3|16 The customer magazine from Phoenix Contact | September 2016 Device intelligence Versatile solutions for PCB connections and housings
02 Editorial UPDATE 3|16 Volker Koppert, Head of Business Unit PCB Connectors We make smart devices even smarter Dear readers, When it comes to the industrial production of the future, one pair of words always gets a mention: smart solutions. They are just two words, but they are hard to define individually. What does "smart" really mean? What makes a product a solution? And how are simple solutions made smart? There can be no doubt that active electrical and electronic components like controllers, I/O modules, sensors and actuators are essential to highly automated production systems. Without efficiently interacting and largely independent open-loop and closed-loop control circuits, providing a batch size of 1 at costs equivalent to mass production would still just be a dream. Passive components like PCB connections, field connectors and electronics housings are just as important. They play a critical role in determining the extent of a device's functionality and the level of flexibility it can have when used in different application areas. The amount of data throughput and power supplied through device connectors continues to increase as the connectors get smaller. As the interface for all centralized and decentralized components, they have an enormous impact on installation, service and maintenance costs. In this edition, we present high-performance PCB connections, multifunctional electronics housings, standardized devices and robust hybrid connectors. And one thing is certain: We make smart devices even smarter! Editorial 02 Volker Koppert Interview 03 Torsten Janwlecke, Device Connectors Cover story Connection technology 04 Device connectors for THR and SMT soldering Technology PCB connection technology 06 SKEDD direct plug-in technology brings new levels of convenience to PCB connections Connection technology 08 Saving space and time with hybrid connectors PCB connection technology 10 New technologies for transferring high currents to PCBs 16 Housings Industry-ready housing solution for Raspberry Pi microcomputers On site Housings 12 Compact control cabinet module for AS-Interface Connection technology 18 Hybrid connectors in the Energy Neighbor storage system New products 21 DC/DC converter for solar applications 21 21 21 Space-saving wiring with UT 6-3L three-level terminal blocks PTSM 0,5/..PL PCB connectors for LED applications FKDSO 2,5/..L1 orthogonal PCB terminal blocks News 22 Phoenix Contact now has an advisory board 22 New training center dedicated in Schieder 23 Phoenix Contact invests in startup for sensor systems 23 "Europe's Best Workplaces 2016" phoenixcontact.com
UPDATE 3|16 Interview 03 "Proximity to the market means proximity to the customer" Device Connectors business area sets the course for future growth The world of work is changing. Numerous international initiatives are contending with the challenges and opportunities of automation and digitalization of industrial production. UPDATE's editorial team spoke to the new President of the Device Connectors business area, Torsten Janwlecke, about what effects this trend will have on device connection technology. adaptive, device connections will also have to follow this trend. Hybrid connectors and quick connection technologies will play a role of increasing importance due to their flexibility. Putting aside specific technical solutions, I believe that standardization and digitalization of device connections is one of the most important trends. Torsten Janwlecke, President of the Device Connectors business area UPDATE: Mr. Janwlecke, you have been involved in the device connection market for more than a decade. What major trends have shaped the market? Torsten Janwlecke: Beginning in the 1980s, the variety of products on offer started to increase substantially. PCB terminal blocks gave way to UPDATE: How is the Device Connectors business area adapting to these requirements? Torsten Janwlecke: Working in a forward-looking and sustainable manner is an essential feature of Phoenix Contact. We must never lose the courage to take innovative approaches and new paths. As a business area, our close, international network of development, production, marketing and sales units help us to adapt to the design-in and development cycles specific to the device market. Maintaining a close proximity to the market means a close proximity to our customers. This proximity secures our leading position as a driver of innovation. connectors and panel feed-through terminal blocks that put connection convenience in focus. This development has accelerated enormously in recent years. With the rise of smart, networked communication nodes, the need for connection solutions increased. Today, there is no single universal PCB connection, but instead custom solutions for various requirements in international markets. UPDATE: What trends will shape the device connection market in the future? Torsten Janwlecke: Because devices are becoming increasingly smaller and more powerful and "Hybrid connectors and quick connection technologies will play a role of increasing importance due to their flexibility." UPDATE: What solutions for the production of tomorrow does the Device Connectors business area have to offer? Torsten Janwlecke: We offer an extensive portfolio of solderable and pluggable PCB connections, a comprehensive line of M5 to M58 circular connectors, data transmission solutions for copper and fiber optic cables and a variety of electronics housings for numerous applications. These products are not just intended for traditional industrial production, but also for emerging markets such as infrastructure, renewable energies and smart buildings. UPDATE: Thank you very much for talking to us.
