direct industry

Information for Electrical Engineering and Industrial Automation

August 2014

SHIPBUILDING
Special Topic Issue

SHIPBUILDING
DRIVE TRANSPARENCY / Page 10

top
NatioNaler
arbeitgeber

2014
INDIVIDUALITY FROM MODULES / Page 07
SAFETY, EX, AND GL: ALL-IN-ONE MODULE / Page 18 DeutschlanDs
Beste
arBeitgeBer
im Vergleich

in Kooperation mit:

Photo: SAM Electronics

 CONTENTS
HIGH-SPEED MONITORING ON BOARD A LUXURY YACHT Page 04

INDIVIDUALITY FROM MODULES Page 07

DRIVE TRANSPARENCY Page 10

SYSTEM WIRING UP TO THE EX AREA Page 13

SUPPORT FOR THOR Page 14

SEAWORTHY: THE WAGO-I/O-SYSTEM 750 XTR Page 17

2
SAFETY, EX, AND GL: ALL-IN-ONE MODULE Page 18

CAN FOR FULLY FLEXIBLE INTEGRATION Page 20

COMPACT AND CONVENIENT: PROPORTIONAL VALVE CONTROL Page 20

HIGH SEAS, HIGH DEMANDS Page 21

EPSITRON® CLASSIC POWER – REDESIGN Page 23

IMPRINT Page 24

EDITORIAL
Dear Readers,

You probably think that you know our company and products fairly well. But did you know
that WAGO is built literally close to the water’s edge? Our headquarters in Minden are
located near the largest canal intersection in the world and its associated industrial harbor.
This geographic connection fits the topic of this edition very well: we have identified for
years with the demands of shipping and offshore applications.
In this issue, claims about the safety and availability of our products will be made in an
extraordinary measure. We will demonstrate how the economic viability and handling
comfort are decisive factors during operations and, in particular, during the development
phase of projects. We have accepted this challenge and have created a powerful portfolio,
characterized by high quality and technical innovation, for the globally-increasing shipping
and offshore markets.
The suitability of the mechanical and electrical features has been documented by compre-
hensive shipbuilding approvals and references. Our customers thus profit from universal
solutions, which enable applications from the bridge down to the engine room, and include
all important protocol interfaces. This naturally includes fail-safe applications (SIL3) and
intrinsically safe areas (Ex i). By using the WAGO-I/O-SYSTEM 750 XTR for extreme envi-
ronmental conditions (GL Cat. “H”), special demands are met that far exceed the standard.
In addition, radically new control architectures can also be created through the consistent
use of the “industrial ETHERNET”, which fulfills the demands for increased modularity and
flexibility at a completely new standard of quality. In a strong, globally-competitive field,
tasks can be executed faster and more economically, and adapted to the individual require-
ments.
To see how such solutions look in practice, read on in the present edition of WAGOdirect
industry. Enjoy!

Best regards,

Marc-Andree Paul
Manager Business Development Automation

direct industry 3
 HIGH-SPEED MONITORING
ON BOARD A LUXURY YACHT
besecke designed a complex automation solution for a large
luxury yacht, which was recently launched at the Bremer Lürs-
sen shipyard. WAGO’s high-performance ETHERNET con-
trollers are also on board.
■ At 100 meters long and equipped with engines providing tens of
thousands of HP, the yacht represents a new high in design and
commissioning for the Bremer Lürssen shipyard. The firm is the
world leader in constructing mega yachts up to 60 meters in length.
The automation system was designed, planned,and realized by
besecke, a subsidiary of the Lürssen shipyard. The long-time spe-
cialist for ship automation relied on 125 WAGO ETHERNET con-
trollers (750-881/882).
The bar was set extremely high – in terms of innovation, customiza-
tion, and technical perfection – for the luxurious mega yacht,
which made automation a great challenge, even for a specialist
like besecke. The mid-sized, German company has a workforce of
approximately 175 spread among three facilities in Bremen, Em-
den and Riga. Due to its proximity to the Lürssen shipyard, the
“Ship Automation” business unit is primarily based at the Bremen
headquarters. The Ship Automation portfolio includes: design and
construction of control cabinets and central control systems, devel-
opment of application-specific software for control units, a propri-
etary central monitoring control system (MCS), control of the pow-
er distribution system, onboard safety monitoring, as well as
technical support for the entire lifespan of a ship.
■ Advancing in New Dimensions
A large number of signals need to be collected, processed and vi-
sualized on the mega yacht. The areas to be monitored and con-
trolled include: the ship’s engine, generators, door positions, hy-
drant valves, fire alarms, National Marine Electronics Association
(NMEA) data, security, fill levels, operating hours, alarm services,
wastewater, helicopter landing pad, anchor winch, power man-
agement (EPMS), HVAC, video surveillance (CCTV), as well as
maintenance and entertainment systems.
When combined, more than 10,000 raw signals must be pro-
cessed for the mega yacht. The WAGO controllers directly collect
4
approximately 5,000 signals. The remaining 5,000 signals are
recorded via specialty communication modules. The main engines
and generators create the highest data volume, with up to 700
signals to be recorded by each controller. In the MCS, approxi-
mately 10 variables are created from the raw signals, e.g., warn-
ings, color changes, or service messages from a pressure or tem-
perature sensor. From the 10,000 recorded data points measured,
a total of about 100,000 variables flow into besecke’s central
MCS for further processing. To ensure the continuous availability
of this huge amount of data, the controllers require extremely high-
performance CPUs.
“In general, the trend in luxury yacht automation is toward a con-
stantly growing number of signals to be processed. Furthermore,
customers expect more and more information to be visualized via
a central monitoring system,“ explains Henry Fischer, Sales Man-
ager at besecke in Bremen. “This in turn requires increasing com-
puting power, without increasing the dimensions of the control
units. It’s nearly impossible to get more compact than the WAGO
controllers.“
■ High-Performance Controllers Keep Data Flood under Control
What Fischer is referring to are the 125 programmable ETHER-
NET controllers (750-881/882), which are used as distributed
control units and form the basis for the yacht’s automation solu-
tion. The controllers are mounted close to the measuring points,
minimizing the amount of individual wiring between the I/O mod-
ules on the automation level and the sensors and actuators in the
field. Both PLC functionality and an integrated web server make
the controllers fully independent. These modular units simplify con-
figuration, start-up, and operation, as well as maintenance and
future expansions. These units also increase both reliability and
system availability, since controller failures will not impact the
overall system. This eliminates the need for a complex, redundant
server configuration.
 WAGO’s technology is ideal for duty aboard small
and large Lürssen yachts (picture shows the mega
yacht, “Topaz”).

