Electrical and Automation Specification

Specifications for Machine
Automation Systems
Document Version Tracking
Version History
Specifications for Machine Automation Systems
Version Date Changes and Description
V.0.1 10 April 2018 Preliminary release
Machine Automation Specifications

V0.8, preliminary release 12/20168 2
Table of contents
Table of contents
1 Overview ............................................................................................................. 4
2 General requirements........................................................................................ 5
2.1 Supplier responsibilities........................................................................ 5
2.2 Documentation ..................................................................................... 5
2.3 Push button and light column ............................................................... 6
3 Machine specific standards .............................................................................. 8
3.1 Machine topology ................................................................................. 8
3.2 Human Machine Interface .................................................................... 9
3.3 Programmable Logic Controllers (PLC) ............................................. 10
3.4 Motion Controllers .............................................................................. 12
3.5 Variable Frequency Drives ................................................................. 13
3.6 Motors................................................................................................. 15
3.7 Safety ................................................................................................. 16
3.8 Plant Data Interface (PDI) .................................................................. 17
3.9 Power Monitoring and Management .................................................. 20

1 Overview
1 Overview
Introduction
This document represents an electrical technical specification for machines and
utilities designed for FNUL.
It is based on an architecture and standard to have a Plant Data Interface (PDI) to

facilitate and implement in the near future, systems for line monitoring, automatic
KPI calculation and MES connectivity for lines, processes and utilities of the plant.
Objectives
The specification is intended to provide the minimum acceptable standards for a
supplier to follow when supplying equipment to FNUL .
The objective is to have a high degree of standardization of hardware and software
components to optimize on spares and inventory costs, and ultimately reduce total
cost of ownership (TCO) during the operating life of the machines and process.
Rationale of this Specification is to achieve uniformity in the systems:

 to maximize transparency, quality and energy efficiency.
 to reduce the costs of new installations, maintenance and spare parts.
 to reduce integration time and costs.
 to provide basic information for consultants, contractors, suppliers.
 to maximize and harmonize safety of the electrical installations.
 to provide information for technical personnel.
CAUTION All exceptions to this document must be identified in writing to the project
manager and will not be considered acceptable until approval is granted.
If deviations from standards are deemed necessary, the supplier must submit in
writing to the project manager a list of deviations with detailed reasons.
Deviations shall not be considered acceptable until approval is granted.

2 General requirements
2.1 Supplier responsibilities
Overall requirements
1. This specification is intended to provide the minimum acceptable standards for a
supplier. The supplier is required to furnish any information not covered by this
specification which the supplier feels is necessary for the equipment to operate
properly, safely, and in conformance with project requirements.
2. Equipment, panels, assemblies, etc. must be completed before delivery and
must not require any field fabrication other than to connect external elements
such as power, air, dependent external controls, or connections between
equipment.
3. All electrical materials, enclosures, and assembly must be equal to or exceed
the requirements of this specification and the minimum requirements of all local
laws and international standards.
4. Where a conflict exists between this document and the local code, the local code
shall prevail. It is the supplier’s responsibility to obtain a copy of the local code
and to adhere to it.
5. The project manager reserves the right to inspect project equipment and to
observe an operating test of the supplier-furnished electrical equipment prior to
shipment. Failure to exercise this right will not relieve the supplier of any of its
responsibilities to provide a well-engineered, reliable, and safe piece of
equipment/system.
6. All electrical devices and components must be installed according to
manufacturers’ specifications.
2.2 Documentation
1. The supplier shall furnish the following documents in electronic format:
– Software programs
– Installation manuals
– Maintenance manuals
– Description of operation
– Spare parts listing
– Drawings
2. Other documentation shall be supplied in a standard Microsoft Office or Adobe
Acrobat (PDF) formats.
3. The list of recommended spare parts shall clearly show supplier descriptions,
supplier part numbers, component vendor names, component vendor part
numbers, and norm description in EXCEL.
4. All documentation shall be supplied to the responsible corporate engineer, or
designee, at the following project phases and in the required languages:
– Preliminary drawings and documentation: One copy in English
– Construction and commissioning drawings and documentation: One copy
in English , one copy in the project country language

