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On the Cover... Q4X Laser Distance Sensor Provides Superior Performance for Challenging Applications

R SEPT/OCT 2015 Volume 18.5

Editor Debbie Scott

Advertising Sales Manager Roxanne Bredenkamp

Published by What’s New in Publishing cc ck 2000/037639/23 P O Box 2214 Primrose 1416 South Africa

Tel: 0861 PROCES (776 237) Fax: 086 723 5321 Printed by: Raptor Print Views expressed in this publication do not necessarily reflect the opinions of the publisher. Copyright reserved on all material


ET Automation Controls is proud to present the Q4X laser distance sensor from Banner Engineering. Featuring superior, versatile sensing performance, the Q4X sensors are available with bipolar discrete (NPN and PNP) and analog (0-10 V or 4-20 mA) output options. With highresolution capabilities, discrete models can detect objects as thin as 0.5 mm, while analog models precisely inspect part dimensions and positioning with resolution down to 0.15 mm. The Q4X is available in two sensing ranges, 25 to 100mm or 25 to 300mm. Banner’s Q4X is ideal for difficult distance-based sensing applications as it easily detects objects regardless of target surface reflectivity, including black foam on black plastic, black rubber in front of metal, multicolour packaging and targets of all colours. Also available with a dual teach mode, discrete Q4X sensors can detect clear objects or changes in signal intensity due to changing colour or reflectivity.The dual teach mode in the Q4X sensor combines window thresholds on both target distance and target reflected intensity, allowing the Q4X to reliably solve difficult applications with ease. The Q4X can now detect clear objects without requiring a retro-reflector. Dual mode can be used to error-proof applications by ensuring the correct colour part is located at the correct position. With the dual teach mode, the sensor can detect small changes in reflected intensity for targets inside the distance threshold. This powerful combination allows the Q4X to solve many new applications. “Incorporating the innovative dual teach mode into the next-generation Q4X sensor provides our customers with a more powerful sensing solution for their most difficult applications,” said Dennis Smith, Senior Technical Marketing Manager, Banner Engineering.

“With combined intensity and distance thresholds, the Q4X extends its world class sensing performance to clear object detection and common error-proofing applications.” Offering a simplified user experience, the Q4X provides a clear distance readout from the highly visible, angled four-digit display that is easily viewed from multiple vantage points. The Q4X also offers intuitive user setup utilizing three tactile buttons conveniently located below the display. For use in wet and high-pressure washdown environments, the Q4X is constructed with robust housing rated to IP69K. Durable FDA-grade stainless steel resists mechanical impact, over tightening and extreme vibration. To accommodate diverse industries and applications, the Q4X provides reliable detection of: • Black foam in front of black plastic in automotive interior and exterior assembly • Parts of varying colours in consumer packaged goods and automotive industries • Black rubber in front of metal in robotic assembly, especially automotive • Multicoloured packaging and secondary packaging in food, beverage and cosmetics • Part-in-place for error proofing of assembly steps • Small parts for automated assembly processes, such as caps, seals, o-rings, washers, vials and jars • A wide array of parts in vibratory feeder bowl equipment, including part level detection in the bowl (bowl empty, bowl full), and part present in the feeder track (i.e. track full) • Fill level indication, part positioning, roll diameter, loop control and thickness/ height verification • Clear object detection applications such as thermal formers, blow moulding, bottle filling, bottle handling, shrinkwrap packaging, and bottle, jar or tray detection. Contact RET Automation Controls to see if we can solve your challenging applications or to arrange a demonstration. Tel. 011 453 2468


18.5 A highly accurate picture of health … Each g-mac unit within the MTN/5000-16 can accept any standard two-wire accelerometer; but the data can be viewed and interpreted as acceleration or velocity. However, the g-macs can also be used with other transducer types and the MTN/5000-16’s software can, upon request, be written to display virtually any parameter (e.g. temperature, light, voltage and so on). Systems are made-to-order and customers can specify how many channels they require (1 to 16), the condition to be monitored by each channel and what levels of control they wish to have over each channel. Customers can also specify what power source the system should utilise and whether or not they want the system to do any direct switching for emergency shutdowns.


nnouncing the launch of UK-based Monitran’s MTN/5000-16, a robust and reliable microcontroller-based condition monitoring system. The system contains up to 16 Monitran g-mac signal conditioning units and features a 7cm TFT touchscreen with an easyto-navigate menu that enables users to set data sampling periods, ranges and accuracy levels plus vibration threshold (alarm) levels; on a channel-by-channel basis or across all channels. In addition, the system has 20 digital I/O channels, enabling the MTN/5000-16 to be integrated with other systems. The MTN/5000-16 is a versatile system that can be used at the heart of a plant/machine protection scenario or as the monitoring system within a condition-based predictive maintenance strategy.

The MTN/5000-16 is initially available in a 350 x 250 x 200mm cabinet, though other cabinet sizes may become available later in the year.

New signal generators boost performance

he AFG3000C Arbitrary/ Function Generator Series has been expanded with two 150 MHz models (one or two channels) that deliver more performance

than competitive offerings while holding the line on pricing. Slotting between existing 100 MHz and 240 MHz models in the Tektronix AFG3000C

lineup, the new AFG3151C and AFG3152C deliver 25 percent more bandwidth and 59 percent more output zone with +/-5 V DC offset at the same price as competitive offering in this segment. Beyond delivering leading price-performance at a popular bandwidth level, the AFG3000 Series feature an intuitive user interface that shows more information at a single glance, boosting productivity by allowing users to focus on the task at hand. Today’s complex designs require a variety of stimulus signals during test. All models in





the AFG3000C Series include 12 standard waveforms, arbitrary waveform capability, and signal impairment options to support a wide range of application needs with one instrument. A large display and 25 shortcut keys make these instruments both easy to learn and easy to use. Included ArbExpress software allows waveforms to be easily created from any Tektronix oscilloscope, or defined by standard functions, equation editor and waveform math.


Float Level switch for Pump Control

➢ 011 314 1391

➢ 011 695 8000

➢ 012 345 1005

➢ 011 465 8066


18.5 Non contact radar level sensors increase reliability on river sluices


n the River Weaver in the northern England county of Cheshire, the Dutton sluice site consists of eight large sluice gates lifted by Rotork actuators. The water level in the river determines when to open or close the sluice gates and navigation is closed to river traffic if the water level is too high. The Dutton sluice site is a key measurement point and the level monitoring needs to be very accurate. Consequently the level of the River Weaver is now measured by four instruments. The first two are ultrasonic sensors (for redundancy) mounted in stilling tubes. These tubes are required in order to reduce loss of echo issues from weather and surface conditions. However the tubes can require substantial engineering to install, and generally they need continuous on-site maintenance to prevent blockages, or repairs to keep measurement errors to a minimum. Even with this stilling tube installation, the SCADA Maintenance engineer has commented, “In recent years we have experienced issues where either one or both of the ultrasonic sensors loses echo or drifts, causing level sensor failure alarms to be sent out.” As a result the Canal & River Trust (CRT) has installed two other devices alongside the ultrasonic sensors, as test instruments. The radar level sensors VEGAPULS WL61 are unaffected by weather or surface conditions and were simply mounted on a unistrut adjacent to the stilling tubes. CRT has compared the data from both sets of instruments over several months and found that there was no drift with the WL61 water radars since installation. “Whilst we have seen occasions where the water level on one or both of the ultrasonic units rises, the radars have not,” commented the engineer. “As far as I can see, the WL61 radars provide more reliable data than the ultrasonic devices.

My concern with the ultrasonic sensors is that drift could create nuisance alarms and result in staff call outs.” This yet another example of how radar is increasing reliability and accuracy on open water applications.


18.5 New simplicity in explosive environments


ieldbus systems are about to create a whole new foundation for process automation. As well as forming the infrastructure that enables the use of big data for the first time in the process area, they also represent the key technology for intelligent process control in terms of Industry 4.0. All this and with considerably simplified planning, installation, commissioning, and maintenance, including in explosive environments. In principle, an infrastructure based on FOUNDATION Fieldbus H1 and PROFIBUS PA is a fully logical system. This starts as early as the planning stage. The trunk-and-spur topology has almost become a standard for process systems. It follows a simple structure, and is therefore transparent from planning through to installation. Based on the familiar principle of the old terminal board, each field device is connected to its own spur and can therefore be easily accessed. The system structure is intrinsically safe from the ground up. Proof of intrinsic safety according to FISCO can be included in the system documentation with no additional work required. The segment can have a total length of up to 1900 m. For example, the highpower trunk cable with a length of 700 m, and field devices on spurs of 100 m each. This enables simple, trouble-free implementation in most situations, even in Zone 0 explosive environments. Simply plug and play The PA profile for PROFIBUS already includes standard variables for the different instrument types. Through the use of typical installations, patterns, and templates, the installation of a PROFIBUS infrastructure can be greatly simplified and accelerated. Then only two more steps are required to connect a device: set the address, and connect. And there’s more. The high level of standardization means that 80% of all loops can be planned, tested, and optimized, even before one component of the automation system is physically installed. The individual field devices are then ordered directly from the manufacturer with details of the required parameterization, and are already preconfigured on delivery. The same procedure applies here: simply install, connect, set the address, and away you go. The same advantages apply if a field device needs to be replaced at a later time. Where service technicians previously had to pay careful attention to the compatibility between the device and control technology, they now have to simply install a replacement device, set the address, and everything runs smoothly. This requires neither a notebook on site, nor any settings from the control center. The physical installation of digital field devices does not differ significantly from the traditional process with analog 4 mA...20 Ma devices. Only with the shielding is special care needed, to ensure that the device delivers an

uninterrupted signal, including in the long term. Intelligent diagnostics, directly on site

Checked in advance: Length expansion of a typical segment in the explosive environment.

