Category Archives: Control & Industry Solutions

PLC Logic – The Better Smart Relay

From rebuanlim | October 18, 2018

There are numerous smart relays in the market but PLC Logic is perhaps the only one that can have both control and monitoring capabilities while linked to an Apple iPad. This is done by using Bluetooth dongle, which turns the PLC Logic into a modern wireless control system. The range of Bluetooth devices is 100 meters with unobstructed line of sight and this translates to a lot of cost savings for applications that require control and monitoring remotely without the need to spend money for installation of communication devices and cable installation. The best thing is that the app is free from the Appstore. An additional plus point is that the interface looks really cool and clean, similar to what you can expect from an Apple Interface.

The PLC Logic also has versatile communication options to any higher level control system. It can support protocols such as PROFIBUS RS-232 RS-485 Modbus/TCP DeviceNet™ CANopen® PROFINET EtherNet/IP™ with just a change of gateway. With so many protocol options, there is no need to worry if the PLC Logic can support any higher level controller in the market.

One of the advantages PLC Logic has over the many smart relays in the market is that the relays are pluggable and replaceable. This solves the problem of the need to change the whole smart relay module in the event of a faulty relay. This translates to lower replacement cost. More importantly, downtime is greatly reduced and one just needs to change a relay instead of reprogramming the smart relay if the unfortunate relay gets faulty.

Another game changer in the smart relay market is that the analogue cards, both input and output, can be inserted as part of the main PLC Logic module without the need to attach a separate analogue module. This translates into cost savings as well as space savings. The analogue card supports both mA and V in full ranges. Besides that, there is also an analogue input card that supports PT100 or PT1000 sensor.

Last but not least, the PLC Logic comes with an option of full Push In connection technology. This can be found on the PLC Logic controller itself as well as all the corresponding relays that can be supported. The advantage of Push In is evident in applications that are prone to vibrations – you are well assured that none of the wires from the PLC Logic will be loosened.

Choosing the Right Signal Conditioner

From Nguyen Son | September 24, 2018

Leave a reply

Basic 4-20mA current loop Sensors and other devices with 4-20mA current loop output are very popular in industrial fields. We can find them from Process Control to data logging systems. A basic current loop has parts as stated below:

Sensor: a device which draws current from its power source in direct proportion to the value it measures (level, pressure, etc.).
Power source: supplies DC power to sensors or any device in the loop.
Reading devices: a PLC, a controller or data logger which reads the current value provided from the sensor and uses it for the next step of controlling or data logging.

In order to isolate, convert, filter and amplify or duplicate control signals we use signal conditioners. Signal conditioner makes a simple 4-20mA current loop into a field loop and control loop like below:

The devices in both the field loop and the control loop need to be powered. They can be powered by a DC Auxiliary power supply or by another active device in the loop. That being said, we have many types of Signal Conditioners (According to how it is powered or can it supply power for other device) that can be used in this scenario.

Types of sensors

The most common 4-20mA sensors in industrial fields are 4-wires sensors and 2-wire sensors. The difference lies in how they powered.

A 4-wire sensor is an active device which has a separate power supply for itself (from DC or AC power supply).

4-wire sensor

On the other hand, a 2-wire sensor is a passive device which draws power from a DC auxiliary power supply in the loop or from other active devices in the loop (like a repeater power supply signal conditioner)

2-wire sensor

Types of 4-20mA Signal Conditioners:

Passive Signal Conditioner: A passive signal conditioner doesn’t need a separate power supply for itself. It draws power from the field loop or control loop. This means there are 2 types: one powered by a field loop and one powered by a control loop. As passive signal conditioners can cause a drop in voltage in the loop, if there are too many passive devices in loop it could lead to inaccuracies in the measured values. In the picture below is a field loop powered signal conditioner with 2-wire sensor, where the devices in the field loop are powered by an auxiliary power supply.

Active Signal Conditioner: This type of signal conditioner is powered by a separate power supply so it doesn’t cause voltage drops in the loop. It can also provide power for the control loop. For example, an active mini MCR Pro signal conditioner can drive up to a 600 Ohm load in a control loop. The field loop still needs an auxiliary power supply when using a 2-wire sensor. Pictured below is an active signal conditioner and 4-wire sensor. In the control loop is a passive analog input controller.

