siemens AG
with current detection, and there is a

separate energy module to measure
relevant energy parameters for the
Reports, data analyses
new ET 200SP distributed I/O system.
Profinet and I/O-Link are the most imEnergy manager
Evaluation
Cost savings
Measures
portant prerequisites for easy integration of systems into the control topology of machines and plants. The Sirius
line also features complementary monElectricity 1101101
itoring devices that report the required
101
11101
Water 1100100
1110101 EnergyBox
energy information to the distributed
I/O system via I/O-Link. Sentron PAC
Plants
multifunctional measuring devices also
Energy Service Center
create a perfect foundation for comprehensive energy management.
Schmidt is convinced that equipped
Customer
Siemens
Monthly fee
with such technology, clear facts
emerge that automatically lead to improvement and consequently result in The energy data management system from Siemens
savings. The collected values can be
directly displayed in the visualization
software and can be used for specific
Siemens offers scalable software that transmitted to the control and visualenergy data analyses, with, for in- can be used to capture and evaluate ization level, where it is allocated to
stance, envelope curves, load profiles, data and optimize the energy use of specific loads, clearly visualized, and
trend charts, and selective peaks. Indi-
entire plants. This also allows plant saved with the Simatic powerrate
vidual processes such as cleaning owners to monitor success. As a sup- software, for example enabling hidphases can be evaluated very precisely plement to the energy data manage- den savings potential to be reliably unin this way. In many companies, it has ment software, Siemens also offers the covered. Simatic powerrate also helps
long been common knowledge that resulting work as a service.
eliminate load peaks by temporarily
production plants consume up to 50%
switching off specific loads via Profiof their total energy during downtimes. Energy-efficient data management energy. Thus, energy management is
Many suggestions to increase energy
becoming an increasingly active, inteefficiency made by employees have Energy data management in manu gral element of state-of-the-art producalready been implemented at the plant facturing plants is taking shape. Via tion.
in Amberg, for example, by attaching Profinet and Profienergy (the energy
thermal collars to the plasticizing units management profile based on Profinet),
of 33 injection-molding machines. Ac- measuring, switching, protection, and
cording to Schmidt, thermal losses control devices can now be easily linked
were drastically reduced, resulting in with integrated measuring technology.
INFO AND CONTACT
savings of approximately 250,000 kWh This allows the most important inforsiemens.com/energy-efficient-production
mation on energy consumption to be
per year.
9
advance 3/2014 | Automation technology
Our customers
IVAT GmbH, Germany
Wireless
flexibility
particularly appreciate
the fact that we almost
exclusively use
Siemens switchgear.
Frieters Innovativ, Innovative Absaugtechnologie (IVAT) has

developed an interesting solution for switchgear without
busconnectivity, which is usually connected to the Simatic
device using cables: the FRI-LAN wireless connection.
FRI-LAN enables the wireless transmission of signals to the
Simatic control system, which is particularly useful in larger
factory buildings.
Its quality has been

tried and tested, and
worldwide availability
is guaranteed.
Oliver Frieters,
Managing Director,IVAT GmbH
siemens.com/s71200
michael.ambros@siemens.com
10
Siemens AG/W.Geyer
liver Frieters, managing director Innovative wireless connection

of Frieters Innovativ in A
ugsburg,
Germany, already has experi- The company has developed the FRIence with remote-controlled extraction LAN PLC solution to ensure a reliable
systems in wood and metalworking wireless connection to the Simatic conplants. The aim is to wirelessly activate troller. Each device is equipped with an
the extraction system when, for exam- integrated radio transmitter that can be
ple, a saw is turned on and to deacti- accurately identified with a code. Addivate it some time after it has been tional signals from switches and transturned off. Usually, this does not re- ducers, or also analog signals, can be
quire a control system, as the drives are processed with different radio modules.
switched directly. Integrating the ex- Additional switching outputs are availtraction system into Simatic, however, able as well.
The Frieters Funkmaster acts as an
opens up a great variety of other pos
analysis unit and converts all signals
sibilities.
Frieters can envisage the solution into RS232 signals and also provides
being applied in building management thecorresponding radio data block in
systems or in machine control systems. Step7. This makes it possible to transWireless switches can be installed in a mit signals even in large factory buildfixed location or be used as mobile re- ings or over several floors of a building
mote controls. Switching operations without having to lay cables. The s ignals
can be activated manually or triggered can be visualized with a Simatic S7-1200
or S7-1500. Then actions can be trigby a mechanical signal.
Another interesting potential applica- gered depending on specific conditions.
tion is to monitor certain states. This is
The solution developed by Frieters
possible thanks to visualization with a Innovativ also impressed the team at
Simatic panel. Are the roof windows Bayern Innovativ GmbH. Frieters Innoclosed? Is the ventilator still running? vativ has been invited to participate
As long as the signals are not relevant asan exhibitor at the trade fair booth
for safety, there is no reason why they ofthe Bavarian State Ministry for Ecoshould not be sent via radio waves in- nomic Affairs and Media, Energy, and
stead of through cables. Our custom- Technology at SPS IPC Drives in Nuremers particularly appreciate the fact that berg.
we almost exclusively use Siemens
switchgear. Its quality has been tried
INFO AND CONTACT
and tested, and worldwide availability
siemens.com/s71500
is guaranteed, says Frieters.
These tried and tested Siemens switches

havebeen equipped by Frieters Innovativ
withantennas and now feature a wireless
connection to the Simatic controller
Automation technology | advance 3/2014
ow can workpieces made of extremely expensive special materials be measured with micro
meter precision or tested for special
quality characteristics during production? The German company Wisatec in
Schaafheim is the first choice for many
manufacturers if they require the highest precision and need to test complex
components, perhaps with the additional challenge of compensating for
high temperatures or vibrations. Managing director Ralf Elbert knows what
to do when a renowned car manufac- The testing spectrum includes dimenturer wants to make sure that small sional measuring technology, thread
tube filters whose net structure is invis- inspections, and surface inspections as
ible to the naked eye fully meet the well as layer thickness measurements,
quality requirements without having structure tests, and air permeability
to stop the conveyor belt during pro- tests to name just a few tasks. Preciduction.
sion is becoming ever more important
Wisatec equipment handles the qual- in almost all industrial sectors, whether
ity control of safety-relevant power to ensure that complex systems run
plant components and can be found in smoothly, to save resources, or simply
the clean rooms of microelectronic to stand out from the competition,
production plants but it also measures Elbert confirms. When the managing
consumer products used in daily life. director talks about the problems his
Wisatec Messtechnik GmbH, Germany
Perfection in
measuring technology
For Wisatec, precision and productivity are the highest priorities. At

theVISION trade fair in Stuttgart, the measuring technology company
presented an automated testing machine equipped with two innovative
cameras for testing 3-D objects or structured surfaces. A Simatic S7-1500
controller ensures that the measured results are processed quickly.
11
company has already solved, it is clear

that he likes difficult challenges and
gets to the root of things in the process. Innovation starts with vision is
his creed.
Collaboration between
specialists
To ensure that the testing equipment
reaches its full potential, Wisatec
works with leading sensor manufacturers for inductive, pneumatic, and optical measuring technology. The compa-
planning, mechanical set-up, electrotechnical equipment, programming,

commissioning, and service. Special
development projects have also been
realized together with sensor manufacturers. So far, we have found a
solution for every requirement, Elbert
says.
Innovation in
image processing
In the area of optical measuring and
testing, Wisatec partners with Keyence
olution and measuring accuracy of the

cameras for themselves on two Simatic
flat-panel monitors. The plant is operated using a Simatic Comfort Panel.
Production efficiency
makes all the difference
Regardless of what is being tested, the
testing system must not threaten production efficiency. This is why speed
always has top priority. The efficiency
of the automated testing machine presented at the VISION trade fair is deter-
Innovative testing systems

Wisatec presented Keyence's new camera
systems in a testing machine at the VISION
trade fair:
XR with 3-D stereo fringe projection image
processing: particularly stable with shiny
surfaces such as solder joints and contacts
Keyence
LumiTrax with Shape from Shading

technology: an easy-to-implement system
that steadily and reliably differentiates
prominent faults from impurities
The LumiTrax camera system
nys own know-how consists of select- Deutschland, the leading manufacing the most technologically and turer of optical measuring systems.
economically appropriate measuring Keyence presented two innovative
method, building customer-specific 3-Dcameras for testing 3-D objects or
measuring and testing equipment, and structured surfaces at the VISION trade
integrating this equipment into the fair in Stuttgart. The camera systems
customers manufacturing plant. De- were shown in action in an automated
pending on the complexity of the task, testing machine from Wisatec. The
the equipment can also be implemen testing machine is a flexible handling
ted as fully automated continuous-pass system that takes the parts that are to
plants with the corresponding hand be tested off the running conveyor belt
ling capabilities. The measured data and delivers them in short sequence to
can be used for automatic machine various testing positions. If the parts
corrections or can be transmitted to pass the test, they are returned to the
higher-level quality management sys- belt; if not, they are removed. Visitors
tems. The Wisatec offering includes to the trade fair could see the high res12
mined by the precise and highly dynamic positioning of the gripper. It is

moved horizontally in an axis portal
with two fixed Simotics servomotors
with a speed of 2 m/s and is raised and
lowered using a stepper motor. In addition to converters capable of recovering energy, making high braking resistors unnecessary, the high computing power of the Simatic S7-1500 is
crucial for the plants dynamics. As the
core of the plant, it not only processes
the measurement results but also converts the coordinate systems for both
servo-axes at high speeds. This conversion is complex, as the circumferential
belts create a coordinate system that the very efficient programming of

isrotated by 45. The machine is con- theCPU 1511 with SCL and the step sefigured and programmed in TIA Portal, quence programming with S7-Graph.
including assigning the parameters of All our program flows are clearly structhe Sinamics S120 converters, which tured as step sequences. The library
are integrated as GSD files. The safety concept with the option to store blocks
functions integrated into the Sinamics globally results in additional synergies
S120 make the drive solution afford- during the collaboration.
able and efficient. The Sirius safety
The automation and drive technolswitching technology and the door ogy chosen for the trade fair model is
safety switch with tumbler are also a Wisatec standard configuration that
integrated into the TIA solution. Direct has already proven itself multiple times
access to the Simatic S7-1500 is possi- and that can be flexibly adapted to difble using a Scalance router, either via ferent requirements. For instance, an
Step sequence
programming with
S7-Graph is perfect
for us, since all
program flows are
clearly structured
as step sequences.
Wisatec's testing machine presented at the VISION trade fair
the customers network with VPN connections or via a mobile network for
remote maintenance.
Integrated and future-proof

