2|17 The customer magazine from Phoenix Contact | June 2017 Clever switching Phoenix Contact offers a wide range of switching devices for various applications
02 Editorial UPDATE 2|17 Carsten Thörner, Vice President Interface Components Business Area ICE Switch at another level! Dear readers, Switching devices are crucial in every control cabinet and automation does not work without them – this also holds true for the omnipresent Industrie 4.0. As a specialist for the interface level, Phoenix Contact offers the right solution for coupling, splitting, boosting, starting, securing or monitoring for nearly any application and industry. We have a tradition of innovation. It's already been 21 years since we developed the PLC-Interface relay in the groundbreaking lead frame technology. We introduced the pluggable relay components where fixed soldered relays had been the state-of-the art previously for coupling modules. The modules accept system accessories for bridgings and markings and still are only 6 mm wide – a market standard that remains in place today. In 2008, we set another benchmark with Contactron, the hybrid motor starter system. The system offers lots of functions for many drive applications in a very small space, combining the advantages of semiconductor and electromechanical switching in one device. In the latest version, the devices can now also be coupled to many common fieldbus systems by way of a gateway. We are also proud of our PSRmini safety relay that offers the highest functional safety on a width of just 6 mm. The innovative Push-in connection technology combines all of these switching products – a systems approach that is unrivaled in terms of its variety. See for yourself in this booklet that Phoenix Contact has elevated the "Commodity" switching devices to another level. Editorial 02 Carsten Thörner Interview 03 Friedrich Wöstehoff, Rotork Fluid Systems Cover story Click-click and done! 04 Phoenix Contact offers switching devices for all usage ranges Technology Safe switching in the potentially explosive area 14 Highly compact PLC-Interface relay family Set in concrete with Bluetooth 16 Wireless signal transmission in a concrete factory The many faces of round 18 M8 and M12 device connectors On site Motors make reports 08 Network-capable hybrid motor starters on the painting line 10 This is how to keep things flowing PLC logic in actuating drives for oil pipeline New products Space-saving surge protection Cable routing to the control cabinet door Connector for safe power transmission 21 21 21 21 WLAN solution for machine building News 20 Phoenix Contact invests in future markets Early Adopter program for PLC next 22 22 Phoenix Contact Energy Automation GmbH founded Etherwan Systems Inc. acquired 23 Find out more with the web code For detailed information, use the web codes provided in this magazine. Simply enter # and the four-digit number in the search field on our website. Web code: #1234 (example) phoenixcontact.com
UPDATE 2|17 Interview 03 Compact and reliable Switching devices from Phoenix Contact at Rotork Fluid Systems Friedrich Wöstehoff is an Application Engineer at Rotork Fluid Systems, a leading provider of actuator technology. For the electrical equipment of the valve actuators, the company mainly uses the switching devices from Phoenix Contact – currently also the PLC logic relay system (see also page 10). The UPDATE editors visited Friedrich Wösthoff at the Melle site and talked to him about the background and experiences. UPDATE: Mr. Wöstehoff, you are increasingly using Contactron hybrid motor starters for motor control of your actuator technology. What is the key reason for this? Wöstehoff: It's the number of functions that come together in one device in a small space. Actuators from Rotork Fluid Systems are used in pipelines around the world We try to build cabinets that are as compact as possible and we see the advantages in the flexible configurability. If we would install regular bi-relays, then we would also have to keep different types in store depending on the motor current. We now have a standard device Friedrich Wöstehoff, Rotork Fluid Systems “Contactron combines a vast number of functions in very little space.” that we parameterize. The device maps multiple functions – contactor, reversing circuit, overload and short circuit protection. The current consumption is regulated and is very reliable thanks to the hybrid technology. We have never had any complaints and use the device frequently. UPDATE: You have also started to use PLC logic for controlling valve actuators. What or who made you aware of the module? Wöstehoff: We already use a broad range of switching devices from your company, so we asked your sales representatives to give us some advice when we were looking for a small, compact and expandable solution for valve actuation. In addition to the space, the ratio of the price and the functions offered was also important to us. UPDATE: For which types of applications is PLC logic suited? Wöstehoff: I think that the module is a great solution when a customer mainly wants to switch the relay reliably, the function should largely run autonomously and no major requirements are placed on the ability to communicate. We continue to rely on PLC-based solutions such as your Inline controllers when we also require communication with a control room by way of a fieldbus such as Profibus, HART or Foundation Fieldbus. UPDATE: What type of relays do you mainly use for valve actuators? Do you have special requirements? Wöstehoff: Absolutely. The valves have a switching frequency to control the damper actuators hydraulically. Therefore, we mainly install solid state relays and thus avoid bouncing and welding of conventional electromechanical relays. UPDATE: Thank you very much for talking to us!
