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Information for Building Technology, March 2013
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Foto: fotografie-grimm-leinefelde
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Dear reader,
“In March, the farmer spans his teams to prepare his fields, woods,
and streams.” It is appropriate that these lines from an old German
folk song dance through my head upon the appearance of this
WAGOdirect building magazine. March is – in a metaphorical
sense – very similar at WAGO, only our fields and woods are events
like the ISH Trade Fair. At the world’s leading trade fair for building,
energy and air-conditioning technology in Frankfurt, we will shine
the spotlight on our newest products, and primarily on our individualized consultations, which provide our customers with solutions tailored to their needs.
For a glimpse into what such projects can look like, read on! For example, Leitec combined the WAGO-I/O-SYSTEM with automation,
energy and building technology to make their new company headquarters especially efficient. WAGO developed a lighting concept
for BMW that reduces lighting power consumption in the production
facilities by more than 30 percent, and which is being gradually
expanded as the new standard for the company. We were also active in university research: The team from RWTH Aachen used our
automation components in their “Counter Entropy House” to achieve
one of the highest honors at the “Solar Decathlon Europe 2012” in
The new HVAC macros for the WAGO-I/O-SYSTEM demonstrate
that standardization, ease of operation, and energy efficiency are
not excusive at all. They provide specialists with ready-to-use solutions allowing them to perform a wide variety of applications at the
push of a button. Expensive programming falls by the wayside because individual adaptation is carried out using parameter settings.
Solutions like these, paired with your good ideas and creativity, provide the best conditions for a “successful harvest”!
It is in this sense that I wish you the best of times while reading
WAGOdirect building!
Best regards,
Karl-Heinz Sanders
Manager of Market Management Building Automation
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WAGO’s newly developed lighting concept reduces lighting power
consumption in BMW production facilities by more than a quarter
Focus on user-friendliness: The area-oriented software can
be called up and parameterized using any type of Internet
browser – additional programming is now superfluous.
■ For decades, BMW has been a household name among car and
motorcycle enthusiasts alike, and now the same holds true for building and automation engineering experts. While the first group associates the brand with innovative motors and vehicles, the latter thinks
of a new lighting control system, which lowers the energy costs of
the popular Munich-based company by around 30 percent. BMW
is gradually expanding this solution based on WAGO components
to make it a company-wide standard as part of its sustainability
Environmentally responsible action is only really effective when
both sides of the coin are taken into account: the product itself,
along with its entire development process. BMW is an automotive
manufacturer that places priority on ecological and social aspects;
as such, the company has been a permanent member in the “Dow
Jones Sustainability Group Index” since 1999. And to ensure that it
will also remain on the stock index for companies exercising sustainable business practices in the future, the Munich-based company is
continuously working on programs for active energy optimization.
■ Building Lighting under Scrutiny
One such measure even applies greater scrutiny to the existing lighting technology in the production facilities. This project was undertaken even though substantial optimization had already been achieved
recently in this sector using a new central I&C system. This included,
among other improvements, switching off the main lighting in the
production facilities during idle times. Likewise, BMW was already
employing the possibility of switching off individual phases in the
three-phase power bus as needed. However, without making any
changes to the busbars, which were installed with traditional electronic ballasts, the potential for savings was soon exhausted.
A quick glance at the lighting plan from that time sufficed to show
management how far the lights were from the desired optimum:
All lights had been planned based on the reduction in luminosity
that would occur as the lights aged. However, because the technical expense for frequent manual adjustment would have been too
costly, and the technology necessary for automatic adjustment had
not yet been developed, the lights were installed from the beginning with significantly over-designed luminosity. This was the only
means for ensuring that the lighting intensity, required by the pertinent standards, would still be achieved at the predefined time for
maintenance. This concept inevitably resulted in inefficient lighting,
as energy consumption was unnecessarily high.
■ User-Friendly and Area-Oriented Concept
The next logical step, after upgrading the central I&C system, was to
modernize the hardware at the automation level. In fact, this required
a solution that could be used both in newly constructed production
facilities, which are equipped in the field with DALI and EnOcean,
as well as in retrofit projects, in which BMW planned to retain the
existing, conventional technology. The fact that the two technologies,
i.e., old and new, could be easily combined was one reason that
Jörg Tratzl, the electrical systems planner responsible, ultimately decided on components from WAGO. Another reason was the particularly user-friendly handling for controlling I&C operating devices that
WAGO developed for BMW.