Construction and commissioning

1. Construction and commissioning documentation shall include:
– Equipment installation manuals
– Equipment operation manuals
– Parts listing for equipment and systems
– Software programs
– Description of operation for each piece of equipment
– Description of operation for system or line
2. Construction and commissioning drawings shall include:
– Power wiring schematics
– Electrical layout—line schematic showing locations and identifiers for all
motors, sensors, solenoid valves, control panels and operator stations, or
any other electrical component/device
Built documentation and drawings

1. Final documentation shall include all documents and drawings required for the
Preliminary and Construction/Commissioning phases, and final documentation
shall be corrected to as-built specifications.
2. All final documentation shall be placed in hard binders.
2.3 Push button and light column

1. “Normally open” types of photo eyes, sensors, or switch contacts must be used
in all applications unless a fail-safe operation is needed.
2. Sensors and photo eyes must have integral LED indication of switch activation.
3. Push button and light column have to be LED type.
Pilot devices
1. Push buttons, pilot lights, selector switches, etc. must have a diameter of 22
mm and NEMA 4X for all applications.
2. All pilot devices must be 24 VDC.
Stack light columns

1. Stack lights must have a diameter of 70 mm.
2. In all applications, colors and the sequence of colors must conform to those
shown in the picture. The same colors are also specified for visualization and
HMI systems. When stack light columns are mounted vertically, red is at the
top and white is at the bottom.

Color Meaning Description and operator task Light Signal

Emergency Hazardous condition. Static Bit[0]
Red Immediate action to deal with hazardous Flashing Bit[1]
condition (e.g. switch off energy supply).
Abnormal Abnormal condition impending critical Static Bit[2]
conditions.
Yellow Monitoring and/or intervention (e.g. by Flashing Bit[3]
reestablishing intended function).
Mandatory Indication of a condition that requires an Static Bit[4]
Blue operator action.
Flashing Bit[5]
Normal Normal condition Static Bit[6]
Green Flashing Bit[7]
Neutral Other condition; may be used whenever Static Bit[8]
White doubts exist about the implementation of
Flashing Bit[9]
RED;YELLOW,BLUE or GREEN
3. The colors red and green are mandatory, all others are optional. Machines
where additional colors would be useful should provide them.
Emergency buttons
1. Emergency Stop push buttons must be located on each operator station and
control panel. Other locations shall also have Emergency Stop push buttons
installed, as deemed necessary.
2. Depressed Emergency Stop buttons must be independently identified on the
HMI screens.

3 Machine specific standards

3.1 Machine topology
Overview
This section will describe the basic machine topology from an electrical system
point of view. Each segment has a similar requirement, whether that segment is a
machine such as Filler or Packer or an entire process such as the Water Process.
Within this specification, each segment or unit will hereinafter be described as a
“machine.”
1. Each machine will consist of a selection of components that must have a high
level of standardization in order to accomplish the following objectives:
– Minimize Training
– Minimize spare parts
– Assure technical compatibility of all components to allow for the access
and routing of data
– Simplify the replacement of damaged or failed components
2. Communication networks above the PLC shall be PROFINET (Ethernet
based).
3. Communications networks below the PLC / Motion Control shall be PROFINET
(PROFIBUS DP with Project Manager approval)
4. Communication busses, together with the choice of components, shall have
the following capabilities:
– Access to diagnostics
– Access to peripheral devices
– Ability for remote access via networks
5. Two different machine topologies are specified

a. machines with small number of IP addresses
b. machines with large number of IP addresses
Machine Topology with small number of IP addresses

Machine Topology with large number of IP addresses
6. It is intended to facilitate remote access in future by a scheme such as shown

below with the SINEMA Remote Connect server and clients.
3.2 Human Machine Interface

Machine HMI
The primary purposes of a Machine HMI are for visualization and control of a
machine and for access to visualization screens and information stored on a Line
Server of a system, which may be installed in future. Therefore, OEM-specific HMI
must have the capability to exchange data with the PLC and with a Line Server.
Machine visualization and control must be able to be maintained locally in the
event connection to the Line Server is lost.

