ATEX Sensor Solutions for Explosive Situations

Rechner Sensors produced their first certified sensor for an explosion potential application back in 1974 making them one of the oldest and most experienced producers of these application critical sensors. With so much experience and expertise, you can rely on Rechner ATEX sensors for applications in explosive environments. Ideal for any sensor installation in DUST or GAS explosion zoned applications, including certified sensors for the defined zone in a broad range of sizes and formats. Rechner also manufactures cable connections and approved ATEX interface amplifiers for interconnection to the system control.

Atex Sesnor with cable

26 Series – Capacitive Sensor with Cable, KAS-80-26-A-K-G1-PTFE-STEX

ATEX Applications

In some cases non-ATEX applications can become re-zoned as ATEX and all of the installed sensors must be replaced with suitable certified product. Rechner’s All-In-One ATEX Sensor Range is the perfect choice as it can be interfaced to the existing control but also has ATEX certification for detection in the ATEX rated zones for DUST Zone 20 and GAS Zone 1. These sensors do not require expensive interface barriers to connect them to a control system in ATEX applications.

Atex sensor capacitive

Capacitive Sensor -26 Series,  Pluggable, KAS-80-26-A-K-G1-PTFE-Y5-STEX

Encapsulated

ATEX rated sensors achieve protection by encapsulation including a non-replaceable fuse. Rechner’s ATEX certified Sensors come in capacitive as well as inductive formats for direct PNP or NPN system connection. Inductive sensors are available in M12, M18 and M30 Flush configurations.

Rechner’s Capacitive ATEX Sensors have a wide portfolio of shapes and sizes from the compact M18, G1/2” up to G1”, M32, including Tri-Clamp options, for both Flush and Non-Flush sensors. Cable and connector versions of each sensor type are available and Clips to prevent disconnection while powered are supplied with each pluggable sensor.

Atex sensor flush mount

M30 Non-Flush Mount Sensor, KAS-80-A24-A-Y10-STEX

Pharma and Food

The sensor housing materials used, such as Stainless Steel, PTFE, PEEK etc. have FDA certification and are approved for Food and Beverage as well as Pharmaceutical industries and for most other market applications.

Rechner All-in-One ATEX Sensor Overview

  • Most experienced supplier of certified sensors for explosion applications on the market
  • A wide range of ATEX sensors, connector cable and amplifiers
  • All-In-One options for simple system design upgrades and sensor installation
  • Easy set-up and reliable fit and forget installations
  • Approved housing materials for Food + Bev, Pharma as well as most industries
  • Media optimised to sense similar products with one setting
  • Solid-state electronics with no moving parts for long in-service life
  • A large range of process fittings are available including Tri-Clamp and other formats

Kempston Controls stocks a comprehensive range of Rechner ATEX rated Sensors and a large range of capacitive and inductive sensors for general industrial automation and process control applications. Give our dedicated sales team a call on +44 (0) 1933 411411 or email them at sales@kempstoncontrols.co.uk to discuss all your sensor requirements.

Further Reading

ATEX Mobile Communication

Laser Safety Scanning Solution

Kempston Controls

Top Ten Posts

Kempston Controls Top Ten Blog Posts of 2019

After publishing 65 posts this year, we’ve decided to take this time to reflect and round-up our most popular articles this year. Here are our top ten blog posts from 2019:

10. PROTECT PSC1 Safety Controllers – Total Control

By Rick Morgan – 21 October

The multifunctional PROTECT PSC1 safety controllers from Schmersal consists of a range of very capable freely programmable compact safety controllers with an impressive offering of I/O extension modules ideal for a wide range of industrial and commercial safety and control applications. Consisting of two comprehensive families, the PCS1-C-10 and the PSC1-C-100, these capable safety controllers can cover all your potential industrial signal processing and control requirements.

