direct energy
Information for the Energy Industry and their Suppliers
February 2014
SMART GRID
SMART
GRID
Special edition
Products, Solutions and Expertise for the Energy Networks of the Future
top
CONTROLLING ENERGY
FLOWS SAFELY / Page 13
TAKING IT TO THE EXTREME – THE
STANDARD FOR 750 XTR / Page 36
NatioNaler
arbeitgeber
2014
DeutschlanDs
Beste
arBeitgeBer
im Vergleich
in Kooperation mit:
CONTENTS
EDITORIAL
Dear Readers,
LIMITING OUTPUT AT SOLAR POWER STATIONS
Page 04
THE PFC200 PULLS FURTHER AHEAD OF THE COMPETITION
Page 07
DISCONNECT/TEST TERMINAL BLOCKS FOR CURRENT TRANSFORMER CIRCUITS Page 07
NETWORKS ORIENTED TOWARD THE FUTURE
Page 08
TELECONTROLLER FOR VIRTUAL POWER PLANTS
Page 10
CONTROLLING ENERGY FLOWS SAFELY
Page 13
TELECONTROLLER CONVERTS THE WAGO-I/O-SYSTEM INTO A TELECONTROL SYSTEM
Page 16
NEW FREEDOM IN TELECONTROL TECHNOLOGY
Page 19
OUTPUT MEASUREMENT IN A REGIONAL NETWORK STORAGE UNIT
Page 22
INTELLIGENT NETWORKING AS THE KEY TO SUCCESS
Page 24
DISTRIBUTED SYSTEM AUTOMATES HISTORIC HYDRO-POWER PLANT
Page 27
PHOTOVOLTAICS ARE RADIATING ENERGY
Page 30
A MORE COMPREHENSIVE REMOTE ACCESS
Page 33
SNMP GOES IEC 60870/61850
Page 33
AUTOMATING INFRASTRUCTURE NETWORKS
Page 34
TAKING IT TO THE eXTReme – THE STANDARD FOR THE 750 XTR
Page 36
TRANSPARENCY PAYS DIVIDENDS
Page 38
INNOVATIVE ENERGY STORAGE DEVICES ON THE TEST STAND
Page 40
IMPRINT
Page 44
It’s happening slowly but surely: the small, decentralized systems are
overtaking large power plants. This is great for the environment; however, it presents tremendous challenges for energy suppliers, network
operators, and the grids themselves. It sounds so simple, yet the truth
is that decentralization has required a complete 180 in thinking about
electrical generation.
One effect of the transition to renewable energy: suppliers, like current
and new network stations, have to be monitored and controlled with
respect to voltages, frequencies and reactive power. Secure archiving,
evaluation, and transmission of the data generated is necessary for
this purpose. A large portion of these tasks will be undertaken by
distributed automation systems. The demands placed on these systems
are correspondingly high: compact design, flexible usages, support
for multiple interfaces and fieldbus protocols combined with high
availability.
As a developer of the first decentralized and modular automation
system, WAGO has dealt with exactly these requirements for more
than 20 years. Now, WAGO has developed components for the next
logical step. The 750 XTR was designed to withstand the harshest
of conditions, like freezing cold, blazing heat, strong vibrations and
overvoltages.
If your equipment is subject to temperatures between -40 °C and +70
°C, or vibrations up to 5g; if you require impulse-voltage withstand
and EMC immunity according to EN 60870-2-1 and IEC 61850-3,
then the new WAGO-I/O-SYSTEM 750 XTR is made to meet your
challenges. It includes data transmission according to IEC 608705-103 and IEC 61850, including GOOSE messages and MMS
communication, and additionally speaks the same language as the
station’s control system. Among other possibilities, this enables the
connection of protective devices by implementing IEC 60870-5-101/104 protocols, and also the connection of control systems. And finally,
all XTR components share the same flexibility and compact design as
the proven WAGO-I/O-SYSTEM 750.
With all of these features, XTR is the ideal component for the energy
transition.
See if the following pages convince you. Consider which solutions are
possible using WAGO technology. Don’t hesitate to entrust us with
your problems.
We hope you find the articles electrifying.
Best regards,
Daniel Wiese
Market Management Industry & Process
Energy/Smart Grid
/ Page 36
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LIMITING OUTPUT AT SOLAR POWER STATIONS
The Halberstadt municipal utility uses WAGO telecontrol technology to control their solar arrays in a way that satisfies the EEG regulations.
■ The Halberstadt residential housing cooperative has set ambitious goals: they are constantly working to supply their housing
stock with renewable energy as much as possible. The more than
4,000 members of the cooperative have made their roof surfaces
available for photovoltaic systems, which currently generate electricity for solar heating, heat pumps, controlled residential ventilation, and heat recovery. Halberstadt is using a telecontrol solution
from WAGO in order to achieve the power reductions, prescribed
by the Renewable Energy Act (EEG), through technology.
Only the stairway, made of sturdy wood, appears to be original on
the four-story residential building on Steinstraße in Halberstadt. Everything else was renovated after German Reunification – primarily for reasons related to energy savings. Anyone who looks up
with Michael Zawisla is struck by the dark, shimmering roof sur-
faces that line the inner courtyard. The photovoltaic systems on the
total of four roofs of the housing complex provide an output of 100
kW. Zawisla is the CEO of DOMICIL Energiepartner GmbH – a
fully-owned subsidiary of the Halberstadt residential housing cooperative. All building services for the Halberstadt cooperative’s
building stock lie within his purview.
■ Network Operators are Responsible
More than 100 kW: The photovoltaic system distributed across the
building complex thus comes under the regulations of paragraph 6,
section 2 of the EEG. This standard prescribes technical devices for
remote-controlled reduction in energy output. These regulations
were primarily designed to maintain the power quality in the distribution network and to safely prevent overloading. “That kind of
thing can occur, for example, during vacation times, when the in-
dustrial users shut down their large consumption loads due to company holidays,” reports Sven Bendix, Automation Team Leader at
Halberstadt’s public utility. The communal enterprise is responsible
for the electrical grid in the region, and thus for network electrical
quality.
Moving beyond this role, the Halberstadt utility increasingly appears as a complete solution provider for controlling and monitoring renewable energy generation systems – like the one on the
roofs of the local housing cooperative. The TO-PASS® Telecontrol
Modules from WAGO use an integrated Web Connector, located
at the control station in the municipal utility, to provide the connection between the solar loggers on site and the WAGO telecontroller. The heart of the Web Connector is a special function block
for the CODESYS development topology. TO-PASS® delivers the
signals that are bundled by the Web Connector and subsequently
transmitted in a standardized telecontrol protocol. As the end user,
the Halberstadt public utility employs these data to control the photovoltaic system according to EEG regulations.
■ Lean Technology, Powerful Solutions
The WAGO technology is designed to be lean: it provides, in combination with the TO-PASS® transmission module, economic control
of systems with nominal outputs between 30 and 100 kW, according to the prevailing actual values. In this output range, ripple control systems based on long wave radio technology are usually
used, due to cost reasons. While output reductions can indeed be
switched using this technology, there is no possibility for feedback
about the actual operating status of a photovoltaic system. By using
TO-PASS® in this range, it is now possible to gain the same effective
solutions demanded by larger systems at low financial costs.
The solar array on the roofs of the four buildings on Steinstraße in Halberstadt produces more than 100 kW, which
must be remotely reducible according to the EEG.
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Control cabinet on the roof: TO-PASS® ensures contact
with the control station via mobile radio communication.
Even smaller solar systems can be switched by TOPASS® depending on output.
Sven Bendix (Halberstadt utilities), Manuel Schmidt (WAGO),
Matthias Schöps (WGH technician), and Michael Zawisla (DOMICIL) in the inner courtyard of the residential block on Steinstraße:
Together they develop suitable technology for the customers of the
Halberstadt utility.
The compact TO-PASS® device functions using the same GSM network as mobile telephones. Looking back over their decision making
process, Sven Bendix explains, “We looked into the least expensive
solutions so that the investments in technology did not become an
excessive burden on the solar energy yields. We have to be able to
offer our customers suitable technology as energy partners.” During
operation, the expenses incurred for hardware are only one aspect
of this. The second results from the monthly connection charges. “The
more often the cyclical transmission of data occurs, the higher the
data volume. Therefore, we advise our customers to go with a flat
rate, so that there are no surprises later during invoicing.”
■ Communication with the Control System
In the residential building in Steinstraße, DOMICIL Energiepartner
GmbH has positioned the central control cabinet on the roof of
one of the buildings, where it will completely control all four partial systems. Inductively functioning sensors constantly measure
the currently available electricity. WAGO has provided 789-620
Current Sensors, which have a measuring range from 0 to 80 A,
and 789-621 Sensors with a range from 0 to 140 A. They are
mounted on the top-hat rail and transmit their measured values
directly to the installed control technology for additional evaluation – without the need for dedicated cables.
Communication with the control system takes place within the context of the standardized transmission protocols according to IEC
60870-5-101 for serial connections and IEC 60870-5-104 for IP
communication. The web connector in the WAGO telecontroller is
also able to generate and transmit data protocols in accordance
with IEC 61850. In contrast to the signal-oriented functionality of
IEC 60870, the system of the future is strictly object-oriented. Instead of individual signals, it is possible to consider entire objects
in the data transmission as plain text. For example, this can be the
entire rotor for a wind energy system or – as in Halberstadt – an
entire photovoltaic system on a residential complex. In these cases, IEC 61850-7-420 for decentralized energy supply specifically
applies. WAGO offers software interfaces to configure the corresponding telecontrol technology. These interfaces can be operated comfortably using drag-and-drop, and automatically display the correct IEC codes.
Text: Manuel Schmidt, WAGO
Photo: WAGO
WAGO provides compact and economical
solutions to control photovoltaic systems according to the EEG.
Using TO-PASS®, even smaller systems with a
nominal output between 30 and 100 kW can
be controlled economically.
WAGO current sensors enable
constant electrical current measurements from
the photovoltaic system during operation.
6
THE PFC200 PULLS FURTHER AHEAD OF
THE COMPETITION
For small and large applications alike: the entire spectrum of modern
telecontrol solutions are covered by two new PFC200 telecontrollers.
■ Compact, powerful and versatile: The two new telecontrol versions
(750-8202/025-001 and -002) of the PFC200 support the IEC
telecontrol protocols 60870-5-101, -103 and -104, 61400-25, and
61850, including GOOSE telegrams. The PFC200 telecontrollers
each come equipped with two ETHERNET and one RS-232/RS-458
interface, and have an expanded temperature range of -20 to +60°C.
All standard internet protocols, in addition to TCP/UDP/RTU, are available for communication with master and slave systems. In the future, the
PFC200 telecontrollers will also support IPsec and VPN to provide the
highest security standards.
The ECO version (750-8202/025-002) of the PFC200 telecontroller is
a reasonably priced alternative for customers with smaller applications.
