Automation and electrification from a single source

Green hydrogen is set to replace fossil fuels in many industries, and Enapter AG has developed the AEM Multicore to make production cost-effective and flexible. Phoenix Contact experts assisted in engineering, programming, and outfitting the electrolyzer system with key components for automation and electrification. Green hydrogen’s intrinsic value stems from its ease of storage and on-demand transportation. Enapter specializes in AEM “anion exchange membrane” electrolyzers, which are more cost-effective than PEM electrolyzers while being just as flexible. The company plans to mass-produce these stacks in the medium term using a highly automated process.

Fully developed AEM stacks for series production

Enapter has introduced the AEM Multicore 450, a modular, preassembled container capable of producing up to 450 kilograms of hydrogen per day. The multicore consists of 420 AEM stack modules, each with a 2.5-kilowatt power, allowing for greater flexibility and greater process redundancy. The container also includes power supply, regulation of the electrolysis process, heat dissipation, and monitoring of process parameters, including hydrogen purity, through sensors. The fully developed stacks have already been sold in large quantities.

Close collaboration in the area of functional safety

Phoenix Contact supported Enapter, a company that developed a power supply and controller for a 1-megawatt system. The company’s services range from the development of the first small test system to the commissioning of the 1-megawatt system. Phoenix Contact’s project manager, Ayhan Birinci, highlighted the importance of functional safety in these projects. The team started working on a risk assessment before the design phase, which laid the foundation for essential design elements, including the controller. The software for the safety controller was compiled by Phoenix Contact engineers. Andreas Lautmann, Business Development Manager for power-to-X, emphasized the importance of a structured, well-documented process for design and engineering for the safety of the overall system. Furthermore, two Phoenix Contact programmers assisted the Enapter team in building a smaller test system with ten electrolysis stacks.

A challenging market situation, particularly regarding microchips

The team worked on planning control technology, which was revised seven times before the control cabinets were built. The departure of the original system planner in spring 2022 added extra work. The final changes were made during the design freeze in December 2022. Constructing the control cabinets was challenging due to supply chain issues, particularly with microchips. Phoenix Contact and Enapter worked together to keep the ambitious commissioning date, with the AEM Multicore 450 system inaugurated on May 24, 2023.

Control cabinets fully equipped with Phoenix Contact components

Phoenix Contact has installed components and systems in an electrolyzer, including connectors for sensors and controllers, and a PSU compartment for control. The control cabinets are equipped with Phoenix Contact components, including real-time and safety-oriented control technology up to SIL 3. The superordinate system controller is built with PLCnext products, fulfilling functions like ventilation, water pretreatment, emergency shutdown, fill level monitoring, and electrolyte solution supply. In-house 24 V DC power supplies, signal converters, and connection technology are also included.

Compact AC/DC converters

Phoenix Contact’s Charx power system converts 400-volt AC voltage into direct current for electrolysis. The original converters were not suitable for controlling electrolysis, leading to a replacement with a Charx series converter. The converter is more compact and efficient, ideal for installation in larger systems. Enapter ordered a complete set of AC/DC converters in mid-2022, enhancing efficiency and optimizing the PSU compartment’s cooling system.

Smooth modification of the first system

Enapter has received orders for seven more AEM Multicore systems since its first system was inaugurated in May 2023. Phoenix Contact is also able to play its part here by supplying a complete solution package of services. Enapter CEO Sebastian-Justus Schmidt stated that AEM technology will make hydrogen more economical than fossil fuels. Pre-series maturity for AEM Multicore is projected for 2024 due to strong demand. Andreas Lautmann expects IT security importance with IEC 62443 certification and integration into existing systems.

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A Digital Factory approach that conserves resources and is economical at the same time

Phoenix Contact focuses on sustainability and balancing its carbon footprint by developing automation solutions. The company aims to help other manufacturing companies achieve carbon neutrality by electrifying loads, creating energy transparency, and using renewable energies in daily operations. The All Electric Society concept describes a future where renewable energy is available worldwide in sufficient quantities and economically. Phoenix Contact’s holistic digitalization concept, “Digital Factory now,” integrates consumption data into distribution, visualization, and control of process data, aiming to control energy consumption and achieve carbon-neutral production.

