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This issue is sponsored by — Emerson Process Management — 1





Emerson has been delivering wireless products and solutions at the plant network level since 2001, when IEEE 802.11 became an accepted standard in the process industry, and understands the importance


Motion programming comes of age

and benefits of using WLAN technology in manufacturing and processing plants.

PLCOpen Motion Control is providing a standardised way to code motion control applications


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NOW in DIGITAL! Your copy of What's New in Process Technology is now available as an online eMag. This month’s eMag is proudly sponsored by

Emerson Process Management

MOTION PROGRAMMING COMES OF AGE Toby Kilroy, Senior Engineer, Omron Electronics Australia


This issue is sponsored by — Emerson Process Management —

Motion control systems have been evolving for decades now, as applications have demanded an increasing level of innovation and simplification. Complex operations are becoming easier to implement, at higher speeds and with greater accuracy. Now PLCOpen Motion Control is providing a standardised way to code these applications for cross-platform compatibility and code re-use.


or the most part, manufacturers of motion control have been creating their own propriety solutions, with their own unique method of programming, distinctive syntax and semantics. Solutions developed on one platform are tied to that particular hardware and considerable engineering input is required to recode the same functionality into a different motion controller. While PLC ladder code will require some effort to transcode into a different vendor system, motion control programs are far more difficult to recode as motion controller architectures are too diverse and performance is highly hardware specific. Motion controllers have typically been dedicated devices and have used a large variety of different languages to program. They use either high-level languages resembling C or BASIC, ladder variants or visual block diagrams. So system programmers have had to move between typical PLC-based systems, and the more specific and specialised motion controller language and environment, as well as handle data between the two systems, typically over a fieldbus system. The challenge then is to create a development environment where motion programming is fully integrated with the typical PLC languages such as Ladder (LD), Structured Text (ST) and Function Block Diagram (FBD). Data handling should also be common throughout, and the entire program should run on one hardware platform. PLCopen Motion Control is providing greater exposure for PLC programmers and general system integrators alike to what is a rather specialised field. PLCopen is an international, vendor-neutral and product-independent association responsible for promoting the IEC61131 suite of standards which relates to programmable logic controllers. The 61131 specifications were created by the International Electrotechnical Commission (IEC) in order to standardise the methods by which PLCs are

programmed and operate. It incorporates both programming languages and data types, and has formed an ideal basis on which to build further standardised methods of operation. PLCopen Motion Control has been based on this underlying level of standardisation and in combination the two standards have created an opportunity for high-level re-usability of code and minimal transition time between different platforms for the motion control domain.

How do we standardise motion control across all platforms? The motion control system is defined as a state system. These states are mutually exclusive and define all possible states of a motion control axis. It is important to note that the motion controller and servo actuator are not differentiated in this model; they are effectively integrated into one device in this state definition. An axis in fault can be caused by a physical axis error (such as overload or overtravel) or by a programming error (out of software limits or impossible command velocity), and while the fault code will be different, the behaviour of the system will be consistent. Figure 1 shows these states and also includes some of the function blocks which act on the particular state. For instance, an axis starts in the Disabled state. It can then be powered up and will move to the Standstill state. Once in Standstill, it is possible to transition to other states of motion. This is an important stage of the standardisation process as it clearly defines the base behaviours of a motion system. In a similar manner, all aspects of motion control can be logically defined and standardised. Many functions are quite straightforward - for example, a relative move is a benign function which is easily

This issue is sponsored by — Emerson Process Management — 5

Motion control

Figure 1: State diagram for an axis.

comprehended in any system. The process of defining standard behaviour becomes increasingly beneficial as the complexity of the motion increases. For instance, discrete motion (positioning) functions where the transition velocity is zero are readily coded in any system. However, when multiple motion functions are required to create a more complex motion path, blending from one motion operation to another is required. An opportunity to simplify the process is available and PLCopen Motion Control defines standard blending operations. Following this theme, and increasing the complexity of motion control, the advantages of a standardised set of coordinated motion for 3D space is also clear. One common issue with motion systems is that when multiaxis control is performed, it is sometimes performed with mathematical models which link the axes. However, it is not always clear to the motion controller which axes are critical to be moved in synchronisation. Hence, when a fault occurs, the motion controller will not always ‘know’ which other axes will be affected. By defining an axis group, however, the motion controller can perform better error response for other axes which are in the same group but not in error. Also, trajectory planning can be improved with better definition of the grouped axes. This formalisation of concepts into a standard is forming a bridge between the once distinct worlds of PLC and CNC/Robotics. It is now possible to run robots with complex coordinate transformations from a PLC-type system. While this is possible, it does require substantial processing power to perform in real time; hence, controllers with this capability will tend to be based on non-ASIC platforms,


Figure 2: Example of similar programming sequence based on a BASIC language system.

such as the ubiquitous Intel chipsets. This standardisation has allowed robots to become an integral part of a control system, rather than an independent asynchronous system. Such systems can be termed ‘machine controllers’ due to the level of integration of motion control and logic control, the two primary requirements for modern machine control. There are definitive advantages to having both the motion control and logic control in the one package, including, but not limited to, practically unlimited exchange of data between the logic and motion engines, without the latency which can limit performance in traditional systems. In fact, it is now possible to perform perfect synchronisation between a robot and additional servo axes using a machine controller, a feat which was previously only possible to achieve purely in the robot controller domain.

Hardware independence Underlying this abstraction is the axis variable structure with a structured data type of AXIS_REF. The composition of this structure is flexible and specified by the manufacturer and is a comprehensive structure of data which fully defines the state of the axis. An axis is referred to by this variable and passed to and from the function block as an input/ output type. This allows any function block to read and modify the axis data as well as contain the state with easy accessibility and standard methodology. The ultimate goal of all this standardisation is the independence of the program code from the underlying hardware. If controllers from different manufacturers support the same functions, rely on the same syntax for programming and behave in exactly the same

manner, the programmer is liberated from working with the particular characteristics of a specific motion manufacturer’s system. However, to achieve this, the program code must be completely abstracted from the hardware. This will allow the programmer to concentrate on the code required, without having to be particularly concerned with the hardware platform. IEC61131 disassociates the programmer to a large extent from the hardware platform. In a similar vein, PLCopen Motion Control does the same for the programmer of a motion control system. Importantly, the PLCopen methodology is able to be implemented on hardware which has not necessarily been designed with this in mind. Since it is effectively a layer of abstraction, it can be implemented over the top of most hardware using function blocks which interface between the expected PLCopen operation methodologies and the underlying hardware. This makes this approach easier for vendors to implement without a hardware redesign. PLCopen compatibility is possible by providing a set of function blocks which serve as a gateway between the standard I/O of the function block and the low-level, controller-specific control of the hardware. The development of intellectual property and ‘know-how’ for a system integrator or machine builder is extremely important. Often a particular motion platform is chosen by a machine builder or specified by an end user, and while the PLC may be readily changed, the motion system is ingrained and represents the single largest cost for a user to request a change of hardware. The cost to supply the same machine with a different motion control system is therefore prohibitive

This issue is sponsored by — Emerson Process Management —

Motion control

Figure 3: Sequential motion programming using PLCopen function blocks.


for all but the largest of customers. This is due to the level of integration between the code and the hardware - the program is so specific to that hardware that to recode for a new system and achieve exactly the same behaviour is very time consuming and costly. In fact, some machine manufacturers will not contemplate this change at all, an attitude of ‘get what you are given’ is prevalent from some OEM machine builders. This portability of code has some caveats, however. For instance, it has not been defined how to transport graphical language code, such as Ladder, between different programming packages. An intermediate language is required at this stage, such as a mnemonic language. This has been defined, however, for the Structured Text (ST) language as the code is portable as ASCII text. It is possible to export/import using text files or use the ubiquitous cutand-paste method to move ST code between packages. However, once the code has been transported from one package to another, the variables, structures and behaviour of the system will be the same, even if a different controller or servos are used. This is still a very large step forward and will dramatically reduce the programming

for a different vendor system. It becomes essentially a manipulation of code, rather than a complete rewrite, that is required. Nonetheless, a system coded with PLCopen function blocks will be instantly much more recognisable and supportable by general-purpose PLC programmers, especially when the code for motion and logic coexist in the one controller. Having a look at a sequence of moves, it can very readily be seen that the function blocks in Figure 3 will trigger four discrete moves on two axes, and the target position and status of each move can be seen at a glance. Also, the current state of the control sequence is visible as the ‘Done’ outputs will turn green as each step is completed and lead to the execution of the next function block. This shows the level of integration between the motion control and logic engines of an IEC61131 and PLCopen Motion Control compliant controller. For contrast, a program for a dedicated motion controller system (based on the BASIC programming language) is shown in Figure 2. Tracing of the GetPart and InPos variables is very easy when the logic and motion controller are united; a dedicated motion controller will require tracing of these variables to the PLC controller,

which will likely be handling the remainder of the logic. It is also more difficult to assess which step the motion controller is currently executing, compared with the graphical ladder version of the same program. There are clear benefits for a combination of logic and motion control engine in the same controller. While PLCopen Motion Control and IEC61131-3 have enabled PLC programmers to take on motion control programming with a relatively short learning curve, it is the combination of the motion and logic engines as well as the standard programming of PLCopen Motion Control which will be responsible for a reduction of total cost of ownership for motion-controlled machines. Omron Electronics Pty Ltd Contact info and more items like this at