The ECO telecontroller does not forfeit any functions; however, it is limited to a maximum of four modules. Any of the more than 400 modules
in the WAGO-I/O-SYSTEM 750 can be used without any restrictions,
for example, for remote control of transformer stations, monitoring substations, executing feed-in management for EEG systems, or for controlling virtual power plants.
DISCONNECT/TEST TERMINAL BLOCKS
FOR CURRENT TRANSFORMER CIRCUITS
Simply test, then automatically disconnect: the current transformer modules
from WAGO can be operated intuitively and comfortably.
■ The new 2007 Series Disconnect/Test Terminal Blocks are specially
designed for use in current and voltage transformer circuits. They feature a highly functional design and are just 99.6 mm long and 8.0 mm
wide. Intuitive orange disconnect links simplify operation: Closing the
link automatically short circuits the transformer via an inserted adjacent
jumper for switch lever.
The circuit state can be easily, safely and reliably determined via open,
touch-protected design. The 2007 Series also includes through and
ground terminal blocks with identical profiles. All of the terminal blocks
are designed for 30 A and 500 V according to IEC, and 300 V in compliance with UL. The maximum nominal cross section for ferruled conductors
is 6 mm² (AWG 10), and 10 mm² (AWG 8) for solid and fine-stranded
conductors.
“The TOPJOB®S current transformer terminal blocks combine an extremely compact design with a high level of functionality, such as automatic transformer short-circuiting,” states Burkhard Niemann, Product
Manager for ELECTRICAL INTERCONNECTIONS at WAGO Kontakttechnik GmbH & Co. KG.
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NETWORKS ORIENTED TOWARD THE FUTURE
SWO Netz GmbH is running a pilot project using WAGO technology to test how to hold costs down during an expansion of the mains supply.
■ Can the construction of expensive, underground infrastructures,
necessary for conventional expansions to the electrical grid, be
avoided by using intelligent equipment? SWO Netz GmbH, a subsidiary of the Osnabrück municipal utility, is using a smart grid pilot
project to research this very question. They are using a WAGO solution with components for an intelligent mains network.
The Smart Grid Pilot Project started up at the end of 2012; located in the Wüste district of Osnabrück, the project covers 60 buildings, 125 residences, and 7 EEG systems that supply a peak output of 38 kW to the grid. When ranked according to the quality
of the electricity supplied, the Osnabrück municipal utility regularly appears among the top 5 in Germany. “It is an additional
motivation for us to employ new technologies in order to remain in
the lead.” According to Heinz-Werner Hölscher, CEO at SWO
Netz GmbH, “our Smart Grid Pilot Project is designed to test the
scope of future investments in intelligent equipment.”
“The WAGO components meet our requirements due to their
very compact design. We were also convinced by the functional
aspects of their technology, particularly the new version of their
3-Phase Power Management Module, which has the potential to
carry out harmonic analyses,” explains Christian Drecksträter.
■ Powerful measuring and telecontrol technologies for electrical
grids
Five cable distribution cabinets and a transformer station were equipped
with powerful measuring and telecontrol technology for the pilot project. Since the distribution cabinets are quite compact, there was very
little space available for additional technology. SWO considered technology from several manufacturers before ultimately selecting WAGO.
“Our goal was to continue using existing equipment as much as possible in order to complement the new technology. Due
to their very compact design, the WAGO components corresponded to
our requirements. We were also convinced by the performance aspects
of their technology, particularly the new version of their 3-Phase Power
Management Module, which has the potential to carry out harmonic
analyses,” explains Christian Drecksträter, Project Manager at SWO
Netz GmbH, when asked about the decision.
The fieldbus independent WAGO-I/O-SYSTEM, with up to 16 channels
and a module size of only 12 mm, is among the most compact systems
on the market. The components required to execute the respective tasks
only need to be inserted, due to the modular design. A large portfolio
of I/O modules are available: from high-compression, 16-channel digital input/output terminal blocks, through specialty modules, like the
3-Phase Power Management Module, up to monitors for distribution
cabinets or transformer stations. WAGO telecontrollers are suitable for
use with protocols according to IEC IEC 60870-5-101, -103, -104, IEC
61850, as well as many other standard protocols, like MODBUS.
The 750-49x 3-Phase Power Management Modules provide current
and voltage values for each other the three phases; they also calculate
power consumption and provide numerous other values, from active
energy to reactive and apparent power. In addition to energy consumption measurement and harmonic analysis, they also feature additional
functions for a comprehensive grid analysis, enabling the localization
of grid “disturbances”, such as interference spikes. The 4-quadrant display also indicates the type of load (inductive, capacitive) and whether
it is an energy consumer or producer.
■ Initiating the Smart Grid Pilot Project
A 750-880 ETHERNET controller was
used, which included a 750-494
3-Phase Power Management Module
and an 855 Series current transformer.
This technology allowed SWO Netz
GmbH to monitor the three phases
used in the pilot area, retrieve 215
measured values per WAGO module/
line, transmit the data to a control center, and save them in a database. In addition, the pilot region could be monitored from the control center in real time
using a web interface.
Text: Martin Ortgies, professional
journalist
Photo: WAGO
In the first phase of the project, the grid in the pilot area was equipped with WAGO technology for measuring consumption and supply. ETHERNET controllers were used that have 3-Phase
Power Management Modules, Pt100 resistance sensors, and Rogowski coils.
The compact design of the WAGO-I/O-SYSTEM
met all requirements presented by SWO Netz
GmbH.
WAGO telecontrollers comply with IEC protocols
60870-5-101/-103/-104, IEC 61850, as well
as other protocols.
The 3-Phase Power Measurement Modules provide all relevant voltage and current values for
each of the three phases.
8
“The Smart Grid Pilot Project is representative for our urban supply
area and should help to answer questions about additional network
expansion. We wanted to clarify whether we could keep costs down
by using intelligent technology,” reports Christian Drecksträter, Project
Manager at SWO Netz GmbH.
By using intelligent local substations, additional measuring, safety, and
control devices can be integrated into the local network. Previous pilot
projects indicate that the expansion of decentralized intelligence can
provide an alternative to conventional network expansions, since critical network loads only prevail for a few hours each year.
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TELECONTROLLER FOR VIRTUAL POWER PLANTS
The WAGO telecontroller with IEC communication convinced Transferstelle Bingen
during the automation of their infrastructure networks.
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Wood pellet boiler
É
É
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Photovoltaic system
Latent heat storage unit
É
Heat pump
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■ Distributed Power Generators
in a Virtual Power Plant
Since Fall of 2010, the TSB has actively operated two virtual power plants in the network. Both
function by bundling approximately 100 local
power generators – such as combined heat and
power plants, emergency power generators,
and gas turbines – into a power plant with a
total output of more than 20 megawatts apiece.
An electricity trader markets the energy produced by this system on the electricity exchange
as regulating energy to compensate for energy
fluctuations or forecast deviations. The technical
challenge for the TSB was to unite the decentralized generators into a large power plant
using control and monitoring technology. As
a result, these plants can now be continuously
monitored from one central point: failures can
be managed, signals are bundled, and systems
switched on and off.
Since the beginning of the project seven years
ago, the Transferstelle Bingen has gained a lot
of experience in how smart grids can be monitored and controlled. In so doing, TSB’s attention has been drawn to WAGO as a supplier
of automation technology and modular fieldbus
systems. This has developed into a continuous
collaboration using the WAGO 750-872 Telecontroller.
Combined heat and power plant
É
The TSB established the Smart Grid/Virtual
Power Plant competence center on behalf of
the Rhineland Palatinate, and took over network
support for it. The center’s focus is on practical
technology developments, including smart grids,
virtual power plants, balancing power, power
storage, and controlling the supply and demand
of electricity.
É
É
■ Intelligent controllers for distributed power
generation in a smart grid are a central topic
of the Transferstelle Bingen (TSB). The TSB − an
institute at the Bingen Technical College − is
currently working on a project for controlling a
virtual power plant. The TSB had been seeking a
suitable telecontroller for their project.
Thermal solar system
Heat
Electricity
Schematic of a virtual power plant
Many micro power plants are combined to form a virtual power plant; this provides internally available balancing power as well as energy to trade on the electricity exchange.
11
■ Telecontrol Technology for Virtual Power
Plants
After the auction process on the electricity exchange, the output of the virtual power plant
must be set to “provision.” This is followed by
a call-up from a transmission network operator,
such as Amprion, who specifies the quantity to
be delivered. The connected, distributed systems
are then started up using TSB’s control technology. During the startup process, the output is
monitored, the measured values are summed,
and transmitted to the control center as minute values. According to the specifications, the
virtual power plant must achieve its maximum
output within 15 minutes at the latest. WAGO’s
telecontroller ensures the reliable transmission of
the measured values to the transmission system
operator.
TSP defined and tested several criteria in advance in order to select the telecontrol technology best suited to their needs. The winning technology had to fulfill both the transmission system
operator’s technical criteria and the smart grid
requirements for the virtual power plant. The
IEC protocol format was initially significant for
connecting to the control centers used by the
transmission system operators. TCP/IP transmission (MODBUS) was specified within the TSB
network. The telecontroller was required to transform data from IP format into the IEC telecontrol
protocol. Additional tasks include using digital
output modules to log errors and visualize them
via the controller’s web interface. The technology also had to be demonstrably safe and reliable, and at the same time it had to satisfy the
cost frameworks of small, distributed systems.
WAGO’s technology was extremely well-suited
for these requirements.
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■ Telecontrol and Automation in Smart Grids
“We selected WAGO’s telecontroller because it communicates according to IEC protocols and is ideally suited as a component for
automating infrastructure networks. In addition, it had the best priceperformance ratio,” explains, Tobias Langshausen, project director
for virtual power plants at TSB. In his experience, innovative telecontrol technology is an advantage when dealing with the challenges
of smart grids. The WAGO controller conforms to the following
telecontrol protocols: IEC 60870-5-101 (serial), IEC 60870-5-104
(TCP/IP-based), and IEC 61850 for safety and control technology in
medium and high-voltage electrical switching systems, for example in
wind power systems (IEC 61400) and in distributed power generation (IEC 61850-7-420).
The WAGO telecontroller is a component of the modular, fieldbusindependent I/O system for the incorporation of sensor and actuator
signals. The system has been successfully used for many years in
automation technology. The values measured on the field side are recorded via connected I/O modules. Due to the diversity of industrial
requirements, there are more than 400 different I/O modules available. Direct contacting is also an advantage that saves space for
an additional terminal strip. Additional functions can be integrated
using I/O modules, such as the control of building technology.
and its handling is clear and logical. The requirements of the transmission system operators can also be fulfilled without any problems.
From TSB’s point of view, the modular nature of the system is crucial
for its flexible use. Modular systems have a module for each signal,
so everything can be connected to the controller and called using
just one data set. Additional separate components are not required.
According to the director, the parameterization and visualization using CODESYS (Code Development System from 3S-Smart Software
Solutions GmbH) is also simple and easy to understand. The integrated sample projects are very helpful for implementation.