1. HMI must be capable of local machine visualization and control.

2. Some HMI (tbd. with Project Manager) must be able to connect with the Line
Server where additional visualization and information is accessible such as
Line Overview screens, Help files, etc. (PC based HMI, Internet Explorer for
WEB client functionality). Latest client software has to be installed.
3. HMI must be able to switch between local machine visualization and control as
well as Line-Server visualization (PC based HMI).
4. Visualization application software must be SIMATIC WinCC.
5. Machine PLC and Machine HMI must be connected directly to a monitored
Ethernet switch, which will be mounted within the machine control cabinet.
6. OEM visualization must be installed on the Machine HMI.
7. Machine PLC to Machine HMI connections must have local communication via
Industrial Ethernet.
8. Machine HMI-to-Line Server connections must have web client communication
via Industrial Ethernet.
9. Machine HMI shall have Smart Server functionality to enable access and
visualization by another HMI or PC with a web browser.
10. Machine HMI screens shall preferably follow the User Interface Style Guide.
11. In order to ensure hardware and software standardization, machine HMI must
be limited to the following models only and programmed in the TIA Portal
engineering software
a. Simatic HMI TP900 Comfort Inox

b. Simatic HMI TP1200 Comfort Inox
c. Simatic HMI TP1500 Comfort Inox
d. Simatic IPC 277D 19” Inox Pro for support arm mounting
3.3 Programmable Logic Controllers (PLC)

Overall requirement
1. PLC hardware and software must be the latest versions available at final
design acceptance.
2. The vendor shall supply all PLC-controlled systems fully programmed and
ready to operate.
3. PLC systems must consist of the following components:
– CPU with integrated PROFINET port
– Memory card
– Power Supply
– Input/Output Modules (I/O)

4. The I/O equipment in the PLC configuration may be local, expansion, or

distributed.
– Expansion / Distributed I/O must be connected to the main processor via
suitable interface modules (IM).
– Distributed I/O must be of ET200SP series
5. The I/O structure must provide a minimum of 10% spare rack capacity for
future expansion needs. The I/O structure must maximize the use of distributed
I/O.
6. I/O modules must have a minimum of 10% spares available at the time of site
acceptance. In the event of an additional I/O requirement within the
commissioning period (prior to site acceptance), the OEM or equipment
supplier shall add the additional I/O.
7. In order to ensure hardware and software standardization, machine PLC
CPU’s must be limited to the following models only and programmed in the
TIA Portal engineering software
a. Simatic S71200, CPU 1217C, DC/DC/DC
b. Simatic S71500, CPU 1513-1PN
c. Simatic S71500, CPU 1515-2PN
d. Simatic S71500, CPU 1517-3PN/DP
8. Scalance Switches provided in the machines must be limited to following
models only. Where applicable, it is mandatory to use Key plug to store
configuration data
a. Scalance X208
b. Scalance X204IRT
c. Scalance S615
d. Scalance XM416-4C
PLC software
The controller generation SIMATIC S7-1200 and S7-1500 offers with the TIA Portal
efficient options of programming and configuration. To create an optimal program
regarding technical possibilities and consistency, it is recommended to use the
Programming Guideline and Programming Styleguide for S7-1200 and S7-1500.
1. Single PLC programming software tool must be capable of configuring I/O as

well as communication parameters and network components.
2. PLC programs must be written and documented in English.
3. Each PLC station and HMI shall be created, configured, and programmed in a
single TIA project.
4. Individual TIA projects shall be combined into a single, all-encompassing
integrated system/line project.
5. Programs must have the ability to be backed up. The backup must be possible
without the use of a password or other restriction. (Backing up a file does not
mean viewing or editing of software.) All programs must be able to be
automatically restored from backup.
6. Program logic shall not be password protected. No protection against CPU
change.
7. Final archived projects shall be stored on PLC memory cards.