Elbert appreciates working with customers and suppliers on a partnership
basis. This is why he also obtains all the
automation and drive technology from
one source. For him, the essential advantage is in the reduced training effort required. The result: his employees
know TIA Portal perfectly. The quality
of the project benefits from this and
we can keep relatively tight schedules,
he says. Special highlights for him are
additional Sinamics S120 double motor

module suffices for two additional
servo-axes for example, to rotate and
swivel the gripper. The Simatic S7-1500
would easily be able to handle the resulting additional coordination tasks.
INFO AND CONTACT

siemens.com/s7-1500
siemens.com/tia-portal
benedikt.hartmann@siemens.com
Moreover, the
library concept
results in additional
synergies during
the collaboration.
Ralf Elbert, Managing Director,
Wisatec Messtechnik GmbH
CP Kelco, Finland
At its Finnish production site in nekoski, CP Kelco

produces powder that can be used, for example, as a
thickening agent in toothpaste
14
CP Kelco
Perfect
modernization
Automation technology | advance 3/2014
When it came down to modernizing

with an S7300 or an S71500, the
expected long product lifecycle of
the new Simatic S71500 was the
decisive factor for us.
CP Kelco
Arto Vartio, Chief Operating Officer, Protacon
The CP Kelco group is a global market

leader in hydrocolloid a gel-forming
substance for the food industries
manufacturing. This forward-looking
company has upgraded to the control
systems of the Simatic S71500 series
atits Finnish production site. With
TIAPortal, the update was quick and
trouble-free.
Working faster with TIA Portal
The Finnish planning and service company Protacon,

which has significant experience in the areas of technical assessment, planning, implementation, and maintenance, was in charge of updating the 12 control systems. When it came down to modernizing with an
S7300 or an S71500, the long service life of the Simatic
S71500 was the decisive factor for us, states Arto Vartio, chief operating officer at Protacon. The installation
progressed faster than expected, and we were able to
commission the system in October 2013 only two
months after the contract was signed, adds Protacons
P Kelcos largest production site for carboxy project manager, Ossi Laitinen.
methylcellulose (CMC) is located in ne
The new control systems were implemented with
koski,Finland. The production lines produce the TIA Portal engineering framework. Because all
cellulose-based CMC powder that can be used as a functions are contained within one tool, the controlthickening agent in, for example, ice cream, tooth- ler was programmed in no time. Thanks to the inte
paste, paints, and detergents, around the clock. grated system diagnostics of the S71500 CPU, which
Over 90% of our products are exported, says Pekka provides all the information on imminent errors and
Rnk, project manager at CP Kelco. To guarantee displays them as notifications, the team was able to
continuous production as well as the availability correct errors much easier during commissioning.
ofspare parts, CP Kelco updated the automation
system that had been in use since the 1990s. For No production downtime
theupdate, all Simatic S5 control systems were replaced with controllers from the Simatic S71500 In addition to the modification itself, maintaining
and S71200 series. In total, the new PLCs have theautomation solutions and keeping them in good
more than 2,700 inputs and outputs.
working order was also important. Protacon employees Vartio and Laitinen made sure that updating the
The perfect decision
automation system would not cause any unnecessary
production downtimes in the CP Kelco plant: The emCP Kelco is one of the first companies in Finland to ployees were trained according to their specific needs
use modern control systems from the S71500 se- on how to use the new control systems and automaries. When it was time to make a decision, we tion programs.
wanted to have the very latest technology available.
That was the best decision we could have made. In
our view, the modernization went smoothly, says
INFO AND CONTACT
Rnk. We did not consider any other control syssiemens.com/s7-1500
tem manufacturer than Siemens because we alsiemens.com/tia-portal
ready had good experience with the S7 control sysjoni.myrberg@siemens.com
tems that had been used up to now.
15
advance 3/2014 | Drive technology
Waltec Maschinen GmbH, Germany
Energy-saving
glass pressing
In order to meet the demand of glass manufacturers for significant energy
savings, Waltec has replaced the hydraulic drive technology of its machines
with servo-pump technology. The results speak for themselves: a much more
compact design, increased flexibility, higher output, and energy savings of
more than 50% in glass pressing machines.
altec Maschinen GmbH, a German company

based in Wilhelmsthal near Kronach, in Bavaria, is the worlds leading manufacturer of
automated, electronically controlled feeder, pressing, press-and-blow, and centrifugal machines; laser
cutters; sanders; and polishers as well as handling
and transportation systems for the glass industry.
The company was founded in 1889 and today is a
single-source supplier that, upon request, also delivers complete turnkey glass production plants. The
task at hand was to equip automated glass pressing
machines driven by classic valve hydraulics with an
energy-saving servo-pump system. Waltec was motivated by glass manufacturers demand for significant energy savings. The servo-pump system works
only as much as absolutely necessary in the respec-
The servo-pump
system works
onlyas much
asabsolutely
necessary in the
respective phase
ofthe pressing
process. This
results in energy
savings of more
than 50 percent.
Rainer Wagner,
Head of Engineering and Purchasing,
Waltec Maschinen GmbH
16
Drive technology | advance 3/2014
Control of:
Control of:
Cylinder
Cylinder
Position
Direction
Speed
Force
Position
Direction
Speed
Force
Oil pumps
Asynchronous
motor:
50 Hz
Siemens AG
Servomotor:
Variable speed
and direction
Pressure accumulator 30 l
Oil pump
Tank capacity 1,000 l
tive phase of the pressing process. This results in

energy savings of more than 50%, explains Rainer
Wagner, head of engineering and purchasing at
Waltec.
Within the innovative servo-pump systems, the
pressure and flow rate of the hydraulic system are no
longer regulated by the restricting effects of valves
but by the torque and speed of a servomotor. Consequently, power is supplied only when the hydraulic
cylinder really needs it. This significantly increases
energy efficiency. In addition, a comparatively small
accumulator replaces the oil tank of the traditional
hydraulic system, making it possible to install the
compact system in the immediate vicinity of the machine. The systems short line lengths and low oil volumes minimize pulsations, ensuring high rigidity and
control precision.
Siemens AG
Waltec servo-pump system
Traditional hydraulics
pumps that are arranged longitudinally behind each

other along the motor shaft and operate in opposite
directions. The direction in which the oil flows is determined by the direction of the motors rotation,
sono directional control valves are necessary. The
decisive advantage of a servo-pump solution, however, is that the servomotor only works as much as
absolutely necessary for the respective phase of the
pressing process. To enable this, Waltec uses double
rod cylinders with identical flow volumes for both
pumps. The solution can also be used for differential
cylinders: the pump sizes are then simply selected in
proportion to the cylinder surfaces. In this case, the
different volumes are compensated by a compact
pressure accumulator that keeps the system under
permanent tension.
Tried and tested solution

Energy-efficient design
For decades, Siemens has been providing virtually all
Waltec machines with automation technology. The
processes of the new servo-hydraulic pressing machines are also controlled by a Simatic S7-300 and
operated and monitored with a Simatic HMI unit. The
servo-pump system is independently controlled by
the control unit of the Sinamics S120 servo-frequency converter and can therefore be integrated
into existing plant designs with relative ease. If regenerative infeed is chosen, the energy released
during the braking action of the pressing machines
ram can be fed back, further increasing energy efficiency.
The servo-synchronous motor, operated with a
Sinamics S120 frequency converter, drives two oil
Waltec glass pressing machines with energy-saving

servo-pump systems have been used by renowned
manufacturers all over the world since 2012. They
have proven to be practical and efficient even during
continuous operation under harsh conditions. While
only single-piston machines were initially equipped
with the servo-pump solutions, they have since been
proven to be effective in machines with two and
three pistons as well.
INFO AND CONTACT

siemens.com/motioncontrol/glass
christian.reuss@siemens.com
lutz.georg@siemens.com
17
Dafeng Industry Co. Ltd., China
Dancing screens
Cutting-edge drive and motion control systems based on Sinamics S120 converters with an
integrated Simotion D455-2 axis controller allowed systems integrator Dafeng to create a
spectacular stage design for the worlds largest TV show. During the Spring Festival Gala on
Chinese television, five gigantic LED screens had to move freely around the stage, precisely
synchronized with the performance.
rive and motion control systems are not usu- vided on-site support throughout the entire project
ally displayed in front of very large audiences, up to the live broadcast of the show on January 30,
but there are exceptions. During the Spring 2014.
Festival Gala on Chinas national television network
Watching the Spring Festival Gala on the eve of the
CCTV a show that holds the Guinness World Record Chinese New Year is a tradition that is deeply embedfor the most-watched national network TV broad- ded in Chinese culture and is a real family ritual not
cast an enormous crowd was able to witness what to be missed. With an estimated audience of 800 milIntegrated Drive Systems (IDS) are capable of. For lion, the show has always placed high demands on
this event, the stage technology systems integrator the stage set. Dafeng, the leading stage design comDafeng created a stunning display involving five pany in China, has been responsible for the stage
large LED screens that moved freely around the technology at CCTVs New Years gala for years and
stage to provide a background projection space, always viewed the annual challenge of entertaining
serve as large stage props, and interact with the art- the Chinese public as something of a national duty.
ists on stage. Siemens delivered the drive solution to For 2014, however, the gala organizers asked for
overcome this motion control challenge and pro- something more spectacular than ever.
18
Drive technology | advance 3/2014
The LED screens served