125 WAGO ETHERNET Controllers (750-881) collect ap-

proximately 10,000 signals on the yacht.

direct industry 5

The on-board automation configuration is based on a 1 Gbit ETH-
ERNET fiber optic ring. A ring switch interfaces 100 Mbit copper
cables with the individual controllers, creating a uniform ETHER-
NET configuration from the field up to the control level. Further-
more, the WAGO controllers (750-881/882) feature a two-port
switch or two independent ETHERNET ports, simplifying the cre-
ation of line topologies. The numerous systems and interfaces are
integrated into the central MCS. The controllers provide the col-
lected data points measured and alarm messages to the displays
at the monitoring stations via a besecke-developed OPC server,
which is six times faster than commercially available products.
Cross-communication between controllers is carried out using
Modbus/UDP, with each device serving as a master or slave.
CODESYS codes can be automatically created from an Excel pa-
rameter list using a program developed by besecke. Alarms are
processed by the controllers in a standardized manner, making
them less prone to errors.
“WAGO’s components are extremely robust and fail-safe. The
I/O system’s modularity permits easy and fast retrofitting of indi-
vidual modules,” says Fischer. “This is important for us, since, of
course, requirements may evolve during a project spanning 1.5
years, from order to delivery. Due to the wide range of signals, we
opted for fast ETHERNET controllers, which – despite their com-
pact design – provide high computing power and feature two
ETHERNET ports. The high-performance CPUs were a basic pre-
requisite for implementing our monitoring system.”
■ Full Control from the Bridge to the Engine Room
The modular and fieldbus-independent WAGO-I/O-SYSTEM is an
ideal automation solution for shipbuilding. The system has consis-
6
All recorded measurement data are collected and visualized
in besecke’s central MCS monitoring system. Up to four sub-
views can be displayed on the screen simultaneously (picture
shows fire-fighting pumps and hydrant valves).
tently demonstrated its suitability for marine applications aboard
various Lürssen yachts, over hundreds of nautical miles in rough
seas. Therefore, the components have received all required inter-
national shipbuilding approvals, such as GL, LR, DNV, BV, RINA,
KR, NK, and BSH. Given these qualifications, direct operation on
combustion engines and compressors, as well as operation near
the compass are allowed. Therefore, the WAGO-I/O-SYSTEM
permits consistent automation solutions from the engine room right
up to the bridge.
In addition to the technical features of the WAGO-I/O-SYSTEM,
good cooperation and proactive support also contributed to the
long-term, close partnership between WAGO and besecke. “We
can see that ETHERNET has prevailed over other fieldbus systems
in yacht automation applications. The future calls for open, non-
proprietary solutions, as offered by WAGO and besecke,” con-
cludes Fischer.
Text: Jörg Schomacker, WAGO
Photo: Lürssen Yachts, besecke
125 programmable WAGO ETHERNET Control-
lers process more than 10,000 raw signals.
Simple design of line topologies due to two sepa-
rate ETHERNET ports.
The WAGO I/O SYSTEM enables fast and easy
retrofitting of individual modules.
INDIVIDUALITY FROM
MODULES
WAGO pluggable connectors support high efficiency
at HanseYachts.
■ As one of the largest German manufacturers of sailing yachts, Han-
seYachts AG is known for high-performance ships with good sailing
characteristics, ease of handling, individual comfort – at compara-
tively favorable prices. This combination is only possible due to highly
optimized manufacturing processes. With regard to the connection
technology in the boat’s electronics, the company from Greifwald de-
cided on a standardized solution that is based on WAGO compo-
nents.
The experience of being on the water has an emotional component.
For this reason, purchasing a sailing or motoring yacht is often a very
personal matter, since everyone has different plans and aspirations for
the time spent on board the boat. A ship builder must therefore be able
to offer flexibility in order to adjust to the individual desires of their
customers. However, flexibility is usually connected to higher costs.
HanseYachts, which currently owns six brand names – Hanse, Dehler,
Moody, Varianta, Fjord, and Sealine – decided to use a model estab-
lished in the automobile industry, in which multiple brands share com-
ponents. This approach enables them to produce different boat types
on one production line and thus to reduce costs. The result: Every
buyer can customize his or her Hanse yacht from about 40,000 poten-
tial combinations – design variants, types of wood, fabrics, and colors,
up to the on board electronics – and the dream still remains afford-
able.
direct industry 7
 ■ Implementing the Multiple Brand and Shared Component Strategy
The implementation of the practice took place along two produc-
tion lines in Greifswald, one for the smaller boats and one for the
larger, all of them between 10 and 20 m in length. The yacht’s hull
and deck are produced at a factory in Poland and delivered as
separate units. The complete construction and assembly takes
place along 18 stations in the production line.
In order to optimize the manufacturing process, HanseYachts also
carefully scrutinized the onboard electronics. These were becom-
ing increasingly more complex and sophisticated, since many cus-
tomers desired not only the most innovative technologies for navi-
gation and steering, but also an increasing number of electrical
consumers that are related to comfort on board – from dish wash-
ers, washing machines, and portable wine coolers to air condition-
ing systems and up to electric toilets.
“It was our goal to develop the most standardized solution possi-
ble for electrical supply and distribution, which corresponded to
our high quality demand, and which could be easily integrated
into our manufacturing processes,” recalls Thorsten Stein, the man
responsible for electronics in Development at HanseYachts. In the
past, they had used multi-pole plugs with crimping contacts. Laying
the cables was confusing and changes to the cable harness were
expensive.
Due to pre-assembly, a fast and easy wiring of the Power
Boards is possible during the yacht assembly.
Hull and deck or each yacht are likewise delivered with
a cable harness including connectors.
8
■ Flexible, Fast, and Safe, Due to the X-COM-SYSTEM®
After in-depth testing, WAGO’s pluggable X-COM-SYSTEM® rail-
mounted terminal block system convinced them. This is a construction
kit for universal system wiring for nominal currents of up to 32 A and
voltages up to 500 V. Using this kit, it is possible to combine compo-
nents to create customized solutions according to client demands.
Electrical connections are based on the proven CAGE CLAMP®
spring clamping technology so that all contacts are connected in a
way that is vibration-proof, fast, and maintenance-free. In addition,
when disconnected, the system offers complete touch-proof protection
and, due to the ability to code the slots, protection against mismating.
“X-COM® pluggable connectors are ideal for us, since we can easily
equip each individual DC consumer with the same two-pin plug,
which reduces our assembly time,” explains Stein. Typically, around
80% of the consumers on board are supplied using the 12 VDC net-
work. This includes devices like lights, pumps, refrigerators, naviga-
tional instruments, radio equipment. The electrical engineer explains,
“As a consequence, since all of these consumers now have a separate
connector, we are more flexible and can carry out the cabling for
each device when it makes the most sense in the assembly process.”
This not only simplifies the standard cable harness at HanseYachts,
but it also reduces the work required for incorporating all of their op-
tions.
The complete construction and assembly of the sailing
yachts takes place along 18 stations in the production
line in Greifswald.
■ Efficiency through Pre-Assembled Components
In order to further simplify the wiring, HanseYachts decided to de-
velop a so-called Power Board: the X-COM® male connectors for
supplying the DC consumers can simply be pressed into this circuit
board, and the connectors for the 230 V AC network are already
integrated into it. The 12 V negative terminal is directly looped
through the circuit board. The positive terminals are all clearly num-
bered, so that the electricians in Greifswald can easily find the
correct position for the appropriate mating connector.
Hull and deck or each yacht are likewise delivered with a cable
harness. The cable harness manufacturer equips the cables for the
12 V consumers with standardized, two pine X-COM® connectors
in advance. All ends are thereby clearly marked with regard to
function and slot on the circuit board. This minimizes errors in the
final assembly steps.
There are currently only two versions of HanseYachts’ “Power
Boards”, a smaller one and a larger one, to match the size of the
ship, and they are used across all brand names and boat types.
This is possible because the circuit boards have a generously di-
mensioned reserve, which enables them to supply the most com-
prehensive equipping according to customer request.
■ Experienced Partners for Sea Faring
In addition, there is a panel board for the operating and control
panel. This is also based on the same principle and components. In
addition to the X-COM-SYSTEM®, HanseYachts uses other WAGO
components, including the WINSTA® pluggable connection system,
proven in building technology, for the 230 V consumers on board, or
the MCS-MAXI connectors for connecting to onshore power sup-
plies.
“It is important to us to be able to work with partners who know ship
building and are conversant with the specialized demands that pre-
vail here. It is therefore advantageous, that around 90% of WAGO
products already have the corresponding certifications,” exclaims
Stein.
Text: Frank Sellke, WAGO
Photo: HanseYachts, Hendrik Roggemann/vor-ort-foto.de
The X-COM-SYSTEM® creates standardized solutions for electri-
cal supply and distribution.
All contacts are connected vibration-proof, fast, and mainte-
nance-free.