9. Important Update Concerning SICK Automation and Control Product Availability from Kempston Controls.

By Rick Morgan – 25 February

SICK, one of the World’s leading manufacturers and suppliers of automation and control products will be staging a phased removal of a number of ranges of their existing product portfolio during the Spring and Summer of 2019.

8. Switching Power – Craig & Derricott Automatic Transfer Switch Range

By Rick Morgan – 24 September

The Automatic Transfer Switch Range from Craig & Derricott is the perfect choice when you need to ensure that your power network is protected from outages.

7. Top 5 Inductive Proximity Sensors

By Rick Morgan – 27 August

Inductive Proximity Sensors are an essential addition to countless process automation and control installations in all manner of industries. Designed to ensure that your process, whatever it may be, from a heavy industrial robotic welding installation to managing warehouse conveyor systems performs the best it can at all times. Whatever your flavour of Inductive Proximity Sensor, from the toughest to the economical Kempston Controls has just what you need. Here, we get up-close and personal with our Top 5 Inductive Proximity Sensors.

6. Industry 4.0 – the Digital Backbone of Modern Manufacturing

By Rick Morgan – 29 April 2019

Industry 4.0 is known as the fourth industrial revolution, changing the way we manufacture an ever-increasing spectrum of products all thanks to the digitisation of the mechanism involved in their creation. The change is rapidly growing pace, due in part to increased demand for newer smarter products and with leaps in innovations in the manufacturing industry.

5. PRC Series Circular Connectors – A New Angle on Connectivity

By Rick Morgan – 19 August

When it comes to industrial connectors, the PRC Series of circular connectors from Phoenix Contact has been designed to enable robust, reliable and stable cable-to-cable connections that demand precision real estate management in a multitude of installations from industrial and outdoor to commercial buildings. Incorporating weatherproof materials in their construction and with an impressive IP69K rating, the PRC series of connectors are capable of high current transmission even in the most demanding environmental conditions.

4. Lighting Up Danger with ATEX Flashlights

By Joe Shipton – 29 October 2019

Kempston Controls is pleased to announce that we now offer a range of intrinsically safe flashlights ideal for hazardous areas from ecom – a Pepperl+Fuchs Brand.

3. IO-Link? Bi-directional Data Exchange? What’s that?

By Rick Morgan – 10 June 2019

IO-Link is an industrial communication network standard (IEC61131-9) that allows the easy extraction of data from process control and automation sensors that support the IO-Link protocol and are connected to a device master. IO-Link is the first globally standardised IO-technology that has been designed to allow communication from the primary controller down to a basic automation level.

2. Are you SIRIUS about Spring-Loaded Terminal Technology?

By Rick Morgan – 1 March 2019

Whether you are reversing a motor starter or building an infeed system, the Siemens SIRIUS range of modular low voltage products, available from Kempston Controls, is the ideal solution to the ever-accelerating world of modern industry. The SIRIUS modular system provides the most comprehensive switching device portfolio currently available in the marketplace, exceeding 50k tested and approved control set-up combinations.

1. Safety Handle Revolutionised with the new Pizzato P-KUBE Krome

By Rick Morgan – 13 June 2019

A revolutionary new product from Pizzato, the P-KUBE Krome series combines the functionality and characteristics of your typical enclosure safety handle, but with an ergonomic rounded grip, illuminated control button and unique customisable LED notification functionality. The multitude of signalling illumination options available (on the illuminated White P-KUBE Krome version) gives the end-user the added security of the safety guards status or any other processing condition.


Honourable Mentions outside of the Top Ten:

Our favourites from this year:

“I would have gotten away with it if it wasn’t for those meddling Data Loggers” Next level Data Logging.

By Mark Jansen – 31 October

With it being Halloween, we were struck by a Ghost Hunting project that we recently read about that has taken place at Motley County Jail, in Matador, Texas.

Ultra-Low Emissions. Will you be Leading the Charge When it Comes to Electric Vehicle Supply Networks?