8. The memory space available - after downloading the entire configuration,

program, and archived project - must not exceed 20% of the total memory card
capacity.
9. The OEM or the equipment supplier shall provide a ‘first-out’ fault word that is
in standard integer format. This word captures the first fault that causes the
machine to go down, and that fault will be maintained until all faults are cleared
and the machine is ready to run.
10. All fault logic must be located in a single program function.
11. For Diagnostics all controller shall activate the WebClient.
3.4 Motion Controllers

Overall requirement
Motion Control Systems must be of a compact, drive-based system, which
combines PLC, Motion Control and Technology functionalities. The integrated PLC
in accordance with IEC 61131-3, will support control and of motion the whole
machine. HMI devices can be connected via the integrated Ethernet interface for
operating and monitoring.
1. Motion Control hardware and software must be the latest versions available at
final design acceptance.
2. All Motion Control Systems must be fully programmed and ready to operate.
3. Motion Control Systems shall consist of the following components:
– Integrated PROFINET port
– Power Supply extern
– Interface Module (IM)
– Expansion I/O
4. The I/O equipment in the Motion Control configuration can be local, expansion,
or distributed.
– Expansion / Distributed I/O must be connected to the main processor via
suitable Interface Modules.
– Distributed I/O must be of ET200SP series
5. I/O structures must provide a minimum of 10% spare rack capacity for future
expansion needs. The I/O structure must maximize the use of distributed I/O.
6. I/O modules must have a minimum of 10% spares available at the time of site
acceptance.
7. The equipment supplier shall individually wire all Motion Control Systems to
terminal strips located inside the local control panel. Field wiring shall also
terminate on these same terminal strips.
8. In order to ensure hardware and software standardization, motion controllers
must be limited to the following models only and programmed in the TIA Portal
engineering software
a. Simotion D425-2 DP/PN
b. Simotion D435-2 DP/PN
c. Simotion D445-2 DP/PN

Motion Controller Software

1. The Motion Control Programming software shall be capable of being operated
through the TIA Portal engineering software.
2. The Motion Control programming software must be capable of configuring I/O
as well as communication parameters and network components.
3. Motion Control programs must be written and documented as outlined in
section supplier responsibilities.
4. Each Motion Control station shall be created, configured, and programmed in a
single project.
5. For diagnostics all controller shall contain Webserver functionality.
6. Program logic shall not be password protected.
7. Final archived projects shall be stored on Motion Control Systems memory
cards.
8. The memory space available—after downloading the entire configuration,
program, and archived project—must not exceed 20% of the total memory card
capacity.
9. A ‘first-out’ fault word that is in standard integer format must be used. This
word captures the first fault that causes the machine to go down, and that fault
will be maintained until all faults are cleared and the machine is ready to run.
10. All fault logic must be located in a single program function.
3.5 Variable Frequency Drives

Variable Frequency Drives (VFD) and Soft Starters (SS) control the operation of
connected motors over a wide range of speeds, matching the motor shaft torque
and speed characteristics to the application. Variable Frequency Drives are
preferred over Soft Starters due to enhanced starting and stopping characteristics.
Variable Frequency Drives and Soft-Starts can be used in three types of
applications:
 Standard Drives
 Servo Drives
 Soft-Starters
Standard Drives
Standard Drives (SD) are used when external speed or positioning feedback is not
a concern. They are used in simpler applications such as:
 Conveyors
 Pumps
 Fans
 Compressors
 Single main drive units

Servo Drives
Servo Drives are used when external speed or positioning feedback is a concern.
They are used in applications when you need:
 Drive shaft position synchronization
 Highly dynamic response requirements
 Torque control
Soft Starters
Soft Starters are used when starting and stopping motors to control electrical surge
currents and mechanical stress. They do not provide speed control.
Hardware
1. Operating temperature will range from nominally 0°C to 40°C (32°F to 105°F).
Any specific location may require de-rating for extreme temperatures.
Humidity, max. 95% at 40°C. condensation and icing not permissible.
2. Variable Frequency Drives must be supplied with input line filters that are
appropriate for the installed environment. Due to the variance of environments,
each site will have to be evaluated for necessity of filtering. Power filtering may
be needed for two reasons:
– Suppression of incoming voltage spikes, harmonics, or other disturbances
and surge suppression of equipment following brownouts or blackouts.
– Requirement for Electro Magnetic Disturbance or Electro Magnetic
Interference (EMI). Depending upon the class of suppression required, the
use of specialized filtering might be required.
3. Centralized motor control devices must be mounted in control cabinets with
following functionality:
– Where applicable, braking energy recovery through active infeeds
– Where applicable, buffering/balancing of power in a common DC bus
system
– Preferably, no introduction of harmonics to the power network. In any case
Harmonics must be within regulatory limits.
4. Decentralized motor control devices are exposed to the same environment as
the motors and should only used for motors with long distances to the cabinets.
Supplier must submit to Project Manager to use decentralized concepts.
– Levels of protection for motor control devices will be more severe and are
defined in section on Specific Area Requirements.
– Decentralized solutions require a motor disconnect switch between the
motor control device and the motor, as defined in section on Motors.
5. To ensure hardware and software standardization, use of Variable frequency
drives with onboard PROFINET ports shall be limited to the following series
a. Simotion with Sinamics S120 for Servo applications
b. Sinamics G120C / G120 for general purpose or standard applications
c. 3RW series for soft starters

