process improvement Archives - Kempston News | Specialist electrical and electronic components news

EX-Z Series Photoelectric Sensors – Small is Beautiful

Posted on September 8, 2021 by Rick Morgan

Photoelectric Sensors come in a wide variety of sizes, shapes and variants including reflective and through beam all of which essentially perform the same purpose, the detection of objects crossing the path of the beam which then leads to a given response from the control system. This could be an alarm if an item is missing or a signal triggering another function of an automation and control process.

Big Things Come In Small Packages

For your average industrial installation there will typically be a suitable photoelectric sensor available, but when the application is very restricted in terms of available real estate, then you will need to look beyond the average sensor offering. The biggest challenge when designing and manufacturing miniaturised industrial photoelectric sensors is combining both the optical and electronic components into one housing, which as you can imagine is a complex engineering solution. Panasonic, with decades of experience with electronic design and miniaturisation were the obvious candidates to develop and manufacture a high-performance range of diminutive photoelectric sensors.

With a width of only 3mm, the EX-Z Series of Miniature Thru-beam Photoelectric Sensors is one of the smallest in the world that also contains a built-in amplifier making them ideal for mounting in tight spaces. This small but mighty range of miniature photoelectric sensors are not only small but have been designed to detect even the smallest objects with a fast response time and with the highest precision. The EX-Z series is especially suited to precise object detection within a limited and challenging installation space. Even though the housing of the sensor is only 3mm deep it contains all the essential technical elements, such as optics, electronics, indicator LEDs, and transistor output. A 2-metre cable is built-in as standard with special lengths being available upon request.

Packed with Technology

Although small in stature these Miniature Through-beam Photoelectric Sensors pack a powerful punch, with the ability to detect objects as small as 0.3 mm diameter without the use of an optional slit and identify objects as small as 1 mm in diameter at up to 500 mm distance (depending on the chosen model), a world class achievement among self-contained miniature photoelectric sensors. The low power consumption of these detection sensors makes them appealing to many industries and coupled with IP67 protection and their excellent vibration and shock resistance the EX-Z series is ideally suited for use in challenging and harsh industrial automation and control environments. Supplied as an emitter and a receiver pair. 3 stainless steel mounting brackets are also available separately along with a polyacetal spacer for through wall sensing, providing numerous mounting and installation options.

EX-Z Photoelectric Sensors Key Features

Miniature Thru-beam Photoelectric Sensor with built-in amplifier
Slim 3mm design – including optics, electronics, indicator LEDs, and transistor output
Front and side sensing types, sensing range 50, 200, 500 mm (model dependant)
NPN and PNP output versions available
Response time 0.5 ms or less
Detects objects with a diameter of as little as 0.3mm (EX-Z11 Version)
Built-in short circuit protection
Light-ON, Dark-ON types available
Voltage rating 12 to 24 Vdc
Typical dimensions 14 x 8 x 3mm (front sensing type)
Clearly visible LED spotlight, 650 nm
Built in LED indicator lights
Robust PBT enclosure, Polycarbonate lens, 2 metre cable
Protection rating IP67
Robot-cable version option

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DIL Contactors from Eaton Moeller, the Energy Efficient Choice

Posted on August 25, 2021 by Rick Morgan

A contactor is a device designed for switching an electrical circuit on and off, similar to relays in operation, however, contactors find their application in higher current capacity installations than those typically attributed to relays.

In an industrial or commercial setting, any high-power device that is frequently turned on and off, will employ a contactor within its electrical supply system, differing greatly in their configuration depending upon the current requirements of the electrical devices downstream of the contactor. Contactors are commonly used in applications incorporating powerful motors, lighting circuits, heating, and other electrical loads.

If you are looking for a powerful, versatile and efficient contactor range, then you need look no further than the impressive range of Moeller DIL contactors from Eaton.

