ATEX Sensors

ATEX Sensors you can depend on from Rechner, Brought to you by Kempston Controls

Rechner is renowned for the design and manufacture of one of the widest ranges of fully certified ATEX sensors and probes available in the marketplace, including capacitive and inductive versions. This broad ensemble of sensor options covers all markets and applications and they are produced using approved materials for each market sector. With hundreds of years of collective expertise in the creation of sensors for demanding areas, Rechner sensors are the ideal solution for whatever your ATEX installation demands. All of which are available to purchase from Kempston Controls.

Choosing the right ATEX Sensor

It’s vital that you select the correct sensors for your specific certified ATEX Zone, considering all the safety objectives, responsibilities and all the critical steps that need to be appraised. All of these considerations will help you ensure the full protection of your employees working in ATEX zones, along with the installation itself.

Typical applications for ATEX rated sensors include: Chemical production, Pharmaceutical, Distilleries, Flour and Grain handling, Landfill sites, Offshore Oil and Gas and so much more.

Speak to the ATEX Sensor Specialists at Kempston Controls

If you have an ATEX application or installation that requires sensor control feedback, please call the specialist Sensors Team at Kempston Controls to discuss your requirements. Their expertise ensures the best technical and commercial solutions, including an extensive knowledge of ATEX sensor installations.

The impressive range of Rechner hazardous area sensors are available to buy today from Kempston Controls, suitable for a multitude of intrinsically safe zone applications covering both ATEX and IECEx certifications. Additionally, if your application requires a bespoke sensor solution, Kempston’s dedicated specialist sensor team are there to help you achieve your goals.

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RECHNER ATEX Sensors Overview

  • Wide range of ATEX sensors and probes including ATEX and IECEx certified
  • Certified Capacitive and Inductive sensors
  • ATEX interface barriers and amplifiers for all system requirements
  • Approved sensor materials for Chemical, Pharmaceutical, Distillery and Food processes, Bulk Handling, Landfill, Oil + Gas and more
  • Reliable detection of low dielectric media ≤ Ɛr 1.1
  • Sensors are media optimised to detect similar products with one setting
  • Wide range of sensor and probe formats and lengths to suit all set-ups

Whatever sensors your ATEX rated zone needs the dedicated Sensors Team at Kempston Controls are here to help. With specialist technical advice to help you choose the right ATEX rated products to ensure that your installation is as safe as possible. Speak to us today 0n 01933 411 411.

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

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

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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Kempston Controls and the SICK SPEETEC Sensor Help Solve a Real Steel Processing Problem

Recently, Kempston Controls eagerly answered the call when TATA Steel Tubes, who are based in Corby, Northants, called asking for a demonstration of the versatile non-contact SICK SPEETEC sensor to help them solve a processing issue.

TATA Steel Tubes manufactures a wide range of steel products and they were looking for a way of using the SPEETEC sensor system to monitor the speed of tubing travelling through a process, and another SPEETEC sensor to verify the length of the material being cut.

After an initial discussion with the engineering manager at TATA Steel a demonstration was arranged. A member of Kempston Controls technical sales team, along with a sensor specialist from SICK would be onsite. The production line would be stopped so they could set-up and test the advanced SICK SPEETEC sensor within the actual process itself.

The operating environment in a steel processing plant is, as you can imagine, very demanding, and during the demonstration the sensor was sprayed with industrial machine coolant and exposed to swarf from the cutting process which had no effect on the performance of the robust non-contact SPEETEC sensor.

During the Demonstration the Following Issues were Found:

  • The existing process demanded that an encoder be mechanically coupled to the tube, resulting in a potential for damage to valuable equipment and material
  • The speed reference provided to the flying saw was incorrect, resulting in angled cuts in the tubing with unwanted axial forces being placed on the cutting blade. Ultimately leading to damage to the processing equipment and unwanted down time
  • The typical speed of operation was 20m/min – 180m/min
  • For the second cut-to-length application the goal was to reduce material tolerances and waste

The Actual  SICK SPEETEC sensor within the Processing Machine

The Savings

The invoice cost of steel tube at the time of installation was approximately – £1000/ton. The Kempston Controls technical sales engineer based the calculation around using a typical mild steel tube of 50mm diameter and a 3mm wall thickness weighing 3.5 kilograms per metre. The steel processing line was running at approximately 90 metres per minute.