This issue is sponsored by — Emerson Process Management — 7


INDUCTIVE ENCODER RANGE Zettlex IncOders are a range of inductive non-contact encoders designed for measuring absolute angle. The range has recently been expanded to cover 30,000 different product variants. The range includes high- and low-resolution versions (14-21 bit options), and IP67 integral cable, a servo clamp format with plain rotor, and a -55°C operating temperature option, as well as mix and match rotor and stator mechanical formats. The encoders are suitable for applications that need precise measurement in harsh environments - where electrical contacts, optical or capacitive encoders may prove unreliable or where traditional resolvers, synchros or Inductosyns are too bulky or expensive. Encoders have two parts - a powered stator and a passive rotor. Each is shaped like a flat ring.The large bore makes it easy to accommodate through shafts, slip rings, optic fibres, pipes and cables. The stator contains all electronics necessary to receive power and generate the output signals. The output signals from the stator show the absolute position of the rotor relative to the stator right from power up. There is no need for compliant couplings and the rotor and stator can simply be connected to the host system. Precise mechanical mounting is

FAILSAFE CONTROLLER The Triconex General Purpose system is a SIL2-certified, high-availability, failsafe and faulttolerant controller. Redundancy, diagnostics,

not required and there are no bearings. Operation is unaffected by condensation or dust.  Robust, anodised aluminium alloy housings and monolithic constructions are used for both rotor and stator, and there are no contacting, delicate or wearing parts which means there is no need for periodic replacement, service or maintenance.

error checking and failure modes are built into

Motion Technologies Pty Ltd

the system as standard.

Contact info and more items like this at

No knowledge or understanding of redundancy is required to make the system work. Users simply wire up the inputs and outputs and then write the logic for the piece of equipment they need to control or protect. Compared to traditional programmable logic controllers, the Triconex General Purpose System is designed to optimise total cost of ownership, maximise return on investment, increase overall equipment efficiency, minimise maintenance costs and reduce the likelihood of unscheduled asset downtime or production loss. The latest version also features OPC Universal


Architecture communications connectivity, which

A companion piece to Swagelok jacketed tubing, the jacketed tube connector (JTC) is engi-

maximises interoperability between systems

neered to connect jacketed tubing systems while protecting tubing from external degradation in

and streamlines connectivity through an open

corrosive environments. Designed to safeguard against environmental ingress in the chemical,

platform architecture and future-proof design.

petrochemical, oil, gas and pulp industries, the JTC provides a leak-tight, tube fitting connection

The updated communications interface module

between sections of single jacketed tubing, eliminating the need for sleeves and sealing tape.

contains an embedded OPC UA server to

The jacketed tube connector’s design combines proven tube-fitting technology with an O-ring

provide a cohesive, secure and reliable cross-

seal and an environmental jacket seal nut, providing a leak-tight seal on the stainless steel core

platform framework for real-time data, alarms

of the jacketed tubing and a water-tight seal on the outer diameter (OD) of the jacketed tubing.

and events. It also implements X.509 certificates

The JTC design promotes streamlined installation and high performance. Ease of assembly

for additional, enhanced security protection.

is afforded by a knurled jacket seal nut that allows for easy, hand-tight assembly. Seal perfor-

Invensys Process Systems (Australia) Pty Ltd

mance is maintained through repeated reassembly of the connector, and visual confirmation

Contact info and more items like this at

of leak-tight assembly is achieved when the jacket seal nut covers the vent O-ring. A vent port also prevents accidental pressurisation of the jacket cavity. The connector is available in all standard tube fitting configurations and for use with 1/4, 3/8, and 1/2″ jacketed tubing with up to 1/16″ in nominal jacketed thickness. Operating temperature ranges from -55 to 82°C and working pressures up to 5100 psig (420 bar). Swagelok Corporation Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


ON WWW.PROCESSONLINE.COM.AU THIS MONTH CORIOLIS METERS TRICOR Coriolis mass flow meters from KEM/AW are now available with IECEx hazardous area approval. Control Components Pty Ltd



BLUETOOTH WIRELESS MODULE The FL BT EPA MP Bluetooth module transfers ethernet data over a distance of up to 250 m at a rate of up to 3 Mbps. Pilz Australia Industrial Automation LP





Opto 22’s groov is claimed to be a new way to build, deploy and view simple, effective, scalable operator interfaces. Systems 22 Pty Ltd




The NI cRIO-9082 system provides Intel Core i7 dual-core processing at 1.33 GHz and a built-in VGA display output. National Instruments Australia



This issue is sponsored by — Emerson Process Management —


DAQ APPLICATIONS AND ACTIVEX LIBRARY ADLINK Technology has announced the free download availability of AD-Logger, its ready-to-run data-capture application,


and DAQBench, providing ActiveX controls for creating profes-

Acromag’s ST130 Series head-mount temperature

sional instrumentation applications using ActiveX development

transmitters have recently received ATEX Certifica-

environments. AD-Logger and DAQBench are compatible with

tion approval for use in explosive atmospheres.

the company’s range of data acquisition modules and digitis-

The ATEX certification is Ex II 3 G Ex nA IIC T4

ers, and are fully downloadable from the company’s website.

Gc -40°C ≤ Ta ≤ +80°C (explosion protected for

In addition to data collection and monitoring, important tasks

Category 3G, Group II, Zone 2 gas atmospheres;

such as graphing collected signal data, zoom observation, file

non incendive).

saving and dynamic transfer to third-party software (such as

The temperature transmitters are USB

Microsoft Excel, National Instruments LabVIEW, and MathWorks

configured and loop powered, and

MATLAB) for post-analysis is also available. A system with

provide a proportional 4-20 mA output.

compatible company DAQ devices and AD-Logger installed

Three models are available - ST131 for

allows immediate data collection and monitoring once sam-

RTD sensor or 100 Ω resistance input

pling conditions are configured via the company’s DAQPilot

(non isolated), the ST132 for thermo-

interactive wizard, all with no need for programming.

couple or 100 mV input (non isolated),

The company also provides DAQBench, an ActiveX Controls

and the ST133 for thermocouple or

Pack for measurement and HMI applications. DAQBench is

100 mV input (isolated).

compatible with software development tools such as Microsoft

The ST130 transmitters feature updated

Visual Studio, Borland C++ Builder, and others. DAQBench’s

microcontrollers and ASICs to minimise tempera-

various ActiveX controls include user interface, data analysis,

ture transmitter conversion errors, and offer a fast

data integration, data acquisition and SCADA controls, enabling

response with flexible I/O ranges. They also have

easy development of powerful and flexible measurement or

a high immunity to surges, electrical noise, shock

SCADA/HMI application tools.

and vibration.

AD-Logger and DAQBench are compatible with 32-bit Windows XP/7/8.

Metromatics Pty Ltd Contact info and more items like this at

ADLINK Technology Inc Contact info and more items like this at

ELECTROMAGNETIC FLOW SENSOR The Series LOFM low-flow electromagnetic flow sensor is a liquid mag meter that uses the conductivity of fluids to measure flow. Liquid flow through its magnetic field produces a voltage which is measured and translated into a pulse output signal. The flow sensor can be combined with the Dwyer Series RTI for flow rate and total display. This meter comes with a variety of factory-installed adapters and O-rings. It comes in versions to suit either 19 mm or 9.5 mm pipe. The flow meter can accurately measure flow rates as low as 0.12 lpm, and is housed in splashproof HDPE plastic, making it suitable for chemical injection applications. With no metal parts, the device is corrosion resistant and compatible with a wide range of chemicals - and with no moving parts, the meter can handle dirty-water applications where moving parts might cause jamming or clogging. The flow meter comes standard with Flaretek fittings and NPT adapters are also available. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


FIXED GAS MONITOR Bacharach has expanded its GDX-350 Series of fixed gas-detection transmitters. Designed to withstand the harsh environments common in industrial applications,


the industrial transmitters offer an expanded

Honeywell has announced the integration and certification of

range of sensors for the detection of toxic,

the FMC722 subsea automation protocol with its Experion

combustible and asphyxiate gases in an intrinsi-

Process Knowledge System (PKS) C300 controller as a native

cally safe or explosion-proof housing.

interface. A global provider of technology solutions for the

Fu l l - f e a t u r e d t r a n s m i t t e r s , t h e y a r e d e -

energy industry, FMC Technologies supplies the automation

signed for integration into any existing system

platform as part of subsea production systems for control

or as a complete solution for new installations.

and monitoring of offshore oil and gas fields.