bothas backdrop and as
freely moving stage props
Siemens provided the answer to this challenge

with an integrated solution combining a Simotion
D455-2 axis control system with Sinamics S120 converters and Siemens/Beide motors. This solution not
only saved valuable space but also provided outstanding response speed. Communication problems
between the individual components often with
respect to timing were completely resolved. The
Simotion D455-2 was able to precisely synchronize
the 50 motors and corresponding movements along
the traversing axis: rising or falling, movements to
the front and back as well as left and right, and rotations of up to 270 with an error angle of 0.1.
Synchronized and safe
Siemens AG
The three-dimensional geometry on stage proved to

be the most challenging task, as it involved precisely
calculating the clearances between the individual
screens. The movements of the performers represented an additional challenge. Because the stage
got chaotic at times, we wanted to provide additional
protection to avoid collisions. The Siemens experts
had to rack their brains over this issue, and they
worked very hard in the process, recalls Dafeng engineer Xue Huanxin. To enable smooth and safe
screen motion, the Siemens engineers combined
simulation tests based on space coordinate models
and reduced the complexity by planning optimized
paths. They proactively used the advantages of IDS
An integrated solution to meet
to compensate for mechanical errors not caused by
their system, therefore addressing a major challenge
challenging demands
for us, adds Xue.
This year, the director of the show made extremely
The reliable service and support Siemens provided
high demands on the stage equipment, explains throughout the entire project played a key role in the
XieHaiqi, deputy director of the Dafeng Stage Design successful performance. Between mid-December
Institute. We needed an extremely flexible system 2013 and the Chinese New Years Eve, two engineers
tocontrol up to 50 motors for the five LED screens, to were continuously stationed at CCTVs Studio One to
allow them to move freely and precisely. They were provide on-site technical support to Dafeng. It was
to be either positioned to create a huge backdrop or fascinating to see how quickly and professionally the
individually moved to various positions on the stage Siemens engineering team reacted to feedback, Xie
to enhance the choreography of each performance. recalls. We were absolutely impressed by their dedWe also had to make sure that the five screens would ication and attention to detail and felt very secure
not bump into each other. And finally, the lead time partnering with Siemens at all times. As a result,
for the project was extremely short less than 20 Dafeng wishes to strengthen its partnership with
days, to be exact. On top of this, each LED screen Siemens in the motion control domain. In fact,
measured 7 m x 3.5 m and weighed almost 1.5 t, and Siemens is already involved in a new project for CCTV
most importantly there was no leeway for even and the Cixi Grand Theatre Project in Zhejiang.
the slightest mistake during the live broadcast of the
show. Dafeng knew it needed a partner that could not
only provide an extremely reliable and flexible
INFO AND CONTACT
solution but that could also offer extensive technical
siemens.com/simotion
support over the course of the whole project. The
hammer.josef@siemens.com
company found this partner in Siemens.
19
Sinamics G110M
Andreas Messner
Conveying expert
The new Sinamics G110M distributed inverter with a loop-through power bus
performs typical conveying tasks without a higher-level PLC, including placing
items onto a cross belt. Considerable savings can be achieved in conveyor
technology applications in this way. The G110M series supports USS / Modbus
RTU, Profibus, and Profinet / Ethernet IP without piggyback modules.
20
this option is usually more economical than planning for and installing an additional low-voltage
line.
Transport without a PLC

The Sinamics G110M can independently perform
many typical conveying and transport tasks. This
can reduce the complexity of the programs in the
higher-level control system or even make them
unnecessary. The Quick Stop inverter function is an
Siemens AG
he distributed Sinamics G110M inverter is a

modular and flexible drive that simplifies logistics applications. The inverter is easy to use
throughout its entire lifecycle, from installation
andcommissioning to servicing and maintenance,
thanks to the mechanical design that eliminates the
usual piggyback modules for fieldbus versions. The
modular inverter consists of a control module with
the desired communications interface and a power
module that matches the motor. Users can choose
from two housing sizes for devices with power
ranges from 0.37 to 4 kW. The Sinamics G110M is
the only device of its class that also has a loopthrough power bus, which makes all T-connectors
of the 380480 V three-phase power supply redundant. This saves time and reduces costs during configuration and installation, especially in logistics
and distribution applications, which have numerous
individual drives. The frequency inverters are available with cable entries with an IP66 degree of protection as standard.
The inverters are also available with HAN-Q4/2
plug-in connectors for applications that need quick
device replacement when serviced. An integrated
24-V power module ensures that the electronic components are supplied with 24-V power within the inverter itself. For drives that are positioned far apart,
The Sinamics G110M performs typical conveying tasks without

ahigher-level PLC
At a glance
Voltage/frequency: 3 phases, 380480 V
10%, 50/60 Hz 5%
Safety technology: STO as per IEC 61508
SIL2, ISO 13849 PLd, EN954-1 Cat. 3
Power range: 0.374 kW
Communication: USS / Modbus RTU,
Profibus, Profinet / Ethernet IP
Control mode: U/f, sensorless vector
control (SLVC)
Functions: Quick Stop, limit switch function,
free function modules (PLC function)
EMC: as per IEC 61800-3, Cat. 2
Brakes: Motor holding brake,
software-based braking technique
Conveyor, logistics, and transport applications need easy-to-use

distributed drives such as the Sinamics G110M
example of this. If items need to be transferred from Starter parameterizing software or with Startdrive
one conveyor belt to another, this function stops the in the TIA Portal engineering framework easy. The
belt containing the incoming goods if the space software can be updated and the parameters of the
onthe target conveyor belt is occupied. As soon as inverter can also be set with the help of an SD or
there is enough space, the inverter sets the con- MMC memory card. This simplifies serial commisveyor belt back into motion. To do so, it needs only sioning and also makes it easier to exchange the
two input signals: Goods received at the transfer device if the system needs to be serviced, as the
location and Target belt free/occupied.
inverter adopts the modified settings from the memThe inverter reacts independently of the PLC cycle ory card when it is booted. The handheld version
or cyclical communication. This means that the ofthe Intelligent Operator Panel (IOP) can be congoods can be transferred quickly and with precise nected via an optical interface and is another option
repeatability. These and similar functions can be for commissioning and diagnostics. In addition to
immediately used without modification, or they can the new functions and features that have been taibe fine-tuned or enhanced with the help of function lored to conveyor and logistics applications, the
blocks and logic modules. The STO (Safe Torque Off) Sinamics G110M also offers functions that are typisafety function is also included in the basic version cal for all Sinamics inverters, such as flying restart,
of the drive. It can be activated with a Profisafe pro- DC braking and holding brake control, automatic retocol or with two digital inputs from the frequency start, and the use of the inverters I/O including as
inverter that can be combined to create a fail-safe a distributed I/O of the higher-level control system.
digital input (F-DI). This makes it possible to connect The Sinamics G110M is easy to use and thus offers
safety systems easily and directly, and the drive potential for great savings in all phases of a plants
canbe integrated into the safety reaction of a fail lifecycle.
safePLC.
Easy commissioning
For many applications, a DIP switch is all that is
needed for commissioning. This is especially true if
the inverter is delivered with a Simogear geared
motor, as it already comes with all the relevant
motor data. This makes classic commissioning with
INFO AND CONTACT

siemens.com/sinamicsg110
michael.schmidbauer@siemens.com
johanna.gebhardt@siemens.com
21
Liebherr-International Deutschland GmbH, Germany
Perfectly
optimized
logistics
The Liebherr technology group has equipped its plant
in Biberach, Germany, with a fully automated high-bay
warehouse. The goal: to optimize this area of logistics
and install a highly available and automated complete
solution.
t its plant in Biberach, the

L iebherr corporate group manufactures rotating tower cranes
and mobile cranes that are used all
over the world. The production plant
is supplied from a high-bay parts warehouse that previously operated with
forklifts but was converted by Siemens
Stuttgart to a fully automated solu
tionwith four storage and retrieval
machines in two project stages. The
greatest benefit of this solution is the
consistency of the drive technology
achieved in the storage and retrieval
machines and in the conveyor tech
nology in the picking zones as well as
inthe shipping and
r eceiving area.
Siemens calls such perfectly coordinated drive solutions Integrated Drive
Systems (IDS).
Consistency begins at the

configuration stage
Siemens AG
The solution reduces interfaces and

thus significantly simplifies engineering starting from the very first stage
of the project, when all the drive technology is optimally configured with
the Sizer software. The values thus obtained form the basis for commissioning with the Starter software, which is
used as a parameterizing tool for the
drives. Even safety-related considerations can already be put into practice
at this stage because the Sinamics
S120 frequency converters that have
been incorporated into the storage
and retrieval machines for hoisting,
longitudinal, and fork movements have
integrated safety functions that can
beactivated with the control system
via Profisafe. In the event of an em
ergency stop, the fail-safe Simatic
S7-315F control system transmits the
corresponding command and the fre
quency converter stops the motor.
View into Liebherrs fully automated

high-bay warehouse in Biberach
22
Integrated Drive Systems | advance 3/2014
The buffer monitoring system is

alsooperated by the fail-safe control
system. If the storage and retrieval
m achine approaches its limit stop,
themotor speed is automatically reduce d.Both of the large drive motors

