Category: Process Control Products

Inductive Sensors for Valve Position Detection – for Regular & Harsh Industrial Environments

Posted on by Rick Morgan

The Pepperl+Fuchs’ family of inductive valve position sensors helps provide modern industry with the most contemporary direct-mount open solution products available. These dual inductive sensor models include the F25 series for smaller pneumatic actuators and manual valves, the F31 series for small or medium actuators, and the robust F31K2 sensors. The F31K2 is the most flexible, rugged and weatherproof sensor model, ideal for use in demanding working environments.

Direct mount valve position inductive sensors minimise space requirements, maintain sensing distance, and offer simplicity and reliable monitoring. Designed to meet the requirements of the process valve market, these inductive proximity sensors are easily mounted onto the actuator enabling fast connection and easy replacement. All of these products are available to purchase from Kempston Controls today.

F25 Series – Basic, for manually operated valves and small/medium sized actuators

The F25/F25K series is available as a cable, plug, or terminal compartment version and combines the two sensor elements in the smallest possible space. Perfect for small basic applications, such as manual valves in indoor areas.

Versatile, the F25 sensor series is an effective solution for valve positioning, the two sensing elements in one device reduces installation and maintenance costs considerably. The F25 sensors are suitable for both the switch box enclosure as well as for direct mount onto the actuator.

F25 Inductive Proximity Sensor Features

  • The sensor mounts directly to manual or automated rotary valves using NAMUR 30 mm – spaced mounting holes
  • Adjustable-free mounting, maintains accurate sensing distance
  • Actuator target for position monitoring applications
  • Direct assembly on standard actuators
  • Dual sensor with two active zones
  • Small construction with sturdy plastic housing, IP 67
  • 2-wire DC sensor with minimum off-state current
  • For use with manual valves
  • Finger safe design
  • Namur, Safety Namur, SIL3, DC 2-wire, DC 3-wire
  • M12 male connector or cable
  • Construction PBT plastic

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F31/F31K – Standard, for direct mounting on actuators either indoor or outdoor

The F31/F31K series are used in applications on standard valve actuators in indoor and outdoor areas. They are very easy to assemble and are also available for hazardous areas.

The standard series F31/F31K are best suited for position feedback that enables direct, stable, and durable mounting of the sensor and actuator. The variable dual sensors are suitable for all normal actuators and are easy to mount.

F31/31K Inductive Proximity Sensor Features

  • Small sensing face ensures no pinch point hazard between sensor and puck
  • Direct mounting on actuators in indoor and outdoor areas
  • Versions include cable connection, plug and socket, and terminal compartments
  • Clear LED indication of switch status, supply voltage, and solenoid activation
  • Compact design (F31), F31K features a terminal compartment
  • 1 or 2 solenoid outputs
  • NAMUR, SIL2, DC 2-wire, DC 3-wire, AC/DC, AS-interface

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F31k2 Series – Premium – optimised for outdoor applications

The F31K2 series is specifically designed for uncompromising use outdoors, combining durability and flexibility with excellent performance, even under extreme working conditions. Easy to mount on standard valve actuators without the need for additional mounting aids, these proximity sensors feature a highly visible integrated valve position indicator and translucent housing. ­

The F31K2’s unique double housing construction provides double mechanical protection and is tightly sealed, optimised for outdoor use with a high resistance to UV, temperature, and salt water. Thanks to the open solution and the translucent housing, the integrated beacon is highly visible.