The GDX-350 can be used with the GDA-400 or

Within Honeywell’s Experion PKS solution, the Experion

GDA-1600 controllers to provide simultaneous display

C300 controller executes control strategies, interfaces to

and alarm functions for up to 16 monitors.

various types of I/O devices, and directly hosts custom

The series features a large, graphic LCD that shows gas concentrations

programmable applications. The FMC722 subsea automation

and engineering units, along with the flexibility to show the last 30 minutes’

interface provides integration of the FMC protocol on the

worth of historical data. Using the display panel, users can also navigate

controller, enabling seamless peer-to-peer communication

through the menu to change alarm set points, instrument configurations, or

between topside and subsea control assets. The solution

enter into maintenance mode for sensor calibration. Standard LED alarm

gives operators access to thousands of process parameters

indicators accompany the display, indicating when low and high alarm

without the need for any intermediate hardware or protocol

conditions are met. An optional relay board is available to provide three

conversions, leading to fast response, reduced downtime

5 A relays that can be used to drive audible/visual alarms, or activate

and greater ease of maintenance. The integration and certification of these solutions is de-

exhaust fans. Pre-calibrated, user-replaceable ‘smart-sensors’ are available for the

signed to boost the productivity of oil and gas field operators

GDX-350 transmitters which minimise downtime, reduce costs and simplify

and engineers by providing them with a precise view of the

basic instrument maintenance by eliminating the need for technicians

field’s process status, and to simplify the way the subsea

to perform gas calibrations in the field.

automation system interacts with the topside distributed

System Control Engineering Pty Ltd Contact info and more items like this at

control system. Honeywell Limited Contact info and more items like this at

New ST50 Air Flowmeter for 2" to 24" diameter lines FCI's ST50 Series is the most efficient and economical flow measurement solution specifically designed for larger line size air flow measurement in plant operations. Utilizing thermal dispersion mass flow technology ST50’s compact size and simple single-point insertion makes installation a breeze and accurate, fast-response measurements a sure thing. Its rugged construction ensures long, continuous service in demanding plant environments. ST50 is ideal for: • Compressed Air Management & Cost Reduction Initiatives • Burner, Oven and Furnace Air Flow Controls • Exhaust System and Ventilation Air Controls • Water Treatment Aeration • Industrial Dryers • Blower Air

Unit 20, 51 Kalman Drive Boronia, VIC 3155 Australia 03-9017 8225

03-9729 9604

To get full product specifications and a free application evaluation, contact AMS today.

This issue is sponsored by — Emerson Process Management — 13


ANGLE ENCODER The ASM PRDS1 is a compact magnetic


angle sensor that provides wear-free angle

The EKI-3000 series unmanaged ‘light industrial’ ethernet switches are 5- and an

measurement over a range of up to 360°

8-port ethernet switches in both 10/100 and gigabit versions. They offer dedicated

and is suitable for machinery applications

priority ports, up to 60% reduction in power consumption and smart diagnostics,

where accuracy and trouble-free mainte-

making them suitable for a wide range of industrial automation functions.

nance are critical.

Priority ports prioritise the traffic coming over those ports and delay the less

Measuring 12 mm in diameter and

immediately necessary data over the remaining ports. This is useful for high

50 mm in depth, the PRDS1 is suited to

bandwidth applications such as video streaming where latency would cause

applications where access is difficult. By

problems. Smart diagnostic functions provide a way to discover a fault on the

using an independent target magnet that

system without painstaking port analysis.

provides an air gap between it and the

In energy-sensitive applications where power consumption is a factor, these

sensor, the complete measuring range of

switches come with advanced power-saving functions that save up to 60% on

up to 0 to 360° is obtained in a totally

power consumption by shutting down ports that

non-contact manner. This overcomes any

have no link and by budgeting power based on

connection or alignment problems often

the length of the ethernet cable.  This is part of

experienced if sensors with connecting

the IEEE 802.3az Energy Efficient Standard.

shafts are used.

Gigabit ethernet provides users with the fast-

The sensor has a range of incremental

est possible data transmission speeds for high-

digital outputs available and is manu-

definition video streaming and the ability to sustain

factured from stainless steel. An integral

constantly high traffic loads in the EKI-3725 and

M12 thread incorporated into the M12

EKI-2728 models. For applications that don’t

body provides sealing options from IP67

require the benefits of gigabit ethernet but still

to IP69K.

want the priority ports, energy saving and quick

Automated Control Pty Ltd Contact info and more items like this at

diagnostics, Advantech has the EKI-3525 and 3528 models which have 10/100 Mbps ports. Advantech Australia Pty Ltd Contact info and more items like this at

PLANT DOCUMENTATION MANAGEMENT Intergraph has released SmartPlant Fusion to specifically addressthe challenges faced by plant operators and engineering, procurement and construction (EPC) companies in accessing, organising and managing unstructured legacy engineering information of an operating plant. Concurrent engineering projects, turnarounds, equipment changes and even plant acquisitions flood operators with information in multiple formats, often distributed around the organisation, potentially duplicated and inaccessible to support critical decisions. SmartPlant Fusion ‘crawls’ through all these information formats and locations, automatically reads and extracts meaningful content and assembles a highly organised plant record that can be simply navigated via an intuitive photo-realistic web portal. This ‘as-is’ repository can be purged of duplicates, thus highlighting the true master information. Inconsistent tag naming and numbering, often the result of different engineering projects, can be ‘aliased’ and harmonised. SmartPlant Fusion captures high definition surveying (HDS) - combined laser scan point clouds and digital photography - and integrates it with the as-is documentation to present a digital and physical record of the plant. This can be used for maintenance and safety planning, remote engineering design using integrated point cloud and 3D, as well as operating configuration capture where the true as-built state of the plant is required. Intergraph Corporation Pty Ltd Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —

Full-profile insertion mag meter improves city water management The City of Geneva, Ohio, resides in Ashtabula County, east of Cleveland, along Lake Erie. Founded in 1816, this picturesque city is now home to 7000 residents. The City of Geneva Water Works Department is responsible for managing the city’s 1.3 megalitre per day drinking water operation. The City of Geneva’s water distribution system has a unique history and structure. Ashtabula County bought its water system from a private utility in 2003, which includes booster stations and storage facilities, but no treatment plants. The county purchases finished water from the private utility’s treatment plant. The City of Geneva bought its water system in 2004, which is a distribution network connected within the county system. This system had no bulk metering to measure the city’s actual consumption. The city has been billed by Ashtabula County according to an agreed formula that apportions an amount of the overall county consumption to the city. Geneva’s Water Works Department determined that in order to begin its own metering system, eight individual metering locations were needed around the city. The city management had several primary considerations when selecting a metering solution. Firstly, as a smaller municipality, Geneva has a limited budget. Securing the operational efficiency gains would depend on finding a very cost-effective solution. Since most of the city’s water mains are in the road or right-of-way, an installation solution that could support the weight of vehicles was required since rerouting pipelines away from traffic was financially infeasible. Geneva also needed flow meters that could be installed without the need for a line shutdown, since each of the metering sites is a connection to a county distribution artery that serves both the city and county consumers on the opposite side of the city. Thirdly, to meet Geneva’s cost-savings goal, a minimum of 1% accuracy was required and a bidirectional metering capability was necessary because the open nature of the distribution system allowed for water to flow in either direction in the pipelines. Also, since the city’s distribution system had no bulk water metering, the nominal flow rates within the pipes were unknown. Finally, as a scenic, residential community, Geneva had to find locations for above-ground meter reading stations that were close to primary electrical service but would not compromise the aesthetic appeal of its properties. The Water Works Department reviewed a number of technology options, ultimately deciding that an electromagnetic flow meter would provide the accuracy and reliability needed. Different electromagnetic technologies were considered. They concluded the McCrometer FPI Mag was the only solution that addressed all their unique challenges.