for h orizontal and vertical movement
are equipped with position control and
one incremental HTL speed encoder
each. While the chassis is controlled
with a laser using an SSI signal, the
hoisting unit uses an absolute value
sensor with Drive-Cliq that is driven
with a toothed belt. For the asynchronous AC motors, the project team
d ecided to use energy-efficient IE2
motors. It is also possible to feed energy back into the grid. Due to their
integrated efficient infeed technology,
the Sinamics S120 frequency converters feed the recovered energy back
into the grid instead of into the intermediate circuit when the device is lowered.
Conveyor technology
withcompact drive motors
For the conveyor technology, approximately 180 Simogear drive motors are
used for the horizontal and vertical
movements. Here, a function rectifier
located in the terminal box rapidly position the hoisting device with great
ctivates the integrated drive brake precision. A Sinamics drive with posia
and increases the stopping precision. tion control is used here, a technology
Siemens project manager Klaus Po- permitting the necessary accuracy for
cesny recalls: The space available for the varying weights.
drive technology was extremely limited for this project, which is why we Implementing a highly
used Simogear drive motors with flat availablelogistics solution
gearboxes. According to Arno Raisch,
execution manager for logistics proj- This example of how a high-bay wareects at Siemens, another advantage of house was converted from forklift opthe new series of motors is their com- eration to fully automated warehouse
patibility: Compatible flanges make it management with associated drive
possible to quickly adapt the new technology is proof that the consisdrives to existing conveyor technology tency provided by IDS offers many adsolutions. The motors are operated vantages. To Raisch and Pocesny, the
with Sinamics G120C frequency invert- projects success is beyond any doubt.
ers. In their basic configuration, these Seamless drive technologies not only
compact inverters include everything open up more possibilities but also inthat is needed to drive conveyor tech- crease the reliability of transportation
nologies for example, an integrated and warehousing in logistics, says
interface. The possibility of encoder- P ocesny.
less speed control has proven to be yet
another great advantage. All the inverters are connected to the plants
Simatic S7-319F control system via
Profinet.
The hoisting devices of the conveyor
technology show how a standardized
INFO AND CONTACT
control technology simplifies the syssiemens.com/ids
tem. Due to the heavy transportation
joerg.raible@siemens.com
loads of up to 1.5 t, it is necessary to
Seamless drive technologies not

only open up more possibilities
but also increase the reliability of
transportation and warehousing
in logistics.
Siemens AG
Klaus Pocesny, Project Manager, Siemens
23
Siemens AG
Simotics FD /
Sinamics G120P: a
powerful, highly
energy-efficient
system that is
optimized for
pump and fan
applications
New EN 50598 energy-efficiency standards
From product to system

The new European EN 50598 standard that will soon come into effect describes,
among other things, a method to identify the losses of frequency converters.
Withthis standard, drive system operators can determine how much power their
applications need based on application-specific load profiles. Integrated Drive
Systems create the best conditions for meeting this goal.
24
Integrated Drive Systems | advance 3/2014
nergy is becoming an increasingly scarce and

expensive resource. For this reason, one of the
five high-priority targets of the Europe 2020
strategy is to reduce primary energy consumption by
20% by the year 2020. Since electrically driven systems account for 70% of the power demand in industrial plants, the European Union issued the product-
related 640/2009/EU Motor Regulation in July 2009.
This regulation is based on the so-called ErP (Energy-related Products) regulation of the EU, which sets
minimum standards for energy-related products
from the domestic, services, and industrial sectors.
Emphasis on drive systems

Measures that apply only to products or components
will not be enough if the EU is to meet its carbon reduction targets. This is why the most recent activities
of the EU culminated in the new European energy efficiency standard that will come into effect at the end
of 2014. It is a series of EN 50598 standards entitled
Ecodesign for power drive systems, motor starters,
power electronics and their driven applications.
The new standard resulted from the close colla
boration of Europump (the European Association of
Pump Manufacturers), machine builders, and manufacturers of motors and drives and is based on the
concept of an extended product approach that also
takes the energy efficiency of the products method
of operation into account. The standard was jointly
developed in the technical committee of CENELEC,
the European Committee for Electrotechnical Standardization, and is intended to address not only
pumps but all production machinery. This is why the
new standard now considers all the relevant parameters that are needed to determine the energy efficiency of electrically driven production machinery.
Rating the energy efficiency

of drive and motor systems
With EN 50598, the focus shifts from individual components to entire systems. Now, the energy efficiency requirements extend from individual drive
components to all electrically driven production machinery, for example, pump systems. In this context,
EN 50598-2, the second part of the three-part standard, is particularly relevant. It defines which information is needed to evaluate the energy efficiency
of drive and motor systems and explains how losses
are calculated. To minimize effort, the standard defines a total of eight operating points for which the
losses must be determined and documented by the
manufacturer. In the future, operators can calculate
the power demands of their production machinery
with their respective drives based on application-
specific load profiles.
At a glance
Simotics SD VSD10 line / Sinamics G120:
investment-optimized drive system with
low power demands (up to 200 kW)
Simotics FD / Sinamics G120P: powerful
system with high energy efficiency,
optimized for applications with pumps and
fans (from 200 kW) power loss more than
35% lower than in the reference system
Concept study of a motor with synchronous
reluctance technology / Sinamics G120:
highly efficient system with innovative
synchronous reluctance technology
(up to 200 kW)
There will also be an efficiency classification system with which components and systems can be
comparatively ranked in terms of their energy efficiency. This means that frequency converters must
be classified into categories IE 0, IE 1, or IE 2 and
drive systems into categories IES 0, IES 1, or IES 2. As
with the existing motor classes, higher numbers
mean lower losses and thus higher energy efficiency.
Perfectly prepared for the standard

The new standard must be used for nonregenerative
AC/AC frequency converters, motors with integrated
converters, and converters with a power range of
0.12 kW to 1,000 kW and a supply voltage of 100 V
to 1,000 V. Optionally, the standard can also be applied to regenerative AC/AC frequency converters,
AC/DC and DC/AC converters, and converter and
motor combinations.
With the triple integration of Integrated Drive
Systems (IDS), Siemens offers its customers a perfectly matched system that can enable them to tap
into the full energy-efficiency potential of their electrically driven production machinery. They can use
the perfectly attuned portfolio of drives to optimize
the entire drivetrain while also using the communication capabilities of higher-level processes as well
as tools and services for lifecycle integration that
take into account operating costs and environmental impact over the entire lifecycle of the machinery.
25
advance 3/2014 | Integrated Drive Systems
Well-matched combinations
save energy
tages of this technology are the fast cold restart

times, high controlling dynamics in encoderless operation, and low system costs thanks to the coordiMotors in the Simotics SD VSD10 series, combined nated power modules. All the drive systems have
with Sinamics G120 inverters, have a system energy special energy-efficiency functions such as Profiefficiency class of IES 1 and are an investment- energy and Eco Mode. In addition, all the necessary
optimized drive system with low power demands. data for higher-level power management systems
The perfectly matched components contribute to are made available.
lowering the energy costs. For instance, the currents
and voltage of the motor are precisely matched to Manufacturers and users benefit
the inverter, making it possible to operate the sys- in equal measure
tem at the operating point with the highest energy
efficiency. In class IES 2, the Simotics FD and Sinamics With EN 50598-2, converter and drive manufacturG120P units are a powerful drive system with high ers will be able to determine the power loss of their
energy efficiency. Once a fan, pump, or compressor products with a reasonable amount of effort. They
has been optimized for a squared load characteristic, will also benefit from reproducible testing condi-
this combination, which has been especially adapted

for applications with pumps and fans, has only minimal losses at partial-load points. The motor and
inverter combination is ideal when it comes to energy efficiency: the Sinamics G120P inverter has extremely low power loss and a variable-speed inverter
fan that regulates itself according to the systems
cooling needs. The rotor design of the Simotics FD,
in contrast, has been optimized for speed control.
This results in power loss that is more than 35%
below the level of the reference system. The concept
study revealed that the combination of an innovative
motor with synchronous reluctance technology and
Sinamics G120 inverters has the highest power efficiency in class IES 2 and at the same time the lowest
lifecycle costs. The control has been optimized for
synchronous motors and offers highly dynamic maximum efficiency at all operating points. The advan26
Siemens AG
The new EN 50598

standard imposes
stricter requirements
regarding the energy
efficiency of entire
systems, for example,
pump applications
tions. In turn, users will be able to determine the

power loss or rather the power demand of their
applications based on application-specific load profiles and compare products in terms of their energy
efficiency. In view of rising energy prices and the
growing resource shortage, these factors are increasingly important; supported by the new standard, they will pave the way for sustainable economic activity.
INFO AND CONTACT

siemens.com/ids
daniela.heckel@siemens.com
Training | advance 3/2014
Fotolia/Dayzi
On-site training
Fit for the

mining
industry
ue to the political situation, Ukraine is currently making

headlines around the globe. However, there is also other
news from this country located in the middle of Eastern
Europe. One company making news is the public stock corporation Poltave Ore Mining and Processing Enterprise, a giant in
the Ukrainian mining industry. Located in the small town of
Komsomolsk in the central Ukrainian district of Poltava, about
350 km southeast of Kiev, the company produces mainly iron
ore concentrate with an iron content of up to 65% and fluxed
iron ore pellets for blast furnaces and metallurgical operations
28 million t of unprocessed iron ore, more than 10 million t of
iron ore concentrate, and 10 million t of iron ore pellets per year,
according to the Poltavia Chamber of Industry and Commerce.
The company is currently switching to Siemens automation
systems, explains Yuliya Aleksandrova of Sitrain Training for
Industry in the Ukraine. Like many big Ukrainian companies,
they would like to train their own employees so that the company does not have to rely solely on external specialists for service and project purposes.
First steps into the world of Siemens

For this reason, the company approached Sitrain with the request to develop a training program that is comparable to the
German standard. The employees are to be included in the development of their own production processes so that they will
be able to service their plant later. The Sitrain training is the
first step into the world of Siemens for most participants, which
means it is important to give good initial insight into Siemens
industrial products and solutions. The participants already have
basic knowledge of automation and HMI. The training courses
for Simatic S7 and Simatic WinCC build on this previous knowledge. The next step then is the integration of industrial networks and SCADA into the MES and ERP system. The target
groups are project engineers and service personnel. So far, 31
employees have taken part in the training courses.
Poltave Ore Mining and Processing

Enterprise, a Ukrainian mining company,
wishes to train its own employees for
service and project purposes in order to
avoid relying solely on external specialists.
For this reason, the companys employees
received the appropriate training from
Sitrain.
Employees with expert status