04 Cover story UPDATE 3|16 UPDATE 3|16 The advantages are on the PCB M8 and M12 device connectors for THR and SMT soldering The intelligent production of tomorrow needs easily scalable and adaptable automation components. Manufacturers of device connections also have to follow the trend toward decentralized intelligence and provide suitable solutions for new installation processes and application areas. Circular connectors from Phoenix Contact enable maximum fl exibility in the production process. Originally, circular connectors were designed for the fi eld cabling of sensors and actuators. Since then, they have developed into a versatile industrial standard for signal, data and power transmission. Device connectors used as an interface between fi eld cabling and device connections drive the trend toward expandable, decentralized modules. Automated installation processes Most market solutions for M8 and M12 still have to be installed manually into the device. Connectors designed with litz wires or round cables cannot be integrated into automated PCB soldering processes. Thus, each device undergoes an automated soldering process for surface-mounted components on the PCB and a manual installation process for connections in the housing panel. Using new device connectors for direct PCB assembly, Phoenix Contact reduces the required eff ort and makes device design more fl exible. The two-piece pin and socket contact supports are produced from temperature- resistant plastic, making them ideal for the increased thermal loads of refl ow soldering processes. The advantage: The M8 and M12 circular connectors can be positioned on the PCB using an automated pick-and-place procedure and then soldered on using the THR or SMT process. This allows electronics and device connection technology to be installed on the PCB in a single process step. Costs for additional PCB connection technology or manual installation processes are eliminated. The device connectors also have uniform design-in types and can optionally be routed directly through a threaded hole in the housing or integrated into the device panel using a screw connection. Tolerance-compensating housing screw connection The Varioport housing screw connections compensate for production tolerances of up to 1 mm between the PCB and housing feed-through. These deviations can lead to mechanical tension between the device port and PCB connection, putting strain on the solder joints. In the past, assembly jigs were used in the soldering process or the front plates were produced using a precise, yet complex CNC process. This eff ort was intended to eliminate resulting malfunctions. The
Cover story 05 robots. The shield spring integrated directly into the PCB connector makes additional measures such as soldering lugs unnecessary. The user benefi ts from low component costs and shorter installation processes. Straight or angled versions, signal connectors with up to 17 positions and M12 compact hybrid connectors for transmitting signals and power complete the portfolio. For the fi rst time, the entire infrastructure (from the control level to decentralized ≤ 1 mm M12 Varioport: The self-adjusting housing screw connection compensates for production tolerances up to 1 mm devices, sensors and actuators) can be fully implemented using one standard. This does more than just reduce storage and maintenance costs. Thanks to the standardized interfaces, system planners and operators can also ensure easy integration of additional decentralized modules and that the existing infrastructure continues to operate without errors. Marco Stapelmann phoenixcontact.com Device connectors for THR and SMT soldering off er fl exible solutions for connecting decentralized devices tolerance-compensating M12 screw connections off er an effi cient and reliable alternative. The housing screw connections are easy to install, self-adjusting and lock reliably as soon as the cable connector is screwed onto the device port from the outside. The screw connection prevents water and dirt from getting into the device, even when it is not plugged in. The shock and vibration-resistant screw connections are also shielded completely against electromagnetic infl uences and are therefore well-suited for use in harsh industrial conditions such as decentralized fi eldbus distributors. Circular connectors for all situations The Phoenix Contact product range off ers connection solutions for numerous application areas. Contact inserts with a complete shield connection to the PCB meet increased requirements for electromagnetic compatibility (EMC), for example, in areas with welding
06 Technology UPDATE 3|16 No soldering necessary… SKEDD direct plug-in technology brings new levels of convenience to PCB connections Press-in technology, wave soldering, THR and SMD soldering – these are established processes in PCB assembly. New SKEDD direct plug-in technology does not require these processes and breathes new life into PCB connection technology. Printed-circuit boards are the central nervous system of modern devices whose performance has steadily increased in recent years due to technical progress. Conversely, the dimensions of devices and PCBs are becoming increasingly smaller. This presents manufacturers with the challenge of fitting as much device functionality as possible into a small amount of space. At the same time, the demand for flexible and efficient production processes is growing. Greater focus is being placed on PCB connections in an effort to achieve optimized production processes and competitive industrial production. Reliable – and permanent PCB terminal blocks or PCB connectors are used to transmit signals, data and power reliably between the device and field level. Automated soldering processes or automatic press-in