Recording, evaluating, and managing loads

Phoenix Contact has developed an architecture called “More than Measure Energy” to integrate existing systems into modern IT systems. This architecture includes a Data Collection Box for secure integration of process and consumption data. Users can choose between a standardized Data Collection Box or a fully customized version. Phoenix Contact uses a programmable logic controller (PLC) from the PLCnext Control product family in its Digital Factory at the Bad Pyrmont location for secure communication with the OT world and IIoT devices. The company also provides solutions in the immediate production environment as well as its own EMMA cloud service for energy management.

Turning findings into optimization measures quickly

A soldering system in the Digital Factory in Bad Pyrmont integrates energy-saving measures by analyzing energy data from a Data Collection Box. The system identifies standby energy consumption and allows for dynamic switch-off and switch-on times based on order data and energy data analysis. This allows for more efficient order planning in the long term. Phoenix Contact’s “MLnext” machine learning solutions can help predict field-level information, such as manual workstation utilization status, ensuring data availability. A holistic approach to optimization involves collecting and analyzing data throughout the entire production process using AI-based algorithms.

Energy data reflects the system behavior

Energy data can be used to evaluate machine performance, availability, and product quality using artificial intelligence (AI). Anomalies can be detected and quantities and operating states can be predicted. Collecting and storing data benefits users differently, accelerating the payback period and revealing potential. The Big Data approach applies, focusing on data-driven patterns and providing suggested solutions to domain experts. Collecting energy data leads to direct and indirect benefits, ensuring resource-efficient and competitive production.

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Cost-saving solution with lots of potential

G.hn technology expands network range and speed by extending the physical limitations of Ethernet transmission. This enables distances of up to 1000 meters over simple 2-wire cables at a maximum data rate of 1 Gbps. This technology is beneficial for industrial applications, such as computers, automation controllers, surveillance cameras, traffic regulators, building automation, and household appliances. It provides longer communication paths and a more simplified cabling structure.

High data rate and good transmission quality

G.hn, or Gigabit Home Networks, is a carrier frequency method originally designed for home networks. It offers high data rates and good transmission quality on every line. It can adapt to existing line attenuation. Moreover, it can bridge cable lengths up to 1000 meters, This value exceeds the standard Ethernet range by a factor of 10. G.hn offers greater flexibility for retrofitting systems and simplifies network structure, allowing complex topologies to be implemented even with passive connections. Thanks to these benefits, the end result is a standard that will become more important in future industrial, infrastructure, and IoT applications.

Further use of the existing cabling

Phoenix Contact’s new Gigabit Ethernet extender product family allows users to convert Ethernet communication to G.hn communication. This reduces effort and costs. The technology allows for the use of various transmission media, such as twisted pairs, coaxial conductors, or unused power cables, making it a cost-saving alternative to fiber-optic cables for Ethernet connections exceeding 100 meters.

Especially suitable for video surveillance systems

G.hn technology is ideal for applications with high data volumes, such as those found in video surveillance systems due to its bandwidth and transmission distance. It can integrate remote cameras with high bandwidth requirements into the network, reducing the distance between cameras and network components. This technology replaces analog cameras with IP cameras. Consequently, allowing existing cabling to be used and maintaining high video image resolution without sacrificing resolution.

Easy plug-and-play installation

G.hn, a technology that distinguishes itself from other technologies like SHDSL, VDSL, and SPE, describes both the physical layer (first layer) and data layers (second layer) of a network. This way, G.hn opens up the option to build and manage more complex network topologies. Phoenix Contact’s Gigabit Ethernet extenders allow you to interconnect network devices in various topologies, including line, star, and tree structures. They can manage up to 15 devices, which do not require any settings to be made, However, users should note that the maximum data rate of 1 Gbps may decrease as the number of extenders increases.

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Less fossil-fuel energy and lower emissions

Phoenix Contact offers a solution for energy-intensive glass manufacturing to achieve Net Zero climate goals, using PLCnext Technology’s IIoT framework. An auxiliary heating system was integrated into a glass plant in Egypt in 2009 to enhance glass quality and reduce emissions. This decision now plays a crucial role in transforming the glass industry into sustainable factories amidst rapid changes driven by factors like climate change and digitalization.