Text: Volker Allgeier, WAGO
Photo: WAGO
From TSB’s point of view, the system’s modular structure is crucial for
its flexible use in a smart grid. Modular systems have a module for
each signal, so everything can be connected to the controller and
called using just one data set.
The telecontroller satisfies all technical criteria
and smart grid requirements for the virtual power
plant.
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TSB Bingen profits from the modular structure
and flexible applications of the
WAGO-I/O-SYSTEM.
A virtual power plant run by Vattenfall uses a PLC - PFC200
Telecontroller to communicate encrypted information to
the control center via OpenVPN.
■ Vattenfall Europe Wärme AG has combined
small, distributed electrical generation units
with controllable electrical consumers – combined heat and power stations with heat
pumps, for example – to create flexible, controllable aggregate systems. Their goal is to
provide flexibly deployable power plant capacity in order to balance out temporary fluctuations in the grid and to better integrate renewable energy into the electrical supply.
Automation components from WAGO, including the new PLC - PFC200 Telecontroller, are
used to centrally control the four distributed
systems and the energy storage unit.
■ Technology that is Reliable and Flexible
“As a relatively small institution, we often have a hard time getting
our special requirements across to larger manufacturers. So we were
surprised by WAGO’s support. Product development at WAGO immediately understood our experience with smart grids, and implemented our ideas,” reports Christian Pohl, CEO of Transferstelle Bingen. “Their excellent support helped us to solve all existing problems
quickly and efficiently.”
According to TSB, the telecontroller has proven itself in practice. “The
flexibility that comes from automation technology is a big advantage
for us. The system has a clearly comprehensible ‘common theme’,
and all tasks can be easily performed,” says project director Langshausen. He confirms that the telecontroller works absolutely reliably
WAGO telecontrol technology ensures reliable
transmission of measured values to the transmission system operators.
CONTROLLING ENERGY
FLOWS SAFELY
Germany is currently in the midst of nothing less
than a renovation of the complete energy system as part of the transition to renewables. The
standard system of centrally controlled supply
based on large power plants is being increasingly replaced by a distributed system of many
small units, among them combined heat and
power plants (CHP’s). The greatest challenge posed by
renewables, like solar and wind, is the strong fluctuation in energy supply, which remains difficult to anticipate. In order to ensure
a stable and secure electrical supply, solutions for controlling supply
and storing excess are a necessity Vattenfall Europe Wärme AG and
their virtual power plants provide a solution based on a type of energy that can already be easily stored: heat.
■ Virtual Grid Guarantees Network Stability
Vattenfall has created a virtual network by interconnecting electricity
generating CHP’s with electricity consuming heat pumps to form a
large aggregate. The virtual power plant fulfills two tasks that are
incompatible with a traditional power plant: it enables better integration of renewable energy into the heat and electrical supply, and simultaneously ensures balancing of excessive and insufficient electrical supply to the grid. If wind and solar stations produce less
electricity than anticipated, the gas-driven CHP’s can generate the
missing kilowatt hours, additionally producing heat, which can be
used immediately at their respective locations, or stored for later. In
The mini combined heat and power plants use the
principle of cogeneration to generate power as
well as heat . The systems function very efficiently
and utilize fuels at levels of more than 90%.
the case of excessive supply, the energy consuming heat pumps are
switched on.
An energy storage station, like the one that began operating in February of 2013 in Berlin-Treptow, is also connected to Vattenfall’s
virtual power plant. The 2 MW storage station can store electricity
during a corresponding excessive supply, and then feed it back into
the grid as needed. Balancing power can thus be provided from the
battery-powered system in a way that is extremely flexible and environmentally friendly. Up to 2500 tons of CO2 can be saved annually per megawatt used.
■ Interconnection with other types of systems is currently underway
Central control of the virtual network is carried out from the Vattenfall Wärme control room in Berlin. This is where, the distributed systems are monitored, controlled, and optimally operated, in addition
to the large district heat plants run by the company.
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■ WAGO Controllers Have Been with the Project Since Its Inception
By the middle of 2013, more than 150,000 residents of Berlin and
Hamburg were already being supplied by the virtual power plant.
Telecontrollers from WAGO have been used as control and communication units between the distributed systems and the heat control center since the start of the project in 2010. Vattenfall decided
to use WAGO products because they wanted controllers from a
renowned manufacturer. In addition, the controllers had to be compact, programmable, and flexible, as well as enabling communication according to IEC 60870-5-104. The broad modular structure
and the variety of WAGO controllers were additional reasons for
the decision.
Since then, around 100 decentralized systems have been linked to
the heat central control using WAGO 750-872 and 750-880
Controllers. The 2 megawatt battery is also linked to the control
center using a telecontrol IPC from WAGO. The 758-875 Industrial PC with PROFIBUS Master Interface reads the process values
from the S7 controller for the energy storage unit, converts them to
protocol variables according to IEC 60870, and thus connects the
battery to the control center.
During a current tender from Vattenfall, regarding completely
wired system distributors for the decentralized CHP’s and heat
pumps, WAGO was also able to score an important victory. The
new generation of PFC200 controllers will be incorporated as
standard in the total of 163 system distributors. The new standard
configuration of the 750-8202/025-001 telecontrol PLC’s will
consist of a GFM modem, some digital input and output modules,
analog input modules, the EPISTRON® COMPACT Power Supply
and a magnetic base antenna.
WAGO’s new PFC200 Compact
Controller provides important security
functions in addition to high performance.
■ Maximum Performance in Minimum Space
As a component of the modular WAGO-I/O-SYSTEM 750, the
PFC200 provides high levels of computing power in minimal space,
thanks to Cortex-A8 technology. Two ETHERNET ports provide communication with other control systems; depending on the model, additional interfaces are available, such as CAN, PROFIBUS, RS-232/
RS-485). The new telecontrol PLC is programmable according to IEC
61131, supports the required telecontrol protocol IEC 60870-5104, as well as the serial pendant according to IEC 60870-5-101
and communicates according to IEC 61850. In addition to programming the controller, the processes can also be visualized as needed
using the CODESYS programming environment.
The PLC provides two ETHERNET interfaces for the TCP/IP-based
104 protocol and a serial interface for the 101 protocol. A software
tool is integrated for configuring the IEC communication; this means
communication only requires parameterization. A PLC program controls the system to ensure autonomous heat supply in case of interruptions in communications. The PFC200 calculates the energy content of
the heat storage (in kWh) and transmits the values to the control center. The control center provides the telecontroller with a daily timetable
once each day, so that the controller can autonomously control the
connected power units over the next 24 hours.
■ Playing it Safe
In addition to high performance, the PFC200 offers important advantages in terms of IT security. The PLC can establish a VPN tunnel directly via OpenVPN or IPsec in order to transmit encrypted data to the
control center and receive the same from there as well. An upstream
GSM-VPN router is no longer necessary. This not only provides additional security, but the elimination of the router can also offer significant cost savings. Communication with the control center can now be
established using a simple serial GSM modem.
The WAGO-I/O-SYSTEM also corresponds to the latest version, 3.0,
of the open source industrial standard, VHP Ready (Virtual Heat &
Power Ready), provided by Vattenfall for distributed energy supply
systems. The technical standard for CHP’s and heat pumps enables
easy integration into the virtual power plant. Units that satisfy the prerequisites of VHP-Ready can be connected to the system without any
additional installation measures. Vattenfall is currently working with
Fraunhofer FOKUS to expand VHP-Ready into a B2B standard: the
cooperating partners are founding a VHP-Ready industrial forum, in
which additional market partners can participate.
■ Conclusion
Vattenfall’s virtual power plant connects distributed energy units, like
CHP’s, heat pumps, and the 2 megawatt energy storage, into a networked, flexibly adjustable, and centrally controlled aggregate system. Renewable energy can thus be optimally linked into the electrical supply. Vattenfall’s customers, who participate in the virtual
power plant, are provided with supply security, an efficient system
operation, and the possibility of actively participating in climate protection. The virtual power plant has used WAGO automation components since 2010. An important component is the new Telecontrol
PLC - PFC200 with IEC communication. As powerful as it is compact,
the controller provides encrypted communication, according to IEC
60870-5-104, directly to the decentralized units.
Text: Daniel Wiese, WAGO
Photo: Vattenfall, WAGO
The WAGO-I/O-SYSTEM corresponds to the
latest version of the open source industrial standard, VHP-Ready 3.0.
The 750-8202/025-001 PFC200 can establish
a VPN tunnel to the control center directly via
OpenVPN.
Connection of a 2 megawatt battery to the control center using the 758-875 Telecontrol IPC
from WAGO
The completely wired WAGO system distributors
include the Telecontrol PLC - PFC200 as well as
serial digital input and output modules for complete management of the system control. They
reduce assembly time and support error-free installation.
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TELECONTROLLER CONVERTS THE
WAGO-I/O-SYSTEM INTO A TELECONTROL SYSTEM
Decentralized control and telecontrol unit: during the modernization of a network coupling point,
Thüringer Energie AG falls back on WAGO automation.
Two main pressure lines (> 25 bar) meet at the network coupling point in Bodelwitz, Germany.
This is also the exit point for the medium- (16 bar) and low-pressure levels (1 bar).
■ At the network coupling point located in Bodelwitz, Germany,
lines that were dedicated to obsolete modem usage drove the conversion to the IEC 60870-5-104 telecontrol protocol, and thus, to
modernization of the station itself. Originally, functions were realized
using various components, including some analog ones, and data
transmission to the control system was carried out via modem. The
WAGO-I/O-SYSTEM’s flexibility convinced Thüringer Energie AG,
as it features PLC functionality and also supports the most varied of
telecontrol protocols according to to IEC 60870 and IEC 61850.
The main pressure lines for natural gas transportation, which belong
to Thüringen-Sachsen mbH (ETG) and Thüringer Energie AG, converge at the Bodelwitz network coupling point of located in the
Saale-Orla district of Thuringia, Germany. This is the gateway to the
downstream gas network belonging to Gasversorgung Pößneck
GmbH. The Thüringer Energienetze GmbH (TEN) is a distribution
network operator, whose pipeline networks are utilized by Thüringer
Energie AG to fulfill their function as the natural gas supplier for the
majority of Thuringia. Exceptions to this include the south-eastern
part of Thuringia and independent municipal utilities. All process and
billing data is collected redundantly. Gas volumes, which are obtained via the coupling station, are specified by the control system
located in Erfurt. Up until recently, the data were transmitted via modem over dedicated lines. When modems became obsolete, modernization of the telecontrol substation became necessary. This is the
context, in which Thüringer Energie AG went looking for a suitable
automation system, capable of serving both as a decentralized controller and telecontrol system. In addition, the system had to be capable of processing signals from hazardous areas. The WAGO-I/OSYSTEM and telecontroller were the obvious choice.
16
The WAGO-I/O-SYSTEM unites traditional
automation and telecontrol applications into one
system.
Redundant structures: The telecontroller communicates with up to four higher level control systems
according to IEC 60870-5-104.