Repeater Power Supply Isolator: This type of signal conditioner is powered by a separate power supply and it can supply power for the sensor’s loop and also for the control loop (with a maximum load of 600 Ohms). It can be used for 2, 3 or 4-wire sensor without the need of a power supply for the field loop.

So depending on the type of application, we can choose the right 4-20mA signal conditioner. Based on information about the type of sensor, whether the field loop has an auxiliary power supply as well as if the control loop has a passive or active controller, we can choose the suitable 4-20mA signal conditioner.

If you have any questions, feel free to contact us!

Phoenix Contact Bluetooth

From witonosurya | September 13, 2018

Leave a reply

Wireless connectivity replacing rotary slip ring technology

The Rotary Slip Ring is the oldest technology used to transfer power and signals between stationary and rotating structures/equipment. The Rotary Slip Ring allowed free rotation even when the rotating side was at high speeds. Many machines that involve rotation movement, for example in the cable, packaging, paper & tissue industries have utilized slip ring to transmit & receive power and signals.

Rotary Slip Ring is made up of stacks of several rings which are normally made from copper in the rotary side, with a carbon brush touching the ring on the fixed side. This combination allows electricity to flow between the fixed side and the rotating side.

Rotary Slip Ring technology was the only solution in the past for transferring power & signals from rotating equipment, but at the same time, it also brought about the consequences of higher maintenance effort & cost.

The carbon brushes will erode during the operation and need to be replaced regularly. Any impurities such as dust and oil on the surface of the ring will caused greater resistance or even will prevent electrical current from flowing.

Signal transmission requires a stable and constant flow of electrical current. Due to this reason, the digital signal will have a pulse effect when impurities are present and analog signal will have a voltage/current drop.

Factoryline Bluetooth EPA in combination with ILC series can become the solution to these problems. Signal transmission from the rotary slip ring can easily be retrofitted with a short implementation time. Customers can forget about maintenance and the analog & digital signal will flow seamlessly 24/7.

The Bluetooth EPA modules enable fault-free parallel operation with other WLAN systems, thanks to efficient use of frequency gaps. In addition to the automatic coexistence mechanism of Bluetooth, the EPA modules also offer the following:

Low emission mode: for low interference emissions when establishing connections
Black channel listing: allows configuration of up to three WLAN channels whose frequency ranges will not be used by the EPA module

The Ethernet port adapter is the simple solution for enabling the Bluetooth capability of industrial automation devices with Ethernet connection quickly and easily. The IP65 turnkey solution is installed directly in the field and connected to the automation device via an M12 Ethernet cable.

Your advantages:

Compact IP65 module with integrated antenna
M12 connections for Ethernet and power
Easy installation in the field

Axioline E – fast, robust, easy

Axioline E is the I/O system with a block design for field installation. Open to all Ethernet-based communication protocols and available in two different housing versions, Axioline E offers maximum flexibility.

The SPEEDCON fast locking system ensures quick and

easy installation, thereby minimizing assembly times. Axioline E is particularly robust when it comes to mechanical loads, EMI, and environmental influences. The M12 power connector simplifies installation thanks to the reduced number of terminal points and 2 x 12 A in just one cable.

Extend Axioline E in a distributed and flexible way in the field using IO-Link I/O boxes.

If you would like to find out more, feel free to contact us!

Benefits of Signals

From sukayapong | August 23, 2018

Leave a reply

Nowadays, information is necessary in improving productivity. Data collection from devices is one consideration point which Phoenix Contact specializes in. As many of you may know, several of our products have been integrated with signal indicators, such as power supply, Ethernet switch, surge protection etc.

A case in point for the benefits of signals would be for redundancy power supply units

Question: Why are signals so important in this particular system?

Answer: Because of dual PSU redundancy system, we always have spare power source in the event that we face problems from one of two power supply units. The purpose of the other device, which remains fully functional, is to provide a backup supply of energy to the system when the other unit fails. So the signal that indicates the non-functioning status of the failed unit can be sent to other systems which are integrated with this system via dry contact or analogue signals.

Case Study

Imagine systems such as QUINT and ORING [Fig – I], under normal circumstances, if the voltage between two PSU is the same level, the ACB function should be activated to balance supplied current to load.