The X-COM-SYSTEM® offers, in addition to protection against

mismating, complete touch-proof protection when disconnected.

The cable harness manufacturer equips the cables for

the 12 V consumers with standardized, two pin X-COM®
connectors in advance. The cables are also clearly
marked regarding function and slot on the circuit board.

The operating and control panels for the yachts are

based on the same principle as the Power Boards.
direct industry 9

DRIVE TRANSPARENCY
From the bridge to the engine room –
The WAGO-I/O-SYSTEM for marine applications
■ Whether it’s a luxury yacht, a cruiser or a specialty ship –
diesel-electric drive systems provide great benefits wherever
electrical energy consumption is high. This is one of the core
competencies of SAM Electronics. The company specializes in
marine electrical and electronic systems. In designing innova-
tive drive solutions, the Hamburg-based company relies on the
flexibility and reliability of WAGO’s I/O system.
10
Cruise ship “Seabourn Odyssey”
SAM Electronics, a subsidiary of L-3 Communications, is among the
worldwide leaders in marine electrical and electronic systems world-
wide. For more than 100 years, the company has developed prod-
ucts and systems for both shipping and naval applications. With more
than 600 employees at its headquarters in Hamburg, Germany and
nearly 1,400 staff worldwide, SAM Electronics offers innovative and
customer-oriented solutions. These include energy production and dis-
tribution, ship communication and navigation, maritime automation,
safety and monitoring systems, as well as consumer and drive tech-
nology. The company’s service portfolio runs the gamut from smaller
packages on up to integrated systems and turnkey solutions, includ-
ing planning, engineering, production, and on-board installations.
■ Using Data to Enhance Reliability
Diesel-electric drives offer great advantages – particularly for cruise
ships, yachts, and specialty ships. The drives run quietly, with mini-
mal vibration, and can be incorporated as redundant systems to
provide exceptional reliability, yet they also offer maximum maneu-
verability and a high level of automation. In order to prevent faults
and operating errors, it is crucial to monitor and control all functions
and key parameters. Therefore, a variety of on-board, process-relat-
ed data must be collected from decentralized nodes. For example:
what are the capacities for the different propeller and thruster en-
gines? How many operating hours can they run? Are the engine
shafts sufficiently lubricated? How do the temperatures for the trans-
formers and cooling fluids relate to each other? Answering such
questions enables streamlining of the drive, while still increasing
system reliability.
In order to provide absolute reliability, SAM Electronics employs a
redundant diesel-electric drive solution. Conventional mechanical
diesel systems usually operate with diesel engines directly coupled
to a specific propeller; diesel-electric drives, on the other hand, ben-
efit from diesel engines that can power any propeller. The engines
drive generators, which feed electrical power to a common busbar
that supplies the electrical drives and all other consumers. Therefore,
the availability of a drive is independent of the availability of an in-
dividual diesel engine. This advantage provides a ship with maxi-
mum maneuverability – even in extreme weather or environmental
conditions. At the same time, only as many diesel engines are con-
nected to the on-board power supply as are required by the current
energy demand. This economizes diesel engine operation, while
enabling the engines to operate at peak efficiency. This solution is
used for a wide variety of engine sizes ranging from 1 to 21 MW.
Each drive is usually equipped with its own frequency inverter,
often with corresponding transformers, and operates indepen-
dently. Therefore, data exchange between these units and the
central unit becomes all the more important.
■ Relying on Uniform Standards
SAM Electronics relies on the WAGO-I/O-SYSTEM 750 to col-
lect all relevant data from the drive system and to remotely
control the system from the Engine Control Room (ECR) or from
the bridge. With this system, SAM Electronics can configure
each node to meet individual requirements. The system offers
modules for various potentials and analog signal forms. The 1-,
2-, 4-, 8- and 16-channel digital input/output modules can be
combined as needed, providing a high degree of granularity
and flexibility. This finely modular design allows for extremely
compact sizes. Up to 16 channels can be accommodated in a
12 mm-wide module.
This modular design is also revealed in the fact that the system
offers appropriate fieldbus controllers and couplers for all stan-
dard protocols. A variety of fieldbus systems is generally used
in shipbuilding applications, depending on the level within the
ship. While communication is mainly carried out via ETHER-
NET on the bridge, data from the ECR system is primarily ex-
changed via MODBUS or CAN. The RS-485 interface is also
used in many areas. This diversity has led SAM Electronics to
rely on the WAGO-I/O-SYSTEM as a scalable standard com-
ponent from the engine room right up to the bridge.
“It is a part of our strategy to rely on standardized components
wherever possible,” explains Rainer Genilke, Project Manager
for Drive Systems at SAM Electronics. “It’s extremely advanta-
geous for us to flexibly tap all important data in the entire drive
system using the WAGO-I/O-SYSTEM and a handful of com-
ponents – and this ability extends across all types of ships and
drive capacities. This aspect plays an important role not only in
planning and inventory management, but also for the spare
parts package that is carried on board.”
The WAGO-I/O-SYSTEM is used from the bridge to
the engine room.
direct industry 11