The capable DC devices stand head and shoulders above the competition with their reduced power consumption, making them more energy-efficient and reducing the size of power supply units utilised. Suitable for use all around the world the DIL contactors cover a huge output range, from mini contactor relays (up to 7A) to power vacuum contactors (up to 3180A).

Communications-enabled thanks to the SmartWire-DT, the contactors can be controlled remotely and they can be combined with Eaton’s full range of electronic overload relays and bimetal relays.

DIL Contactor Series Core Features

DILM up to 170 A & 4-Pole DILMP contactor up to 200 A
DILM frame sizes: 45 mm for up to 32 A; 55 mm for up to 72 A; and 90 mm for up to 170 A
UL, CSA, Marine approvals, GOST-R and Ukrain-GOST approvals
Temperature range -25 °C to +60 °C
Uniform accessories for 3-pole and 4-pole contactors
Double box terminals for reliable wiring of different cross-sections
The contactors up to 38 A can be controlled directly from a PLC
DC-operated devices with integrated suppressor circuits

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Rapid Wiring with One-click Push-in Terminals

Innovative push-in terminals provide quick, safe, and easy control-panel wiring with just one click. You can expect to decrease your wiring time by 50 % without the need for any additional tools. DIL contactors with this push-in technology typically have the same footprint as conventional Eaton contactors for easy integration into existing systems.

DILM Contactors – Small but Powerful

They may be small, but they can certainly punch above their weight, both the DC and AC DILM contactor series can switch motors up to 170 A and come with an already integrated auxiliary contact (up to 38A). The auxiliary NC with mirror contacts is suitable for use in safety-related applications, simplifying project planning, installation, and commissioning.

DILL Lighting Contactors – Managing Lamp Loads Safely

The DILL series is based on the DILM contactor, and it has been specifically designed for switching lamps across three current ranges (12A, 18A, 20A). These contactors have a high switching capacity, enabling them to handle the inrush currents for all types of lamps, even over long distances.

DILMP 4-Pole Contactors

These versatile 4-pole contactors come in four sizes, from 20A to 200A, and they have been designed for use specifically in AC 1 circuits. DILMP contactors are ideal for applications that are characterised by frequent mains switch-off or switch-over, as well as for heating systems and for switching 4-pole loads. The uniform accessory range means that all the proven components of the 3-pole series can also be used.

DILK Contactors – Reactive Power

The DILK contactors are typically used in reactive-power compensation equipment where capacitor banks need to be switched. Capable and dependable, integrated series resistors can reliably switch capacitors with very high peak inrush currents, up to 180 times the normal current.

Combination Contactors – DIUL and SDAINL

The contactor combinations range consist of the completely pre-wired DIUL reversing combinations up to 30 kW and the SDAINL star-delta combinations up to 132 kW, pre-wired, their installation is rapid and simple.

Kempston Controls are the people to speak to when it comes to sourcing your ideal contactor solution. Call us on +44 (0) 1933 411 411, email us at sales@kempstoncontrols.co.uk or you use the enquiry form below. Our professional technical and sales teams are ready to help you today.

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Safety Light Curtains with Advanced Bluetooth Interface

Posted on July 5, 2021 by Rick Morgan

Safety light curtains, or as they are often known as – light barriers, light grids and light guards to mention just a few alternatives are classed as Electro-sensitive Protective Equipment. Consisting of a transmitter and a receiver head, light curtains generate a field of infrared light between these heads which is classed as the detection zone.

Invisible Light Protection

Typically, these diligent devices are situated around access points to a piece of processing machinery, shutting down the device should a person, or a part of a person, cross the beams of the safety grid. Advantages of a light curtain include reduced operator fatigue, when compared to mechanical options such as gates and barriers, and the subsequent upkeep of these mechanisms and simplifying maintenance and set-up times.

Utilised across numerous industry sectors for many years, light curtains come in many shapes and sizes. Schmersal, renowned for their impressive range of Safety Light Curtains decided to add yet more functionality to these popular process safety devices by adding a built-in high specification Blue Tooth interface.