Assuming the tolerance could be reduced by 0.1% this would result in an additional invoice value of material of:

  • 90 x 3.5 x 0.1 / 100 = 0.315 Kg per minute
  • If the process was to be run continuously for 8 hours this would equate to 0.315 x 8 x 60 = 151.2 Kg
  • At £1000/ton that effectively means £151.20 per 8-hour shift

On this basis alone TATA Steel would see the return on investment of a SICK SPEETEC sensor system in only a matter of weeks!  Over a longer period-of-time the process savings will quickly add-up, not just by reducing the manufacturing cost of the product itself, but also by improving the reliability of the process, through-put, reducing wear on process machinery, and helping to keep downtimes to a minimum.

The SPEETEC Sensor

The rugged and maintenance-free non-contact SICK SPEETEC laser surface motion sensor has been designed to detect movement via the surface of a product. Measuring the speed, length, movement direction and the position of objects of almost any surface type. The ideal solution for use in encoder-based applications that feature fast and dynamic processes.

SPEETEC Sensor Features

  • Non-contact measurement speed, length, and position of objects
  • Compatible with multiple materials, colours, and surfaces
  • Very high measurement accuracy and repeatability, speeds up to 10 m/s
  • Laser class 1, rugged design, compact dimensions, low weight
  • Standardised communication interface
  • Maximum resolution 10 m/s
  • Wear free

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Read More about the SICK SPEETEC Sensor Here

Ultrasonic Sensor Technology for Safety in All Areas with the Pepperl + Fuchs USi- safety

The USi-safety ultrasonic sensor system from Pepperl + Fuchs is breaking down the barriers imposed by other sensing solutions. Whether operating in challenging, dusty conditions or outdoor  – industrial machines, vehicles, processes  and the people using them can be protected using the advanced ultrasonic technology utilised in these sensors.

Intelligent Design for Every Situation

When a miniature sensor unit is detached from the control interface it means the sensor system can be used in confined spaces, and the unique design allows the sensor to cover an elliptical 3-D sound field with opening angles of ± 17° and ± 5°, providing improved safety.

Manipulation protection and Parameterisation

Preventing safety functions from being overridden is challenging, the USi-safety system features a teach-in process when a machine part is used as a reference target, the sensor can register deviations immediately. Comprehensive parameterisation software and automatic documentation make commissioning the ultrasonic sensor system quick and simple.

Elliptical Sound Field for a Wide Sensing Range

The USi-safety features a strongly elliptical sound field, creating a wide sensing range in one plane and a narrow sensing range in the other. The system can be used just above ground level or close to a wall, allowing the sensor to detect targets or obstacles that are overhanging or near to the ground.

Two Category 3 PL d Safe Systems in a Single Evaluation Unit

A maximum of 2 ultrasonic sensor units can be connected to the evaluation unit. These ultrasonic sensor units have a single-fault tolerance, 2-channel structure. A safe sensor system is achieved even when only one sensor unit is connected. One signal output and safe OSSD outputs in accordance with category 3 PL d are available.

This capable ultrasonic safety sensor system can be used in applications where left/right or forward/reverse movements need to be safeguarded, such as on Auto-Guided Transport (AGT) Systems. Applications can be implemented in which both sound fields are focused directly adjacent to each other or overlapping, securing the widest possible collective sensing range.

ultrasonic sensor USi-Safety

A Complete System

The USi-safety ultrasonic sensor system consists of an evaluation unit, a sensor unit, a temperature sensor, and the software.

The evaluation unit contains two microcontrollers that monitor the connected sensors, their own hardware, and each other to ensure that the components are functioning correctly. In addition, there is an input for a temperature sensor and a USB interface for parameterisation via a PC.

IP69K protection makes the system’s 2 ultrasonic sensor units suitable for even the most demanding conditions. With their miniature design, they can be flexibly integrated into numerous applications. The system reliably detects even the smallest objects within their wide 3-D sensing range.

The parameterisation software allows a wide range of settings such as switch points, output logic, safety parameters, and ultrasound-specific parameters to be customised. The interface can be used to initialise periodic tests and automatically generate safety protocols.