The new lighting distribution system is not only up-to-date from a technical standpoint, it also puts special focus on the needs of the end
customer: In contrast to the lighting distribution systems used previously, the electrical installation specialist does not have to perform
any complicated programming during commissioning or during his
everyday work. Instead, the area-oriented software can be adapted
to individual needs using only the parameter settings – and this via
the graphic user interface provided by any Internet browser. This
saves time on the one hand and also eliminates the need for additional expertise, which results in significant reductions in both energy
costs and the expenses associated with engineering. The basis for
this are the WAGO-I/O-SYSTEM 750 ETHERNET Controllers, which
are installed in the local control cabinets in the production facilities
with I/O modules for DALI, EnOcean, as well as standard analog/
digital inputs and outputs. From there, they control each and every
electronic ballast.
This allows the lighting to be automatically dimmed according to the
lighting schedule. This achieved the first noticeable savings in energy
costs, which were generated while simultaneously complying with
stringent operating standards. A further advantage is also achieved
using DALI: Instead of having to activate entire circuits, so-called short
addresses are used to control each individual light. The individuality
achieved thereby allows the short addresses to be assembled into
groups. Thus, virtual rooms can be depicted on the display using
WAGO’s Web visualization, which – just like physical rooms – can
be autonomously regulated. For the BMW production facilities, this
means that lighting can be optimally adapted for construction work
or building re-assignment with only a few clicks of the mouse.
Lighting energy reduction by more than 30%
Commissioning and adjustment without any
Parameterization via Internet browser saves
time and requires no additional expertise.
Locally automated: The ETHERNET Controller for
the WAGO-I/O-SYSTEM 750 and all necessary
I/O modules are accommodated in the local control
cabinets in the production facilities.
■ Automated and Integrated Workflows
The lighting distribution boards standardized by BMW have proven
themselves in more than 100 installations at a wide range of locations within the corporate group. Simple configuration of the WAGO
control system via an Internet browser has reduced the commissioning time for each lighting distribution board from several days to only
a few seconds. Relays can be installed or removed with just a few
turns of the hand using pluggable sockets. “This, of course, also reduces costs during ongoing operations, as the maintenance work can
be performed much more quickly,” explains Jörg Tratzl.
Replacement of the hardware is, however, the only activity that still
needs to be performed manually at BMW, stresses the electrical
systems planner: “Since the WAGO ETHERNET Controllers communicate directly with the plant management software, we have been
able to practically perfect this workflow: The exact position of defective lighting is reported, operating hours counters are reset after replacement of the components, and the brightness levels are adjusted
Text: Jürgen Pfeifer, WAGO
Photo: WAGO
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Building Automation on the iPad
■ Low energy consumption was one of the main goals that Günther Heumann pursued when he was planning his new corporate
headquarters. At the same time, he wanted to demonstrate modern building automation to his customers. A WAGO ETHERNET
Controller and an app for the iPad form the basis of the building
The new corporate headquarters for Elektro-Service Heumann
GmbH offers Managing Director Günther Heumann and his ten
employees 400 m² of office and storage space. During planning,
special focus was placed on guaranteeing an optimal climate in
the space while maintaining low energy costs. Thus, for example,
the south-facing facade is nearly all glass, so that the sun warms
up the rooms during the colder seasons. Blinds ensure that the
temperature does not climb too high in the summer.
A wood-fired furnace with an output of 14.5 kW provides the
building with warm-air heat if the solar radiation alone is not sufficient. In cold weather, a cross-stream heat exchanger uses the
At the corporate headquarters for Elektro-Service Heumann
GmbH, the company demonstrates how versatile building
automation can be.
exhaust air to warm the supply air so that very little energy is
required for heating. It is also possible to cool the rooms using the
supply air. To accomplish this, flat collectors were located under
the parking garage, which use a brine pipeline and a heat exchanger to cool the supply air.
■ Central Control of the Air Conditioning
Günther Heumann uses the WAGO-I/O-SYSTEM with the 750-881
ETHERNET Controller to automate climate control. The ETHERNET
Controller adjusts the supply and exhaust air flaps in the individual
rooms, the cross-stream heat exchanger, the ventilator motors, the
heating, the pump for cooling, and the SMI drives for the blinds. Temperature sensors in the rooms provide the current actual value; the
controller compares this to the value set by the user in order to adjust
the flaps of the ventilation accordingly. The WAGO-I/O-SYSTEM
thus controls and regulates the entire climate control. Günther Heumann and his team created the CODESYS programming themselves
in accordance with IEC 61131-3.
Lighting energy reduction
Parameterizing and visualization of the
building automation using an iPad
Control of HVAC, lighting, video monitoring,
and the Bose multi-room sound system
All building automation functions can
be programmed and operated easily
using an iPad.