The Schmersal SLC440/COM Safety Light Curtain range with built-in Bluetooth BLE (BLE stands for Bluetooth Low Energy) is an active optoelectronic protective device that can provide real-time status and diagnostic data of the light grid on a smartphone or a tablet via a Bluetooth interface.

Ideal for Predictive Maintenance

The Bluetooth interface allows easy start-up using a smartphone or tablet with the integrated set-up aid. There is also the useful option of saving the data, which can then be used to document a repeat test or for predictive maintenance purposes. The transmission of data to smartphones / tablets (Android, IOS) is facilitated by an app developed by Schmersal.

NFC technology has been used successfully in the past when it came to recording and monitoring device diagnostic data, however it is limited to only a few centimetres. The Bluetooth BLE interface contained within the SLC440/COM Light Curtains can achieve a range of up to 100 times more, around 5 metres in total.

This means the BLE interface is perfect when the safety light curtain installation is in a relatively inaccessible position. Bluetooth BLE also offers a greater range of applications because not all smartphones or tablets are equipped with NFC. As Bluetooth is an international industrial standard, the SLC440/COM range can be used all over the world.

Safety and Efficiency

The SLC440/COM Safety Light Grid with BLE are ideal for improving efficiency and availability in manufacturing processes as their status can be accessed easily and in real-time, meaning issues can be captured early. Status information and diagnostic data enables processes to be reactivated quicker, particularly in the event of a system shutdown if a hazard is detected.

It also represents an economical innovation as, compared to classic Bluetooth, BLE is characterised by considerably lower energy consumption and reduced costs at a similarly high communication range.

All of the SLC440/COM range of light curtains are available from Kempston Controls, give our sales team a call on +44 (0) 1933 411 411 or email them at sales@kempstoncontrols.com, or use the enquiry form below and let us help you select your ideal light curtain solution.

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The PP20H Pressure Sensor from Baumer, the ideal Hygienic Pressure Sensor Solution

Posted on June 30, 2021 by Rick Morgan

There are many manufacturing and processing industries that demand high levels of hygiene, such as the food and beverage industry and pharmaceutical manufacturing. Within the installations that operate in those sectors there will probably be a need to accurately measure and monitor the pressure of fluids and gasses, which is where the need for a dependable pressure sensor comes in. The pressure sensors will of course need to guarantee that they can withstand demanding cleaning schedules, won’t trap and harbour processing media traces and are as accurate, robust and dependable as possible. Baumer are renowned for their impressive pressure sensor portfolio and they have the ideal sensor solution for demanding applications.

The PP20H Hygienic Pressure Sensor

With its modular design, pressure ranges from –1 to 40 bar and a wide array of process connections the PP20H Hygienic Pressure Sensor series from Baumer is of a fully welded stainless steel construction and features a condensation-resistant silicon measuring cell. This top-spec Pressure Sensor can be configured from a wide range of parameters to suit your process requirements including measuring range, accuracy, type of pressure, output signal, process connection and more. Available optionally with IOLink, (in parallel with 4 … 20 mA) they meet the high hygienic requirements of the food and pharmaceutical industries and are CIP and SIP-capable.

Processing Safety

Excellent temperature and long-term stability coupled with high accuracy guarantee the safe monitoring, operation and control of demanding hygienic processes in a humid environment, even with frequent temperature cycles.

Small form factor means greater flexibility
The pressure sensors cover a wide media temperature range from –20 °C to 125 °C without a bespoke cooling line. More compact, less space is required in the system.