Capturing all utilities efficiently, and intelligently, with minimal process interventions

The “All Electric Society” envisions a world where renewable electrical energy is the main energy source, abundant, cost-effective, and environmentally friendly. Industries, like glass manufacturing, must adapt their processes across various areas, from raw materials to production, for sustainable climate strategies. Existing factories using different media face challenges, especially in optimizing fuel and water use efficiently and resourcefully. These improvements should be applied in both traditional and modern networked factory settings.

ML-supported process optimization with the PLCnext Technology

Early detection of anomalies in sensors and actuators along the glass manufacturing process brings several benefits. Firstly, it prevents disruptions, allowing for uninterrupted production. Secondly, it improves equipment efficiency, resulting in cost savings. Additionally, it optimizes fuel-air ratios and electrical heating, reducing energy consumption. Furthermore, it enables smart monitoring of various parameters for enhanced process control. To assist specialists in process optimization, Phoenix Contact offers MLnext, a machine learning system available on the PLCnext Store online marketplace. To ensure global accessibility, Phoenix Contact has introduced the Digital Factory Now initiative. This initiative provides open and standardized automation solutions based on PLCnext Technology. Consequently, it facilitates tailored solutions, from glass production to building-specific applications, in alignment with the goals of the All Electric Society.

International certification for safety and security

The OT Security certification of the PLCnext Control family by TÜV Süd, aligned with IEC 62443-4-2, along with existing safety certifications, establishes new industry standards. IEC 62443 is the primary global standard for OT security, while functional safety is defined by standards like IEC 61508, ISO 13849, and IEC 62061. Future automation solutions must bridge both perspectives. Due to the need for protection against tampering and remote access considerations, OT security is gaining prominence in the upcoming Machinery Directive. The certified PLCnext Control family already complies with the Machinery Directive requirements.

Field-side signal connection using smart signal conditioners

Users want to optimize fuel-to-air ratios securely using a parallel sensor system or their DCS. They aim to incorporate AI and implement a segmented network per IEC 62443. This is achievable by connecting signals through PLCnext Edge Devices or utility metering control cabinets, enabling real-time data exchange with IT/cloud, ERP/MES, or DCS systems. The glass industry can now advance sustainability and secure networking with these solutions.

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Narrow Ex i signal conditioners with functional safety for all signal directions and types

Phoenix Contact has introduced the Mini Analog Pro series to address issues related to intrinsically safe explosion protection and functional safety in process plants and power-to-X systems. Furthermore, these devices offer slim designs, user-friendly operation, and support various signal types, including analog, digital, control, and measuring signals. Moreover, they provide intrinsically safe explosion protection and SIL 3 functional safety for all signal directions and types in a compact 6.2-millimeter width. As a result, this eliminates the need for redundant SIL 2 components in SIL 3 applications. Additionally, these products hold international Ex approvals, making them suitable for global use.

Space savings of at least 50 percent

The Mini Analog Pro series offers slim signal conditioners and measuring transducers for space-efficient signal processing in process technology. They reduce cabinet space needs by at least 50% and feature front-facing terminal points, coded connection blocks for easy replacement, and an integrated disconnect function for servicing, all while maintaining stability in demanding applications.

Current measurement without disconnecting the current loop

The Mini Analog Pro series terminal blocks simplify current measurement without the need to disconnect the current loop, ensuring uninterrupted operation. These devices have integrated current measuring points in their connection terminal blocks, allowing safe current measurement. They are designed for safety-related applications according to IEC 61508, achieving SIL 3 safety integrity levels in single-channel (1oo1) configurations.

Wide temperature range and extended altitude range

The new circuit technology in Mini Analog Pro devices allows them to operate from -40°C to 70°C, covering all signal types, unlike most wider devices on the market. These products also simplify use at high altitudes by documenting suitable Ex i values up to 5,000 meters, reducing user calculations.

Wide range of configuration options

The Mini Analog Pro series offers versatile configuration options for its devices. Users can connect them to a PC for setup using an isolating programming adapter, while the ClipX Engineer Device Parameterization software simplifies configuration with step-by-step wizards. Additionally, a free classic FDT/DTM solution supports manufacturer-independent configuration. These devices also support configuration via DIP switches and a built-in NFC chip, and a new Signal Conditioner app with extended features is available for iOS and Android.