By Rick Morgan – 8 April

In 2018 the UK Government launched its Road to Zero strategy, with ambitious targets of at least 50% and as many as 70% of new cars constructed to be ultra-low emissions by 2030 and by 2050 they want almost every car and van to be zero-emission. Outlined in the Government document, The Road to Zero, the plan promises a huge expansion of the vehicle charging infrastructure that will be needed to keep these electric vehicles moving efficiently. Plans are afoot to increase the level of charge-points, with one every 20 miles along the strategic road network by 2020, along with charging points in all new homes and the retrofitting of lampposts with charging fixtures.

Thank you for supporting our blog posts this year and we hope you enjoyed this top ten round-up. We look forward to bringing you more industry news and insights in 2020!

Omron E2A3 Replacement: E2E NEXT

E2E NEXT Proximity Sensors – When Proximity Matters

Proximity sensors are found in all manner of industrial and commercial applications, from monitoring the position of product and processing jigging to measuring the speed of a motorised conveyor. The undeniable practicality of proximity sensors and their use in multiple industries is a testament to their effectiveness.

Industry proximity sensors have characteristically always had short sensing distances, bringing with them certain risks.

Typical examples include:
  • Excessive equipment vibration that can cause a sensor body to move away from or come in contact with the sensing object
  • Process failures due to vibration-related incidents are said to account for approximately 20% of stoppages

proximity sensor process line

Unforeseen production problems are a major headache, resulting in serious processing delays and a catalogue of issues that could lead to unexpected expenditure, loss of orders and so on. To minimize downtime, production and manufacturing facilities have relied upon maintenance personnel reacting to unforeseen issues. Today, manufacturers are embracing smart devices and the IoT to maintain and improve facility operation rates without relying on expensive service schedules and reactive maintenance protocols.

Increasing the Proximity

Omron, one of the World’s leading authorities on the design and manufacture of industrial automation equipment have recently released 2512 new proximity sensors. These new additions to the ever-expanding Omron range of proximity sensors are called the E2E NEXT series boasting the World’s longest sensing distance*1 with the addition of future-proof IO-Link communication features.

E2E NEXT – they don’t have to be that close…

These advanced IoT enabled proximity sensors to help reduce the risks of sudden manufacturing stoppages by one third*2.  detecting the initial warning signs of potential issues and notifying you via an IO-Link network to your control system and HMI. All this data can be used to facilitate real-time monitoring and contribute to predictive maintenance, helping to reduce your facilities downtime and increase its profitability.

proximity sensors comparison

E2E NEXT Sensor Features

  • Up to 4 times the sensing range of standard inductive sensors
  • Monitor all of the E2E sensors range with IO-Link
  • 2512 different models in a selection of sizes
  • DC3 and DC2 wire versions
  • PNP or NPN units (3 wire versions)
  • Space-saving design- smaller sensors have greater range than previous larger models
  • Short and long body versions
  • High-visibility 360 Degree LED indicator
  • Resists 2 years of exposure to machine cutting oil
  • -25 to 70 Degrees C operating temperature range
  • Excellent environmental protection- resists hot pressure washing and steam
  • Pre-wired and pre-wired connector models: IP67, IP67G and IP67K
  • Connector models IP67, IP67K
  • Available with splatter resistant coating
  • Upgrade existing sensor installations quickly with e-jig mounting sleeve
proximity sensors size comparison
Connection Options:
  • Pre-wire PVC
  • Pre-wire Robot PVC
  • PVC Pigtail
  • Robot PVC Pigtail
  • M8 3 pin
  • M8 4 Pin
  • M12 4 pin
  • UL, CSA, CE Certification

 