F31K2 Inductive Proximity Sensor Features

  • Inductive dual sensor with extended sensing range
  • Optimised for outdoor use, rugged construction
  • Electronic amplifiers with Ex approval
  • Fully encapsulated sensor housing for non-contact sensing
  • Plug-in screw or cage clamps
  • Connections for cable or conduit fittings with long screw threads
  • Temperature, UV resistant and waterproof polycarbonate or aluminium housing
  • Connection of 1 or 2 solenoid valves, large terminal space
  • Flexible and modular housing with highly visible beacon
  • LEDs for sensor output and control of solenoid valves
  • Direct installation on NAMUR actuator holes 30 x 80 mm, 30 x 130 mm

See the Range at Kempstons

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

Posted on by Rick Morgan

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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The Commander S – AC Drive Controllers, Optimised for Simple Motion Cycles

Posted on by Rick Morgan

Leading the way in putting you in charge of motor control and making your processes more efficient is the latest addition to the Nidec Control Techniques motor drive portfolio. With a comprehensive feature set optimised for simple motion cycles the Commander S Drive range provides a cost-effective solution for drive applications that require plug and play convenience straight from the box.

The Commander S drive is the first drive to come with a built-in Near Field Communication (NFC) App interface as standard. The Marshal app (which is downloadable for free on a mobile device for Android/OS) is a revolutionary way to communicate wirelessly with a motor drive using NFC, covering commissioning, monitoring, diagnostic and support. The NFC technology utilised in these versatile drives has a communication time of less than 0.5s, helping to speed up and simplify your set-up times considerably.

Sleek Design Simple Operation

The sleek curved design and small footprint of the Commander S range optimises component layout and with easy access to angled terminals and the click-on/click-off DIN rail mount make installation remarkably easy. With a wide range of power, voltage, mains filter options and frame sizes available to choose from you are certain to find a model to suit your application and using the Marshall App you can be up and running in under 60 seconds.

As you might expect from Control Techniques, the performance of the Commander S range is guaranteed throughout its whole lifetime and is packed with features to help save you time, space, energy and money.

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The Marshall App – revolutionising the motor drive interface

Marshal is the motor drive expert in your pocket. A content rich interface means you can easily commission, clone parameters, back-up settings, share data and configurations via Outlook & OneDrive, diagnose issues and create report logs/error reports, visualise settings and monitor the drive in just a few taps of your smartphone’s screen.

commander s

Marshall App Advantages

  • Power off commissioning with FastStart assisted commissioning
  • Advanced parameter settings, pre-set application configurations
  • Easy parameter cloning and transfer, simple back-up process
  • Share configurations via Outlook, OneDrive, WhatsApp, export as PDF
  • Guided diagnostics, error logs and active error diagnosis
  • Quick view of parameter settings and drive status, restrict access
  • Easily visualise I/O, motor and speed settings

Commander S Motor Drive Features

  • NFC communication App interface
  • Power range 0.18 to 4 kW (0.25 to 5 HP)
  • Supply requirements 100V (100-120 V), 200V (200-240 V) 400 V (380-480 V)
  • Marshal App interface enables drive set-up in only 60 seconds
  • FastStart commissioning menu – 4 simple steps to get your motor running
  • 3 frame sizes available
  • Simple setup routines tailored to your application
  • Inputs and outputs – 2 Analogue Inputs, 1 output, 4 Digital inputs, 1 I/O, 1 Relay
  • Fixed display with 4 control buttons
  • RJ45 connector for Modbus RTU
  • Intelligent fan control reduces energy usage
  • Integrated C1 EMC filter for residential installations
  • Choose your preferred interface; Marshal App, drive keypad, Connect PC Tool
  • Finger proof terminals
  • Restrict unwanted access via a PIN

commander s

The Commander S AC Drive has been designed for a wide range of industrial motor control tasks, including:

  • Fan, Pump, Compressors
  • Improved energy efficiency during low demand
  • PID functionality -advanced control, no need for an external controller
  • Avoid equipment resonant frequencies & reduce high-vibration levels
  • Catch an already spinning motor to reduce start-up time and increase productivity
  • Motor thermal protection prevents overheating during operation

Conveyors, treadmills, automatic doors & barriers

  • Reliable speed control with onboard communications
  • S-ramp acceleration/deceleration profiling minimising machine jerk
  • Linear V to F with a controllable boost to get the machine running
  • Drive overload capacity up to 150% for increased acceleration or load changes
  • DC braking with stop indication