Spool-type electromagnetic meters would require large vaults that would have to be installed away from traffic because these vaults could not support vehicle loading. The FPI Mag flow meter’s compact insertion design allowed Geneva to use small manholes with metal covers designed to support the load of residential traffic. The FPI Mag insertion design also meant that installation could occur without interrupting service, dewatering lines, cutting pipe or welding flanges. Geneva spent approximately five days installing each of the eight meters in lines ranging from 6″ to 16″. This included four days to install the manholes and also electrical service to the new above-ground meter reading stations. Installation of the FPI Mag full profile sensor and electronic converter only took a combined half day, including the pulling of wiring from the sensor to the converter at the meter reading station. Accuracy requirements were met with FPI Mag due to the FPI Mag flow meter having multiple electrodes across the entire pipe diameter. Full flow profile measurement enables a very accurate, average flow rate calculation of ±0.5% of reading in the 0.3 to 1 m/s velocity range. Additionally, the availability of the bidirectional model also fit the city’s needs, allowing it to account for water regardless of the flow direction in its distribution system. Due to the absence of bulk metering, McCrometer used its NIST-certified, full flow test facility to calibrate the units to a reasonable maximum flow velocity for each pipe size down to a minimum velocity reflecting very low flows. Once the meters were installed, Geneva and McCrometer worked together to confirm the calibration in the field using hydrant flows and individual consumer readings collected over a span of time. Lastly, with the FPI Mag meters requiring such little installation space, Geneva gained multiple siting options that were aesthetically satisfying. The Geneva Water Works Department concluded McCrometer’s FPI Mag full-profile insertion flow meters met their accuracy, reliability and bidirectional requirements with an installation approach that satisfied their cost and siting requirements, as well as their need for uninterrupted operation. All eight McCrometer FPI Mag flow meters were installed in aesthetically pleasing locations, in minimal time, with minimum investment and with no operational interruptions. They are all currently performing successfully and Geneva anticipates operational cost savings of 8-12% per year as a direct result of their investment in the McCrometer FPI Mag flow metering system. As David Corbin, McCrometer Product Manager, said, “The application for the City of Geneva benefited from several differentiators that the FPI Mag delivers. Any one of these benefits - lower total installed cost, ease of installation or accuracy - can separate the FPI Mag from other meter options, but in the case of Geneva, they were able to realise several of these benefits all at once.” AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at

This issue is sponsored by — Emerson Process Management —


RUGGED CONTROLLER The AXC 1050 controller from Phoenix Contact’s Axiocontrol range is particularly suited for installation in harsh industrial settings. For the construction of local stations, the I/O modules of the Axioline I/O system can be added on to the controller directly via the built-in Axiobus. The controller’s ethernet interfaces enable integration with existing networks and connection to other decen-


tralised I/Os. A range of communication protocols are available,





including TCP/IP, UDP, Modbus/TCP and Profinet. With a built-in uninterruptible power supply (UPS), the controller is particularly resilient against power outages. This means that if there is a power outage, measures to ensure system availability can be activated. Designed for deployment in highly demanding environments, the AXC 1050/XC mini-controller operates at an extended temperature range of -40 to +60°C. Phoenix Contact Pty Ltd Contact info and more items like this at



AC/DC DIN RAIL SWITCHMODE POWER SUPPLIES HMI/SCADA SOFTWARE WITH MULTTOUCH InduSoft has released the first service pack for its SCADA software InduSoft Web Studio v7.1. The service pack adds multitouch development capabilities for touch-screen enabled devices. Unlike traditional touch-screen designs, multitouch systems


can recognise the position of several touch contacts and finger movements (gestures) at the same time. Without a keyboard or pointing device, users can navigate screens and issue commands for an entire system. Training time is reduced because many gestures, like zoom and pan, function in the same way as they do for smartphones and tablet devices. Besides lowering training time, multitouch technology provides much faster execution of commands. The average multitouch-screen users finish an action three times faster than they would by using a keyboard and pointing device. Above all, multitouch capability can improve safety. Certain actions

120W 240W



























78 × 93 × 56


78 × 93 × 56


65.5 × 125.2 × 100


125.5 × 125.2 × 100 $109.60*

(30W & 75W also available - call for pricing)

• Wide power range 30W to 240W • Universal AC input voltage 90-264VAC • Voltage tolerance +/-1% • Adjustable output voltage +/-10% • High efficiency & reliability • 100% full load burn-in

• Cooling by free air convection • LED power indicator for power on • International safety approvals • Local stock • Low cost solution • 2 year warranty

may require operators to keep their hands away from a machine; the multitouch screen can be configured to require users to have both hands on the screen before the command can be executed.

* Price excludes GST and ONLY available to approved business and/or trade customers. Bulk pricing available on request.

In addition to multitouch development capabilities, the version also offers an enhanced mobile access client and new language

interfaces, including Spanish, for the development environment. AU 1300 365 551 NZ 0508 765 956


Dominion Electronics Contact info and more items like this at

This issue is sponsored by — Emerson Process Management — 17


COMPUTER RANGE The Microbox Simatic IPC427D supersedes the IPC427C series, bringing performance increases with the Intel Core i7 processor. It offers higher functionality and flexibility than the C series with an iAMT, PCIe, display port and Gigabit Ethernet, and can be configured and adapted to the user’s requirements and applications. Fanless and maintenance free, the modern-designed computer maintains a small footprint with higher industrial functionality, system availability and robustness, due to a non-volatile memory. Its high operating reliability, including safety against voltage failures, makes the computer suitable for harsh industrial environments where heavy vibration and shock loads are common. Remote access for identification, analysis, administration and upgrade is possible even when the computer is switched off. With up to 8 GB of RAM, the mass memory can be configured as CFast cards up to 16 GB, high endurance or standard solid state drive or 2.5″ hard disk with 250 GB. Siemens Ltd Contact info and more items like this at

OPTOCOUPLER AND INTERPOSING RELAY MODULES Acromag’s BusWorks XT Series multichannel optocoupler and interposing relay modules connect discrete field devices to measurement and control system I/O modules. The XTA-120V-6 optocoupler modules have six individually isolated 120 VAC/VDC digital (discrete) inputs to sense on/off levels and provide 5-32 VDC logic outputs to a fieldbus input module or a controller. The XTA-MRNO-6 interposing relay module receives 4-32 VDC logic-level signals from an output module or controller to switch six mechanical relay outputs. These two high-voltage relay interface modules offer a high-density, cost-effective solution to safely monitor or control inductive and other high-power loads (such as motors, valves and solenoids) with control system I/O modules that only support low-level DC signals. These multichannel discrete contact sensor and relay output modules offer a safe, isolated interface between high-energy field devices and sensitive control system I/O modules. By adding optocouplers and relays, users can use PLC, DCS, or remote I/O modules with 5-24 V logic circuits to operate 120 VAC/VDC contactors. Both modules can drive audible or visual alarms. Common uses involve operation of stack lights, bells, whistles, lights and horns. While the XTA-MRNO-6 is intended for switching AC/DC inductive loads at high currents, the XTA-120V-6 is designed to drive low-current devices such as solid-state relays, LEDs, relay coils, solenoids and incandescent lamps. The housing is only 22.5 mm wide and features removable front-facing terminal blocks for easier wiring. All units run off a 12-32 VDC power source at the terminals or through an integrated DIN-rail power connector. Fail-safe operation is supported. Metromatics Pty Ltd Contact info and more items like this at

LASER CODER RANGE Markem-Imaje has launched a generation of SmartLase CO2 laser coders with performances claimed to be 30% higher than market standards due to its patented SCT (SmartLase Code Technology). The SmartLase range has been designed to meet the need for higher speeds in the beverage industry. It is capable of coding up to 108,000 bottles/h with high print quality and code legibility. To improve traceability and fight diversion in the food industry, the print capacity of each code has increased from 30 to 120 characters. The range also offers a good availability ratio of the coding equipment. It can be up to 99.9% with a specific service contract, the company says. The laser source benefits from an extended lifetime of nearly 30% due to reduced laser duty cycles. The coders’ modular design makes maintenance easy; the laser head can be changed in ten minutes without alignments and a built-in sensor facilitates diagnostics by assessing the laser power. The SmartLase range can print all types of products regardless of the production rate. Several versions are available. Paper and cardboard can be coded with the standard models C150 (10 W) and C350 (30 W). The C350 L (30 W) version is suitable for flexible packaging (BOPP) and laminated cardboards (PE). The C150 S (10 W) and C350 S (30 W) versions have been designed to code PET bottles, reducing the risk of piercing even if very thin. Markem-Imaje Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


PHOTOELECTRIC SENSORS The O6 wetline series photoelectric sensors are diffuse reflection sensors that provide noiseimmune background suppression. Even highly reflective backgrounds, such as stainless steel, do not affect the background suppression. The sensing range is independent of the type and colour of the object to be detected. A feature of the O6 sensor is the automatic sensitivity adjustment which guarantees safe functioning even in case of vapour, smoke and strongly reflective environments. The clearly defined round light spot in the operating area provides consistent light intensity in the light cone. Scattered light around the light spot that could disturb other sensors by reflections is avoided. The compact O6 is perfectly sealed and the two setting potentiometers have a double sealing. The stainless steel housing provides a  IP68/IP69K protection rating. The transparent black housing cover provides good contrast for the integrated LEDs (operating state, switch point) so that they are clearly visible even in bright environments. The coated front lens consists of resistant, splinter-free plastic. ifm efector pty ltd Contact info and more items like this at

COMBUSTIBLE GAS DETECTOR The Model IR400 point IR combustible gas detector from General Monitors features a 3 s T90 response time to the presence of combustible hydrocarbon-based gases, which allows plant operators to respond quickly to gas leaks and avoid potential accidents. The fast response time is guaranteed even with a splash guard installed. The IR detector monitors hydrocarbon-based gases including methane, propane, ethane, ethylene, butane, hexane, pentane and benzene. It features a self-diagnostic design to prevent false alarms and process shutdowns, and it monitors conditions such as supply voltage and optical path integrity. The device also features heated optics to eliminate condensation, and a dirty-optics indicator helps discriminate between true alarms and maintenance needs. The device operates by measuring the absorption of infrared radiation passing through a volume of gas using a dual-beam, single-detector method. The IR detector measures the intensity of two specific wavelengths, one at an absorption wavelength and another outside of the absorption wavelength.  The gas concentration is determined by comparing these two intensities.