The drive system’s Motor Control Center (MCC) controls
numerous fans and pump engines.
WAGO’s proven CAGE CLAMP® technology enables sim-
ple, reliable, and vibration-proof wiring of the WAGO-I/O-
SYSTEM.
MCC data is transmitted via MODBUS or CAN in the cen-
tral control cabinet (Main Propulsion Control, shown here
on the production line) of a drive line, and additional in-
formation is collected from the propeller or thruster engine,
12 transformer, and other devices.
■ Maintaining Flexibility from Ship Design to Launch
Adjustments and changes are often required during the one-to-two-
year construction phase of a ship. Electrical systems also need to be
adapted and extended if another type of onboard system interface
or additional components are required. This can be easily imple-
mented using the modular WAGO-I/O-SYSTEM; the only require-
ment for long-term planning is sufficient space in the control cabinet.
Furthermore, Genilke appreciates the fact that distributed units can
be easily configured using WAGO’s remote I/O solution. Configura-
tion is performed using the WAGO-I/O-CHECK commissioning tool,
which provides a comprehensive evaluation of a system’s wiring and
functionality, without necessitating the installation of the system’s
control unit. Afterwards, all that remains is the connection of the
power supply and fieldbus cables, and the system is ready for op-
eration.
“Our most recent design provides us with insight into all relevant
drive systems data via satellites after release by the crew,” explains
Genilke. If faults occur while at sea, remote diagnostics can be per-
formed directly from the office to determine whether a service team
is required or whether spare parts must be sent to the nearest port.
“The WAGO-I/O-SYSTEM convinced us, since it allows us to meet near-
ly all of our customer requirements for drive technology,” summarizes
the drive system expert. “We also value our cooperation with WAGO
due to their experience in the marine industry. Like so many WAGO
components, the I/O-System has received all major international
shipbuilding approvals and is suitable for use on the bridge near the
compass. WAGO has even gone above and beyond to successfully
certify non-approved components to support us.”
Text: Jörg Schomacker, WAGO
Photo: SAM Electronics, Hauke Hass/vor-ort-foto.de
The WAGO-I/O-SYSTEM 750 collects all
relevant data from the drive system.
The system can be checked in advance using
WAGO-I/O-CHECK.
In case of a service call, diagnostics can be
performed remotely.
SYSTEM WIRING UP TO THE EX AREA
The X-COM®S-SYSTEM is the first pluggable rail-mounted terminal block
system with “nA” type of protection that can be used in Zone 2 hazardous
areas.
■ In railway transportation, ship building, machinery and equipment
applications: For many years, the X-COM®S-SYSTEM has been most
impressive, wherever time- and cost-saving system wiring is required.
Approval for use in Zone 2 Ex areas greatly expands the range of
applications for WAGO’s pluggable X-COM®S-SYSTEM rail-mount-
ed terminal block system.
■ X Good Reasons
For customers, there are “X” good reasons for using the pluggable
rail-mounted terminal block system from WAGO: Due to their pre-
assembled and pluggable options, the connectors can be prepared
independently from the final assembly, and pre-assembled groups
can be tested before installation. Components can be quickly and
reliably replaced due to the 100% protection against mismating and
their touch-proof protection. This modular design significantly stream-
lines servicing, even in Ex areas (e.g., offshore platforms). This not
only saves time and money, but also allows assembly by external
service providers and subcontractors.
lever, which is already factory-mounted on the female plug, makes
accidental disconnection even more difficult. Removing the female
plugs is only possible using an operating tool, which provides ad-
ditional safety, particularly for sensitive applications in hazardous
areas.
■ Preparation and Testing
X-COM®S female plugs for Ex applications are available in 1 to 15
pole versions. The connectors can be prepared independently from
the final installation requirements, and pre-assembled groups can be
tested prior to installation. Groups having the same number of poles
can be mechanically coded, preventing any mismating right from the
beginning. The carrier terminal blocks and female plugs are avail-
able in gray, blue, and green/yellow. Each Ex module is subjected
to a high voltage test during the manufacturing process.