■ Light, Sound, and Video Monitoring
The building automation at Elektro-Service Heumann is also supposed to fulfill another important requirement: The company would
like to demonstrate to its customers what is possible using this type
of solution. To achieve this, all systems were supposed to be incorporated into the central automation if possible. Thus, in addition
to HVAC for individual rooms, the WAGO controller regulates the
lighting via a DMX bus, and also controls video monitoring and a
Bose multi-room sound system. Touch-panel controls in the individual
rooms transmit user inputs to the automation technology using EnOcean wireless technology. Special sensors in the window handles
also communicate via EnOcean; signaling the controller whether the
window is open, tipped, or closed.
the “AmbientRC” app, created by Günther Heumann, provides an
overview of the current status of the building automation – the current electrical power consumption for the entire building is depicted,
among other things. To display the building automation information
on the iPad, the controller generates the appropriate xml files and
stores them on the internal Web server. The app then visually displays the information on the iPad.
Company owner Heumann is completely satisfied, “From the lighting control through the blinds to the incorporation of sound systems,
the WAGO ETHERNET Controller offers a lot of possibilities that we
have exploited here in our own building.”
Text: Detlef Holfelder, WAGO
Photo: Elektro-Service Heumann, WAGO
■ Operation via iPad
However, the highlight of the entire automation system is the user
interface on the Apple iPad. The user can program all automation settings centrally and call up all functions individually. At the same time,
controller and numerous interfaces communicates with all building automation components.
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The WAGO-I/O-SYSTEM 750 in conjunction with 1around 70 percent of the otherwise standard capit
■ Energy efficiency and sustainability ensure significantly lower operating costs, even in building technology. However, the initially higher capital costs
spook many owners away from intelligent building
technology. The “1-wire” project at the Berlin MICClinic clearly demonstrates that costs are already
dropping, even for investments in innovative technology.
The clinic for Minimally Invasive Surgery (MIC) in
Berlin Zehlendorf wanted to renovate and modernize
48 rooms distributed over two floors of the of their
current, older building. Every room was to be made
energy efficient and provided with HVAC that was
both individually adjustable and could be simultaneously centrally controlled and monitored. So-called
1-wire technology was employed, which transports
the electrical supply as well as transmission and reception data over one wire. If needed, an additional
electrical supply for specific sensors can be incorporated using a ground wire. It is possible to connect
multiple sensors via one wire.
“With the help of a programmable ETHERNET controller, we were able to centralize the climate controls into one easy to operate control that includes all
pumps, chillers, and valves, as well as the automation
and monitoring of heating, cooling, and shading. We
already saved around 70 percent of the usual capital
costs during construction by using both 1-wire technology and WAGO’s automation solution,” confirms
Marco Puchalski, CEO of the leading project partner,
TPN Service GmbH & Co. KG.
■ Capital and Operating Costs are Reduced
Single-wire technology involves a very simple bus
system using only a single microcontroller pin and
simple configuration. Since 1-wire sensors are already being used on a large scale and at low cost
per unit (e.g., in mobile data acquisition units), the
costs for the clinic project could be significantly reduced by around 70 percent. Using a corresponding interface for the WAGO controller, all necessary
measured values can be acquired, while integrating
any switch program, independent of manufacturer.
Up to 60 sensors can be connected and processed
using a single 1-wire module. A standard telephone
cable with a protective extra-low voltage of 5 V
suffices for connecting to the 1-wire sensors, which
again avoids expensive cabling and installation
Error signaling integrated into the sensors indicates
faults in the cable connection or in the hardware,
among others. A display visualized on a Web server
is used for operation instead a classic, building control system. Thus, any PC or mobile device with a
browser is sufficient to control the system, even remotely.
An additional aspect in reducing the capital costs
was the flexible use of the WAGO controller. Inexpensive standard pumps could be combined with a
reasonably priced rotational speed control and regulated using the 750-881 ETHERNET Controller. 50
percent of the acquisition costs were saved up front
by not purchasing high efficiency pumps.
There were special challenges presented by the
cooling ceiling: According to the manufacturer’s
guidelines, the dew point must be constantly monitored in order to carry out a safety shutdown, if necessary. Instead of installing relatively expensive and
difficult to maintain dew point sensors, the WAGO
controller calculates the dew point using sensor data
about air temperature, humidity, and air pressure. To
prevent condensation from forming, each individual
room can be shaded or the flow temperature can
be increased. Depending on the season (heating
or cooling operations) the controller autonomously
adds an offset value to the system in order to compensate for changes in temperature perception.
-wire technology saved the MIC Clinic in Berlin
tal costs
“We have a reliable cooling system that is guaranteed to be germfree, and which is both energy efficient and easy to operate,” reports
Dr. Omid Abri, Medical Director at the MIC Clinic.
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A display visualized on a Web server is used for operation instead
a classic, building control system.
■ Controlling the Systems via Web Browser
Other performance requirements included the regulation of the radiators already existing in the building, the integration of wind and
rain monitoring, and overriding the current fire alarm system so that
all shading systems automatically rise during an emergency, or the
pumps for the cooling ceiling automatically switch off when the pressure drops.