Perfectly Equipped

The E2E NEXT Series, DC 3-wire Proximity Sensors are equipped with OMRON’s own Thermal Distance Control 2 and PROX3 hybrid circuitry technologies, enabling sensing distances that are at least twice as long as in the previous models*3. The operational distances between the sensors and detectable objects are always being monitored and can send you notifications via IO-Link*4 if operational parameters are exceeded. This enables you to quickly identify the early warning signs of sudden facility stoppages and analyse data patterns which in turn allows for the creation of data-driven maintenance schedules based on condition monitoring.

proximity sensor range

Kempston Controls wants you to provide you with the best selection of proximity sensor options, and that’s why, as a supplier partner for Omron, we can offer you the best selection at the best price. Even if the Omron proximity sensor you require isn’t stocked we can certainly source it for you as we have access to the entire Omron range! Give us a call on +44 (0) 1933 411411 or email us at sales@kempstoncontrols.co.uk to discuss your proximity sensor requirements.

View our range of Omron E2E Next Proximity Sensors

 

Have you seen these articles?

Our top 5 encoders

Trapped Key Interlocks

Logging the data

 

Kempston Controls

References:

*1 Based on December 2018 OMRON investigation of DC 3-wire models.

*2 Based on December 2018 OMRON investigation.

*3 Comparison between previous products (2-wire models) and E2E NEXT 3-wire model series.

*4 Standardised technology for communicating with sensors and actuators, prescribed by the international standard IEC 61131-9.

Supplier Round-Up from Kempston Controls

[vc_row][vc_column][vc_column_text]Welcome to our supplier round-up. With so much to keep up with and all of the great content that is being published by our partners, we’ve been keeping up-to-date with all of their activities in the digital world and have compiled a supplier round-up. Here is a summary of some articles that we think you might find useful![/vc_column_text][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][vc_single_image image=”1699″ img_size=”full”][/vc_column][vc_column width=”1/2″][vc_column_text]

Making the workplace safer with Multi-colour LED Strip Lights Selection from Banner

Multi-colour LED strip lights from Banner Engineering offer high-quality lighting, long-lasting low maintenance operation, robust housings built for industrial use, and a variety of styles to suit any application–from harsh environments too hazardous locations and tight spaces.

Learn More

View the Range

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][vc_column_text]

Pepperl+Fuchs have been teaching us more about their 5-Way Inductive Sensors

The mechanical limit switch is a staple in automation. The switch detects the presence and position of objects by making direct contact with a target, but this direct contact can cause wear on the mechanical parts of the limit switch and cause reliability issues with its object detection capabilities. With limit switch style inductive sensors from Pepperl+Fuchs, non-contact sensing of targets is the sensible choice.

Learn More

View the Range[/vc_column_text][/vc_column][vc_column width=”1/2″][vc_single_image image=”1701″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][vc_single_image image=”1704″ img_size=”full”][/vc_column][vc_column width=”1/2″][vc_column_text]

Imagine being able to use your AC drive as a smart sensor in your food and beverage application? Danfoss show us how!

All of this is possible with the VLT® Automation Drive FC 302 which is embedded with predictive and condition-based maintenance functionality to secure your uptime!

Learn More

View the Range[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][vc_column_text]

Pizzato – New versions with control devices for NG switches

NG series safety switches equipped with RFID technology has been expanded further and now includes new versions with integrated buttons for control and signalling functions.

Learn More

View the Range[/vc_column_text][/vc_column][vc_column width=”1/2″][vc_single_image image=”1717″ img_size=”full”][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]Kempston Controls is a leading supplier of industrial process control and automation devices and equipment, with extensive stock of all the worlds premier brands ready for prompt delivery. Contact our dedicated sales team on +44 (0) 1933 411411 or email sales@kempstoncontrols.co.uk to discuss your applications requirements.[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]

 

Kempston Controls Supplier Round-Up[/vc_column_text][/vc_column][/vc_row]

Top 5 Inductive Proximity Sensors

Inductive Proximity Sensors are an essential addition to countless process automation and control installations in all manner of industries. Designed to ensure that your process, whatever it may be, from a heavy industrial robotic welding installation to managing warehouse conveyor systems performs the best it can at all times. Whatever your flavour of Inductive Proximity Sensor, from the toughest to the economical Kempston Controls has just what you need. Here, we get up-close and personal with our Top 5 Inductive Proximity Sensors.