machines are used to establish a nearly permanent connection of the terminal and header to the PCB. Previously, direct pluggable and detachable connections could only be established on PCB edges using edge connectors, which were connected to solder pads. The new SDC 2.5 connectors from Phoenix Contact combine the advantages of established installation technologies. For the first time, SKEDD direct plug-in technology enables direct pluggable and detachable connections to any position on the PCB. The connectors do not require any headers and can be plugged into plated- through bore holes on the PCB manually. Lateral body-bound rivets on the connector establish an additional mechanical connection. The locking function of the body- bound rivets is designed for printed-circuit boards with a thickness of 1.6 mm, which is a standard dimension for PCB production. Detaching only requires opening the lateral lock and then the direct connector is removed from the PCB. Up to 25 insertion cycles can be performed without noticeably impairing the quality of the connection. Direct plug-in technology with new convenience The new connectors, with a pitch of 5.0 mm, are available in versions with 1 to 16 positions. They are designed for voltage levels up to 320 V and current levels up to 12 A. The conductor is connected using the common Push-in spring connection with a spring lever for conductors with a cross-section of 0.2 to 2.5 mm². Solid and stranded conductors with ferrules are contacted without opening the clamping space. The conductor can be detached by pushing the color-contrasted spring lever with a screwdriver. A voltage test can be performed using an integrated touch connection. The lateral body-bound rivets establish a vibration-proof mechani- cal connection between the connector and PCB
UPDATE 3|16 Saving on process and component costs Currently, the SMD process is the first processing step for many PCBs. This is followed by a wave soldering process for PCB terminal blocks or the header. This second soldering process can be eliminated by using SKEDD direct plug-in technology. This also makes all logistics and materials planning for the headers unnecessary. Equipment costs and feeder space requirements are also reduced when using the SMD soldering process. In an ideal case, additional modules can even be produced on the same system without converting. Versatile fields of application The application areas for connectors that use SKEDD direct plug-in technology are many and varied. They are a good choice for traditional industrial applications for measurement and control technology, as well as for building automation, heating and household appliances. Potential applications include controllers for heating and air-conditioning systems, large household appliances and smoke and fire detectors. Additional options for use include applications where various components are fitted and soldered to the front of the PCB and the connector is contacted on the back. If a plug with SKEDD direct plug-in technology is used, rear-side assembly and soldering of the headers is no longer necessary. This also avoids exposing the PCB to additional thermal loads. Pia Horstmann phoenixcontact.com The new connectors with SKEDD direct plug-in technology can be plugged into the plated-through bore holes of the PCB directly and without the use of tools
08 Technology UPDATE 3|16 Three components connected to one cable Save space and time with hybrid connectors Providing machines, systems and automation devices with separate cables for signals, data and power is time-consuming and cost- intensive. The more complex the regulation and control task, the greater the cabling complexity and, thus, the eff ect on the availability of the entire system. Hybrid connectors from Phoenix Contact are a smart solution. connectors. One of these is equipped with pin contacts and the other with socket contacts. The connectors are based on the design for servo motors and combine the contacts for transmitting signals, data and power in one housing. This makes the M40 hybrid connector suitable for high voltages up to 630/850 V AC/ DC and currents up to 70 A. The hybrid connectors provide fl exibility when transmitting signals, data and power in automated systems. Along with the established application for cabling servo motors, hybrid connectors are well-suited for a variety of sophisticated tasks. Phoenix Contact off ers robust M23 and M40 hybrid connectors specially designed for serial cabling between fi eld devices. Hybrid connectors for serial cabling In frequency-controlled drive solutions, the circuit connecting the control cabinet to the engine still commonly uses a star distribution. Previously, almost all serial cabling solutions were bus systems. Using the new M40 hybrid connector and hybrid servo cables, serial supply and control of consumers with signals, data and power is achieved. To do this, each device in the supply chain is equipped with two device Higher system availability, less space, lower costs Hybrid connection technology does more than just reduce the space requirements on the device or in the control cabinet. Machine and system cabling is also more clearly arranged, because only a single cable has to be routed. The narrower cable routes that result also reduce the costs for the cable run and cable duct. An additional advantage of hybrid system cabling: Because up to two- thirds fewer connections have to be installed, devices, machines and system parts can be commissioned and serviced more easily. Manufacturers and users in particular benefi t from the SPEEDCON fast locking system. This is used to lock the cable connector with its counterpiece by turning it a half turn. Thus, devices can be connected quickly and reliably with two hand movements.
