Ethernet IO Modules with Integrated IO-Link Master – the best in Industrial Communication

Pepperl+Fuchs’ Ethernet IO modules offer an array of innovative features. With a versatile multi-protocol capability, they provide optimum efficiency for standardizing manufacturing facilities. IO-Link and comprehensive diagnostics are important for maintaining and troubleshooting your machines. These innovative, high-performance ethernet communication modules can help optimise your installations.

Managing the Demands of Modern Industry and Beyond

If industrial process control sensors are to manage the demands of the future manufacturing processes, they need to do more than simply deliver process data to a PLC. An industrial process control sensor must be able to communicate with multiple receivers and send and receive data to and from higher-level information systems efficiently.

Ethernet IO modules

The Pepperl + Fuchs Ethernet IO modules with integrated IO-Link master deliver first-class communication between system management and process sensors and actuators as they assume a gateway function between Ethernet and IO‑Link. With these capable ethernet modules up to 8 IO‑Link devices may be directly connected, with 4 channels available for sensors and 4 channels for actuators.

The ICE1 series IO-Link master enables integrated diagnostics and parameterisation from the control level right down to the process sensor level, and commissioning times will be  reduced primarily in large production plants. Ultimately, this means that Ethernet IO modules with integrated IO-Link master can be incorporated into the requirements profile of innovative machine and plant manufacturers easily, forming a crucial component of Sensorik4.0.

Ethernet IO modules

Sensorik4.0 is the next generation of interconnected sensor solutions from Pepperl + Fuchs that helps bring Industry 4.0 to life. The integrated Ethernet IO-Link masters bring the concept of Sensorik4.0 to reality. IO-Link sensors and actuators can be easily connected across all technologies creating a whole range of possibilities for the user, ranging from parameterisation to diagnostics down to actuator/sensor level and simplifying maintenance, paving the way in the digitalisation of factories of the future.

IO-Link Masters with OPC UA Interface, Dependable Information Exchange from Field to Cloud

In addition to the ICE1 masters, designed for PLC-based applications, two other modules are available for use in cloud-based and hybrid systems: the ICE2 (EtherNet/IP) and ICE3 (PROFINET) IO-Link master series.

These 2 ethernet modules support industrial protocols such as EtherNet/IP, PROFINET, and MODBUS TCP, and provide an OPC UA (Open Platform Communication Unified Architecture) interface in addition to real-time fieldbus protocols.

Ethernet IO modules

The open architecture of OPC UA allows cross-vendor, platform-independent, and the interoperable collaboration of machines in processing environments and makes communication between machines and computer or cloud-based systems possible, both in closed networks and via the internet.

Both IO-Link masters come with web-based configuration for setting all module parameters and all connected IO-Link devices (web IODD operation).  When replacing or expanding modules, all the module settings can be saved as a separate file and transferred to a new device using the module cloning function. OPC UA ensures a constant exchange of information across all levels so that plant processes can be designed more efficiently.

IIoT Starter Kit—Connecting Factory Floor Sensors to the Cloud

With the IIoT starter kit and the user-friendly IO-Link masters from Pepperl+Fuchs simple visualisation and analysis of sensor data becomes a reality. Discover the advantages of IO-Link and experience the seamless integration of IO-Link sensor data into your Industry 4.0 application.

The kit includes among others:

  • An IO-Link master, (3) IO-Link sensors, an Ethernet switch, a power supply, RFID tags and all the necessary cabling to get started
  • A quick start guide for connecting the IO-Link master and IO-Link devices
  • Connections for various platforms such as AWS, PTC, AVEVA

Connect your software dashboard via OPC UA or MQTT for easy interpretation of real-time data and start the digital transformation of your installations now with the IIoT starter kit, available from Kempston Controls.

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A Change is Brewing – the VLT AutomationDrive FC 302 – Making Beer Smarter

Within industry today terms such as ‘Smart Maintenance’, ‘Smart Factory’ and the ’Factory of Tomorrow’ are becoming more and more commonplace.

These terms are the ideal end goal for many businesses, ultimately leading to a highly efficient and well-run operation.  Making the transition to a Smart Factory isn’t without its challenges and can feel more like a leap into the unknown, rather than a small step in the right direction.

Brewing giant HEINEKEN decided that to secure a more robust and sustainable future in its Netherlands based Den Bosch facility, required stepping into unknown territory by using the innovation offered by Danfoss VLT drives with integrated condition-based monitoring (CBM) capabilities to reach their goals.

By 2025 the European beer market is expected to have grown by a further 15.2%, HEINEKEN knows that to meet this expected growth their production lines must always be on task with all assets delivering a reliable and consistent performance 24/7.

