B-I/O-nade: everything bio with I/O

The new filling system from Bionade Abfüll GmbH consists of components from many manufacturers. The WAGO I/O SYSTEM ensures smooth cooperation among these components.

Due to the unrivaled success and cult status of their all-natural and organically manufactured beverages, Bionade Abfüll GmbH had a need to dramatically expand their capacities in a short time frame. In order to limit the costs, used components were implemented. After a purchasing spree throughout Europe, a filling system was built in Ostheim, Germany, with a capacity of 35,000 bottles per hour. The trick for this project was to provide the individual sections of the plant with one common control system. "Here, only a concept that could be adapted to all particularities in each phase of the project was helpful," recalls Matthias Hansmann, head of the Bionade electrical workshop. Martin Husslein, from Husslein Controls & Automation Ltd. & Co. KG in Eltmann adds, "The WAGO-I/O-SYSTEM was, and is, ideal for us. I am able to add whatever I need. When I need more I simply plug in more. We have never yet had to set a second node because one was full."

It quickly became clear that none of the common bus protocols would fulfill all technical and economic requirements of the patchwork filling system. The decision was therefore taken to implement a Profibus/CanOpen combination configuration throughout the system. Communication between the machines was accomplished via Ethernet. An exception was the palletizing, for which there was a recently written S7 program for the neighboring line. For this Profibus application, both the WAGO-I/O-SYSTEM 750 and the IP67-protected components of the 755 Series are used. The I/O system was rounded out with Series 788 and 859 optocouplers and relays.

A 16 mm² thick equipotential bonding conductor is installed parallel to the bus line to prevent and EMC-induced faults. If the bus line is applied, e.g., upcircuit of the field bus nodes, the equipotential bonding conductor is routed directly next to it via a WAGO ground conductor terminal block, which automatically maintains the connection to the DIN rail. The bus cable itself has a WAGO 790 Series screen clamping saddle. This allows the screen to be laid directly in front of the field bus node, to keep the section of the line that is prone to faults to a minimum. At the same time, the line is supported mechanically.

Besides the WAGO rail-mounted terminal blocks for conductor cross sections up to 16 mm2, the WAGO X-COM-SYSTEM, a combination of rail-mounted terminal blocks and plug-in connectors, is also installed in the system as well. New, low-priced Japanese frequency converters that have no integrated plug-in assembly are equipped with this system. In the event of a failure, these components can be replaced rapidly and without any risk of wiring errors.