04 Cover story UPDATE 2|17 Click-click and done! Phoenix Contact offers switching devices for all usage ranges Switching devices work unspectacularly in the background in automation technology, but they significantly influence the function of the overall system. In the world of interfaces, important technological developments have taken place almost unnoticed with relay and semiconductor switches, which influence the performance of modern automation systems. It is therefore time to take a closer look at the actors of the automation world with their special performance spectrum. As a whole, the various switching devices from Phoenix Contact offer advantages that are essential in most industrial areas: This includes easy handling, time savings, reducing the space required and high system availability. In addition to the conventional screw connection, the devices are also available with the convenient and time-saving Push-in connection technology. Basic features such as the professional bridgability of potentials as well as the unique marking of devices and connections are also standard for the switching devices. After all, in addition to the individual performance characteristics, they provide a real benefit to the user; from mounting and wiring to daily operation.
UPDATE 2|17 Cover story 05 Intermediary between controller and field level: PLC-Interface Top hat rail mounted coupling relays serve as potential separation, power amplification, and contact multiplication between the controller and field level. The compact, modular structured relay system PLC-Interface saves a lot of space in the control cabinet and offers electrical designers the right solution for every application thanks to its comprehensive portfolio. System accessories accelerate and facilitate assembly and wiring. This includes plug-in bridges for potential distribution, marking material for unique marking, as well as adapters for a quick connection with the controller. Special sensor and actuator versions are used to bridge the supply of the connected periphery directly to the coupling relay. All connections are thus on the module so that separate potential distributors are unnecessary. The components have a long service life and can be replaced easily when they wear out, which allows the automation system to run around the clock. Contrary to the coupling relay from modular systems with pluggable input circuit, the PLC relays are always equipped with circuitry integrated in the housing, for example, for protection against polarity reversal and limitation of the switch-off overvoltage of the coil. The input and output are isolated safely in accordance with EN 50178, which prevents danger to persons and machines. The relays and optocouplers with IP67 protection are reliable in nearly all applications against external influences such as moisture, dust, or aggressive ambient conditions. The sealed housing keeps the harmful influencing factors away from the relay mechanism and the contact surfaces (p. 14). Logic for mounting: PLC logic The programmable PLC logic logic relay system is simply plugged onto a block of eight standard PLC-Interfaces as a compact, small-scale controller. The device is only 50 mm wide and controls 16 inputs and outputs, whereby eight can be freely assigned as analog or digital signal or as input or output. The basic module can be extended by two devices so that up to 48 I/O signals can be acquired and switched. If an individual relay has reached the end of its service life, the user exchanges it within seconds without having to replace the entire control unit. Wiring of the PLC logic can also be done with the Push-in connection technology. For this, solid conductors and conductors featuring ferrules are plugged into the clamping part pockets without tools. The logic relay system is programmed quickly and intuitively by way of the Logic+ software and this only requires general switching and digital technology knowledge. Similar to a game, programs are created as a ladded diagram (LD) or function block diagram (FBD) by drag & drop selection of the respective function blocks and their connections. The entire program can be simulated and tested both offline and online. The clever add-on is connected to common PLC-Interface for field wiring with convenient device connection and low space requirements PLC logic for modular, flexible and compact controlling of up to 48 I/O signals
06 Cover story UPDATE 2|17 fieldbus systems by way of Bluetooth or an app or by way of a gateway. The logic relay system can be used to implement in particular remotely distributed or functionally secondary control units quickly and conveniently. Possible applications include building automation – such as sunblinds, ventilation and lighting in an underground garage – to decentralized machine or system components in factory automation (also see p. 10). functions. Independent of the control level, they take over specific time sequences and control processes precisely, which is why the ETD modules often present an economical alternative to the PLC. The mere 6.2 millimeter narrow time relays can be conveniently adjusted by an illuminated thumbwheel. In this way, both the compact and the multifunctional variants fulfill high requirements in terms of precision, easy handling and setting possibilities. Many functions for industrial relays: Rifline and ETD Controlling and stopping movements: Contactron and ELR Rifline complete is the perfect solution if the user needs pluggable standard coupling relays with up to four changeover contacts. From the six millimeter narrow normally-open contact to the robust 3x16A contactor, the industrial relay system encompasses all designs. As with the PLC relay, uniform plug-in bridges are available for potential distribution, universal marking material, as well as adapters for easy connections to the controller. Different modules that were plugged into the input increase the benefit: They protect from highly induced voltages, signal the switching state of the relay by way of LED or turn it into a time relay with many functions. From three time functions, the user can select a time range from 0.5 seconds to 100 minutes. The timer relays of the ETD product range demonstrate their strengths when the application requires easily configurable time As soon as