UPDATE 3|16 Technology 09 Transmission in the most confi ned space: Featuring contacts for signals (top left and right), data (center) and power (bottom) and +PE (top) in sets of four for each transmission type, the M40 hybrid connector allows for versatile use Same function in a smaller size The new M40 hybrid connector has a wide application area. Users can implement simple three-phase supply with L1-L3, N, PE, signals and data at 630 V AC as well as alternating current supply with up to 850 V DC as it is required for decentralized servo drives. Mismating is prevented mechanically using four diff erent codings and visually using housing markings with color rings. The standardized size M40 off ers great, space-saving advantages compared to rectangular connectors. Circular connectors are much more compact without reducing performance. Regardless of the size, four-position CAT5 elements are used for data transmission in the robust hybrid connectors from Phoenix Contact. These can be used to cable nearly all common bus systems and custom data interfaces. The integrated data connector is designed with 0.8 mm contacts. Compared to 0.6 mm contacts, they are signifi cantly more robust and enable easy, reliable assembly. Various versions for diff erent applications The CAT5 data element can be replaced by a 4-position unshielded signal element in applications that do not require a shielded data interface. As such, the connector features eight 1 mm signal contacts, while the power contacts have the same performance characteristics in all other respects. Currents up to 8 A per contact and a wire cross-section up to 1.5 mm² make it possible to implement applications for control electronics including hardware shutdowns. Thanks to appropriate air clearances and creepage distances, the signal contacts can even transmit supply voltages of up to 500 V AC. Space advantage: Round hybrid connectors are compact and save space Gerhard Liewer phoenixcontact.com
10 Technology UPDATE 3|16 Power looking for a connection Versatile technologies for transferring high currents to PCBs Conductor connection technology for the coming generations of devices has to provide more performance in less space while still allowing for safe, convenient operation, even in installation conditions with limited space. The new connection solutions from Phoenix Contact make those conditions a reality. Manufacturers of devices such as drive regulators, power supplies and I/O systems frequently manufacture goods for international use. They have to do more than just follow international standards and safety regulations, such as those from International Electrotechnical Commission (IEC) or Underwriters Laboratories (UL). They also build their devices with an eye toward different user behavior. While system builders and installers in the United States prefer screw connections, European users have been using fast connection technologies, such as spring- cage and Push-in connections, for decades. This difference stems from the geographical and historical characteristics of the local industries. The importance of properties such as intuitive operation, mechanical design, connection time, material quality and procurement costs are weighted differently depending on the region. These criteria also affect the functionality of the device. Connection technology performance center The design-in of the connection technology early on decides the versatility in use offered by the device later. As a literal performance center, connection technology requires continuous development for this reason. Transmitting large amounts of current and power while still offering convenient operation will continue to be important for future application areas as well. Not all connection technologies are cut out for demanding high-current applications in devices such as power supplies, frequency inverters or drive regulators. In addition to the required conductor size, the PCB layout and the device design are the primary limiting factors in the choice of connection technology. Specifically for applications with conductor cross sections of more than 35 mm², Phoenix Contact offers a solution portfolio that is ideal for numerous industry and infrastructure applications. The selection ranges from a PCB terminal block with an SPT 35 Push-in spring connection, to a detachable PC 35 connector and from an MKDSP 50/95 screw terminal block suitable for wave soldering to a TW 50/95 panel feed-through terminal block. Tested safety The power connections from Phoenix Contact are the perfect fit for user requirements with regard to convenience in operation. They also meet the high safety requirements for material and processing quality. The electrical suitability of the components is demonstrated by resistance measurements or rated impulse voltage testing. In addition, the mechanical contact reliability is tested as well. This factor plays an important role in the decision- making process for fast connection technologies in particular. Because the conductor cross sections as well as the potential mechanical forces that may occur increase with the transmitted electrical power, power connections are subjected to high safety requirements. Depending on the conductor cross section, connections properly wired in accordance with DIN EN 60947-1 may have to withstand huge pull-out forces of several hundred newtons. Standardized flexural tests and conductor pull- out tests give device manufacturers and users the peace of mind that even easy-to-operate terminal blocks and connectors like the TW 95 ensure solid contact over the long term. Outlook The trend towards miniaturization in components for power electronics
UPDATE 3|16 Technology 11 means less installation space is available for frequency inverters, drive regulators and similar devices. Conductor connections become smaller and more difficult to access as devices become smaller. While numerous connection technologies offer flexible solutions for smaller conductor cross sections today, fast connections for large conductor cross sections of 35 mm² are becoming increasingly important. Phoenix Contact offers ideal solutions for this area, covering a wide range of applications. Marco Stapelmann phoenixcontact.com SPT 35: The Push-in spring connection does not require any tools and allows for intuitive operation and solid contact over the long term TW 95 and MKDSP 95: End-to-end connection solutions for high currents of up to 232 A
