Electricity + Control February 2019

FEATURES: · Cables + accessories

· Control systems + automation · Sensors, switches + transducers · Transformers + substations

COMMENT

ON THE COVER

FEATURES: · Cables+ accessories

· Control systems+ automation · Sensors, switches+ transducers · Transformers+ substations

Industry 4.0: an enabler

A s I write this comment, 8% of the year has passed. An interesting thought, and a moment for reflection. Of late, and not as a result of any fault of my own, I have been engaging more and more with the mining industry. Since I am not a miner, my involvement, as it were, has been at a broader level. But it has been driven to a large extent by everything 4.0, something readers of this magazine have been dealing with some decades, really – though maybe not as forthrightly as they are now. I concede that my last comment may be a little facetious – but actually it is not that far off the mark. Think about the evo- lution of control systems since the mid 1980s, and then consider the explosion of electronics and communications systems into our plants – and the impact they had on how we managed, monitored and con- trolled every aspect of the plant. That is what we have been doing. As I mentioned in an earlier comment, the point now is that Industry 4.0 is be- coming more and more pervasive – to the extent that every industry is making the obvious observation. It is an enabler: The proper use of digitalisation will ensure that you do what you do – but better. In this regard the mining industry has become a major player in the sector. The reasons, of course, relate to a wide range of issues not least of which will clearly be to ensure improved safety in every part of the mining value chain; but obviously also to ensure better operations at every level. It is therefore not surprising that read- ers of Electricity + Control will be observ- ing a growing interest from authors, and advertisers, in applications around the

mining industry. And this is actually an ex- citing development. I was intimately involved in the pow- er industry in the mid 1980s (also no fault of my own), and databases, knowl- edge-based systems, and even CFT moni- tors were invading that industry – and folk who were then as old as I am now (pos- sible) were both excited and terrified. A wondrous combination of feelings, really! This is where we are headed. And with this comes the daunting realisation that many tasks currently undertaken by humans will, indeed, be better done by smart machines. Not all such tasks; but many. This implies the urgent need to im- agine how re-skilling can take place, and to what extent it is likely to be success- ful; and equally speaks to the current, and quite rapid, evolution of all the edu- cation and training programmes preparing youngsters to enter our profession. As it was when I was entering the pro- fession; I have no doubt that we will be enthused by what these young people are bringing to our industry – and possibly just a bit scared.

EC_Feb 2019 cover.indd 1 1/31/2019 8:57:14AM www.electricityandcontrolmagazine.co.za

ifm 's IO-Link master serves as a gateway between intelligent IO-Link

sensors and the fieldbus. (Read more on page 11).

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CONTENTS

4

Features

CABLES + ACCESSORIES 4 Cables to the crater Bernd Müller for LAPP

8 Round UP

CONTROL SYSTEMS + AUTOMATION 12 Recognising optimisation potential in electrical engineering

16 Round UP

SENSORS, SWITCHES + TRANSDUCERS 20 Accurate tank level management in dairy production

22 Tooling up for improved efficiency

24 Flexible automation system for mini pilot hydropower plant Vishal Bachoo, ifm electronic (SA)

27 Round UP

12

TRANSFORMERS + SUBSTATIONS 30 Integrated electrical make-up for Cullinan’s diamond processing plant

32 Transformer design: changing for a better tomorrow Aaron Rost, Trafo Power Solutions

38 Round UP

20

Regulars

1

Comment

11 38 39 40

Cover article Light+Current

Engineering the future

Write @ the back

2 Electricity + Control

FEBRUARY 2019

CABLES + ACCESSORIES

by Bernd M ü ller for LAPP Cables to the crater

Source: Icelandic Meteorological Office

Hekla is one of Iceland’s most active volcanoes and scientists hope to use a network of seismometers to peer into the belly of the mountain and warn of an impending eruption. Connecting this network called for an especially tough cable, as the envi- ronment in the mountains of Iceland is anything but friendly.

Take Note!

Six seismometers have been installed on top of Hekla, one of Iceland’s most active volcanoes. The chosen cable fea- t u r e s f o u r t w i s t e d pairs surrounded by an aluminium-coated plastic band.

1

2

V olcanoes are just as much a part of Ice- land as geysers, elves and trolls. One of the most active and dangerous of these is Hekla, located in the south of the island. It erupts approximately every ten years, most recently in 1970, 1980, 1991 and 2000, spewing fountains of

ash up to 30 kilometres into the sky. But since the last eruption in 2000, the volcano appears to have been on a break. This is good news for tourists, who come in their droves to hike to the crater rim 1 491 m above sea level, but it makes geophysi- cists nervous. “Hekla could erupt at any minute”, warns Martin Möllhoff, “and the longer this quiet period goes on, the more violent the eruption will be”. The German geophysicist works at the School of Cosmic Physics of the Institute for Advanced Studies in Dublin, Ireland. Here, he leads the tech- nical division that uses seismometers to monitor countless volcanoes around the world, including Hekla. If these probes detect minor tremors in the ground, it is red alert. This is because the last erup- tions were only detected in seismic measurement curves around 30 to 80 minutes in advance. As a result, all visitors to Hekla must download an app to their smartphone that receives warning mes- sages via SMS. Detecting the warning signs Möllhoff’s team is in the process of installing six seismometers on top of Hekla. Each of these

Figure 2: Cables for Icelandic Volcano.

