Smart Grid Master Plan

nosejasonElectronics - Devices

Nov 21, 2013 (3 years and 7 months ago)


New Standard for electrical safety
in hospitals
Mining technology fit for the future
Innovative shearer loader for safe and highly
efficient coal mining operations
No revolution without standards
Smart Grid Master Plan
Bender visualisation and communication solutions for buildings
COMP460IP has never been so convenient and user-friendly
MONITOR | 2/2012
For decades, Bender has been known for developing, producing and delivering special solutions to meet
particular customer requirements. In line with this tradition, over the last few months we have made good
progress on the development of a special ISOMETER
for electro-mobility and photovoltaics and a new
system and plant protection (NS protection) system. I am pleased to be able to announce the market
launch for these devices for spring 2013.
At the same time, we have decided to provide our customers with a series of devices which measure cur-
rent and voltage quality and energy. The fi rst devices in our new PEM range (power quality and energy
management) are presented in this edition and are available to order now. The range of devices will also
be launched by the spring.
There is another special application in the form of our ATICS
automatic transfer switching devices with
built-in ISOMETER
for operating theatres and intensive care units, which we launched a year ago. On
23/10/12, I accepted the DEKRA Award in the safety category on behalf of all the staff. The jury praised
the uniqueness of the safety standards - including with respect to this particularly critical application.
Last but not least, we are proud of the fact that the production
department in Grünberg has moved into our new production
building. All employees and their families were invited to the
opening party on 17 June. In the evening, we watched Lars
BENDER score the winning goal against Denmark. So a twofold
cause for celebration for Bender. We are sure that the new pro-
duction site will help us improve our high quality standards still
further. To make sure you can benefi t from this, we have been
giving a fi ve year warranty on all our products since the beginning
of the year (
Dear Reader,
Dirk Pieler
Bender GmbH &Co. KG.
Londorfer Straße 65
35305 Gruenberg/Germany
Fon: +49 6401 807 - 0
Fax: +49 6401 807 - 259
E-Mail: info
Editorial staff:
Marita Schwarz-Bierbach
Anne Katrin Römer
Graphic & layout:
Natascha Schäfer,
Timothy Hörl,
Bender Archiv, S!Designment Archiv,
bendersystembau Archiv, Eickhoff GmbH
Bochum, DEKRA Stuttgart, CADOLTO GmbH &
Co KG Cadolzburg, Henrich Publikationen GmbH, ag visuell, N-Media-Images,
zhu difeng, psdesign1, Rohrbach + Schmees
Planungsges. mbH Gießen, Bundesnetzagentur Bonn

Druckhaus Bechstein, Wetzlar, Germany
2/2012 |
Reliable statutory and regulatory
boundary conditions required for engineers
Standards – sounds very dry, has nothing to do with
the industry in practice and nothing at all to do with the
energy revolution!? Wrong. The experts in the German
Commission for Electrical, Electronic & Information
Technologies of DIN and VDE (VDE|DKE) know better ...
No revolution
without standards
Page 04
Smart Grid Master Plan
New standard for the supply of electrical power
to medical locations – International collaboration, the
implementation of European contracts and, of course,
increasing economic globalisation make it necessary to
subject standards to an international comparison and in
this way to make them effective across borders ...
Electrical safety
in hospitals
– the European way
Page 10
Smart Grid Master Plan –
No revolution without standards

All in one: safe – compact – user-friendly
Bender receives DEKRA Award 2012 in “Safety” category
New Standard for electrical safety
in hospitals
isoPV425 and isoEV425:
New compact insulation monitoring devices
Network and system protection compliant with the standards
(decoupling protection) using the new VMD460 from Bender
Dirty electrical power
Bender visualisation and communication solutions:
COMP460IP has never been so convenient and user-friendly
Mining technology fi t for the future:
Innovative shearer loader 24
for safe and highly effi cient coal mining operations
Fault location within a shorter space of time but
longer maintenance intervals: Residual current monitoring
in German Red Cross Blood Donation Headquarters in Ulm
Forward-looking Bender fi nal assembly works
in Gruenberg starts production
Safely switching and distributing electrical power in
industrial production processes: bendersystembau GmbH
Enhanced safety in the world's largest wheel loader
Professional quality and reliability lead to success
GHV Trading – 13-year distributor of the company Bender

Cadolto – Company portrait 38

High-tech modular hospital and laboratory buildings
EXHIBITIONS 2012/2013 41
Exclusive interview with Dipl.-Ing. Helmut Muhm 42

Head of the T-MTS Bender GmbH & Co. KG

Cadolto is the world's leading specialist for the
construction of complex, technically demanding build-
ings using modular construction techniques ...
Page 38

High-tech modular hospital
and laboratory buildings
MONITOR | 2/2012
2/2012 |
Standards – sounds very dry, has nothing to do with the industry in
practice and nothing at all to do with the energy revolution!? Wrong.
The experts in the German Commission for Electrical, Electronic &
Information Technologies of DIN and VDE (VDE | DKE) know better.
No revolution without standards
The standardisation organisation is requesting a "Smart Grid Master Plan" from politicians.
Dr. Bernhard Thies, spokesman for the senior management of the DKE, has called for a reli-
able statutory and regulatory framework for quick and comprehensive standardisation.
"The linking of different technologies, both familiar and new, requires standards that
guarantee the necessary functionality," Wolfgang Hofheinz, chair of the VDE|DKE and
general manager at electronical engineering manufacturer Bender, reports to ZfK
(Zeitung für kommunale Wirtschaft, a German newspaper dedicated to municipal
economic issues related in particular to energy). He also quotes from the German
Standardisation Roadmap: "The core of the frequent demands for linking of the new
distributed system components with the existing infrastructure is technical and semantic
interoperability of components from various manufacturers in different sectors of industry.
This can only be achieved by means of norms and standards."
Smart Grid

Reliable statutory and regulatory
boundary conditions required for engineers
MONITOR | 2/2012
Europe is also a player
Where is Europe in all of this? "One of the roles of the
DKE is to be involved in the standardisation brief relat-
ing to e-energy/smart grid and to represent German
interests. All specifi c national issues are generally
included in European standards," explains Hofheinz to
our newspaper. Due to the intelligence in the grid and
the communication between the devices via Internet-
based systems, it is clear to the experts that data
protection is of "tremendous importance". However,
standards for software and systems can only be for-
mulated if politicians have fi rst agreed on the basic
society requirements in terms of data protection and
security. "The necessary hardware and software are
largely available," stated DKE general manager Thies at
the DKE conference in Offenbach (10 May): "After all,
whether you are controlling a factory or a city, the task
is more or less the same in technical terms. However,
for the purpose of standardisation we need a framework
that defi nes how we can implement the technology",
the engineer explained to politicians in Offenbach.
No smart grid without standardisation
DKE annual conference: VDE standardisation organi-
sation refers to the challenges of supplying megacit-
ies with energy.
The VDE standardisation organisation, DKE German
Commission for Electrical, Electronic & Information
Technologies of DIN and VDE (VDE|DKE), called
for a "Smart Grid Master Plan" from politicians at
its annual conference held at the end of May in
Offenbach based on the motto "Smart Solutions for
a Complex World". "The ministries and departments
responsible must coordinate and agree if the energy
revolution is to succeed”, said Dr.-Ing. Bernhard
Thies, spokesman for the DKE senior management,
which is funded by the VDE. He claims that the exam-
ple of solar subsidies has clearly shown what could
happen if all the consequences of measures are not
Complex interaction
A broad range of businesses with widely varying structures
and interests (energy, automotive, IT) need to cooperate
on smart grids and agree on norms and standards. "How
can that work?", the ZfK asked Hofheinz and got a clear
reply: "The core role of standardisation work is to monitor
the different structures in German businesses and to take
them into consideration when drafting standards." Nearly
all the relevant German sectors are represented in the DKE
steering committee and have the opportunity to infl uence
the development of the standards. Examples of these
interdisciplinary activities could include the development of
standards in e-mobility or photovoltaics, where it becomes
clear that different specialist areas need to work together at
an interdisciplinary level. Hofheinz continues to say"One of
the principles of standardisation work is that all stakehold-
ers (in the case of the smart grid, the grid operators/suppli-
ers, manufacturers, consultancies, the scientifi c community,
the authorities and other organisations) are called together
around one table to draft the relevant standard within a spe-
cifi c application area and time-frame as briefed." However,
there are also other approaches, e.g. joint working groups,
where the DKE comes together with other associations in
working groups.
2/2012 |
Very limited grid construction. The grid platform of the Federal Ministry of Economics and Technology is aiming to start opera-
tion of what is known as a wind busbar between Schwerin (Mecklenburg-West Pomerania) and Krümmel (Schleswig-Holstein) by
the end of the year. The South West interconnector from Bad Lauchstädt (Saxony-Anhalt) through Altenfeld (Thuringia) is to follow
in 2015 and the connection between Osterath (North Rhine-Westphalia and Weissenthurm (Rheinland-Palatinate) in 2016. It is
already needed: the current map from the Federal Grid Agency clearly shows that there is a large gap between line construction
requirements and reality. Only a few sections have been realised. (
MONITOR | 2/2012
thought through. The German government has recognised
the value of standardisation. ”However, there is a need for
more coordination and consolidation across the board”,
Thies explained, calling for a reliable statutory and regula-
tory framework for rapid, comprehensive standardisation
in the area of smart grids. Otherwise the achievement of
the century, the energy revolution, could succeed.
Due to the intelligence in the grid and the communica-
tion between the devices (M2M) via IP-based systems, it
is clear that data protection and data security are also of
tremendous importance. However, standards for software
and systems can only be formulated if politicians have fi rst
agreed on the basic society requirements in terms of data
protection and security. The necessary hardware and soft-
ware are largely available.
„ Megacities with their millions of inhabitants are currently regarded
by the VDE|DKE as the greatest challenge for standardisation in the future. ”
Translated from ZfK Zeitung für kommunale Wirtschaft 06/2012
Editor: Gottfried Hiesinger
Megacities with their millions of inhabitants are cur-
rently regarded by the VDE|DKE as the greatest
challenge for standardisation in the future. One issue,
for example, is harmonising the generation and con-
sumption of energy via energy saving systems. It is
also necessary to ensure that energy generation also
matches local and regional consumption.
In the area of electro-mobility, the VDE|DKE has also
submitted a standardisation roadmap for shared
e-mobility across Europe. ”At voltages of up to 1000 V
in future electric cars, electric shock protection also
needs to be factored in, especially during charging”,
explains Wolfgang Hofheinz, chair of the VDE|DKE.
The newly established DEKRA Award, organised by
inspection organisation DEKRA and business news
magazine WirtschaftsWoche, highlights a different
topical issue each year in three focus categories. The
award recognises the best sustainable solutions for
future economic and social issues and rewards out-
standing performances in the categories of “Health”,
“Environment” and “Safety”. The DEKRA Award is run
under the auspices of Germany’s Federal Ministry of
Bender GmbH & Co. KG won the DEKRA Award in the
category “Safety – Focus 2012 Safety Concepts for New
Products” for its functionally safe ATICS
range of switch-
over and monitoring systems. In their announcement the
judges stated: “In its products and a submitted safety
project, Bender GmbH demonstrated a consistently sys-
tematic design. This consistency is extremely important
for safe products. This is clearly illustrated in the ATICS