12 UPDATE 3|16
UPDATE 3|16 On site 13 Form follows function Pepperl+Fuchs is developing a highly integrated control cabinet module for AS-Interface with Phoenix Contact Compact modules with a large number of terminal points are still a rare sight in systems manufacturing at the lower field level. Pepperl+Fuchs has developed an installation- friendly, cost-effective control cabinet module for AS- Interface in co-operation with Phoenix Contact. There is usually a long path from development of a new device to real-world deployment. Taking the detailed requirements of the end user into account during development of the components is a rather special approach for this reason. This is the approach taken by Pepperl+Fuchs, a company based in Mannheim, Germany that specializes in plant and process automation. The company brought Phoenix Contact on board as a partner in the new development of an I/O module for a beverage filling system. "With Phoenix Contact as a specialist for PCB connection technology and electronic housings, we were able to break down the requirements from beverage industry systems manufacturing into specific components," recalls Dr. Konrad Kern, who serves as the Product Manager for Factory Automation at Pepperl+Fuchs. He works at the main headquarters of the family-owned company in Mannheim, which also houses the company's Development and Marketing departments. In developing the KE5 module, those involved in the project at Pepperl+Fuchs and Phoenix Contact exchanged a wealth of ideas and were able to implement and test them in Mannheim. This led, for example, to the The new KE5 AS-i control cabinet module for sensors and actuators was created at Pepperl+Fuchs in close cooperation with Phoenix Contact EMC tests for radio frequency emissions and interference radiation in the EMC measuring chamber at Pepperl+Fuchs. In addition, the EMC laboratory tested the noise immunity in a GTEM (Gigahertz Transverse Electromagnetic) cell. Compact and efficient with AS-Interface AS-Interface, or AS-i for short, plays an important role for manufacturers of filling systems. It has been developed as the standard for fieldbus communication for connecting actuators and sensors and offers an excellent price/performance ratio. Due to its simplicity and flexibility, the decentralized interface system is also beloved by design engineers. Energy, digital data, analog data as well as safety signals are transmitted over a two-core ribbon cable. This reduces installation time and significantly increases productivity. As the leading provider of AS-i solutions, Pepperl+Fuchs has succeeded in developing an efficient system in a compact design with its KE5 device series. In an overall width of less than 19 mm, the front area provides convenient access to 28 terminal points. "We were able to increase the packing density by 50% compared to other solutions," Kern says, explaining the benefits. This can save customers a lot, especially in terms of high-cost control cabinet space. Since typical solutions have terminal points on both sides, they require a cable duct on the top and bottom. Thanks to the front-side connection, now only the lower cable harness is required. This creates a wiring design that is easy to follow. The shallow design enables installation in class 100 control boxes without any problems. In addition to the wiring design, the assignment of terminal points has been changed as well. Additional colored terminal markers are stored in the transparent hinged
14 On site UPDATE 3|16 cover. They are visible immediately after opening the cover for wiring. A centralized, back-lit numerical display provides good visibility even in harsh ambient conditions. In the event of an output overload, the number for the affected duct lights up red, enabling duct-specific diagnostics for the fault. This makes the use of AS-i in a control cabinet even more efficient. It all comes down to the connector The innovative connection technology is especially efficient for housings. The Push-in spring-force connector provides convenient wiring without any tools, which is simply not possible for conventional screw or spring-cage connections. A special contact spring provides high contact and conductor pull-out forces as well as vibration-resistant and gas-tight contacting. The encodable connectors can be detached quickly and conveniently using a locking system, supporting error-free device replacement. This saves time in the field and results in less stress for installers. To date, both the AS-i and the AUX interface have required complex looping through double- wire ferrules. Internal bridging in the connector has now eliminated that installation task. "Our KE5 module uses a bridged connector so that AS-i and AUX can now be looped through four additional terminal points," explains Frank Ebert, the Head of Development in charge of the KE5 project. "And it does this under a full current load of 8 A." For electrical isolation of the switching outputs, relay modules have been developed that enable connections of third-party systems with different potential levels. In addition, the relay modules enable switching with a higher load at 230 V AC. There is a two-position version specifically for this as a complement to the four-position standard connector. Two contact points on opposite sides are eliminated, replaced by a blind cap. This increases the air clearances and creepage distances; the connector is ideal for the requested application area. "The electronic modules have an innovative PCB design, allowing safe separation of AS-i and AUX," says Kern. "This functional The noise immunity of the KE5 module is tested in accordance with the IEC 61000-4-20 standard in a GTEM cell at the Pepperl+Fuchs facility