■ Additional Safety
All X-COM®S Carrier Terminal Blocks and Female Plugs, which are
approved for Ex applications, are identified by the extended item
number suffix “…/0999-0953”. With a maximum wire size of 4
mm² (AWG 12), they are designed for a nominal current of 20 A.
Compared to standard X-COM®S components, the shorter locking

Extended application possibilities: The X-COM®S-

SYSTEM for Ex applications is designed for a maximum
wire size of 4 mm² (AWG 12) and a nominal current up
to 20 A.

Additional safety: The shorter locking lever makes

accidental disconnection even more difficult; removing
female plugs is only possible using an operating tool.

direct industry 13
14
SUPPORT FOR
THOR
Safe handling of fluid systems demands innovative control tech-
nology with approvals for maritime use.
■ Diesel, ballast water or bilge water ─ proper monitoring and reli-
able control of key fluids on board a ship is an absolute must. BESI
Marine Systems GmbH & Co. KG in Bremen is a specialist in the
field of flow and tank management. The company not only installs
these systems on container ships, bulk material cargo liners, tankers,
river steamers, and luxury yachts, but has also been involved in proj-
ects such as Thor, the first jackup platform. For more than 15 years,
WAGO has been BESI’s partner in all things pertaining to automa-
tion and connection technology.
Construction of offshore wind farms is in full swing. The first test field
has been feeding power into the grid since 2009; a number of fa-
cilities are currently being erected and new areas are under review
for approval and licensing. Installation of wind turbine plants is tech-
nically and logistically an extremely demanding task: How do you
transport a 360 metric tonne generator nacelle and 61 meter long
rotor blades out to sea? Special jackup platforms and vessels are
currently being developed for this purpose for use in the North Sea.
One of the first platforms of this type, Thor – named after the Norse
god of thunder – began commercial operation in 2010. One of the
two cranes on board can lift up to 500 metric tonnes while being
extended up to 51 meters. With its dimensions of 70 x 40 meters,
Thor looks more like a football field than a ship. Four 82 meter long
pillars are lowered when loading and unloading this floating “field.”
Pressure is applied to the pillars through a control fill using ballast
water and by lifting the platform above the surface of the sea, form-
ing a unit that is in firm contact with the seabed.
■ Safe and reliable control of more than 260 remote-controlled
valves
BESI Marine Systems has specialized in the area of flow manage-
ment, which also includes the field of anti-heeling systems (AHS).
This system actively controls the heel of a ship. BESI develops, pro-
duces, and markets control and isolation systems based on hydraulic,
pneumatic, electric, and electro-hydraulic drives, with the associated
automation and visualization systems. Control cabinets located in the
ECR (engine control room) or in the ship office control the compo-
nents. This is where all the signals from the valves and from the tank
filling level, temperature, inclination and ship draught measuring sys-
tems come together. Via an ETHERNET link, the operator can control
and monitor the system from a central location or locally by computer
or using a touch panel. The company was also responsible for ballast
water control for loading and unloading at Thor, and has thus contrib-
uted to the successful implementation of the jackup platform.
Whereas two of these control cabinets were sufficient for Thor, the
current jack-up vessel requires six, distributed throughout the ship for
optimal routing of piping and wiring. The AHS system alone requires
its own dedicated control cabinet. In contrast to Thor, which does not
have a dedicated drive, the new ship will be equipped with its own
diesel drive. Add to this more than 260 remote-controlled valves,
which the system must also control; just to illustrate the sheer size of
this project, a medium-size container ship normally has around 80
valves.
■ Priority on Safety – Automation Becomes More Important
As Michael Borchers, Chief Technical Officer at BESI explains “For
us, such complex applications now rely less on classic relay technol-
ogy and increasingly more on high-performance automation systems
and decentralized concepts. The demand is for more functions, with-
out adding to spatial requirements or making any concessions on the
topic of safety.” BESI’s flow management systems are classified as
safety-relevant systems and must therefore meet the most stringent re-
quirements.
Redundancy is standard for all components and functions, from the
computer up to controlling the valves. If the power supply system
fails for a hydraulic system, for example, a defined number of safe-
ty-relevant valves can be operated directly from the control cabinet
via an emergency hydraulic system using solenoid valves. Should
these also fail, the responsible engineer can still operate the drive
directly at the valve using an emergency, manually-operated pump.
“Safety and quality are values that we live,” declares Malte Konk-
en, Managing Director at BESI. “Our systems will be in operation
for 25 to 30 years on the high seas throughout the world and must
always function properly for our customers.
direct industry 15
 We recently processed an inquiry from a customer requesting a
spare part for the very first system that we produced. And to put
this into perspective: we have supplied more than 5,000 systems
since our company was founded.”
■ BESI and WAGO: Cooperation for more than 15 years
BESI and WAGO have worked in close cooperation since 1997.
Then as now, the focus was on time savings and fault minimization
in connection technology. Today, BESI continues to rely on WA-
GO’s extensive portfolio, and also because the family-owned
company from Minden possesses the necessary shipping industry
certifications, such as ABS, DNV, GL, LR, and NKK, for a wide
range of its components. Besides WAGO’s TOPJOB®S rail-mount-
ed terminal blocks, interface components, and optocouplers, as
well as intrinsically safe EX-i modules, the fieldbus-independent
and decentralized 750 Series I/O system is the most important
element in BESI’s control cabinets. The 1-, 2-, 4-, 8- and 16-chan-
nel modules, which can be linked in any conceivable combina-
tion, provide a high degree of granularity. The 750 Series offers
fieldbus couplers for all standard protocols, with programmable
control systems adding PLC functions to the system. ETHERNET
and MODBUS are the most widely used bus systems at BESI, and
programming is conducted primarily with CoDeSys. Even the re-
dundant systems so important to BESI can be economically imple-
mented using the 750-871 Ethernet TCP/IP controller.
16
“There are two things that are important to us when it comes to se-
lecting the right supplier,” states Michael Borchers. “First, the quality
and durability of the products offered must be optimal, and we sub-
ject them to extreme stress tests to ensure this. Secondly, we need a
partner who has experience in the shipbuilding industry, for it is a
decisive factor in our business not only to have a good supplier, but
a partner with whom we can be jointly innovative.” It was in this vein
that technology meetings were held in the last few years in which the
two teams collaborated on mutual concepts for control cabinet opti-
mization. One result of this concentrated input is a universal transfer
module that can be used in all BESI systems, and which saves a
great deal of wiring effort. This transfer module, with WAGO’s
16-channel PCB connection technology, connects lines that supply
check-back signals from the valves, such as “open”, “closed”, and
filling levels, with the I/O control system.
Text: Jörg Schomacker, WAGO
Photo: HOCHTIEF, BESI
Redundant systems were cost effectively converted
using the ETHERNET Controller 750-871
WAGO automation technology qualifies for
all necessary maritime certifications
16-channel components at just 12 mm in width
save space in the control cabinet.
In addition to WAGO’s TOPJOB®S rail-mounted terminal blocks,
interface components, and optocouplers, as well as intrinsically
safe EX i modules, the fieldbus-independent and decentralized 750
Series I/O system is the most important element in BESI’s control
cabinets.
Sea-Worthy
GL for the WAGO-I/O-SYSTEM 750 XTR
Certified safe and reliable: with approvals from KC, UL508, and, in
particular, GL, the WAGO-I/O-SYSTEM 750 XTR is well equipped for
applications in the maritime industry.
■ The WAGO-I/O-SYSTEM 750 XTR is the automation system for
extreme demands. Shipping and the entire offshore sector should
be included, without doubt, among the most stressful environments.
Thus, it is no surprise that the 750 XTR Series has already received
approvals from Germanischer Lloyd, Underwriters Laboratories,
and the National Radio Research Agency (RRA, South Korea).
Temperatures between -40°C and +70°C, vibrations up to 5 g,
and EMC stability according to EN 60870-2-1 — the WAGO-I/O-
SYSTEM 750 XTR is made to meet your difficult challenges. Expen-
sive special solutions, like air conditioning and protection circuits,
are no longer needed.
■ Extreme Resistance to Adverse Weather Conditions
The error-free start-up of automation systems, for example, after
a power outage, can be critical at very low temperatures. The
WAGO-I/O-SYSTEM 750 XTR succeeds even at a frosty -40°C,
and doesn’t even require pre-warming. At the other end of the tem-
perature scale: it is easy to reach +70°C when a control cabinet
is placed in direct sunlight. Even in this case, the XTR version of the
I/O system appears unimpressed.
■ Extreme Isolation and Resistance to Interference
With an increased impulse-voltage withstand, according to EN
60870-2-1, of up to 1 kV (< 60 V, class VW1) and 5 kV (>= 60 V,
class VW3), the WAGO-I/O-SYSTEM 750 XTR ensures continuous,
smooth operation because the electronics are protected against
malfunctions. The optimized EMC behavior also prevents nega-
tive electromagnetic interference emissions, which thus enables its
use even in direct proximity to highly sensitive third-party systems.
This allows complete satisfaction of demands regarding dielectric
strength and EMC interference immunity, including requirements
posed by telecontrol devices and for use on the bridge of ships in
close proximity to the compass (“Compass” certification from BSH).
■ Extreme Vibration Resistance up to 5g Acceleration
Increased vibration- and shock-resistance are required, particularly
when the modules are located in direct proximity to high perfor-
mance maritime diesel engines or power circuit breakers. With a
vibration resistance of 5g, which corresponds to an acceleration
of 50 m/s², and a resistance to continuous shocks of 25g, the
WAGO-I/O-SYSTEM 750 XTR has set the bar high.
■ Extreme Flexibility in Use
The automation system is based on the proven WAGO-I/O-
SYSTEM, and thus profits from all of its positive features. The XTR re-
tains the especially compact construction, finely modular and field-
bus-independent design, and the extremely flexible potential for ap-
plications. With approvals from KC, UL508, and, in particular, GL,
the WAGO-I/O-SYSTEM 750 XTR is well equipped for applications
in the maritime industry. Other approvals will follow.
direct industry 17
 SAFETY, EX, AND GL:
WAGO’s compact I/O modules with ship approvals simultaneously
integrate functional safety and explosion protection into the
WAGO-I/O-SYSTEM 750.
■ The Europe Commission’s functional (EN IEC 62061) and control
(EN ISO 13849) safety standards, and, in particular, the Machinery
Directive have increased the safety demands placed on marine sys-
tems and applications. These requirements apply equally to software
components. All related marine equipment, such as access points,
bulkhead or tailboard controls, as well as conveying machinery,
cranes, and dredging vessels must comply with these increased stan-
dards. This is particularly the case for offshore drilling and extrac-
tion platforms, where the most stringent requirements are placed on
protecting people, equipment, and the environment. For example,
danger to persons must be eliminated in the hazardous area of hy-
draulic pipe handling arms.