Source: Icelandic Meteorological Office

4 Electricity + Control

FEBRUARY 2019

Figure 1 (left): The equipment, including 3 000 m of cable from LAPP, was transported through ice and snow up the slopes of the Hekla volcano in Iceland.

CABLES + ACCESSORIES

Source: Icelandic Meteorological Office

The goal is to discover how eruptions are reflected in the measurement data.

in summer. The aim, however, is to keep overall energy consumption as low as possible. The cable was supplied by Johan Rönning, the market leader for electrical equipment in Iceland. Johan Rönning imports and sells LAPP products in Iceland, and supplies electrical components to most geophysical installations. The company has been working with LAPP since 1985.

metal cylinders contains a mass made from a thermally stable metal alloy. This is kept virtually motionless by means of an electronic feedback loop. Tremors in the ground cause the housing to vibrate, while the mass does not follow the motion due to its inertia. The position of the mass relative to the housing is measured and the feedback loop executes a magnetic or electrostatic counterforce, depending on the model. The voltage required to generate this force is the measurement value that is digitally recorded. This makes it possible to de- tect movements of just a few nanometres (1 nano- metre = 1 millionth of a millimetre). As Hekla offers so little warning time, it is not possible to save the measurement values in the seismometer and take readings on site every few months as is usually done. Instead, they must be communicated immediately. This system usually occurs via 3G mobile modems, but is not possi- ble in this instance for all six seismometers as the modem requires up to 5 W of electrical power. In the gloomy Icelandic landscape, where the sun only rises for a few hours a day, if at all in winter, solar cells cannot provide enough energy. And this is why Möllhoff’s team decided to use a cable from LAPP to transfer the data.The cable transfers data, and the energy required to run the seismometers, which is generated by three independent small wind turbines. Each wind turbine is supported by a solar cell to compensate for periods of low wind

“We are very happy with the coop- eration”, says Óskar Gústavsson, key account manager at Johan Rönning. Gústavsson praises the excellent support from LAPP’s experienced experts, adding: “They’re also fantastic with delivery times”.

Figure 3: Conditions at the peak of Hekla, almost 1 500 m above sea level, place special demands on the material.

Source: Icelandic Meteorological Office

CABLES + ACCESSORIES

On the positive side, this inhospitable landscape is not home to any voracious animals that could gnaw away at the cable. The job of selecting the right cable fell to Bergur Bergsson. The engineer from Iceland’s meteoro- logical office went looking for a Vaseline-filled Eth- ernet cable with four twisted-pair cores, screening and a robust outer sheath. Bergsson’s colleagues have been using these cables in seismic measure- ment networks for 15 years, such as in a similar project on Vatnajökull, Iceland’s largest glacier. The decision to choose LAPP was largely thanks to the company’s good website and search function. “We were able to find exactly what we were look- ing for”, says Bergsson. “LAPP is also a trustwor- thy brand in the cable sector”. Watertight in every direction On the LAPP website, Bergsson found an outdoor cable for connections in telecommunication. The

Across razor-sharp volcanic rock The distances between the wind turbines, data transfer centres and the seismometers are rel- atively short. In many sectors, LAPP is known for not having minimum order quantities. This al- lowed the scientists to order the three kilometres of cable they needed for their entire installation. But the main argument in favour of the LAPP ca- ble was its robustness. The hard volcanic stone makes it impossible to install a cable underground, meaning it has to be rolled out over razor-sharp rocks. Here it has to withstand mechanical abra- sion and sub-zero temperatures in the Icelandic winter. Snowfall can also occur all year round. Another important factor is heat. Above the thin crust of the Mid-Atlantic Ridge, the rock can be very warm. Geophysicists have already measured temperatures of 50 degrees Celsius at a depth of just half a metre. Furthermore, highly corrosive gases flow out of the ground in some places.

Author, Bernd M ü ller.

Figure 4: At 1 300 m. Source: Icelandic Meteorological Office

6 Electricity + Control

FEBRUARY 2019

CABLES + ACCESSORIES

cable features four twisted pairs, surrounded by an aluminium-coated plastic band that acts as screen- ing. The PE outer sheath resists UV light and is transversely waterproof, meaning that it does not allow moisture to penetrate through the sheath. If water penetrates at the ends of the cable, in this case at the connections to the seismometer and the modem in the data centre, or through a tear caused by a sharp object, the water is prevented from spreading through the cable. This is because the cable is filled with petroleum jelly, commonly known as Vaseline. Möllhoff thinks the choice of cable is a good one. The 60-volt direct current power supply to the seismometers is stable, as is the data transmis- sion in both directions via separate wire pairs. This allows the volcanologists to adjust the seismom- eter settings from afar. The measuring system for the first installed seismometer works perfectly, collecting 1.5 gigabytes of data per month and

transmitting it live to Reykjavík and Dublin.

Measurement campaign until the eruption So far, there is nothing to suggest that Hekla might be about to erupt. The measurement campaign is planned to continue until the next eruption oc- curs. The goal is to discover how im- minent eruptions are reflected in the measurement data and to provide insights into developing a permanent early warning system. Such a system could then also be installed on other volcanoes. At any rate, the research goes on; as Möllhoff says, “There are still plenty of volcanoes we have not explored yet, and plenty of unan- swered questions”.