Software
1. Drives must be connected to their controlling PLC / Motion Controller via
onboard PROFINET ports
2. Drive parameters must be saved and archived for future reference. Parameter
data must be archived or stored using the following methods:
– Method 1
Most drives facilitate the use of flash memory cards. The use of memory
cards is recommended due to ease of use. Should the drive suffer
catastrophic failure, the flash card may be compromised. For this reason, it
must not be used as the only backup.
– Method 2
Drives connected to PLCs via networks must use the configuration tool
SINAMICS Startdrive / Starter. This method allows parameter storage on
PCs or on the Line Servers.
Use of passwords for the purpose of remote diagnostics or access is prohibited.
3.6 Motors
1. DC motors are not allowed unless specific permission is asked for and granted
by the project manager.
2. For all applications, the use of IEC-specified motors is preferred over NEMA-
specified motors.
3. Motors for conveyors and applications requiring cycling with direct on line
(DOL) operation must have a minimum service factor of 1.15. Geared Motors
must have minimum service factor of 1.5 of DOL.
4. The insulation class of motors must be class F.
5. Motor size which over 7.5 kW should be at least start by soft/start.
6. To avoid damage of the bearings by possible bearing currents, isolated
bearings must be used with IEC motor sizes ≥ 55 KW when supplied by an
inverter.
7. The motor housing must be selected for the environment in which it will be
operating (e.g. wash-down, severe environment).
8. A stranded copper insulated ground wire shall be terminated at each motor and
originate from the motor control panel.
Descriptions and applications

Motors may be split into three basic, differing areas of application:
 General Purpose Motors
used for general-purpose applications. They are typically squirrel-cage
induction motors with standard windings built to IEC specification. These
motors are normally suitable for use on main supplies or for inverter operation.
a. Selection of a suitable motor considering the application and
environment is the responsibility of the OEM / system integrator.
b. Motors shall preferably be ordered with 50 Hz 230 VD/400 VY 60Hz
460 VY winding
c. the efficiency class of the motors must be at least IE3
o

 Specialized / Servo Motors

used for specialized applications. They are typically servomotors, positioning
motors, etc. These motors may have a special winding and may not be suitable
for use on main supplies.
a. Selection of a suitable motor considering the application and
b. Motors with water-cooling are not allowed.
 Hazardous Area Motors

Hazardous Area Motors are typically squirrel-cage induction motors with
adapted windings and construction to specialized standards.
a. Due to the limited scope of their application in the typical facility and
their specialized nature, Hazardous Area Motors will be selected on an
as-needed basis.
b. Selection of a suitable motor considering the application and
3.7 Safety
1. Safety circuits shall be based on codes as described in chapter on Supplier
Responsibilities as well as the suppliers’ preferences, which shall be
determined by their system requirements.
2. The system supplier is responsible for implementing an adequate safety
solution.
3. Machine zones that are deemed dangerous during operation shall be guarded.
4. Emergency stop when depressed, shall illuminate, activate a PLC input, and
activate an emergency stop routine.
5. Emergency Stop circuits shall not automatically restart the equipment when
deactivated.
6. Emergency Stop push buttons must be wired in series. The activated push
button must illuminate when the push button is depressed. Each push button
shall be connected to a separate PLC input to indicate when it has been
activated.
7. Emergency Stops shall override automatic, hand, and jog modes.
8. Guard door safety switches shall be individually wired to separate PLC inputs.
9. Safety systems can be implemented by the use of Siemens safety relays and
hardwired system
10. If necessary, following Safety functions have to be Integrated into the Motion
control system:
– STO - Safe Torque Off
– SBC - Safe Brake Control
– SS1 - Safe Stop 1
– SS2 - Safe Stop 2
– SOS - Safe Operating Stop
– SLS - Safety Limited Speed
– SSM - Safe Speed Monitor