To check whether everything is running smoothly mechanically and electrically, the system can be inspected quickly and easily using a handheld diagnostic device. The FDH1 is a typical and practical example of this type of device. The abbreviation stands for fieldbus diagnostic handheld, and describes an intelligent diagnostic device that enables a reliable analysis of the physical fieldbus layer, without requiring deeper detailed knowledge for correct interpretation of the measured electrical values. The FDH-1 functions in connection with the FOUNDATION fieldbus H1 and PROFIBUS PA. This effectively provides an embedded expert system, which can check a wide range of parameters that provide specific information about the signal quality of a field device. The parameters that are checked include signal strength, noise, grounding, operating voltage, and jitter. The measured values are displayed on a small graphical display, either as measured values or an oscilloscope curve. If all values are within the green range, a perfect physical connection to the field device can be assumed. If the device detects deviations from the optimum possible installation, an expert system interprets the measured values and provides information about possible causes. It then proposes actions for identifying and resolving these faults. This provides definitive information for security during installation, and in the case of servicing can deliver rapid information about possible causes of problems. The FDH-1 is the first diagnostic device of its type that can provide information about the behavior of a field device in the event of electromagnetic interference. It can also determine the fault tolerance of a device or a whole segment and thus determine the range within which reliable communication is guaranteed. This is performed using an additional fully automated test. Proof of intrinsic safety simpler than ever before The safe use of field devices in explosive environments is an important topic in the process industry. Once again, the combination of FOUNDATION fieldbus H1 and PROFIBUS PA has made things far easier. The only

technology named in this respect is Dynamic Arc Recognition and Termination (DART), a new technology that enables the use of field devices with higher power ratings in explosive environments. The key word here is: intrinsic safety (Ex i). Unlike mechanically protected installations (EX d and EC e), for intrinsic safety according to the Fieldbus Intrinsically Safe Concept, IEC 60079-2 (FISCO standard), clearly defined electrical parameters apply for a fieldbus segment in the explosive environment Zones 2, 1, and 0. For field devices with FISCO certification, as are standard nowadays, these limit values are precisely complied with. A separate calculation to prove intrinsic safety is therefore no longer required. For cables, a manufacturer’s declaration is sufficient. For all other devices, only the certificates need to be documented.

Handheld diagnostics: The “expert to go” evaluates the installation quality in all explosive environments

High power on the trunk The high-power trunk principle eliminates many of the disadvantages and limitations previously associated with intrinsically safe operation of field devices in explosive environments. Not only does the trunk provide a consistently homogeneous topology for all areas of the communications infrastructure. With its design in ignition protection class Ex d/e, it also delivers high power (typ. 30 V/500 mA) directly to explosion Zone 1 and 2, and with field barriers guarantees ignition protection class Ex i/a for Zone 0. This provides consistent intrinsic safety, which enables you to work safely on the field device without a hot work permit. As a result, a modern bus system is not only much simpler to connect by cable. If it is designed in the tried-and-tested trunkand-spur topology, it is also considerably less complex than the solutions of the past. With the high-power trunk, it offers certified intrinsic safety in explosive environments. Added to this are the much more extensive diagnostics options and the fact that a majority of the functionality can be run and optimized even before installation. And to think that only a few years ago, few believed that digital technology and process control would ever be successful partners.


18.5 New optical spectrum analyzer for improved measurement accuracy in the 2 μm band


ased on the company’s highly successful AQ6375, an optical spectrum analyzer that utilizes the dispersive spectroscopy technique*¹, the AQ6375B incorporates a number of new features that improve the accuracy of measurements made in the 1.2 to 2.4 μm wavelength range. With the growing effort in recent years to reduce the amount of greenhouse gasses and other harmful substances that are released into the atmosphere, increased attention is being paid to techniques such as laser absorption spectroscopy*² that can perform highly accurate measurement of carbon dioxide, methane, and other gasses that have a harmful effect on the environment. The use of near-infrared lasers with a 2 μm wavelength is essential in laser absorption spectroscopy, and this laser emission spectrum needs to be measured with high accuracy. Large-scale measuring systems with spectrometers are generally used to measure the emission spectrum of near-infrared lasers in the 2 μm band. In November 2007, Yokogawa launched the AQ6375, a first-of-its-kind bench-top optical spectrum analyzer that uses dispersive spectroscopy and supports the near-infrared wavelength range, and has continued to make contributions in this field. There are some issues, however, that can affect the accuracy of measurements made with such instruments. One such issue is the negative impact that water vapor can have on the accuracy of spectra measurements in the upper near-IR wavelength region. Another issue is that there are some cases where the original optical spectrum cannot be accurately measured due to the effect of higher order diffracted light*³ with a longer wavelength than the input wavelength. The AQ6375B incorporates a number of new features that eliminate these effects and thereby improve the accuracy of measurements made in the 2 μm band. Product Features Purging mechanism to eliminate water vapor inside the spectroscope 1. The spectrum of the light under measurement can be measured with greater accuracy by eliminating the absorption of particular spectra that occurs as the result of water vapor being trapped inside the spectroscope. This is accomplished by a purging mechanism that eliminates the water vapor by continuously supplying a gas such as nitrogen through a connector on the back panel of the device. 2. Light blocking filter that reduces the effect of higher order diffracted light The effect of higher order diffracted light with wavelengths that are two to three times longer than the wavelengths of incident light is reduced by a light blocking filter. This removes the light with wavelengths that are shorter than the range of measurement wavelengths contained in the incident light. *1 A technique whereby light with a wide range of wavelengths passes through a diffraction grating and a narrow range of wavelengths are extracted via a narrow opening. An optical spectrum analyzer is a measuring instrument that separates the wavelength components of the light and measures the distribution of those components. *2 The use of a laser beam to irradiate molecules, which will absorb light of a particular wavelength depending on their type. This principle is used to analyze the optical spectrum and quantitatively assess atoms and molecules in the gas phase. *3 Light with a wavelength that is an integer multiple of the input wavelength


18.5 FieldComm Group announces release of FDI Package IDE and Common Host Components Version 1.1


he FieldComm Group have announced release of the first update to its newest tool deliverables, the FDI Package IDE and the FDI Common Host Components. Version 1.1 of the development tools introduce exciting new capabilities for FDI product developers including an automated device package test tool, support for PROFINET based device packages, and support for developing device packages capable of offline configuration, including upload and download features. Since the dissolution of the FDI Cooperation July 28, 2015, both PROFIBUS and PROFINET International and FieldComm Group, as co-owners of the tools and components, have partnered together to support, maintain and enhance FDI products. Development of a single software product across all protocols will be performed at FieldComm Group in collaboration with PROFIBUS and PROFINET International through the Group’s working group model. FDI tools and host components are currently available for purchase from FieldComm Group across FOUNDATION Fieldbus, HART and PROFIBUS/PROFINET protocols.

FDI makes it easier for automation suppliers to develop and integrate intelligent devices because suppliers only need to create a single, unified package for each intelligent device that can work with all host systems and tools. This reduces overall development costs, while preserving and expanding existing functionality. Users will also find it easier to manage information from intelligent devices with a single device package, instead of managing multiple file types for disparate solutions and investing significant capital in custom integration efforts to connect multiple technology platforms. FDI Package IDE 1.1 has been feature enhanced with the following improvements; • Device Package Test Tool • Enables automated testing of device packages • Support for PROFINET • Tool now supports HART, FOUNDATION Fieldbus, PROFIBUS and PROFINET • Offline Configuration Capability of Devices • Enables configuration of devices prior to connection to the system • Upload/download Features • Enables offline configuration to

be downloaded/uploaded on the system • Bug Fixes The FDI Device Package IDE is a tool for device developers to create FDI Packages and includes everything a host system needs to integrate the intelligent device into their system. With FDI, a single FDI Device Package makes it easier for device suppliers to develop and integrate their device across a wide range of host systems and protocols. FDI Common Host Components 1.1 have been feature enhanced with the following improvements; • Offline Configuration Capability of Devices • Enables configuration of devices prior to connection to the system • Upload/download Features • Enables offline configuration to be downloaded/uploaded on the system • Bug Fixes The FDI Common Host Components are software components for host system manufacturers that allows for rapid development and support of FDI device packages into their host systems. The components help system suppliers ensure

they properly comply with the standard and consume device packages correctly. The FDI Common Host Components fully support both the new unified EDD file format as well as legacy EDD formats to protect end user investments. About the FieldComm Group The FieldComm Group is a global standards-based organisation consisting of leading process end users, manufacturers, universities and research organisations that work together to direct the development, incorporation and implementation of new and overlapping technologies and serves as the source for FDI technology. The FieldComm Group’s mission is to develop, manage and promote global standards for integrating digital devices into automation system architectures while protecting process-automation investments in HART and FOUNDATION Fieldbus communication technologies. Membership is open to anyone interested in the use of the technologies. For more information, visit their web site at

Pocket-sized OTDR with SmartAuto and LinkMap


ptical Time Domain Reflectometers (OTDRs) are used to verify or certify new fiber installations as well as troubleshoot and locate faults in already deployed fibers. AFL’s newly launched FlexScan OTDRs

enable both novice and expert technicians to quickly and reliably troubleshoot optical networks or fully characterize newly installed or repaired networks. Using the innovative SmartAuto mode, multiple OTDR scans detect, locate, identify and measure network components and faults. After applying industry-standard or userset pass/fail criteria, the characterized network is displayed using FlexScan’s intuitive, iconbased LinkMap view. FlexScan automates test setup, shortens test time and simplifies results interpretation, improving efficiency and reducing the cost of test. Acquired results may be stored internally or externally. Internally stored results are easily accessed via USB, Bluetooth or Wi-Fi. With optional connector inspection, integrated source, power meter and VFL, FlexScan offers an all-in one solution, ensuring technicians have everything they need to locate and resolve optical network issues.

Specifically designed for field use, FlexScan is robust, rugged, lightweight, powerful and flexible. FlexScan is available in two models: • FS200-50: 1550 nm only version for cost-effective network troubleshooting, including detection of high-losses due to macro-bends • FS200-100: 1310/1550 version for more complete installation verification, as well as troubleshooting. By testing at both wavelengths, FlexScan can differentiate poor splices from macro-bends, as well as qualify the network for operation in both 1310 and 1550 nm windows. Both models include an integrated VFL and are available with optional integrated source, power meter and Bluetooth/Wi-Fi wireless communications. FlexScan test sets are available in three standard kit configurations.