UPDATE 3|16 On site 15 safety is particularly important because it also allows KE5 modules to be used in safety applications as an output multiplier." This enables straightforward, cost-effective implementation of safety concepts for machines. One example of such use is the safe shut-off over AUX with decentralized multipliers using the AUX outputs on the KE5 module. "All of the sensor signals continue to remain available through the inputs on the module," adds Kern. "And end users receive all the relevant information about the system status even with auxiliary energy turned off." Advantages for both cooperation partners Phoenix Contact now offers the new ME-IO series with its integrated connection technology to device manufacturers in other industries as well. In this housing family, up to 36 pluggable connection positions can be implemented on the front in an overall width of just 18.8 mm. The housing system was devised based on a modular design principle. Various cover length versions can be combined with a multitude of connection As a product manager at Pepperl+Fuchs, Dr. Konrad Kern (left) knows the require- ments of his customers. The KE5 module was created in close coordination with the project team headed by developer Frank Ebert Compact ME-IO housing system with front connection The ME-IO housing system is ideal for applications with minimal installation space. The Push-in front connection technology and compact housing design lends itself to the implementation of small devices with up to 36 positions. This simplifies the use of input and output signals in automation. The benefits at a glance: • Tool-free Push-in wiring on the front • Up to 36 positions with a module width of 18.8 mm • Connector version with TWIN connection • Error-free connection of connectors and headers, thanks to coding • Safe connector locking and unlocking, thanks to the Lock and Release system positions. Design engineers often rely on DIN rail connectors to provide simple communication between several modules. This is a T-shaped connector that snaps onto the DIN rail. The modules are then swiveled in and snap onto each other immediately. Conclusion Close cooperation between participating partners at an early stage leads to user-friendly solutions. The KE5 housing serves as an apt demonstration of this potential. An innovative control cabinet module for filling systems in the beverage industry was developed using experience relating to the requirements from systems manufacturing. Krones AG in Neutraubling plans, develops and manufacturers machines and complete systems for process, filling and packaging technology. The module is currently in testing at its facilities. Marta Ciesielski phoenixcontact.com
16 Technology UPDATE 3|16 RPI-BC gives the Raspberry Pi professional packaging for industrial applications The perfect packaging for raspberries Industry-ready housing solution for Raspberry Pi microcomputers The Raspberry Pi has seen great success among hobbyists and amateurs. If the microcomputer hopes to replicate this success in professional applications in control cabinets or installation distributors, it needs a functional, secure housing with connection technology for DIN rails. Phoenix Contact has the perfect solution with its RPI-BC electronics housings. The Raspberry Pi microcomputer has earned an almost legendary status among hobbyist developers and educational institutions. More and more companies and institutions are also finding uses for the Raspberry Pi platform in their applications in commercial building automation and industrial applications. These ideas range from use in development environments to prototyping to cost-effective small-scale controllers and data loggers. Device solutions for professional use Professional use of the Raspberry Pi requires functional, high-quality housing and connection technology. Installing and operating the devices in installation distributors or control cabinets with reliability and in line with standards is especially important for applications in building and industrial automation. Many standard housings on the market only incorporate the actual Raspberry Pi board. They are often used as table-top housings and have the option of being mounted on
UPDATE 3|16 Technology 17 the wall. These standard solutions are not intended for DIN rail mounting in control boxes. The housings are available in many colors and designs and can be made of plastic, metal or even wood. A ribbon cable provides access to the connections for the Raspberry Pi programmable interface, called GPIO (General Purpose Input/Output). In contrast, the RPI BC DIN rail housing for the Raspberry Pi offers secure, standardized installation of the module in control cabinets or installation distributors. Additional boards can also be integrated into the housing and the GPIOs can be incorporated using connectors common in industrial applications. The RPI-BC housing solution provides a practical, reliable HDMI, USB, RJ45 and Micro USB power supply connection or makes it possible to set up a device system using bus connectors. The housing is compatible with the Raspberry Pi series A+, B+, B2 and B3. The USB connection for version A+ uses an adapter. connection allows for tool-free wiring. The additional boards can also be snapped into the housing without any tools and offer space for additional custom circuit ideas. Phoenix Contact has the perfect perfboards for creating simple circuits. The additional boards are connected to the Raspberry Pi and to the bus system automatically during device assembly. This is made possible by the corresponding PTSD terminals soldered onto the additional boards that also form a mating connection with the GPIOs from the Raspberry Pi and the bus slot. The Micro SD card acts as a hard drive for the computer and is a key component for the Raspberry Pi. To prevent computer failure or tampering with the device, the RPI-BC housing can be secured with a seal sticker. The seal is placed over the slot after the card is inserted. This sticker leaves a mark on the housing surface if the card has been removed. This makes any tampering evident and prevents any unintended removal of the card. Anke Beck phoenixcontact.com DIN rail connectors for easy wiring Bus connectors such as H bus offer an advantage for device development. Among other functions, this lets the Raspberry Pi act as the CPU while the additional modules built using the BC housing family serve as I/O modules. Simply stringing the devices together on the DIN rail allows the different device types to communicate over H bus. Connection technology for professional applications Simple, reliable wiring, such as for the sensors on the GPIOs, is essential if the Raspberry Pi is used in a production environment. In particular, it should be possible to combine GPIOs with additional printed circuit boards without complex work steps. The RPI-BC housing uses PTSM connectors to make these connections. The Push-in