POWERED STRIPPING AND CRIMPING TOOL Phoenix Contact is offering a tool for fast and easy wire preparation, the Crimphandy. The wires are stripped, fitted with end sleeves, and crimped in one single step. Everything takes less than two seconds. Automatic cross-section checking, together with robust mechanics, ensures moulding that exceeds normal requirements. The end sleeves are fed automatically out of the internal magazine in strip form. The square mould is suitable for all common conductor types.

Using only 4.8 W of power, the device requires no

Using the device is easy: three LEDs provide information at all

routine calibration. It can be configured for analog output,

times about operating status. The lithium-ion battery has a capac-

Modbus and HART, providing a 2-wire RS485 addressable

ity for 2000 crimping procedures and can be fully charged within

communication link that is used to monitor status and

one hour with the included charging device. The handheld tool is

settings in order to simplify installation and maintenance.

no larger than an electric screwdriver and weighs 430 g. An easily

Its electronics are contained within a rugged, explosion-

removable container for leftover insulation ensures a clean working

proof housing, and it has FM, CSA, ATEX, IECEx and

environment and enables use of the device inside control cabinets

BV approvals, the CE Marking, and is suitable for use

and switching systems as well.

in SIL 3 systems.

Phoenix Contact Pty Ltd

Aquip Systems Pty Ltd

Contact info and more items like this at

Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —




ASEPTIC VALVE RANGE The EvoGuard range of valves manufactured by Krones AG, Germany, includes all valve designs required in the beverage and dairy industries. The range includes: disk valves and single-seat valves for simple pipe shutoff tasks; double-seal valves for use in separating hostile media; and double-seat valves for highly automated sequences.


The aseptic valves are used for shutting off pipes in aseptic and sterile processes, or for separating hostile media in aseptic and sterile processes.


The aseptic seat valves handle tasks like rerouting and shutting off product flows, or emptying tanks. The aseptic double-seat valves are used for separating hostile media in aseptic and sterile processes. With double-seat valves, the routings in the production

25W 60W 100W

operation can be run under preprogrammed control. All cross-sectional areas have been responsively




























98 x 97 x 35


159 x 97 x 38


199 x 98 x 38


215 x 115 x 50


designed to match the nominal diameter involved, eliminating any restrictions on the flow rate. A modularised range of choices is available, from which individual components can be selected to suit the particular application concerned. The range of aseptic valves is monitored by the company’s stringent quality assurance systems, with batch tracking for all components and certified pressurised parts.

• Wide power range 25W to 500W • Universal AC input voltage 85-264 VAC • Voltage tolerance +/- 1% • Adjustable output voltage +/- 10% • High efficiency & reliability • International safety approvals

• Safety standards (EN60950-1) • EMC standards (EN55022 Class B) • Low cost solution • Local stock • Local engineering and sales support • 2 year warranty

JL Lennard Pty Ltd Contact info and more items like this at

* Price excludes GST and ONLY available to approved business and/or trade customers. Bulk pricing available on request. RANGE - RELIABILITY - STANDARD - CUSTOM AU 1300 365 551 NZ 0508 765 956

This issue is sponsored by — Emerson Process Management — 21


NON-CONTACT ENCODER The RI360P-QR24 is a non-contact inductive universal encoder with high-resolution, wear-free operation, which is at the same time immune to


magnetic fields.

The SafetyBridge I/O modules from Phoenix Contact expand

The sensor and the positioning element of the encoder are

the network-independent SafetyBridge system in flexibility,

fully encapsulated and therefore designed as two independ-

functionality and application areas. These modules include

ent and fully sealed units that work together without contact.

a safe input module with added inputs, as well as a logic

Any vibration or shock from the shaft is not passed on to

module with extensive functional upgrades.

the sensor. With a high degree of protection to IP69K and

The logic module can now communicate with up to 16

over 18-bit resolution, machine downtimes and maintenance

remote safe I/O modules. Together with the input mod-

times resulting from encoder wear are eliminated, even with

ules featuring 16 safe inputs each, a SafetyBridge island

high-precision and high-speed applications. Turck has developed a new parameterisation and mounting concept for the encoder. This turns the RI360P-QR24 into a universal encoder for any standard industrial application. Users can parameterise the device either as an incremental, multiturn or singleturn encoder. This variant allows operators to also set output signals, switch points and measuring ranges individually via IO Link. Turck also offers a high-resolution variant with an SSI output, a Modbus and voltage/current version, as well as an encoder compliant with the e1 specification, for use on mobile machines. The mounting concept of the encoder also extends its application range - adapter rings enable the encoder to be fitted on all standard shafts with diameters up to 20 mm. Turck Australia Pty Ltd Contact info and more items like this at

can encompass up to 256 safe inputs. Up to 31 such islands can be operated from a standard control unit. These systems are able to exchange safety signals with each other. SafetyBridge technology is therefore suitable for installation in large-scale and modularly structured machines and systems. The modules and the safety logic are easy to set up using the Safeconf software. There are 14 different safe function modules in total, ranging from a simple emergency stop through to various muting blocks. The safety solution is independent from the network and the control units, which makes it highly flexible when it comes to integrating functional safety into machines and systems. The safe modules mixed with non-safety inline I/Os, can be distributed across the network below a range of different standard control units. Phoenix Contact Pty Ltd Contact info and more items like this at

VAPOUR-ACTUATED THERMOMETERS Noshok’s heavy-duty, vapour-actuated remote thermometers provide highly accurate temperature indication. These thermometers are suitable for remote panel installations on service trucks in the oil and gas industry, as well as temperature measurement in power transformers, paper mills, refineries, petrochemical, chemical, HVAC/R, food processing and pharmaceutical applications. Because they are vapour actuated, they are not subject to error due to ambient temperature variations along the capillary tube, so they provide highly accurate readings above and below ambient conditions. These thermometers indicate media temperature using a temperature-actuated liquid in the sensing element and an accurate, high-quality pressure gauge. As the media temperature increases, the capillary fill fluid vaporises, increasing pressure in the Bourdon tube to activate the movement and pointer for indication. Noshok offers vapour-actuated remote thermometers in 2½, 4, 4½ and 6″ sizes, from -40 to 60°C through 100 to 350°C. They are available with a brass or stainless steel case, with bottom, back or lower-back connections. Options include dry or liquid fill (optional fill fluids include glycerine, glycerine-H2OD and silicone), front or rear flange, bezel and U-clamp. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


PANEL PC RANGE The Simatic 477D panel PC is an upgrade that replaces the previous C range comprised of the Simatic HMI IPC477C and HMI IPC577C, to provide higher system performance for demanding computing, control and visualisation tasks in an industrial environment. Processor options include Core i7, Core i3 and Celeron. The DDR memory technology is boosted up to 8 GB of RAM and the system is fully compatible with Windows Embedded Standard 7 or Windows 7 Ultimate. Resistant against dirt, oil and grease, the front panel design comes in a 12, 15, 19 or 22″ widescreen display. Combined with its high operating reliability, luminous displays for clear readability, added protection against voltage failure (NVRAM) and remote access while powered down (iAMT), the IPC477D is suitable for industrial environments. The Simatic 477D system is expandable by the end user with a variety of interfaces (PCIe, DVI-I, display port, Gigabit Ethernet), and a variety of ports - both on the rear and front - for quick and convenient connection to additional hardware. Siemens Ltd Contact info and more items like this at

This issue is sponsored by — Emerson Process Management — 23


ATTRITION MILL The Model SK-24-MS attrition mill from Munson Machinery reduces friable chemicals and minerals, as well as metal powders, wood flour, fertilisers, insecticides and fibres, producing particles within relatively narrow size ranges from 10- down to 100-mesh. The 61 cm diameter mill is equipped with an outer stationary milling disc and an inner rotating milling disc that adjusts to vary the gap between the discs. Material enters the gap through the centre of the outer disc and is ground between the discs as it travels radially by centrifugal force created by the rotating disc, with greater reductions achieved by reducing the gap. Capacity is generally dependent on the required output size of the reduced material, with coarser products produced at higher rates. Precise machining and alignment of the discs, together with constant spring pressure, maximise size uniformity of the reduced material, while static and dynamic balancing of the rotating runner head assembly provides vibration-free operation. Plate patterns are selected to optimise the reduction of specific types of materials. Quick-release separation of the grinding discs allows thorough washdown between product runs. Access panels can be added to the rear of the housing for cleaning, inspection and maintenance. Models are available with rotor diameters from 30.5 to 91.4 cm, constructed of carbon steel and are available in #304 or #316 stainless steel to sanitary or industrial standards.