New high-resolution 3D camera captures scenes and objects in real time


sing PMD technology, the new 3D camera sees at a glance, various scenes and objects in spatial dimensions. The heart of this device is a new image chip with 23 000 receiving elements. Output is via a greyscale value and distance image, while evaluation is possible using common libraries. In contrast to laser scanners which only have one receiving element, the image chip of the new O3D type device features 23 000 pixels. Therefore the 3D

Always a good solution


camera has no moving parts, making it wear-free and robust. The intuitive parameter setting software allows easy and quick setting of the camera-specific parameters. Connection to MATLAB, HALCON, PCL and ROS is possible. As each individual pixel measures the distance, it is, for example, possible to precisely size and position cases, parcels and pallets. Moreover, the device facilitates automatic loading and unloading of containers, storage room optimisation, collision avoidance, navigation of driverless transport systems, as well as counting people and room monitoring. Even trunk measurement in a saw mill poses no problem. There is a wide selection of applications for different industries.

Universal electronics housing with integrated connection technology

Are you looking for a truly universal flowmeter? OPTISONIC 3400 is the answer. The unique 3-beam device measures conductive and non-conductive, low and high viscous liquids from –200 to +250 °C / –328 to +482 °F medium temperature. The full bore unobstructed sensor features an all-welded construction without moving parts and can measure bidirectionally, starting at nearly zero flow. And the advanced signal converter covers all I/Os, HART® 7, FOUNDATIONTM fieldbus, PROFIBUS® PA and Modbus communication protocols and features enhanced diagnostics and status indications according to NAMUR NE 107.


he new EH electronics housing system enables device applications to be designed with ease. With seven overall widths, two overall heights, and three cover versions, there are over 100 possible combinations. Various different PCB connection technologies can be integrated conveniently and easily for applicationbased device concepts. The PCB installation in all directions in space also guarantees a high level of flexibility. The electronics housings can be snapped onto DIN rails without tools or

mounted on the wall as usual. An integrated labeling field makes it easy to identify the housing directly. The electronics housings are made of ABS and have a flammability rating of HB according to UL 94. The targeted material selection makes for efficient pricing. With the new electronics housings from the EH series Phoenix Contact has rounded off its product range in the field of DIN rail mountable housings.

OPTISONIC 3400 is a tough and durable device for just about any environment or application – the accurate and ultra-reliable flowmeter of choice. KROHNE – Process instrumentation is our world. KROHNE South Africa 8 Bushbuck Close Corporate Park South Randtjiespark, Midrand Tel.: +27 113141391 Fax: +27 113141681 Cell: +27 825563934 John Alexander


18.5 Groundbreaking high definition handheld thermal camera

829 FLIT TK1 thermal imaging camera

829 FLIR MCC hot spot shows failing connection

829 Using Flir TK1 to inspect indoor electrical panel

nnouncing the release of the FLIR T1020, also known as the FLIR T1K, a premium thermal camera for use in a multitude of industrial and building diagnostics applications. The T1K is a high definition handheld instrument featuring exceptional measurement performance, outstanding image clarity, and a highly-responsive userinterface. The T1K allows users to find hot spots quickly, measure them precisely, and streamline their entire work process. The T1K features outstanding image quality due to the 1024 x 768-pixel uncooled

infrared detector that offers twice the sensitivity of the industry standard for uncooled sensors. This resolution is further boosted by the addition of FLIR Vision ProcessingTM, which combines FLIR’s unique UltraMaxTM super resolution process with FLIR’s patented MSX® image enhancement software that overlays important visual details and perspective, such as numbers and labels, over the full resolution thermal image. The advanced image processing features provide the highest quality images available in a compact system.

High definition imaging requires high precision optics and the T1K’s lenses deliver best-in-class performance. The T1K features FLIR’s OSXTM Precision HDIR optics, which deliver superior image quality and range performance and allow for accurate temperature measurements from twice as far away compared to the industry-standard lenses. The T1K also features a new focusing system that offers continuous autofocus as well as a dynamic manual focus.


Now MIMO capable access points can be deployed in hazardous areas


nnouncing the launch of the iWAP107, the latest in the iWAP series of ATEX and IECEx approved access point enclosure systems. The new iWAP107 brings the advantages of MIMO technology to hazardous process areas. Previously, WiFi links in heavy process areas have been badly affected by multipath interference created by the abundance of metallic structures causing the signal to scatter before arrival. In contrast, MIMO uses multipath algorithms to increase the range, throughput and robustness of the data link by capturing the scattered signals

and recompiling them. The new iWAP107 enclosure system allows the latest MIMO Access Points from market leaders such as Cisco and Aruba to be deployed in hazardous areas to significantly improve wireless performance and reliability. The iWAP107 also comes with the revolutionary iSOLATE500 RF galvanic isolators, which makes all the antenna points intrinsically safe. This enables any standard antenna to be used with the system and allows conventional wiring of RF connections. Designed for use in ATEX and

IECEx Zone 1 hazardous areas, the iWAP107 is a perfect system to allow data to be unlocked from difficult process areas such as oil rigs and heavy petro-chemical sites. The iWAP107 has already been commissioned for use in deep water production platforms where its gigabit Ethernet capability is vital in providing the necessary bandwidth. Extronics have long been pioneers in developing wireless solutions specifically for hazardous process areas and the iWAP107 is the latest in a product line going back to 2005. “We have recently experienced

a dramatic upsurge of wireless enquiries in hazardous areas” said John Hartley, M.D. Extronics. “The iWAP107 is part of a substantial programme of product development designed to costeffectively address this growing demand. It’s use of the new iSOLATE500 RF galvanic isolator means far simpler and more costeffective deployments.” Extech Safety Systems are sole agents for Extronics in Southern Africa and will provide local IA certification for all hazardous area products.

Optimum readability in all positions – new mechatronic flow meter with digital display


new inline flow meters has been fitted with a rotatable

multi-colour display which is clearly visible from all sides. A red/green colour selection of the display values clearly signals to the user when the set values are too high or too low. Moreover, the device has a fast response time of < 10 ms. The piston located in the valve seat in the housing is lifted by the flowing medium against the spring. The piston position is

monitored via a magnetic field sensor and output as an analogue signal. The spring resistance forces the piston to return to its original position with decreasing flow. This ensures positionindependent installation of the flow meter preventing backflow. The sensor head can be rotated by 360°C so that it can be read in any position. Two switching status LEDs on the sensor head,

which are clearly visible from all sides, indicate the set and reset points. The device is rated for medium temperatures up to 100 °C and it can also measure and display the temperature. Thanks to its three pushbuttons, setting is quick and easy. With the IOLink functionality the user is more than fit for Industry 4.0.



Promoting ideas. Building on experience. Remaining curious. We are your reliable partner in the search for tomorrow’s solutions. We provide a wealth of experience, but we’re always open to new ideas. For us, thinking one step ahead is just what we do. Innovation is our passion – and your competitive advantage.


18.5 To repair or to replace – how to best serve your servo motor


he servo motor has an air of mystique around it, even after such a long service life in industry. As a result, there are plenty of maintenance engineers who choose not to repair such equipment themselves. There are others who do try to fix their own servo motors, often with disappointing results. The third group simply replaces faulty equipment – which can lead to repeated problems or unnecessary downtime if a repair is more appropriate. Here, Tony Young, of service, maintenance and replacement specialist CP Automation, explains the key points to consider when deciding whether to repair or replace a servo motor. When making a decision about a faulty servo motor there are three points to bear in mind. These are the cost of the repair versus the cost of the replacement, the speed with which the overall system needs to be up and running again and the availability of spares from the servo manufacturer or its agent. The first of these points is a simple decision based on economics. A good service partner will always provide two quotes – one for repair and one for replacement so you can compare easily. You should never be driven down one route or the other by the repair partner. The second point is normally a question of downtime. If you have a paper mill incurring

thousands of pounds of downtime costs an hour, the decision to simply take the quickest route is a no brainer. However, the question of the availability of spares is slightly more complex. If a manufacturer requests that you deal with its agent to replace an encoder or resolver for instance there can be a delay due to stock levels (or conversely, some agents might speed the process up). The crux of the issue is that while you may have the skills to repair a servo, if you don’t have the contacts you might still incur unnecessary costs. When making these decisions, the principles remain the same throughout industry; the size and rating of the servo doesn’t make much difference, nor does the application in which it is used (except in so far as these factors will influence the three points I have already outlined). In addition to these basic choices, there can be benefits to a repair that aren’t associated with a replacement, and vice versa. If you choose to send a servo to be repaired, your maintenance partner might discover that the route cause of the problem is elsewhere and that the malfunctioning servo is only a symptom of a greater ailment. Because the motor is the portion that revolves, when it isn’t working one assumes that the problem lies with it. However, the motor is often fine when it is tested; this tells us that the problem is elsewhere. Normally, such further repairs are confined to the servo drive or controller but it isn’t unknown for this analysis to diagnose a bearing misalignment, for example. Of course, if a problem with another piece of equipment is spotted, there is a cost associated with replacing or repairing it. However, there is also a saving attached to not having to replace the servo again a few months down the line. In any case, if a servo is replaced by one from another manufacturer then the associated drive and control

electronics will often have to be replaced at the same time. As a director of a company that performs these repairs, I’m very conscious that I’m protecting the good name of the OEM when I make any recommendation. If a customer elects to replace a motor and then discovers further problems like those I’ve already outlined, he may decide that the fault lies with the goods and not their use. This could unfairly bias him against a particular manufacturer. If the decision to repair a servo motor is made, it’s essential that it is sent to the repair partner ‘as failed’. It can then be set it up on a test rig to get an accurate diagnostic before it’s dismantled. This also provides a footprint of the positioning of the electronic commutation device in relation to the motor windings. As a result, it can be precisely realigned after the repair - exactly as it was when it left the manufacturer. This isn’t to say that if a motor has had some work done on it in-situ it can’t be resurrected, simply that the process will be more difficult, longer and more expensive in terms of both charges levied and downtime incurred. It’s a bit like calling in a PC Doctor to your home – if a virus had created problems in the settings on your computer it would be better to leave the virus where it was so that the IT engineer can get a good idea of what caused the problem and thus of all the associated side effects. The principle applies across all areas of repair really. To conclude, the utopian solution when a servo motor problem is identified is to both repair and replace. This is especially true if you have a number of similar systems using identical servos. It provides the quickest solution and insurance against any future problems – because you have an identical spare on site that can be slotted into place.

Speed monitors with high input frequency


range of speed monitors with high input frequency from as low as one pulse per minute up to 60 000 pulses / minute now include an extended operating temperature range down to 40°C below zero. Their luminous OLED display is not only clearer but also brighter.