Industrial Processing

  • Mixers, crushers, agitators, centrifuges, kneaders, spinning & braiding machines for textile
  • Ease of integration to external PLC or other systems with on board communications
  • Stability optimiser for improved motor control
  • Resistance compensation for excellent torque performance
  • Built-in EMC filter effectively reduces electromagnetic Interference

The Commander S is the next in line of a hugely successful portfolio of innovative advanced motor drive products from Nidec Control Techniques that are available to buy today from Kempston Controls, your trusted industrial processes and control supplier.

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PS1000 Power Supplies from Pepperl + Fuchs for ATEX Zones 2/Div. 2

Posted on by Rick Morgan

The Pepperl + Fuch PS1000 Power Supplies have been created for industrial applications where high system availability, redundancy and efficiency are demanded. In industrial and process systems, control cabinets and field boxes, the PS1000 range of power supplies ensures a reliable and efficient power supply from 5 to 40 Amps, for 12 VDC, 24 VDC or 48 VDC output.

Designed with versatility and for extended use, the PS1000 Power Supplies feature ATEX, IECEx, and EAC approvals and can be utilised in applications up to ATEX Zone 2/Div.2. The extensive range includes 1 and 3-phase power supplies, redundancy modules and PSUs with built-in redundancy. Suitable for universal use across all sectors, including applications with stringent requirements on reliability and quality and providing optimal immunity to interference.

Reducing Costs and Improving Efficiency

The PS1000 power supplies have reliability built-in and are up to 95% efficient. This efficiency reduces the need for additional hardware, due to minimal losses in terms of the power fed in, minimising cabinet cooling and reducing energy costs.

Compact, the PS1000 takes up very little space and is easily mounted on DIN rails and can be used in ambient temperatures of up to +70 °C, the cable length can be compensated in the application as the output voltage is adjustable.

Versatile Combinations

These versatile power supplies can be combined with other Pepperl+Fuchs DIN rail mounted devices in the control cabinet, including intrinsic safety barriers, signal conditioners and surge protection modules. When the input voltage is applied, the inrush current is actively limited, and networks and devices are protected. The ‘Peak Output Power function’ enables heavy loads such as motors and electronic devices to be switched on.

The Features at a Glance

  • Compact design saves space in cabinets
  • Suitable for a wide range of applications including Zone 2/Div. 2
  • Withstands temperatures up to +70 °C
  • N+1 and 1+1 redundant power supply configurations
  • Excellent energy efficiency – up to 95 %
  • Low inrush currents protect the network and components
  • Remote control for ON/OFF
  • I/O Link option
  • Relay contact for remote monitoring
  • Safe operation due to uninterrupted voltage supply of up to 40 A

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Redundant Power Supplies

Power supply redundancy is important for increasing system reliability. Industrial facilities depend on bulk power supplies as they power the control system architecture and the process measurement instrumentation. Business critical applications can’t afford to be offline due to a power supply failure which could lead to a substantial amount of lost revenue for every minute the process is down.

This need for system integrity and dependable performance in demanding conditions necessitates power redundancy. N+1 and 1+1 are two reliable redundancy methods that ensure system functionality even during a power failure.

PS1000 Power Supplies

N+1 and 1+1 Topology?

The PS1000 Power Supplies can be used redundantly in both an N+1 and a 1+1 topology. With an N+1 redundant configuration, multiple components (N) have at least one independent backup component (+1) ensuring continued functionality during power loss. All the modules in a configuration share the load and if a system module fails, the functioning modules continue to share the load without compromising system integrity.

The 1+1 configuration provides redundancy with 2 power modules of the same power coupled by a MOSFET to supply the same load. Using MOSFETs instead of diodes in the redundancy function reduces heat generation and the voltage drop between input and output.