Despite these safety standards, proprietary applications continue to

be used in many areas, even though they may be extremely dan-
gerous and expensive. This presents unnecessary risk, as qualified
safety components are not only safer, but also easier to use and
often less expensive overall. WAGO’s safety modules are based on
PROFIsafe, a protocol for safe communication, which is certified for
PROFIBUS and PROFINET in accordance with IEC 61784-3-3.

■ Safe and GL-Certified

Vibration, shock loads, fluctuating temperatures, supply voltage
variations, and electromagnetic interference are among the major
challenges faced in shipbuilding and on/offshore applications.
Safety modules in the WAGO-I/O-SYSTEM 750 Series are certi-
fied by the Germanischer Lloyd (GL) classification society for marine
applications. They meet the requirements for both functional safety
(SIL, Safety Integrity Level) and explosion protection (ATEx, IECEx).
With a width of just 24 mm, the modules are also extremely compact
and robust. Furthermore, their DIN-rail-mounted design permits easy,
tool-free handling. One of the system’s highlights is its ability to safely
and economically create mixed nodes by combining safety modules
with the more than 400 digital, analog and specialty, non-safety-
related I/O modules to expand application functionality.
WAGO’s I/O safety modules include:

18
ALL-IN-ONE MODULE

WAGO Safety Modules can be used up to

categories 4, PLe and SIL 3.

At just 24 mm installation width, the Safety

Modules are especially compact.

The digital input module combines functional

safety and explosion protection.