machine and system components move, safety and control over the dynamic processes are what matters. Nevertheless, the devices that are installed there should require little space, provide high performance, and function reliably. The Phoenix Contact motor starters show what optimization potential can be accomplished with Contactron hybrid technology. Electromechanical contacts and semiconductor switches are used in parallel so that the entire switching unit is only 22.5 millimeters wide. Nevertheless, the device offers a reversal function, motor protection, safe shutdown up to SIL 3 and PL e as well as the communication connection so that up to 75 percent space is saved in comparison to conventional technology. Internal load and locking circuits as well as push-in connection technology also lower the wiring effort by about 75 percent. The microprocessor-controlled combination of robust relay technology and The Rifline complete relay system encompasses all relevant designs Hybrid motor starters from the CONTACTRON product range switch, reverse, and protect the motor
UPDATE 2|17 Cover story 07 wear-free solid-state technology extends the service life of the motor starter by ten times in comparison to electromechanical switches. If an almost unlimited service life with very high cycle frequencies is necessary – e.g. for switching heaters or lighting – the fully electronic switching devices of the ELR product range are recommended. The devices ensure freedom from wear in both the single and two-phased version and ensure continuous maintenance-free operation of the system or machine. Its resistance to vibration and hazardous substances makes it possible to use it in the industry universally. In addition, the ELR modules can be wired quickly and easily since the interlock and load switching are integrated. Ward off danger: PSR When it comes to the protection of persons and machines, the safety relay modules are essential. From emergency stop to speed monitoring, the PSR product range fulfills the necessary requirements. The space requirements in the control cabinet can be further reduced with the PSRmini coupling relay, which features certified force-guided contacts in accordance with EN 50205. The narrowest SIL coupling modules in the world encompass the performance of devices in standard overall width. The compact housing dimensions result from new relay technology that has been developed by Phoenix Contact. The minimized elementary relay uses less power for its drive and offers a high output density and system availability. The optimized load contact makes the relay very short-circuit proof. Through its compatibility with various sensors and controllers, the PSRmini can be used in machine building and in the process industry. For this purpose, the relay has a comprehensive approval package and can thus also be operated in environments that go beyond the standard. Monitoring: EMD and ETD Even though we trust the fault-free functioning of the system, it is still essential to monitor important system parameters. This is why the monitoring relays of the EMD product range record all important parameters such as voltage, current, performance, and temperature. They can be conveniently adjusted using rotary switches mounted on the front of the housing. Deviations from central setpoint definitions are reliably reported, which ensures the desired process sequence. For many users of monitoring relays, control of the input voltage during the feed-in in machines is a top priority, because voltage fluctuations in the mains power supply or an incorrect phase sequence can cause damage to the installed components. The EMD modules therefore detect faults early during operation, in this way avoiding unplanned machine or system standstills. The relays themselves can be clearly diagnosed by status LEDs. Frank Herden phoenixcontact.com The 6 and 12 mm narrow PSRmini safety relays offer all safety functions Monitoring and timer relays monitor operational parameters or control time sequences
08 On site UPDATE 2|17 The network-capable hybrid motor starters control the transport devices for automotive production Motors make reports Network-capable hybrid motor starters on the painting line Dürr Systems AG provides conveying technology which is used for transportation of automobile bodies during painting and final assembly. With the Contactron network-capable hybrid motor starters from Phoenix Contact, the information from installed motors can now be accessed worldwide. One of the international production and assembly plants of Dürr AG is in Radom, Poland, about 100 km south of Warsaw. Systems for transporting car bodies during painting and final assembly are produced here. The product range for companies that commission a conveyor system goes from the assembly of the conveyor systems to creating the complete documentation to software and visualization to accompanying and training the employees. No additional remote I/Os required Dürr's position on the market is very much a result of the high quality standard as well as the company's innovations. The machine building and systems manufacturer maps out the market for new innovations to always offer its customers state-of-the-art solutions. Possible suitable devices are checked comprehensively and added to the global Dürr standard for a positive assessment. The most important criterion here is the added value for the customers. In the past, Dürr already used compact, digitally controlled hybrid motor starters from Phoenix Contact for simple conveyor technology tasks in addition to contactors. A new addition to the product range now is the network-capable device version that offers even more possibilities. The network-capable hybrid motor starters are connected to a controller by way of a gateway that is available for Profinet, Profibus, Modbus TCP, Ethernet/IP and CANopen. In so doing, multiple Contactron devices can be coupled to the respective gateway by way of a DIN rail connector. The motor starters are triggered directly by way of the bus line, eliminating digital outputs and the need for costly parallel wiring. The advantage is that the gateways have eight freely parametrizable digital inputs and four digital 24 V outputs. Therefore, no additional remote I/Os are necessary for decentralized applications in particular.