VLT AutomationDrive FC302

Producing beer on a large scale can be demanding, and with all applications containing difficult to access motors Heineken faced costly and lengthy disruptions whenever a machine fault occurred.

Danfoss was tasked with helping the brewery to:

  • Increase uptime
  • Lower overheads
  • Improve management of spare parts and stock
  • Access new levels of machine data
  • Boost application and system performance

Technology with the Edge

Danfoss Drives proposed HEINEKEN install VLT AutomationDrive FC 302 drives with embedded intelligence, connectivity, and sensor capabilities. Condition-based monitoring signals were integrated into the brewery’s maintenance system using edge computing.

The brewery also utilised some vibration sensors and Danfoss assisted further with project scoping, commissioning, training, as well as holding workshops.

As the VLT drives also support existing industrial ethernet communication interfaces and software such as VLT Motion Control Tool MCT 10, meant that HEINEKEN didn’t have to invest in new parallel systems as part of the upgrade.

Jan Brouwers, Detail Engineer at HEINEKEN’s Den Bosch said – ‘Condition Based Monitoring is a great addition to an already very good drive. Now, HEINEKEN is standardised on the VLT AutomationDrive FC 302.’

VLT AutomationDrive FC302

An Optimised Conclusion

The VLT Motion Control Tool MCT 10 plug-in was a game changer, enabling seamless commissioning with consistent parameter settings, with the power to gather more critical application data in real time than ever before. HEINEKEN, thanks to the efforts of Danfoss Drives, was able to optimise its Den Bosch production line while solving all its pain points while building a total value proposition.

As a result, HEINEKEN retrofitted the rest of its drives in its other facilities with condition-based monitoring functionality. The Den Bosch upgrade proved that condition-based monitoring is no longer a premium product meant for a few critical assets, but an affordable solution for all.

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RFID Sensor – the SICK RFU61x, Big Ability in a Small Package

What is RFID Technology?

RFID, or Radio Frequency Identification, is a method of transferring information between two entities, these being an RFID tag that carries information and a RFID scanner or reader to decode that data. Using electromagnetic field technology, when an item adorned with an RFID tag passes a suitable scanner that information is captured, extracted, and acted upon, or not, by the control system that is interpreting the data.

RFID tags and readers do not need a line of sight to function, they merely need to pass within the detecting range of each other. RFID Sensor tags can be found in many applications, such as attached to clothing in a store, under the skin to identify pet ownership, in a car key fob or in production operations, monitoring the progress of a product through each stage of manufacture, all of them containing data that is accessible by a suitable reader.

RFID technology exists in many forms and for many purposes and SICK, world-renowned manufacturers of sensors and sensing solutions are no strangers to RFID technology, here we preview the RFU61x UHF RFID Sensor.

The RFU61x UHF RFID Sensor, Small and Powerful

The RFU61x RFID Sensor from SICK, is one of the smallest read/write device of its type on the market, ideally suited for IIoT applications involving the identification of production workpieces or components.

RFID Sensor SICK RFU61x

The diminutive stature of this RFID Sensor enables versatile application possibilities even in the most limited installation spaces, and the rugged design provides reliable operation even in demanding industrial environments.

Installation is quick and easy thanks to the integrated process logic which means data gathered by the sensor can be processed directly within the device itself, performing triggering, reading, and writing which is passed onto the control system for interpretation.

Easy to connect, the RFU61x has a wide range of interface options allowing for the direct connection of trigger sensors meaning this capable RFID Sensor can be used as a remote, self-supporting unit.

 

The RFU61x UHF RFID Sensor – Packed with Features:

  • Extremely compact design, ideal for demanding environments
  • Frequency band UHF 860 – 960 MHz (region specific)
  • Read range up to 0.5 metres (depending on transponder and ambient conditions)
  • Connection option for trigger sensors
  • Connectivity – Ethernet (TCP/IP, PoE, OPC UA), Profinet, EtherNet/IP, USB
  • Link option to PC control systems or directly to the cloud
  • Antenna and data processing integrated in the sensor
  • Configuration via SOPAS ET and/or AppSpace Software or integrated web server
  • Rugged design in accordance with IP67
  • Large range of differing region-specific radio approval versions available

RFID Sensor SICK RFU61x

Configuration and set-up can be simplified further by using the free-to-download SICK SOPAS ET software or the integrated web server which helps reduce commissioning time. The versatile SICK APPSpace software (available via a monthly licence), which can also be used with other SICK Radio Frequency Units (RFU), helps provide users with maximum flexibility when programming. The RFU61X is available in a range of radio approval variants to cater for the individual broadcasting demands of specific countries and regions.