A special challenge in integration was presented by the various shading systems present, such as Venetian blinds, fabric awnings, and interior curtains with the electric motors, as well as the wireless connection
of the skylights with the shades. Since each blind has a different, specific sensitivity to wind, and the awnings have to be retracted during
rain, individual programing was essential. This had to be as flexible
as possible, for example, to automatically close the curtains at dusk.
All requirements could be implemented using the WAGO controller.
CODESYS (Controller Development System) was used as the development environment for the programmable controller. This program has
established itself as the standard in the field of automation technology,
is relatively easy to use, and is supported by WAGO’s ready to use
program modules and application examples. CODESYS visualization
is rendered “Web compatible” by using the integrated Web server for
the ETHERNET controller.
“We already saved around 70 percent of the usual capital costs
during installation by using 1-wire technology and WAGO’s automation solution,” confirms Marco Puchalski from TPN Service
GmbH & CO. KG.
A significant energy savings potential can be realized using a demand-actuated climate control shading for each individual room.
■ Investments Pay Off
“The project at the MIC Clinic is a good example of how investing in
intelligent building technology can quickly pay for itself. Both 1-wire
technology and WAGO’s automation solution are very powerful
and have a decisively good cost-benefit ratio,” states Marco Puchalski about the project results. He also highlights the flexibility and the
scope of services. According to his experience, even complex datetime controls can be set using a simple Web operation. “We are very
satisfied with the technical equipment for air-conditioning the patients’
rooms. We have a reliable cooling system that is guaranteed to be
germ-free, and which is both energy efficient and easy to operate,”
confirms Dr. Omid Abri, Medical Director at the MIC Clinic.
Text: Stephan Lampe, WAGO
Photo: MIC Clinic, WAGO
The 1-wire technology in conjunction with
the WAGO-I/O-SYSTEM is a solution from
TPN Service GmbH & Co. KG.
BACnet/IP - The Building Automation Controller
New solutions for complex or large applications
via high-performance CPU
Easy controller data back-up via SD card for
BACnet/restore functionality
External trend data storage and Web visualization on SD card
• BACnet Building Controller (B-BC) Device Profile
• Freely Programmable to IEC 61131-3
• Integrated Web Server
• Highly Modular I/O
• Supports SD Card
• 2-Port ETHERNET Switch
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The WAGO-I/O-SYSTEM 750 assumes center stag
ge in RWTH Aachen’s “Counter Entropy House”
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The WAGO-I/O-SYSTEM 750 forms the communication and control center for the building.
■ The ingredients: WAGO’s modular control technology, a hearty
serving of good ideas, a large dollop of creativity, some technical
skills, fresh university knowledge, and a lot of endurance. The results:
One of the highest awards at the “Solar Decathlon Europe 2012”
goes to the “Counter Entropy House” built by the team from the
RWTH Aachen. This “decathlon of endurance” took place in Madrid for the second time, with 20 groups competing this year. Visitors experienced life in the future under the Spanish sun.
“There was nothing here. The house was created in an empty facility at the Jülich Research Centre,” Julian Kremeyer narrates the
project’s history while observing the construction process on the
frame house, designed for occupancy by two people, with a certain tension. If anything is missing, it has to be ordered. There is no
small parts storage here for screws, connectors, or tools in order
to facilitate the work. Pioneers have always had to do more with
less. Julian Kremeyer studied engineering at the RWTH Aachen,
not far from the Jülich Centre, and is the team member responsible
for ensuring that the building automation truly does deliver what
was promised during planning.
The “Counter Entropy House” is visually dominated by the overhanging, rectangular roof. With almost 150 square meters of surface, it optimally uses the maximum buildable area, as determined
by the competition rules, and serves as a solar energy collector in
addition to its usual role as protection from sun and rain. The actual living spaces evolve from the space defined by the roof, and
extend for a total dwelling area of 72 square meters.
■ Total Regenerative Package
The use of completely new methods for heat dissipation, dehumidification supported by sorption, as well as classic water storage improved by phase change materials, form the foundation for
the actual energy concept. In order to configure the solar energy
inputs to be as efficient and sustainable as possible, solar thermal
modules were used in addition to thin-layer photovoltaic cells. A
regenerative heat recovery system and intelligent controlling devices help to keep the heat losses in the house to a minimum and
to round out the energy efficient design.
For WAGO, all of these appeared as good reasons for supporting
the project with technology and applications support, in collaboration with on-site system partners.
What they created in an old brick building at the Jülich Research
Center will become, after its completion, a positive energy building, with a sustainable, energy-optimized life cycle at its core. Specifically, this means that the production of the components, their
transport to the site, and their eventual disposal, were all considered individually, and as a whole.