WIRELESS POINT-TO-MULTIPOINT ZigSense Model ZS-P2MP-002 is the latest addition to the ZS-P2P-001 wireless cable replacer system. It supports point-to-multipoint (P2MP) technology transferring wired sensors data and I/O control commands between a local master node and two slave nodes installed in separate remote locations. High-speed communications combined with ZigSense P2MP bidirectional data transfer enable digital and analog signals to be reliably transferred over short, medium or long distances using licencefree 2.4 GHz, 900 MHz or 868 MHz radio frequencies. Analog signals such

iBulk Solutions Pty Ltd Contact info and more items like this at

as tank level, temperature, pressure and flow, as well as digital signals for alarm conditions or devices such as pumps, motors and start/stop switches can be exchanged simultaneously between a master

BIOMETRIC SWITCHES Schneider Electric’s Harmony biometric switches are based on sophisticated fingerprint recognition, and are designed to help eliminate security risks associated with lost, forgotten or stolen keys, cards and passwords. The switches allow industrial users to limit access to specific or dangerous machine functions to trained and authorised operators. Designed for use in industrial environments, the entire range offers IP65 water and dust protection, 50 gn shock and vibration resistance, -5 to +55°C operating temperature range, and a response time of less than 1 s. Benefits include: increased security, due to user database management and access-attempt logging capabilities; increased productivity, by enabling simple and quick touch entry for authorised users; smart access control, with the ability to assign different clearance levels; and reliability, due to the ruggedised design and high-performance specifications.

node in one location and two slave nodes in other locations - eliminating the need for long cables, conduits or cable trenches. Upon loss of communication, ZigSense wireless cable replacer nodes will deactivate their outputs based on the default fail-safe mode. A local independent alarm output can be used to sound a siren or a buzzer. Conlab Pty Ltd Contact info and more items like this at

Schneider Electric (Aust) Pty Ltd Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —

Aeration for a cleaner, greener MCG As part of a multimillion-dollar project to build Victoria’s largest underground recycled water treatment plant at the iconic Melbourne Cricket Ground (MCG), Compressed Air and Power Solutions (CAPS) Australia was selected to supply aeration blowers for the facility. CAPS supplied four Robuschi Robox positive displacement blowers which are used to aerate the water during treatment and to provide backwash to clean membrane filters. The lead contractor for the project, Tenix, supplied process, mechanical, civil, electrical, instrumentation and control design and construction.

The water treatment plant - jointly funded by the Melbourne Cricket Club (MCC) and the Victorian Government - produces 600 kilolitres of ‘Class A’ recycled water each day. This water is used to irrigate Yarra Park and Punt Road Oval, and for cleaning and flushing the toilets at the MCG. The plant will reduce the MCG’s reliance on drinkable water by 50% and remove it from the list of Melbourne’s top 100 water users. Eric Low, blower specialist with CAPS, said that during initial project discussions with Tenix, CAPS learnt that the blowers needed to fit in a limited space within a confined underground site. “I realised that the Robuschi blowers sold by CAPS would be ideal, and proposed two models, the ES45/2P-11 KW and the ES85/3P-55 KW, for the aeration and the membrane systems of the MCG’s treatment plant,” he said. According to Daniel Haworth, Tenix Operations Supervisor for the MCG recycled water treatment plant, the blower solution had to fit in a

very constrained narrow space. “Service access in our bunker is difficult, but the solution recommended by CAPS - with maintenance access via top and front panels - fitted our site’s needs perfectly,” Haworth said. “Another service feature of the blowers that we really appreciate is the inclusion of an automatic belt tensioning system, which increased the operational time between servicing.” The MCG treatment plant is one the first of its type in Victoria and was built underground to preserve valuable surface land use and park amenity. Everyone involved in the scheme wanted the design and construction of the plant to have minimum impact on the park and the public. Consultation during development involved local residents, regulatory authorities and members of the MCC. A major requirement was to not disturb the aesthetics of the existing parklands or reduce current parking availability. “In the MCG plant, two Robuschi blowers are in operation 24 hours a day, with two in standby mode,” explained Low.  The underground plant is contained in a 12 x 4.8-metre diameter pumping station bored into the ground adjacent to the MCG. Innovative construction techniques utilising fibre-reinforced plastic for walkways reduced construction time as they could be cut to size on site and were much lighter than traditional metal construction materials. Associated infrastructure on the inlet side includes the sewer connection, diversion chamber and a rising main. Other infrastructure includes connections under the concourse to a pre-existing storage tank beneath the MCG. There are also connections to Punt Road storage, a pump station and sludge return gravity line downstream of the sewerage takeoff. The water treatment involves screening and grit removal, biological treatment of the sewage and addition of chemicals to remove phosphate. Filtration methods used include membrane bioreactor (MBR) and ultrafiltration (UF) membrane systems. Disinfection of the water is by both ultraviolet (UV) and chlorination. Low is proud that CAPS could provide a unique solution to meet the needs of this groundbreaking project. “Blowers are a common part of water treatment systems but it is unusual for them to be located in a bunker. The Robuschi blowers were the right equipment to meet the specific project requirements,” he said. CAPS Australia Pty Ltd Contact info and more items like this at

Is your

Emission Monitoring System saving you money and fully compliant with EPA requirements? Leading technology for emission monitoring and process control Tel: 07 3255 5158

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This issue is sponsored by — Emerson Process Management — 25


REMOTE-MOUNT DIGITAL VALVE CONTROLLER The Fisher Fieldvue DVC6205 remote-mount digital valve controller is a suitable solution for applications in which accessibility, extreme temperatures (up to 120°C), extreme vibration or confined space make integral mounting difficult or impractical. Industries such as pulp and paper and nuclear power have typically preferred to isolate valve-mounted instruments from harsh environments. With the DVC6205, only the valve position feedback is mounted on the control valve, while the remainder of the digital valve controller can be mounted over 100 m away in a less severe or more accessible environment. The remote valve-mounted feedback unit utilises the Fieldvue linkage-less, non-contact feedback technology in which physical contact has been eliminated between the valve stem and the instrument. With no linkage to wear, loosen, corrode or vibrate, the feedback unit can withstand a plant’s operating extremes. The DVC6205 is offered with CSA, IECEx, ATEX and FM hazardous area approvals as well as other certifications and approvals. It is also listed in the Lloyd’s Register for industrial, marine and offshore use. Emerson Process Management Contact info and more items like this at

SAFETY INTERFACE MODULES The PDP20 F 4 mag interface from Pilz Australia allows series connection of various sensors up to Category 4 of AS4024.1-2006. Up to four sensors can be connected to each PDP20 module, and PDP20 modules can be cascaded to increase the number of sensors that can be monitored. The interface module can be connected to dual-channel evaluation devices (such as PNOZsigma, PNOZmulti and PSS) to interface with the machine control system. Multiple sensor types can be connected to the PDP20 including safety gate sensors such as PSENmag, PSENmech and PSENhinge, as well as emergency stop devices such as PITestop and PSENrope. Each device is monitored separately, allowing the highest level of safety. The PDP20 removes the need for an evaluation device per sensor, with just a single safety monitoring device required in conjunction with the PDP20, saving space in the control cabinet. Diagnostic LEDs on the PDP20 ensure that it is possible to identify which sensor has been operated or if there is

STAINLESS WASHDOWN SERVO MOTORS Motion Technologies has available Kollmorgen USA IP69K full stainless washdown servo motors. Available in five frame sizes and 16 frame/stack length combinations, they supply torques up to 80 Nm (390 Nm peak) and speeds up to 7500 rpm. Cables are available as either 3 or 6 m as standard, with other options available. All motors have round stainless bodies with etched nameplate for aseptic applications. Air-purge ports are standard and motors are manufactured to be customisable. Motion Technologies Pty Ltd Contact info and more items like this at

fault in the sensor. Pilz Australia Industrial Automation LP Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


SURGE LOGGER The Varitector Logger 30 is designed to register and document large current pulses as well as the frequency and time of incidents. It counts current pulses greater than a set threshold value which are discharged by PE conductors on surge protection devices. Any lightning strikes and surge voltages are continuously recorded. Each measurement is issued with a timestamp accurate to the hour and both the time and date of their occurrence are recorded. The logger 30 features an external sensor with a ferrite toroid. Clipped to the earth cable, it detects current peaks on the PE conductor which can be caused by events such as a lightning strike. The date and time documentation allows the user to historically document incidents to help determine the cause of the surge. A large and clear, two-line LCD provides easy visualisation of current/incident data. The buttons on the device allow the menus to be navigated effortlessly. The Varitector Logger 30 also features a standard internal CR123A replaceable 3 V battery with at least a four-year service life. This allows the device to be conveniently connected to the mains at all times. Complementary to Type-II and Type-III VPU surge protection devices, the Varitector Logger 30 can be quickly and simply installed on the terminal rails in almost every switch cabinet via its plug-and-play housing. The device has an operating temperature range between -20 and +60°C. It also has a V-0 flammability rating in accordance with UL94 and meets EN62561-6 and VDE 0185-561-6 standards. Weidmuller Pty Ltd Contact info and more items like this at

Served up on a plate Using AirLINE Quick manifolds, Bürkert is able to assemble control cabinets extremely qickly, inexpensively, and to a very high standard (IP66). Introducing Smart Panel, with systems typically despatching within 48 hours. Bürkert. We make ideas flow.