UPDATE 2|17 On site 09 Significant benefit during maintenance The network-capable Contactron devices offer another advantage: If required, the customer is able to receive clear status reports from the motor starters such as a notification about the failure of one or multiple phases, an overload warning and report, underload report, the number of switching cycles or the currently flowing motor current. It thus is a multifunctional component that combines a motor starter and motor current measurement in one housing. This is a big step regarding the provision of all operating data in the framework of digital@DÜRR, the Industrie 4.0 strategy of this systems manufacturer. This makes information about motors that are installed in networked systems accessible worldwide. This offers advantages during maintenance and also saves space in the control cabinet since the measuring technology is not required. Dürr relies on Profinet and Ethernet/IP for its communication protocols. Since the gateways were already in use for this purpose, the advantages of the network-capable hybrid motor starters had an immediate effect. Electrical control gear at Dürr usually has a decentralized setup. The motor starters are installed in small control cabinets below the roller conveyors in the immediate vicinity of the motors. The cabinets include terminal blocks and miniature circuit breakers as well as a Profinet gateway and four hybrid motor starters. The gateway takes on the task of the bus coupler and collects the signals of the proximity switches in the system as a digital input module with eight usable digital inputs. Digital extension module makes space Since April 2016, Phoenix has also been able to fulfill another Dürr requirement. For even more compact control cabinets, Dürr will connect eight hybrid motor starters to a Profinet bus coupler in the future. This version requires an additional I/O module of the same design. Phoenix Contact offers a digital extension module in the matching building dimensions with eight digital 24 V inputs and four digital 24 V outputs for this purpose. Dr. Guido Mertens Web code: #1077 32 Contactron network- capable hybrid motor starters (middle) can be connected with common bus systems by way of an IFS gateway (left). Two electronic motor management modules on the right
10 On site UPDATE 2|17 The configuration, parameterization and programming of the PLC logic relay system take place with Logic+ software
UPDATE 2|17 On site 11 This is how to keep things flowing PLC logic in actuators for oil pipeline Rotork Fluid Systems is a specialist for valve actuators. For the first time, the company is using PLC logic as a controller in a new system for an oil pipeline. The flexibility when using the relays and the compact dimensions make the module an ideal replacement for conventional switch technology. The experiences are so good that the company wants to offer the small control module as a standard solution in the future. system is based on the PLC logic", confirms Friedrich Wöstehoff, Application Engineer at Rotork Fluid Systems in Melle, Germany. Maximum safety and reliability are the trademark of the Rotork valve actuators. This, for example, includes the oil storage tank that provides enough pressure to be able to safely close the valve. The Rotork equipment also stands out due to the fact that there are drive products for Valves and the drives that go along with them are essential for oil and gas to safely reach the consumer from the pumping site. One of the world's most well-known manufacturers of such devices is Rotork, which offers a comprehensive range of actuators, controller and associated equipment. The Rotork Fluid Systems division specializes in manufacturing and supporting hydraulic control systems. In addition to production sites for serial production in Sweden, Italy and the U.S., the Lower Saxon Melle, in Germany, is an important site for manufacturing non-series tied valve actuators. In so doing, the roughly 60 employees not only build and sell control valves for oil and gas pipelines, but also for water treatment plants, wastewater treatment plants, ships and tankers. Controlling actuators with PLC logic Six actuators were recently built for an oil pipeline in the Arabian region. For the first time, the actuators are equipped with logic controls based on PLC logic. A hydraulic drive opens and closes the valve with a quarter turn of the flap. The valve receives the order to do so either by way of the buttons on site or centrally from the control room by way of potential-free contacts. The PLC logic controller executes the order for opening and closing, monitors the pressure as well as the runtime of the pump and takes on the end position control. "Thus, the entire The actuator is installed in an oil pipeline particular climatic conditions such as low temperatures (-60 °C). The product combination of Contactron hybrid motor starters, PSR safety relay, Macx Analog Ex-Namur and PLC logic signal conditioner, all from Phoenix Contact, provide for reliable operation. The entire electrical equipment is housed in a cast iron control cabinet for flameproof enclosure with Ex d protection and bolted with massive nuts. Compact and flexible The compact design of PLC logic was a good fit for Wöstehoff. "We used to map the functions with conventional relay technology, which used to take up much more space for