■ Control Taps Savings Potentials
Against this background, the complete building automation is designed such that it taps the energy savings potentials to the greatest extent possible and thereby simultaneously offers the maximum
living and operating comfort. A central role was assigned to the
WAGO-I/O-SYSTEM 750. First, all of the conventional signals
– from the ventilation system through the air conditioning up to
heating and hot water – were collected using standard I/O modules. Then, the PLC was directly connected to the KNX network.
Finally, the whole was designed so that the entirety of the technology could be comfortably controlled using an iPad. For the
WAGO-I/O-SYSTEM 750, it made sense to bring all of the functions and technical systems into one communication track, in this
case, ETHERNET. One of the engineering students explains, “In
our house, building automation morphs into the home office and
flows into entertainment, including sound control.”
■ iPad Operation
During their project, the students determined that customers specifically search for modern solutions; for instance, they keep watch
for iPad apps for building automation. By this means, light, sound,
blinds, temperature, ventilation, and heating can be controlled in a
way that is simple, cost-efficient, requires no additional wiring, and
is visually much more stylish. The alternatives would have involved
separate room operating devices, switches or buttons, which would
have then required holes or slits in the walls for their installation.
The WAGO-I/O-SYSTEM 750 also offers a web-supported visualization interface for more ease of use. “We’re only using this for the
house commissioning,” according to Kremeyer, “the residents will
use applications specially adapted as apps.” Aside from a purely
operational function, the WAGO solution is assigned the task of collecting data from the sensors in order to eventually centrally evaluate it. In the end, the “Counter Entropy House’s” level of energy
efficiency can only be proven using numbers and graphs.
Text: Thomas Schaaf, WAGO
Photo: Tobias Schell, Kai Kasugai, WAGO
Maximum degree of freedom for communication interfaces
WAGO-I/O-SYSTEM scores with its integrated
Web-based display
Programming that is configured so flexibly that
continuous adaptation is possible.
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■ There are a lot of concepts for energy-efficient industrial and
commercial buildings. However, the combination of modern automation, energy, and building technology found in the company
headquarters for leitec® Gebäudetechnik GmbH is something
quite different. It is not only aesthetic, but with its 400 m³ ice
bank, it is also especially efficient.
The building, located in between Göttingen and Erfurt in Heiligenstadt, is visually attractive and simultaneously a model
for the use of energy and resource saving technologies. Three
primary elements are interconnected: an extraordinary energy
design (including ice bank, photovoltaics, and heat pump), an
efficient heating and ventilation design, and exemplary controls
using an innovative, building automation that crosses disciplines.
“Our building was constructed in 2011 as a center for modern
energy and building technology and has served as a reference
project ever since. Whenever we show this building to customers, we can usually count on interesting projects as a result,”
reports Bernd Apitz, CEO of leitec® Gebäudetechnik GmbH.
■ Innovative Engineering Technology
The building is completely supplied with heat and electricity
without the use of any fossil fuels. On the 1200 square meter
roof, more than 900 photovoltaic modules annually generate
around 100,000 kWh of electricity – enough for use in the
building, as well as generating an excess to feed into the grid.
The large roof surface also serves as a collection point for the
thermal energy needed in the building. A thermal absorption collection system was installed between the photovoltaic elements
to capture thermal energy. This energy is then fed to a 400 m³
ice bank. The capacity of this robust and relatively inexpensive
storage is sufficient for a period of 60 days without solar energy.
The functionality of the ice bank is based on the fact that as
much energy is used to phase transition water from a cold liquid
to solid ice at zero degrees Celsius as is needed to cool hot water from 80 degrees Celsius to zero. The thermal energy stored
is sufficient to heat the entire building in winter and to cool it in
the summer.
■ Efficient Heating and Ventilation Design
The building is equipped with underfloor heating. For the offices, however, leitec® had something different in mind. “By using individual room control for lighting, heat, and ventilation,
we can save a lot of energy while still increasing the comfort
of our employees,” explains Bernd Apitz. To accomplish this,
we installed a new type of low-temperature radiators in the offices, which output two to three times as much heat and are
approximately five times as effective as conventional radiators
of the same style. Controlled by CO2 and presence detectors,
the rooms are heated very quickly when an employee enters the
office to their individually adjusted comfort level. In addition, a
ventilation system supports the effective regulation of room air
conditioning and ensures the offices remain cool in the summer.
Bernd Apitz calculates the energy savings associated with heating to be 40 to 50 percent.
■ Building Automation Across Disciplines
The lighting, heating, ventilation, electrical, and security systems
are comprehensively controlled using the WAGO-I/O-SYSTEM
750. The WAGO-I/O-SYSTEM serves as the global connection
piece between the various disciplines and their bus protocols,
such as BACnet, LON®, and KNX, and can thus simultaneously
ensure heating and ventilation, an on demand illumination control, blind regulation that is sensitive to weather, and the connection of the safety system with the heating functions.