product which is the world’s only safe switchover device
for hospitals.”
All in one: safe – compact – user-friendly
These devices are used wherever a safe switchover
to alternative power supplies (“emergency power sup-
ply”) is required, as in computer centres and hos-
pitals. In the medical sector in particular, stringent
demands are placed on the reliability of power supplies.
These demands are set out in DIN VDE 0100-710 and
IEC 60364-7-710 which specify power supply via two
independent feed-ins and insulation monitoring of the
non-earthed power supply (IT system) for operating
theatres and intensive care units. The compact ATICS

series of switchover and monitoring devices, which have
been consistently developed in accordance with the
functional safety specifi cations of IEC 61508 (SIL 2), is
available to perform these tasks.
The integration of the power circuitry and the electron-
ics in a low-profi le, compact device reduces the space
requirement in the switchgear cabinet, minimises the wir-
ing input and lowers the potential for faults. The patented
switching technology in the power circuitry guarantees
reliable switchover by means of mechanical and electri-
cal interlocks and a high level of dynamic strength in the
contacts. The insulation, load and temperature monitor-
ing module monitors the IT system with precision and
reports discrepancies at an early stage. ATICS
process and alarm signals to signalling modules or con-
trol systems. All events are also written to a datalogger
and are used for self-diagnosis.
This award demonstrates once again, in the words of
Stefan Köbl, Chairman of the Management Board of
DEKRA e.v., that with courageous investments and deci-
sions, the company has found answers to issues of the
future in order to make the world better and safer.
Marita Schwarz-Bierbach, S-COM
2/2012 |
MONITOR | 2/2012
Electrical safety in hospitals
– the European way
International collaboration, the implementation of European contracts and,
of course, increasing economic globalisation make it necessary to subject
standards to an international comparison and in this way to make them
effective across borders. With the appearance of the European standard
HD 60364-7-710:2012, a common basis for the supply of electrical power in
medical locations has been established at the European CENELEC level for
the fi rst time, the issue now is to implement it.
New standard for the supply of electrical power to medical locations
2/2012 |
Historical development
As early 1962 when the fi rst standard VDE 0107/12.62
"Bestimmung für das Errichten und Instandsetzen
elektrischer Anlagen in medizinisch genutzten
Räumen" (Regulations on the installation and repair
of electrical installations in medical locations) for the
hospital was published, the protection of the patient
had top priority. Starting from the specifi c situation
of the patient during diagnostic or therapeutic meas-
ures, the issue has always been to install a safe and
reliable supply of electrical power, to ensure medical
electrical equipment is safe and, last but not least,
to ensure a safe application. Nothing changed sig-
nifi cantly in this approach with the appearance of
the new DIN VDE 0100-710 (VDE 0100-710):2012
and the protection objectives and application areas
it contains.
When DIN VDE 0107 (VDE 0107) "Starkstromanlagen
in Krankenhäusern und medizinisch genutzten
Räumen außerhalb von Krankenhäusern" (High
power electrical installations in hospitals and medical
locations outside hospitals) appeared in 1994, it was
clear that this would be the last national "0107" stan-
dard. After IEC 60364-7-710:2002-11 was published
in 2002, the European standardisation body started
to prepare a draft European standard under German
leadership in 2003. The fact that this was not an easy
undertaking is demonstrated by the almost 10 years
it took for the majority of countries involved to agree
with the standard "HD 60364-7-710:2012" that is now
Changes in the contents compared
to DIN VDE 0100-710 (VDE 0100-710):2002-11
The classifi cation and signifi cance of the standard
installation regulations for locations used for medical
purposes has remained the same. It is still part of the
DIN VDE 0100 (VDE 0100) series of standards and
it is necessary to take into account all the necessary
parts of this set of standards. For this purpose, the sec-
tion numbering has been updated and adapted to suit
the current structure of the standard.
For linguistic reasons and also in parts of reasons
related to the approach, references to medical electri-
cal equipment (applied parts) are again included.
The defi nition of medical locations of groups 0 to 2
has been shortened and made more precise. However,
reference is made several times to the need for a risk
analysis during design.
The classifi cation of the supply of power is defi ned
more clearly than in the current German standard. For
the supply to the infrastructure, supply after 15 s is
correspondingly emphasised. Also the equipment that
must be supplied within 0.5 s is clearly defi ned and
However, overall there is signifi cantly less information
and data related to implementations, as a result of
which a high level of specialist knowledge is required
of those people responsible for the planning and
implementation of the electrical installation. The large
MONITOR | 2/2012
Power supply for medical locations of group 2
Areas in group 2 used for medical purposes re-
present the highest safety level. This area meets
the prerequisites for the care of patients using
complex, highly technical medical electrical equip-
ment. Protection by shutdown is avoided by using
the IT system with insulation, temperature and load
monitoring. Thereby not only is the loss of power on
a fi rst fault avoided, it is also possible to realise the
installation based on a max. permissible touch volt-
age ≤ 10 mV. Isolating transformers in accordance
with DIN EN 61558-2-15 (VDE 0570-2-15):2012-09
are required for the installation.
The technical requirements on the insulation monitor-
ing device (IMD) are now described in annex A and B
of DIN EN 61557-8 (VDE 0413-8):2007-12. For the fi rst
time equipment for insulation fault location in accor-
dance with DIN EN 61557-9 (VDE 0413-9):2009-11
number of national variations listed in the annex makes
it clear that intensive standardisation activities will need
to be continued in coming years.
Types of system earthing – TN-S systems
For the basic design of the supply of power, along
with the basic standards in the DIN VDE 0100
series, it is also necessary to take into account, e.g.,
DIN VDE 0100-444 (VDE 0100-444):2010-10. In accord-
ance with section 444.4.3.2 the TN-S system is to be
used from the start for installations in newly erected
buildings with information systems and equipment.
It is also recommended to continuously check the
effectiveness of the TN-S system by means of residual
current monitoring system (RCM) in accordance with
DIN EN 62020 (VDE 0663):2005-11.
As before in the past, in accordance with section
710.411.4 TN-S systems are to be monitored and the
responsible technical personnel informed if the insula-
tion resistance drops below a minimum value.
For this purpose there is a cross-reference to DIN VDE
0105-100 (VDE 0105-100):2009-10 "Operation of elec-
trical installations". In accordance with section 5.3.101
"Wiederkehrende Prüfungen" (Periodic verifi cation) it
is possible to supplement the periodic verifi cation with
continuous monitoring, e.g. RCMs.
Each fi nal circuit is still to be protected with a residual
current device (RCD) I
≤ 30 mA. However, from now
on it is necessary to defi ne the maximum number of
outlets (section 710.55.101) that are protected by this
(one) residual current device (RCD). In accordance
with section 710.411.3 this requirement does not apply
to medical IT systems.
2/2012 |
are listed; these devices can be used to quickly and
reliably locate insulation faults in IT systems.
In the IT system it is required that the outlets are marked
with the change-over times (0.5/15 s). The obligation to
provide information becomes a more important issue
in the medical IT system. In medical locations there
must be an easy-to-read explanation that describes
the signifi cance of all the types of signals and alarms
provided in the event of a fi rst fault. In practice, e.g.
alarm and indicator panels with plain text displays are
therefore to be favoured.
A striking change is the fact that from now on outlets
supplied from a TN-S system and protected with a
residual current device (RCD) are no longer allowed in
medical locations of group 2.
Safety power supply sources
The route from the feeder to the outlet in the group 2
area is now described signifi cantly more briefl y and
concisely. In accordance with section 710.512.1.102
the electrical supply is to be designed so that on the
occurrence of a fi rst fault, total loss of power is pre-
vented. This can be ensured, as also in the past, in
accordance with section 710.512.1.102 by means of:

Two independent supplies, or

Additional local power supply units, or

An additional electrical supply for medical
locations of group 2, or

An equivalent measure.
Electric sources for safety services and the electrical
supply system for safety services should be arranged
to where periodic verifi cation and the necessary main-
tenance can be performed without reducing the
availability or degrading the supply of electrical power
supply for safety services. The procedure for periodic
verifi cation must be prepared in close collaboration
with the medical personnel to minimise the risk for the
patient (section 710.62/710.560).
In accordance with section 710.560.6.104.1 from now
on the following are to be supplied from a power source
t ≤ 0.5 s:

Operating theatre lights,

ME equipment that contains light sources that are
imperative for the usage of the equipment, e.g.
endoscope, including the related essential items of
equipment, e.g. monitors,

Critical life-supporting ME equipment.
Other essential lights may also be sources of light for
the illumination of the area for endoscopic surgery.
Change-over devices
Change-over devices are used at various points depend-
ing on the system layout. In accordance with section
710.536.101 they must be continuously functional. This
means that for these devices not only a high degree
of intrinsic safety is required, but also regular mainte-
nance and testing are more clearly required.
In the case of automatic change-over devices atten-
tion must be paid to reliable isolation between the
DI N VDE 0100- 710 ( VDE 0100- 710):2012
New standard for the supply of electrical power
to medical locations
MONITOR | 2/2012
DANCE WI TH DI N VDE 0100- 710 ( VDE 0100- 710):2012
2/2012 |
isolating transformer for the IT system, but also a TN-S
system with a large number of loads, there is a risk
that switching actions could be triggered by a fault in
the TN-S system that could, in turn, cause problems in
the IT system and therefore interfere with a possible
surgical intervention. To prevent this situation arising,
it is appropriate to arrange a change-over device for
the safety power supply in the TN-S system completely
separate from the IT system.
In relation to the obligation to also take into account
the other parts of DIN VDE 0100 (VDE 0100), at this
point reference is made to DIN VDE 0100-557 (VDE
0100-557):2007-06 "Auxiliary circuits". Section 557.7
"Funktionale Sicherheit" (Functional safety) highlights
that, e.g. auxiliary circuits used for changing over
safety power supplies can be part of the overall
requirement in relation to functional safety in accord-
ance with the DIN EN 61508 (VDE 0803) series of
standards, and the planner must defi ne the require-
ments for the auxiliary circuit based on a risk assess-
ment (SIL categorisation).
In principle the IT system has special protection
within the concept for the supply of electrical power
for a medical installation. This aspect must be
appropriately taken into account in the design of the
electrical supply. If, e.g., after a change-over device
in medical locations of group 2, there is not only the
On the route to a European standard for the supply of electrical
power in medical locations, a major step has been taken with the
publication of HD 60364-7-710. The issue now is to complete the
implementation in national standards. No major changes are neces-
sary for Germany, instead the high level of electrical safety will conti-
nue to be retained.
Dipl.-Ing. Wolfgang Hofheinz, CTO
Dipl.-Ing. Harald Sellner T-NOR
Hofheinz Wolfgang
VDE series volume 114, 3rd edition Schutztechnik mit Isolationsüberwachung, published by VDE
Flügel Thomas
Die derzeitig gültige Norm DIN VDE 0100-710 (VDE 0100-710):2012 wird europäisch - Ausblick auf Neuerungen und Änderungen,
Belecker Fachtage 2012
New standard for the supply of electrical power
to medical locations
MONITOR | 2/2012
I SOMETER® i soPV425 and i soEV425
The devices are confi gured via the LC display and the buttons on the front, or via the RS-485 interface. The
function of the device and the correct connections to the system and to earth, as well as the coupling device,
are monitored cyclically every 24 hours or on the actuation of the Test button, and after the application of the
supply voltage. If a malfunction occurs or there is a break in the connecting wires Earth/KE or L1/ L2, the alarm
DC charging points in electric mobility are mostly confi gured as unearthed power supply
systems (IT systems); this also applies to many photovoltaic installations. The ISOMETER®
in the compact device series isoEV425 with the related coupling devices AGH-EV and
isoPV425 with AGH420 monitor the insulation resistances of the stated systems and
comply with the equipment standard IEC 61557-8. The actual insulation resistance is
indicated on an LC display.
New compact insulation monitoring devices
2/2012 |
The compact designs of the devices provide a
fl exible and cost-effective option for insulation
In practical operation this means:
• Insulation faults that occur are reliably
signalled in accordance with the standards
• Space-saving version in the 2-module enclosure
• Space-saving coupling in the 2-module enclosure
• The two devices can be mounted in different
positions in the switch cabinet or in different
switch cabinets, they are connected using 4 wires
• Direct indication of the insulation resistance on
the LC display
• Integrated alarm relay
• RS-485 interface for data transmission.
relay K2 switches and both alarm LEDs as well as the "ON"
LED fl ash. An error message is indicated on the LC display,
this information is also available via the RS-485 interface.
The isoPV425 and isoEV425 are only functional as a pack-
age with the related coupling devices. The ISOMETER