Easy integration into existing systems

The Mini Analog Pro series is compatible with the MACX Analog product family, offering versatile options for signal conditioning and measuring. These devices are intrinsically safe and functionally safe (SIL 3 1oo1), suitable for safety-related applications in extreme conditions. They integrate easily into existing systems, providing comprehensive solutions for functional safety and explosion protection.

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End-to-end safety from the sensor/actuator to the controller

IO-Link technology has become crucial in machine and system integration due to its ability to enhance data collection from sensors and actuators. In 2021, over 6.3 million IO-Link devices were installed, totaling more than 27 million to date. However, while IO-Link offers benefits, it previously lacked a safety solution for integrating safe sensors and actuators. The release of IO-Link Safety expansion V1.1.3 in March 2022 addresses this by allowing the use of IO-Link Safety masters and devices for a standardized and integrated solution in automation systems.

Manufacturer-independent use of IO-Link Safety devices

Since 2016, automation has witnessed safety-over-IO-Link solutions dominated by manufacturers, which deviate from IO-Link’s core principles. For instance, PROFIsafe-over-IO-Link devices are limited to matching masters and the PROFIsafe system. In contrast, IO-Link Safety offers benefits like network independence, standardized connections, configuration via IODD, and interchangeable devices. It’s versatile, as IO-Link Safety devices, following specifications, can be used with any manufacturer’s IO-Link Safety master, giving users flexibility in device selection.

Flexible use of the IO-Link Safety master even for the standard IO-Link

IO-Link Safety solutions provide flexibility with the master functioning in classic IO-Link mode. Future developments may enable mixed operation for additional information transmission, especially useful in complex control units. This emerging standard envisions a single device combining IO-Link and IO-Link Safety, simplifying functions and data transmission through the IO-Link Safety master. This concept is expected to expand to devices like light grids, laser scanners, and IO-Link Safety hubs, offering similar advantages.

Various configuration options for the IO-Link Safety ports

The IO-Link Safety system expansion offers extensive configuration options for each IO-link safety port through “Feature Levels.” These ports can handle safe and non-safe digital signals with modes like IO-Link, IO-Link Safety, and a mixed mode, enhancing flexibility. For instance, users can configure a Class A port to support IO-Link, IO-Link Safety, or both, Digital output (DO), and Two-channel safe digital input (FS-DI). The system expansion also includes Class B ports that will supply higher current to IO-Link devices in the future. This standard enables a smooth migration of existing safety solutions in the field and ensures a future-proof approach for implementing their digitalization strategies.

Easy parameterization with IODD

Introducing the new IO-Link Safety standard has integrated functional safety into the benefits associated with IO-Link technology. Users can easily configure parameters using IODD, and they can align device replacement with IO-Link’s core advantages. IO-Link Safety is emerging as a crucial element in connecting sensors and actuators to the control level in machine building. Multiple suppliers are expected to introduce IO-Link Safety masters and devices in 2023. Ultimately, this standard offers a manufacturer-independent pathway for users in the realm of machine and plant digitalization.

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Data-driven analysis options for the factory

Data-driven analysis of production systems enables predictive insights for machine condition, energy use, and performance. Furthermore, As a part of the “Digital Factory now” concept, Phoenix Contact offers modular hardware and software solutions for independent data acquisition. Control cabinets like Data Collection Box and Secure Edge Box integrate with existing infrastructure, with adaptable source code. Moreover, open-source tools like Grafana, Node-RED, and InfluxDB enhance flexibility.

Creating, training, and executing machine-learning models with MLnext

Once the data has been stored in a database, the user can use the MLnext software portfolio from Phoenix Contact to create, train, and execute machine-learning models. With the MLnext Framework, developers can evaluate time series data, while the MLnext Creation app offers ready-made templates for model creation and testing. The MLnext Execution app allows model creation without programming, supporting the entire application cycle for uncovering potentials and issues.

Planning needs-based maintenance measures

The condition-based maintenance system uses energy and process data to plan maintenance based on the condition of the system, creating a digital system representation. Furthermore, data is collected by the Data Collection Box, standardized, and sent to the Secure Edge Box. A time series database archives the data, which can be visualized via a web app. Users can then use MLnext Creation to build a machine-learning model for comparing normal behavior during production.