Numerous automated functions in the building regulation ensure
high energy efficiency for the entire leitec® building. An important element is the automated room control. If, for example, an
employee opens a window, then the radiator is automatically
shut off and the ventilation is regulated using a motorized ventilation damper. Corridor lighting is controlled using movement
No consideration of the final fieldbus was required for the
field-side wiring of the I/O modules. Due to the modularity
of the WAGO-I/O-SYSTEM 750, any combination of digital/
analog inputs and outputs is possible. ETHERNET serves as the
automation medium. The KNX/EIB world is connected to the
ETHERNET using the KNX IP controller. Thus, conventional sensors and actuators as well as complex connections to DALI (Digital Addressable Lighting Interface), for the control of the lighting,
or to SMI (Standard Motor Interface), for control of the blinds,
can be inexpensively integrated.
Using DALI modules, individual lights and entire lighting groups
can be centrally controlled, and configuration data can be regulated and stored. In addition, sensors for brightness measurement and presence detection, for example, can be integrated
into a DALI network. All electrical data from the supply network,
from the actual consumers to the values of the heat pumps, is
continuously detected using 3-phase power measurement modules for on-going energy monitoring and management.
No consideration of the final fieldbus was required
for the field-side wiring of the I/O modules. Due to
the modularity of the WAGO-I/O-SYSTEM 750, any
combination of digital/analog inputs and outputs is
The leitec® building is visually attractive and is a model for the use of
energy and resource saving technologies. Electricity is generated using
photovoltaic modules and thermal energy, which is generated by a thermal absorption collection system on the roof, and then fed to an ice
“By using individual room control for lighting, heat, and
ventilation, we can save a lot of energy while still increasing the comfort of our employees,” explains Bernd
Apitz, CEO of leitec® Gebäudetechnik GmbH.
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■ Flexibility for Individual Solutions
This type of building automation is distinguished by high flexibility
and for unusual and innovative solutions, according to the point
of view of the CEO of leitec®. Of particular relevance is the open
programmability according to the IEC 61131-3/CODESYS Automation Alliance. Bernd Apitz has had good experiences with
WAGO’s open I/O system. The independence from specific fieldbus types and the large number of available interfaces has vastly
simplified the integration of the various disciplines. The modularity
of the technology was very convincing for him. Since the electronics are incorporated into the module, it is easier to exchange a
module than to switch out an entire actuator. Finally, the availability of several modules from industrial automation technology
and also the cost-benefit ratio were very attractive. The CEO of
leitec® also mentions the constant availability of his WAGO contact person.
leitec® plans to use its positive experiences with automation, energy, and building technology for additional expansions of the
design in the future, for example by integrating eMobility or wind
energy. Bernd Apitz considers his company to be well positioned
for supplying the growing demand for intelligent controls in private residences.
Text: Karl-Heinz Sanders, WAGO
Photo: fotografie-grimm-leinefelde,
leitec, WAGO
The heating and ventilation design saves
40 to 50 percent of the heating energy
The cross-discipline building automation
includes heating, ventilation, lighting, and
Flexible due to fieldbus independence
and large variety of interfaces
In the leitec® building, one communication network connects the entire
building. The WAGO-I/O-SYSTEM serves as the global connection
piece between the different disciplines and their bus protocols, like BACnet, LON®, and KNX.
The new WAGO components for the universal lighting connection
system means Linect® leaves no desires unfulfilled.
■ The newest components from WAGO’s Linect® portfolio: 294 Series
Linect® Lighting Connector, WINSTA® Linect® T-Connector for threephase current applications, and Linect® Connector for pluggable lighting connection in conventional installations.
■ Linect® Connectors for Three-Phase Current
WAGO’s new Linect® Connectors for three-phase current applications
now provide easy plug-in connection of lighting systems with threelevel circuit topology. This simplifies and expedites lighting installations
in shopping centers, sporting facilities and more. The new Linect® connector from the WINSTA® MIDI family provides a pluggable lighting
connection. It accepts conductor cross sections up to 4 mm² (AWG
12) and a maximum nominal current of 25 A. Therefore, this new connector is ideally suited for long cable runs that are commonly used in
large-scale projects.
WAGO has developed the matching counterpart for the lighting industry: The new 5-pole Linect® Lighting Connector. It is designed for
standard connection of solid, stranded and fine-stranded conductors
with cross sections ranging from 0.5 mm² to 2.5 mm² (AWG 20–14).
The maximum nominal current is 24 A. The 294 Series Linect® Lighting
Connector is available with a variety of ground contacts. A snap-on
type strain relief plate is also available.
■ Pluggable Lighting Connection in Standard Installations
The Linect® Pluggable Connector is part of a standard pre-installation.