 

Typical Fields of Application

  • Component identification on assembly lines
  • Identification of production material in machines
  • Load identification on mobile platforms
  • Material procurement in E-Kanban
  • Container identification in conveyor systems

 

RFID Sensor Technical Data

  • Supply voltage 18 to 30 VDC
  • RFID standard EPCglobal UHF Class 1 Generation 2, ISO/IEC 18000-6 C
  • Modulation – PR-ASK, Read range ≤ 0.5 m
  • Integrated antenna, adjustable transmitting power, circular polarisation
  • Housing construction – die cast aluminium
  • Dimensions (L x W x H) 92 mm x 80 mm x 38 mm
  • Optical indicators 4 LEDs, multi-colour (device status), 4 RGB LED (Process feedback)
  • Memory card type – microSD (for parameter cloning, data storage)
  • Protection class III
  • Weight 313 g

RFID Sensor SICK RFU61x

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APM-MAX 21 and 23 Panel Meters, Process Signal & Power Monitoring in Full Colour!

The APM-MAX 21 and MAX 23 panel meters have been designed especially for engineers who need an effective way to monitor and display a range of power monitoring, process signals and analogue data. The capable metes combine the instant visual representation of an analogue meter with the unrivalled speed and accuracy of a digital meter. Accepting a wide range of electrical inputs, the APM-MAX 21 and 23 Panel Meters can display essential data via their full colour RGB LCD in a positive or negative format.

APM MAX Range

 

Feature packed,  including:

  • 16 million colour, RGB display, back light
  • 60 segment curve bar graph with programmable scale
  • 2 independent alarm set points
  • Combined digital and bar graph display
  • Positive or negative display type
  • Programmable 4-digit starburst display, custom messages and annunciators
  • 2 digital outputs, 1 analogue output
  • Modbus, RTU comms with optional TCP/IP connectivity
  • Selectable to measure voltage, current, frequency or watts

 

The MAX 23 is ideal for use as a process meter or a shunt meter, perfect for low-voltage applications, while the MAX 21 is perfect for measuring amps, voltage, frequency and power in high voltage applications.

Easy to configure, you can plug your APM-MAX 21, or MAX 23 into a computer using a USB cable and easily upload and download new configurations using the free-to-download configuration software.

Versatile and dependable, the MAX 21 and Max 23, with a 25% larger screen than the standard APM Panel Meters, are easily installed into electrical cabinets and display panels and come as standard with two digital inputs and one serial input providing a capable colourful solution for your power display needs.

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The APM-Max 21 Full Colour Panel Meter

AMP MAX 21

The APM-MAX M21, with either a negative or positive full colour RGB display, can be configured to measure amps, voltage, frequency or power (Watts, VA, VAR & Power Factor) and almost any analogue signals and feature an array of configuration options, ideal for high voltage industrial and commercial applications.

 

APM-Max 21 Panel Meter Specifications

  • Full-colour, 4 digit, RGB backlight for endless configuration options
  • Positive or negative LCD display options, 2-line display
  • Measures and displays amps, voltage, frequency, power,  analogue signals
  • Frequency 0-400 Hz, Input range (V1) 0 – 600 VDC/AC (47-63 Hz)
  • Current input range, direct- 0-5 A DC/AC (45-65 Hz), with shunt 0-500 mV DC
  • Outputs – 1) digital (open collector), 2) digital (open collector), 3) Analogue (4-20 mA)
  • Power measurement – Watts, VA & Power Factor
  • Accuracy (DC & Frequency) 0.1%, AC – 0.5%, RMS display modes
  • Power supply – 100-240 Vac, 50-60 Hz
  • Dimensions 108 x 108 x 45 mm, Screen size 81.5 x 66 mm
  • Certifications – CE, cUL, UL

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The APM-Max 23 Full Colour Panel Meter

APM MAX 23

The APM MAX 23 is an all-round panel meter with endless configuration options. This panel meter, with positive or negative full colour RGB display and Modbus RTU communication as standard and optional TCP/IP, can be configured as a process meter or a shunt meter for multiple low voltage applications, ideal for monitoring almost any analogue signals.