3.8 Plant Data Interface (PDI)

Data interfaces are for systems, lines, and machines to exchange communication.
Data interfaces do not affect a machine’s internal communication.
Plant Data Interface standardization is based upon existing standardization
committee’s: (Approval by Project Manager).
It is mandatory for every filling / packaging machine to comply with and

provide the Plant Data Interface as below. For other areas, e.g. Process and
utilities, interface shall be provided in consultation with the project manager.
Additionally, possibilities also exist for the extension of data interfaces for additional
functionality. Refer to the document
86302104_FuB_LineIntegration_PDI_OMAC_DOC_en.pdf
1. Machine PLC’s and the Line Server shall communicate via PROFINET or
Industrial Ethernet. The Server will read information by using the standardized
Data Blocks, as described in PDI (Plant Data Interface).
2. Current process data shall be accessed directly or via OPC interfaces.
Plant Data Interface

The PDI is provided below. For detailed description of the interface, refer to the document
86302104_FuB_LineIntegration_PDI_OMAC_DOC_en.pdf
Group Name Type OMAC Mandatory Description

(Interface
description)
Status.PDIVe PDI version info. “PDI V2.0.0” fix

Status rsion STRING[10] for this implementation
Status.Projec
Status tVersion STRING[10] Project specific version
Status.UnitM Values indicates the current unit
Status odeCurrent DINT mode ID
Status.State Machine state ID related to the
Status Current DINT machines state model
Describes the set point for the
Status.Mach current speed of the machine in
Status Speed REAL primary pieces/minute
Status.CurMa Value of the current machine
Status chSpeed REAL speed in primary pieces/minute
Status.Equip Indicates that the downstream
mentInterlock machine is not producing or
Status .Blocked BOOL transfer is blocked
Status.Equip Indicates that the upstream
mentInterlock machine is not producing or
Status .Starved BOOL transfer is blocked.

Status.Param Machine powered up time

Status eter0.Value DINT accumulated in hours
Status.Param Consumed electrical energy in
Status eter1.Value REAL kWh
Status.Param
Status eter2.Value DINT ProductRatio in primary pieces
Status.Param 1=depacker, 0=packer: Packer
Status eter3.Value BOOL will be default
Status.LightS Represents the machine light
Status tack DWORD stack with different color levels
Admin.ProdP Counter of products (good +
rocessedCou defective) by the production
Admin nt[0].Count DINT machine.
Admin.ProdP
rocessedCou Accumulated counter of products
nt[0].AccCou processed (good + defective) by
Admin nt DINT the production machine
Admin.ProdD
efectiveCount Counter of products rejected by
Admin [0].Count DINT the production machine.
Admin.ProdD Accumulated counter of products
efectiveCount rejected by the production
Admin [0].AccCount DINT machine.
Max value of machine speed in
primary pieces/minute in the
Admin.Mach installed environment based on
Admin DesignSpeed REAL currently processed product.
Machine Stop Reason is used
Admin.StopR for“First Out Fault” Stop Reason
Admin eason.ID DINT MessageID (OMAC RC)
Admin.StopR OEM specific Message
Admin eason.Value DINT Identification Number
Standard Libraries
For communication between machines and to the line overview, there are existing
libraries for all listed controllers available.
1. Predefined libraries for standard communication and functions with core data
points.
2. Functionality of data points must be compliant to the interface description.
3. If additional data points are required, machine specific interfaces may be
generated in addition to the standard PDI (Approval by project manager
necessary).
4. Data interface to the line has to be implemented and tested by the machine
builder.
Libraries and source code will be provided from the project manager.

OMAC Standard
OMAC (Organization for Machine Automation and Control) has standardized the
Packaging Machine Language called PackTags — and the operating Modes and
States in packaging machinery.
1. Mode State Manager:

Packaging State & Mode – control the modes and operational states of a
machine.
2. Data interfaces shall:

– Provide the core data required for all known requirements like visualization
and maintenance.
– Be capable for future adaptation to changing requirements.
3. Data interfaces must allow:
– Machines to be clustered for common visualization
– Common data format for the processing and correlation of data
– Common standard for any machine-to-machine control
Light Stack Information

1. Light Stack information for machine status visualization in the line/plant
visualization (refers to chapter Stack Light Columns).
2. The machine light stack easily indicates the machine state on operators view.