Source: Icelandic Meteorological Office

Electricity + Control

FEBRUARY 2019

7

round up CABLES + ACCESSORIES

Improved efficiencies with automated cable identification

barcoding and much more. Brady also offers technical support via customisable service agreements which can include on-site installation and setup of solutions, preventive maintenance, training and fast response on top of a standard one-year warranty.

Industries that work with large volumes of cables and need to be able to identify and trace cables quickly can increase pro- duction efficiency and performance with Brady Corporation's complete and auto- mated cable identification solutions. Both cable sleeves and wraparound la- bels can be applied speedily. The Wraptor A6500 can print and wrap a label around a cable in five seconds, saving time in cable production when traceability and identifi- cation requirements need to be met. If the cables are to be identified with sleeves, Brady offers the BSP45 Automated Sleeve Applicator to remove sleeves from their liners and apply them on the cables by ac- tivating a foot pedal. Sleeves can be print- ed with precision using the BradyPrinter i7100, or with the BBP72 Sleeve Printer to print both sleeve sides simultaneously. Brady's wraparound labels and sleeves are of enduring quality and can resist chal- lenging industrial environments.The B-472 self-laminating vinyl label offers abrasion, fuel, oil and outdoor resistance and comes in a wide range of colours, and the B-499 nylon cloth wraparound label additionally offers dirt, heat, cold and chemical resist-

ance. Both these labels work seamlessly with the Wraptor A6500. For the BSP45 Sleeve Applicator, Brady recommends its B-342, B-7646 and B-7641 sleeves which include diesel resistant or low smoke zero halogen properties. All identification ma- terials have been tested using ASTM test methods for optimal reliability. Technical data sheets are available from Brady's website. Easy label and sleeve design support is provided via Brady Workstation apps which are available with a 30-day free trial period. Users can simply select the apps they need after trying them. Features in- clude adding text, symbols, serialisation,

Enquiries: Brady Corporation. Tel. +27 (0) 11 704 3295 or email: info_africa@bradycorp.com

Pow-R-Way III Busway System IRISS and EATON joined forces to manufacture the Pow-R-Way III Busway Sys- tem which enables safe and accurate energised infrared inspections under full load. The UL listed joint cover design, with the polymer infrared window, ena- bles Pow-R-Way III users to perform critical condition-based maintenance in- spections of busbar joint connections inclusive of infrared, ultraviolet and visual inspection. The Busway System allows infrared inspections to be conducted, safely, at any time. The joint cover with the polymer window is designed for industrial environments where mechanical stresses are common. Enquiries: R&C Instrumentation.Tel: +27 (0)11 608 1551 or Email: info@randci.co.za

The cable solution for all industry sectors

PSA Cables, in partnership with TKD Kabel from Germany, offers a wide range of cables for all sectors of industry. TKD Kabel is re- portedly the third largest cable supplier in Europe and PSA Cables is bringingTKD products to South Africa with the goal of supplying quality cables to the African continent. PSA Cables can supply data and network cables, motor and servo-motor cables, control, electronic and robot cables as well as PVC and rubber cables and panel wires. In addition to the standard product range, PSA Cables can supply a variety of cables, includ-

ing speciality cables such as crane and conveyor cables, cables for fixed installations, oil-resistant cables, halogen-free and flame-re- tardant cables, and aluminium cables. With a comprehensive range of over 10 000 of the best quality European cables as well as a team of highly motivated, qualified and competent technical staff, PSA Cables is positioned to meet all industrial cable requirements. Enquiries: PSA Cables.Tel. +27 (0) 11 457 2500 or email info@psa-technology.net

8 Electricity + Control

FEBRUARY 2019

NewTaper-Tech ® brass compression cable gland Pratley recently launched its Taper-Tech ® brass compression cable gland for circular unarmoured cable.TheTaper-Tech ® clamping sys- tem features a differential taper design. Using specially-formulat- ed, high-performance, compression-set resistant rubber, the grip- ping force of the bush increases proportionally with the axial load on the cable. This means that the cable remains safely secured, and undamaged, even at very high pull-out loads. Another major advantage of the Taper-Tech ® brass compression cable gland is its industry-beating IP68 ingress protection rating, which can withstand a water head pressure of 150 m. “We believe there is no other cable gland that performs to this level on the world market,” says Pratley marketing director, Eldon Kruger. The Taper-Tech ® compression cable glands are manufactured from nickel-plated brass. They can accommodate all circular ca- bles with outside diameters from 3 mm to 73.8 mm, in addition to an array of non-circular cables when fitted with appropriate bushes. The glands are supplied complete with nipple gaskets and nickel-plated brass locknuts. The IP68 rating means that the Pratley Taper-Tech ® brass com- pression cable glands seal the bore automatically against the in- gress of pressurised water and ambient moisture. In addition, gland sizes 00, 0, 1 and 2 are available ex-stock with Pg and Npt threads. Pg and Imperial threads can also be accommodated by means of Pratley adjustable cable glands fitted with com-

pression conversion kits and thread adaptors. Exceptionally thick gland plates can be accommodated by fitting adjustable glands with long nipples. With over 65 years’ experience and a substantial portfolio of patents under its belt, Pratley prides itself on the local produc- tion of highly innovative cable glands, junction boxes, and related accessories. Variants for use in hazardous locations comply with international IECex Standards for Ex n, Ex e and Ex d explosion protected equipment. Many Pratley cable glands and boxes also comply with the European ATEX directive. The Pratley group of companies is known for its innovative prod- uct developments serving the manufacturing, mining, construction and petrochemical sectors in many countries. It manufactures over 1500 products and is an ISO 9001:2015 accredited company. Enquiries: Pratley.Tel. +27 (0) 11 955 2190 or email: sales@pratley.co.za

PSA Technology PsaAfrica Psaafrica PSA Global Find Us:

Contact Us: t: +27 11 457 2500

e: info@psa-global.co.za w: www.psa-global.co.za

 PSA CABLES, IN PARTNERSHIP WITH TKD,  OFFERS A WIDE RANGE OF CABLES FOR ALL SECTORS OF THE INDUSTRY.