APM-Max 23 Panel Meter Specifications

  • Full-colour, 4 digit, RGB backlight for endless configuration options
  • Positive or negative LCD display options, 2-line display
  • Monitor universal process signals such as 0-10 V and 4-20 mA
  • Frequency 0-400 Hz, Input range (V1) 0-10 VDC, input range (V2) 0-5 A DC
  • Current input range, direct – 0 -50 mA DC, with shunt – 0-500 mV DC
  • Outputs – 1) digital (open collector), 2) digital (open collector), 3) Analogue (4-20 mA)
  • Accuracy (DC & Frequency) 0.1%, AC – 0.5%, RMS display modes
  • Power supply – 100-240 Vac, 50-60 Hz
  • Dimensions 108 x 108 x 45 mm, Screen size 81.5 x 66 mm
  • Certifications – CE, cUL, UL

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Contact Kempston Controls today to and let us help you choose which APM MAX Panel Meter is suitable for your application. Call us on +44 (0) 1933 411 411, email us at sales@kempstoncontrols.co.uk, or use the enquiry form below.

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RocketLinx – Industry 4.0 Ethernet Switches you can depend on from Pepperl + Fuchs

Dependable production and industrial processes rely upon a whole series of activities and events to take place concurrently when required, from the press tool forming component parts to film packaging machines at the end of a conveyor. Ensuring these events occur when they should typically relies upon digital communication between the various mechanisms at play such as PLCs, computerised monitoring systems and the machines themselves.

Industrial ethernet has a long-established history of providing reliable and dependable factory floor communication in numerous industries and applications.  When a demanding working environment calls for an capable industry 4.0 ethernet installation solution the RocketLinx Range, designed by Pepperl + Fuchs, is the perfect go-to solution which is available to buy from Kempston Controls.

Meeting and exceeding digital communication demands

Pepperl + Fuchs RocketLinx Ethernet Switches have been designed to meet the demanding requirements of industrial ethernet networking and industry 4.0. This impressive offering consists of managed and unmanaged industrial Gigabit and Fast Ethernet switches to suit numerous applications and budgets.

RocketLinx Communication

RocketLinx switches are robust, with a rugged metal construction, (either steel or aluminium depending on the model) which increases thermal conductivity and heat dissipation, extending operating temperature ranges. The slim, space-saving design of these ethernet switches allows for easy integration within control cabinets and panels, while compliance with industry standards including Class I, Div 2, CE, FCC, and UL508 ensure safety and reliability.

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Unmanaged Ethernet Switches

  • Cost-efficient -industrial-grade solution
  • Simple plug-and-play network expansion at the field level

Models:

RocketLinx Communication

Managed Ethernet switches

  • Rapid reliable expansion of Ethernet connectivity, Industry 4.0 ready
  • Advanced management, security, network redundancy, mission-critical reliability

Models:

 

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Reliable Industrial Communications

These capable Ethernet switches combine reliable and cost-efficient RJ45 connections for short distance communication and SFP fibre ports for areas with high electronic noise or for long distance communication up to 120 km. Ideal for PROFINET IO and EtherNet IP, Industry 4.0 applications.

RocketLinx CommunicationDepending on your installations requirements the connections can be individually tailored to the network application. Even if the configuration needs to be adjusted due to network infrastructure changes, hot-swappable SFPs allow for individual transceivers to be replaced rather than the entire switch.

 

 

 

 

RocketLinx Security and Performance Features

  • Improve reliability and supports deployment in a wide range of industrial environments
  • Incorporated VLAN support for network segmentation enhances security and performance
  • Redundant power inputs offer guaranteed uptime in the event of a power supply failure
  • Rapid Spanning Tree and ring protocols, loops are eliminated and network redundancy is established
  • Built-in configurable alarm relay provides on-site notifications for port link and power events

RocketLinx Communication

Configuration Software

PortVision DX is free software from Pepperl + Fuchs, that allows you to configure network settings of all of their managed Ethernet switches within the network. In addition to simplified configuration, this software also provides real-time monitoring and diagnostics of connected switches and easy firmware updates.

 

Kempston Controls has a long-established relationship with Pepperl + Fuchs which gives us access to the RocketLinx range along with their entire product portfolio. Speak to us today either by phone on +44 (0) 1933 411 411, email via sales@kempstoncontrols.co.uk or using the contact form below. We will be happy to discuss your requirements and help you ensure that your new installation or retrofitting project goes exactly as planned.

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Kempston Controls

Talking Intrinsically Safe with the Ex-Handy DZ Feature Phones

When it comes to mobile communication in dangerous working environments where there may be a chance that an errant spark or excessive heat could ignite a volatile atmosphere, your mobile communication device needs to be intrinsically safe.

What are intrinsically safe devices?

Intrinsically safe devices are defined as: ‘Equipment and wiring that is incapable of releasing sufficient electrical or thermal energy under normal operating conditions that could lead to the ignition of a specific hazardous atmospheric mixture in an easily ignited concentration’.  It stands to reason that in environmental conditions like these the equipment used in those areas will need to certified to specific intrinsically safe directives such as ATEX and IECEx.