Visualization of the actual health, process, and consumption data

The created machine-learning model is stored and used for predictions. MLnext Execution on the Secure Edge Box evaluates system data in real time. If the model detects an anomaly, alarms are triggered via email or message. This proactive approach helps prevent downtime and enhances maintenance planning, ultimately increasing production availability.

Reducing or preventing system downtimes

At Phoenix Contact PLCnext Factory, a condition-based maintenance system monitors energy usage in production, tracing anomalies and reducing downtime. MLnext also analyzes critical supply units to prevent wear-related downtimes. The “Digital Factory now” concept predicts product quality and reduces rejects during restarts.

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Solving the challenges of the future with swarm intelligence

The significance of interdisciplinary collaboration between a company’s internal and external experts is increasingly recognized as essential for solving complex tasks efficiently. The PLCnext Community from Phoenix Contact exemplifies this approach in the open PLCnext Technology ecosystem. Just as collaboration is crucial in building a house with various specialists, it’s similarly vital in today’s digitized work environment across industries. Challenges like skilled worker shortages highlight the importance of cooperation among employees. In the automation industry, developers and engineers face intricate technological problems, often requiring collaborative efforts. This is especially valuable in new business areas where a company lacks experience. Online forums and digital communities facilitate information exchange and experience sharing among developers.

Reducing travel and office costs

In the 1970s, digital exchange methods existed even before public Internet access. In 1979, students from Duke University created Usenet, a virtual platform for cross-border forum-based collaboration, using the UUCP protocol. Organizational psychologist Prof. Dr. Guido Hertel from the University of Münster highlights the benefits of internet-based collaboration, such as international teams working across time zones and involving experts with minimal costs. Virtual collaboration reduces travel and office expenses, and the rise of online meetings due to COVID-19 has made web-based video conferences normal. With increasing home office adoption, network-based collaboration tools like Slack, Wire, and Rocket are gaining importance.

Increasing sales growth

A notable trend is the increasing reliance on cross-functional collaboration by large, globally operating companies as part of their digital transformation. A 2020 Accenture study found that companies using this approach achieved more than double the sales growth compared to those that didn’t. Effective collaboration across functions reduces costs and leads to measurable returns. Companies benefit even more in innovation and speed when they involve external partners in their development processes, alongside internal efforts. This shift turns a closed company system into an open ecosystem, tapping into external knowledge and creativity. Deloitte highlights this openness as a critical competitive advantage in the fast-paced digital economy.

Platform for subject-oriented exchange

The terms “collective intelligence” and “group/swarm intelligence” refer to intelligent decision-making through collaboration among individuals, often observed in decentralized systems with non-hierarchical cultures. Phoenix Contact exemplifies this with PLCnext Technology in industrial automation. It reimagines automation for digital transformation, using a Linux-based real-time-capable PLCnext Runtime System that’s open to various protocols and tools. The PLCnext Store, an online marketplace, enables exchanging reusable blocks and apps, fostering collaboration. The PLCnext Community supports this ecosystem, aiding users in using the hardware and software, sharing experiences, and enabling project success. Notable examples include students using community resources to measure social distances and companies benefiting from shared insights for automation app development.

Project for protecting bees

The PLCnext community is working on a sustainable project with the “Beehyve” campaign to protect bees using advanced automation. ChatGPT, an AI-based system, represents a new form of collaborative technology. Phoenix Contact has been working in collaboration with its customers, the science community, and society ever since it was founded 100 years ago.

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Easy qualification of time-sensitive networking (TSN) solutions

The Linux OS, especially with PREEMPT-RT, is widely used in automation devices, with growing popularity. Recent Linux versions support Time-Sensitive Networking (TSN). Phoenix Contact’s PLCnext Tech ecosystem, based on RT Linux, supports TSN on suitable Ethernet hardware.

Testing hardware uniformity in Linux for easy integration into systems like PLCnext Control is the next step. Linux-based automation devices consist of hardware (CPU, TSN-capable MAC, PHY), kernel (core functions, network driver), network interfaces, industrial middleware (e.g., Profinet, OPC UA), application, and synchronization.