SA Cables can supply various cables including the following:

• Data and Network Cables • Control, electronic and robot cables • Motor and servomotor cables • Drag chain systems and cables • Crane, conveyor and lift cables

• Cables  for fixed installations • Oil resistant cables • Heat resistant and compensating cables • Rubber cables • Aluminium cables

Electricity + Control

FEBRUARY 2019

9

With access to a wide range of the best quality cables, PSA Cables can supply cables for a wide variety of operations.

round up CABLES + ACCESSORIES

Industrial connectivity solutions in the range of different housing-styles, codings and a large number of cables, customers will find the right solution for any given application. Whether it is M8- or M12-connectors, RJ45- or valve-connec- tors – all products are available in many ca- ble-lengths. Useful T- andY-splitters, recep- tacles, adapters, and I/O-modules provide for flexible wiring structures. If the standard range proves insuffi- cient, ESCHA modifies and adapts existing products to customers' needs. This may involve a specific cable quality, a particular colour, or a special circuit. ESCHA is also the right partner for customer-specific de-

Prime Automation, sole agent for Pilz Safe- ty Systems in South Africa, has a distribu- tion agreement with the ESCHA Group, a leading international supplier in the field of industrial connectivity solutions. For more than 35 years, the family-con- trolled company has been developing innovative products for the automation components market. Based on its stand- ard product programme, the German com- pany also designs custom-made connec- tivity and individual specialised solutions. ESCHA standard connectivity stands for diversity, quality, and reliability in pro- tection classes IP67, IP68, and IP69. With-

velopments from scratch. Staff specialised in electrical engineering and plastic tech- nology will develop a solution to meet the customer’s specific requirements. With more than 900 employees in five countries and through its in-depth develop- ment and production, ESCHA is extending its product portfolio constantly and inde- pendently. The company guarantees high availability and consistent quality of its products worldwide via a network of inter- national sales partners and companies. Enquiries: Prime Automation.

Tel. +27 (0) 41 819 7746 or email: sales@primeautomation.co.za

Prime Automation now supplies ESCHA connectivity solutions for industrial automation.

PVC or PUR: Choosing the right cable

As cables are an essential part of any industrial application it is important to choose the appropriate cable material for the environment, especially where chem- ical cleaning solutions, cutting fluids, and other caustic liquids are present. The two main types of cables used in industrial ap- plications are PVC and PUR, and they are Polyvinyl chloride, or PVC, cables are sheathed and insulated. They are an excel- lent choice for most chemical wash-down applications in the food and beverage industries. They have good-to-excellent resistance to common cleaning solvents including, but not limited, to: • Sodium hypochlorite • Sodium hydroxide • Potassium hydroxide • Per acetic acid • Hydrogen peroxide • Quaternary ammonium compounds It is important to take into consideration chemical concentration, process temper- suited to different environments. PVC cables: when to use them

ature, and duration and frequency of ex- posure, since these factors can impact the suitability of PVC for the application. PVC has limited resistance to oils, making it less suited for automotive and machine tool industries. In addition to being resistant to com- mon cleaning chemicals, PVC cables are generally more rigid than other types of cables. This makes them suitable for use in applications where they will be exposed to high temperature, high pressure wash- down. The rigidity of the PVC sheathing protects the cable from damage and ex- tends the life of the cable. A PVC cable with a rating of IP69K means it is sealed against the ingress of water even during wash-down. However, the rigidity of the cables can be a disad- vantage in freezer applications, where low temperatures can cause the materi- al to crack if the cables are being flexed. Discuss specific application requirements with an expert to determine the best cable material in these circumstances.

PUR cables: when to use them PUR (or polyurethane) is a thermoplastic material used for cable jackets. Because PUR cables are resistant to cutting fluids, oils, and other harsh chemicals, they are a good choice for many automotive man- ufacturing, stamping and machining appli- cations. PUR cables have high tensile strength, tear resistance, and abrasion resistance. They are also extremely flexible, with a small bend radius.This makes them ideal for appli- cations where connections move or bend frequently, such as robotic applications.