18 UPDATE 3|16 Plug-in approach for the battery compartment: 200 kWh of storage capacity from eight racks of 13 modules each Batteries with the best connections Hybrid connectors in the Energy Neighbor storage system Decentralized stationary battery storage systems that efficiently utilize renewable energies and stabilize the power grid in the process are key to shaping the energy revolution. The Energy Neighbor battery storage systems got their start in Moosham in Upper Bavaria. They feature a modular design and are connected using square hybrid connectors from Phoenix Contact. Varta Storage GmbH, headquartered in the Bavarian town of Nördlingen, is a leading specialist in temporary energy storage. The company is part of the Varta Microbattery/ Varta Storage group of companies and specializes in innovative lithium-ion battery storage for private homes and industrial applications. Varta Storage is contributing to the energy revolution through an assortment of research and development projects. This led to stationary storage for renewable energy developed in collaboration with the Technical University of Munich (TUM), Kraftwerke Haag GmbH and the Bavarian Center for Applied Energy Research (ZAE). This storage system was put into operation as the Energy Neighbor. In today's typical battery storage systems, the individual battery modules are connected together in a complex process, almost always using lithium-ion batteries. "If connection lines are used for the series connection, the cables are screwed to the positive and negative terminals on the battery blocks," explains design engineer Eugen Budjugin from Varta Storage GmbH. "This leads to a lot of time and effort spent on cabling when putting large- scale storage systems into operation." The risk of installation errors also increases with the number of battery modules with this approach. Connectors as a flexible interface Instead of wiring the storage modules, they should be connected via connectors. Battery storage systems are generally built with one or more battery modules. Each battery module contains battery cells and a battery management system responsible for monitoring the cell parameters. Thus, a battery module is a mechanical and an electrical unit. Budjugin: "Our battery modules are equipped with a connection system from Phoenix Contact, so that when the modules are inserted, contact is automatically made with communication and power connections." Up to 100 amperes can flow through this flexible interface at several hundred volts. As a result,
UPDATE 3|16 On site 19 making contact with the modules is not only more reliable, but also simpler and faster. A hybrid connector that meets these special requirements has been developed by Phoenix Contact in cooperation with Varta Storage. The connector is based on the Variocon product range. This compact rectangular connector system based on IP 67 is ideal for use in devices, as well as junction boxes and control cabinets in harsh industrial environments. Five power contacts and eight signal contacts The decision to produce a modular storage system was made during the design phase for the Energy Neighbor. During development of the connector system, we relied on other connectors from other battery storage projects that had already been tested. Electrical energy storage units are not only becoming more important in stabilization of the power grid, but also in portable tools und machines as well as E-Mobility. The version developed for the Energy Neighbor has a total of 13 contacts: five power contacts and eight signal contacts. High contact density places special requirements on tolerance compensation during the connection process. This is where the special design of the battery swapping connector comes into play. The 13 contacts are arranged in a contact insert with a floating design and additional guide pins. The guide pins protrude beyond the contacts and ensure that the battery module plug is correctly aligned during the connection process. Stringent requirements for connectors With a storage capacity of 200 kilowatt hours and output of 250 kilowatts, the storage system can absorb power peaks from solar and wind power plants and compensate for consumption peaks in households that are connected locally. Energy Neighbor also provides reserve power and other power grid services. The battery storage system is integrated into a container and consists of eight racks, each with 13 battery modules. These are supplemented by the power electronics as well as energy and battery management systems. The complete system has a total weight of eight metric tons. "If necessary, we can add additional racks to our storage system in 25-kilowatt- hour increments," Budjugin reports. "With an additional transformer, it could even be used as an isolated solution or UPS system disconnected from the power grid." Stringent requirements are also placed on the performance and connection reliability to ensure easy installation and fast replacement of battery storage modules. When manually connecting the socket and pin of a connector, the installer intuitively compensates for the Installation errors are prevented by the special contact geometry of the battery connectors