Several versions are available: speed monitors DD2503 and DD2603 monitor the rotational speed of one channel with two separately adjustable limit values. A separate switched output is assigned to each limit value and an analogue signal is provided for further processing or display. The DD2505 and DD2605 monitor two separate input channels, each having one switch point. The DD2603 and DD2605 can also check that the sensor cabling is intact (when used with the recommended sensors). Other devices in the range fulfil other vital functions: the DR2503 and DR2505 will check that a piece of machinery, such as a hoist or

a pump, is rotating in the desired direction, as dire consequences can result if the direction is wrong. Additionally, the DS series monitors slip or synchronous running. The DS2503 and DS2603 will check for slip between two sides of a drive system by looking for a relative pulse difference per rotation. Other devices in the DS range, the DS2505, DS2506 and DS2605 monitor for absolute pulse differences, so will ensure for example the synchronous operation of two spindles on a lifting platform, or that a gantry crane does not become wedged by moving too fast on one side. In all units, the high-contrast luminous OLED display and the

menu-guided parameter setting are designed for maximum user-friendliness. All units in the monitor range will operate on a wide range of voltages, AC or DC, and provide DC supply to pulse pickup sensors. ifm electronic can advise on and supply suitable inductive sensors, encoders etc. as pulse sensing devices. Speed and standstill, direction, slip or synchronous motion is monitored reliably and accurately with the new features, allowing an immediate response in case of malfunction. Therefore, expensive consequential damage is a thing of the past.


18.5 Compact smart relay offers greater flexibility

Engineered as a plug and play solution, the compact WEG SRW01 is ideal for applications where space is limited.


he modular design of the WEG low voltage electric motor management system offers flexibility by allowing expansion of its functionalities. Engineered as a plug and play solution, the compact WEG SRW01, with state of the art technology and network communication capabilities, is ideal for applications where space is limited.

Designed for use with power supplies from 24 to 220 V AC/ DC, the WEG SRW01 has a facility, if selected, to monitor voltage up to 690 V AC and measures current from 0.25 A up to 840 A. The reliability and precision achieved with the WEG SRW01 smart relay makes the device suitable for the toughest industrial applications. Pre-programmed operation modes allow use in several starting and monitoring configurations, and this includes a mode which allows the device to be programmed for an individual application allowing optimum flexibility. The unit provides LED indication for input and output activations status, operation mode status, power supply status, and alarm status. The digital input and output functions of the control unit are automatically configured as operation mode is selected. The system will also automatically recognise which protocol is in

Designed for use with power supplies from 24 to 220 VAC/ DC, the WEG SRW01 has a facility if selected to monitor voltage up to 690 V AC and measures current from 0.25 A up to 840 A.

use. The digital inputs can be configured to monitor external digital signals. Using this feature, the output contact from an external relay can be connected to the digital input of the smart relay. Significantly, it is this feature which enables the user to incorporate various protection mechanisms, such as earth leakage and thermal (PTC), in the same relay. The WEG SRW01 supports

a range of communications networks including DeviceNet, Modbus-RTU, Profibus-DP, and Ethernet (2016). The communications modules can be easily exchanged due to the design of the system. The WEG SRW01 has a USB port for relay monitoring, programming and online back-up through a PC when using WLP software. Rapid system monitoring and relay parameterisation is done via a Human Machine Interface (HMI) keypad, and the deviceâ&#x20AC;&#x2122;s internal memory makes it possible to record up to three parameter settings or user programmes. The relay incorporates a thermal memory circuit which will maintain the motor thermal image, even in the event of power loss. This handheld keypad allows engineers to link up to 250 WEG SRW01 smart relays offering great flexibility.


18.5 Digital converter


o provide accurate control of, for example, the speed of a conveyor motor, often requires a feedback of the actual speed of the adjacent machine. If this is only available as a pulse sequence, the DW2503 digital converter from ifm electronic offers a solution. The upgraded DW2503 can accept high-frequency incoming pulses up to a maximum 10 kHz, from as low as 1 pulse per minute. The user can scale the conversion of these pulses into the desired

0/4 to 20mA or 0 to 10V signal. If needed, the DW will also invert the signal. As a bonus the DW also features a switched output in the form of a relay and a solid-state transistor, allowing the user to set an alarm signal. The output can be set to stay on for a chosen time. ifm electronic has upgraded the original DW frequency converter to cover an extended operating temperature range down to 40ºC below zero. The

newly developed luminous OLED display is not only clearer but also brighter, and the menu-guided parameter setting is designed for maximum user friendliness. The DW2503 will operate on a wide range of voltages, AC or DC, and provide DC supply to input sensors. As a market leader in the field, ifm electronic can advise on and supply suitable sensors, such as inductive or magnetic pulse pickups, or shaft encoders.

Servo drive offers cabinet space savings and faster commissioning for large machines


achine builders that have traditionally used separate servo drives to meet high axis-count and power requirements for large custom machines can now consolidate to a single platform with the new Allen-Bradley Kinetix 5700 servo drive. The Kinetix 5700 servo drive offers dualaxis servos, a large 1.6 to 60 kilowatt power range, and time-saving tuning technology.


Used in place of multiple servo drives, this next-generation platform can help machine builders reduce cabinet-space requirements by up to 70%, reduce wiring requirements by as much as 60%, and achieve easier configuration and commissioning. The Kinetix 5700 servo drive delivers new levels of simplicity, power and space savings to help machine builders develop leaner machines and get them to market faster. End users also benefit from receiving highperformance machines that are easier to maintain and more flexible to enable faster changeovers. The Kinetix 5700 servo drive uses Load Observer real-time tuning technology, which helps remove the need to tune each individual axis. This can help machine builders deliver high-performance motion control out of the box, and reduce commissioning time by days, weeks or even months for the largest machines. Once a machine is operational, the Kinetix 5700 servo drive uses Tracking Notch Filter technology to detect and remove resonant frequencies, and automatically make tuning adjustments over time to help optimise machine performance. This can reduce the need for regular tuning maintenance and help prevent machine failures. DSL feedback ports provide support for


Kinetix VP servo motors with single-cable technology. This enables machine builders to package motor-power, brake and feedback wires all in a single cable, helping to reduce motion wiring requirements by as much as 60%. The Kinetix 5700 servo drive also combines high-performance vector and servo motor control to help reduce machine complexity, and reduce time and labour costs during integration. Additionally, the Rockwell Software Studio 5000 Logix Designer software provides a single, easy-to-use design environment for configuring the Kinetix 5700 servo drive and integrating it with Logix controllers for both motion and safety applications. From a safety standpoint, the Kinetix 5700 servo drive supports both hardwired safety and integrated safety over EtherNet/ IP, in which safety data is transmitted using the same wires and IP addresses as motion and control data. Integrated safety can help reduce overall system wiring, save time and money during installation, and help remove potential points of failure. Integrated safety also makes safety zoning and configuration changes easier for end users by eliminating the need to physically re-wire devices.



Level switch for Solids/powders

➢ 011 314 1391

➢ 011 695 8000

➢ 0012 345 1005

➢ 011 465 8066


18.5 Wireless tower light provides reliable remote monitoring and visual status indication


ombining the company’s industryrecognised tower light family with its field-proven Sure Cross® wireless technology, the TL70 wireless tower light provides superior monitoring and visual status indication for remote applications, general and machine status, mobile call for parts, mobile work stations, threshold sensing and other applications where wired solutions are not cost-effective, practical or possible. With a Banner Sure Cross wireless node built into the tower base, the TL70 offers two-way wireless communication to

eliminate costly and time-consuming wiring requirements. The TL70 is available in 900 MHz or 2.4 GHz configurations, allowing them to be used with matching, standard Banner wireless gateways. Offering superior flexibility and customisation, the bright 70-mm light tower can display up to five colours—plus an audible alarm module—in one tower. The loud 92 dB adjustable alarm features four user-selectable tones, including pulsed, chirp, siren or continuous. Each light segment can be selected solid ON or flashing, and appear grey when off to eliminate false indication from ambient light. By combining the versatility of the modular tower lights with the reliability of Sure Cross wireless technology, the TL70 wireless provides a unique lighting solution. With high-visibility indication and remote, two-way operation, users can achieve realtime communication to enhance monitoring applications.Banner’s TL70 wireless tower light is available in pre-assembled or modular segments, allowing users to build a custom device. Light and audible segments are

easily configured using DIP switches on each segment. For use in harsh environments, the TL70 wireless tower light features rugged, waterresistant IP65 housing with UV stabilized material. Housing is available in black or grey, which allows users to match the device to their application. Recently, the demand for reliable data transmission between the harsh industrial environment and the office communication network has been increasing.


18.5 Connectors for Industrial Ethernet


ecently, the demand for reliable data transmission between the harsh industrial environment and the office communication network has been increasing. ESCHA offer the appropriate connectivity components for this interface solution. These components include M12x1 round connectors, flanges, and built-in plugs with X-coding for the harsh environments experienced at the field level as well as RJ45-connectors for IT-wiring. Connectors for the field level The four-pair M12x1 round connectors for the field level are based on the 360° shielding concept developed by ESCHA. Thereby, the shield connection is effected through a reliable crimping with the shield housing and not through a crimped plug-connection on the cable. Therefore they meet the IP67, IP68, and IP69K protection class requirements and moreover guarantee a safe and reliable 10 Gbit/s data-transmission speed according to Cat6A. In addition to the manufactured connection and junction cables, ESCHA has added a field-wireable connector to the product line. The portfolio also includes housing feedthrough receptacles for front and back wall installation and an M12x1-flange with angled contacts for direct mounting onto boards. Moreover, a reflow-capable built-in socket for device installation is available and can be adapted to custom-specific housings. The shielding concept has been consistently implemented with these products as well.