Pneumatics - AirLINE Quick HP.indd 1 1300 888 868 0800 BURKERT (287 537)

20/05/2013 3:50:07 PM This issue is sponsored by — Emerson Process Management — 27


UPDATED SCADA SYSTEM Version 7.2 of the Simatic WinCC SCADA system offers extended system frameworks and further improvements with regard to handling and


usability, as well as two new options

Sampling systems expert Tony Waters and Swagelok

making it expandable into a plant-wide information system.

for archiving and reporting functions,

have created a comprehensive reference covering the

The scalable SCADA system now supports integration of up to 18 optionally

engineering involved with designing and operating a

redundant WinCC servers in a single project. This advanced system framework

sampling system for a process analyser. Industrial Sam-

comes with extended archive functions such as consumption counters, and includes

pling Systems offers in-depth analytical instrumentation

editing features, for example, for manual input of laboratory values. In WinCC V7.2,

material suited for anyone from a novice to a degreed

the archived values are now written to compressed weekly, monthly and yearly

engineer. Along with recent innovations such as the

archives. This functionality forms the database for reporting and analysis across

Swagelok Process Analyzer Sample System live training

business-related periods.

course, and the Swagelok Pre-Engineered Subsystems

The Simatic Process Historian (system-wide long-term archive) and Simatic Infor-

product line, this reference fills a critical need for those

mation Server (reporting and analysis system) options in WinCC achieve maximum

who design, engineer and maintain sample systems

system transparency.

for online process analysers. Industrial Sampling Systems is a book that captures the experience and knowledge that Tony Waters has

WInCC V7.2 also offers Unicode support, and two-finger multitouch gesture capability. Siemens Ltd Contact info and more items like this at

acquired over a career of more than 50 years. Waters, who collaborated with Swagelok engineers and associates, has created a book that balances theory and practical examples, making it an ideal read for students as well as experienced engineers, designers and technicians. The book also provides readers with a sampling of information featured in Swagelok’s intensive 40-hour complementary Process Analyzer Sampling System (PASS) training classes. Industrial Sampling Systems contains more than 750 pages of full-colour technical content in a hard-bound cover of twelve chapters and three detailed appendices. Worked examples illustrate calculations and how to apply equations, and there are numerous sidebars which explain basic scientific concepts, as well as ‘Case Files’, which show the practical application of concepts. Self-assessment questions within the chapters are provided

CLOUD-BASED PLANT DESIGN SOFTWARE Intergraph has launched SmartPlant Cloud, the company’s software as a service (SaaS) solution, a dynamic cloud computing environment to support the SmartPlant Enterprise portfolio. The service removes the need for customer hardware and infrastructure and allows users to access SmartPlant Enterprise applications, project and plant maintenance environments via a simple URL, regardless of global location. SmartPlant Cloud presents all users with their relevant information, data and documents to support each user’s work processes and decision-making. The service provides a software ecosystem that allows engineering, procurement and construction (EPC) and owner operator companies to provision users with the required engineering software tools and utilities. The service, which is accessed through an intuitive web-based portal, has been configured to adapt to company-specific standards, engineering workflows and processes. SmartPlant Cloud provides rapid deployment, robust security and a dynamically scalable environment that has been designed to specifically support all sizes of projects and assets for both the owner operators and EPCs, regardless of global location.  Intergraph has been supplying SaaS to a select customer base for a few years already, and it is now making it commercially available.

to help ensure reader comprehension, and a glossary

Intergraph Corporation Pty Ltd

of more than 1000 terms and definitions is included.

Contact info and more items like this at

Swagelok Corporation Contact info and more items like this at


This issue is sponsored by — Emerson Process Management —


SANITARY BOX TIPPER The Tip-Tite Sanitary Box Tipper from Flexicon forms a dust-tight seal between the container and the equipment, tips the container, and discharges bulk material at controlled rates. The unit is intended for tipping of bulk foods, pharmaceuticals and contaminationsensitive chemicals from boxes weighing up to 1134 kg and measuring 915 to 1220 mm on a side and 990 to 1117 mm in height. The container platform is raised by dual hydraulic cylinders, creating a dust-tight seal between the top edge of a box and the underside of a discharge hood. Twin hydraulic cylinders then pivot the platform-hood assembly, with dust-tight seal intact, to 45, 60 or 90° beyond horizontal, including a motion-dampening feature at the termination of container rotation. A pneumatically actuated slide gate at the discharge end of the cone controls the flow of material into storage vessels or process equipment. An optional, gasketted discharge gate actuated by twin pneumatic cylinders provides a large opening with chute for the passage of larger objects or non-free-flowing bulk solids that may otherwise bridge across smaller openings, and allows control of the material discharge. The tipper is constructed of stainless steel with continuous welds ground and polished to sanitary standards. All horizontal frame members are fabricated of round stainless steel tubing to promote water runoff in washdown environments. Other sanitary features include capped threads, sloped-top control enclosures, guarding stand-off brackets and food-grade epoxy paint on hydraulic cylinders. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at

This issue is sponsored by — Emerson Process Management — 29


POWER CONDITIONER BACKPLANE Turck’s Diagnostic Power Conditioner (DPC) Backplane for FOUNDATION Fieldbus H1 segments provides up to four segments with redundant power and 800 mA per segment. In addition to delivering reliable power, the DPC backplane communicates diagnostic data back to an asset management system via high-speed ethernet to alert operators of any communication challenges. With a built-in, high-speed ethernet web server, operators can connect the DPC backplane to the field device and access live H1 diagnostic data from any LAN-based computer without having to install additional software. This saves time and cost by streamlining the implementation of a monitoring solution. Turck’s diagnostic power conditioning system features an integrated diagnostics module that provides users with statistics that ease the task of diagnosing any problems associated with the FOUNDATION fieldbus physical layer. The information provided by the DPC system is therefore designed to also assist in the commissioning and maintenance of a FOUNDATION fieldbus system. Turck Australia Pty Ltd


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The Allen-Bradley PowerFlex 525 AC drive is designed to help machine builders and end users simplify equipment design and operation, and speed installation and configuration. It features a modular design in power ranges from 0.4 to 22 kW at 100-600 V input. It’s embedded EtherNet/IP, safety, USB programming, energy savings and a variety of motor control options are suited for machine-level and stand-alone applications or simple system integration. Suitable for a wide range of applications, including conveyors, material handling, compressors, fans and pumps, the PowerFlex 525 AC drive provides a variety of motor control options to accommodate open- and closed-loop applications. To help simplify and streamline set-up, users can configure the PowerFlex 525 AC drive through its HMI, Rockwell Automation Connected Components Workbench software or Rockwell Software Studio 5000 Logix Designer. Machine builders can easily download the completed configurations and share with multiple drives, which greatly speeds up commissioning time. A SIL2/PLd-certified, embedded safe torque-off feature helps prevent drive restarts after a safety circuit is tripped, while the drive’s economiser mode helps optimise motor energy consumption by monitoring an application’s current demand and automatically refining operating parameters accordingly. The AC drive requires 50 mm of clearance on the top and bottom when installing into a cabinet and can be mounted zero stacked both horizontally and vertically. It is rated for operation up to 50°C, and with an optional fan kit the drive can withstand temperatures up to 70°C with current derating. Rockwell Automation Australia Contact info and more items like this at