PVC cable

PUR cable

Condition

Cleaning chemicals X Wash-down applications X Cutting fluids/oils

X X

Repeated flexing

Enquiries: BrandonTopham, brandon. topham@retautomation.com

10 Electricity + Control

FEBRUARY 2019

COVER ARTICLE

FEATURES: · Cables+ accessories

· Control systems+ automation · Sensors, switches+ transducers · Transformers+ substations

ifm’s IO-Link master modules in the control cabinet

EC_Feb2019 cover.indd 1

1/31/2019 8:57:14AM

i fm’s IO-Link master serves as a gateway be- tween intelligent IO-Link sensors and the field bus. In addition, important information of the in- telligent sensors can simultaneously be sent into the IT world. With a separate IoT Ethernet socket, the IT network can be set up completely separate from the automation network. Sensor information is transferred into the IT world via the established TCP/IP JSON interface. Advantages and customer benefits Separation between automation and IT network Machine uptime is of highest priority. The automa- tion network must by no means be interrupted by external factors. Therefore, the unit features a sep- arate IoT Ethernet socket separating IT and auto- mation network. This means that important sensor information can be safely sent to the IT and ERP systems. Sensor configuration with LR DEVICE Intuitive software finds all IO-Link masters in the network and creates an overview of the whole plant. In addition, all connected sensors are dis- played with the respective parameters.This makes it possible to set the parameters of all sensors in the system from one central point. Easy sensor connection The sensors and actuators are connected via standard M12 connection cables without screen- ing. The connection cables are fixed via removable COMBICON connectors on the IO-Link master. Up to 8 IO-Link sensors can be connected and be supplied with up to 3.6 A. The cable between the IO-Link master and sensor can be up to 20 m long.

analogue signals, contact resistance and EMC interference cannot corrupt the signals. The part number used for the hydro power plant solution is AL1930. Advantages of the IO-Link master: • Separation between automation and IT network • Industry 4.0 ready via new IoT core • 8 IO-Link ports with full V1.1 functionality • PROFINET, EtherNet/IP, EtherCat, • Modbus TCP or TCP/IP JSON • Master and device configurable via the LR DEVICE software

Enquiries: ifm electronic ZA,Tel: +27 (0)12 450 0400

http://www.ifm.com or email: info.za@ifm.com

Reliable digital data The sensor data is transferred digitally. Unlike

Electricity + Control

FEBRUARY 2019

11

CONTROL SYSTEMS + AUTOMATION

Recognising optimisation potential in electrical engineering Article supplied by Siemens

Planning and design of machine control panels are essential steps in the production of a new machine. As in all other engineering disciplines, the procedures and meth- ods are subject to constant change.

Electrical planning is re- sponsible for engineering the electrical equipment of the machine. Take Note!

1

Engineering costs must not increase The principle of keeping costs as low as possible remains in force – even in the face of ever increas- ing requirements. This represents a contradiction that increasingly poses a problem. Ultimately, more and more control panels have to be designed and built in the same amount of time. The total costs in- curred for this, i.e. the total cost of ownership, can be subdivided into the following cost items: • Engineering: Costs that arise during electrical design (around 45% on average). • Devices and materials: Costs for integrated products, cables/wires and control panel ma- terials such as metal sheets and rail systems (around 45% on average). • Assembly and wiring: Costs for labour and ma- terials that arise during assembly and wiring of a control panel (around 10% on average). The engineering costs for a control panel account for a significant portion of the overall costs and yet they must decrease in order to remain competi- tive. This is what is behind today's growing cost pressure, and requires greater efficiency and opti- misation to counteract.

Digitalization and Industry 4.0 are often mentioned when a new software solution is introduced or processes are modified. But what is driving this change and what opportunities exist to further op- timise engineering to meet the growing demands? Time is always the problem Electrical planning – An important compo- nent of every machine planning In addition to the mechanical design and devel- opment of the automation concept, planning the electrical power supply and distribution is the third engineering discipline involved in production of a new machine. Electrical planning ensures that all components in a machine are supplied reliably and safely with power. In most cases, it provides the framework for the automation engineer; spec- ifying things like communication, topology and control concept. The documentation created in the process is, in effect, a certificate of insurance and serves as proof that the electrical equipment of the machine is designed in conformance with applicable guidelines and standards and that the required protection goals are met. All switching, contacting and controlling components find their place in the control and machine panels. Electrical planning is responsible for engineering the electri- cal equipment of the machine.

Reasons for the growing cost pressure Reasons for the increasing cost pressure are var-

12 Electricity + Control

FEBRUARY 2019

CONTROL SYSTEMS + AUTOMATION

programs offered functions for easy and precise placement of circuit diagram symbols and their interconnection. Soon, that was not enough for efficient working. The concept of object orienta- tion was added to the software. A placed symbol is no longer just a collection of drawn lines; it is one of many views of a device that is to be inte- grated later in the real control panel. To create a plan that is as exact as possible, you need various representations of a device. In the circuit diagram, for example, one places a coil. In the assembly plan, it is a true-to-scale drawing, which shows the dimensions of the device. For the software, however, it is only different views of one and the same object. With the object orientation and the automation functions available in practically every ECAD software, it is possible to take advantage of many benefits for daily work. This starts with generating simple output lists and proceeds to automatic renaming or displaying and hiding of layers up to complete modular engi- neering. When using new software, many users do not change their habits. In exaggerated terms, these users continue to draw with the new software as before. New software is intended to simplify daily work and the investment, which can represent a burden for the company, would not be justified. Take advantage of the possibilities of the soft- ware, even if this means extra effort or a training course. It will certainly be profitable in the subse- quent project. This requires leaving the comfort zone but, the first time the motor feeder or supply no longer has to be drawn or copied but only con- figured and generated, you will quickly want more. The tasks to be mastered have expanded From designer to data manager The above-mentioned reasons for increased time pressure in electrical planning are dictated by the customer. Other factors to be overcome come with ongoing digitalisation in electrical engineering. The daily work of electrical designers should consist of planning activities. However, more and