Connectors for the office level At the office level the sealing requirements are lower than those at the industry level. For this application area, various RJ45-solutions are available that meet protection class IP20. The 4-pole and 8-pole connection and junction cables of the RJ45-connector provide for data transmission according to Cat6 and are also available in an overmolded as well as a field-wireable version. All variants are multiport capable through their compact housing style. Applications with high data-transmission speeds Given the ever-increasing higher datatransmission speeds, ESCHA is quite confident that they will be able to meet their customer’s current and future requirements with its comprehensive product program for Industrial Ethernet applications. According to ESCHA, there are three main industrial areas that require high datatransmission speeds. These are building wide management systems being installed in industrial facilities, device installation on the production line and the area of vision and scanner systems for production monitoring and real-time data evaluation. In addition to the industrial application areas, there are more application environments. For example, rail and security applications. In particular, entertainmentsystems on trains that provide passengers with a reliable seat-internet connection and monitoring cameras which place similarly high requirements on data transmission and

the robustness of the connector. Apart from high transmission speeds, the trend will also continue to move towards quality. It is only when misinformation during data transmission is avoided, that the available high transmission speeds can also be used. In new applications with higher data volumes, inferior cables cause transmission errors. That means, data packages have to be resent which in turn leads to higher network traffic and longer protocol-processing periods. Particularly sensitive systems may even experience a bus crash. At this point, ESCHA has high-grade M8x1 and M12x1 Industrial Ethernet components for all common Ethernet protocols (sercos, EtherCAT, ProfiNet, Powerlink and EtherNet/ IP). The connector and housing manufacturer has launched connectivity products that provide for measurable high data-transmission speeds. All products guarantee a reliable, fast and safe futureproof data transmission through increased signal reserves. Comprehensive portfolio for IEapplications Besides the M12x1 connectors with X-coding and the new RJ45-products, ESCHA continue to offer its proven M12x1-portfolio with D-coding designed for Industrial Ethernet applications with a data-transmission speed of Cat5e. This comprehensive 4-pole product range is also based on the proven 360° shielding concept and guarantees better network traffic through high signal reserves.

New compact hand-held vibration meter


nnouncing the launch of UK-based Monitran’s MTN/VM220, a compact, handheld meter for measuring vibration levels. It is a rechargeable, portable instrument designed to operate with a constant current accelerometer to provide accurate vibration measurements. Conforming to ISO10816-3, the MTN/VM220 is engineered to detecting the early signs of component wear or failure in pumps, motors, gearboxes and other mechanical assemblies. Measuring only 122 x 78 x 28mm, the MTN/VM220 has an easy-grip, rubberised case and a long-life rechargeable battery. The unit is shipped in a foam-lined, durable carry case and includes the MTN/2200, a general purpose sensor probe with a default sensitivity of 100mV/g, as well as a magnetic base and spike (for use with the probe), a coiled cable with a 4-pin Lumberg connector at each end, and a universal battery charger. The meter features a colour LCD display and has the ability to store up to 100 readings against a real-time clock.


18.5 Heavy-duty fiber optics *Additional 6 months warranty guaranteed on all field instruments purchased with any surge arresters* - NEW


ntroducing new heavy-duty Vantage Line fiber optics to complement its industry-leading fiber amplifier product family. Featuring a flexible 304 stainless steel tube, the polyethylene jacketed plastic fiber is protected from crushing or abrasion in harsh industrial environments. To accommodate diverse applications, the heavy-duty Vantage Line plastic fibers are available in eight different models, four with opposed sensing mode and four with diffuse sensing mode, in one and twometer options. All heavy-duty fibers are compatible with Banner’s existing plastic fiber amplifiers, including the DF-G family. The new heavy-duty vantage line of plastic fibers offer enhanced durability and stable performance at a cost effective price. With these heavy-duty models, customers can use plastic fibers in rugged environments where they previously used more expensive glass fibers. Banner’s DF-G fiber amplifiers deliver stable sensing performance with fast response rates. With a thermally stable and high performance electronic design, DF-G fiber amplifiers feature dual display, digital readouts and an improved fiber clamp. DF-G fiber amplifiers also offer complete user control, providing manipulation of all operating parameters, including switch point threshold, light operate or dark operate, various output timing functions, electronic gain level and sensor response speed. With a wide range of fiber amplifiers, Banner can effectively serve a diverse range of industries and applications, including small part or wire break detection on electronics assembly machines, pill and caplet counting and high-speed detection for registration mark or product leading edge detection.

Powerful PV overvoltage protection DC application requirements and


he new VAL-MB product family provides powerful and compact protective devices for photovoltaic applications with generator voltages of up to 1500 V DC. The protective devices are specially adapted to

certified by KEMA. Longer inlet funnels and higher screw shafts provide additional protection against arcing. The product range includes protective devices for generator voltages of 600 V DC, 1000 V DC and 1500 V DC, as type1/2 lightning current arresters, as well as pure type 2 surge protection devices. Variants are available with or without remote signaling contact. All protective devices have a short-circuit protection of 2000 A and can also be used in high-altitude plants up to 6000 meters in altitude.

A bull’s eye in quality. Highest safety at the lowest price! Surge arresters HAW569 • Compact device for the protection of signal/communication lines or for the simultaneous protection of signal, communication and supply lines • Optionally available with SIL2 intrinsically safe approvals


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18.5 Power distribution enclosures comply with new IEC standards


he new range of XL³ modular power distribution enclosures complies with international IEC 61439 standards that have replaced the previous edition of IEC 60439. The certification of enclosures is defined by IEC 61439-1 and IEC 61439-2 for power switchgear and controlgear assemblies. This accreditation formulates the definitions, operating conditions, structural provisions, technical characteristics and tests for low voltage wiring accessory assemblies. Modifications to these IEC standards encompass three different, but equivalent types for verifying requirements. These are verification by a test, verification by calculation or measurement, or verification by satisfying design rules. Unlike IEC 60439-1, conformity cannot be established simply on the basis of the general rules of the standard. Assemblies must comply with the specific standards dedicated to them. Compliance with standard IEC 61439-2 also enables the CE mark to be attached, if required. There are 13 standard tests for the certification of pre-equipped enclosures, which are an additional guarantee of safe operation. Legrand is also committed to

carrying out ten type tests. Characteristics that need to be checked include resistance of materials and parts, temperature rise, degree of protection (IP), dielectric properties and short circuit resistance, as well as electric shock protection and integrity of the protective circuit. Clearances and creepage distances, mechanical operation and electromagnetic compatibility are also important. Standards IEC 61439-1 and IEC 614392 also require final checks on all wired assemblies. These checks certify that the essential characteristics linked to safety are fully complied with. The XL³ cabinets and enclosures - for sites between 160 A and 6 300 A - provide solutions adapted to meet exact site power distribution needs in industrial, commercial and residential environments. Most importantly, these units comply with every part of the standard IEC 61439 to guarantee reliability and total protection of the installation. Each model in this range includes a selection of sizes, versions and equipment. XL³ enclosures are enhanced by Legrand devices for optimum protection and efficient distribution. These devices include DMX³ air circuit breakers, MCCB’s, DX³ DIN rail mounting circuit breakers, busbars and modular distribution blocks. XL³ metallic or plastic enclosures, with index protection ratings between IP 30 and IP 55, have a short circuit resistance from 20 kA to 110 kA. This flexible power distribution system, which can be adapted at any time, includes either standard or optimised distribution. Standard distribution allows the user to choose busbars and their supports, with a personal configuration for efficient power distribution. The optimised distribution system, which ensures freedom of assembly, eliminates the

need to create special connections upstream and ensures time savings during installation by being able to connect appliances on preequipped units. Also available to optimise the design, is user-friendly XL Pro panel design software, incorporating XL Pro Calculator software, which automatically calculates the total power consumption, required protection devices and cable selection for the circuit, as well as cascading and discrimination solutions.

New pressure-resistant sensors for hydraulic cylinders detect ferromagnetic metals


his latest development features an innovative operating principle and has a pressure rating of up to 500 bar. With a one-piece metal housing, the MFH / M9H series pressure resistant sensors are extremely robust. They offer IP 65/68/69K protection rating for harsh environments and temperature stability from -25 to 120 °C. The technology relies on a MR measuring cell with a permanent magnet all in one housing, so only ferrous metals, like tool steel, are detected and an external magnet is not necessary. Other metals such as aluminium or stainless steel do not have any effect on the sensor. The units can not only be used as limit switches in hydraulic cylinders, but also on other hydraulic components like valves or

pumps, in mechanical engineering or in the process industry. The MFH design offers a bursting pressure exceeding 2 000 bar. The full-metal housing assures permanent mechanical resistance to pressure fluctuations, shock and vibration. By contrast, ceramic active surfaces, however, can be easily damaged by impacts. The high temperature stability allows the unit to maintain its full functionality both in extremely hot machines and in outdoor applications in direct sunlight. The new easy-to-mount sensors come with a M12 or M14 housing and offer high performance at a very attractive price.


18.5 Precise measurement of consumable fuels in automobile industry


OBOLD Instrumentation was asked to look into, and supply a solution to an on-going “headache” for an established Japanese automotive company – how to accurately record the exact quantity of fuel received on-site, daily. In order to track every single part and consumable needed to get the 28 000 cars this manufacturer produces monthly, up and running, it goes without saying that the logistics department’s records have to be highly accurate and instantly accessible. One of the most important consumables is fuel, both gasoline and diesel. These fuels are not only used for car testing, but also for utility purposes like fork-lifts, emergency electric generator, inter-plant transportation, etc. The flow and level metering of the fluids, had always been of concern to management. The automotive company routinely purchases fuel, which arrives at

the plant site by fuel truck. It is unloaded and stored in several dedicated storage tanks. The existing gear flow meters had been running for more than 10 years and the operation was handled by a single field operator, using simple log book. The level meters were even more traditional, using only mechanical floats and simple “onthe-tank-side” scale. KOBOLD’s aim was to provide the automotive company with more accurate measurement, while minimizing human error and providing on-line data acquisition, which also generates a separate report for management use. In order to improve the quality of measurement, KOBOLD also urged their distributor to provide the customer with adequate air eliminating units, which resulted in the entire flow metering piping system being modified. KOBOLD proposed using their TME coriolis mass flow meters and NMC capacitance level transmitters, integrated with a PCbased centralized data acquisition unit, to be located in the Logistics Room. Thus giving the company a completely new flow metering and level measurement system for the client’s truck unloading and storage system, which has been running effectively since installation.

The Beckhoff Automation IPC & Applications Seminar.

Rob Rawlyk, Senior Application Engineer, Beckhoff Automation, Germany with local Managing Director Kenneth McPherson and Roland van Mark, Product & Marketing Management Industrial PC, Beckhoff Automation Germany.