No components for Ex separation necessary: Ex
and non-Ex signals are processed in a node.
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The WAGO-I/O-SYSTEM collects all relevant measured variables via
I/O modules, including data from hazardous areas. The programmable
telecontroller consists of a software controller and converts data into the
appropriate telecontrol protocol.
Gas supply and gas pressure control
Field devices such as pressure and temperature transmitters send input
values to the control system.
18
■ All in One: Telecontrol and Automation...
Ulf Quasnica, explains the decision, “We opted for WAGO because the telecontroller allows us to implement both standard automation and telecontrol applications within a single system.” The telecontroller converts process or telecontrol variables into data in
compliance with IEC 60870-5-101 (serial) or IEC 60870-5-104
(TCP/IP-based). Appropriate CODESYS programming in the controller and the implementation of CODESYS libraries make this possible.
In addition, the programming is based on the IEC 60870-5-104 redundant communication architecture, allowing the controller to communicate with up to four higher-level control systems. Many functions
that were previously performed by different components are now
carried out by the WAGO-I/O-SYSTEM and telecontroller. The I/O
modules connected to the controller collect all relevant measured
variables, such as temperature, pressure, throughput, and fill level,
using analog and digital input/output modules. In addition, energy
data about the gas distribution system, such as voltage, current, output, cos phi, etc. are directly detected using a 3-Phase Power Management module. The Bodelwitz location now has a DSL line, allowing use of the IP-based 104th telecontrol protocol for communication
with the control center.
■...up to Intrinsically Safe Areas
“Both telecontroller and connected I/O modules reduce the local
control unit to a single system, while considerably simplifying operation. Signal processing from hazardous areas is easily solved using
Ex-i I/O modules, because we don’t need any additional components for Ex separation, like Zener barriers,” comments Quasnica,
specialist at TEN. The telecontrol station conversion was carried out
by the civil engineering firm, Streicher GmbH Tief- und Ingenierbau
Jena. Roland Pfeifer, Service Manager for ELT and Automation at
Streicher, was surprised by the simplicity of the solution, and concisely summarized the advantages, “Signals from the hazardous areas can be directly wired to special I/O modules in the WAGO-I/OSYSTEM. This requires fewer components and reduces cabling
expenses. In addition, the system performs all functions required for
the station: generation of odorizer pulses, control of gas preheating,
pressure and gas volumes, and also telecontrol functionality and
process visualization.”
■ PI Controller Implemented in Telecontroller
A high-performance software control within the controller replaces
the separate industrial controller and analog interface for controlling
gas supply and pressure. The programs, designed by 3S-Smart Software Solutions GmbH, are stored on the controller as control applications.
Programming takes place via CODESYS in compliance with IEC
61131-3. The following functions are included: meter protection, volume and pressure control, bumpless changeover, intermittent operation, manual control, and adaptation to the present system technology. In the event of a communication failure, the station can be
tested and controlled – like an end station – using the controller’s
decentralized control function and on-site visualization.
Text: Ulrich Menzel, WAGO
Photo: WAGO
NEW FREEDOM IN
TELECONTROL TECHNOLOGY
The WAGO Telecontrol Gateway offers an industry-spanning, manufacturer-independent connection of up to 64
telecontrol substations with the control center.
■ Regardless of whether they supply water, electricity, or gas, the importance of decentralized participants and the complexities of the
control systems are constantly increasing. Intelligent, flexible telecontrol solutions are thus more necessary than ever. WAGO’s new, compact telecontrol gateways enable connection of up to 64 substations
in an open structure at the control level. This provides suppliers with a
new degree of freedom, transparency, and cost efficiency.
The dynamic expansion of renewable energies has led to a massive
increase in the number of distributed energy producers. Today, the
trend extends from power networks, in which centralized electricity
production methods dominate, to structures comprising numerous heterogeneous systems, such as combined heat and power units, solar or
wind farms, biogas producers and hydroelectric plants. These new
challenges demand modern, intelligent electrical networks – so-called
“Smart Grids” – that manage the generation, load distribution, storage, and supply of electricity. Similar developments can be observed
in the control technologies related to other utility branches, such as gas
distribution, drinking water supply, and wastewater processing.
Often, a network arises in these situations through aggregation, combining interfaces from different manufacturers as well as a number of
closed, proprietary systems, which leads to a level of confusion that
provides customers with all of the clarity of a black box. Operators are
thus forced to involve the control system manufacturers with every system adjustment, programming change, or parameterization. This leads
to inflexible structures and additional service costs. Up until now, operators generally had to employ products from the manufacturers of
the control technology for communicating from the field to the control
level. Few possibilities were available for ‘shopping around’ for less
expensive and better alternative products. This situation, which is inconvenient for customers and presents obstacles for business, could be
radically altered by the new telecontrol gateways (WTG) from
WAGO.
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19
bundling, the WTG also supports coordination of incoming and outgoing analog, GSM, or ISDN dial-up connections to substations. No
special parameterization software is required for operation. Using
Web-Based Management (WBM), operators can, within the parameters of their license agreement, add participants and carry out system adjustments. This simplifies the installation of telecontrol substations and reduces integration costs. Costs arising from external
servicing are eliminated as unnecessary. The improved data transparency allows operators to recognize potential errors at field devices at the transmission level, and thus these errors can often be independently alleviated.
By any account, the WAGO Telecontrol Gateway presents a costefficient telecontrol solution that convinces due to savings in service
costs, an attractive purchase price, and operator-specific scalability.
In addition to the WTG version, which can control up to 64 substations, a “light” version is available, which is limited to four field lines
and enables connection of up to 16 telecontrol substations. Just because it controls fewer substations does not mean that the “WTG
Light” is functionally limited. This sleek unit is particularly suitable for
decentralized use in the generation of renewable energy, such as in
solar or wind farms, and represents a novel solution to process controls with regards to scalability.
■ Scalability and Cost Efficiency
The WTG enables comprehensive data collection from all telecontrol
substations, regardless of manufacturer or industrial sector, and centralized transmission to the control level. In addition to data transfer
■ Modularity and Flexibility
The WTG is part of the fieldbus-independent WAGO-I/O-SYSTEM,
which, due to its finely modular design, accommodates the particular demands made on fieldbus systems by applications in the fields
Field level
Transmission
level
Control level
■ Market Deregulation
The WTG introduces, for the first time, an open transmission level
between participants in the field and the control levels. An industrial
PC with WAGO telecontrol software, which serves as a communication gateway, connects a maximum of 64 telecontrol substations (according to IEC 60870-5-101/104) to the control level (according to
IEC 60870-5-104). Up to twelve RS-232 I/O modules can be connected to the industrial PC for serial communication in the field. The
WTG can be used everywhere that telecommunication substations
are supposed to be powered up, independent of the manufacturer,
or where limitations in control technology with regard to the number
of possible connections need to be alleviated.
Connections to the field level are provided via standard wiring, dialup connections, or transparent TCP/IP connection (DSL or GPRS
router), and to the control level via ETHERNET or serial communication. Data are communicated securely with one-to-one reliability,
such that no additional parameterization is necessary. An optional
redundant structure is also possible via a TCP/IP connection of two
industrial PCs to a control system. This ensures increased security for
critical applications, such as effluent disposal, where environmental
contamination must be avoided at all costs. Likewise, two control
systems can also be connected to one IPC.
■ Increased Economic Value
By spanning industries and third-party systems alike, the WTG enables connections of up to 16 or up to 64 remote substations to the
control technology. By this means, it uniquely increases the operator’s freedom to act and the scope of potential components. Thanks
to increased transparency, the WTG can alleviate technical faults at
the field level without involving the control manufacturer. In addition,
operators can freely determine system expansions without being tied
to a specific manufacturer. This opens up potential savings and facilitates system modifications. As an easy to handle remote interface
for reliable data transmission, the WTG provides an efficient controller for complex control systems and simultaneously offers a particularly economical solution to operators.
Text: Kay Miller, WAGO
Photo: WAGO
The WTG introduces, for the first time, an open
transmission level between participants in the
field and the control levels.
The simplified installation of telecontrol substations via web-based management reduces integration costs.
New concepts in scalability: the “WTG Light”
is especially suited for use in generating renewable energy.
WAGO Telecontrol Gateway acc.
to IEC 60870-5-104
and IEC 60870-5-101
WAGO Telecontrol Gateway “light”
for up to 16 substations
Router with
fixed IP
Transmission acc. to
IEC 60870-5-101/-103/-104
Transmission acc. to
IEC 60870-5-101/-103/-104
Transmission
acc. to IEC
60870-5-104
via IPsec VPN tunnel
GSM
Modem connection
1 ... 64 telecontrol substations
20
of energy generation and distribution, water and gas supply, and
wastewater removal. Within the context of the WAGO system, more
than 400 I/O modules are available to satisfy the diverse demands
for different analog and digital inputs and outputs – from highly
compressed 16-channel digital modules to special modules, like the
3-Phase Power Measurement Module. Wireless communication and
solutions for potentially explosive areas using intrinsically safe components (Ex-i certified) can also be integrated.
With its flexible I/O system, WAGO offers ideal components for
optimized monitoring in energy transmission and distribution networks to ensure that the supply of electricity is based on efficient and
reliable system operations. The I/O system speaks the same “language” as the supplier, following IEC protocols 60870-5-101 and
-104 as well as IEC 61850/61400. A configurator allows it to generate IEC messages without extensive programming. The WTG itself
thus forms a uniform hardware basis for secure data transmission
within a mixed network and thus ensures planning reliability on the
part of the operator.
1 … 16 telecontrol substations
with modem connection
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OUTPUT MEASUREMENT IN A REGIONAL NETWORK STORAGE UNIT
Could some of the network expansions be unnecessary? IBC SOLAR relies on WAGO automation technology for their
energy storage unit for regional networks.
■ The transition to renewable energy in Germany is fundamentally
changing the generation and distribution of electrical energy. Solar
and wind farms, as well as network expansions, are the most commonly discussed topics. In addition, storing electrical energy at the
local or regional level is an important component, which could even
make part of the network expansion superfluous. IBC SOLAR uses
controllers and power measurement modules from WAGO for their
solutions to energy storage in regional networks.
Network expansions are at least partially connected to very high
costs. It would therefore be ideal to use the energy right where it is
generated. This is where the disadvantages in photovoltaic and wind
farms become painfully obvious: they only generate electricity when
the sun shines and the wind blows. In addition, the low voltage supply
network is often relatively under-dimensioned in rural areas where
these are located, and thus a supply back to the medium voltage
level is often impossible without expanding the network.
If several photovoltaic systems are operated in a single regional grid,
the network often quickly reaches its limits during times of maximum
supply. A substantial rise can occur around noon. A local energy storage unit that takes in excess energy during the midday hours and
discharges it as needed in the evening forms a sensible alternative to
energetic recovery into the medium voltage level and the expansion
of the local network.