12 On site UPDATE 2|17 individual PLC-Interface modules. The system can be extended with additional modules as required. The possibilities of PLC logic go beyond mapping relay functions: "With PLC logic, we can implement runtime monitoring and even timing elements – a traditional controller uses much more space and is more complex in terms of the engineering. The menu-led, intuitively usable programming interface also lets beginners fi nd their way easily and virtually wire initial simple projects. "Any electrician who has ever worked with traditional relay switches and is familiar with a circuit diagram can learn the system and then quickly go into depth with training", says Wöstehoff . New digital perspectives Mapping the logic in digital data opens up new potential for accelerating start-up. The program for the valve controller on the fi rst system was simply copied to a confi guration stick after a successful test and then copied to the fi ve remaining valves that are equipped Compact structure of the control cabinet in an encapsulated control cabinet fi eld connectors. We also weren't as fl exible as we are now", explains Wöstehoff . With PLC logic, the required number of inputs and outputs can now be assigned precisely to the PLC logic combines interface technology and the logic module in one device Using logic modules in an application usually requires separate interface blocks such as relays or optocouplers that are installed before or after the inputs and outputs. The PLC logic relay system from Phoenix Contact combines the logic module with relays that can be plugged in individually. This eliminates wiring eff orts and additional switching elements. A programmer tool that is intuitive to operate helps to implement the application simply and quickly. In addition to the pluggable PLC logic, the solution consists of the PLC-Interface relay system and the Logic+ programming software. The units that were created by plugging in the logic modules onto the relay without any tools continue to off er all advantages of the small coupling relay. This includes the simple bridging of the coil and contact side, various connection techniques as well as replacing worn out relays conveniently and quickly. Due to the integrated logic control, all contacted relays can now be programmed freely. Depending on the relay module used, every connected relay can be confi gured as an input or output. The logic unit therefore is fl exible regarding the number of I/O signals used and thus can be adapted to the respective application. The stand-alone logic module is a device that processes 16 I/O signals on an overall width of only 50 millimeters. To do so, the logic module just has to be plugged into eight relay modules that are in a row. In addition, there are another eight digital inputs on each logic module. Two of these inputs can be confi gured in such a way that analog voltage signals (0 - 10 V) can be processed as well. Should the user require more I/O signals, combining a basic and two extension modules makes it possible to connect a maximum of 48 I/O signals. Every extension module thus comprises the same number of inputs and outputs as the basic module. Phoenix Contact has developed the Logic+ software
UPDATE 2|17 On site 13 Christoph Manegold Web code: #1487 Friedrich Wöstehoff is very satisfi ed with the fi rst deployment based on PLC logic identically. "With conventional relay technology, we had to wire the logic as 'hardware' fi ve times", says Wöstehoff . Even changes to the design in retrospect, often at the last minute, are not as scary thanks to the new fl exibility. This is made possible by simply changing and adding inputs and outputs as well as the quick modifi cation in the software. "Detecting bugs now is more structured and we can issue many more notifi cations to the customer, are more fl exible and can also address special requests. This can now be handled very conveniently", explains Wöstehoff . The control module is simply plugged into an eight-block PLC-Interface for confi guring, parameterizing and programming the PLC logic relay system. With this tool, it is possible to conveniently create the corresponding project on your own PC. It is then sent to the connected device and executed on the logic module. Logic+ supports the user in all development phases of the project – from the planning to the confi guration or programming to program start. The project can either be designed with a ladder diagram (LD) or a function block diagram (FBD). Each channel can be confi gured as an input or output and with relay or analog modules. The inputs and outputs and the logic modules are inserted into the logic diagram via drag & drop. Use the simulation function to easily check and simulate the programmed functions.
14 Technology UPDATE 2|17 Relay modules in the corrosive gas test: Temperature and high relative humidity favors corrosion Safe switching in the potentially explosive area The highly compact PLC-Interface relay family was expanded with Ex approvals Since its launch in 1996, Phoenix Contact has continually further developed the PLC- Interface product range. Electromechanical and solid-state relays are now also available with Ex approvals, which means that many more industrial sectors can benefit from the numerous advantages of the series. for explosive gases from the surrounding atmosphere. Phoenix Contact has extended the portfolio of the PLC-Interface with Ex approvals for this purpose. Therefore, the components can now also be used in oil and gas production, refineries, as well as in the process industry. In industry, potentially explosive environments pose higher requirements on the safety and reliability of the switching components installed than standard applications. The areas of application of Ex switching devices are not restricted to the chemical, oil, and gas industry. Explosive atmospheres may also occur in wood, metal or plastic-processing. The same applies to food production, paper making, in gas turbine construction as well as in the textile industry and water management or in painting systems. Here, the use of standard switching components would pose a risk. Sparks created by switching processes can result in explosions for components that are not encapsulated.Here, too, high surface temperatures may prove a source of ignition Narrow overall width of just 6.2 mm As the standard basis for ATEX and IECEx approval, EN 60079-7 and EN 60079-15 are used in type of protection “ec nC”. Certification in accordance with UL Class 1 Zone 2 (hazardous locations) is granted pursuant to UL ANSI-ISA 12.12. In order to safely perform switching processes in potentially explosive areas and subsequently prevent potential ignition by sparks or electric arcs, all system components must be carefully and thoughtfully selected. In addition to further components, such as fuses, the focus is placed on switching elements, i.e. electromechanical relays.