USi-safety Ultrasonic Sensor Application Examples

ultrasonic sensor USi-Safety

Collision Avoidance in the Fork Tip

Reliably preventing collisions involving driverless forklifts is ideal for the USi-safety ultrasonic sensor system. As the technology is resistant to dirt, temperature, air currents, and humidity, it significantly expands the area of use for these automated guided transport systems.

Machine Safeguarding in the Wood Industry

Usually, machines are safeguarded by photoelectronic light curtains. The USi-safety, used as a sound curtain, is insensitive to wood dust and other particles and can withstand demanding environments.

Personal Safety in Lane-Guided AGVs

Lane-guided AGVs follow a lane on the ground and transport goods from one station to the other. In this process, the detection range of the sensors can be quickly and easily adapted via the parameterisation software to help prevent collisions.

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SICK PBS plus Pressure Sensor – Added Versatility for Pressure Monitoring Installations

The PBS plus Pressure Sensors from SICK, expands upon their existing PBS Sensor range, they have been purposely designed for demanding industrial applications, providing an electronic pressure switch, pressure transmitter and display all-in-one, available with up to two switching outputs, analogue output and IO-Link communication.

PBS plus Pressure Sensor in actionSimple to set-up, the PBS plus features three large pushbuttons and an easy-to-read display and they can be set-up using IO-Link, which also provides diagnostic functions and simplifies predictive maintenance, external parameterisation also makes handling easier and ensures lower maintenance costs.

 

Easily adapted for countless installation possibilities

The PBS plus range of Pressure Sensors are easily adapted to suit numerous installations, for example, the housing can be rotated twice, once at the process connection and then at the display cap, meaning the electrical connection can be rotated in the desired direction at any time.

Versatile, thanks to the large number of available process connections, including a flush-mounted membrane for sticky, crystallising and viscous media, helps to widen the integration possibilities of the PBS plus Pressure Sensor series. With measuring ranges of 0.4 bar to 1,000 bar (gauge pressure), the PBS plus can be used in many different applications. It also has absolute pressure and vacuum measuring ranges.

PBS plus Pressure Sensor Applications

  • Measurement of system pressure in hydraulic systems
  • Control of the clamping pressure in CNC machines
  • Monitoring of the cylinder pressure in hydraulic presses
  • Control of the pressure in cooling and lubricant systems
  • Hydrostatic level measurement
  • Measurement of system pressure in PET bottle production

 

 

The best in challenging conditions

Whether in aggressive environments, with measuring ranges of 0.4 bar to 1,000 bar, or when used with viscous liquids, the PBS plus takes challenging environments in its stride. Due to the integrated electrochemical cell with fully welded stainless steel membrane, it can withstand even aggressive media, as no sealing medium is required between the electrochemical cell and the membrane. Temperatures between –20 °C and +85 °C are no problem for the PBS plus.

 

PBS plus Pressure Sensor in action

 

This series of robust pressure switches have been designed for optimum functionality and range of use, resulting in a wide range of setting options reducing the number of sensor variants required within a production process ultimately reducing costs for customers.

 

SICK PBS plus Sensor Benefits

  • Switchable switching outputs (PNP/NPN) and analogue output (current/voltage)
  • Scalable analogue output (5:1 turn down)
  • High measurement accuracy: ± 0.5%
  • IO-Link for transmitting process data to the control system, measured values in bar
  • Housing can be twisted in two places (process connection/display), display can be rotated 180°
  • Common process connections, also with flush-mounted membrane
  • Rugged design: stainless steel measuring cell
  • Extensive diagnosis options via IO-Link
  • Economic solution for hydrostatic level measurement
  • Reduced installation time

PBS plus Pressure Sensor Technical Features

  • Gauge pressure – 0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 1,000 bar (0 psi …14,504 psi)
  • Absolute pressure -0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 25 bar (0 psi … 363 psi)
  • Compound pressure  -1 bar … 0 bar (-14.5 psi … 0 psi) to –1 bar … +24 bar (-14.5 psi … +348 psi)
  • Pressure unit – bar (can be switched to psi, MPa, kPa, kg/cm2)
  • Accuracy  ≤ ± 0.5 % of the span
  • Setting accuracy of switching outputs  ≤ ± 0.5 % of span
  • Output signal – Output 1: PNP/IO-Link, Output 2 (optional): PNP/NPN switchable, Analog output (optional): 4…20 mA / 0…10 V switchable
  • Electrical connection M12x1 round connector
  • Approvals CE, cULus
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