■ Regional Network Storage as Pilot Project
The SWN Stadtwerke Neustadt [municipal utility] and IBC SOLAR,
a photovoltaic specialist headquartered in the neighboring country,
are collaborating on a pilot project for regional network energy storage, located in Fechheim, a district belonging to Neustadt by Coburg, The regional network storage unit, which began operation in
September of 2012, consists of lead batteries with a total capacity
of 236 kWh, bidirectional inverters, and comprehensive measuring
and control technology.
The WAGO-I/O-SYSTEM 750 forms the core of the measuring and
control technology: the programmable 750-880 ETHERNET controller is equipped with a 750-494 3-Phase Power Management Module and I/O modules for serial communication with the inverters. The
power measurement module measures the voltages as well as the
currents of all three phases and is thus ideally suited for use in an
energy distribution network. “The operating strategy of the regional
network storage unit is ultimately based on controlling the voltage to
a certain, predetermined value,” explains Marco Siller, the engineer
at IBC SOLAR responsible for the project. To accomplish this, you
have to know the exact voltages in the low-voltage network. If the
voltage increases too sharply, then the storage batteries are charged.
This occurs, depending on solar radiance, between late morning
and early afternoon. When the photovoltaic system is no longer supplying energy, during the evening hours, the batteries feed the stored
energy back into the local network.
A regional network storage unit in Fechheim makes the expansion
of the regional network superfluous, despite the many photovoltaic
supply systems.
■ Trust in Standardized Components
During the pilot phase, the specialists at IBC SOLAR worked on,
among many other tasks, optimizing the regulation of the system. For
example, a somewhat slower regulation protects the batteries. The
control algorithm, which runs on the WAGO controller, was programmed in CODESYS. This also enables use of the integrated web
visualization. Remote access to the visualization is also possible using
the ETHERNET interface. “By this means, we can check the current
status of the storage unit, for example, or the charge status of the batteries,” Siller explains. The control parameters can also by changed
via the remote maintenance function, which was very important, especially during the optimization phase.
■ Optimizing Control
During construction of the storage unit, IBC SOLAR relied on standardized components that would guarantee fast replacement in case
of a service call. WAGO controllers were used primarily because
they can be used universally. According to Siller, “The different energy suppliers sometimes employ different bus systems and interfaces in
order to communicate with the control rooms.” For example, Modbus/TCP is used in Fechheim. However, the controllers can be delivered with other interfaces as well. At IBC SOLAR, they wanted to be
certain that the architecture of the regional network storage unit could
be used everywhere without any problems.
In the mean time, the regional network storage unit has been operating without fault for more than a year. “At the very beginning of the
project, we received a lot of support from WAGO during the software
development phase,” remembers Siller. The programmers at IBC SOLAR have since surpassed their teachers. They optimized the control
during the pilot phase to such a degree that automated operation is
currently possible. The storage unit charges and discharges according to the energy supplied to the batteries, and thus ensures a stabilization of the voltages in the low voltage network. A traditional network expansion, which would otherwise have been required, has
proven unnecessary.
Text: Manuel Schmidt, WAGO
Photo: Henning Rosenbusch/vor-ort-foto.de
The 750-880 Controller from WAGO regulates
the charging and discharging processes for the
batteries of the energy storage unit.
Lead batteries with a total capacity of 236 kWh store excess energy from photovoltaic electrical production during the day.
In addition to the batteries that are located in a separate room, the
regional network storage unit consists of fast, bidirectional inverters
and a control cabinet housing the measuring and control technology.
A 750-880 Controller from WAGO, equipped with a 3-Phase Power Management Module, as well as other modules, controls the
charging and discharging processes for the batteries.
The integrated web visualization for the ETHERNET controller can be accessed remotely.
The architecture of the regional network storage unit can be installed anywhere due to the
WAGO-I/O-SYSTEM.
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INTELLIGENT NETWORKING AS THE KEY TO SUCCESS
Sustainable energy storage management with the WAGO-I/O-SYSTEM 750.
■ At first glance, you do not even notice the innovative energy supply system for the health center in Zella-Mehlis in Thuringia. Only the
carport, with its solar array and integrated charging station, and also
the rows of photovoltaic modules on the roof, lead one to suspect
that the people here are striving for environmentally-friendly energy
generation. A more exact look will reveal the extent of the “solar
MobileStorage” model, which the community of Zella-Mehlis (Lerchenberg Service und Immobilien GmbH) has realized together with
their corporate partners, Sinusstrom and WAGO, and the Thuringian
Energy- and GreenTech Agency (ThEGA).
“Solar MobileStorage” connects energy generated by photovoltaic and wind farms to energy consumed directly on site and energy that is not immediately needed, and is thus stored in buffer
storage, and a fleet of electric vehicles. An intelligent controller,
realized with the assistance of a local micro-smartgrid, connects all
of these components. All energy flows can be efficiently controlled
and regulated according to need using this smart grid. A total of
90% of the total energy consumption of the health center can be
covered by renewable energy through innovative networking and
by controlling the photovoltaic system (107 kW), the wind farm (5
kW), powerful buffer stores (68 kWh), the CHP plant (15 kW/15
kW/30 kW), and four electric vehicles.
24
■ System with Brains
The heart of the system is the 750-880/025-001 Telecontroller from
the WAGO-I/O-SYSTEM 750. Due to the numerous interfaces, the
modular automation system can be expanded as needed, without
great expense. The solar array for the system can likewise be expanded without requiring large investments. By using the string concept, modules from different manufacturers, with different outputs,
and with different orientation can be integrated and supplemented
in the system without incurring power losses.
Due to several proprietary developments by Sinusstrom GmbH – for
example the battery management system, the intelligent generator
connection boxes (IGAK), which include DC/DC converters and
MPP tracking, as well as the implementation of regulated functions
(software) in the controller – all energy suppliers and consumers in
the system can be coupled together using a direct current intermediate circuit. In addition, the energy system for the health center manages with only one highly intelligent inverter. All energy generators
and consumers, and the external energy supply, are connected to it.
Solar farms
Wind farms
Conventional
power suppliers
eMobility
Consumers
CHP plants
WAGO 750-880/025-001 Controllers
with I/O modules Examples of energy storage systems:
Battery/Accumulators
Latent heat
storage unit
Pumped-storage plant
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DISTRIBUTED SYSTEM
AUTOMATES HISTORIC
HYDRO-POWER
PLANT
The SPEEDWAY 767 IP67 automation system was used during
The heart of the Zella-Mehlis system:
750-880/025-001 Telecontroller from the
WAGO-I/O-SYSTEM 750.
The 750-494 3-Phase Power Management Modules from the WAGO-I/O-SYSTEM 750 are used to monitor the supply of energy not
generated within the system, and to continually check the energy
needed and generated by the system itself. The modules enable exact
querying of all relevant variables and statuses, including blind function, output, and effective power, output factors, phase angles, frequency, over- and undervoltage, and over- and undercurrent. Based
on the data obtained, energy generation, storage, and use can be
efficiently controlled and coordinated. The intelligent automation system thus enables monitoring and the necessary output reduction for
distributed energy supply systems using the IEC 60870-5-104 telecontrol protocol as required by the Renewable Energy Act (EEG).
■ E-Vehicles Become Mobile Batteries
In addition to a powerful buffer storage with a charge capacity of
68 kWh, the people of Zella-Mehlis use mobile storage in the form of
E-vehicles. The health center’s electric vehicles have traction batteries
that can be charged and discharged. Thus, the E-vehicles can be used
not only for house calls, courier services, or errands, but also as additional buffer storage. Especially on holidays or weekends, when the
electric vehicles are not used and generally less energy is consumed
by the health center as well, additional energy can be stored using
the traction batteries and used on days when consumption is high.
Sinusstrom and WAGO installed a complex battery management
renovations of the power plant control center for RWE Power AG.
system (BMS) for the buffer storage for the system. Using the BMS,
the charge state of each individual battery cell can be detected and
controlled by sensors; the battery cells can be consistently set to a
load state.
■ Project with Brilliance
By developing the system, the city of Zella-Mehlis has assumed a
leadership role in the complex use of alternative energy. The system
is groundbreaking for projects starting at a size of 100 kW, and demonstrates how an intelligent network of different renewable energy
sources is possible, in addition to the usage as needed on site. Soon,
the system should be even more efficient: Sinusstrom is currently
working on programming the micro smart grid to function based on
regional weather data. Together with consumption figures for different times of day and days of the week, the micro smart grid in ZellaMehlis will then function more efficiently due to a self learning mode.
But you still won’t notice it until you cast a second glance at the health
center in Zella-Mehlis.
Text: Olivia Köllmer,
Landesentwicklungsgesellschaft Thüringen mbH [State Development
Corporation of Thuringia]
Photo: WAGO
Sustainable energy storage management
with the WAGO-I/O-SYSTEM 750.
Energy generation, storage, and consumption is efficiently controlled and coordinated.
26
Intelligently connected to each other via a micro
smart grid: Battery storage, energy generators,
electrical consumers, and network operating
means.
The Heimbach power plant is housed in an art nouveau building
that is now an historic landmark. Water from the Urft Valley hydroelectric dam, located 106 meters higher, feeds two Francis turbines,
each of which drives a synchronous generator with an output of 8
MW.
The 750-880 Telecontroller and the
750-494 3-Phase Power Management
Modules form the core of the solution.
■ Over the course of the transition to renewable energy, all available potentialities for power generation must be exhausted. In the mix
of regenerative and conventional power, run-of-the-river power plants,
both with and without storage, fulfill an important function since they can
transform and store energy. RWE Power AG is currently modernizing its
existing hydropower plants in the Eifel mountain region. To accomplish
this, they commissioned the automation firm, F.EE GmbH from Neunburg
vorm Wald, who relied on modular automation systems in IP67 from
WAGO during renovations of the control center.
RWE AG is one of the five largest power and gas suppliers in Europe. It
is active in all value creation phases of power supply. These range from
the conveyance of oil, gas, and coal, through the construction and operation of conventional and renewable energy power plants, including trade
in raw materials, up to transport and marketing of power and gas. The
company employs more than 70,000 people, and supplies around 16
million customers with power, and nearly 8 million with gas. One of its divisions is RWE Innogy GmbH, which connects RWE expertise to renewable energy power plants. In this function, RWE Innology plans, builds,
and operates systems for power generation from renewable energy
sources. Their goal is the rapid expansion of renewable energy sources
in Europe. In particular, RWE Innogy develops wind power systems on
land and sea, and is increasing investments for power generation from
hydropower and biomass. In Germany alone, there are 45 run-of-theriver and ROR storage power stations, for example on the Moselle, the
Rur, and the Saar, with a total output of approximately 541 MW. They
generate approximately 1.4 billion kilowatt hours of power annually,
which corresponds to the yearly power consumption of approximately
400,000 households. These systems are operated and maintained by
RWE Power AG for RWE Innogy.
