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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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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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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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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Pinch Valves for Single Use Applications? You need the Emerson ASCO Series 273!

Pinch valves are an ideal solution for controlling the flow of processing media through a flexible pipe, which is the only wetted part, situated within the pinch valve mechanism itself. This flexible pipe, which helps prevent other components from suffering from contamination during operation, is pinched closed either by the application of fluid pressure or via mechanical means within the valve body, compressing the pipe and ‘pinching closed’ the flow path mechanically.

Emerson ASCO, renowned for high-quality pneumatic valves and fluid automation solutions, created the ASCO Series 273 Pneumatic Pinch Valves for the life sciences market and food & beverage applications. Featuring an innovative design for improved tube retention and a longer lifecycle, this range of pinch valves expands their extensive pneumatic valve offering to single-use batch applications in bioreactor and fermentation tanks, tangential flow filters (TFF), chromatography skids and similar drug discovery lab applications.

Innovative, these durable pneumatic pinch valves feature a pinching mechanism that remains firmly in place, providing better tube retention and eliminating breakage or damage to the soft tubing. They also include a safety guard to prevent exposure to moving parts, as well as a manual override feature that lets operators insert or remove tubing without actuating the valve during unplanned batch switching.

No process media contact

These pneumatically actuated pinch valves make no contact with process media, feature a high life cycle and provide a reliable pinching force over repeated use. Available in anodised aluminium and 316 stainless steel versions these pneumatic pinch valves are suitable for peroxide fumigation and include a position indication option for valve on/off status feedback.

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Pinch Valve Benefits

  • No contact with the process media
  • Easy insertion and removal of flexible tubing
  • High tube pinching cycles, up to 20,000
  • Better retention and protection of tubing during pinching cycles
  • Easy to use built-in protective safety guard
  • Manual override allows for tube insertion removal without valve actuation

Pinch valves in situ

Series 273 Pneumatic Pinch Valve Technical Features

  • 2-way normally open (NO) and normally closed (NC) versions
  • Tube outer diameter range options (OD): 3/8 to 1 inch
  • Tube hardness: 55–80 Shore A (Gamma radiated)
  • Tube material – Silicone, cflex374, 082 and Tygon
  • Media pressure: up to 6 BAR (90 PSIG)
  • Air operating pressure: 4.8 to 10 BAR (70 to 145 PSIG)
  • T-Groove for switch contact
  • Valve position detection: open or closed
  • Media – Inert gases or liquids

 

The 273 Series Pneumatic Pinch Valves target single-use batch applications in the pharmaceutical and biopharmaceutical markets but are also suitable for numerous food and beverage production tasks. The pinch valves can be actuated using ASCO Series 501 or Aventics AV Series pneumatic valve manifolds and ASCO 580 CHARM electronics, which seamlessly integrate into the DeltaV distributed control system.

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