How does the client benefit? The company can use very welltrained employees who work as experts as soon as they enter
the plant. Trained personnel are on-site, and the company can
use its own service staff. Added to this are financial and time
savings due to a reduction in plant downtimes. Siemens provides the products and the required training courses directly at
the clients location. The company is a long-standing customer
of Siemens, explains Aleksandrova. The current contract came
into force at the beginning of 2011 and has been renewed twice
since then. Additional training activities are planned for this
year, the current situation in Ukraine permitting.
The Poltave Ore Mining

and Processing Enterprise mines
Kuptsov Dmitry
INFO AND CONTACT

siemens.com/sitrain
karl-ludwig.weiner@siemens.com
27
Siemens AG / A. Kradisch
advance 3/2014 | Safety technology
In all industries, machines must meet

certain safety requirements. Validation
serves as proof that they do so
T
Validation is an important step
toward the CE marking of
machines and plants. A series
of measures are required in
order to adequately address
the safety requirements of
themachine during the
development of the safetyoriented components of the
control system and to prove
compliance with these
requirements.
28
he safety-relevant components
It is often easier to carry out this deofa machine control system manding task together with the manumustfulfill specific safety require- facturers of the individual components.
ments. Machine validation serves to The free-of-charge TV-certified Safety
prove that they do so. Based on the Evaluation Tool for standards EN 62061
EN62061 and EN ISO 13849 standards, and EN ISO 13849 facilitates and ac
machine validation confirms that the celerates the probabilistic evaluation
safety-relevant components of the ofthe machines safety functions and
control system fulfill the safety require then creates a standards-compliant rements of machines (Safety Require- port to serve as safety certification for
ments Specification, SRS) through the machine documentation. In addi
analysis and/or testing. Validation tion, in the area of functional safety,
proves that the machine will enter and Siemens offers training on safety stanmaintain a safe operating state in the dards, CE marking, risk assessment,
event of a possible error, thus comply- and validation.
ing with Machinery Directive 2006/42/
EC Annex 1 Paragraph 1.2.1. The vali- Correctly assessing risks
dation includes the safety functions, andhazards
the Safety Integrity Level (SIL) and/or
the performance level (PL) and the The verification (proof of the selected
corresponding categories, the appli system design) and validation (testing
cation software, the combination of the efficiency of the safety system) of
safety-relevant components, the envi- machines starts with a risk assessment
ronmental and maintenance require- in accordance with ISO 12100. In this
ments, and the technical documen process, it is important to identify postation.
sible hazards and evaluate their risk
Safety technology | advance 3/2014
levels. On this basis, it is possible to

define technical measures as well as
the designed measures to minimize
the risk through the use of safety-
oriented systems in accordance with
the relevant standards. First, the ar
chitecture of the hardware and softwaremust be selected and assembled.
During the subsequent implementation phase, the functional safety of the
individual steps must be verified and
then validated through special tests.
The next step is proof of meeting all
the requirements based on the documentation. The machine validation is
complete only when all these steps
have been carried out.
Validation
Design,
testing,
documentation
Validation plan is necessary
Validation process in accordance with EN ISO 13849-2
Error lists
Observations
on design
START
Documents
Validation plan
Criteria for
error elimination
Analysis
Is the analysis adequate?
Safety functions
PL and categories:
- Determination of the categories
- MTTFd, DC, CCF
- Systematic errors
- Software
- Verification of the PL for the SRP/CS
- Combination of SRP/CS
Environmental requirements
Basic validation
principles
no
Test
yes
no
Category 2, 3, 4
yes
Test passed?
yes
Testing the safety function
under error conditions
no
Changes
to design
Maintenance requirements
PL
= performance level
MTTFd = mean time to dangerous
failure
DC
= diagnostic coverage
CCF
= common cause failure
SRP/CS = safety related part of a
control system
Validation report
Have all safety functions

been validated?
no
yes
END
Siemens AG
Technical specifications /
user information
First, the manufacturers must draw up

a validation and test plan. The best approach for this is to discuss as a team
how the validation can be executed
while defining the relevant documents and standards for the appropriate analysis and testing methods as
well as identifying the persons res
pons ible for the validation process. It
is imp ortant to describe the requirements for the safety-related parts of a
control system (SRP/CS) in this process
and to indicate the standards and
guidelines that are to be applied as
well as components that have already
been certified.
In addition to all the documents relating to the validation process, the
validation plan should also include the
operating and ambient conditions
under which the validation takes place
as well as which analysis and testing
methods are used. For this, it is necessary to create a test plan with corresponding test specifications. These
specifications include a detailed description of the tests, the set-up, the
test environment, and test programs,
as well as error simulations and the results to be expected of the individual
tests. Information on the development
process as well as the scheduling of
the individual validation steps, including identification of the responsible
persons, should also be part of the
plan. Those carrying out the validation
should preferably not have been involved in the development process
(ENISO 13849-2, Chapter 4.1, Basic
Validation Principles).
29
advance 3/2014 | Safety technology
Validation of the
safety functions
dated the functionality of the components and of the software.
To ensure that the function targets Taking into account the

have been met, the test results must general conditions
be compared with the test plan and
documented. Verification of the safety The ambient conditions must also be
functions is an essential part of the included in the validation. The systems
validation process. Through analysis must withstand certain mechanical, cliand/or testing, the testers must prove matic, and electromagnetic loads, and
that the set-up, cabling, parameter the safety functions must maintain
a ssignments, programming, and all their reliability. Finally, the testers must
safet y functions comply with the spec- create a complete machine validation
ifications outlined in EN 62061 and/ report that is easy to understand and
orEN ISO 13849-1 and 2. In case of de- read and that proves that all the docuviations from the expected results, the ments required by Machinery Directive
system must be corrected and the ap- Annex VII exist, because the CE markpropriate retesting must be carried out ing and thus the overall release makand documented.
ing it possible to put the machine into
circulation is only granted when the
Validation of the application
documentation is complete.
Validation training
For professional implementation
of the validation process,
Siemens offers the one-day
Validation of Functional Safety
in the Manufacturing Industry
(ST-FAVALID) course. In this
course, participants learn
everything that is required
from the scope and the correct
approach to the finalization
andthe documentation of
avalidation process. The
individual steps of the validation
process are both taught
theoretically and illustrated
using examples.
siemens.com/sitrain
software
30
Software validation
Safety-relevant
software specification
Validation
System design
Integration test
Module design
Module test
END
Testing activities
Software design
Design activities
Coding
Function blocks
(created by the manufacturer of
the safety components)
Verification
Siemens AG
Software can pose a special challenge

in achieving and proving compliance
with safety targets, because simple
function tests cannot do justice to the
complexity that quickly results. To ensure that the software is performing
correctly in its overall environment, it
too must be verified and validated.
Since the software specification is an
important part of the realization of
thesafety functions, certain validation
and verification steps, in compliance
with the V-model, are necessary. These
steps include verification of the development documentation in terms of
itscompleteness, accuracy, and avoidance of faulty interpretations as well
as the documentation of sufficient
measures to prevent systematic failures. All options to circumvent the
safety functions must be clearly controlled, and additional simulations or
function tests for complex modules
with rare or undefined signals and/or
provoked errors must be carried out.
Not least, the testers must prove that
all the safety functions have been correctly implemented at the time of the
software implementation.
If only the application software is
being created because the hardw arerelated software functions (see graphic:
blue area of the V-model) of the SRP/
CS are already available through validated F-CPUs, the software validation
is significantly easier. In this case, the
manufacturer has usually already vali-
Result
V-model for application software
INFO AND CONTACT

siemens.com/safety-integrated
heinz.wilhelm@siemens.com
Sitrain courses
Safety training
for industry automation
To ensure safety of people and machines, Siemens offers products with
integrated safety functions. Users can learn how to use these functions for
Simatic S7-1500 and TIA Portal V.13 in new course.
ue to their design and functionality, machines

and plants pose inherent risks to the people
who work with them. The goal must be to
provide optimal protection to these employees. In
the course Fail-Safe Simatic Programming with
Step 7 Safety in TIA Portal (TIA-SAFETY), participants are given a general overview of standards
andguidelines and learn about Simatic S7 Safety,
fail-safe communication with Profisafe, and diagnostics possibilities. They also practice configuring
the f ail-safe distributed devices with Step 7 Safety
Advanced and programming a safety-oriented application program. An important part of the courses
are exercises. Participants learn to set up distributed devices, communication, and troubleshooting
as well as safety-specific programming. Theoretical
knowledge is reinforced by practical exercises on a