TSN’s key feature is precise application synchronization. Recent kernel versions integrate Ethernet TSN mechanisms in RT Linux, benefiting manufacturers by enabling neutral TSN solutions without specialized hardware. The presented test environment validates implementations, promoting TSN’s simple and robust use in Linux-based devices across manufacturers, driving wider Time-Sensitive Network adoption.

Testing on widely used TSN-capable network chips

The responsibility for TSN implementation under Linux has shifted from device manufacturers, like Phoenix Contact, to chip manufacturers. Consequently, an automation device’s performance and quality hinge on the underlying TSN hardware and software. This shift has prompted device manufacturers to develop their network drivers to ensure the desired quality. In some cases, specific hardware, like FPGAs, is required, adding expenses and making hardware changes during a product’s lifespan more complicated.

Hence, the opportunity for independent hardware and driver validation from chip manufacturers before device development and hardware setup is particularly appealing to device manufacturers. Chip manufacturers with TSN solutions not tied to specific automation applications also share this interest.

With Linux now incorporating essential TSN functions, the need for an autonomous TSN test environment has arisen. In response, Phoenix Contact collaborated with chip manufacturer Intel to design appropriate test tools, testing them on widely used TSN-capable network chips. These tools will be eventually released as an open-source solution within a suitable organization, serving all interested parties. This approach enables chip and device manufacturers to validate their respective TSN products. Additionally, the tools can aid in comparing solutions and educating customers or research entities about TSN.

Performing highly accurate measurements of runtimes and deviations

To independently qualify a chip manufacturer’s TSN solution, an emulation replaces the industrial middleware and application. This emulation simulates the behavior of an automation device. After successful testing, the emulation is substituted with the manufacturer’s middleware and device application.

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Smart device connections

Fire alarm systems play a critical role in ensuring building and occupant safety against fire hazards. These systems involve numerous connection points and interfaces, making intuitive and time-saving conductor connections essential during development, alongside connection security considerations.

Standards like DIN 14675-1, DIN VDE 0833-1, and DIN VDE 0833-2 define the planning, installation, operation, and maintenance of fire alarm systems. The fire alarm control panel serves as the central hub, connecting signal lines from fire alarms and internal alarms. Interfaces automate device and air conditioning control, manage extinguishing, voice alarms, smoke, and heat ventilation, and assist transmission units.

Diverse fire alarm types are installed based on building size, layout, and environmental factors. Elements such as the fire’s nature, room structure, and disruptive influences impact selection. To minimize false alarms, appropriate fire alarms like point heat detectors or manual alarms must be chosen and configured.

Specialized applications utilize air intake and linear smoke alarms, equipped with features for reliable detection. These smart device connections allow fire alarm systems to be tailored precisely to specific building circumstances, enabling swift and dependable fire detection in early stages.

Developers and product managers are in control

Examining connection ergonomics during the initial stages of field device development is undeniably advantageous. This process entails evaluating the choice between fixed connections and connector solutions, while also taking into account factors like installation location and protection requirements. Moreover, developers should proactively tackle technical considerations such as connection sizes, voltages, currents, and pitch at an early stage. By anticipating installation conditions and future maintenance needs, developers can intelligently guide device customization, thereby efficiently streamlining the entire installation and upkeep process.

Smart device connections make work easier for everyone – from the installers to the operators

Phoenix Contact offers PCB terminal blocks and connectors for fire alarm systems, notably incorporating advanced lever-Push-in and Push-in connection technologies such as PTS, SPT(A), LPC, and LPT(A) series. This facilitates easy and tool-free connections, accommodating both flexible and rigid conductors. Furthermore, the availability of THR variants serves to enhance automated assembly processes, effectively reducing associated costs.

Secure – you can count on it

Phoenix Contact’s LPT and LPC PCB terminal blocks and connectors feature spring-actuated contacts for reliable connections. Furthermore, an indicator lever shows clamping status, effectively preventing errors. Moreover, the preprogrammed spring force ensures stability without torque-related issues. Notably, these components meet international standards, including UL 1059, greatly simplifying approval for global markets.

Phoenix Contact’s cutting-edge smart device connection technologies simplify fire alarm system installation, reducing costs and ensuring global reliability. Push-in connections benefit manufacturers, installers, integrators, and operators by boosting reputation, expediting work, and enhancing system availability.

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