18.5 Safety in the time of Industry 4.0 - robot protection with laser scanners


safety laser scanner with dynamic protective field switching demonstrates sensor intelligence of the future. With Industry 4.0. this is fast becoming the prerequisite for safe interactions between humans and machines. Safety laser scanners from SICK reliably monitor the hazardous area of stationary or mobile machines and systems

such as welding robots or automated guided systems. The protection of personnel is the top priority: If a person enters the area, the dangerous movement must be stopped safely. In the established systems, this means that the person is protected but production stops. Safety technology of the future In the future, the manufacturers will be able to use intelligent sensor technology within the context of Industry 4.0 to not only ensure the safety of personnel, but to meet ever-increasing production requirements as well. The company already offers up to four simultaneous protective fields, resulting in a significant improvement in the ergonomics and efficiency of complex machines; for example, in the case of tire curing presses. The digital protective fields used today are being replaced by flexible ones. Flexible protective fields are calculated automatically

High-specification Zone 1 smartphone


he new, intrinsically safe, Extronics Rough Pro is a high specification, extremely rugged smartphone with a large, crystalclear 4.5” gorilla glass screen. The unit is ideal for “Smart Worker” solutions in the most extreme of environments. Key Features • Android OS - Extronics Rough Pro smartphones can run numerous applications. • Screen Quality - The large 4.5” screen is easily readable - even in direct sunlight. • 8 Megapixel Camera - High resolution photographs and video streaming. • Highly Connected - Dual SIM quad band, Bluetooth, Wi-Fi and mobile network features. • Rugged & Shockproof - High

build quality and MIL-STD 810G certified. Ideal for the harshest environments. • Waterproof - Rated as IP68 can be submerged in water for 40 minutes. • Fully Featured - With GPS, accelerometer, Gyro and compass, The Extronics Rough Pro is the ideal tool for worker safety solutions such as location tracking and man-down. The Rough Pro is the latest product from Extronics designed to help companies operate with high efficiency in hazardous areas. With ATEX & IECEx Zone 1 certification, the Extronics Rough Pro has the features and pedigree needed to succeed.

for highly dynamic movements and are adjusted according to the hazardous areas of the robot. Intelligent sensor technology also makes commissioning much easier and quicker. An optimal interaction between intelligent sensor technology and modern machine concepts boosts the productivity of the machine and ensures the safety of employees at all times. With its extensive portfolio of safety laser scanners, all requirements are met – mobile or stationary, for area protection or access monitoring. The compact systems scan their environment in two dimensions using an integrated rotating mirror like an optical radar, and measure distances using the principle of time-of-flight measurement. This produces freely definable protection areas.

Durable and powerful type-1 lightning current arrester


he Flashtrab SEC-PLUS type1 lightning current arresters, which are particularly durable and powerful thanks to Safe Energy Control Technology, have just been complemented by two product variants: The Flashtrab SEC-PLUS 440 product variant is particularly suited to special industrial applications with 440/690V networks or 400-V power supply systems. The products impress with their strong shock and vibration resistance. This compact variant can be used up to 400 A without an additional backup fuse. The Flashtrab SECPLUS 350 variant is used in the pre-metering area of the main feed, or in industrial applications. High voltage fluctuations and lightning current loads are no problem for the type-1 arrester.

The good protection level and backup fuse-free use up to 315 A deliver additional advantages. Both variants are pluggable and can be tested with the CheckMaster 2 test instrument for surge protection devices. Like any other SEC family type-1 arrester, the Flashtrab SEC-PLUS devices are also type-2 arrester tested and certified. The protective devices of the SEC product family have been completely redeveloped and are based on Safe Energy Control Technology (SEC). The spark gap safely prevents any power supply secondary current. This means that the load of the entire installation is reduced to a minimum in the event of a lightning event.




18.5 Laser contrast sensor with fixed background suppression


eaturing contrast detection, plus fixed background suppression, the Q3X LD50 reliably detects targets within the desired sensing range while ignoring objects in the background. Out of the box, the Q3X LD50 operates like

a fixed-field laser sensor and detects targets within its 50 mm sensing range. However, the sensor can be programmed for low-contrast sensing within this range, while ignoring objects at least 60 mm away. This allows the sensor to accurately detect its target without background objects affecting its performance. With fixed background suppression, the Q3X overcomes the main problem of standard diffuse-mode sensors where objects in the background affect the application. The Q3X LD50 is an innovative solution for the hardest detection and error-proofing problems. Featuring high-speed part detection as fast as 250 μs, Banner’s Q3X laser contrast sensor can capture up to 2,000 events per second. This, along with background suppression, makes the Q3X ideal for solving applications with small contrast changes where a background needs to be ignored. A typical application is label detection

on a bottle where contrast differences between the label and bottle provide reliable detection but the sensor must ignore the shiny metal rail in the background. The shiny metal background could cause a false trigger for standard diffuse-mode sensors. Banner’s Q3X is designed with a unique angled, three-digit display of signal intensity, which provides high visibility of operating conditions from multiple angles. For an intuitive user setup, the Q3X has two tactile buttons conveniently located below the display. The Q3X’s robust nickel-plated zinc die cast housing ensures reliable performance even in environments with exposure to cutting fluids and oils. Sensors are also rated to IP67, IP68 and IP69K for enhanced protection to water submergence and highpressure washdown.

Three new sensors for conductive conductivity measurement in liquids

Three new 2-wire loop powered sensors SMARTPAT COND 1200, 3200 and 5200 for conductive conductivity measurement in liquids.


ntroduced in 2013, SMARTPAT is a series of digital 2-wire loop powered sensors with integrated transmitter technology. Using a VP cable, any SMARTPAT sensor can be connected directly to the process control

system via 4…20 mA/HART 7 interface. This offers advantages in both handling and costs of a measuring point. An additional transmitter on site is no longer necessary, SMARTPAT sensors can be configured and calibrated offline via PACTware FDT/DTM, on site with a HART handheld or an optional loop powered operating unit.Targeted at the water and wastewater industries, the application area for SMARTPAT COND 1200 (measuring range for cell constant c=1: 100 µS/cm…20 mS/cm) ranges from process monitoring/ control in water treatment plants (industrial and drinking water), water quality/limit values monitoring, to filter monitoring. SMARTPAT COND 3200 (measuring range for cell constants c=0.1: 1…1000 µS/cm, c=0.01: 0.05…10 µS/cm) is aimed at quality measurement in condensate, cooling water, boiler feed water in power plants. Also, it can be used for reverse osmosis, monitoring of

ion exchanger, deionization or desalination processes, e.g. in semiconductor production. SMARTPAT COND 5200 (measuring range for cell constant c=1: 10 µS/cm…15 mS/ cm) is designed for use e.g. in separation processes (caustic solution / water) or process monitoring in water or wastewater treatment in chemical, petrochemical as well as in water and wastewater industries. Each SMARTPAT sensor is specifically designed for its area of application: approvals and certificates range from installation in hazardous areas up to zone 0 to hygienic areas. Along with the sensor family, KROHNE offers a large portfolio of accessories, including loop powered indicators, USB interface cable, junction box, operating unit, standard solutions, sensor cables and mounting assemblies.

New appointments at Yokogawa

Clint Viviers Pressure and Flow Product Specialist

Fanie Ferreira Front Sales Engineer: JHB East and Phalaborwa

Hanno Hartzenberg Analytical Product Specialist


18.5 Point level switch for liquids in the food and beverage industry • • • •


he Liquipoint FTW33 from is a point level switch for liquids in the Food and Beverage Industry and part of the new product line. FTW33 complements the already launched Liquiphant FTL31 and FTL33 and further products are to come with the well-known quality, variety and durability. The new product line offers: • Same look & feel

Easy selection & installation Distribution through Global E-direct Portal Economical pricing Fast delivery time due to global production and logistic concepts Liquipoint FTW33 The Liquipoint FTW33 is a very compact and flush-mounted point level switch for water-based and oil-based media. It is developed for the Food and Beverage Industry and meets all hygienic requirements. The FTW33 is intended to be used in applications with pasty and sticky media. The active build-up compensation guarantees reliable switching even if heavy build-up on the sensor occurs. Advanced: • Oil and water-based fluids and pasty/sticky media • Real flush-mounted Reliable: • Active build-up compensation • Function check with test magnet Easy: • No calibration or adjustment required • Plug & play without any specific tools Benefits: • Perfect fit to the hygienic industry thanks to flush-mounted design, which allows

pigging • Safe and reliable measurement due to active build-up compensation, ensuring reliable switching • No individual adjustment to each medium necessary • Easy installation thanks to compact design, even in tight conditions or where access is restricted • Broad range of process connections for installation in new and existing plants • CIP and SIP cleanability ensured - up to protection class IP69k • LED display for on-site function check Technical details: • Process temperature: -20 to +100°C (-4 to +212°F), up to +150°C (+302°F) for 1 hour • Process pressure: -1 to +25bar (-14.5 to 362.5psi) • Sensor material: 316L/PEEK • The material PEEK meets the requirements of EU 1935/2004, 10/2011 as well as 2023/2006 and FDA 21 CFR 177.2415 • Sensor length: Flush-mounted • Electrical conductivity of media > 1µS/cm or dielectric constant >2 • Approvals: CSA, EN10204-3.1, EHEDG, 3-A

100 95 75

25 5 0

2015-07-DPM_WNIPRev1-0_190x130 28 July 2015 01:25:53 PM


18.5 Contactless temperature measurement


emonstrating innovative market competence in the area of optical sensor technology, the new high performance Wenglor OptoTemp allows contactless temperature measurement within a range of -25 to 350º C based on infrared radiation emitted by the object, regardless of the material it is made of and state of aggregation.