Utilising Redundancy with the PS1000 Power Supplies

These capable power supplies can be used in redundant topologies by using an external redundancy module (PS1000 XXX. RM) that has a decoupling MOSFET on the input, allowing for the connection of 2 power supplies for 1+1 redundancy, or by using a (PS1000 XXX. R) power supply with a decoupling MOSFET for limited space applications.

For power applications requiring less than 40 Amps, 1+1 redundancy is an economical solution when a redundant power system is required, N+1 is for critical applications. The versions featuring IO-Link offer a future-proof interface that allows comprehensive diagnostics and configuration processes to be carried out during operation.

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The King of Level Sensors – The KingCrown CleverLevel PL20 Series from Baumer

Posted on by Rick Morgan

Down with Vibrating Fork Sensors, long live the King! The KingCrown CleverLevel PL20 Series Level Sensors are setting the stage as the most dependable and versatile level detection solution for a wide variety of troublesome media and processes.

With an adaptive-trigger function, these capable level sensors are a step ahead of vibrating fork sensors, automatically adjusting to all media without parameterisation. Applications vary from dry running protection for pumps through reliable overfill protection or leak detection to the selective detection and masking of foam or separating layers.

360 Degree Process Visualisation, Even in Daylight!

Robust process visualisation is built-in using 360° LEDs which provide real-time information on the process status, with 5 defined colours which can indicate whether the process is working as intended, the sensor is switching, or if there is an issue. Additionally, the colours can be used to indicate which medium is being measured and analogue values ranging from 4…20mA can be read out.

It doesn’t matter whether it’s bulk goods, powders, liquids or foam, or if the medium is sticky or has high or low viscosity, the KingCrown Level Sensor is the new King in town!

During industrial cleaning processes, such as CIP cleaning, sensors can switch incorrectly as they cannot differentiate between the process and cleaning media. The PL20 Level Sensors master this challenge by ignoring cleaning media. Also, media adherence, which can be caused by pasty materials, doesn’t affect these sensors, which adjust their switching level without the need for parameterisation.

Hot, Humid, No Problem!

In very humid areas, or those with temperature changes or water spray, a rugged impermeable design is needed to prevent sensor malfunctions. With exceptional resistance to impacts and fracturing during installation and production the KingCrown PL20 Series is perfect for demanding working conditions. Designed according to Baumers proTect+ Impermeability Concept, the PL20 Level Sensors are ideal for these challenging conditions. (Learn more about the Baumer proTect+ here).

Beverage and Rugged Industrial Application Versions

A built-in IO-Link interface provides easy access to valuable data, additionally it allows easy, location-independent parameterisation of the level sensor.

Available in two versions, with multiple mounting options, the PL20H for Food and Beverage process use and the PL20S variants for demanding high-pressure industrial applications.

PL20 Series Level Sensor Features and Benefits

  • 5 Multicolour LEDS, 360° real time status display even in daylight
  • Versions for Hygienic and Industrial applications, can be used in open tanks
  • Long term impermeability over entire service life according to Baumer proTect+
  • Measuring principle – Frequency sweep
  • IO Link interface
  • IP68 and IP69K protection rating
  • Impact and fracture resistant
  • PNP, NPN Output types, NO, NC, short circuit protected
  • Unaffected by temperature changes
  • Electrical connection made of stainless steel
  • Suitable for use in outdoor, hygiene and washdown applications
  • Point level sensor with automatic parameterisation with changing media and adherence
  • Universal for liquids and bulk materials (DK >1.5)
  • Separately adjustable switching outputs with IO-Link, optional 4 – 20 mA analogue output

With a reduction in the wide variety of components needed by using the same sensor type has many advantages including procurement, spares and maintenance costs. The development of new plant and machinery is also more efficient and the large number of available process connections and adapters available for the PL20S and the PL20H Level Sensors simplifies integration into existing systems.

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

Posted on by Rick Morgan

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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