and coupling device are connected using four wires. Due
to the supply of power separate to the system monitored, it
is possible to monitor the de-energised IT system up to DC
1000 V and AC 690 V.
isoPV425 with AGH420
The isoPV425 is specially designed for small and medium
photovoltaic installations up to 300 KW. The supply voltage
is DC 18…276 V or AC 70…276 V, as such the devices can
be operated on AC 230 V or supplied from the DC 24 V
systems, which are mostly available in switchgear.
The isoPV425 can be used for the detection of undervolt-
age for voltages from 10…300 V as well as for the detection
of overvoltage 100…1000 V. The values can be adjusted by
the user to suit the installation.
Insulation faults in the system are indicated via the two alarm
relays with a common reference. The factory setting for the
response value is 6 kΩ. A fault on the positive wire is indicated
via contact 11-14, a negative fault via contact 11-24 and a
symmetrical fault via both relays. This feature is intended to
assist the user by limiting the area for troubleshooting so the
fault can be located more quickly.
isoEV425 with AGH-EV
The isoEV425 is an insulation monitoring device for DC
charging stations (mode 4 in accordance with IEC 61851-
1/CD 61851-12) for charging electric vehicles. During the
charging process the charging station takes care of the
electrical safety on both the charging station and the vehicle
coupled. The ISOMETER
in the vehicle is normally deacti-
vated in this situation.
Due to the active AMP measuring method, the DC side
of the charging station can be monitored as far up as to
the motor with AC 0…690 V without electrical isolation.
Dipl.-Ing. Frank Mehling
Insulation faults that occur are signalled via the integrated
relays, the alarm LEDs, as well as via the RS-485 interface.
Here a differentiation is made between a factory-set pre-
warning value of 300 kΩ and a main warning of 100 kΩ.
Consequently the applicable standards, application
rules and regulations covering this aspect have not only
been further developed, but have also been made sig-
nifi cantly more severe. This statement applies, among
other aspects, to the requirements on network and
system protection or decoupling protection, particularly
in relation to the safe isolation of the generation system
from the grid. Here specifi c national aspects of the elec-
tricity distribution networks must be taken into account
as described in the related standards and regulations.
Bender is already addressing this market with the volt-
age and frequency monitoring relay VMD4105. In the
1st quarter of 2013 this device will be superseded by
the VMD460. This logical further development will meet
the current requirements in the European standards;
the compact design and straightforward commission-
ing are also impressive. The VMD460 meets the spe-
cifi c requirements for different countries and system
types - the related parameters are saved in the device in
basic pre-defi ned programs.
A connection to higher-level systems can be estab-
lished via the RS-485 interface. With a view to addi-
tional standards in the future, the software can also be
updated via this interface. To counteract the risk of the
sudden occurrence of islanding, the VMD460 offers
even more reliability with islanding detection (measure-
ment of df/dt). All the messages are indicated on the
illuminated graphic display in plain text format. The
VMD460 has integrated monitoring for the detection of faults in the bus
coupler circuit-breakers. The integrated history memory stores voltage
and frequency limit infringements with date and time. The necessary
maintenance tasks are effectively supported by the information on the
last 300 distribution network faults recorded.
• Automatic disconnection device between a power generation
system and the grid
• Universal for power generation systems for safe distribution network decoupling
• Application as per
– CEI 0-21
– VDE-AR-N 4105
– BDEW regulations (Erzeugungsanlagen am Mittelspannungsnetz – Power
generation systems on the medium-voltage distribution network)
– C10/11
– G83/2
– DIN V VDE V 0126-1-1
• Straightforward commissioning by means of pre-set basic
programs for national standards and regulations
• Measuring technology with single fault safety
• Monitoring of the bus coupler circuit-breakers connected
• Islanding detection by measuring df/dt (ROCOF)
• RS-485 interface (data exchange and software update via BMS bus)
• Simulation function for the determination of the shutdown time
• The last 300 distribution network faults can be recalled with time stamp
Dipl.-Ing. Marc Euker, T-MTS
MONITOR | 2/2012
Network and system protection compliant
with the standards (decoupling protection)
using the new VMD460 from Bender
The increasing number of power generation systems installed is plac-
ing new challenges on the distribution network and system reliability.
The high portion of the installed power from power generation systems
on the low and medium-voltage distribution networks has in the mean-
time signifi cant relevance for the system.
2/2012 |
or reduced equipment service life, through increased drive
energy consumption, to system failure and the risk of fi re in
the line network. By systematically monitoring the system
quality using Bender power quality monitoring, high avail-
ability and interference-free operation of the power supply
is ensured.
Although even classic loads can cause power quality prob-
lems in the system (e. g. voltage drops when large machines
start – these result in so-called fl icker), the most frequent
problems are, however, due to harmonic components on the
electrical supply caused by electronic equipment.
In modern power distribution systems, interfer-
ence is an increasingly frequent occurrence due
to the increased usage of modern power electron-
ics. Equipment such as frequency converters,
switched-mode power supplies, UPS systems and
electronic ballasts are the cause of this problem.
These units distort the sine wave of the electrical
power and superimpose different frequencies on
it – the electrical power becomes "dirty". System
interactions also occur; these can cause interfer-
ence in neighbouring equipment in various ways.
The problem ranges from restricted functionality
Dirty electrical p wer
Fig. 1: Heavily distorted waveform
(based on typical waveform for an energy-saving lamp)
Fig. 2: Breakdown of the signal shown into the harmonic
components (up to 7th harmonic)
Fig. 3: Harmonic spectrum of the signal shown
Fourier-analysis breaks down a signal (Fig. 1) into
harmonic components (Fig. 2) and in this way pro-
vides the spectrum of the output signal (Fig. 3).
Typically there are increased third order harmonics
with many items of electronic equipment. These
(and all other 3n harmonics, that is multiples of 3)
add together in the neutral conductor.
In the extreme case the resulting current can be
greater than the individual phase currents. The
neutral conductor is overloaded, a situation that
goes unnoticed. There is a risk of fi re.
Harmonic spectrum
Distorted waveform
Breakdown into harmonics
7th harmonic
5th harmonic
3th harmonic
MONITOR | 2/2012
These phenomena and their effects are already addressed
in the standards. For instance, DIN VDE 0100-430 requires
overload detection for the neutral conductor if an excessive
load is to be expected due to harmonics.
If the recommendations in the quoted standard are imple-
mented, the destruction of the neutral conductor can be pre-
vented by the protective device tripping in time. However, in
practice this action only moves the problem elsewhere: the
risk of fi re and the risk of the destruction of the neutral con-
ductor are prevented by a shutdown. Although the operation
of the electrical installation is safe, the availability is reduced
due to the frequent downtimes.
This situation can be rectifi ed by monitoring using a power
quality and energy measurement.
The continuous monitoring of the system quality follows
Bender's basic principle: signal instead of switch. In this way
potentially dangerous situations are detected and signalled
at an early stage – this means there is enough time to take
corrective measures without the need to shut down
equipment or even the entire installation. In the exam-
ple of the monitored neutral conductor, in the event of
an overload less important loads can be shut down
via switching signals before the complete supply is
interrupted by the protective device tripping.
Power quality monitoring as a useful addition
to residual current monitoring (RCM)
By using residual current monitoring, degradations in
the level of the insulation in an installation or specifi c
installation components can be detected before a
high fault current causes protective devices to trip.
This gain in time makes it possible to take the neces-
sary measures and contributes to the high availability
of the installation. Similarly, by using power quality
monitoring, for instance to detect harmonics, a haz-
ard for the installation can be detected at an early
stage before the protective device trips.
Continuous monitoring of the residual
currents reduces risk of fi re
Overloaded N conductor and equipment
overload due to PQ effects at a glance
Installation operated with good EMC
characteristics (no stray protective conductor
currents) ensures trouble-free operation
and high availability
Energy management and PQ monitoring
linked in one device (decentral) and in one
software application (central) permit qualifi ed
evaluation of measures implemented
Permanently installed monitoring with RCM
technology permits modifi ed test intervals in
accordance with BGV-A3 and Betriebssicherhe
itsverordnung (German ordinance on industrial
safety and health)
Monitoring of the quality of the voltage
in accordance with DIN EN 50160,
EN 61000-2-2, EN 61000-2-4 and
DIN EN 61000-4-30
ÜS fehlt
2/2012 |
Power quality monitoring as a practical basis
for energy management
Power quality management provides a basis for the
energy management required in accordance with
DIN EN ISO 50001. The same measuring point that
checks the system quality is also an energy meter at
the same time. As such two important functions can
be undertaken by one device, specifi cally the energy
consumption per cost centre can be determined. In
this way high overhead costs for electrical power can
be avoided. Due to power quality monitoring the effect
of the measures taken to improve the system quality
and to reduce costs can also, at the same time, be
considered from a different point of view:
• How much energy are the measures taken against
system interaction consuming?
• What is the effect of energy-saving measures on
the quality of the electrical supply system?
Due to the double perspective of energy and quality in
one system both requirements, economic energy con-
sumption and high availability of the installation, can be
implemented in the best possible manner.
Power quality monitoring suitably scaled
In a complex installation, structural detail is crucial:
consideration by cost centre is essential for energy
management, for power quality monitoring individual
faults can only be located if the system area monitored
is clearly defi nable. And, last but not least, the usage of
different devices is also an issue of cost.
On the power feeder a PEM735 monitors the quality of
the voltage for the supply in accordance with DIN EN
50160. Transients, fl icker, harmonic components are
measured, data are logged with high resolution.
Outlets on the main low voltage distribution system
are monitored by PEM5xx devices. The sampling rate
is 12.8 kHz, as a result events that occur are clearly
discernible in the data logged.
Devices in the PEM3xx series are positioned such that
they can replace energy meters and represent cost
centres. In this way the basis for an energy management
system in accordance with DIN EN ISO 50001 is formed
and high overhead costs for electrical power are avoided.
In addition a PEM333 also provides information on the
overall harmonic content in the part of the installation
This type of confi guration of the monitoring system
ensures quick, straightforward analysis and locating if
power quality phenomena occur and the availability of
the installation is at risk.
All measured data are collected, fi ltered and evaluated
at a central point. To display this amount of information
in a manner suitable for the target group, Bender has
developed a new generation of gateways, the Condition
Monitor CP700 (available from 1st quarter 2013).
Dipl.-Ing. Sandra Schiffke, T-MTS
Dipl.-Wirt.-Ing. Michael Faust, T-MTS
MONITOR | 2/2012
Two new software options have been
added for the Bender Gateway COM460IP,
as presented in Monitor 1/2010. As well
as the existing functions such as display
of system status, adjustment of Bender
devices, system documentation and the
option to connect to Modbus/TCP, two
extended service packs are now available:
• Option pack A – Individual texts
• Option pack D – Visualisation
Option pack A
provides the option of issuing individual texts for devices
and measurement points, or even individual channels.
This means that the system view can be adapted to the
relevant situation or user. It is also now possible to send
e-mail notifi cations for alarms and system faults to differ-
ent user groups. This function can also be adapted to the
relevant application situation. There are a wide range of
settings options both in terms of timings and with respect
to recipient groups. The software also allows activation of
device failure monitoring. This function can be used both
in combination with alarm messages and with the e-mail
functions. All system device settings can be documented.
This can take place with or without current measure-
ments. This means comparing previous and actual set-
tings is very simple and clear.