• The 750-667 Digital I/O Module with four inputs and four flex-
ibly configurable 2 A outputs. A key feature is the 1:1 relationship
for a reliable allocation of the feedback signals per input.
• The 750-666 10 A Module, which features four inputs and two
power outputs, can also be used separately. This module simul-
taneously disconnects the power supply for a whole group of
outputs (safety switching device), so that all downstream, switch-
connected actuators are deactivated.
• The 750-663 F-EX Module, which is a digital input module for
sensors in Ex Zones 0/20 and 1/21, is ideal for offshore ap-
plications.
The WAGO-I/O-SYSTEM 750 PROFIsafe modules comply with IEC
61508, SIL 3, and can be used in safety applications up to catego-
ries 4 and PLe (EN ISO 13849) or SIL 3 (EN IEC 62061).

Text: Helmut Börjes, WAGO

Pictures: WAGO

direct industry 19
 CAN FOR FULLY FLEXIBLE INTEGRATION
Independent of field- or automation-level: flexible protocol gateway so-
lutions can be integrated into the WAGO-I/O-SYSTEM 750 using the
750-658 CAN Module.
■ The CAN Module supports CAN Layer 2, making it extremely flex- copied from received telegrams into the input process image. Telegrams
ible at the field level: This module can be integrated into a CANopen, may be sent cyclically, manually or event-triggered (change of process
an SAE-J1939, a NMEA2000, or a DeviceNet network, with protocol- value).
specific functions being implemented using an application program.
The SAE-J1939 standard is used by numerous engine manufacturers,
among others, in order to transmit equipment parameters to the elec-
tronic control unit (ECU), which is important for efficient and reliable
operation. ISO 11783 and the maritime derivative, NMEA2000, are
based on the same protocol standard; with regard to maritime opera-
tions, networking of navigation devices or voyage data recorders (VDR)
with the ship’s navigation data are foregrounded.
The CAN Module can be used in three operation modes: Sniffer mode Interface with 12 mm in-
provides a detailed CANbus analysis through passive reading without stallation width: the 750-
658 CAN Module links
interactions with the bus. In transparent mode, the I/O module functions
CANopen, SAE J1939,
as an active CAN device that can send and receive any type of CAN NMEA2000 and De-
telegram. Mapped mode enables CAN telegrams to be generated di- viceNet to the fieldbus of
rectly from the process image. It also allows select process values to be your choice.

COMPACT AND CONVENIENT: PROPOR-

TIONAL VALVE CONTROL
WAGO’s new Proportional Valve Module significantly simplifies the connec-
tion of hydraulic or pneumatic valves to the WAGO-I/O-SYSTEM 750.
■ Large Current Range, Many Features: With a width of just 12 mm, switches, e.g., for end position monitoring. Start-up and valve parame-
the 750-632 Proportional Valve Module is a compact and high-perfor- ter adjustments are easily performed via WAGO-I/O-CHECK software.
mance solution, allowing hydraulic or pneumatic valves to be connected These settings can also be made directly via the controller.
to the WAGO-I/O-SYSTEM 750. Two single-coil valves or one dual-coil
valve can be controlled either uni- or bi-directionally. For each channel
or coil, the output current is 2 A in 1-channel operation and 1.6 A in
2-channel operation. In connection with a lower setpoint/actual value
deviation, both small and larger valves can be controlled reliably and
with high repeatability.
WAGO’s Proportional Valve Module features two current-controlled
PWM outputs (24 V) with adjustable dither. Discrete dither frequency
setting minimizes the motion, which is adjusted to the valve around the
rest position. This allows the set point to be defined without considering
static friction. This also prevents the valve from becoming stuck due to
media residues. Setpoint definition can be adjusted to the application
using both scaling and configurable up/down ramps. Proportional valve module with
Characteristic curve adaptations, such as zero offset, dual gain com- adjustable dither: WAGO’s new
pensation, or range limitations, can be adjusted via parameters. Two 750-632 Module connects hy-
draulic or pneumatic valves to the
additional configurable digital inputs connect directly to sensors or
WAGO-I/O-SYSTEM via one or
two channels.

