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 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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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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ST-G RFID Sensors with Multi-tag Ability for Industrial Process Control and Safety Applications

RFID or Radio Frequency Identification uses a digitally encoded tag with information that can be read and captured by a reader using radio waves. A basic RFID system consists of the tag, and an RFID reader. Typically, an RFID tag transmits digital information to an RFID reader within close proximity, which then converts that information into usable data for interpretation and a system response from another piece of equipment. RFID has found multiple uses within industry, including process control and the increasing the safety of machine guarding.

Pizzato are a well-known manufacturer of process control equipment including a broad range of machine access and safety control devices including Safety Hinges, Safety Modules and Limit Switches.

RFID Sensors – Positional Accuracy

The Pizzato’s ST-G RFID sensors extend all the technology used in their traditional ST-D series sensors, and do that in an even more compact housing.  The RFID technology within provides each actuator with different coding, making it impossible to tamper with a device by using another actuator of the same series. Ultimately, this means millions of different coding options are possible for the actuators, classifying them as high-level coded actuators according to EN ISO 14119.

Versatile, these RFID sensors are suitable for a host of process control applications and the clever housing design allows the same sensor to be used on both left and right-hand safety doors by simply rotating the sensor onto itself. The industry standard 22 mm fixing pattern and compact external dimensions means traditional magnetic sensors can be easily replaced with these more sophisticated RFID Sensors, providing maximum reliability and safety. The robust monolithic housing allows the ST-G RFID Sensors to be used in even the most aggressive industrial environments and the signalling LEDs providing immediate diagnostics of the input and output operating states.

ST-G RFID Sensors and Actuators

Within this range of industrial sensors is an extended temperature version that is certified by ECOLAB, this ensures that these sensors are ideal for machines used in the food and pharmaceutical industry. Constructed with redundant electronics means that the maximum PL e and SIL 3 safety levels can be obtained via the use of a single device on a guard, avoiding expensive wiring and speeding up installation.

ST-G RFID Sensors and Actuators

Multitag Programming

What sets the ST-G series of RFID sensors apart from the competition is an exceptional feature which Pizzato has called Multitag. Multitag is the ability of the sensor to recognise 2 or more actuators in a processing environment. The internal firmware can be factory programmed, memorising up to 16 actuators and associating a different device behaviour to each once the actuator has acknowledged the sensor. This ability allows the user to activate or deactivate the sensor outputs and send information regarding which actuator is in front of the sensor via an O3 signalling output. This signal can be sent to a PLC and processed.

ST-G RFID Sensors and Actuators

This Multitag function is ideal for machines and industrial processes with several workstations that require various operating modes based upon the recognition between different actuators and the sensor – such as during the change-over of machine parts, robot positioning during manufacturing, industrial process rotary tables control and so on.

For safety gate applications the combination of a sensor and 2 actuators can fully monitor safety guard opening and closing by acknowledging when the guard is fully open and again, fully closed, eliminating the uncertainties caused by incomplete guard positioning and ultimately increasing intrinsic safety.

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ST-G RFID Sensor Features

  • Pizzato Multitag programming system, up to 16 actuators
  • Symmetrical easy-to-mount housing
  • 22 mm standard mount hole spacing
  • M12 fixed connector and prewired M12 cable options
  • Compatible with all ST series actuators
  • Process Control and Safety Gate applications
  • Digitally coded actuators
  • Connect as many as 32 sensors in series
  • Actuated from multiple directions
  • IP67 and IP69K protection versions
  • M12 plastic or stainless-steel connector versions
  • Multicolour signalling LED, visible from both sides
  • Approvals CE, cULus, TUV, EAC

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Temperature Control made easy with the K85 Controller from Ascon

The Ascon K85 Mini Programmable Temperature Controller has been cleverly designed to be installed inside an industrial control panel, mounted on a DIN rail and with or without the display showing through a cut-out in the control panel door. Mounting this unit inside a control panel helps remove the possibility of operators changing the controller’s settings and offers an increased degree of physical protection.

Versatile, this PID controller offers more flexibility than other panel mounted equivalents and can be used as an alarm module or PLC expansion module inside a control panel. Configurable and easy to install as either as a PID controller or in an ON/OFF thermostatic mode, programming is carried out using the 4 function keys, a programming device, or by use of a PC.

K85 HCRR Temperature Controller Features

  • Inputs – Thermocouples J, K, R, S, T, pt100, 0/12 – 60 mV
  • Number of Outputs – 2, Relay SPDT, 8 A
  • Single line  4 digit red display and 4 control buttons
  • Digital inputs – 2
  • Programs/Segments – 1 program, 8 segments (optional)
  • Power supply 100 – 240 VAC
  • Control – ON/OFF and PID
  • Communications – RS485 Modbus slave (optional), TTL Modbus
  • Certifications CE, UL
  • Front protection IP40, terminals IP20
  • Operating temperature range 0 to 50 °C
  • Dimensions 70 x 84 – Depth 60 mm

In addition, this temperature controller has a host of additional special functions, including – digital retransmission, hours/days worked, power on delay, soft start, transmitter power supply, user calibration and a Wattmeter.

K85 Mini Controller Applications

This Temperature Controller offers more flexibility than panel mounted equivalents and is often used as alarm modules or PLC expansion modules. In addition, the K85 has been designed to neatly interface with different kinds of HMIs from touch screens to bespoke PCB display boards.

Suitable for a wide range of industrial and commercial control uses including:

  • Laboratory equipment
  • Environmental chambers
  • Packaging machinery
  • Printing machines
  • Food processing machinery
  • Extruders
  • Industrial baking or large kitchens
  • Ultrasonic cleaning equipment
  • Alarm Trip amplifier
  • PLC expansion modules over RS485 comms (optional)

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