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Harvesting unused energy with flat thermoelectrics A large proportion of the energy we produce disappears unused into thin air via waste heat. Tiny thermoelectric generators can tap this potential, producing electricity by way of temperature differences. However, so far their production has been laborious and expensive. At the same time there is a lack of suitable materials. Researchers are now ready to present a new manufacturing process for thermoelectric generators by which they can be costeffectively produced in the form of large-area flexible components from non-toxic synthetic materials. We are all familiar with them - the gigantic white clouds of steam billowing from power station cooling towers. As impressive as this spectacle may be, in reality it represents a waste of energy as large power stations only rarely manage to convert more than 40% of the produced energy into electrical power. The rest is released unused, mainly via the cooling towers, into the atmosphere. Researchers have been working on using the potential lying dormant in the over 150 m high concrete giants. The magic formula for this is known as thermoelectrics. This area of physics is concerned with generating electricity from temperature differences, and it is precisely in cooling towers where there can be very large differences between the hot steam and cooler concrete skin under some circumstances. The scientists’ vision is described by Dr Aljoscha Roch of the Fraunhofer Institute for Material and Beam Technology IWS in Dresden: “Thermoelectric generators (TEG) currently have an efficiency of around 8%. That sounds very small. But if we succeed in producing TEG cost effectively, on a large scale and from flexible materials we can install them extensively on the insides of the concave cooling tower wall. In this way, through the enormous amount of energy produced in the huge plants - around 1500 litres of water evaporate per minute - we could generate large quantities of electricity.” Together with his colleagues at the IWS, Roch has now taken a big step closer to this goal. The scientists have succeeded in producing TEG by means of a printing process. The miniaturised generators can not only be produced cost effectively, on large

surfaces and in a flexibly manageable manner, but an additional major advantage is that the materials used are environmentally friendly. “TEG are today largely produced by hand from toxic components which contain lead, for example. We are now using modern 3D printing technology and harmless polymers (plastics) that are electrically conductive,” explains Roch. The new printing technology functions in a similar way to an ink jet printer. The difference is that instead of a thin jet of ink, a thermoelectrically active polymer paste emerges from the cartridge and produces the around 20-30 micrometre thick thermoelectric layers. “The generators have to be of a certain thickness in order to build up electrical voltage from temperature difference. Currently available 3D printing processes could be very suitable for achieving the required depth,” says Roch. But how is the electricity then ‘harvested’ from these polymer generators which are only a few micrometres in size? The hot steam activates the electrons in the generator, the negatively charged particles migrate to the cooler side and an electrical voltage is produced. Even small temperature differences such as one degree are sufficient for this effect. This has been known to physics for almost 200 years, but due to the lack of efficient manufacturing methods and suitable materials it has not been extensively used. The manually produced, brick-like TEG are used in space travel and are being tested in the automotive industry. Mounted on the exhaust pipe, they supply current for the vehicle’s onboard electronics, for example. To date 600 W, the power output of around six light bulbs, has already been demonstrated. When multiplied by the many millions of vehicles on Germany’s roads alone, several thousand million kilowatt hours could be saved by TEG. Cars and cooling towers are, however, only two examples out of many. “In principle, waste heat is produced through the operation of every technical installation. With TEG fitted on industrial production lines, in sewerage systems, at large computer centres or on any type of exhaust air system, very large and hitherto unused sources of energy could be developed,” concludes Roch. Fraunhofer-Gesellschaft

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PHOTOELECTRIC SENSORS The OI Cube photoelectric sensor is distinguished by long ranges up to 800 mm for diffuse types and up to 15 m for retro-reflective types. For diffuse sensors the range can be set precisely using the multiturn potentiometer. Even under harsh industrial conditions the range remains independent of colour. The OI design is intended for position detection in conveying, where high ranges are needed. As a diffuse type, the sensor operates independently of colour so that objects with different surfaces can be detected reliably without readjustment. The metallic M30 housing is also extremely robust. Even without additional protection the sensor withstands impacts and shocks. A feature of the sensor is the switch-point setting which uses the multiturn potentiometer and a distance scale. The turns and the scale value are linear to the distance (‘1’ = 100 mm, ‘2’ = 200 mm etc). Before connecting the sensor, the switch point can be set and seen from the sensor scale at any time. This easy-to-use, long-range sensor guarantees maximum reliability under severe conditions. ifm efector pty ltd Contact info and more items like this at

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ONLINE RHEOMETER FOR FOOD PRODUCTS The OnLine Rheometer (OLR) from Rheology Solutions is the first to continuously measure, plot and report the flow properties of liquids in process pipes. The OLR assists process monitoring, process control and quality control of liquids in the processing and manufacturing of food products. Flow properties that influence processability or mouthfeel like viscosity, tack, elasticity, body and others are important for a variety of products in the food industry. The OnLine Rheometer (OLR) is able to make measurements that directly relate to these variables and provide feedback to the operator in real time. In this way the operator can make informed process decisions about the quality of the material in the pipe and make changes as appropriate. The OLR can reduce or remove costly waiting times associated with laboratory testing, removing production bottlenecks and increasing effective production capacity. In addition, consumer-critical parameters such as mouthfeel can now be monitored online so that customer satisfaction with the final product can be better assured during production rather than post production from a taste panel assessment. The OLR will consistently measure the properties that define critical mouthfeel attributes that have been previously evaluated as preferred and important from pilot product tests with taste panels. The OLR is tuned to frequencies that probe the relevant microstructures that affect mouthfeel and in doing so provides measurements that can be more easily correlated to the attributes of interest. Rheology Solutions Pty Ltd Contact info and more items like this at

HEAT TRANSFER SYSTEM RANGE Teralba Industries has released the Thermpro range of heat transfer systems. Thermpro systems combine the features of the Dimpleflo and Teralba heat exchangers with a range of control equipment - such as pumps, valves, RTD sensors with provision for thermal expansion - into a skid-mounted system. The packaged systems are mounted on compact frames, configured and customised to fit within users’ operational structure and comply with space restrictions. The systems are fully controlled and monitored via touchscreen electronics. The units can also be configured to incorporate CIP function and steam sterilisation. These are custom-engineered and manufactured units, designed with a variety of standard features and options to meet demanding requirements and to comply with specific design parameters. Thermpro systems incorporate removable panels for protection from hot surfaces and adjustable levelling feet to allow positioning in any location. The systems are suited to demanding applications within the food, beverage, dairy and chemical industries, such as controlled water heating with steam, isolation of ethylene glycol from temperatures above its flash point and refrigeration duties with in-built control requirements. Teralba Industries Contact info and more items like this at

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AS I SEE IT A.B.N. 22 152 305 336


Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 AUSTRALIA ph: +61 2 9487 2700 fx: +61 2 9489 1265 ph: +61 3 9381 2952 Editor Glenn Johnson Chief Editor


he industrial landscape is rapidly evolving to address the challenging economic environment facing Australia today. Organisations need to become more efficient and flexible to maintain competitiveness and improve productivity. This evolution has seen a significant increase in industrial ethernet technologies being applied to control systems and is being used to connect plant to business systems, helping industry achieve operational improvements. Industrial ethernet is based on existing commercial technology; however, the components used are typically optimised for use in harsh industrial environments, where temperature extremes, humidity and vibration exceed the ranges found in controlled commercial environments. Ethernet adoption across a plant or factory provides for easier information sharing and reduces network complexity. A single ethernet network can be used for standard control, as well as safety, motion, process, visualisation and asset management. This allows a reduction in the costs and time associated with the traditional approach using multiple fieldbuses. By providing a scalable platform that can accommodate multiple applications, ethernetbased automation systems can help increase flexibility and accelerate deployment of new applications, providing companies with a futureproof network that can help them achieve their productivity goals. Additionally, major improvements in wireless ethernet’s speed and reliability now bring a new realm of capabilities to controlling plants. Wireless obviously eliminates the need to run network cables across obstacles, further reducing the cost and complexity of installing traditional networks. This allows for great flexibility in an installation, where a combination of wireless and wired solutions may be used where conditions dictate. Ethernet networks also allow for easy access to critically important, real-time data. A well-designed, robust, secure ethernet network can now allow real-time data to be accessed securely from anywhere in the world. Operational dashboards and reports provide increased visibility into current plant operations.


Janette Woodhouse

But exposing process networks to a wider audience raises valid security concerns. Due to their isolation, traditional fieldbuses inherently brought some level of security; although accessing data on these networks can be difficult. As industry moves towards a converged ethernet network, security becomes a prime concern. However, commercial providers of networks based on ethernet have, for the past two decades, been working on mitigating risks associated with viruses, unauthorised access, remote access and external attacks. Leading control system vendors are increasingly collaborating with traditional IT companies to design reference industrial ethernet architectures utilising current best practices. This has led to a cultural change where IT and engineering are becoming closely aligned. In the past, industrial applications were maintained solely by engineers, but now the line between traditionally separate IT and engineering departments is becoming less defined. Engineers are becoming more familiar with IT technologies, and conversely, IT is fast learning the intricacies of industrial ethernet. Researchers are predicting an explosion of end devices connected to ethernet, and as power over ethernet becomes accepted within industry, more and more devices are expected to be shipped ‘ethernet ready’. Manufacturers and automation vendors will continue to take advantage of investment and innovation in compatible commercial ethernet technologies and adapt these innovations to the industrial environment. Robert Hicks has been involved with the pr oc e s s au t o m a t i o n industry for more than 22 years, 10 years of which was spent commissioning process plants internationally. More recent ly, as Product Manager for Controllers and Networks at Rockwell Automation, he advises customers on product selection and best practices.

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March 2013 total CAB audited circulation (Aust + NZ) 6,984 readers (79% personally requested)

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