Linect® luminaries are simply plugged into the finished installation so
that opening the light fixture is no longer required. This makes changing the lighting fixture a “snap” for maintenance work or later application changes. No interruption of the electrical circuit is necessary.
The 3-pole Linect® Connector is protected against mismating and is
equipped with CAGE CLAMP®S connection technology. Any type
of wire (solid, stranded and fine-stranded) with cross sections up to
2.5 mm² (AWG 14) can be accommodated. The maximum nominal
current is 24 A.
In addition to designers, electricians, and wholesalers, light manufacturers will also benefit from the new Linect® Connector. In Scandinavian countries, for example, Linect® lights can be quickly installed using a SCHUKO connection kit.
294 Series 5-pole Linect® Lighting
Connector for three-phase current.
Also designed for three-phase current: The 5-pole Linect® T-Connector, available with A Coding and
white housing.
Text: Stephan Albrecht, WAGO
Photo: WAGO
Linect® Pluggable Connector (7706229): Standard installation with
pluggable lighting connection.
direct building
Parameterizing instead of programming: ready-made system m
■ In order to realize an energy-efficient building, mature building
automation is necessary. In the fields of heating, ventilation, and air
conditioning, which are especially important with regard to energy
consumption, WAGO has made libraries available to their customers that include ready-made system macros. Expensive programming
time can often be skipped when libraries are used. The use of system
macros like these can contribute to standardization and thus to cost
Around 40 percent of the energy used in Germany is consumed
by buildings. Due to increasing energy costs, energy efficiency in
buildings plays an increasingly important role. The DIN EN Standard 15232 defines four energy efficiency classes (A to D), which
represent a method for measuring a building’s energy efficiency.
In addition to the design of the main body of the building and the
technical systems used, automation technology and the corresponding software exert an enormous influence on energy efficiency.
The fields of heating, ventilation, and air conditioning (HVAC) are
of particular interest in relation to energy consumption, as they
consume a relatively large proportion of the building’s energy
needs. Buildings with a high energy efficiency can be certified
according to various standards. Among the most important are
the Australian “Green Star,” the German DGNB, the French HQE,
BREEAM in Great Britain, as well as LEED and “Green Globes” in
the USA.
WAGO provides extensive HVAC libraries
free of charge
Pre-made system macros replace expensive
programming through the use of simple
Initialization takes place using a Webbased user interface
macros ensure standardization and contribute to cost reductions
■ Planning Lays the Foundation
Planning for the technical equipping of a building forms an important foundation for energy-efficient building operation. One
basic requirement is that everyone who participates in the construction shares a common and clear language. Foundations for
this can be found in the Construction Tendering and Contract
Regulations (VOB), the Association of German Engineers (VDI)
3814, and DIN EN ISO 16484-3. However, nothing is said as
yet in the guidelines and standards about the components that
are to be used. This applies for equipment as well as for hardware and software for automation.
In technical building services, there exist a multiplicity of protocols and interfaces, via which the individual components can be
addressed. In addition to simple analog and digital inputs and
outputs, BACnet, MODBUS, LON®, MP-bus, KNX, EnOcean,
and DALI are all well represented in the market, as well as numerous others. In larger commercial properties, a mixture made
of different protocols and bus systems is often used simultaneously. Therefore, there is a need for automation hardware that
can operate all protocols and interfaces in one system, as far as
possible. The WAGO-I/O-SYSTEM 750 is the hardware solution
to meet this challenge. The controller, which takes on control
tasks for the automation solution, can be easily expanded using
various system modules, so that almost any devices can be connected to the system.
■ From Planning to Implementation
The controllers, which use CODESYS Soft PLC, are programmed according to the IEC Standard 61131-3. WAGO has made a comprehensive HVAC library available to their customers in the fields of heating, ventilation, and air conditioning, so that their customers do not
have to do the programming themselves. For many common applications, there are suitable system macros, which the user only has to
configure. After the user has entered data points and system parameters, the ready-made application can be directly commissioned. Complex programming is thereby avoided, which can lead to significant
cost reductions for starting up systems and the re-use of macros simplifies standardized solutions.
Customers can obtain the HVAC system macros free of charge from
the company’s homepage. Even complex applications, such as cascade control using cross-flow heat exchangers and frequency regulated fans, are available in the library. Additional function blocks,
which allow easy expansion of the available macros, are likewise included in the library.
Initializing the application takes place using a Web-based user interface. The user can set parameters using the interface and carry out
any additional configurations of the application. A visualization display is also possible without requiring a large programming expenditure. A Web-server is integrated into the controllers, which graphically
depicts the building services, showing the current parameters of the
different systems and enabling operation. The only thing that the user
has to supply is a standard Web browser. Ideally, WAGO’s operating
panels from the PERSPECTO® Series can also be used here.