Simatic S7-1500F.
After completing the course, the participants are
able to commission fail-safe Simatic control systems
and create programs in F-FBD or F-LAD as well as
carry out diagnostic and troubleshooting tasks in
fail-safe programs. With Totally Integrated Automation and Safety Integrated, they are able to program
safe and productive machines much more easily and
at a lower cost.
INFO AND CONTACT

siemens.com/sitrain-safetyintegrated
marianne.schoch@siemens.com
Siemens AG
Siemens AG
In the TIA Safety course, participants learn how to program and commission the fail-safe Simatic control systems as well as to use the functions
of TIA Portal V.13
31
In the cab, the Simatic

mobile panel serves as
acontrol element and
tachometer
Safe control
of large forces
Safety-related requirements for track moving machines in brown
coalsurface mining are high because they release enormous forces.
Automating machines that were previously operated by handwheel
and switch increases their functional safety while making them easier
for operators to use. Vattenfall recently implemented a new standard
based on a fail-safe control system.
Left: The grappler with

lifting and pushing
rollers lifts and shifts
thetracks
Right: The track moving
machine was automated
for the first time using
afail-safe Simatic
S7-315F-2PN/DP
SAG GmbH, Germany
32
attenfall operates the largest ex- tion of the excavation. This work is
cavating site in Europe in Lusatia. performed by track moving machines,
The unique brown coal seams which look like extra-long railroad cars
with a thickness of up to 12 m run hor- that have a grappler with lifting and
izontally below an earth layer with a pushing rollers in the middle instead of
depth of about 80 m, making highly a pair of wheels. The grappler lifts the
efficient surface mining possible. In tracks, including the ties, and is able to
this operation, huge conveying bridges shift them up to a meter from its axis. It
work together with bucket wheel ex seems impossible, but these machines
cavators to transport the earth over the move the tracks that they themselves
pit and dump it in a targeted manner. In are traveling on.
this process, accompanying raw materials are extracted for industrial use and From handwheel
nutrient-rich soil is recovered for land to automatic control
restoration.
Excavators and transport bridges Vattenfall develops and manufactures
drive for miles on tracks that are paral- the track moving mechanism itself.
lel to the open-pit rim. The rim moves as Themachines are used for many years,
the excavation progresses, so the tracks which is why they are subject to strict
must be moved repeatedly in the direc- monitoring and are regularly overhauled. For the electrotechnical equipment, Vattenfall collaborates with SAG
sag.de
GmbH. Dirk Ldtke, division manager
atthe Schwarze Pumpe location of
SAGGmbH
in Spremberg, Germany,
SAG Germany is one of Germany's the
and his team equipped the first maleading service and system suppliers
chine originally operated via handforelectrical power, gas, water, and
wheel and switch with a fail-safe
telecommunication networks, as well as
Simatic S7-315F-2PN/DP in the rugged
plants generating, providing, and applying
Siplus version for the surface mining
energy, water, and gas. Over 100 locations
operation in Nochten. The machine
in Germany assure good service coverage
weighs about 100 t and is driven by a
for regional and municipal energy
huge ships engine. It needs to be able
providers, industrial companies, power
to handle different soil conditions and
plant operators, and transport services.
react quickly and safely to obstacles or
breaks in the track. The huge forces
SAG GmbH, Langen
could quickly cause great damage and
obstruct the entire excavation operation in the event of a malfunction.
Thefail-safe automation significantly
increases the machines functional
safety and brings it in line with the
Machinery Directive. The software allows for substantially faster identifi
cation and elimination of faults while
simultaneously increasing availability.
It is very important that the machine
be easy to operate, as different employees need to be able to drive it safely.
With a Simatic 277 PN mobile panel, the
driver has a significantly better overview. The panel serves as a controller
forall the important functions and as a
tachometer with a display of the speed.
It also displays relevant machine parameters such as temperature and power
consumption. The driver enters the direction of travel and the desired speed;
beyond this, he or she needs to operate

very few control elements, such as the
throttle and, if need be, the emergency
stop.
Future-proof technology
Ldtke chose up-to-date and future-
proof technology for the automation
and drive technology. For the customer,
one important component of a future-
proof system was integrated Profinet
communication. This will allow the machines to also be monitored from a central location or mobile terminal device
in the future. This is a crucial safety
aspect, considering the extensive and
remote nature of surface mining areas.
One unusual aspect for Ldtke and his
team was the configuration of all the automation including the fail-safe components and the Sinamics inverters
inTIA Portal. Being able to use one in
terface for the entire project is great.
Wewere already familiar with Step 7
andWinCC in TIA Portal; Step 7 Safety
Advanced V12 was new to us. We were
able to integrate even the safety-
oriented system components without
any problems. The Sinamics inverters
were configured using Startdrive via
the same interface. A single compact
project saves time during commissioning and will prove to be a clear advantage for maintenance as well. Faults can
be detected and eliminated much faster,
Ldtke explains.
Proven solution becomes

the standard
The new equipment has already proven
its worth and is to be implemented as
standard in additional machines. Following the same operational procedures and the same maintenance procedures makes the work easier for all
involved and reduces the probability
of faults.
INFO AND CONTACT

siemens.com/safety-integrated
ralf.stegmann@siemens.com
33
The MAPAL setting

fixture handles the
reliable measuring and
marking of the tools
MAPAL Dr. Kress KG, Germany
Clear tool identification

A global automobile manufacturer relies on radio-frequency identification (RFID) to identify
andmonitor its machine tools. The RFID readers capture the geometric and process data stored in
the RFID chips of the toolholders. This ensures a clear and precise assignment of workpiece, tool,
and machining process.
or decades, MAPAL Dr. Kress KG has been one of

the leading suppliers of precision tools for metal
machining. In addition to tool and process solutions for cubic components, the company offers
anextensive and technologically advanced tool program for reaming, boring, drilling, milling, turning,
actuating, clamping, setting, and measuring applications. One highlight is the Tooltronic actuating tool
with its fully interchangeable tool axis. It enables
machining that otherwise could only be performed
by special machines or tools, for example, the machining of contours, recesses, and noncylindrical
boreholes. To record the tool data, the tool can be
34
equipped with an RFID data memory, which ensures

clear and precise assignment to the appropriate machining processes.
RFID data memory in the flange

of the hollow shank taper
For several years, an automobile manufacturer has
been employing cutting tools fitted with Siemens
RFID transponders for the machining of engine
blocks in its North American plant. The data memory
is permanently installed in the flange of the tools
hollow shank taper, which allows for the tools clear
Industrial identification | advance 3/2014
identification at the machining centers and prevents and ensures that the tool data loop in the production
errors due to manual inputs. The identification process is closed. In addition, the integration of
solution is based on high-efficiency read/write de- cutting-edge setting fixtures is possible. The chip
vices of the Simatic RF350R series, which were in- identification simplifies tasks such as scheduling,
stalled at the machining centers along the produc- storing, assembling, presetting, and managing the
tion lines. A production line includes between 20 machining tools. Since all data related to the tool are
and 30 CNC machines, which depending on the located on the transponder, time-consuming manual
task are on average equipped with 50 individual inputs are no longer necessary, Grundmann extools. Because the tools wear out from continuous plains.
A central issue in tool management is service
use and need to be replaced for servicing, a second
tool set is required for uninterrupted operation. To lifeutilization. The RFID reader reads the product-
specific characteristics, such as setting parameters,
be on the safe side, a third set is kept in reserve.
For the connection to the automation level, service life, identification numbers, and dimensions
theSimatic readers feature RS422 interfaces. The as well as cutting and wear data, and the CNC coninterference-proof data transmission between the trol points out an upcoming tool change to the operread/write stations and the mobile data media (tags) ator once the remaining service life has expired. This
takes place via the connected ANT 12 circular anten- helps prevent excessive wear and tear on the tools
nas. The read/write stations transmit the data accom- and at the same time significantly reduces main
panying the tool to the CNC control, where it is saved tenance. The accurate measuring and setting of the
together with the position number in the tool mag- cutting tools is a prerequisite for high-quality parts.
azine. After the machining is complete, the tools re- This is why the automaker employs special MAPAL
maining service life is transmitted from the CNC setting fixtures for the micro-precise measuring and
memory to the transponder. The MAPAL tools are fit- setting of new and reground drill bits, milling cutters,
ted with passive MDS D421 data media by Siemens, and reamers used for machining the engine blocks.
Along with the RFID solution, the setting fixtures also
facilitate and automate the reporting and documentation of the measured values. To save the measured
data, the fixtures likewise work with Simatic RF350R
RFID readers or the more compact RF210R for shorter
distances, whose attached read/write heads write to
the mobile data memory of the tools.
Expectations fully met
The machining tool passes by the antenna at

adistance of 2 to 3 mm and the RFID reader
transmits the data to the machine control
designed for tool encoding in accordance with DIN

69873, which can be used wherever small data
media with exact positioning are required. With a
storage capacity of 2,000 bytes and up to 1010 read/
write cycles, they provide sufficient reserves even for
growing requirements, explains Jochen Grundmann,
vice president of operations at MAPAL USA.
Efficient tool management

Efficient tool management ranks among the central
tasks in CNC production. The Tool Data Information
(TDI) software gives an overview of the tools used
According to the automobile manufacturer, the RFID

marking of the tools has fully met the companys
e xpectations and is contributing to a reduction
inset-up times. Grundmann summarizes the ad

vantages of this solution: High-quality and cost-
intensive products are made at the machining centers of the production facilities. The mobile data
media fitted to the tools ensure their clear assignment to the appropriate machining processes, which
allows the automobile manufacturer to use the tools
in several machines. Based on the chip data, the machine control checks plausibilities and ensures error-free and reliable tool operation. The transponders also document the tool lifecycle and thus make
any operational phase traceable.
INFO AND CONTACT

siemens.com/ident
siemens.com/rfid
mathias.langhans@siemens.com
35
advance 3/2014 | Power supplies
Sitop PSU8600
Well-designed
power supply
In highly demanding production processes, an outage or interruption of the 24-V
direct-current power can significantly affect operations and result in considerable
damage and expense. The new Sitop PSU8600 power supply system can be flexibly
configured in TIA Portal; can be easily integrated into the automation system with
Profinet; supplies comprehensive information for diagnostics and maintenance;
supports energy management; and thus offers greater flexibility, reliability, and
efficiency.
to a standstill, the output currents are and efficiently. If more than 4 outputs
monitored, and every output with an are needed, more can be added with
individually switching threshold can be the expansion modules in increments
selectively shut down in the event of a of 4, to up to 16 outputs. Users can
choose between two expansion moddisturbance.
On the primary side, the PSU8600 ules (CNX8600) with 4 x 5 A or 4 x 10 A.
issupplied with a three-phase wide- These are simply mounted next to the
range input with 400 to 500 V. Due to basic unit on the standard mounting
its high overload capability (Extra rail and connected with the System
Power) up to 1.5 times of the nominal Clip Link, a collapsible system con
current, numerous loads with different nector for data and power supply. The
requirements can be supplied reliably same applies to the optional buffer
Siemens AG / T. Weishart
he Sitop PSU8600s compact basic

unit with 40 A and 94% power
efficiency contains an Industrial
Ethernet / Profinet interface (two ports)
as well as four individually configurable
outputs in as little as 125 mm mounting width. When the power supply
unitis activated, the outputs can be
switched on synchronously, with a time
delay, or with load optimization. To prevent a short circuit or overload in one
DC load from bringing the entire plant
36
Power supplies | advance 3/2014
modules (BUF8600), with which short

power failures of up to 600 ms (at 40 A)
can be bridged. The add-on modules
inthe modular system can be added in
any order, which makes subsequent expansion particularly easy.
Part of Totally Integrated