has never been so convenient and user-friendly
2/2012 |
The developers of the COM460IP are not resting on
their laurels. They are continuously working on develop-
ing new functions. A 24 Volt version of the COM460IP is
already available (Part no. B95061020), with the same
software functionality, of course.
The COM460IP is currently being used as the basis
for a new gateway with very streamlined functionality
for applications which just need an implementation
on Modbus/TCP. A gateway for implementation on
Modbus/RTU is also being developed on the same
basis. Both devices will be available in early 2013.
As well as the hardware options detailed above, the
software is also developing at fast a pace. More pro-
tocols are becoming available in the IP sector. This
means applications can be developed which require
secure remote access.
The CP700 Condition Monitor will also be available in
the fi rst quarter of 2013. This device combines the func-
tionality of the COM460IP with a 7-inch touch screen.
This allows complete visualisation of the system status
and can be installed on-site, e.g. in the control cabinet
door. This provides convenient support for evaluation of
Power Quality device data. - The voltage is the same.
Option pack D
enables fast, clear and simple visualisation of the
entire system without requiring special programming
skills to set it up. It takes very little effort to create
the visualisation and learning how to use it is very
intuitive. This tool means that the system view can be
adapted to a wide range of situations or users. For
example, measurements or alarms can be arranged
and displayed on a building plan. The visual display
is completely in sync with the remaining system
display. All information is available at the same time,
and there are no limits on the size of the system. Of
course, the system display can be broken down into
different pages. There are in-built links allowing users
to jump down to lower level pages and back again.
These lower-level pages can be user-specifi c, i.e.
important information is only visible to the relevant
user. For example, electronic engineers can keep
an overview of all the details of the circuit diagrams,
while the important information for the facility man-
ager is shown in the building plan.
And, of course, using the new options does not
mean buying a new device. All COM4601P units
can be upgraded with the new options. The latest
software including all options is available on the
Bender homepage. This software is then transferred
to the COM460IP based on a menu-based system.
All the new features are active immediately, depend-
ing on the option licences in place. This means the
latest software is always available free of charge.
Any missing licences can be added at any time.
The licence key is available on the Bender home-
page and is transferred to the COM460IP via a
menu system. All software options can be com-
bined. The same applies to future options.
Dipl.-Ing. Joachim Wagner, T-SCT
MONITOR | 2/2012
In global terms, coal is the most important
raw fuel. Its stocks are distributed through-
out the world and are almost inexhaust-
ible. Eickhoff Bergbautechnik GmbH in
Bochum, Germany manufactures high-
performance machines for the domestic
and international mining industry.

Shearer loaders are one of its focuses.
In straightforward terms, these are mining machines
which use large rollers to cut the coal from the seams.
With a power output potential of 300 – 1000 kW, up
to 1 million tonnes per month can be extracted. This
is made possible by the development of a completely
new, extensive automation package. The machine
automatically locates the limits of the bed of coal and
then proceeds to extract it autonomously. A naviga-
tion system guides the machine within the naturally
formed coal seam. The operators, meanwhile, can
concentrate on monitoring functions in a safe, unpres-
sured environment and do not have to deal with the
harsh environment encountered in mining, including
dust, falling rocks, damp, noise and restricted vision.
They can then operate all the system’s monitoring and
optimisation tasks from the control centre. Eickhoff
Bergbautechnik GmbH also clearly emphasises the
aspects of environmental protection and protection of
resources here: “Selective extraction saves over 1 mil-
lion tonnes of CO
per year by bringing less worthless
encasing rock to the surface along several kilometres of
belt conveyors and shafts. The extraction of thin seams,
which otherwise often had to be left in a deposit and
were therefore irretrievably lost, can now be resumed in
fully automated mode. This affects most coal deposits
around the globe.”
The high degree of automation in these systems natural-
ly also calls for an extremely high level of electrical safety
and reliability, with particular care being given to operator
protection. Electrical networks in underground mines
are mainly operated as unearthed systems (IT system)
with warning/shutdown. The standards covering protec-
tion practice in mines to DIN VDE 0118-1 (VDE0118-1)
and DIN VDE 0118-2 (VDE0118-2):2010-06 are appli-
cable here. Under these special conditions the use of the
IT system ensures low touch voltages, low fault currents
and thus a low risk of explosion and fi re. The IT system
Innovative shearer loader for safe
and highly efficient coal mining operations
2/2012 |
Dieter Göbel
Technical Office, North Rhine-Westphalia
also guarantees high availability since an insulation fault
does not result in a power supply failure. This benefi t is
also a key factor in being able to achieve the extraction
performances mentioned. As the insulation monitoring
device used transmits messages as appropriate, this
means maintenance can be optimally coordinated.
The 460…690 volt systems are monitored by type
which feature high shock
and vibration resistance. The AMPPlus measurement
method allows this device to meet the requirements of
modern power supply systems which often include con-
verters, power converters, thyristor regulators and directly
connected d.c. components. Explosion protection regu-
lations require them to be fi tted in pressure-resistant
power distribution systems.
The necessity for insulation monitoring devices came
originally from the mining industry. Company founder
Walther Hans Bender recognised this as early as 1937
and in 1939 patented an “insulation monitor and earth
fault detector for 3-phase systems” under the name
, which is now known throughout the
world. Even back then the main application fi elds were
in potash, ore and coal mines.
MONITOR | 2/2012
Sensitive products
The Institute for clinical transfusion medicine and
immune genetics Ulm (IKT) provides blood products,
stem cell compounds and cell therapy compounds for
the University Clinic Ulm as well as for over 130 other
facilities along with transfusion medical, immune hema-
tology and transplant immune diagnostic. The DRK
Blood Transfusion Service Baden-Württemberg Hessen
nonprofi t GmbH and the shared University of Ulm fulfi lls
duties and responsibilities in the domains fo research
and teaching in the respective area. Altogether there are
a total of 280 employees working at the institute.
Central responsibilities
The German National Bone Marrow Donor Registry
(ZKRD) is the information hub for the search of compat-
ible unrelated blood stem cell donors for Germany. This
is where all donor data within Germany merges together.
As a competence centre of expertise for this highly spe-
cialised area of medical care, the ZKRD arranges the
complex process of donor search for patients at home
and abroad as fast, effi cient, transparent and economical
as possible. It coordinates the search process and in this
context also checks all orders and fi ndings for complete-
ness and plausibility.
Fault location within a shorter space of time
but longer maintenance intervals
Residual current monitoring in German Red Cross Blood Donation Headquarters in Ulm
with Bender RCM-technology
The existing building of the Blood Donation Headquarters of the German Red Cross in Ulm
launched its operation in 1971. Besides that, the building also houses the IKT (Institute
for Clinical Transfusion Medicine and Immune Genetics Ulm GmbH) as well as the ZKRD
(German National Bone Marrow Donor Registry) since 1991.
2/2012 |
Continuous power supply is vital
Due to space constraints and an increased usage over
the years, it was urgently necessary to expand space.
In the fall of last year, the newly built house launched its
operation on-site of the blood donation headquarters. The
new space is predominantly for the production of blood
preservation products. It was obvious that the building
technology has to comply with the highest medical safety
standards for such production. Starting from the laborato-
ries where the blood donations are fi ltered to the point of
the cooling units safekeeping, the power supply has to be
absolutely reliable. Further processing of the blood dona-
tions require promptness and for personnel to rely on its
technology. The blood donation has merely six hours to
be processed otherwise the blood preservation contains
only half of all important substances (based on the plasma
coagulation factor). For example, outages in the cooling
circuit irretrievably destroy the preservations.
Uninterruptible power supply
That is why planners decided in favour of Bender Electrical
Safety Technology: well-proven and known for its reliability,
power supply is warranted at the highest level of safety.
The AC and pulsed DC sensitive residual current monitors
of the RCM series are used for residual current monitor-
ing in earthed systems (TN and TT systems). In case of a
fault, an alarm is to be activated, but disconnection must
be prevented.. The power supply of the new wing of the
building is monitored on four levels with RCM technology
so altogether there are 12 current transformers W35, W60
and W120 installed at the outgoing circuits of the level
distribution cabinets. Several RCMS460D-2 in connec-
tion with Gateway FTC470XET not only allow monitoring
of the power supply but also provide an interface of
communication with higher-level systems of the build-
ing management system. In addition, an MK800-12 is
installed in a control cabinet for local information.
Time and cost saving
The planning of the electrical installation took place with
the support of the technical offi ce in Stuttgart by the
planning group M+M in Böblingen; responsible com-
panies were EET in Reutlingen as well as RS-Technik in
Neu-Ulm and Elektro Hofmann in Blaustein-Herrlingen.
Due to the built-in residual current monitoring it is
now possible to detect occurring errors in a prompt
manner. Furthermore, the inspection intervals can be
signifi cantly prolonged according to the specifi cations
of BGV A3 (German Accident Prevention Regulations).
After implementation of the newly built house, parts
of the existing building will be retrofi tted one after the
other with Bender RCM-technology. Many thanks for
the support of generating this report to Mr. Harald
Schlumpberger (Electrical master technician) from the
Engineering Department in Ulm.
Jürgen Eisfeld, Technical Office Stuttgart
MONITOR | 2/2012
Almost exactly two years ago to the month, work
began on detailed technical construction plans
based on the possible building design in accord-
ance with the local conditions and building regu-
lations. From the very beginning, the aim was to
achieve a quality build combined with energy-
effi cient building technology with internal and
external aesthetics to match.
Unconventional detailed plans and clever infrastruc-
tures systems for energy and media supply within the
building should guarantee maximum fl exibility and
modularity within the building to optimise future use.
The considerable scale and its division into a wide
range of different functions for the technical produc-
tion workfl ow required very careful planning - after
all, the plan was to produce short routes with loca-
tion-optimised functional areas despite the size of the
Right in the heart of the building, in a direct, central
position, a universal production space has been cre-
ated which is framed by a u-shape of free logistics
routes and directly adjacent areas which either work
physically with production or provide an additional
Forward-looking Bender final assembly works in Gruenberg
starts production
All the offi ce space for the employees in the relevant
planning and management roles is directly adjacent to
the production area or integrated within it. This com-
pletely removes the previous boundaries and struc-
tures required from a technical building perspective.
This new production building marks an end to the fi rst
phase of building within the overall strategy. The next
few years will see a whole new set of buildings rise
up on the current and extended company premises in
order to centralise and amalgamate the current func-
tional departments.
But the focus is not just on the building itself, but on
the comprehensive plans and investigations tackling
the ground-breaking question of what will come into
the new building.
MONITOR | 2/2012
In specifi c terms, it is a question of fi nding an answer to
what production methods will be like in the future. It has
long been clear to all those involved that the successful
methods applied thus far need to be further developed
and enhanced to ensure an integrated future strategy
based on new methods and ideas.
With respect to future-proof and future-oriented Bender
production at its German site, the idea was to make
a crucially important, fundamental corporate decision.
With increasing size and globalisation, market conditions
are changing, as are the challenges the company faces.
This means not only increasingly exacting demands in
terms of quality, both internally and externally, but also
increased product manufacturing complexity. In order
to ensure successful and economical production of tiny
to huge unit numbers at the same time as high levels of
product type variance under the current market condi-
tions, it is crucially important that the production system
is geared towards this.
There are also
fundamental guiding principles such as
• concentration on value added
• shorter throughput times
• effi cient production methods
• handling and large-scale elimination of waste
• continuous increase in productivity
which need to be implemented within
the new Bender production system.
2/2012 |
We were prepared for this challenge. A planning team
covering a wide range of expertise had been investi-
gating potential solutions and methods even clearly
before the planning stage. What are the requirements
for the factory of the future? What are the design and
research areas from a scientifi c perspective? What
production principles, systems and methods should
be considered and which fi t best with Bender?
All these elements led us to a comprehensive pre-
sentation of ideas, methods and tools which work
together to improve the effi ciency and effectiveness
of the entire production workfl ow. The idea was
then to apply this to the fundamental level of an inte-
grated production system adapted to the needs and
peculiarities of Bender as a company. This Bender
production system is primarily oriented towards the
principles of what is known as "Lean Production",
whose basic paradigms are process-orientation, par-
ticipative/cooperative work-system design and con-
tinuous improvement.
The practical implementation of this Bender produc-
tion system and the associated measures within the
management process have allowed us to lay the
foundations for modern, future-proof and employee-
oriented production.
Dipl.-Ing. Manfred Nicklas
MONITOR | 2/2012
In every building it is necessary to reliably and safely provide the necessary amount of
electrical energy. This statement applies especially in the case of complex production
processes where unreliability in the supply of power will cause high costs. The prereq-
uisite for reliable, trouble-free, safe operation is low voltage switchgear designed to
suit current and future processes.
Here it is important that detailed information is avail-
able on utilisation, needs, connection ratings and
simultaneity factors as early as the start of the plan-
ning. The process is made more diffi cult because
planning is time and again knocked off track by
changes at almost any point.
Defi nitely not a simple task for the electrical planner –
but an everyday occurrence for the project planners at
bendersystembau. With comprehensively thought-out
electrical planning orientated on the future for the
construction of a new production building at Bender
GmbH & Co. KG. in Carl-Benz-Strasse in Gruenberg,
bendersystembau GmbH was once again able to
demonstrate its competence as a solution fi nder. Here
the design and implementation of a highly effi cient
low voltage installation took only six months; the instal-
lation was placed in operation on schedule in June
2012 and will also provide the basic supply for further
planned building complexes.
Copper busbar systems HSS
Measuring current transformers for AC/DC sensitive
residual current monitors
Measuring and monitoring fi eld: residual cur-
rent monitoring system RCMS460-D-2 for all
outgoing circuits in the main distribution board
Safely switching and distributing electrical
power in industrial production processes
2/2012 |