The perfect distance and end position inductive sensing partner

Standard non-flush inductive proximity sensor

 

Perfect for distance measurement and end position detection, with great shock resistance, this M18 non-flush, NPN switching output, IP67 rated, nickel-plated brass inductive proximity sensor is the perfect cylindrical detecting solution. With a sensing range of 12 mm, NO output function, DC 3 wiring, M12-4 pin connectivity it’s the ideal cost-effective industrial inductive proximity sensor solution, perfect for a whole host of applications where performance and cost are key.

Learn More

 

 

 

 

When you need chemical resistant and food safe inductive proximity sensors

Chemically resistant non-flush inductive proximity sensor

When you are working in the food and beverage industry you need to be resistant to a whole host of cleaning chemicals and regular washdowns. Plus, if you can communicate via the IO-Link protocol and feedback vital data to enhance production performance, that’s the icing on the cake! With a stainless steel M30 thread, PNP switching output, NO output function, 20 mm sensing range provided by the food-safe LCP plastic sensing face and IP68 and IP69K ratings. This non-flush inductive proximity sensor can withstand all the food and chemical abuse you can throw at it.

Learn More

 

 

Proximity detection in-between the Welders and Robots with Reduction Factor 1

Reduction factor 1 inductive proximity sensor

When you are spending your days detecting the proximity of mixed metal processing devices or manufactured parts in a harsh environment with lots of welding and associated spatter you need to be tough, durable and capable and have Reduction Factor 1 abilities. Designed to last, this ultra-tough flush sensing face inductive proximity sensor features a PTFE coated brass body with an M12 thread, PNP switching output, NO output function, M12 4 pin – DC-3 wire connection and a sensing range of 4 mm. Ideal for when you need to make the issue of sensing multiple metals in a vicious welding environment – no issue at all.

Learn More

 

 

Machine cooling lubrication with IO-Link? Durable proximity detection at its best

Machine coolant resistant sensor

Industrial machining can be demanding work, metal components and tools moving at incredible speeds ultimately leads to things getting a little hotter than most of us would care to touch. Making sure all components and tools are in place and ensuring your proximity sensors don’t fail due to the corrosive effects of machine cooling lubricants is this M12 non-flush PNP inductive proximity sensor. With an 8 mm sensing range, M12 4 pin – DC-3 wire connection, IP68 and IP69K protection and the ability to communicate effectively using IO-Link, when it’s machine cooling lubricants you need to deal with, this M12 inductive proximity sensor is a perfect choice.

Learn More

 

 

When rugged all-metal Inductive Proximity Sensors are the only solution

 

All metal proximity sensors

When the situation calls for a proximity sensor that has been built to take the knocks then this is the sensor of choice. With a cylindrical M12 closed housing made entirely of stainless steel, including the flush sensor face, this inductive proximity sensor can withstand shock, rapid temperature changes and resist harsh cleaning chemicals and machine cooling lubricants. With a PNP switching output, NO output function and the usual M12-4 pin, DC 3-wire, plus IO-Link communication a 6 mm sensing range and very long service life mean that this durable detector is the perfect choice for food and beverage use and all manner of heavy industry applications.

Learn More

 

 

Kempston Controls stocks a huge range of inductive proximity sensors from a wide selection of market-leading brands including Baumer, Turck Banner, Pepperl + Fuchs, Omron, SICK and many more available in a variety of styles to suit a wide range of industrial proximity sensing applications. If you need a different inductive proximity sensor than any one of our Top 5 – Contact us on +44(0) 1933 411411 or via email at sales@kempstoncontrols.co.uk to discuss your industrial process sensor requirements.