Automation
tion into Step 7 user programs. The tive overload conditions can be debroad functionality is complemented tected early on and the necessary meaby tailored PSU faceplates used for sures can be initiated before a disturmonitoring and operation with Simatic bance or outage can cause damage to
panels and Simatic WinCC. All these op- the plant.
tions reduce the engineering effort,
saving time and therefore reducing The best support for
costs.
energy management
Comprehensive monitoring
The new Sitop systems wide range of anddiagnostics
functions, which significantly exceeds
what conventional power supply units Integrated monitoring and diagnostics
can offer, is based to a large extent on functions for example, to determine
its integrated communication capabili- whether the outputs are active or inacties via Industrial Ethernet/Profinet. tive are crucial to ensure the susThe system is thus easily integrated tained reliable and efficient operation
intoautomation solutions with Simatic, of the power supply and the plant comSinumerik, or Simotion. Engineering is ponents. Information is also available
quick and easy in TIA Portal. Using the on network and phase failures, the
portals hardware catalog, the PSU8600 times of which can be recorded and
is dragged and dropped into the net- used for network quality analyses, for
work view and then connected to the example. All this information can be
Profinet component with which data is evaluated with Simatic S7 and visualto be exchanged. Next, in the device ized with WinCC. This allows disturview, again by means of drag and drop, bances and unusual operating states to
the desired add-on modules are se- be detected and identified early and erlected. Finally, all further parameters, rors to be corrected quickly. The system
such as output voltage, threshold cur- also enables efficient preventive mainrents, and diagnostic information noti- tenance. The currents and voltages of
fications, can be set. Ready-made func- each output are measured and transtion blocks for Simatic S7-300/400/1200 ferred to the control level with Profinet.
and 1500 are available for easy integra- Thus, dynamic, continuous, or cumula-
The new power supply system supports

energy management with Profinet and
Profienergy, meaning that all outputs
can be activated and deactivated in
dividually. They can be deactivated
during breaks, for example, when specific loads do not require any power
and therefore no DC supply and can be
turned off. The PSU8600 also separately records the current power and
voltage values of each output channel
and makes these data available for archiving and evaluation purposes, for
example, in higher-level energy management systems.
INFO AND CONTACT

siemens.com/sitop
peter.hager@siemens.com
The Sitop PSU8600 is comprehensively integrated into the machines or plants

automation system through its open Profinet communication
ADVANTAGES
Simatic
S7-300/400/1200/1500
Step 7
Modular expandability without extra wiring effort for

additional outputs or for modules to buffer short power
failures
Panel / PC
WinCC
PC / PG
TIA Portal, Step 7
Engineering
Controller
HMI
Integrated Industrial Ethernet / Profinet communication

for perfect integration into the machines or plants
automation system
Profinet
Time and cost savings during engineering and operation

thanks to integration into Totally Integrated Automation
24-V DC
further monitored
load circuits
Comprehensive in-operation monitoring and diagnostics

for preventive maintenance
Sitop PSU8600 power
supply system
Siemens AG
Support for energy management through power data

recording and targeted output switching
37
advance 3/2014 | Industrial controls
Sirius modular system
Standards-compliant
control cabinet design
As of January 1, 2015, machine and plant manufacturers must use highly
energy-efficient IE3 motors in order to comply with EU regulation 640/2009.
Furthermore, the new IEC 61439 standard, which regulates how control
cabinets must be built, will come into force in the European Economic Area in
fall 2014. Both regulations will have a significant impact on how low-voltage
switchgear is used and control cabinets are built.
Siemens AG
38
The Sirius switching devices

arecompatible with class IE3
energy-efficient asynchronous
AC motors, which will
becompulsory beginning
January 1, 2015
emand for higher energy

e f
ficiency has become a regular
feature of day-to-day industrial
operations. EU regulation 640/2009,
which has been valid since June16,2011,
requires manufacturers in the E
uropean
Economic Area to gradually transition
to energy-efficient electric motors. According to this regulation, asynchronous motors for mains operation with
a power range of between 7.5kW and
375kW must have the efficiency-class
IE3 rating as of January 1, 2015. Standard IEC 60034-30 regulates the required efficiency of asynchronous motors and specifies the efficiency levels
for the respective energy-e fficiency
classes. Similar measures toincrease
energy efficiency are also being consistently applied in other countries around
the world.
Lower rated currents during ra-
tedoperation increase the motors
e nergy efficiency. However, such high-
ef
f i
c iency motors usually also have
higher starter current ratios. Often,
they have superimposed inrush currents that arise immediately after the
motors have been connected to the
Industrial controls | advance 3/2014
Siemens AG
New IEC61439 standard
grid. Low-voltage switchgear must be

adapted to handle these changes.
The new IEC 61439 standard

for low-voltage switchgear
and controlgear assemblies
replaces the old IEC 60439
standard. Control cabinets
must now be built in
accordance with the new
technical regulations
When the EU regulation on the use of efficiencyclass IE3 asynchronous AC motors comes into
effect on January 1, 2015, changes to how control
cabinets must be planned and designed will
alsocome into force. The new IEC 61439 standard
forlow-voltage switchgear and controlgear
assemblies will replace the old IEC 60439 standard.
The new standard includes more specific regu
lations regarding the attestations that the
manufacturer must provide for switchgear and
controlgear assemblies, or for the entire control
cabinet, and requires more tests. Compliance
withthe reference design is also more strictly
regulated. Siemens offers comprehensive support
in this area, from straightforward advice on the
new standard to workshops and training sessions
at customer facilities.
You can find more information on this topic at
siemens.com/iec61439
the new Sirius series is that it is notonly

suitable for the new IE3 motors but
also has high power density. The effiCoordinated system
ciency of the just 55-mm-wide size
S2devices was significantly increa
with high power density
se dwith a maximum rated current of
The so-called inrush current varies 80Aand a switchable motor power of
depending on the motor, application, 37kW. In practical terms, this means
and operating conditions. Compared that if a user previously needed devices
toolder generations of motors, the in- with a mounting width of 70 mm,
rush current increases up to 50% in IE3 55mm are now sufficient. This saves
motors due to their increased magne- space in the control cabinet and retization and decreased winding resis- duces costs. The same accessories
tance. Inrush currents arise within the thatare available for sizes S00 and
first half-wave after the motor has S0can also be used for the innovated
been connected to the power supply size S2,for example, contactor funcgrid. Together with the current load tion m
odules for IO-Link, AS-Interface,
rating and bouncing effects, this can and logic, which is quite practical. This
cause electric arcs in switching devices, significantly reduces the variance of
which can in turn lead to main contact the devices and limits the quantity of
welding. Brief excess currents can also required article numbers.
accidentally trigger circuit breakers
that are not designed to be used with Service increases competitiveness
IE3 motors, as the switch interprets
In addition to the features of the dethem as short-circuit currents.
Siemens has calibrated the devices in vice themselves and documented comthe Sirius modular system to deal with pliance of the control cabinet design
this characteristic of energy-efficient with the new standards, receiving supIE3 motors. The greatest advantage of port during the planning and acquisi-
tion phase is an increasingly impor

tant factor for global competitiveness.
Siemens supports machine and plant
manufacturers with a wide range of
service measures and thus underscores
the Planning Efficiency trend. This saves
valuable time and makes a significant
contribution to the sustainability of
technical solutions. The entire Sirius
modular system is available electro
nically as a CAx catalog with all the
necessary measurements, 2-D and 3-D
images, certificates, licenses, test cer
ti
ficates, user guides, operating ins
truction manuals, and so on. Regular
demand-based workshops complete
the training portfolio. The Technical
Assistance department also provides
detailed 24
/
7 support for specific
issues.
INFO AND CONTACT

siemens.com/sirius
helene.steuer@siemens.com
39
Cultura Travel / Dan Dunkley
Approved Partners are

geographically close to
thecustomer and inspire
confidence with their
competence and absolute
delivery reliability
Siemens Partner Program
Global network
of experts
To offer a portfolio of products, services, and solutions that meet customers
automation, drive technology, and power distribution needs even better,
Siemens works in close collaboration with specialized external partners all
over the world. The global Siemens Partner Program for industrial technology
distinguishes between Solution Partners and Approved Partners.
he goal of Siemens Solution Partners is to use

Siemens systems and products to supply customers in the automation and drive technology
industries with top-quality future-proof solutions
that are cost-efficient, highly productive, and tailored to their needs and thus provide them with a
competitive advantage. The Solution Partners certified technical competence, outstanding industrial
knowledge, and distinct solution expertise ensure
high efficiency. These partners demonstrate comprehensive practical knowledge about the applications and systems and proven project experience.
The right partner for each task

Siemens has worked with systems integrators for
many years, but it also has long-standing business
40
relationships with companies in the distribution and

service sector around the world. To strengthen the
collaboration and systematically promote select
partners based on contractually agreed criteria, and
also to set a globally consistent quality standard,
Siemens has introduced the label Approved Partners.
We are gradually building our network of Approved Partners. Siemens Approved Partners provide their customers not only with Siemens products
but also with modifications and a broad range of services. Approved Partners can be companies in the logistics and service sectors or value-added resellers.
For anyone who needs fast delivery of a product
orsystem from the Siemens portfolio, a nearby
Approved Partner in the logistics sector is the right
company to turn to. Customized services such as
Services | advance 3/2014
Pointing the way in automation, drive technology, and power distribution
Solution Partner
Approved Partner
Solution Partner
Approved Partner Logistics
R
educed risk thanks to comprehensive practical knowledge
ofapplications and systems and
proven project experience
Excellent industry expertise for
future-proof tailored solutions
ofthe highest quality
Highest stock availability

ofa comprehensive portfolio
of Siemens products
Efficient ordering processes,
absolute delivery reliability,
and optimized logistics
all from a single source
Solutions
Approved Partner
Value-Added Reseller
Deep technical product
knowledge combined with
qualified technical advice
Delivery of high-quality
product and systems
packages accompanied
by superb technical support
Approved Partner Service