20 On site UPDATE 3|16 offset between the two components, centers these parts with each other and manually inserts one part into the other. The user receives direct tactile feedback indicating whether the pin and socket have been connected correctly and securely. This feedback is not possible for Energy Neighbor battery swapping systems. The installer always inserts an entire battery module into the rack and, therefore, cannot sense whether the pin and socket contacts are in the correct position just by touch. For this reason, all components involved must interact with a high degree of precision. Conclusion The compact, modular rectangular connector from Phoenix Contact acts as the interface for energy and data in the battery storage system from Varta Storage GmbH. The interaction between connection technology and battery modules considerably reduces the commissioning and replacement time for the large accumulator because the individual modules do not have to be wired manually. Thus it is possible to design turnkey, energy storage solutions of different capacities that are disconnected from the power grid and provide an environmentally friendly and future- proof alternative to existing diesel generators. The prototype of the Energy Neighbor battery storage system from Varta Storage has been demonstrating its capabilities in the field since late 2015. The integration of the container- sized battery into the grid at the Haag power station on the outskirts of Moosham is providing important insights for shaping the energy revolution. Pioneering work for the energy supply of tomorrow is being provided in the field test in Moosham. "We are gaining insights from daily use that we are utilizing to continue development of our storage systems," explains Budjugin in closing. "Existing solar systems are already pushing many local transformers to their load limits. We expect to gain important insights into the effects of this kind of storage on the stability of the low-voltage network." The innovative connection technology from Phoenix Contact will be there every step of the way with its Variocon product range. Peter Richter phoenixcontact.com Battery module in the rack receiving bay
UPDATE 3|16 New products 21 Minis for the PCB The new PTSM 0,5/.. PL PCB connectors feature locking tabs on the side. The white connectors are laid out with a pitch of 2.5 mm and designed for currents up to 6 A and voltages up to 320 V. Thanks to the Push-in con- nection, conductors with cross sections from 0.14 mm² to 0.75 mm² can be connected quickly and reliably. The small and fl at design makes the entire PTSM series ideal for LED applications. The range includes PCB connectors and PCB terminal blocks, as well as board-to-board and wire-to-wire connectors. From the string to the control cabinet The DC/DC converter from the Uno Power family en- ables direct connection to string voltages. As such, the string combiner box is supplied from the photovoltaic system and there are no additional installation costs. With its wide-range input, the device converts input voltages between 300 V and 1000 V into an electrical- ly isolated 24 V output voltage. Thanks to its robust design, it works reliably at temperatures between -25 °C and +70 °C. Thanks to the compact housing and the high effi ciency of more than 90 percent, it can also be used in small control cabinets. Space-saving wiring up to 10 mm² Orthogonal PCB terminal block The new UT 6-3L three-level terminal block is used for wiring conductors of up to 10 mm² in a confi ned space. Thanks to the function shafts on each level, it is possi- ble to distribute up to three potentials in one terminal housing. The conductors are connected using a mainte- nance-free screw-in principle. All of the terminal points are marked individually, providing clear arrangement as a result. The new three-level terminal block can transfer outputs of up to 1000 V and 50 A and can be outfi tted with CLIPLINE complete system accessories. The FKDSO 2,5/..L1 and R1 PCB terminal blocks allow for an orthogonal alignment with the PCB. The terminal blocks with 5 mm pitch are therefore particularly suit- able for DIN-rail-mountable devices, as the conductor outlet can be fl exibly integrated in customer-specifi c device designs. The one to four-position PCB terminal blocks are suitable for currents up to 20 A and voltages up to 320 V. Using the Push-in spring connec- tion with color-contrasting push button, conductors with cross sections between 0.2 mm² and 2.5 mm² can be connected easily and reliably. phoenixcontact.com
22 News UPDATE 3|16 The Phoenix Contact Group now has an advisory board Chaired by Dr. Eberhard Veit Phoenix Contact is a family-owned company and now has an advisory board on hand to assist the executive board. Klaus Eisert, Prof. Günther Schuh, Christine Eisert, Dr. Frank Eisert, Dr. Eberhard Veit, Ralph Heuwing, Oliver Hoffmeister (from left to right; Prof. Helge Hohage is absent) The advisory board consists of three external members and two representatives from the eleven shareholders. The advisory board is headed by Dr. Eberhard Veit. He studied mechatronics and precision engineering in Stuttgart and most recently served as Chair of the Executive Board for automation company Festo AG. Dr. Günther Schuh from RWTH Aachen is another member of the board. He is a mechanical engineer who also has a degree in engineering management and has held a chair in production engineering since 2002. The third advisory board member is Ralph Heuwing, who studied mechanical engineering in Aachen, Germany and Cambridge, MA in the United States. He also earned an MBA at the business school Insead in Fontainebleau, France. He is the chief financial officer for Dürr AG. The family shareholders are represented by Christine Eisert, wife of the late Gerd Eisert, and Dr. Frank Eisert, the son of Klaus Eisert. Shareholders Klaus Eisert, Oliver Hoffmeister and Dr. Helge Hohage are also members of the board. Investment in knowledge New Phoenix Contact training center opens The new Phoenix Contact training center was opened at the Schieder location on June 10, 2016. The multi-story building offers 13,000 square meters of space for initial vocational training and further education. In the future, training workshops, laboratories, and seminar rooms will be available not only to Phoenix Contact Group trainees and staff, but also external providers such as adult education centers, Chambers of Industry and Commerce or colleges and universities. A particular area of focus this year is the qualification of employees for digitalization in industry (Industrie 4.0), which affects all the business divisions along the value added chain. A digitalization laboratory has been set up on site for training production staff, where they will be able to try out and test processes in practice. The high value placed on basic and further training is reflected in the sum of 30 million euros invested as well as in the elaborate building architecture. Phoenix Contact has been providing training in skilled professions since 1957. The center is currently providing vocational training to 380 young people, 180 of whom are combining their training with a study program.