UPDATE 2|17 Technology 15 The new versions of compact relay modules from the PLC-Interface series fulfill the described requirements and thus ensure safe switching in Ex areas. Broad product range for numerous requirements Ignition of a potentially explosive atmosphere, which is composed of various gases, can be avoided by the maximum defined surface temperature of the equipment. Even in the approval-related tests in full load and directly aligned installation, the PLC-Interface relay modules achieve the optimum temperature classifications T5 (≤ 100 °C) or T6 (≤ 85 °C). The permitted ambient temperature range of Atex- certified relay modules varies from -40 °C to 60 °C (1 changeover contact relay) and even up to 70 °C (2 changeover contact relays). Numerous test scenarios passed successfully The electromechanical and solid- state relays from the PLC-Interface series are sealed according to IEC 61810-7 RT III – therefore watertight as per the definition. Furthermore, they can be installed according to EN 60664-1 in environments with pollution degree 2, whereby the installation in a control cabinet with at least IP54 protection is presupposed. An independent test institute also subjected the relay modules to a four component corrosive gas test under laboratory conditions. EN 60068-2-60 serves as the basis of the test specifications. A corrosive gas concentration specified in standards favors corrosion, in combination with a correspondingly high relative humidity and ambient temperature – in this case, 75 percent relative humidity at 30 °C. The requirements of the ISA standards ISA S71.04-1983 G3 are also fulfilled under these test conditions. Within the scope of the test, the testers have simulated the harsh environmental conditions in a practical manner. Following the maximum selected test duration of 21 days in line with standards, the relay modules had to perform subsequent functional tests as well as microscopic examinations. In particular, metallic materials prove to be prone to corrosion. All the new components of the PLC-Interface product range passed the final check without any issues. Neither impairments to the device function nor to the materials, especially the metals, were found. Aggressive gases can therefore not damage the modules. Their functionality has been fully ensured. Fast installation thanks to the thought-out device design As for all relay modules of the PLC-Interface product range, the well-known feed-in bridges and signal bridges as well as marking material, separator plates, and feed-in terminals can be freely used. This provides for the usual clearly arranged wiring in the control cabinet and The 24 new complete modules have various coil voltages, connection technologies, and performance data saves time during mounting. All components can be aligned directly. The easily accessible connection terminal blocks enable safe electrical connection. And the user is able to flexibly extend or change systems. If an electromechanical or solid-state relay fails, a spare one can be ordered separately for all new complete modules. Florian Sawitzki Web code: #0688
16 On site UPDATE 2|17 A current trend: Building with precast concrete parts Set in concrete with Bluetooth Wireless signal transmission in a concrete factory Wireless solutions from Phoenix Contact ensure error-free communication at the So-Con concrete factories in a harsh industrial environment. The experiences they had with the solutions are so good that the wireless multiplexers are implemented as standard in many production areas. In so doing, numerous Bluetooth systems can be operated in parallel in a single industrial building without interfering with one another. So-Con Leit- und Steuerungstechnik GmbH, located in Asperg, Germany, specializes in automation for these kinds of concrete factories. Since 1987, the company has focused on assembly systems and control technology for the automotive and concrete industries. Fifteen employees plan every project individually in accordance with the requirements from each particular customer as well as according to the newest technical perspectives. The range of services from So-Con spans from consultation about project planning, programming and visualization to the assembly and installation of the corresponding hardware. The So-Con concrete factories are designed in such a way that fresh concrete is transported from the mixing station to the concrete spreaders via bucket conveyors that can be up to 200 meters long. Depending on the concrete element, the buckets may weigh up to a maximum of 3.8 tons when they reach the concrete spreaders. Bucket conveyors generally travel through the halls lengthways, while the concrete spreaders are arranged crossways. The concrete spreaders fill various formwork types quickly and precisely with all kinds of concrete. The filling and spreading processes are fully automatic. The entire circulation system process is controlled by a central PLC. "If we were using traditional trailing cables, communication between the controller and the moving buckets and concrete spreaders would prove to be expensive, prone to failure and require a high degree of maintenance", says Johann Klotz, Executive Vice President of So-Con. The production becomes more efficient thanks to the modern automation technology. The work processes can be planned better. This results in higher delivery reliability of the precast concrete parts in conveyor belt production. Simple forwarding of signals "We became aware of the wireless technology from Phoenix Contact while searching for an alternative transmission solution", says Klotz. This is why So-Con now uses wireless multiplexers as replacements for cables. Using the Bluetooth technology-based devices, signals from the buckets and the concrete spreaders are sent to the central machine control