In close co-operation with the client, a distribution system for
a rated current of 2500 A was designed. bendersystembau
designed the power distribution for the entire production facil-
ity as well as for two combined heat and power plants based
on the stipulated power supply scheme.
The main low voltage distribution system is supplied from
two transformers with a power rating of 630 (800) kVA each.
It supplies the sub-distribution boards, ventilation system,
air-conditioning system, UPS system and emergency lighting
in the entire production building and has suffi cient reserves
for further buildings that will be built in future. The two com-
bined heat and power plants with a power rating of 50 kW
each are integrated into the supply concept, a system isola-
tion device as per the standard VDE-AR-N 4105 is integrated
in the CHP panel.
This equipment is installed at a central point in the basement
of the new building in a system that comprises 12 distribution
panels with a total width of nine metres.
To facilitate a high level of ease of maintenance and at the
same time to save costs, a feeder panel with six fuse switch
disconnectors of size 3 was installed. In this way individual
cable areas can be accessed separately and can be cor-
respondingly straightforwardly maintained. At the same time
increased reliability is achieved and the safe operation of the
installation guaranteed.
As a further safety feature, bendersystembau integrated Ben-
der residual current monitoring to continuously monitor all
output circuits for fault currents. The data are transmitted via
BMS bus or Ethernet, acquired and logged in real-time. Due to
this continuous monitoring of the electrical installation and the
equipment, the intervals for the regular testing in accordance
with BGV A3 and the Betriebssicherheitsverordnung (German
ordinance on industrial safety and health) can be adjusted to
suit practice. This aspect saves time and money.
bendersystembau GmbH is a partner company of the BENDER
Group and a specialist in the planning and implementation of
electrical installations with rated currents up to 4000 A for the
control of industrial production processes in a very wide range
of sectors.
Friedhelm Leckel
bendersystembau GmbH
• Main low voltage distribution system 2500 A
• Type testing in accordance with
DIN EN 60439-1 (VDE 0660-500) TTA and PPTA
• Main busbar system: 2500 A, 4-pole
• Rated current: 2500 A
• Rated dynamic withstand current: 165 kA
• Rated short-time withstand current: 75 kA
• Cabinet depth: 625 mm
• Cabinet width: 12 panels with a total width
of nine metres.
• Feeder panel with six fuse switch disconnectors of
size 3, 400 A for six cables NYCWY 4x185/95 mm²
• Coupling panel with feeder circuit breakers 2500 A,
4-pole withdrawable
• Main busbar system 2500 A, 4-pole + PE
• Outlets with circuit breakers and fuse switch
disconnectors, 4-pole
• CHP panel with system isolation device as
per VDE-AR-N 4105
• Internal sub-distribution in form 2b, cable outlet
panels form 4b
• AC/DC and pulse current sensitive residual
current monitoring of all output circuits
(approx. 700 measuring points)
• Data transmission via BMS BUS and Ethernet
to a central monitoring point.
One of the highlights of this fair was the “L-2350
Generation 2” from LeTourneau Inc. based in Longview,
Texas (USA). This is the world’s largest wheel loader,
whose operating weight of almost 263 t outstrips any-
thing that has come before. The L-2350’s enormous
strength comes from its 2300 hp turbocharged inter-
cooled 16-cylinder diesel engine. Reaching its maxi-
mum output at only 1800 rpm, the wheel loader has a
payload of 73 t, corresponding to a bucket capacity of
some 40.5 m³. The external dimensions of this giant are
also impressive: it is approx. 20 m long, 6.8 m wide and
has an overall height of 6.7 m.
This wheel loader is mainly used in quarries, in coal, ore
and copper mines and in other large opencast mines.
In such a harsh operating environment, as a result of
the unusually high mechanical loads, insulation faults
cannot be ruled out. To ensure safe, reliable operation,
the Bender ISOMETER
IR685 monitors the complete
electrical power supply for the colossus and immedi-
ately signals any insulation faults that occur.
In the same month Bender exhibited at Solar Power
International (SPI) in Orlando. The two trade fairs
could scarcely have been more different: whereas Las
Vegas saw the gigantic, energy-consuming machinery
and plant from the mining industry on display, the
exhibitors in Orlando were showing technologies to
convert energy from the sun into usable form.
What the fairs had in common was that the issue of
energy played a major role in both. In the fi rst case
effi cient use, in the second effi cient generation. In the
trade fair locations themselves – in the cities of Las
Vegas and Orlando – an observant visitor could easily
see the importance of these issues for the future.
Marita Schwarz-Bierbach, S-COM
Dr. Dirk Pieler, CEO
MONITOR | 2/2012
Enhanced safety in the world's largest wheel loader
with Bender technology on board
2/2012 |
Professional quality and reliability lead to success
Originally, of course, the situation was different. In its
early days, the company faced a shortage of working
capital and insuffi cient business and entrepreneurial
experience. The most valuable asset contributed by
the founders to the newly established company was
professional knowledge in the fi eld of measuring tech-
nology and an appetite for work. Shortly thereafter, the
business strategy of the company developed out of this
Our company GHV Trading with its headquarters in Brno was established in May,
1991. From the very beginning of its existence the company has focused its busi-
ness activities on consulting, sale and servicing of measuring technology. Its team
currently consists of 18 employees and it is a notable entity in its fi eld of business
activities in the Czech Republic.
initial contribution to the professional level and reliability
to which the company adheres up to this day.
Negotiations with Bender were fi nalised with the
signing of a distributor´s contract, which meant a big
challenge for us. We expected that this cooperation
would enhance our economic growth and awareness
of our company among the professional community.
Zděnek Hašek, Geschäftsführer
Roman Smékal, Leiter
MONITOR | 2/2012
held in Grünberg, we were troubled by doubts that we
had not met the expectations of Bender. I still remember
the encouraging words that Mr. Lampe had for us. He
expressed his appreciation for our pre-sale efforts and
assured us that every beginning was hard and that even
they could not have expected better results.
We succeeded in increasing our sales six times in the
second year of our cooperation, and after twelve years of
working together, Bender became our biggest supplier.
The development of the situation in Slovakia was
analogous when we took over distribution of Bender
products after the year 2008. We succeeded in achiev-
ing almost double those sales in the fi rst year. We
achieved a purchase volume of 628 thousand EUR for
the fi rst eight months of the year 2012 in Czech and
Slovak Republic. Surely, the quality and reliability of the
Bender products have been the guarantee of our suc-
cessful sales. The customers, who decided in favour of
this brand despite the fact that the price of our product
is slightly higher than the price of the product used so
far, have never regretted their decision.
In order to promote our compa-
ny and the Bender products and
enhance awareness of our company
we display our products at trade
fairs, and organise and participate
in workshops for designers, not only
as exhibitors, but also as lecturers.
We lecture to students at universi-
ties. Our company is a member of
the Commission for Standardisation
and closely cooperates with design
offi ces for drawing project documen-
tation. We write articles for journals,
and in cooperation with schools cre-
ate demo panels and switchboards
for laboratory tasks, perform the set-
up, programming and revitalisation
Our cooperation commenced in January 2000, when
we received our fi rst products (IRDH265-4).Then we
focused on promotion of the manufacturing program
of Bender during the years 2000 – 2001. Six profes-
sional promotional articles about individual Bender
product groups were published in Czech professional
journals in 2000. We also produced promotional pan-
els, and visited trade fairs and exhibitions. We pro-
duced complete catalogues of Bender products in the
Czech language, translated the user´s manuals and
created web pages.
We placed our greatest emphasis, however, on enhanc-
ing edifi cation among designers and design fi rms. We
organised professional workshops and took the time
to visit the most important design organisations in the
Czech Republic.
In 2000, we achieved more than double the turnover in
sales of Bender products compared to our predeces-
sor in 1999. Nevertheless, we were not entirely satisfi ed
with the achieved result, since it did not refl ect the work
expended on it. When we came to our fi rst meeting
2/2012 |
of apparatuses on building sites and of course we
offer catalogues, manuals and web pages in both the
Czech and Slovak languages.
It is very diffi cult to summarise in a few sentences the
hundreds of projects which we implemented during
our cooperation, but I would like to mention some
projects as examples in individual categories.
Cooperation with companies manufacturing means of
transportation designed for heavy operations (trams,
trolleys and locomotives) and also railway communi-
cation and alarm systems proved to be very success-
ful. In this area, mainly untypically adapted IR145,
IRDH265 or new IRDH275 and IR425 insulation
guards or special measuring cards were applied. In
order to succeed in these projects, the helpfulness
of Bender in adapting standardised devices as per a
client´s request and the national standards requiring
signalling of 1000 Ohm/V was of key importance.