The sensor measures temperature with a spectral sensitivity of 8 to 14 µm. The measured value appears at the integrated. Intuitively-operable display and is read out via the outputs of the RS 232 port. Due to its two switching outputs and an analog output, the sensor is suited for various measuring applications, for example target versus actual value comparison and absolute measurement. The integrated laser alignment tool and teachable emission factor make initial start-up quick and easy. This is a genuine allrounder with applications from conventional target versus actual value monitoring of liquids and raw masses, as well as process control for the prevention of temperature violations at nonmetallic surfaces, right up to the monitoring of engines and system components in the

automotive industry. Downtime is avoided, scrap can be reduced in production and uniform product quality can be assured throughout the entire value creation chain. Features: • Contactless temperature measurement within a range of -25 to 350º C • Two switching outs for simple setup versus actual value comparison • Freely scalable analogue output for absolute measurement • Output functions can be configured as desired (PNP/NPN, NO/NC, 4 – 20 mA / 0 – 10 V) • Emission factor adjustable from 0.1 to 1 • Integrated laser alignment tool • Easy adjustment via intuitive menu and 7 segment display or wTeach2 (RS 232) •

Laser distance sensor with new dual mode solves clear object detection and error-proofing applications


eaturing new firmware, the Q4X dual teach mode sensor combines window thresholds on both target distance and target reflected intensity, allowing the Q4X to reliably solve difficult applications with ease. The Q4X can now detect clear objects without requiring a retro-reflector. Dual mode can be used to error-proof applications by ensuring that the correct colour part is located at the correct position. Banner’s Q4X reliably detects distance changes as small as 1 mm and covers a 25 to 300 mm range. The sensor was already ideal for difficult distancebased sensing applications as it easily detects objects regardless of target surface reflectivity, including black foam on black plastic, black rubber in front of metal, multicolour packaging and targets of all colours. Now with the dual teach mode, the sensor can detect small changes in reflected intensity for targets inside the distance threshold. This powerful combination allows the Q4X to solve many new applications.

Incorporating the innovative dual teach mode into the next-generation Q4X sensor provides customers with a more powerful sensing solution for their most difficult applications. With combined intensity and distance thresholds, the Q4X extends its world class sensing performance to clear object detection and common error-proofing, or poka yoke, applications. Offering a simplified user experience, the Q4X includes a bright readout on a highly visible, angled four-digit display that is easily viewed from multiple vantage points. The Q4X also offers intuitive user setup utilizing three tactile push-buttons conveniently located below the display. The Q4X is constructed with robust housing rated to IP67, IP68 or IP69K, allowing use in wet and high-pressure washdown environments, durable FDA-grade stainless steel resists mechanical impact, over tightening, extreme vibration and aggressive cleaning procedures.

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Laser measurement sensor now available in analog models


Wireless Networking Extended


he Q4X lasers distance sensor is now available with an analog output. Featuring 4-20mA and 0-10 V output options, the Q4X analog models expand the variety of applications Bannerâ&#x20AC;&#x2122;s Q4X laser distance sensor can solve, including fill level indication, part positioning, roll diameter, loop control and thickness/ height verification. Providing continuous measurement and versatile sensing performance, Q4X analog sensors provide resolution as small as 0.15 mm and cover up to a 300 mm range. The sensors deliver reliable measurement regardless of colour or reflectivity of target object or background. While the original Q4X has become a problem solver for many customersâ&#x20AC;&#x2122; challenging sensor applications, the manufacturers discovered a need for an analog model to satisfy additional applications such as fill level verification. Advanced measurement modes, including the averaging trigger, provide more consistent measurements across inconsistent surfaces, such as pills inside a bottle. With a combination of analog output and durable stainless steel housing with IP69K rating, the Q4X analog provides a truly unique and reliable sensing solution. The Q4X analog offers a simplified user experience with analog (V or mA) or distance (mm) readout from the highly visible, angled four-digit display that is easily viewed from multiple vantage points. The Q4X also offers intuitive user setup utilizing three tactile buttons conveniently located below the display. For use in wet and high-pressure washdown environments, the Q4X is constructed with robust housing rated to IP69K. Durable FDAgrade stainless steel resists mechanical impact, over tightening and extreme vibration.

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Power cables with M12 connectors for worldwide use


he M12 Power cables for assembly are now listed according to UL 2237 and CSA C22.2 No. 182.3 (Canadian Standards Association). This means that they can be installed in machines that are exported to North America. The product range comprises M12 power cables with S and T coding that were developed and added to the IEC 61076-2-111 standard. The S coding with up to 630 V and 12 A is designed for AC applications such as those in motors. The T coding with up to 63 V and 12 A is suitable for DC applications such as those in network components. The range is rounded off by connectors with screw connection for assembly, a Y-distributor, and a distributor box with four connections for decentralized power distribution.

Easy distribution On the I/O module, the thumb wheel is also used to assign the inputs and outputs, thereby easily distributing the I/O signals in the system. Easy addressing Set the address on the wireless module by simply turning the thumb wheel. Easy installation Create a modular wireless station in the control cabinet and extend or replace it easily during operation. Phoenix Contact Offer a Wide Range Of Industrial Wireless Solutions. Call us today for your solution. JHB: 011 801 8200 CT: 021 930 9666 DBN: 031 701 2701 PE: 041 3640415


18.5 Dependable electricity production


lternators ensure dependable electricity production in diverse industries, including the telecommunications sector. Telecommunications plays an increasingly vital part in all aspects of commerce – particularly in data processing centres and base transceiver stations (BTS) - and requires absolute dependency on a reliable power supply. In the event of a power cut, back up generator units are used to ensure continuous and efficient operation of the network and can maintain power for several days. Low voltage generators, fitted with alternators from the Leroy Somer Partner range, offer reliable solutions that are specially adapted to back up BTS sites in the telecoms industry. These robust alternators ensure an uninterrupted power supply for the continuous reception and transmission of data; power to the computer and storage systems and power for the building’s lighting, air conditioning and safety systems. A data centre, which hosts computer systems and associated components - including telecommunications and storage

systems - is the nerve centre of the network. Because data has to be accessible to users at all times, a dependable supply of electricity, without interruption, is critical. Data centres house uninterrupted power supply (UPS) systems that are sensitive to external interference. For this reason, the sizing and selection of the correctly specified alternator is critical. Leroy Somer Partner alternators, from 250 kVA to 3250 kVA, are designed to meet the demands of data centres. These energy efficient alternators have low reactance and improved performance with distorting loads. They have a greater starting capacity and are capable of supporting high load variations. The company also has specific winding designs to reduce harmonic distortion, with a 2/3rds winding pitch or 5/6 winding pitch, depending on which harmonic wave needs to be compressed. Base transceiver stations, with relay emitters, also require a continuous power supply to facilitate dependable radio access for cell phones in their coverage area. In the event of a power cut, one or more back up generator units are used and can maintain power for several days.Solutions for BTS relays include Leroy Somer Partner alternators, from 8,5 kVA to 80 kVA. These units have low reactance and reduced sensitivity to distorting loads. This energy efficient range, with more power from the same engine, has a greater starting capacity and is capable of supporting high load variations. The company also offers a variable DC generator, designed especially for this application. The variable speed option optimises fuel consumption, as the engine speed is reduced according to the load requirements. Maintenance charges and associated costs with the delivery of fuel are also reduced. An additional benefit is the need for fewer components used in the rectification from AC to DC as used in a traditional power generation system.The company’s EPG range also includes DEIF generator controls and Covrad heat exchangers.

Connecting IO-Link sensors to Ethernet media converters for Profibus DP basic requirements


he number of devices with IO-Link built in is increasing rapidly, and so is their popularity, as users realise the advantages of the transparency, ease of configuration and flexibility offered by the technology. IO-Link transmits not only digital, but also analogue signals from an IO-Link device directly as values, reducing conversion losses from the original measured value to 4 to 20mA and back again.The AC2625 provides four connections for IO-Link devices and, in common with the others in the range, has an additional port for optional external power as well as the Profibus DP in and out connections, yet is still only 30 mm wide and 210 mm long so none of these modules will take up much space.With the compact fieldbus module, IO-Link sensors and other ifm sensors can be connected directly to Profibus DP. Configuration and diagnosis comply with Profibus standard IEC 61158 (DP V1), which allows acyclic data transmission. Other members of the product family have digital or analogue inputs and outputs. Offering maximum flexibility, the FieldModuleDP is the ideal solution for manufacturing and process automation applications. Compact, sturdy and using standardised M12 connections for sensors and actuators, quickly integrated into the machine, with no need for a control cabinet, make this module a top choice. Moreover, the corresponding GSD file provides a full and unambiguous description of the unit type characteristics in a precisely defined format.


he new class 1000 Ethernet media converters are designed for industrial applications with basic requirements. They offer a simple and cost-effective entry into optical transmission technology. Data transmission via fiber optics optimizes Ethernet

applications in terms of performance and transmission reliability. In addition to a higher range, the benefits of electrical isolation are also reaped. The compact units in robust metal housings bridge distances of up to 9.6 kilometers. Multi-mode glass-fibers are used, optionally with SC duplex or B-FOC (ST) plugs. Start-up is simplified by auto negotiation and auto crossing. In addition, data rates of 10 and 100  Mbps can be firmly set. Besides numerous diagnostics LEDs, the media converters are equipped with LFP function (Link Fault Pass-through). This ensures permanent and continuous monitoring of the connection. In the event of a connection loss, redundancy mechanisms can take over operation immediately.



Machine-mountable EtherCAT Box I/O also offers considerable benefits for PROFINET applications


hrough the openness of PC-based control technology, major technological benefits can be leveraged in conjunction with numerous communication networks. The new EP9300 EtherCAT Box, for example, provides a gateway to PROFINET RT networks. This enables the use of the high-performance EtherCAT Box I/O system as an integrated IP 67 solution in PROFINET environments. The IP 67-protected EP93000022 EtherCAT Box connects PROFINET RT networks with EtherCAT I/O modules, enabling local installation in the field. This extends the higher-level network – entirely without the use of a control cabinet – with a subordinate, high-performance, and ultra-fast I/O solution. The telegrams are transferred from PROFINET RT to EtherCAT and vice versa, so that the EtherCAT Box modules can be integrated seamlessly. The shock- and vibration-resistant, sealed EP9300 EtherCAT Box is connected to PROFINET via a d-coded M12 socket.

The I/O system consists of an EP9300, to which a wide range of standard digital and analog EtherCAT Box modules can be connected, as determined by the respective process data volume. IP 67 I/Os for all applications The three EtherCAT Box series – EP, EQ and ER – provide a wide range of IP 67 I/Os, which can be installed directly in the field. The range includes standard digital I/Os and modules with special integrated functions, such as stepper motor modules or modules for highly complex measuring tasks. The EtherCAT Box I/Os are available with different housing types to meet the requirements of a wide range of industrial applications. The EP series with plastic housing is ideally suited for moist, dirty, or dusty conditions in general machine construction, in assembly applications, or in semiconductor and logistics environments, for example. The EQ module series, with its stainless steel housing and IP 69K protection, is designed for applications in the food/beverage, chemical, and pharmaceutical industries. The modules from the ER series have a particularly robust, fully sealed die-cast zinc housing, making them ideal for harsh industrial and process environments, such as pressing systems and metal foundries, or automotive environments and robotics applications where weld spatter resistance is a key requirement.


