Terminal and Junction Boxes you can depend on from Pepperl + Fuchs

Pepperl+Fuchs design and manufacture a comprehensive range of terminal boxes and junction boxes for the installation of signal and power distribution networks in areas where there may be an atmosphere conducive to an explosion. These versatile junction and terminal boxes are certified to the latest ATEX and other international standards, including Ex e, Ex ia, Ex tb, Ex tD, and Ex op pr.

This extensive range of enclosures comes in a wide range of sizes and materials such as glass fibre reinforced polyester (GRP), electro-polished stainless steel and aluminium.

These terminal and junction boxes provide reliable operation in very harsh environments and in food and beverage processing applications with demanding hygiene requirements. The high-quality materials used are robust, durable, and resistant to high temperature. Terminal boxes and junction boxes come with ingress protection and wide ambient temperature ranges and are easy to install and maintain. Below we take a quick look at some of the enclosure which are available to purchase from Kempston Controls.

Terminal and Junction Boxes in GRP – GR Series

Available in a range of housing dimensions with various depths, designed for easy installation and handling with features such as dedicated pry points for opening and foamed gasket for IP66 and protection of the sealing edge. With an expanded operating temperature range down to ­-60 °C, the GR enclosure series is a cost-effective choice for many installations that would otherwise require stainless steel enclosures. Suitable for installation in Zone 1, 2, 21 and 22, Class I,II division 2, Class I Zone 1 and Class II Zone 22. Ex eb, Ex ia and Ex tb certified.


Terminal and Junction Boxes in Stainless Steel – SR Series

Designed for use in hazardous and harsh environments, the stainless-steel terminal boxes and junction boxes from the SR enclosure series are a benchmark in flexibility. Their modular design allows the integration of accessories, such as flange plates, hinges, mounting brackets and lid security. These junction boxes are suitable for wall mounting and can be screwed in directly using 90° rotatable mounting brackets or rivet nuts. Suitable for installation in Zone 1, 2, 21, 22. Ex eb, Ex ia and Ex tb certified.


Terminal and Junction Boxes in Stainless Steel SL Series

With several sizes of stainless-steel enclosures, the SL series offers a cost-effective installation solution for many industrial and commercial applications. Terminals and cables entries are freely configurable. Suitable for installation in Zone 1, 2, 21 and 22, Class I,II division 2, Class I Zone 1 and Class II Zone 22. Ex eb, Ex ia and Ex tb certified.

 

 


Terminal and Junction Boxes in Stainless Steel with Gland Plates, Hinged Lid, Return Flange – FXLS Series

The FXLS series features a range of electropolished stainless steel enclosures. They feature a robust sealing method to prevent dirt and moisture ingress when opening. Available with a wide choice of terminals, cable glands, and accessories, the FXLS terminal box series is the perfect solution for any application. Suitable for installation in Zone 1, 2, 21 and 22, Class I,II division 2, Class I Zone 1 and Class II Zone 22. Ex eb, Ex ia and Ex tb certified.

 


High Voltage Terminal Box in Stainless Steel – HVB Series

The HVB series is specifically designed for the installation of high-power distribution networks. Made from 316 stainless-steel, with an M10 internal/external brass earthing stud. Suitable for installation in Zone 1, Zone 2 and Zone 22, Ex e certified.

 

 

 


Terminal and Junction Boxes in Aluminium -EA/DA Series

The EA/DA series terminal and junction boxes are based on different sizes of Ex e and Ex td certified enclosures manufactured from marine-grade aluminium with increased corrosion resistance, IP66 protection rating. Suitable for installation in Zone 1, Zone 2, Zone 21 and Zone 22.

 

 

 


Fibre Optic Splice Boxes in Glass Fibre Reinforced Polyester – GR.TFO Series

The GR.TFO splice boxes constructed from glass fibre reinforced polyester enable safe protection of fibre optic cable splices in hazardous areas. Featuring up to 8 splice trays with 12 fusion-type splices per tray. Suitable for installation in Zone 1, 2, 21 and 22. Ex op pr and Ex tb certified.

 

 


Fibre Optic Splice Boxes in Stainless Steel with Return Flange – SR.TFO Series

The SR.TFO series is a range of fibre optic splice boxes designed for protection of optical fibre cable splices in hazardous areas. Up to 8 splice trays with 12 fusion-type splices per tray are installed inside the sturdy stainless-steel enclosure with return flange sealing. Suitable for installation in Zone 1, 2, 21 and 22. Ex op pr and Ex tb certified.

 

 


Fibre Optic Splice Boxes in Stainless Steel with Return Flange – FXLS26 Series

Safe connection of fibre optic data cables in hazardous or harsh areas is ensured by the FO splice trays installed in FXLS26 series stainless steel enclosures. Up to 8 splice trays with 12 fusion-type splices per tray are installed inside the sturdy stainless-steel enclosure with return flange sealing.  Suitable for installation in Zone 1, 2, 21 and 22. Ex e, EX, ia and Ex tb certified.

 

 

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

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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FlexAlert from Trumeter, the Perfect Universal Small-form Countdown Timer

The FlexAlert is a lightweight, small-form Countdown Timer range that can be used in a wide variety of applications where a countdown and reminder notification is required. This capable range of timers can be easily attached in the location required where they can be left to count down to the pre-set duration. When the allocated time-period has been reached the timer will produce an audible alert warning users that attention is required within a specific process or application, which will continue until it has been turned off. Typically, this alert will run for a minimum of 60 days until the timer has been reset so there can be no excuses!

Ideal for Service Intervals

The FlexAlert’s flexibility and versatility make it an ideal unit for domestic and industrial uses, suitable for a wide variety of applications that require interval notifications such as service intervals and equipment checks as well as reviews and component changes. Designed to be tamper resistant, the time interval is pre-set by design and requires the use of a screwdriver to access the battery reset function. Dependable, the FlexAlert range of small-form countdown timers ensures that those important activities are carried out on time, every time.

Compact and lightweight in design, only 40 mm in diameter and a tiny 60 grams in weight, this versatile range of countdown timers are small and discrete enough to be placed just about anywhere. Available with a wide range of standard options there is a countdown timing alert solution readily available straight out of the box.


FlexAlert Models Available:

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Easy to Install, Simple to use

Cable tie and hook and loop mounting fixtures help ease installation and the FlexAlert range is simple to use as well, just place one timer with a specified countdown interval in the location desired, pull the battery insulation tab free to start the timer and go. Suitable for use just about anywhere without making changes to an installation with their unobtrusive and sleek design

 

 

FlexAlert Countdown Timer Specifications

  • Timer Type – Alert Timer, audible beep, minimum 60 days until reset
  • Alert amplitude – >50 dB A
  • Manual Reset function
  • Unobtrusive design
  • Uses readily available CR2032 Battery (1000 days typical life)
  • Supplied with hook and loop adhesive pad and 200 mm cable tie
  • Protection rating – IP30
  • Dimensions 39.7 x 18.3 mm (16 mm deep without fixing pad)
  • Operating temperature -10 to + 60 ° C
  • Storage temperature -20 to + 70 ° C
  • Weight – 16 grams
  • White in colour
  • Design life – 10 years

Powered by the common CR2032 battery (with a typical life of 1000 days) that ensures you will never be searching for expensive hard-to-source batteries on a regular basis. Whatever you countdown timing application requirements the Trumeter FlexAlert range is here to help you achieve your goals. The FlexAlert can also be customised to meet your applications requirements with options including countdown timer duration and customer branding, speak to Kempston Controls for availability.

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

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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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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