Other interesting areas are, without question, the safety
circuits of power plants. A system for the Dukovany
Nuclear Power Plant with 12 IRDH575 systems and 120
measuring transformers was introduced as a sample
project in the Czech Republic. Later a project for the
Mochovce Nuclear Power Plant was introduced in
Slovakia, where SUA, SUD, VME and VMD monitoring
relays and the EDS localisation system for monitoring
DC 220V and 24V networks with 10 IRDH575 sys-
tems and 70 measuring transformers were installed.
Similar projects were implemented for several gas sta-
tions of the companies Eustream and Unipetrol and
Chemopetrol refi nery companies, and several other
industrial installations. It is necessary to point out that
switchboards designated for nuclear power plants
required the carrying out of demanding seismic and cli-
matic tests, all of which the devices of Bender passed.
Systems and components of the production line
MEDICS signifi cantly contributed to the sale of Bender
products. These products underwent signifi cant
changes during the years of our cooperation. New
generations of devices always offer something new
and interesting to our customers.
Within the framework of a pilot project for the MOTOL
Prague hospital, in total 81 pieces of 107TD47 insula-
tion monitors, 25 pieces of MK2430 signalling pan-
els, 16 pieces of FTC470XMB converters, 3 pieces
of FTC470XET converters, 37 pieces of UMC710
changeover modules and 11 pieces of TM panels for
operating rooms and 3 touch panels with power sup-
ply system visualisation were installed.
People stand behind our success, and therefore I
would like to express our thanks to all the employees
of Bender, as well as to our own team, because without
their work we would not have achieved these results.
Ing. Zděnek Hašek
GHV Trading, spol. s.r.o., Tschechien
Dušan Zoğiak, Produktmanager Eduard Chvátal, Techniker Jiří Ondřík, Produktmanager
MONITOR | 2/2012
High-tech modular hospital and laboratory buildings
– Company portrait
Cadolto Forum I and II, Cadolzburg
Cadolto is the world's leading specialist for the construction of complex, technically
demanding buildings using modular construction techniques.
Our core expertise lies in the high level of industrial building production. This allows
us to complete turnkey construction projects quickly and effectively. Ongoing opera-
tions remain almost completely unaffected because the new premises are ready for
use quickly, an aspect that is of central importance in our core areas of medical and
laboratory buildings.
Our comprehensive planning and consultancy services, the industrial production and
the fast, cost-effective, high quality execution of construction projects combine to
provide our customers with the peace of mind that a professional partnership offers.
2/2012 |
Cadolto was founded back in 1890 so it has been around
an impressively long time. Today, its continuous growth is
due more than ever to our willingness and ability to constantly
change and improve.
The willingness to innovate and the creativity of 4 generations of
the family have turned what was a small wheelwrights shop in
the 19th-century into the market leader in pre-fabricated build-
ings with 400 staff. The success of our work is evidenced by
the two highly modern company sites in Cadolzburg, Bavaria
and in Krölpa, Thuringia, as well as the numerous buildings
constructed for satisfi ed customers; buildings that have carried
the "Cadolto — made in Germany" seal of quality to many parts
of the world.
An impressive technology
High-tech buildings – mainly in the medical and laboratory sec-
tors – represent signifi cant challenges these days. Technology
and functional requirements are changing at an increasing rate.
Cadolto's modular construction technology provides a fascinat-
ing answer to these developments.
Unrestricted architecture and comprehensive planning
Cadolto's modular construction technology is a construction
method that consolidates the depth of planning, close coordi-
nation of work, industrial manufacturing quality and smooth
logistics like never before. Speed, cost-effectiveness and fl ex-
ibility go hand in hand with complete architectural freedom.
An experienced team will ensure you receive an individual and
intensive consultancy service from the start. The intelligent build-
ing concept ensures individual, unrestricted architectural imple-
mentation and is based on individual modules up to 25 metres
long and 6 metres wide, all of which can be transported.
Modular work planning
Our planning specialists convert the individual architectural
design into a modular work plan. This plan also covers the tech-
nical fi ttings and equipment. The interaction of between sani-
tary, heating, air-conditioning and electrical trades means that
comprehensive know-how is perfectly coordinated and comes
together in one place.
Cadolto's modular construction technology
Istituto Europeo Oncologia, Milan, Italy
Dermatologische Universitätsklinik Essen
Westfälische Wilhelms-Universität Münster "Meet-Arkaden"
MONITOR | 2/2012
Hermann Bauer
Cadolto Fertiggebäude GmbH & Co.
Industrialised production
Cadolto guarantees the highest level of industrial building pro-
duction in the world. 90 % of the work is undertaken in modern
production facilities – not affected by the weather, with constant
quality control, on schedule and cost-effectively. The precise,
perfectly coordinated production processes provide the best
prerequisites for the quality, durability and service life of the
Transport and setup
When the building modules leave our factory, they already con-
tain everything, including all the medical, laboratory and building
services and installations, as well as tiles, curtains and facades.
On the construction site, the modules are simply erected and
connected together. This also minimises the disruption caused
by the building site.
Cadolto combines the expertise in all the necessary technologies
and the know-how of all the necessary trades into small project-
based, experienced teams with the excellent skills and the ability
to react quickly and fl exibly.
This ensures optimum involvement of planners, engineers, trades-
men and even suppliers in the entire process from the start.
The most impressive evidence that this interaction works is in
the fi gures: for the planning, construction, erection and turnkey
handover of around 3,000 m
of building fl oor space, on average
less than 4 months are required — and this time pays off hand-
Global presence
Cadolto is local all around the world. This means we are familiar
with the regional situation, regulations and standards and close
enough to the market to ensure we can react quickly. In this way
Cadolto combines its know-how, developed over many years,
with local knowledge for maximum customer benefi t. With its own
international sites and production works as well as a comprehen-
sive sales and consultancy network, Cadolto can deliver high-tech
buildings worldwide and provide direct support to all customers
throughout every project phase.
delivery suite in Jyväskylä
Hybrid operating theatre: the standard of the future,
exhibit at Medica 2012
2/2012 |
Biggest regional Trade Fair for the Electrical Sector
Event dates: 20.03. – 22.03.2013
Location: Stuttgart
Hall 9 / Both C45
Hannover Messe
Event dates: 08.04. – 12.04.2013
Location: Hannover
Hall 12 / Booth D66
The world’s largest Exhibition for the Solar Industry
Event dates: 19. 06. – 21.06.2013
Location: Munich
Trade Fair for the Electrical and Electronics Industry
Event dates: 11.09. – 14.09.2013
Location: Dortmund
International Fair for Electric Mobility
Event dates: 15.10. – 17.10.2013
Location: Munich
World Forum for Medicin
Event dates: 20.11. – 23.11.2013
Location: Düsseldorf
SPS IPC Drives
Electric Automation – Systems & Components
Event dates: 26.11. – 28.11.2013
Location: Nuremberg
Event dates: 24.02. – 27.02.2013
Location: San Francisco – USA
Booth 234