Color Meaning Description and operator task Light Signal

Emergency Hazardous condition. Static Bit[0]
Red Immediate action to deal with hazardous Flashing Bit[1]
condition (e.g. switch off energy supply).
Abnormal Abnormal condition impending critical Static Bit[2]
conditions.
Yellow Monitoring and/or intervention (e.g. by Flashing Bit[3]
reestablishing intended function).
Mandatory Indication of a condition that requires an Static Bit[4]
Blue operator action.
Flashing Bit[5]
Normal Normal condition. Static Bit[6]
Green Flashing Bit[7]
Neutral Other condition; may be used whenever Static Bit[8]
White doubts exist about the implementation of
Flashing Bit[9]
RED; YELLOW, BLUE or GREEN.
3.9 Power Monitoring and Management
Overview
Power monitoring allows the capturing of power information so data can be
processed, stored and monitored. Power information is captured by PLC’s from
meters and monitored in a server (to be installed in future) that will initiate alarm
conditions when power quality does not meet system demands.
Metering Concept
From a top down approach the metering shall be installed in following levels:
- Plant level
- Department level, like production, packaging, administration
- Process level, like mixing or filling
- Key equipment, like compressor, steam production, refrigeration
For the first three levels all consumables and energies shall be acquired e.g.
- Electricity
- Natural gas
- Steam
- Refrigeration
- Pressurized air
- Water & wastewater
- Nitrogen N2, Hydrogen H2, Carbon Dioxide CO²

1. Power meters shall only be mounted in the Low Voltage System (400V to 480V
nominally) power.
2. Power Monitoring requires two components:
3. Power Monitoring Meters. Meters shall be installed with the machines and utilities
although the monitoring and management system may be installed later.
4. Server archiving Power Monitoring data(to be installed later)
5. Power Monitoring Systems must be connected to Industrial Ethernet with connectivity to
plant networks. The meter must be capable of supplying data by Profinet to a PLC
which is connected to the power monitoring server.


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Specifications for Machine

Machine Automation Specifications

Machine Automation Specifications

It is based on an architecture and standard to have a Plant Data Interface (PDI) to

Rationale of this Specification is to achieve uniformity in the systems:

Machine Automation Specifications

Machine Automation Specifications

Construction and commissioning

Built documentation and drawings

2.3 Push button and light column

Stack light columns

Machine Automation Specifications

Color Meaning Description and operator task Light Signal

Machine Automation Specifications

3 Machine specific standards

5. Two different machine topologies are specified

Machine Topology with small number of IP addresses

Machine Automation Specifications

Machine Topology with large number of IP addresses

6. It is intended to facilitate remote access in future by a scheme such as shown

3.2 Human Machine Interface

Machine Automation Specifications

1. HMI must be capable of local machine visualization and control.

a. Simatic HMI TP900 Comfort Inox

3.3 Programmable Logic Controllers (PLC)

Machine Automation Specifications

4. The I/O equipment in the PLC configuration may be local, expansion, or

1. Single PLC programming software tool must be capable of configuring I/O as

Machine Automation Specifications

8. The memory space available - after downloading the entire configuration,

3.4 Motion Controllers

Machine Automation Specifications

Motion Controller Software

3.5 Variable Frequency Drives

Machine Automation Specifications

Machine Automation Specifications

Descriptions and applications

Machine Automation Specifications

 Specialized / Servo Motors

 Hazardous Area Motors

Machine Automation Specifications

3.8 Plant Data Interface (PDI)

It is mandatory for every filling / packaging machine to comply with and

Plant Data Interface

Group Name Type OMAC Mandatory Description

Status.PDIVe PDI version info. “PDI V2.0.0” fix

Machine Automation Specifications

Status.Param Machine powered up time

Machine Automation Specifications

1. Mode State Manager:

2. Data interfaces shall:

Light Stack Information

Machine Automation Specifications

Color Meaning Description and operator task Light Signal

3.9 Power Monitoring and Management

Machine Automation Specifications

Machine Automation Specifications

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