Customer application 18 June 2021
The Green Light for Blue Gold

These days, a constant 24 VDC power supply for automated applications is no longer the only demand placed on power supply units. Maximum efficiency, adequate power and current reserves – even under critical grid conditions – and protection of the load circuit with ECBs all belong to the state of the art now. And let’s not forget the comprehensive communication options offered by modern power supply systems, which make the distance between the system location and the service team nearly insignificant, as illustrated in the example below.

The distance btw the serene community of Thundorf in Lower Franconia in Germany and the bustling metropolis of Shanghai in China is a good 8,700 km as the crow flies. When Christian Müller, managing director of the engineering firm IDEAS mbH, based in Thundorf, opens a secure VPN tunnel on his computer at 1:00 p.m. and opens a dashboard, it’s already 8:00 p.m. in Shanghai. “The power supply voltage for the test unit is 23.92 V – exactly within the acceptable range”, he is pleased to report. Together with his team, Müller provided automation, electrical equipment and commissioning for the water test unit on behalf of Mösslein GmbH Wassertechnik – and did this all from Thundorf. “Because of the strict entry and travel restrictions resulting from COVID-19, it was impossible for us to commission the unit on site in Shanghai,” Müller explains. To solve this problem, he and his team needed creativity and the right selection of technical components.

“The system simulates typical stagnation and flow conditions in eight different pipe materials – both with and without the inhibitor additive.

Günter Mösslein, Managing Director of Mösslein Wassertechnik

In Focus: Drinking Water Quality in Shanghai

Shanghai is one of the largest cities in the world. Around 15 million people live in the downtown area alone. Over the past years, the Chinese government has invested very heavily in ensuring access to clean drinking water, especially for the populations of large metropolises. One of the primary hurdles in Shanghai is its water mains system, with more than 35,000 km of piping, some sections of which are more than 100 years old. “Shanghai’s water treatment systems produce high-quality drinking water. Unfortunately, this quality seldom makes it to consumers’ taps”, says Günter Mösslein, managing director of Mösslein Wassertechnik, based in Lohr am Main in Lower Franconia, Germany. And he knows what he’s talking about: With more than 70 employees, his company, founded in 1989, ensures water quality meeting German hygiene standards for consumers around the globe. Since 2019, the water specialists from Lower Franconia have not only supplied special chemicals to China for cleaning water facilities and systems, but have also been providing on-site maintenance and service. Mösslein is supplying a water test unit as part of a scientific research project with the objective of testing a silicate inhibitor for pipe maintenance to prevent rust, corrosion and deposits both, in order to assess its impact on drinking water quality and on the pipes themselves in Shanghai. “The system simulates typical stagnation and flow conditions in eight different pipe materials – both with and without the inhibitor additive“, explains Mösslein. “Pressure, temperature and flow must not only be reliably and exactly regulated for this test setup, but must also be documented as well.”

Reliable Power Supply

Mösslein Wassertechnik hired IDEAS GmbH, a company with which Mösslein had already implemented solutions very successfully in the past, for the automation and electrical configuration of this system. This electrical engineering company specializes in energy data acquisition and management, combined heat and power plants, power supply for data centers and drinking and wastewater systems in general. “One of our first assignments was designing the sensors for the 2 × 8 test sections”, explains the IDEAS managing director. “We decided on combined pressure and temperature sensors that can be integrated via IOLink . This allows us to both provide complete diagnostics and also keep the spare parts required to a minimum.” Müller’s team then turned its attention to control and power supply systems: “It goes without saying that the top priority here an efficient, reliable power supply.

But we were also looking for a solution that would give us secure, comprehensive remote access. On-site technical support was just not possible due to the COVID-19 pandemic.” This circumstance alone ruled out any classical approach to the power supply. “We rely on a WAGO PFC200 Controller with cloud connectivity for the control system. Together with the diagnostics data via IOLink , it gives us the wide range of options we need even when we can’t be present on site. For the power supply, it was crucial to choose a solution that offered secure, comprehensive data access”, says IDEAS project manager Andreas Kröber in summary. Müller adds: “The Pro 2 Power Supply WAGO introduced in 2019 was a real gift: a broad input voltage range, intelligent load management and a communication module that supplies vital current and voltage data via IOLink .”

Not only can we read out the most up-to-date, precise values from here – we can also extrapolate trends. That allows us to react quickly to overload situations.

Andreas Kröber, IDEAS Project Manager

“DC OK” Is No Longer Enough

Before the test facility in Shanghai was commissioned remotely, it had to prove that the application would run reliably through several weeks of continuous operation in Thundorf. The engineers were especially interested in remote monitoring and maintenance functions: “A classic power supply combined with safety fuses or circuit breakers doesn’t give me any information about current or voltage. ‘DC OK’ just tells me that 24 V is present at the output end”, explains Müller: “That was definitely not enough for our project.”

The Pro 2’s mountable communication interface enables cloud communication and provides not only current and performance data, but also status information, such as whether a short circuit is present or if output voltage is missing. Current and voltage data can be represented over time. “Not only can we read out the most up-to-date, precise values from here – we can also extrapolate trends. That allows us to react quickly to overload situations”, explains Kröber, adding: “The loads of all consumers can be recorded individually when the system starts up. I can then use this data to significantly improve the voltage quality for restarts following any power failures. We also take advantage of the option of configuring the Pro 2 Power Supply remotely during ongoing operation – including overload behavior and non-disruptive adaptation of the voltage.” The WAGO power supply can be parameterized as an electronic circuit breaker using this function. In the event of overloads, the output can be reactivated after tripping – including by remote access. In the event of a short circuit, the configurable TopBoost overload response allows up to 600 % output current and reliable activation of the electronic circuit breaker.

The comprehensive diagnostics data and the remote access options make the Pro 2 the ideal power supply for the water testing facility. “The main thing is for the system to run reliably. The employees in Shanghai are interested in seeing the measured data but don’t have power supply training,“ continues Kröber. He explains: “In Thundorf we can track what’s happening in Shanghai and intervene when required, or assist the personnel in Shanghai with particular issues.” The two IDEAS engineers are just as pleased with the solution as Günter Mösslein is. He points out a further detail: “The racks are provided with color-coded strips that indicate the condition of the station. Green, for example, is the “Everything OK” signal for the staff – this makes the test station a real centerpiece and offers true value added.” The next joint projects are already planned – perhaps to be implemented right in Lower Franconia again. “But these days, distance doesn’t really matter anymore – provided you have the right technology”, concludes Müller with a grin.

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Everything in an acceptable range: The control cabinet with the controller and power supply is located in the center module of the test facility, with the two outer modules each supporting eight test sections with different pipe materials.

Let Power Communicate!

WAGO’s Pro 2 Power Supply: As the requirements on them – both quantitative and qualitative – become more and more demanding, control cabinets are undergoing a transformation. Greater networking, rising energy costs and increasing customization mean control cabinets need to offer cost-effectiveness, speed and flexibility in a minimum footprint.

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