Event dates: 27.02. – 28.02.2013
Location: London – United Kingdom
Booth J60
KazAtomExpo – Kazakhstan International
Exhibition and Conference

Nuclear Energy and Nuclear Industry
Event dates: 09.04. – 11.04.2013
Location: Astana – Kazakhstan
Event dates: 30.04. – 02.05.2013
Location: London – United Kingdom
Booth F57
AAMI 2013 Annual Conference & Expo
Event dates: 01.06. – 03.06.2013
Location Long Beach – USA
Booth 654
Elektro 2013
Event dates: 17.06. – 20.06.2013
Location: Moscow – Russia
MONITOR | 2/2012
Dipl.-Ing. Helmut Muhm
Head of the T-MTS
As well as monitoring relays, one of your main roles
is in building engineering security. Many buildings
are facing retrofi tting or renovation works with space
for technical equipment normally limited in old build-
ings. But the requirements in terms of modern
building technology and how it works are becoming
increasingly demanding. Customers often demand
no interruptions to supply. How can you bring this
down to a common denominator?
When developing new measuring and monitoring devices,
we believe it is important to ensure that they can be
fi tted in complex environments and confi ned spaces.
Many universal measurement functions are built into
small space-saving casings. Meters are connected via
split-core measuring current transformers and voltage
transformers so that the devices can also be fi tted into
a live system.
Normally, system messages are sent to a central
building control panel. With the new "Condition
Monitor" product, this information can be prepared
on a target-group-specifi c basis. What developments
are in the pipeline in terms of visualisation and power
quality monitoring?
Many small and medium-sized companies do not have
a central building technology system or a control panel.
But they still need permanent monitoring of the system
and information if any problems occur. Bender uses state-
of-the-art information technology to take over the job of the
control panel and provide the operator of the electrical system
with information on its current status by means of regular
status reports. Service intervention can be scheduled for pre-
ventative maintenance and trouble-shooting purposes so that
the operator can rely on a high-availability and safe electrical
supply at all times.
We take customer requirements for permanent monitoring and
easy-to-understand visualisation solutions seriously and are
launching a solution, the Condition Monitor, in early 2013.
Operators of commercial systems and buildings are sub-
jected to safety standards for system and personal pro-
tection. With the Bender RCM series, resource-intensive
and time-consuming inspections of electrical loads, as
stipulated as mandatory in accident prevention guideline
BGV A3 and the Betriebssicherheitsverordnung (German
ordinance on industrial safety and health), can be signifi -
cantly reduced. Will the market accept this step to make
things easier?
Many operators of commercial systems are not aware of their
obligations to carry out periodic tests in accordance with BGV
A3 and the operational safety directive. These inspections are
often simply neglected. Hopefully, there will never be a fatal
accident on one of these operator's premises. Other operators
1982 General university entrance qualification
1982 – 1985 Training as a telecommunications engineer at DFG in Marburg
1985 – 1990 Studied communication and microprocessor engineering at FH Giessen
1990 – 1993 Multiwire® product developer at Schoeller Elektronik
Development of
• impedance circuit boards
• Multiflex circuit boards
• HF circuit boards
1993 – 1998 Sales engineer at Bender
1998 – 2009 Product manager at Bender
• Residual current monitoring devices
• Measuring and monitoring devices
Since 2009: Responsible for T-MTS department
2/2012 |
want to carry out these safety inspections but are wary of the
high levels of personnel involvement, time and costs involved.
The important insulation measurement is often impossible to
carry out from a technical perspective, as it means shutting
down parts of the system, which is not possible in many pro-
duction systems and data centres which need to guarantee
permanent availability. These customers come to Bender look-
ing for practical, cost-effective and norm-compliant solutions.
Permanent residual current measurements allow faulty sections
of the system to be pinpointed, thus restricting the possible
fault location. This means insulation resistance needs only be
tested in the faulty parts of the system after shut-down, repair
and commissioning.
There is no need for random insulation measurements in fully
functional parts of the system to use up valuable resources.
Any faults which occur are immediately transmitted to the elec-
trical engineer responsible in visual form so that specifi c repair
measures can be initiated.
High levels of system reliability with immediate fault notifi ca-
tions by means of continuous system monitoring from Bender
– a practical solution used by our customers across a range
of systems.
Bender network protection systems are the undisputed
technical market leaders. At the same time, the company is
quick to emphasise, both internally and externally, that it will
not be resting on its laurels. What are its latest targets?
In many industrial and purpose-built buildings, cost restric-
tions mean a lack of qualifi ed electrical engineers and a lack
of proper support for the electrical system. Instead, perma-
nent monitoring systems are increasingly being used. Other
important measurement functions such as loop resistance,
magnetic fi eld strength and temperature will be integrated into
these monitoring systems in the future. The large volume of
measurements and information from the monitoring devices
needs to be centrally stored, analysed and prepared on a
user-specifi c basis. Bender will defi ne new targets to develop
user-specifi c graphic displays and clear target-group-specifi c
instructions which are available all around the world thanks to
modern information technology.
Bender aims to extend this service area and act as a solution
provider to the customer. So the service will not be limited to
the exchange or adaptation of Bender devices. We will high-
light problems in the system early and provide advice on
resolving the problem in service reports.
If you review the last few years of the BENDER Group
and try to anticipate future developments: What will
be the important factors in network safety engineering
in the future?
Electrical engineering has not reached the fi nish line yet
– and it may never do so. There are always new areas
of application where solution options can be developed
to improve electrical safety. These include, for example
e-mobility, renewable energies and information technol-
ogy. Things will carry on being exciting, but hopefully
safe too.
Permanent availability and maximum system safety are
musts for operators. Planners and builders need to har-
monise all the target specifi cations for modern electrical
installation, such as standards compliance, lightning and
overvoltage protection and protection in the event of
overcurrent or electric shock. High levels of wide-ranging
knowledge of standards and practical systems are clear
prerequisites. This knowledge is becoming increasingly
rare but represents a major asset for Bender.
System-specifi c risk analysis can be utilised to reconcile
target safety specifi cations and technical device solu-
tions. However, this poses the question as to whether
the target specifi cations can be achieved with switching
protective devices alone or whether continuous meas-
urement and monitoring systems are also required - in
future, there will be more and more decisions for each
monitoring system.
Operators of electrical systems often complain about the
fact that the planners and setup engineers have too little
interdisciplinary specialist knowledge, especially where
standards are concerned. Constant technical training
is a must. Customers are happy to accept training and
practical seminars. But it becomes clear here again that
the real assets at Bender are not its equipment, but the
know-how of its employees. As know-how is an experi-
ence-based variable and cannot simply be copied, we at
Bender are in an excellent position to face the challenges
of the future.
Mr Muhm, thank you for the interview!
Timothy Hörl
Bender GmbH & Co. KG
Londorfer Str. 65

Gruenberg / Germany
Fon: +49 6401 807-0

Fax: +49 6401 807-259
E-Mail: info
The Bender Group with its main offi ce
in Gruenberg/Hesse has 60 agencies with
nearly 600 employees worldwide.