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A broad range of Cable Accessories, form part of the extensive range offered by Helukabel This includes Protective Tubing, Sleeving, Compression Glands, Reducers, Enlargers, Braids, Tube Holders, Drag Chains, Connectors and much more

Installation system for small cross sections

he QPD installation system with Quickon IDC fast connection technology is now available for conductor cross sections from 0.5 mm² to 1.5 mm². This compact product group is particularly suitable for applications with limited installation space.

Cables, Wires & Accessories

The entire product portfolio now covers conductor cross sections from 0.5 mm² to 6 mm² and is suitable for power up to 690 V/40 A in power distribution in widely distributed machines, systems, and buildings. The fast connection technology of the installation system allows savings of up to 80 percent installation time. For connection, only the cable sheath must be removed; the litz wires are arranged in the splice body, cut flush, and screwed. No special tools are required. Another advantage is the robust design and therefore the flexible use of the products. They satisfy the requirements of protection classes IP68/IP69k and IK07 impact strength. The product range includes panel feedthroughs, cable connectors, connectors, and H- and T-distributors.

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18.5 Bar code scanners with dual port on board to reduce cabling for logistics


he new CLV615 Dual Port bar code scanner features an integrated switch that makes it easy to install the sensor in a PROFINET IO network. Installation in a line and ring topology reduces the amount of cabling, time and money required for mounting, whilst the compact housing, simple configuration and reading field optimized for intralogistics make it quick to integrate into a conveyor system. With the CLV615 Dual Port, SICK is adding to its portfolio of flexible fieldbus identification sensors. A bar code scanner with a PROFINET Dual Port already integrated into the housing now complements the PROFINET

on board Single Port for bar code scanners, image-based code readers and RFID devices. This means that either the existing solution with the external CDF600-2 fieldbus module or the variant with Dual Port on board can be used to integrate the scanner in a ring topology as required. The cross-technology platform strategy, 4Dpro, guarantees that all devices are compatible in terms of network connection and can be linked in a network with other SICK ID sensors. CLV61x Dual Port – the network pro This compact laser scanner is the optimum solution for identifying totes within picking and conveyor systems. With a scanning frequency of up to 1000 scans per second and a reading field of between 25 mm and 330 mm, it is ideally suited for intralogistics. Even where space is limited, the compact housing with rotating system plug makes it is easy to mount. In addition to the two SPEEDCONcompatible “PROFINET” connections (M12 female connector), an integrated power cable with an M12 male connector provides a simple power supply via a flat ribbon cable. A total of five LEDs provide detailed status information

for the scanner and PROFINET, so faults can be rectified in an efficient and targeted manner. Flexible configuration for flexible networks There are a number of different configuration methods. As well as typical configuration direct in the control environment (via a GSDML file), the scanner can also be configured using the SOPAS ET user interface. Diagnosis and reconfiguration are made easy by an auxiliary USB interface, as well as the two Ethernet ports. To save time, identical control and software structures and settings can be duplicated in further sensors, speeding up the commissioning process. If the bar code scanners are installed in a ring topology, the redundant setup means that the system is guaranteed to continue running, even if there is an isolated fault in the cable or a field device. This is due to the fact that the CLV615 Dual Port supports the media-redundant protocol, thereby ensuring continued data communication with every device in the network after a short switching time.

Eliminate pump damage


umps are indispensable in mining, petrochemical, irrigation, food, refining and many manufacturing operations, so their failure causes costly unscheduled downtime. In the case of an electrical ground fault the pump’s drive motor can be destroyed, and it can result in high voltage potential on the pump equipment framework that is a serious

safety hazard to personnel. Pumps can run dry, while jammed pumps can cause the motor to overload, leading to catastrophic damage to the motor and other electrical system problems.The KC pump motor protection relay provides a platform for effective protection that includes overloading, load loss, under-voltage, over-voltage and running stall protection. The relay also has phase loss and unbalance protection, as well as the optional capability for automatic restarting of a pump that has run dry after a user selected time period. In instances where overload protection is already available for a pump, this may be complemented by adding a load loss protection relay to the existing protection in the form of the NewElec UCR 80 undercurrent protection relay. These relays are effective in providing load loss protection for pump applications or any other situation requiring

the monitoring of motor load. The relays, can for instance, be used to measure the efficiency of motors with regard to impellor wear. KC relays are DIN rail-mounted and offer a very small footprint and low profile making them ideal for chassis mounting. Control panel-mounted LEDs provide maintenance staff with the necessary information to clear the indicated faults. For smaller pumps not drawing in excess of 25 A, the on-board integrated current transformers are all that is necessary for protecting a pump. Larger motors will require the installation of interposing current transformers where the 5 A secondary circuit is wound through the on-board CTs. KC relays are designed for motor full load currents of up to 200 A and are an ideal selection for pump protection.

Robust I/O system classified for shipbuilding


hanks to low noise emission in compliance with EMC Class B and its mechanical robustness, the Axioline F I/O system fulfils the stringent requirements for automation in shipbuilding. As a result, the I/O system has now obtained the approval of all major maritime safety testing associations, including, in particular, the attainment of the BSH certificate and passing the compass test. This certificate allows an I/O station to be installed only a few centimeters away from sensitive standard solenoid compass units. The new XC variants of the I/O system also offer an extended operating temperature range from -40 to +70 °C as well as varnished PCBs. They are therefore ideally suited for use in harsh engine room environments.




18.5 Proximity sensors for use in harsh environments


he inductive IMB proximity sensor is a byword for reliability in harsh working conditions, whether it is in contact with cooling lubricants or being used outdoors. With its extended sensing ranges, made highly precise thanks to the use of ASIC technology, the IMB ensures reliable, stable processes. What’s more, its wide-ranging specification limits allow the IMB to be used in applications where specialist devices were once the only solution – a huge benefit when it comes to product selection and warehousing. The visual adjustment indicator and self-locking nuts save time during commissioning and help cut down on errors. Communication via IOLink is also possible, creating more flexibility and adding more functions for automation

applications. With an extensive standard product portfolio available, even special devices can be put into action quickly and easily. Inductive sensors have to be tough enough to cope with anything that’s thrown at them. So it’s about time that one took the lead and showed the others how it’s done. The IMB is both more resilient on the outside and more intelligent on the inside, boasting levels of chemical and mechanical resistance unmatched by any other device of the same construction, allowing it to withstand lubricants, oils, and coolants, as well as extreme temperatures and weather conditions. The IMB effortlessly defies the preconception that tough guys aren’t very intelligent, with its ASIC technology and the option of communication via IO-Link: Making its switching as reliable as its exterior is rugged. It doesn’t matter how extreme the conditions are at your installation location – from now on the focus is on the survival of the smartest rather than the fittest. Tough on the outside – smart on the inside The IMB Product Family including Types M08 to M30 rounds off this comprehensive

inductive proximity sensor product portfolio, allowing for yet another intelligent solution for your automation tasks. Machine Tooling The IMB is setting a new standard for inductive proximity sensors in the machine building industry: optimal resistance against oils and cooling lubricant, extreme mechanical ruggedness, quick and easy mounting due to visual adjustment indicator, high levels of flexibility and numerous communication options due to IO-Link. Harsh Environment Applications When outdoors or anywhere, in which difficult application conditions prevail, the IMB utilizes its features in a particularly impressive way, its sensor covering a variety of applications. Protected against water, immune to temperature changes, shock and vibration resistant, corrosion resistant and extreme mechanical ruggedness the IMB is the ideal solution for applications relevant for container spreaders, wind power plants, car wash plants and outdoor gates and barriers.

Quad-core processor power in the smallest spaces


he C6915 control cabinet PC extends the range of Beckhoff Industrial PCs with a fanless, extremely compact unit that features state-of-the-art multi-core Atom™ technology from Intel. Thanks to the high computing power of up to four processor cores, scalable to match system demand, this unit opens up a new price-to-performance class for PLC and motion control applications. The new C6915 control cabinet PC, which measures only 48 x 164 x 119 mm (without mounting plate), is the most compact model in the Industrial PC (IPC) range. Thanks to the low heat dissipation of the Atom™ processors, this robust IPC does not require a fan, despite

its compact size. Offering a high degree of application flexibility, the storage medium can be an HDD, SSD or CFast card, as required, and the computing power is scalable to match the demand of the application. Processors with one, two, or four cores are available: • Intel® Atom™ CPU, 1.46 GHz, 1 core • Intel® Atom™ CPU, 1.75 GHz, 2 cores • Intel® Atom™ CPU, 1.91 GHz, 4 cores The C6915 is ideally suited for control tasks in the medium performance range, but also for motion applications and – thanks to the advanced processor platform – more complex

graphics applications. This addition means that the benefits of the cost-effective, low-loss, and high-performance multi-core Atom™ processors are now available for the whole IPC range: as a CP67xx, CP27xx or

CP37xx Panel PC (with single- or multi-touch and 5.7- to 24-inch displays), a CX5100 Embedded PC, and as a C6915 or C6925 control cabinet PC.

Index of Advertisers with relevant page numbers AT Technical Services 4, 14 Asstech 15 Beckhoff Automation IFC Endress+Hauser 17 Extech Safety Systems 7 Helukabel 27 Honeywell 4, 14 ifm electronic OBC Instrotech 23

Krohne 4,9,14 Pepperl+Fuchs 11 Phoenix Contact 25 Prei Instrumentation 5 RET Automation Controls OFC, IBC Sick Automation 21 Temp-Tek 4, 14, 19 Valve & Automation 13




STAINLESS STEEL LASER DISTANCE SENSOR. Q4X Laser Distance Sensor Reliable sensing across a variety of difficult targets, materials and surfaces Real-time distance measurement for faster setup and troubleshooting Reduce downtime due to broken sensors with an IP69K-rated, FDA-grade stainless steel housing

With superior performance and rugged durability, the Q4X provides reliable detection when other sensors can’t. An FDAgrade stainless steel housing means the Q4X stands up in the most aggressive washdown procedures. The Q4X is the right choice for your most challenging applications.

RET Automation Controls (Pty) Ltd P.O. Box 8378 | Edenglen 1613 | Phone: 011 453 2468 B72B71



What's New in Processing September/October 2015  
What's New in Processing September/October 2015