UPDATE 2|17 On site 17 system. This allows data to be forwarded simply and economically, even in this harsh industrial environment. The centrally installed PLC ensures that the concrete spreader moves independently under the bucket in order to take the concrete. Information about the current position, the container weight, interlocks, error messages and signals for the slider width adjustment is transmitted over the wireless system to adjust the flow of concrete. Due to the good experiences they have had with wireless solutions from Phoenix Contact, So-Con is implementing wireless multiplexers as standard in many production areas of their concrete factories. Parallel operation of Bluetooth and WLAN networks The wireless multiplexer functions wherever a few digital or analog input and output signals need to be communicated wirelessly to a distant or moving station. The device has the IP20 The Wireless MUX transmits Sixteen digital and two analog signals bidirectionally degree of protection and exchanges 16 digital and two analog signals bidirectionally – i.e. in both directions – meaning that it replaces a 40- wire signal cable. The international Bluetooth standard in accordance with IEEE 802.15.1 is used as wireless technology, which functions Production area in a prefabricated concrete factory (Image source: So-Con Leit- und Steuerungstechnik GmbH) in the license-free 2.4 GHz frequency band. Due to the integrated, fast frequency hopping method, communication is robust and reliable. In addition, it will not interrupt possible WLAN systems installed on-site in accordance with IEEE 802.11b/g, since Bluetooth detects the corresponding occupied channels automatically and removes them from its own hopping table. This means that both wireless systems can be operated without interrupting each other, even in immediate proximity. Efficient frequency usage also allows for parallel operation of numerous Bluetooth systems in a single industrial building. Furthermore, the system offers a high degree of robustness and reliability due to its wide ambient temperature range from -25 to 60 °C in operation and vibration load up to 5 g and shock load up to 25 g. In addition, the wireless multiplexer is safe from accesses since the security mechanisms are already implemented in its chip. Additionally, the devices are configured so that they cannot be found by other Bluetooth devices. Benjamin Fiene Web code: #1504
18 Technology UPDATE 2|17 Controllers, fieldbus systems and I/Os require interfaces and transfer solutions for signals, data and power The many faces of round M8 and M12 device connectors Due to the manufacturers, there is a large variety of different, and often proprietary, cabling solutions in industry and process automation. To accommodate the trend towards modularization and flexibility of machines and systems in the framework of Industrie 4.0, hybrid compact connectors are developing into a quasi standard. Individualization thanks to standardization? What may at first sound like a contradiction is in fact a pillar of mass production that will also be competitive in the future. This convergence of established industry standards and new materials, technologies and production processes creates a new degree of flexibility with high conformity. An example is size M8 and size M12 circular connectors. These connectors have long become indispensable for cabling sensors and actuators as well as for transferring signals and data from machines and systems. Since the automation components are becoming smaller in the field, the compact connectors are now also used for supplying power. Phoenix Contact already introduced the M12 Power product range to the market in 2011 for providing power to compact motors and devices. This closed the last gap in the continuous classification of the M12 connector system. For users, this means improved electric safety and safety in line with standards since all components are described bindingly in IEC standards and are inspected and approved by the manufacturers. At the same time, the users can now connect their devices by way of a single and continuous cabling system. In so doing, the M12 standard offers a wide range of uses with a high contact density of up to 17 positions, fast transfer rates of up to 10 GB/s and power up to 630 V and 16 A. Hybrid cabling for simultaneously transmitting signals, data, and power with a connector is now also possible. Non-proprietary standards The latest example for non-proprietary interlinking by way of standardization are the device connectors from the M12 Power
UPDATE 2|17 Technology 19 product range in K, L, and M coding. Phoenix Contact has expanded the four-pos. version in S and T coding with five and six-pos. versions and included them in the IEC 61076-2-111 of the international standard at the same time. A usage-specific and at the same time non- proprietary standard has developed based on this standard – in regards to Industrie 4.0. The Profibus and Profinet PI user organization has now defined the M12 Power with L-coding connector as a standard for the low voltage supply of automation devices with up to 63 V and 16 A. Future-oriented modular system The device connectors are suited both for direct assembly on the PCB using wave, THR, or SMT soldering procedures and device and control cabinet assembly with pre-assembled litz wire up to 2.5 mm². An advantage of the modular system is that all pin assignments of a size have an identical design-in type. This lets device manufacturers implement all PCB connections in a size with a uniform level for the printed-circuit board and the device wall. This standardization lowers product overhead for different device designs while at the same time offering highly adaptive devices that can be integrated in established cabling structures. The Varioport housing screw connections particularly simplify manufacturing and 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, device manufacturers used assembly jigs in the soldering process or the front plates were produced using a precise, yet complex CNC process. This effort was intended to eliminate resulting malfunctions. The tolerance-compensating M12 screw connections are an efficient 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 influences and are therefore well-suited for use in harsh industrial conditions such as decentralized fieldbus distributors. Jürgen Sahm Web code: #1287 M12 Power circular connector: Standard in the low voltage supply of automation devices K-coding L-coding M-coding Five contacts (4+PE) for AC applications up to 630 V and 16 A. Four or five contacts (4+FE) for DC applications up to 63 V and 16 A. Six contacts (5+PE) for AC applications up to 630 V and 8 A.