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■ Historic Water Utility Produces 16 MW
RWE Power is currently modernizing the hydropower plants in the
Eifel region and replacing some mechanical components, such as the
plants’ hydraulics and control technology. The Heimbach and Heimbach-Wehr power plants are among those located in the Eifel. They
are both fed by the Urft Valley dam via a a head race tunnel. This
dam, located in the southwest part of North Rhine-Westphalia, was
built in 1905. It is 58 m high and impounds the river Urft in the district
of Euskirchen to form a 2.16 km² reservoir (Lake Urft). In addition to
power generation, this dam also regulates the level of the Rur, which
was subject to destructive flooding in the past, especially during the
winter months. The Heimbach power plant is just as old as the dam
and its art nouveau style building is an historic landmark today. Eight
Francis turbines used to generate power here. After nearly 70 years of
operation, they had to be decommissioned. Today, two new Francis
turbines each drive a synchronous generator with an output of 8 MW.
■ New control technology systems control and regulate both power
plants
The Heimbach power plant is connected to the Urft valley dam via a
2.7 long head race tunnel through the Kermeter ridge and two 200
meter-long penstocks. The penstocks on the mountainside have a drop
of 106 meters. This is how the Urft Valley water is supplied to the two
large Francis turbines. There is another reservoir below the Heimbach
plant to equalize the uneven water output quantity from the Heimbach
ROR station, which is caused by its use as a peak load power plant.
The Heimbach-Wehr run-of-the-river station, which is located eight
meters lower than the Heimbach station, uses this reservoir to feed a
Kaplan turbine with a miter gear. This, in turn, drives an asynchronous
generator with an output of 750 kW. Both power plants received new
local control technology systems during F.EE’s modernization. These
include automation systems, local operator control and monitoring
stations (CMS), as well as a standardized connection to the central
office in Fankel on the Moselle. All of RWE’s Saar, Eifel, and Moselle
power plants are monitored and controlled from there. The automation
firm, F.EE from Neunburg vorm Wald, used their expertise and experience to implement the regulation and control tasks in both hydropower
plants.
■ IP67 System Installed in “Stalactite Cave”
Three PROFIBUS IP67 couplers, from the SPEEDWAY product family,
employ digital and analog I/O modules in three stations to record
signals from sensors and actuators. Data is then transmitted to a higher
level controller. They forward commands to the corresponding control
systems in the field direction. In the Heimbach power station, F.EE installed one coupler each on the generator for the Francis turbines, on
the ball valve, on the hydraulic systems, and on other auxiliary systems
in the turbine basement. The modular structure of the system enables
installation of the I/O modules up to 50 meters away from the fieldbus coupler or controller. In total, one SPEEDWAY station can cover
up to 500 meters. F.EE took advantage of this characteristic, installing the modules near the sensors and actuators. It was therefore possible to reduce the cabling required. “The environmental conditions at
the installation location for the IP67 system are especially harsh. The
head race inlet for the penstock water is level with the bottom of the
28
reservoir, and has a temperature of just 4°C,” explains F.EE, Michael
Hellmuth, Project Manager. The large difference in temperatures, especially in the summer, means condensation is always present. “At that
point, we have the climate conditions of a stalactite cave,” he adds.
A normal IP20 system would require a housing for protection from this
high humidity, which would in turn necessitate more space and lead to
greater installation expenses. “With WAGO’s SPEEDWAY, we have
an IP67-capable remote I/O system that supports classic fieldbus protocols. This simplifies the cabling for the central control system into one
fieldbus line,” summarizes Michael Hellmuth. Furthermore, due to the
Heimbach-Wehr power plant – the I/O modules on the
other side of the turbine are connected to the coupler via
system bus lines (yellow).
standardized connections, the I/O modules can be pre-assembled using standard cables, which reduces cabling errors and simplifies subsequent maintenance.
■ Regulation Improves Turbine Efficiency
Turbines are driven by water to generate electricity. The opening of
the guide vanes determines the quantity of water that drives the wheel.
The guide vanes can be adjusted using the hydraulic system; the vanes
control generator output. Kaplan turbines – such as those used in the
Heimbach-Wehr station – are primarily used in run-of-the-river power
plants with low penstock heights (low pressure) and large quantities
of water. In addition to controlling the guide vanes, the angle of the
turbine blades can also be hydraulically adjusted. The new controller
(PLC) regulates the turbine blades (Phi) depending on the guide vane
opening (a0), thus improving the efficiency of the turbines.
■ Conclusion
During modernization, the RWE run-of-the-river plants, Heimbach and
Heimbach Wehr, received new control system technology. F.EE, under
commission from RWE Power, replaced the existing controller and selected WAGO’s SPEEDWAY 767 as the distributed automation system.
The IP67 system eliminates the need for enclosures in harsh environments. In addition, the I/O modules can be installed in the field, away
from the fieldbus coupler, for example near the ball valve, in order to
forward commands or messages. These features significantly reduce
the expenses required for installation and materials. In addition, F.EE
also took over the regulation and control tasks, and programmed a
regulator for the controller, which increased turbine efficiency.
■ Background
F.EE GmbH is an international supplier of products and services for
production automation, system programming, power generation, and
IT. The company is divided into four areas: electrical engineering, automation and robotics, Information + systems, solar and energy technology. F.EE has successfully completed more than 250 hydroelectric
power projects ranging from 30 kW run-of-the-river plants to plants in
the double-digit MW range. The use of reliable control and regulation
technology also guarantees high availability.
Despite the humid climate, the PROFIBUS coupler and the
six SPEEDWAY modules manage without a control cabinet.
The system controls and monitors the auxiliary systems in the
turbine basement.
Text: Ulrich Menzel, WAGO
Photo: WAGO
+1 MYA40
Turbine basement Machine 1
SPEEDWAY is installed directly at the process
and manages without a control cabinet.
Standardized connection technology enables
pre-fabrication, prevents wiring errors, and simplifies maintenance work.
SPEEDWAY enables station design with a total
extension of up to 500 m.
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PHOTOVOLTAICS ARE RADIATING ENERGY
By employing automation components from WAGO, the technical prerequisites for an efficient usage of electricity can be created.
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Pump storage
Hydroelectric plant
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Cold store
Combined
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Heat pump
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Direct current measuring can be carried out without interruption of the branch cables. The 789620 current sensor has a measuring range from 0 to 80 A, and the 789-621 has a measuring
range from 0 to 140 A.
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Current flow during periods of excess power
Current flow during low energy periods
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pressing challenges at present is that several thousand, mostly privately owned, PV plants feed directly into the grid. At peak times,
this means that there is often an energy glut, which, due to a lack
of storage capacity, leads to instability. A virtual power plant would
have to be controllable by the network operator in cases like this;
according to the EEG, a graduated series of power reductions,
of 0%, 30%, and 60%, is provided for these periods. A technical
prerequisite for this type of regulation is recourse to the distributed
energy producers. So-called “smart grids” form the communicative
foundation for regulating electrical generation, storage, electricity
consumers, and the means for operating the grid.
■ Efficient Generation, Efficient Use
The most widely differing input and output parameters must be
transmitted for the integration of PV plants into “smart grids” and for
permanent monitoring of the plants. WAGO has developed its controls in a corresponding direction to more easily configure communication between solar farms and the control center: WAGO offers a
standardized and easily applicable interface for users, which based
30
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■ Virtual Networking of Real Plants
There are decisive advantages to integrating distributed energy
generators with low outputs into one so-called virtual power plant.
Under central management, small wind farms, hydroelectric plants,
combined heat and power plants, biogas, and even photovoltaic
systems are capable of collectively replacing the electricity produced by large power plants. Temporary fluctuations in the electrical grid can be balanced out by the availability of capacity from
the virtual power plant. When distributed energy generators are
bundled in this fashion, they appear, when viewed from the outside, as a single plant. Their integrated total output can thus also
be managed on the electricity market. This means that the energy
they generate can be marketed by the electricity traders, which was
previously almost never a worthwhile endeavor for the smaller, individual plants.
However, not all problems can be solved by the simple integration of energy producers. Only when the electrical
grid operators are able to assume a regulating
influence can an efficient and stable power
supply be constructed. One of the most
Example of a virtual power plant
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Two-thirds of clean energy is currently harvested from wind farms
and hydroelectric power plants. At just over 15 percent, photovoltaic systems produce the smallest proportion, which can be attributed
primarily to their low efficiency, averaging only 15 to 20 percent.
The high loss of earnings in this sector is doubly embarrassing: after all, the sun provides an amount of energy that exceeds the annual needs of Germany by a factor of 80. However, the electricity
gained in this highly inefficient manner is not even used in a sufficiently efficient manner. Since there is no comprehensive management, much too much energy is lost in the wilds of the electrical grid.
The legislators have finally reacted with a revision of the Renewable
Energy Sources Act. Beginning in January 2012, photovoltaic systems with an output of more than 30 kW must be provided with a
technical interface that enables remote controlled power reduction
by the network operator. This limit was previously 100 kW. As a
second step, operators of PV plants that produce more than 100
kW are obligated to disclose their feed-in power to the network
operators. The goal of these measures is both to strengthen network
stability by avoiding fluctuations in frequency that lead to power
failures, and to make it easier on the part of the network operators to effectively manage the growing number of different energy
sources.
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■ The transition to renewable energy cannot be halted. However,
the mere expansion of the electrical grid is not enough to ensure
that renewables remain successful on the market, and that coal,
uranium, and company can be strongly avoided in the future as
well. Renewable energy sources must be employed far more efficiently, particularly when, as is the case for photovoltaics, they
have low levels of efficiency. This foundation will be created
through the integration of photovoltaic plants into the intelligent
electrical grid as well as continuous monitoring of modules and
inverters.
Control power for the free market (electricity exchange)
on IEC 60870-5-101/-104 and IEC 61850 telecontrol protocols.
More than 400 input and output modules are available within the
I/O system for use at the field level. In addition, there are also diverse specialty modules, among them the 3-Phase Power Measurement Module for energetic monitoring of transformer stations, or serial I/O modules for connecting S0 counters, M-Bus counters and
current sensors.
Telecontrollers or IPC’s carry out communication between field and
control levels. Programmable logic controllers (PLC’s) transmit all relevant measured values, such as current, voltage, or (reactive) power
and receive switching orders from the higher-level control center.
These commands are then implemented by the serial input and output modules. The specific automation tasks are defined in the controllers according to IEC 61131 using CODESYS. For this purpose, a
configuration interface is integrated into the CODESYS development
environment for each of the two telecontrol protocols, IEC 60870
and IEC 61850. By this means, the user avoids the relatively expensive programming labor, as the entire IEC communication can be
parameterized.
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■ Maintain Attractiveness, Increase Development
The proportion of renewable energy that forms part of the more
than 600 terawatt hours, which are annually required in Germany, must and will increase in the future. By employing automation
components from WAGO, the technical prerequisites for an efficient usage of electricity are already available. This will enable
photovoltaic systems to remain attractive, despite a drop in guaranteed feed-in compensation. This is of decisive importance: this
technology will only maintain support for expansion from private
households and corporations if it continues to radiate power.
WAGO ensures continuous monitoring and
reliable integration of photovoltaic systems
into “smart grids”.