Individual support and specific
expertise guarantee high plant
availability
Comprehensive service:
maintenance and repair services,
support during commissioning,
support for retrofitting projects,
and training on Siemens products
Products/Applications/Modifications
just-in-time delivery, a broad range of Siemens products, efficient order processing, and absolute delivery reliability are guaranteed.
When it comes to implementing specific technologies, value-added resellers set themselves apart with
their deep and detailed technical knowledge and can
provide the customer with the best advice. Furthermore, they are suppliers not only of superb technical
support but also of high-quality products and system
packages that are always in stock.
The hallmark of Approved Partners in the service
sector is their expertise in maximizing machine and
plant availability. As they are geographically close to
the customer, they can provide quick assistance in
the event of any problems. The broad range of services includes maintenance and repair tasks (Repair
Service), support during commissioning and operation (Field Service), and services such as retrofitting
projects (Enhanced Service) as well as training
courses on Siemens products and systems.
Comprehensive qualification
The goal of the Siemens Partner Program is to ensure
the highest possible quality. This affects the selection of partners, the commitment to joint technological and strategic development, and the comprehensive know-how about Siemens products and systems.
Competence in terms of advice, support, and
product availability is the key to meeting custom-
Services
An overview of Siemens Approved Partners

and Solution Partners is available via the
Partner Finder. With this tool, you can
quickly and reliably find the ideal partner
foryour specific project.
siemens.com/partnerfinder
ers high demands. This is why systematic competence management, together with a comprehensive
qualification process for partners employees, is a
cornerstone of the Siemens Partner Program. Partners are systematically trained and obtain globally
consistent qualifications and certifications. Partners
employees are trained according to their individual
requirements and acquire the specialized knowledge
they need to carry out their tasks. To identify the individual qualification measures, a thorough analysis
is made and individual training needs are determined
based on the results. In addition to courses on products and systems, staff training includes sales training and courses to develop personal skills. Siemens
partners benefit from a broad range of training
courses and access to useful materials.
INFO AND CONTACT
siemens.com/partnerprogram
andrea.hammerl@siemens.com
41
advance 3/2014 | Dialogue
LOGO! 8 Roadshow through Europe
Hello, Europe Hello, World!

With the LOGO! 8 series of logic modules for smaller automation solutions in
industry and building systems, Siemens
is launching a completely new gene
ration of devices. In November, a European roadshow kicks off to accompany
the market introduction, with stops at
selected business partners. In a fully
equipped roadshow truck with an

integrated presentation forum, business partners clients can experience
the logic modules live in the hands-on
area and even program them during a
short training session.
The LOGO! 8 truck will visit 12 countries on its Hello World tour. From
Library
Technical book series on Simatic
urrent technical literature keeps you up-to-date.

The Simatic book series presents the various hardware components of automation systems together
with examples describing their configuration and parameterization. An in-depth introduction to programming
and troubleshooting with Step 7 Professional helps users
get started with TIA Portal, whether they are beginners
or switching from another system.
www.publicis.de/books
42
You can find Siemens

reference books on
automation technology
and many more subjects
at:
ovember 2014 to April 2015, the truck

N
will make scheduled stops in Belgium,
Denmark, Germany, Finland, France,
Italy, the Netherlands, Austria, Poland,
Switzerland, Sweden, and the Czech
Republic.
siemens.com/logo
Dialogue | advance 3/2014
Multimedia magazines
Print:
Our technical magazines are a real
added value for your business.
Regardless of whether you choose
process news, motion world, or
advance, in our technical magazines
for all areas of automation and technology, the information and technology are interestingly presented, well
researched and up-to-date, and described with application examples.
You as a plant operator or machine
manufacturer are always well informed with information specially
adapted to your industry.
You can order a free subscription of

your preferred technical magazine at
siemens. com/industry-magazines
or subscribe d
irectly to advance at
siemens.com/advance.
Online:
The advance online siemens.com/
advance complements the print
issue and offers current information
on key topics and technologies more
frequently. It provides quick access
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issues but also to additional news, application examples, detailed technol-
Siemens
Publications
for iOS
ogy articles, and videos on the most

important topics.
Siemens Publications app:
You can also download and read
many Siemens customer magazines
on your Android tablet or iPad with
the Siemens Publications app free
of charge, of course. For more information on the Siemens Publications
app, please see
siemens.com/publications-app.
Siemens
Publications
for Android
Newsletters
Siemens Industry on
Twitter @siemensindustry
Blog competitive industries:
https://blogs.siemens.com/
competitive-industries
Siemens offers electronic newsletters on various topics for

subscription. For example, with the Totally Integrated Automation newsletter you will be informed by e-mail about new
hardware and software, services, application examples, and
important dates and events relating to Totally Integrated
Automation electronically and always right up-to-date.
Simply register with your e-mail address.
siemens.com/industry-newsletter
Published by:
Siemens AG
Digital Factory Division
Process Industries & Drives Division
Werner-von-Siemens-Strae 50
91052 Erlangen, Germany
Responsible for content:
Ralf Schmitt (in accordance with
the German press law), Matthias Bruns,
Bernd Heuchemer, Christoph Hotz,
Christiane Rschke, Marcus Wissmeier,
Dr. Thomas Rubach
Publishing house: Publicis Publishing,
P.O. Box 32 40, 91050 Erlangen, Germany
magazines-industry@publicis.de
Editorial staff: Gabriele Stadlbauer,
Susanne Wanke, Verena Debnar
Printed by: Wnsch, Neumarkt (Germany)

Circulation: 9,100
advance appears three times a year; Volume 13
2014 by Siemens Aktiengesellschaft
Munich and Berlin.
All rights reserved.
ISSN 1611 101X (Print)
IWI: TADV
Article number: E20001-M2314-B100-X-7600
This issue was printed on paper manufactured
fromchlorine-free bleached cellulose.
Printed in Germany
The following products are registered trademarks

of Siemens AG:
DRIVE-CLiQ, ET 200, S7-300, S7-400, S7-1200,
S7-1500, LOGO!, SCAL ANCE, SENTRON, SIMATIC,
SIMATIC HMI, SIMOGEAR, SIMOTICS, SIMOTION,
SINAMICS, SINUMERIK, SIPLUS, SIRIUS, SITR AIN,
STEP, TIA, TIA Portal, WinCC
If there is no special mention of trademarks,
trade names, technical solutions, or similar items,
this does not mean that these items are not
protected.
The information in this magazine contains only general
descriptions and performance features which do not
always apply in the described form in the actual
application or which may be subject to change in the
course of further development of the product. The
specific performance features are only binding if they
were agreed expressly in the contract.
Efficient automation
starts with efficient engineering
Totally Integrated Automation: Efficiency driving productivity.
Efficient engineering is the first step

for making things right: faster, more
flexible, and more intelligent. Totally
Integrated Automation saves time in
engineering as a result of the efficient
interoperability of all components. The
result: lower costs, faster time-to-market
and greater flexibility.
Totally Integrated Automation
Efficient interoperability of all
automation components
Totally Integrated Automation spans

the entire production process while
significantly increasing productivity.
Common characteristics create real
value added, in all automation tasks:
Integrated Engineering
Industrial Data Management
Industrial Communication
Industrial Security
Safety Integrated
siemens.com/tia

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Number 3 | November 2014 | siemens.

The road to the

04 Making things right

16 Energy-saving glass pressing

08 Energy management pays off

Integrated Drive Systems

22 Perfectly optimized logistics

11 Perfection in measuring technology

24 From product to system

Cover photo: Siemens AG

advance 3/2014 | Contents

27 Fit for the mining industry

36 Well-designed power supply

28 Design, testing, documentation

38 Standards-compliant control cabinet design

31 Safety training for industry automation

32 Safe control of large forces

40 Global network of experts

34 Clear tool identification

advance 3/2014 | Editorial

The entire value chain of the

Making things right

Editorial | advance 3/2014

advance 3/2014 | Fokus

SPS IPC Drives 2014

The road to the

With the slogan Making Things Right

Focus | advance 3/2014

engineering, the NX Mechatronics Concept Designer Uncovering hidden potential

Seamlessly integrated engineering

into specific recommended actions. This allows for

advance 3/2014 | Focus

Siemens AG, Germany

The Siemens plant Amberg in Germany impressively

During the implementation of an in

Energy management becomes

nergy efficiency and sustainability

Integrated measuring technology

Focus | advance 3/2014

Energy management as a service

with current detection, and there is a

advance 3/2014 | Automation technology

IVAT GmbH, Germany

Frieters Innovativ, Innovative Absaugtechnologie (IVAT) has

Its quality has been

liver Frieters, managing director Innovative wireless connection

These tried and tested Siemens switches

Automation technology | advance 3/2014

Wisatec Messtechnik GmbH, Germany

For Wisatec, precision and productivity are the highest priorities. At

advance 3/2014 | Automation technology

company has already solved, it is clear

planning, mechanical set-up, electrotechnical equipment, programming,

olution and measuring accuracy of the

Innovative testing systems

LumiTrax with Shape from Shading

The LumiTrax camera system

mined by the precise and highly dynamic positioning of the gripper. It is

belts create a coordinate system that the very efficient programming of

Wisatec's testing machine presented at the VISION trade fair

Integrated and future-proof

additional Sinamics S120 double motor

INFO AND CONTACT

The entire value chain of the

Energy management becomes

When it came down to modernizing

Seamless drive technologies not