20 News UPDATE 2|17 Innovation Ventures GmbH focuses on future technologies, such as the application of augmented reality for maintenance Strategic growth Phoenix Contact reinforces its competence for future markets Phoenix Contact has solidifi ed its strategic position in future markets by taking over technology companies in the area of network technology and energy automation. This expansion of the company portfolio is accompanied by stakes in technology startups that receive access to new markets in so doing. With the acquisitions, Phoenix Contact is strengthening its network division, which is considered to be a key technology for digitization. In September 2016, Phoenix Contact acquired Perle Systems Limited, a Canadian company specializing in industrial network technology. This was followed by the acquisition of the Taiwanese manufacturer of Ethernet communication technology in automation, Etherwan System Inc., in April 2017 (see also p. 23). In addition, Phoenix Contact fully acquired Velbert-based Mauell Netzleittechnik GmbH in early April. The company now trades as Phoenix Contact Energy Automation GmbH. With the integration of the automation specialist for energy networks into the Group, Phoenix Contact is driving forward its sustainable growth strategy in the energy market. A separate company was created for promoting and investing in promising high- tech manufacturers in 2015: Phoenix Contact Innovation Ventures GmbH. Start-up help for startups The company has already provided start-up assistance to a number of startups. This includes the Austrian eologix. The company focuses on detecting ice on rotor blades of wind turbines. SecurityMatters B.V. from the Netherlands, another company that is supported by Phoenix Contact Innovation Ventures, focuses on cybersecurity solutions for industrial control systems. Energy Management GmbH Phoenix Contact Innovation Ventures also invested in Windesco, a company based in Boston, USA, that off ers Internet of Things (IoT) solutions for the wind industry. As the latest investment, Phoenix Contact Innovation Ventures bought a share in the Berlin startup smartB Energy Management, which focuses on the energy management in commercial buildings. Christoph Manegold phoenixcontact-innovationventures.com
UPDATE 2|17 New products 21 Cable routing to the control cabinet door The CGS cable guiding system with a swiveling arm facilitates the safe routing of conductors, cables, and cable harnesses to the control cabinet door or to the swiveling mounting frame. The swivel joints, whose patent is pending approval, can be opened and closed without tools. The cables are inserted through the joints or fed through including the connectors. This is easier and saves time compared to traditional installation using cable conduits. The system is designed primarily for standard lines and cables with assembled connectors. Web code: #1146 Web code: #0144 Space-saving surge protection With an overall width starting from 3.5 mm, Termitrab complete off ers the world's narrowest surge protective devices for MCR applications. This means that the protective devices can protect up to 572 signals against surge voltages on just one meter of DIN rail. Protective devices in a narrow design, products with protective plugs that can be tested, signaling, and optional remote signaling modules can be selected according to your specifi c requirements thanks to the product range. The surge protective devices are available both with Push-in connection technology and screw connection. Connectors for safe power transmission WLAN solution for machine building The new connectors of the Push-Pull Advance series can reliably transmit power up to 24 V and 16 A. The design with IP65/67 degree of protection off ers the highest safety in industrial environments. The connectors are equipped with a one-piece zinc die-cast housing that off ers plenty of wiring space for external cable diameters from 6.5 mm to 13 mm. The Push-Pull locking system prevents inadvertent release of the connector. The new WLAN 1100 wireless module makes it possible to install a fast and stable WLAN network at the machine very easily. Featuring integrated antennas and a high degree of robustness, the space-saving module is suited ideally for applications in machine building. The wireless module is as easy to mount as an antenna thanks to single-hole mounting. The connection is made via a Combicon and RJ45 Ethernet connector. Since it does not take up any space in the control cabinet, it can be easily retrofi tted. Web code: #1292 Web code: #1495
22 News UPDATE 2|17 Grow with energy Mauell Netzleittechnik becomes Phoenix Contact Energy Automation GmbH Phoenix Contact now owns 100 percent of Mauell Netzleittechnik GmbH from Velbert. The company, based in Velbert, was founded as a subsidiary of Mauell GmbH in fall last year. Phoenix Contact helped found the new company. Phoenix Contact Energy Automation is headquartered in Velbert Mauell Netzleittechnik is a manufacturer of components and systems and has extensive expertise in the automation of substations and decentral distribution networks. The company with currently 80 employees is based in Velbert. Axel Eberhardt from Phoenix Contact and Dirk Riesenberg from Mauell Netzleittechnik will form the Executive Board. The acquisition will create synergies in research and development. The company has been trading as Phoenix Contact Energy Automation since April. With the acquisition, Phoenix Contact reinforces its market position in the energy sector. Ulrich Leidecker, Chairman of the Management Board of the Business Area Industry Management and Automation (IMA) at Phoenix Contact reports, “With the acquisition of Mauell Netzleittechnik GmbH, we are playing an active role in shaping the changes in energy supply and distribution.”