■ Bottom Line: System Implementation without Programming
Energy-efficient building automation succeeds only with modern automation systems, which integrate all disciplines within a commercial property,
to the greatest extent possible. The HVAC fields play a central role in relation to total energy consumption. Using WAGO’s components and systems for building automation and the appropriate, ready-made applications, which are available at no charge in the HVAC library, the user can
implement an energy-efficient building automation system without excessive programming costs. The visual display of the completed building
automation is also automatically generated to a substantial extent using
the integrated Web server.
Text: Karl-Heinz Sanders, WAGO
Photo: © PantherMedia/Fabian Schmidt, WAGO
direct building
Certified “Maintenance-Free”
■ Compact splicing connectors are commonly used in electrical installations for connecting wires with one another. Compact splicing
connectors that employ Spring Pressure Connection Technology, i.e.,
connectors which do not require the use of any tools, can be installed
extremely quickly. Connections implemented in this manner are pernament and stable. WAGO’s 222 Series Compact Splicing Connectors are the first in the world to be certified according to the British
Standard BS 5733 mf as maintenance-free.
The 222 Series is the first choice among many installers when it
comes to implementing reliable electrical connections easily and
quickly. One of the major advantages of the 222 Series is that finestranded wires can also be connected without first having to prepare the wire ends, meaning that soldering or crimping on of ferrules is not required. This saves quite a bit a time in practical use.
■ High Degree of Reliability during Installation and Operation
These compact connectors are well-suited for wire sizes up to 4 mm2
(AWG 12) and are designed for nominal currents up to 32 A. This
enables these connectors to be used for wiring of low-voltage lighting, which normally carries a relatively high current. The 222 Series
also offers 100% touch-proof protection, both during assembly and
operation. As the wire insulation extends fairly deep into the connector, a minimum distance of 4 mm is always maintained between
the exposed surface and live parts, reliably ruling out any risk to
The quality of electrical contact is also of vital importance for a
compact connector. Depending on the amperage, poor contact,
i.e., high resistance, can result in smoldering of the housing in a
worst case scenario. The funneled wire entry hole of the 222 Series
ensures that, even for fine-stranded wires, all single strands are inserted into the clamping unit, for a secure connection. Once the
spring clamp has ensured proper contact, it is of course essential
that this contact remain permanent. A number of factors, such as
temperature fluctuations, relative humidity or aggressive industrial
atmospheres, can have an impact on the contact. WAGO placed
particular focus on these influences in the development of the 222
Series. This is why these connectors are constructed of high-quality
and high-grade materials.
■ Maintenance-Free - Defined for the First Time in a Standard
Compact splicing connectors such as those of the 222 Series are
subject to numerous standards requirements, such as the UL 486C
and IEC 60998 series of standards. Requirements for maintenancefree electrical connections are defined in Great Britain in the BS
5733 standard. This specification of maintenance-free components
is unique throughout the world. Since WAGO attached great importance to long-term connection stability in the development of the
222 Series, it was decided to conduct certification of the connectors
according to the BS 5733 standard. Besides long-term electrical
connection stability, this standard also describes other influences
which electrical connections must withstand, such as vibrations, thermal loading and short-term overloading.
■ Certified as “Maintenance-Free” by Dekra to BS 5733
WAGO contracted the Dutch testing institute Dekra in Arnheim for
the certification of the 222 Series, where tests as prescribed in the
BS 5733 standard were conducted. This included testing of longterm stability, vibration resistance and behavior under overcurrent
and thermal loading conditions. The 222 Series passed all of the
tests with flying colors. Dekra has thus confirmed that the 222 Series meets the requirements set forth in the BS 5733 standard and
that it is maintenance-free for the applications defined by the standard.
Certification of the 222 Series provides decisive benefits for installation. For example, the compact splicing connectors can now be
used in locations that are not accessible for maintenance work on
conclusion of installation, i.e., non-accessible locations. A typical
example of this are the electrical installation locations in buildings
that are subsequently plastered over or covered by wall paneling.
The British BS 5733 standard only allows components that have
“maintenance-free” certification to be used in such locations.
Up to now, only soldered or crimped connections were permitted for use at these locations and these required a considerably greater amount of time for installation. Now, after
certification of the 222 Series Compact Splicing Connec-
tors, users can use these to easily and quickly install connectors for
these types of installations.
Even though this standard is valid only for the British market, this
certification demonstrates that the quality and level of reliability of
WAGO’s 222 Series Compact Splicing Connectors are exceedingly high — something that users throughout the world can benefit
Text: Andreas Brettschneider, WAGO
Photo: WAGO
Suitable for all wire types
High degree of reliability during installation and operation
Certified “maintenance-free” based on
BS 5733
direct building
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WAGOdirect building March 2013
Torsten Schimanski
(responsible editor)
Phone: +49 (0)571 887-531
+49 (0)571 887-8531
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