A configuration interface for each telecontrol protocol, IEC 60870 and IEC 61850,
is integrated into CODESYS.
No expensive programming is necessary,
because the entire IEC communication can
be parameterized.
Text: Manuel Schmidt, WAGO
Photo: WAGO
A MORE COMPREHENSIVE REMOTE ACCESS
WAGO’s TO-PASS® Web Connector enables simple and comprehensive
integration of fault detectors in control center systems.
components. Together, they enable independent monitoring of remote
■ Telecontrol and monitoring of remote sites or mobile devices is no
objects – at any time and anywhere in the world. TO-PASS® Compact,
problem at all for TO-PASS®. TO-PASS® telecontrol modules can now
be integrated to an even greater extent into the control center by usMobile, and Outdoor modules communicate over wireless links via the
ing the web connector. The heart of the Web Connector is a special
GSM mobile communications network and therefore do not rely on
function block for the CODESYS development topology. This function
data lines or radio links. Data can be sent to a freely selectable target
block registers the HTTP queries from the telecontrol modules, saves the
address, for example to the TO-PASS® web portal.
process image in a global variable list, and transmits a corresponding
acknowledgement. The received data can then be processed by the
WAGO-I/O-SYSTEM as needed.
t
ues
Req
Network service providers can use the economical, bidirectional
TP
T
H
transmission provided by the web connector to comply with the
oder
®
renewable energy act. TO-PASS , provides private power
producers with the technical means for achieving the required power reductions according to IEC 60870-5-104.
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R
GP
ns
e
■ TO-PASS Telecontrol Technology
From a fault message, through process and position data acquisition, up
to a fully functional PLC: the WAGO
TO-PASS® family of products includes
modular and perfectly matched telecontrol
®
o
sp
Re
P
T
HT
SNMP GOES IEC 60870/61850
Supporting the IEC 60870-5-101/-104 and IEC
61850 telecontrol protocols: the 750-872 and
750-880/025-001 telecontrollers as well as the
758-874 and 758-875 telecontrol IPC’s.
32
The WAGO-I/O-SYSTEM 750 uses IEC 60870/61850 and SNMP
protocols simultaneously.
■ PCs, switches, modems, UPS systems: the number of network components is increasing within infrastructures critical to energy suppliers. Most
devices use the SNMP protocol, which can transmit status information as
well as commands. In order to further optimize fault management, a few
important network messages should be transmitted to a central control
center.
WAGO offers the possibility for using IEC 60870/61850 and SNMP
protocols simultaneously through their intelligent 750 telecontrol system.
In this way, information can be read from the devices using a GET command, transformed into IEC variables,
and thus directly transmitted to the
control center. The reverse is also possible: the devices can be written using
a SET command. SNMP and IEC
addresses can be flexibly parameterized by providing an editable CSV file
on the controller’s SD card. WAGO
provides files that are already pre-configured for selected components from
specific manufacturers. Additional de-
vice types can be integrated using the so-called Management
Information Base (MIB).
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AUTOMATING INFRASTRUCTURE NETWORKS
WAGO controllers with IEC communication simplify the automation of infrastructure networks.
■ Classic supply network components, such as counters and power
switches, are supplemented by new modules for an optimal load
management. This, in turn, increases the number of data points
required. Meanwhile, programmable controllers undertaking
telecontrol tasks, in addition to automation tasks, and communicating with the control center via international telecontrol protocols. These “standard” controllers with IEC communication have
a good price-performance ratio and simplify the automation of
infrastructure networks.
The increasing levels of energy feeds provided by renewables on
the market is also leading to new challenges with regard to accounting and load management. Previously, programmable logic controllers (PLC) automated only the distributed units. Now, however, they
are also supposed to transmit the system state to the control system
and implement switching commands in the control direction. Communication protocols, such as MODBUS, DNP3, and IEC 60870
and IEC 61850 with their subnorms, are available for these telecontrol tasks. These protocols differ both technically as well as in their
global distribution.
The IEC 61850 standard was published in 2004 to serve as a
global standard for safety and control technology in medium and
high-voltage electrical switching systems. The functional units are
modeled using an object-oriented approach in this type of com-
Diagnostics using the controller’s web server
34
munication. This contrasts with the other communication protocols,
which work using a signal-oriented approach. As a consequence,
specific extensions must be created for new task areas. Three of
these extensions were defined for monitoring and controlling wind
farms (IEC 61400-25), hydroelectric plants (IEC 61850-7-410),
and distributed electrical generation systems, such as solar farms
and energy storage units (IEC 61850-7-420).
■ “Standard” Controllers with IEC Communication
In order to offer the user a standardized and easy-to-use interface
for communication with the control center, WAGO integrated the
IEC 60870-5-101/-103/-104 and IEC 61850 telecontrol protocols into controllers for the modular WAGO-I/O-SYSTEM. These
protocols are, in the case of IEC 60870-5, signal oriented, which
means that messages, measured values, bit patterns, counter values, and (set) commands are exchanged between control system
and modular controller both with and without timestamps. If you
transfer this approach to IEC 61850, then it would correspond to
the generic object type GGIO as a basic object. However, an essential added value of this standard is the presence of standardized objects. This enables the automation of for example, a network
transformer, a wind power system rotor, or a photovoltaic system. If
all expansions of the IEC 61850 standard are considered, then approximately 220 additional specific object types have been added
IEC 60870 configurator in CODESYS
to the generic object type GGIO. Since the controller manufacturers do not know which IEC object types the user will need, the automation solution must be able to operate all specific objects, for
example an yPtr object for integrating transformers.
The WAGO solution provides the user with the standardized interface to the control system, but not, however, with the internal logic
for the object types. This is due to the fact that it is ultimately the end
user who has the expertise related to the application and who must
implement the logic. Programming for automation task is carried out
using CODESYS, and programs are stored either in the programmable telecontroller or on the compact industrial PC (I/O-IPC). A
configuration tool for both standards (IEC 60870 and 61850) is
integrated into CODESYS, enabling the user to easily initialize the
telecontroller and the I/O-IPC’s for communication with a control
system. This tool enables the parameterization of IEC communication: programming is no longer necessary.
SYS, which are then loaded directly into the controller’s web server.
The end customer thus has a comfortable diagnostic platform for his
solution, which can be accessed using any browser. As an all-in-one
solution, the modular controllers with IEC communication reduce
both installation space requirements and complexity in the control
cabinet, which in turn lowers the costs for the automation tasks.
■ Scalable Controllers for Demanding Environments
Regardless of their specific use, modular controllers contribute
numerous system features that are advantageous for smart grid
projects. The fieldbus-independent WAGO-I/O-SYSTEM, which includes more than 400 modules, can be used to solve a multiplicity
of automation tasks with one controller. The automation system programmability enables the generation of visualizations using CODE-
CODESYS configuration tools simplify
initialization of communications with the
control center.
Text: Martin Paulick, WAGO
Photo: WAGO
IEC 60870-5-101/-103/-104 and IEC
61850 are integrated into WAGO-I/OSYSTEM controllers.
Controllers with IEC communications
reduce space requirements and complexity in the control cabinet.
IEC 61850 configurator in CODESYS
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TAKING IT TO
THE EXTREME –
THE STANDARD
FOR 750 XTR
When you need an extreme insulation withstand to impulse voltages
and resistance to interference, as
well as endurance to freezing cold,
blazing heat and strong vibrations:
the WAGO-I/O-SYSTEM 750 XTR
■ Extreme Requirements? Are in demand for more than automation
systems with high protection classes. Things can get downright
uncomfortable, even in IP20 technologies. In order to successfully
address the harshest demands placed by industry, process technology, or on the high seas, I/O systems on the top-hat rail have
to endure a lot: temperature extremes between -40° and +70°C,
vibrations up to 5 g, insulation withstand voltages according to
60870-2-1. The WAGO-I/O-SYSTEM 750 XTR was designed to
handle these challenges.
Its scope of applications begins where others leave off. The WAGOI/O-SYSTEM 750 XTR belongs everywhere that high temperature fluctuations, electromagnetic sources of interference, and strong vibrations
are found. Expensive special solutions, like air conditioning and protection circuits, are no longer needed. The automation system is based on
the proven WAGO-I/O-SYSTEM, and thus profits from all of its positive
features. The XTR retains the especially compact construction, finely
modular and fieldbus-independent design, and the extremely flexible
potential for applications.
36
■ Extreme Resistance to Adverse Weather Conditions
Automation systems are rarely used in pleasantly temperate
conditions. However, it is much more likely that the thermometer
will rise, or fall, to the limits of reliable operating temperatures.
In energy and process technologies, for example, I/O systems
are commonly installed in wind and solar farms, or local network
substations, which are, in turn, usually constructed in the open and
thus exposed to the most extreme weather conditions.
A particular challenge in these cases is the error-free start-up of
automation systems at very low temperatures, for example, after a
power outage. 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 temperature 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. The
fundamental thought behind the design of the new WAGO solution was components that could handle it all without air conditioning or heating, both of which increase costs and steal installation
space from potential automation components.
■ Extreme Insulation and Protection
From a technical point of view, it is usually bad when voltages rise.
There are various causes of voltage spikes. Tripped circuit breakers
and errors in the electrical grid, transient storm-related surges, stabilization procedures following high load reversals that can lead to
oscillations in the balancing voltage can all cause spikes in voltage
levels. The WAGO-I/O-SYSTEM 750 XTR, with increased insulation
withstand voltage of up to 1 kV (< 60 V, class VW1) and 5 kV (>=
60 V, class VW3), ensures continuous, smooth operation because
the electronics are protected against malfunctions.
The reliable EMC immunity to interference of the XTR version also
plays an important role by guaranteeing secure fieldbus communication, even in less well-shielded areas. The optimized EMC
behavior of the WAGO-I/O-SYSTEM 750 XTR prevents negative
electromagnetic interference emissions, which thus allows it to be
used in direct proximity to even highly sensitive third-party systems.
By this means, the demands regarding impulse voltage withstand
and EMC interference immunity can be completely satisfied, including requirements posed by telecontrol devices according to EN
60870-2-1. This also ensures uninterrupted communication, via the
ETHERNET telecontroller, according to the telecontrol protocols supported, such as IEC 60870-5-101/-103/-104, IEC 61850-7, IEC
61400-25, and MODBUS.
■ Extreme Vibration up to 5g Acceleration
Increased vibration resistance is required in particular when the
modules are located in direct proximity to high performance engines or power circuit breakers, to name two examples. At a vibration resistance of 5g, which corresponds to an acceleration of
50 m/s², the WAGO-I/O-SYSTEM 750 XTR has set the bar high.
WAGO can thus offer continuous, interruption-free operation, including safety factors, even in applications that are exposed to
extreme vibrations, such as tunnel boring machines.
Text: Manfred Kühme, WAGO
Photo: WAGO
An expanded temperature range from -40
to +70°C makes expensive and bulky air
conditioning units unnecessary.