ied. In general, complexity of the documentation increases constantly. End customers and machine builders desire a higher level of detail to enable better and more independent production. This is accompanied by the trend towards outsourcing control panel manufacture to specialised control panel builders. Fewer and fewer machine builders can afford their own in-house control panel build- ing operation. The documents for the control panel must contain detailed information that will enable the customer and supplier to reach a clear agree- ment on the scope of work and prevent possible disputes over any added costs incurred. The communication portion of the integrated components increases continuously. What was once a ‘simple’ controller now includes measuring and monitoring devices for tasks such as energy or condition monitoring. This makes planning more complex and time consuming. But such communi- cation is essential for Industry 4.0 capable plants. There are also changes taking place in the as- sembly and wiring of a control panel, where there is an increasing degree of automation, such as prefabrication of cables and automated machining of sheet metal parts. This calls for more data and details to be included in the plan. Last, but not least, demands on service have increased. Maintenance personnel must receive all the necessary information for a component replacement quickly and efficiently. In this era of just-in-time production, long machine downtimes have a much greater impact than they did 10 years ago. Poor documentation can lead to longer outag- es, which can reflect negatively on the reputation of a machine builder. The changing tools of the electrical planner bring new opportunities ECAD tools can often do more than you think As cost and associated time pressure challeng- es increase, the use of tools for daily work also changes. A few years ago, a ‘drawing’ was the main vehicle for creating electrical plans. ECAD

As demands on service increase, so maintenance personnel need

information quickly and efficiently.

more activities include downloading, storing, processing and backing up data.To some extent, these are clas- sic activities from the field of data management. They have to be done but are not directly remunerated.

Complexity, automated assembly and production, and demands on service and maintenance increasing call for documentation with high-quality, digitally processable information and thus also for efficient engineering.

Electricity + Control

FEBRUARY 2019

13

CONTROL SYSTEMS + AUTOMATION

Here it necessary to work as efficiently and lose as little time as possible. However, the activ- ities often receive little or no attention, which can lead to problems in the long run. The longer one delays addressing these problems, the longer it will take to correct them.

which can be downloaded via their own data por- tals. The use of these data portals is a convenient option for users and has the advantage that many different device manufacturers are represented. For example, Siemens makes available its prod- uct data and graphics in all commonly used data portals such as the EPLAN data portal, wscadun- iverse.com and Traceparts. In doing so, it elimi- nates the need to search for this information on the manufacturer's website. However, product data must contain the right information. Every electrical planner has different needs. Some create the control panel layout in 2D and need DXF or 2D representations of the com- ponent dimensions for this. Others have migrated to 3D and would like to take advantage of different opportunities, such as virtual wiring or automatic drilling and milling. It is worth ascertaining that ad- equate data exists for your engineering process. 2. How efficiently can I obtain data? Downloading product data for the planning software via an integrated data portal is the most convenient way. However, more documents such as manuals and certificates, may be needed. In some cases, the CAE software does not have an integrated data portal. Here, specific documents can be download- ed from the manufacturer's website. Quick access to information can be an advantage. Siemens is committed to making access to technical docu- ments as easy as possible. With the CAx download manager, documents and CAE data can be down- loaded quickly and easily in a single data package. This saves time and money during engineering, and stress on the part of the electrical project engineer. Optimisation does not end with electrical planning Taking advantage of tools for daily work Daily work in electrical engineering is multifacet- ed. A lot of small tasks must be completed before everything fits together. Common individual tasks include product selection, cable dimensioning and incoming unit design. Others include temperature rise analysis, short-circuit rating verification, safety category determination and assembly of the final documentation. Some device manufacturers offer tools that are helpful in accomplishing the respective tasks. Integrating these tools into daily work processes reduces to a minimum the effort required. More- over, it creates a level of uniformity, which is the

Data and tool support are important levers for efficiency improvement Moving away from price-driven thinking to total-cost-of-ownership Generally, all companies operate as economically as possible. Besides the functionality and quali- ty of a device or component, its price is a major criterion for choosing it. However, a favourable purchase price does not automatically lead to an economical control panel. The electrical planner works with a product long before it is purchased or integrated. Unfortunately, the burden imposed by a component on the elec- trical planning is often neglected in the purchas- ing decision. The manual creation of a complete dataset for a new project in the ECAD software takes more than 2.5 hours on average. The ability to use existing data of the manufacturer is thus all the more important. If suitable engineering data are not available or are incomplete, the effort in- volved for manual creation of the product data can add up quickly. What appears to be a favourable price can lead directly to increased engineering effort. Therefore, the following questions should be asked when making a purchasing decision on a component in the control panel: 1. Can I plan efficiently with the product? The availability of data for planning software can save a lot of time and effort. CAE data provided by the manufacturer, such as product data, circuit dia- gram symbols, macros or DXF drawings, can be in- tegrated directly into circuit diagram planning. This eliminates the need for manual, time-consuming creating and importing of data. ECAD systems frequently offer complete data packages for this,