Pressure Sensor Features and Benefits

Absolute pressure, relative pressure and vacuum measurement
All typical hygienic connections options available
Resistant to all common CIP cleaning media
Condensate-proof measuring cell
Optionally available with IO-Link (in parallel with 4 … 20 mA)
Space-saving design
Design and materials meet food and pharmaceutical standards
Versions compliant to 3-A sanitary standards, FDA and with EHEDG certification

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IO-Link for Centralised Configuration

When an IO-Link option is utilised, this makes it possible to configure several pressure sensors simultaneously, simplifying switching point adjustment for different process stages and ultimately saving time and money. Data is the fundamental building block of process and product optimisation and using IO-Link ensures that valuable, additional data is accessible for analysis. Apart from the analogue 4 … 20 mA signal, further data such as cell pressure and pressure sensor temperature can be recorded. This process data can be used, for example, to determine the temperature of the medium being used. Further data that can help to identify the sensor can be loaded at any time using tags that can be configured individually.

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The Baumer PH20H Pressure Sensor range are the go-to-solution when it comes to reliable absolute and relative pressure and vacuum measurement in demanding hygienic environments. As Baumer supplier partners Kempston Controls has access to their entire product portfolio. Call our dedicated call centre on +44 (0) 1933 411 411 or email sales@kempstoncontrols.co.uk, or, alternatively use the enquiry form below to discuss your hygienic pressure sensor requirements with us today.

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In Control – The Kempston HVAC & Process Control Team

Posted on June 21, 2021 by Rick Morgan

Kempston Controls has an enviable reputation amongst it peers for the provision of high-quality products from world leading brands at the best possible prices, all with expedited delivery.

Controlling the Process

To add yet more strings to our bow the newly created HVAC & Process Control Team brings decades of relevant industrial expertise to help provide you with technical product solutions for your next installation or retrofitting project.

Knowing What Works

With Kempston Controls extensive HVAC and control product offering this experienced team knows what works and backed with competitive pricing, exceptional stock levels and exemplary service they have the foundation to help serve you better.

Continually updated and trained by leading manufacturers in the latest design and product innovations, the Process Control Team can source top brand products along with the best value alternatives to suit your needs and pricing requirements.

Extensive HVAC Product Knowledge

The HVAC & Process Controls Team are here to help you choose the right product from a vast range of stocked items including:

Sensors
Metering
Valves and actuators
Level Detection devices
Pressure Sensors and Switches
Thermostats
Heating Controls
Flow Devices

Supplied from a breadth of leading manufacturers including – ABB, BURKERT, Danfoss, Danfoss Heating, Endress & Hauser, Gems, Honeywell, Honeywell FEMA, Schneider Process, SICK and Siemens.

This dedicated team can provide Service and Facilities Management companies with commercial spares as well as Building Controls and BMS peripheral equipment to System Integrators and Mechanical Contractors.

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Meet the HVAC and Process Control Team!

Sandeep Sarpal

Sandeep became involved in the HVAC industry back in 2008, when he joined a leading manufacturer of gas valves, pressure switches, flow sensors, valve actuators, building controls and other control products. Rising rapidly through the ranks from Technical Sales to Sales Manager and Product Champion, he joined Kempston Controls in 2020 as a Commercial Manager of the Process Division.

Paul Earl

Paul’s career began a few decades ago with a 4-year Electronics Apprenticeship which then led to 20 years of service in various roles in the electronics and radio & satellite communications industry. A change of pace led to Paul working as an electrician for a small local building company for a while and then on to Danfoss, joining their heating technical support team for a number of years. Paul has been with Kempton Controls since 2018 working within the technical team.

Luciano Piccini

With an Electrical Engineering BSc degree, Luciano has been engaged with the industrial sector his whole career in a variety of roles and functions: Account, Regional, National and Product, Project, Plant & Production Manager and Sales and Marketing Consultant roles. Providing technical and commercial support for a range of products including Process industries field instrumentation; Control (DCS/PLC), Scada, F&G, ESD, EMS systems; Analytical systems, VSDs, Power Houses (Engineered packaged solutions). At the beginning of his career Luciano was involved with electronic components, ERP systems and embedded electronic system design (HW+SW).