Most modern smartphones may be feature-packed with all the latest hardware and software but when it comes to keeping users safe in potentially dangerous atmospheric conditions they are sadly lacking by not being intrinsically safe and potentially dangerous in certain locations.

ecom, a Pepperl + Fuchs Brand has the intrinsically safe answer to on-site mobile communications in the harshest of environments in the form of the Ex-Handy 10 DZ1 & DZ2 ATEX safe feature phones.

EX handy 10 DZ1 ATEX rated intrinsically safe phone

The EX-Handy 10 DZ1 & DZ2 – Intrinsically Safe Mobile Feature Phones

The Ex-Handy 10 DZ1 & DZ2 are simple to use and extremely robust impact-resistant intrinsically safe feature phones that have been designed for use in potentially hazardous environments, meeting worldwide approvals for Zone 1/21, 2/22 & Class 1 / Div 1 & Div 2.  These Android 8.1 based phones are ideal for a wide range of intrinsically safe uses from push-to-talk (PTT), general phone communication, lone worker protection (LWP) and have the ability to function seamlessly with the Industrial Internet of Things (IIoT).

EX Handy DZ1 Atex intrinsically safe phone and mike

Complete with many of the familiar apps you would find on a regular Android smartphone the Ex-Handy DZ1 & DZ2 enables the use of push-to-talk over 4G, private LTE and WiFi networks via an external Zone 1/21 speaker microphone, ensuring it has optimal safe network coverage in working areas and situations for when workplace safety demands it.

Ex-Handy 10 DZ1 & DZ2 Intrinsically Safe Mobile Phone Features:

  • Worldwide approvals for Zone 1/21, 2/22 & Class 1 / Div 1 & Div 2
  • Push to talk over 4G, LTE and WiFI providing optimal low latency coverage
  • Specials buttons for one-touch (PPT) and lone worker protection (LWP) functions
  • 4G/LTE standard (SIM unlocked) – Nano SIM
  • WiFI 802.11 a/b/g/n/e/k/r/k: 2.4 Ghz and 5 Ghz support
  • Bluetooth 4.2 BLE, GPS and NFC
  • IP68 rated dust and waterproof housing, MIL-STD-810G
  • Designed for the IIoT
  • Temperature range -20 to +60°C

Android 8.1 Driven and Packed with Hardware:

  • Qualcomm Snapdragon MSM8909 processor
  • 2GB Ram, 16GB ROM – SD card up to 128GB
  • 2.6-inch capacitive extra-tough Gorilla glass screen with excellent readability
  • 8 MP rear-facing camera with auto-focus and LED flash
  • 3.5mm jack connection with special ecom mounting
  • 7 -pin waterproof magnetic USB 2.0 connector
  • Forward-facing speakers ensure optimum sound quality even in noisy environments
  • Cabling systems allows the use of Radio Speaker Microphones or headsets
  • Long rechargeable battery life 3920 mAh

 

Certification:

ATEX
DZ1

  • II 2G Ex ib op is IIC T4 Gb IP64
  • II 2D Ex ib op is IIIC T120°C Db

DZ2

  • II 3G Ex ic IIC T4 Gc IP64
  • II 3D Ex ic IIIC T120°C Dc
IECEx
DZ1

  • Ex ib op is IIC T4 Gb IP64
  • Ex ib op is IIIC T120°C Db

DZ2

  • Ex ic IIC T4 Gc IP64
  • Ex ic IIIC T120°C Dc
NEC & CEC
DZ1

  • Class I, II, III, DIV 1, Groups A-G, T4

DZ2

  • Class I, II, III, DIV 2, Groups A-G, T4

 

Android apps for the EX Handy intrinsically safe series

Useful Apps

There is also an extensive application library featuring many Ex-handy 10 DZ1 and DZ2 compatible apps that can help with a variety of communication, tracking and data gathering solutions and IIoT applications, the perfect addition to your intrinsically safe mobile communication solution.

You can never be too safe when it comes to operating within an environment that demands intrinsic safety. Whether it’s the equipment operating the machinery or the mobile communication devices used by personnel working in these areas. Kempston Controls, as a supplier partner of ecom, Pepperl + Fuchs is able to source all the intrinsically safe mobile devices and equipment you will need.  Give our dedicated sales team a call on +44 (0) 1933 411411 or email sales@kempstoncontrols.co.uk  to order your Ex-Handy 10 DZ1 & DZ2 and to discuss your intrinsically safe requirements.

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