The insulation withstand to impulse voltages increases reliability, e.g. by preventing outages due to errors in the grid.
With vibration resistance up to 5g, XTR
can guarantee continuous, trouble-free
operation.
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TRANSPARENCY PAYS DIVIDENDS
WAGO’s automation and interface electronics consistently create solutions for electrical and energy measurement technologies.
■ With a coordinated product portfolio, WAGO continues to creates
solutions for electrical and energy measurement technologies.
Systematic energy management, to achieve significant reductions in
constantly increasing energy costs, is in greater demand than ever before. The use of standardized and cost-efficient automation technology is providing easier solutions for what was previously an exhausting
puzzle made of the most varied of technological components. WAGO
offers a completely coordinated product portfolio for energy efficiency with their interface electronics and the WAGO-I/O-SYSTEM 750.
Many energy management projects show that energy savings of 30%
and more are possible, depending on the operating situation. When
starting this type of project, however, initially only the total costs for the
energy are known. There is a distinct lack of information about which
points use how much energy, and where exactly energy can be saved.
Therefore, improvement processes begin with the systematic recording
of energy consumption in the company, as well as the analysis and
evaluation of the same.
■ Measuring – Systematically Recording Energy Consumption
Anywhere high currents have to be measured and processed, WAGO’s 855 Series Plug-In Current Transformers are the first choice.
With a measuring accuracy of one percent (accuracy class 1), they
transform rated primary currents into electrically isolated secondary
currents from 1 to respectively 5 A. The plug-in current transformers
are inductive, single-conductor current transformers, that function according to the transformer principle, and are designed for use in low
voltage networks of 230 V, 400 V, or 690 V.
If, for example, the energy consumption measurement should be retrofitted on existing systems, 855 Series Rogowski Coils can be used
to avoid disassembly of cables or interruption of processes. The coil
is placed around a conductor or current bar. The magnetic field produced by the AC current flowing through the conductor induces an
output voltage in the coil. This measurement procedure provides galvanic isolation between the primary circuit (power) and secondary
circuit (measurement).
■ Evaluations – Identifying and Planning Energy Use
A total of three different 3-Phase Power Measurement Modules (750493, 750-494, and 750-495) are available for evaluating actual
energy consumption using the WAGO-I/O-SYSTEM 750. They provide voltage and current values for each of the three phases, as well
as data about the reactive, apparent and active power. The power
measurement modules, integrated directly in the I/O system, calculate
consumption values within the module. This eliminates the need for external measuring equipment, which can in turn reduce measurement
costs nearly ten-fold. In addition to energy consumption measurement,
the power measurement modules feature harmonic analysis, neutral
conductor measurement, and additional functions for comprehensive
grid analysis.
Depending on the respective application or customer preference, the
energy data can also be converted to an analog standard signal using the 857 Series JUMPFLEX® Current and Rogowski Transducers,
and displayed using the associated JUMPFLEX®-ToGo app for smartphones. The 857-550 Current Transducer records alternating currents
using a Rogowski coil; the 857-552 Rogowski Transducer detects RMS
values from alternating currents via a Rogowski coil.
■ Visualization and Configuration –
Energy Characteristics according to DIN EN ISO 50001
JUMPFLEX® Transducers and the WAGO-I/O-SYSTEM’s 3-Phase Power Measurement Modules can be configured in multiple ways and also
offer means for visualizing the measured results. For JUMPFLEX®, there
is an app for smartphones and PC tablets, in addition to the classic
PC-based software. The app can be used to change input and output
parameters and to display settings and measured values. The 750921 Bluetooth® Adapter forms the interface between the mobile end
user device and the transducer.
In contrast, configuration of the WAGO-I/O-SYSTEM 750 takes place
using WAGO-I/O-CHECK, an easy-to-use Windows application for
operating and representing nodes. Connection to a fieldbus system is
not mandatory, which means that it can also be used as an autonomous measuring device. With WAGO-I/O-CHECK, it is possible to
display and output the process data from individual bus modules. The
field wiring, including all sensors and actuators, can thus be checked
before startup. Interfaces, like WAGO’s 3-Phase Power Management
Modules, can be configured to suit the application.
From evaluation to visualization: Coordinated products for energy
data management create maximum transparency – and maximum
cost savings. The knowledge thus obtained additionally forms the basis for a constant improvement process according to the “Plan – Do
– Check – Act” method for energy management, which satisfies DIN
EN ISO 50001.
Text: Torsten Klinkow, Michael Meyer, WAGO
Photo: WAGO
JUMPFLEX®-ToGo
configuration app
Convert
JUMPFLEX®
Measure
Visualization &
Configuration
Plug-In Current Transformer, Split-Core
Current Transformer, and Rogowski Coil
Evaluate
WAGO-I/O-SYSTEM
WAGO-I/O-CHECK
38
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INNOVATIVE ENERGY STORAGE DEVICES
ON THE TEST STAND
The Ostfalia University is using the WAGO-I/O-SYSTEM to
establish communication between the generator and storage
unit, which makes for an intelligent communication system.
■ The Ostfalia University of Applied Sciences in Wolfenbüttel is operating an energy park using renewable energy systems. Among other
projects, they are investigating distributed renewable generators and
electrical energy storage units, as well as coupling the two with electromobility devices. A particular challenge has been the integration
of a multiplicity of bus systems with respect to their data. WAGO provided support to the university as a cooperation partner within the
framework of a research project.
The university has been reporting about the increased number of
small concerns that want to store the energy that they generate for
later use. Queries of this type have arrived at the place with the
answers. For more than ten years, the university has been investigating the practical advantages and disadvantages of various storage
technologies within the context of building technology. They have
continuously expanded their own integrated energy system (the energy park) over this same period. The integration and pooling of
process data from different energy generation systems and storage
units remains among the solutions still under development.
40
■ A Small but Refined Integrated Energy System
In Wolfenbüttel, a conventional, oil-powered combined heat and
power plant sits next to renewable generators, like a wind farm, a
photovoltaic system, and a fuel cell. Energy storage units include a
conventional lead-gel battery system, a polymer electrolyte membrane (PEM), an alkaline polymer electrolyte (APE) for water electrolysis, a vanadium redox flow battery, and a charging station for
integrating electromobility into the storage concept.
The systems are connected using a three-phase mains current, and,
by throwing a circuit breaker, they can be operated as stand alone
networks, independent from the mains supply. Load profiles for residential buildings are simulated using programmable, electric loads.
A visualization of the energy park provides a constant overview of
the data from the individual generation and storage systems.
“We are investigating various storage technologies for use in the
context of building technology. We have concerned ourselves with,
among other things, usability, that is, how fast the systems are available, how they function with other technologies, and when it makes
sense to use which storage unit,” explains Prof. Ekkehard Boggasch,
who heads the Laboratory for Electrical Engineering and Renewable
Energy Systems at Ostfalia.
An electric current splits distilled water into hydrogen and oxygen in the
alkaline electrolysis system. The hydrogen can be converted into electricity in a fuel cell in order to actively balance load fluctuations.
The charging station is also being used to test needbased charging, so-called flex charging.
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■ Energy Storage Technology as Applied to Buildings
The storage of renewable energy within the electrical grid is subject
to strong oscillations, which could conceivably be at least partially
contained using suitable storage technologies. One of the innovative
technology undergoing tests in Wolfenbüttel is the vanadium redox
flow battery. It stores large amounts of electrical energy in a liquid
electrolyte that has been enriched with vanadium ions at different
charge states. Output and energy are thus dependent on each other,
such that any level of output and capacity would be possible through
modular expansion.
An electric current splits distilled water into hydrogen and oxygen in
the alkaline electrolysis system. The hydrogen can be converted into
electricity in a fuel cell in order to actively balance load fluctuations.
The possibility for using e-vehicles as mobile storage units for buffering
renewable energy sources is also currently being tested. This required
the integration of a charging station in the energy park.
The charging station is also being used to test need-based charging,
so-called flex charging. The station is provided with more or less energy, depending on the excess supply and on the energy demand. The
charging process can be switched using WAGO’s Pilot-Box into four
levels, 6, 10, 16, and 32 A. The Pilot-Box guarantees the charging
process according IEC 62196 type 2. The programmable 750-872
fieldbus controller for telecontrol systems provides higher level communication between the charging station and the energy park. This
controller can use MODBUS as well as IEC 60870 and IEC 61850
protocols, both of which are widely used in the energy supply sector.
■ All Bus Systems through One Controller
Due to the various energy generating and storage systems, the university was confronted with a multitude of interfaces and bus systems.
WAGO components were installed in order to integrate the different interfaces. For example, the redox flow battery was linked to the
LON® network via a LON® I/O module. The WAGO-I/O-SYSTEM
undertakes a central role in controlling the energy storage unit. In enables the specification of parameters for active current and reactive
power in order to investigate the battery’s behavior and to simulate a
building’s typical electrical load profile. The measured values for the
battery capacity, output, and temperature are recorded using analog
input modules from the WAGO-I/O-SYSTEM 750. More comprehensive data, like electrolyte temperatures and pressures, is detected using a serial module and the MODBUS RTU protocol. Communication
with the inverters is implemented via MODBUS/TCP protocol. In ad-
Prof. Ekkehard Boggasch’s team at the Ostfalia University for Applied
Sciences operates an energy park for renewable energy systems.
42
dition, there are plans to connect the control center to the electrical
engineering faculty at the university using the IEC 61850 telecontrol
interface.
Collecting and distributing data from the PEM battery takes place over
a CANbus: this includes links to the temperature sensors, current voltages at the power adapter, and transmission of set and/or control
signals for the temperature of the process water. The output from the
entire infrastructure is detected by 3-Phase Power Management Modules. The measured data are transmitted via MODBUS to an operating program, set up in LabVIEW, for visualization.
■ Communication Makes the Aggregate System Intelligent
“This aggregate system only becomes intelligent due to communication between generators and storage units,” explains Lars Baumann,
a university research assistant. “The WAGO-I/O-SYSTEM has proven
to be flexible in this heterogeneous environment, and enables simultaneous communication over four different bus systems. Defined experiments regarding static and dynamic behaviors of the batteries and
energy management system for an intelligent aggregate would not be
possible without this multiplicity of interfaces,” he adds. Baumann also
emphasizes the multitude of analog and digital input/output modules,
The storage of renewable energy within the electrical
grid is subject to strong oscillations, which could conceivably be at least partially contained using suitable
storage technologies (photo: vanadium redox flow battery, laboratory bench test system).
the excellent expandability of the modular I/O system, and the ease
of programming with CODESYS.
Text: Daniel Wiese, WAGO
Photo: WAGO
WAGO’s Pilot-Box controls the charging
station that is used to convert e-vehicles
into mobile energy storage units.
The WAGO-I/O-SYSTEM undertakes a
central role in controlling the redox flow
battery.
The output from the entire infrastructure is
detected by 3-Phase Power Management
Modules.
An electrolyzer serves, among others, as an energy
storage unit that buffers energy in the form of hydrogen.
direct energy
43
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