Further Reading:

Our Top 5 Panel Meters

Reduction Factor 1 Inductive Proximity Sensors

 

Kempston Controls

Inductive Proximity Sensors – the Smart Factory’s Friend

Industry applications are becoming more and more dependant on tracking, monitoring, measuring and communication and of course, that vital data is required instantly. To be a truly effective smart manufacturing environment, modern industrial relies heavily on the information and data that numerous sensory devices supply to the control system, ideally in fractions of a second. The sensors you choose are the key to effective system integration as the data they supply is only as good as the device can allow, make a poor sensor choice and the entire process could be inefficient, costly and not very reliable.

Most of the proximity sensors that you will find will be non-contact variants, with mechanical limit switches being the exception and today you will find a wide variety of proximity sensors available in the market such as capacitive, photo-electric, ultrasonic and vision. However, by far the most popular sensor you will find within industry and in commercial applications is the inductive proximity sensor which has been utilised in millions of applications worldwide.

SICK Inductive Proximity Sensor performing a counting function

Inductive Proximity Sensors, what are they?

Inductive Proximity Sensors are, not surprisingly, devices that detect the proximity of ferrous and non-ferrous metallic objects by utilising an electromagnetic field created by a current flowing through a coil located in the sensors face.  When a conductive or magnetically permeable target approaches this electromagnetic field, it changes the coil’s impedance, acting as a signal that an object is near. Conversely, when the object moves away from the sensory face the sensor returns to its normal state.

SICK IMB Inductive Proximity Sensor in action

Inductive proximity sensors are commonly used where a more traditional switch might prove problematic or impossible to use, such as in an application where lots of water and dirt may be present. Typical examples would be a cars ABS system, an advanced CNC machine or a conveyor line in a food and beverage environment and multiple uses in the gas & oil industry.

The output from an inductive proximity sensor can be interfaced with a variety of devices such as control valves, sounder and beacons, relays, PLCs, computers, etc. and it’s here where the sensor can provide real-time monitoring of process applications.

A selection of Omron Inductive Proximity Sensors

Detecting All Areas

Proximity Sensors are available with multiple IP ratings, suitable for clean environments and those which feature washdown conditions or extreme temperature fluctuations. With the many sizes, mounting options and housing types available, proximity sensors can provide a great deal of versatility and application flexibility which ultimately explains their popularity.

Inductive Proximity Sensors Benefits:

  • Robust construction – withstand shock and vibration
  • Available with high IP ratings typically IP69K
  • Ideal for harsh industrial environments (IP specific)
  • Capable of operating in high temperatures
  • Not affected by oil, dirt, water and non-metallic particles
  • Object surface irregularities and colours have no effect
  • Available in cylindrical and block formats

 

SICK SAM Inductive Proximity Sensor in Action

Countless Applications

With the ability to detect both ferrous and non-ferrous metallic objects Inductive proximity sensors can be used to detect the presence or absence of component parts, to monitoring product process speed and count objects, but typically they are used in positioning applications. Inductive proximity sensors are often used as an alternative to the more traditional limit switches, being solid-state they can operate at higher speeds with greater reliability than their mechanical counterparts.

A selection of SICK Inductive Proximity Sensors

Whether you are considering new build or overhaul, switching to inductive proximity sensor technology is certainly worth serious consideration with the industrial environment growing ever-smarter and more demanding when it comes to accurate dependable process data. With the vast array of possible applications, it stands to reason that there is an equally vast offering of sensors to choose from. That’s where Kempston Controls, as a supplier of premium brand inductive proximity sensors such as those from Omron, SICK and Panasonic, comes in, we are bound to have the perfect solution for all your sensory requirements and even if we don’t currently stock the items you require, we can certainly get them for you.

Click here to see more Inductive Proximity Sensors

Call us on +44 (0) 01933 411411 to discuss your Inductive Proximity Sensor requirements