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basis for modular engineering and automated pro- cesses. A tool outputs things the same way every time, no matter who is using it. Subsequent work steps can be adjusted to the standard outputs. Practically all switching, contacting and controlling components in a control panel can be selected us- ing the TIA Selection Tool. The selected products can be exported using the export function, and im- ported into the ECAD system. Work can continue in the ECAD system until time for the temperature rise analysis is reached. The list of products is then exported from the ECAD system and imported into SIMARIS Therm, which calculates the heat balance and outputs a corresponding report that can be added to the verification documents. The temperature rise verification is now available and the heat dissipation concept to be implemented is known. Siemens offers other useful tools that are available for free download, and it would be worthwhile looking at each manufacturer’s tools. The electrical design is not the only development step in the production of a machine. It is closely linked with its neighbouring engineering disciplines: mechanical design and automation. Changes often occur until the last minute and have to be incorpo- rated in the documentation. Fast and easy trans- fer of data and information is thus important. The best solution is to set standards and consistently use them, be it an agreed actuator/sensor/load list that becomes more and more detailed as the project progresses or a tool interface that enables easy data exchange between the electrical planning and automation disciplines. One possible example of such a tool interface is Automation Markup Lan- guage. AML allows the transfer of a complete PLC hardware configuration. The neutral data format, which was jointly developed by a large group of manufacturers, can already be used by some en- gineering tools. For example, AML can be used to exchange data between the SiemensTIA Portal and EPLAN Electric P8. It is even possible to transfer a hardware configuration from the TIA Selection Tool to EPLAN or TIA Portal. This data format is clearly versatile, has a future, and is replacing some time-consuming Excel-based data exchanges. Design manufacturing: the groundwork for production and assembly In reality, the plan is implemented with the con- The journey to standard exchange formats has begun

struction, fitting and wiring of the control panels. The more precisely engineering is performed and the more details included in the plan, the faster and easier it is to produce the control panel. Pro- ductivity is already at a high level, and further opti- misations are difficult to achieve. One possibility for optimisation could be the changeover to 3D design for control panel build- ing. Apart from collision detection, a pure 3D model offers no significant advantages initially. Only additional information, such as the coordi- nates and direction vectors of device connections or the ‘drilling template’, provides engineers with new opportunities for savings during control panel building. Placement information for mounting rails and docking points for accessories also ensures more efficient assembly. This additional informa- tion enables advantages such as virtual wiring: the software generates a list of all cables with length information that is accurate to the millimetre. This list can be used to have all cables automatically prefabricated. The fitter only has to install and con- nect the cables. The same advantage is achieved with drilling information, as this allows fully auto- mated drilling and milling of a mounting panel. When it comes to optimising electrical engi- neering through the use of new technologies, the concept of total cost of ownership applies. Opti- misations are often only achievable when collabo- ration of individual activities is improved even if it means increasing the efforts for an activity. Summary Electrical planning can be complex and multifac- eted. There are many possibilities for improving efficiency. The use of previously unused ECAD software features or the setup of optimised data management is a good first step. The CAx data from Siemens, which is downloaded quickly and easily with the CAx download manager, includes many documents and other types of data needed during the course of electrical project engineer- ing and documentation creation.

Measures such as standardisation and modularisation of engineering and a changeover to 3D design for control panel building open up further poten- tial. Tools like the TIA Selection Tool, SIMARISTherm and SIMARIS design can be integrated for process optimi- sation.

A white paper from Siemens; June 2018

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round up CONTROL SYSTEMS + AUTOMATION

Christian P-4.0 ADVANCED compact motor starter including full motor protection

Today's drive solutions require powerful and flexible instruments. The new motor starter Christian P-4.0 from TELE is de- signed for motors up to 4.0 kW @ 400 V, and includes five functions in one compact unit, requiring only 22,5 mm width. This in- telligent instrument offers soft start, soft stop, forward/reverse, overload protection and an integrated 3 ph motor contactor. With integrated motor protection, the use of an external MCB is obsolete. A sim- ple circuit breaker protects the installation against short circuit and faulty wiring. The soft start and stop function is performed by reliable semiconductors (thyristors) and the reverse function by an internal relay. After performing the start process, the semiconductors are bypassed by integrat- ed relays to minimise power dissipation. The intelligent combination of semiconduc- tors and relays increases the lifetime and

brid design compared to traditional contactor-relay solutions. • Energy saving by bump-less soft start/ stop function.

efficiency of the unit significantly. The over- all combination of the above-mentioned features protects motors, shafts, and in- dustrial plants from mechanical stress and reduces maintenance and standstill times. Advantages at a glance • Up to five functions in one instrument: soft start; soft stop; motor ther- mal protection; 3 ph motor isola- tion contactor; forward/reverse. • Minimised space consumption, 22.5 mm in width. • Only line protection is neces- sary, no motor circuit breaker needed. • Robust semiconductors with 1500 V max isolation voltage. • Increased system availability by the motor protection function. • Increased lifetime through hy-

Enquiries: Vepac Electronics. Tel: +27 (0) 11 454 8053 or Email: sales@vepac.co.za

Economy line in precision measurement technology

real-time information directly back into the process. The speed, reliability and accuracy of production and test processes can be increased significantly with these insights. Efficient data logging for subsequent process analysis and optimisation is also easy. If increased requirements necessitate higher sampling rates, the ELM3x0x measurement modules with up to 50 ksps can be used instead. These are suitable, for exam- ple, for vibration measurement on fast-running machines in order to implement active vibration compensation or predictive mainte- nance. Enquiries: Beckhoff Automation (Pty) Ltd. Tel. + 27 (0) 11 795 2898 or email: info@beckhoff.co.za