20
 HIGH SEAS, HIGH
DEMANDS
Certified from the bridge to the engine room: the
WAGO-I/O-SYSTEM 750 has been a fixed component
in maritime technology and offshore industry for years.
■ On yachts and tankers, on container and cruise ships, WAGO
controllers and industrial PCs take on almost every automation
task. The newest controller generation is ready to take up the torch:
the PFC200 is especially suitable for the the high demands of the
high seas with its multiple interfaces, performance, and compact
dimensions.
Load and ballast management, energy supply, drive control, and
monitoring systems: the control and monitoring tasks on board a
Load and ballast management, energy supply, drive con-
trol, and monitoring systems: the control and monitoring
tasks on board a ship are as complex as they are numer-
ous.
ship are as complex as they are numerous. Ship automation has
therefore followed a trend for several years, in that conventional,
centralized automation systems are increasing giving way to intel-
ligent networks of decentralized solutions. In this way, central con-
trol computers can be done away with altogether. Due to the con-
stant expansion of decentralized structures and the increased
displacement of tasks further afield, the demands placed on distrib-
uted, autonomous controllers have also grown.
direct industry 21
According to the configuration level, the PFC200 is equipped with onboard
interfaces – RS-232/RS-485, CAN, CANopen, or PROFIBUS-DP-Slave – in
addition to the two standard ETHERNET connections.
■ Increase in Automation and Communication Tasks
A multi-client-server-network architecture of this type, which demands a
higher communication capability from the components used, also neces-
sitates the implementation of more sophisticated processes in strict real
time. Corresponding data and incidents are stored on site in text files or
databases. In addition, loading so-called “recipes” of comprehensive
parameter lists for load and ballast management requires a high level of
computing power. In parallel to this, users should also always have se-
cure remote access, including visualization and the possibility to inter-
vene in the configuration.
However, process control and ETHERNET communication haven’t repre-
sented the only challenges for a long time; it is also necessary to synchro-
nously operate a multiplicity of serial communication gateways for gen-
erator sets, electrical devices, and navigation equipment. WAGO’s
PFC200 fulfills this highly-demanded combination of performance and
diversity of applications in real life due to its compact design and the
ease of installation on a DIN 35 mounting rail. This new controller gen-
eration supplements the 750-88x ETHERNET controller family in the high-
end power segment with an almost identical shape.
■ Programming and Engineering
The PFC200 with Cortex-A8 processor architecture, based on a real
time capable Linux® operating system, is compatible with all controllers
and modules within the WAGO-I/O-SYSTEM 750. Due to the new
controller’s complete compatibility with a selection of more than 400
I/O modules, customized nodes in scalable outputs can be config-
ured. This also includes diverse special technical functions, such as
condition monitoring, energy measurement modules, and relevant stan-
dards for maritime technology and the offshore industries like SIL and
Ex i.
Powerful and reliable: The PFC200 is
predestined for use on the high seas.
In addition to two ETHERNET ports, the
PFC200 directs additional interfaces.
Always fitting: The PFC200 offers
different configuration options.
22
The opportunity to migrate existing CODESYS projects, without limita-
tions, creates an unchanged “look & feel” during development work
and contributes to long term investment security. The decision to use the
Linux® platform provides users with maximum configuration freedom
during programming. Due to the open access, existing source codes
and algorithms, for example C routines, can still be used without the
necessity of translation into a PLC language.
■ Safe and Diverse Connections
According to the configuration level, the PFC200 is equipped with on-
board interfaces – RS-232/RS-485, CAN, CANopen, or PROFIBUS-DP-
Slave – in addition to the two standard ETHERNET connections. The
CODESYS configuration tools, a WAGO-specific Modbus-RTU/TCP/
UDP configurator, and numerous function libraries, available free of
charge, also provide a multiplicity of protocols. This means that some of
the most important connections can be realized directly via the controller,
without the need for additional bus modules. Diverse equipment aggre-
gates can be linked using the CAN interface via protocols like J1939 or
NMEA2000, for example The RS-232/RS-485 interface can be freely
parameterized to communicate with voyage data recorders, higher-level
control systems, or navigation devices. These interfaces include Modbus
RTU (Master/Slave), NMEA0183, RK512, 3964R, and many other pro-
tocols.
For data exchange on board using a ship network, as well as for remote
access via LAN/WAN, the PFC200 also supports all relevant protocols
in the TCP/IP family: DHCP, DNS, SNTP, FTP, TELNET, HTTP, and Modbus
TCP/UDP. In order to guarantee the security and integrity of information
during web access and data transfer, SSH and SSL/TLS security proto-
cols for establishing secure HTTPS and FTPS connections are integrated
as standard.
■ Optimal Start Up, Robust Operation
WAGO’s PFC200 can be configured either via embedded web server
(Web-based Management), CODESYS programming environment
(IEC 61131-3), or the configuration dialog (Linux® console). No spe-
cific operating system knowledge is required. Featuring SDHC memo-
ry, the fan-less and battery-free controller is maintenance-free and ex-
tremely robust. In addition to faster read/write access to user data,
such as recipes and log files that are stored as CSV files, the integrated
SD card memory enables a complete system backup & recovery – in-
cluding programming, visualization, and configuration data. This also
facilitates the respective startup of system “clones”, which is relevant
for global use on the high seas.
The WAGO-I/O-SYSTEM fulfills the highest quality demands and
therefore has received all maritime certificates, including GL, DNV,
ABS, BV, and BSH. The PFC200 will follow in this tradition, and can be
used everywhere on the ship – from the machine room to the bridge
– due to extremely low interference emissions, and high resistance to
interference, temperature, vibration, and shock. In these fields of ap-
plication, maintenance free operation is guaranteed for years.

Text: Marc-Andree Paul, WAGO

Photo: WAGO The WAGO-I/O-SYSTEM fulfills the highest
quality demands and therefore has received all
maritime certificates, including GL, DNV, ABS,
BV, and BSH.

EPSITRON® CLASSIC POWER – REDESIGN

With its redesign of the EPSITRON® CLASSIC Power family, WAGO deliv-
ers even more versatile, compact power supply units.
■ Slimmer, more communicative, more attractive. The second generation
of the
EPSITRON® CLASSIC Power supply units save even more space in the
control cabinet. Thanks to their wide input range (85 to 264 VAC) and UL
and GL approvals, the new 787 Series power supply units can be used
throughout the world in the most varied power supply systems and appli-
cations. The total of 14 power supply units with an ambient temperature
range of -25 to +70°C can be used for supplying power to industrial elec-
tric and electronic equipment in IT and automation engineering, in systems
engineering, building automation, and process and control technology.
The units can also be employed near residential areas thanks to their DIN
EN 60335-1 conformity.
Using their newly integrated TopBoost function, these units, with a nominal
rating of ≥ 120 W, supply a brief power surge in the event of a second-

g
ary short circuit. This provides reasonably priced secondary protection
using standard circuit breakers. The new 787-16xx power supply units
are available with nominal output voltages of 12, 24, and 48 VDC, and
outputs of 25 to 480 W. LEDs and an active DC OK signal or a floating
In a compact metal or plastic housing: The new
DC OK contact (depending on the type of unit), indicate to the user what
EPSITRON® CLASSIC Power supply units are ideal for a
the operating status of the unit is at all times.
wide range of applications thanks to their lean design,
additional functions, such as TopBoost, pluggable con-
nection technology, and signaling contacts.

direct industry 23
ADDRESSES
D
WAGO Kontakttechnik GmbH & Co. KG
Postfach 2880, 32385 Minden
Hansastraße 27
D-32423 Minden
Phone: +49 571 887-0
Fax: +49 571 887-169
info@wago.com

A
WAGO Kontakttechnik Ges.m.b.H.
Laxenburger Straße 244
1230 Vienna
Phone: +43 1 6150780
Fax: +43 1 6150775
info.at@wago.com

CH
WAGO CONTACT SA
Rte. de l’Industrie 19
Case Postale 168
1564 Domdidier
Phone: +41/26 676 75 86

0888-0201/0214-6901 • WAGO DIRECT INDUSTRY 2/14 US • 09/2014-00 • Printed in Germany

Phone: +41/26 676 75 01
info.switzerland@wago.com

IMPRINT
WAGOdirect industry August 2014

Editor: 
Stefan Keggenhoff
(responsible editor)
Phone: (0571) 887-9570
Fax: (0571) 887-89570

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Contact person: Stefan Keggenhoff. We assume no liability
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