Comprehensive Support
All of this backed up with comprehensive technical support before during and after the installation process to help you easily integrate your chosen HVAC & Process Control hardware into your system and for any upgrades you might need! Call them today on +44 (0) 1933 411 411, email them at process@kempstoncontrols.co.uk or use the enquiry from to discuss your requirements.

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Safety Door Switches with Highly Visible Indicators – The Panasonic SG-P Series

Posted on June 4, 2021 by Rick Morgan

Over the years within your typical industrial production installation staff and processing machines have traditionally worked separately. Today, with the growth of smart factories and people and machines working in unison the equipment’s ability to recognise interaction with their human counterparts becomes ever more apparent.

Switches and actuators that can disable safety guards and doors are still being used at production facilities, which has proven to be one of the contributing factors in causing serious workplace accidents. However, there was another problem. Machines could not be operated immediately when using switches with small indicators because it took time to check the open/closed status of the doors of the entire production installation.

To try and solve this problem the engineers at Panasonic developed the SG-P Series Safety Door Switches. These durable safety switches enable operators and engineers to view the open/closed state of safety gates, guards of an entire production installation at-a-glance. These clever safety switches incorporate a switch unit and a paired actuator. During operating the switches only detect their matching actuator, this prevents the intentional disabling of the safety interlock and increases the safety of workers during operation and servicing. Other advantages include reducing machine downtime and improving productivity and through-put.

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Prevention of the disabling of interlocks

During the maintenance of industrial production installations, intentionally disabling interlocks when opening equipment doors can be a major cause of accidents in the workplace, such as when another user operates the machine without noticing someone is still inside. The SG-P safety door switches prevent intentional disabling by utilising RFID that detects only the actuator that has been paired with the safety door switch.

Large and bright indicators show the open/closed state of the safety doors

These safety door switches are equipped with a bright and highly visible indicator, despite their small stature. Open safety doors and guards display a bright red light, other safety doors linked to the open doors are identified with green flashing lights to show that there is an unsafe status.

Traditional switches with a small indicator light are not easy to see when mounted on the inside of safety doors, making it hard for staff to identify which doors are open. Overcoming this problem, the Panasonic SG-P visible type features an actuator and switch that are both illuminated, while the switch body of the compact version illuminates on both sides, the actuator has no lighting. This highly visible status identification allows operators to ascertain the switch status and rapidly identify which doors are open, improving safety, reducing machine downtime and increasing through-put.

Panasonic SG-P Series Safety Door Switch Features

Power supply voltage: 24 V DC
Control output: PNP/NPN Transistor open collector 2 outputs
IP65 protection rating
Dimensions:
Compact type: Switch W88×H15×D25 mm, Actuator W56×H15×D13 mm
Visible type: Switch W88×H15×D25 mm, Actuator W52×H15×D32 mm
Applications – safety guards, maintenance access doors, sliding doors, access panels

Parent-child structure saves wiring, up to 30 units to be connected in series

Up to 29 sub switches (child devices), can be connected to one safety switch which functions as the parent allowing up to 30 units to be connected in unison. Only the parent device provides an output which eliminates the need for wiring of the linked child devices, saving installation time, equipment

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If you are looking for the ideal visible safety door switch solution look no further than the Panasonic SG-P series which you can purchase today from Kempston Controls. Speak to our expert sales and technical teams on +44 (0) 1933 411 411, click the Enquire Now button fill and out the form below or email sales@kemsptoncontrols.co.uk to discuss your installations requirements.

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Tag: process improvement

EX-Z Series Photoelectric Sensors – Small is Beautiful

DIL Contactors from Eaton Moeller, the Energy Efficient Choice

Safety Light Curtains with Advanced Bluetooth Interface

The PP20H Pressure Sensor from Baumer, the ideal Hygienic Pressure Sensor Solution

In Control – The Kempston HVAC & Process Control Team

Safety Door Switches with Highly Visible Indicators – The Panasonic SG-P Series

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