The new ELM314x economy line of the EtherCAT measurement modules from Beckhoff Automation supplements the established ELM3x0x line with a lower cost 1 ksps class. This simplifies the use of the system-integrated precision measurement technology, which taps significant optimisation and efficiency potentials in both production machines and inline test benches. The new ELM314x measurement modules are available in 2, 4, 6 and 8-channel versions. High-precision measurements with an accuracy of 100 ppm are possible – and in a wide tempera- ture range from 10 to 40 °C. Each channel of the measurement modules can be set to current or voltage measurements with a sampling rate of up to 1 ksps per channel. Analogue signals in the ranges from ±1.25 to ±10 V, 0 to10 V, ±20 mA or 0/4 to 20 mA can be processed. The economy line offers considerably reduced channel costs, but provides the same wide range of functions as the ELM3x0x line. These include freely adjustable two-stage filters, oversam- pling, distributed clocks, true RMS and scaler functions. The ex- tensive diagnostic features for unattended, long-term use, familiar from the ELM3x0x line, are also incorporated. Sampling at 1 ksps per channel is suitable for a wide range of applications. In particular, the processes of moving machine com- ponents or final inspection in inline test benches can be optimally mapped with the economy line in order to control the processes reliably. Typical examples include part geometry measurement on the fly as well as fast, but highly precise weighing procedures – in bottling plants, for example. In general, the ELM314x EtherCAT measurement modules are ideal for recording data from 10 V/20 mA sensors and for feeding

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Emerson takes the title – Industrial IoT Company of theYear 2019

Global automation technology and software company, Emerson, has been recognised as the Industrial IoT Company of the Year by IoT Breakthrough for the second year in a row. This award recognises Emerson’s innovation and leadership in driving Industrial Internet of Things (IIoT) technologies and strate- gies for customers in the oil and gas, power, chemical, life scienc- es and other manufacturing industries. The IoT Breakthrough Awards, which received more than 3 500 nominations in 2018, recognise innovators, leaders and visionaries from around the globe in a range of IoT categories, including In- dustrial IoT, Smart City technology, Connected Home and others. Selections are made by a judging panel of IoT professionals and experts with hands-on experience within the IoT market, including journalists, analysts and professionals from top start-ups and For- tune 100 companies. With IIoT capabilities, industrial companies have more poten- tial than ever to collect real-time data. However, turning that data into actionable information and game-changing operational perfor- mance can be a complex process. To help customers implement IIoT technologies seamlessly, Emerson pioneered its Plantweb™ digital ecosystem, a scalable portfolio of technologies, software and services that enables performance improvement in produc- tion, reliability, safety and energy management. “As IIoT technologies continue to evolve, customers are rely- ing on us more to help them evaluate and implement digital tech- nologies to show business performance and value,” said Lal Kar- sanbhai, executive president of Emerson’s Automation Solutions

business. “Our goal is to deliver deep industry expertise and auto- mation technologies that empower customers to leverage these capabilities and optimise plant performance.” A recent Emerson study of industry leaders responsible for digi- tal transformation initiatives showed that only 20 % of respondents had both a vision for digital transformation and a clear, actionable roadmap to implement it.The absence of this practical roadmap was cited as the number one barrier for digital transformation projects. To help customers realise the promise of digital transformation, Emerson’s Plantweb digital ecosystem uses a structured, scalable approach that enables companies to focus on priority areas with a practical roadmap tailored to their business needs and readiness. Progressively, these Plantweb solutions help customers reach top quartile performance, measured by optimised production, im- proved reliability, enhanced safety and minimised energy usage. “It is clear that digitalisation is radically changing the face of entire markets and the level of IoT innovation continues to deliver impressive results, in particular for manufacturing, enterprise and industrial customers worldwide,” said James Johnson, managing director at IoT Breakthrough. “In this new world of Industry 4.0, it becomes increasingly difficult for IIoT suppliers to stand out and Emerson has successfully demonstrated a level of innovation and success in the industrial IoT market for a second consecutive year to take home our Industrial IoT Company of the Year Award.” Enquiries: Rob Smith, South & East Africa Emerson Automa- tion Solutions.Tel. +27 (0) 11 451 3700 or email: Rob.Smith@emerson.com

IS³ portfolio includes AVEVA engineering software

software portfolio to its customers. The complete portfolio includes: Asset Perfor- mance Management, Monitoring and Con- trol, Engineering Software, Planning and Scheduling, and Operate and Optimise Solutions.

IS³ – Industry Software, Solutions & Support – recently signed an additional contract with AVEVA which extends its portfolio to include AVEVA’s engineering software. AVEVA’s engineering software, tools and solutions improve engineering effi- ciencies for any industrial process. The engineering portfolio offers integrated pro- cess engineering and simulation, engineer-

ing design, project execution solutions and operator training. It provides efficient and reliable engineering design software and enables customers to reduce capital costs and overall risks, improve operations and project management, and rise above the challenges faced by today’s workforce to drive safety and profitability. IS³ is currently the only distributor in the world that offers the complete AVEVA

Enquiries: Clarise Rautenbach. Tel. +27 (0)11 607 8473 or email: clarise.rautenbach@is3.co.za

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