Fig. 1: System diagram when PSU 2 AC power fails

The signals are meant to display that the redundancy and ACB are functioning normally, and it should be indicated via terminal 13/14 and 23/24 to ORING device, connected via wiring. The indicators also show activity from the PSU side. They include terminal 13/14 and the QUINT V4 model not only includes 13/14, but also includes OUT 1 and OUT 2, indicating the current which they supply to load. All signals have been integrated to DCS or SCADA system.

Fig. 2: HMI indication when PSU 2 AC power failed

Every time when the system detect a fault, all system indicators would be displayed through the monitoring system in the user monitoring screen, triggering SMSes or emails to let operators know and respond to that alarm without any need to send someone to go on site and open the cabinet to investigate what the problem is. Moreover, we can use the data logging and monitoring systems to record any incoming signals in an archive; in case that we need to how frequently and when faults happen.

In this scenario, the verification step is eliminated because the root cause will be indicated instantly via the monitoring system. To collect all the data from this system we only need 6 digital inputs and 4 analogue inputs. It is not too much IO in case we have to compare the benefit against the investment cost.

“Prevention is better than cure”

If you have any queries, feel free to contact us!

Safety Valve Interlocking System

From wendyfoo | August 11, 2018

Leave a reply

The Problem:

In a chemical process plant, emergency situations can be extremely costly, both in terms of equipment and human life. However, under such extreme circumstances, it is rare that operators are able to effectively shut down all of the valves and pumps in the process line.

The Task:

We were given two weeks to install an upgrade to their existing system, along with the programming. The idea was simple – interlock the whole system so that no matter which part of the line the operator was, he/she would be able to shut down the entire system from his/her location.

The Solution:

Human-Machine Interface (HMI)

We integrated Phoenix Contact’s Smart PLC Logic Relay and Human Machine Interface (HMI) into their system, splitting all of their valves and pumps in the process line into three zones. In the event of an emergency situation, the operator need only trigger the relay in one zone to shut down the whole process line.

Why it’s awesome:

Instead of having to run to separate parts of the process line to shut them down individually (and quite possibly realising how much more they need to train their running stamina and cardio over the weekends), all the operators have to do is to trigger the nearest zone. This not only saves time and effort, but more importantly equipment repair costs and human lives. This one-touch-kill-switch also reduces the risk of the operator forgetting to shut down some of the more remote areas of the process line in the heat of the moment, which would undoubtedly lead to higher repair costs.

In addition, our solution boasts the following features:

Easy troubleshooting on HMI with clear indication of which zone the emergency button was activated.
Easy maintenance work with interchangeable plug-in elements.
Reduced risk of system failure.
Allows greater flexibility for future system modifications.
Traceable data logging of system information.

Interested to find out more? Feel free to contact us!

CONTACTRON Hybrid Technology

From William Tan | July 9, 2018

Leave a reply

What happens when relays and transistors are used as one function?

Electric motors are used in a variety of industrial applications for controlling movements. The motors are often started using classic, mechanical contactor circuits. Besides the advantage of the low price, the conventional contactor technology also has major disadvantages such as high space requirements, limited service life and the need for considerable wiring.

The innovative CONTACTRON hybrid technology combines semiconductor and relay technology and thus offers a cost effective and technically superior alternative to the conventional contactor technology. The CONTACTRON solid-state reversing contactor “4 in 1” is the first CONTACTRON product that already works with the hybrid technology. It offers motor protection and a safety function, as well as a complete reversing contactor circuit for a motor – all this integrated in a single device no wider than your thumb.

The wide range includes devices which implement either a simple motor start function (“1 in 1”) or two functions (“2 in 1”, e.g. motor start + safety) or three functions (“3 in 1”, e.g. forward running + reverse running + motor protection).

From the CONTACTRON range, the customer can choose the device that offers the functions required for the respective motor (forward running / reverse running / emergency stop / motor protection).

More importantly, the Contactron has 10 times the service life of the normal contactors.

You will be surprised how much cost savings you will have when you start replacing those faulty contactors within the lifespan of our Contactron.

https://www.youtube.com/watch?v=Ap0iBA-BiqQ

Hybrid Contactors = CONTACTRON from Phoenix Contact.

If you want to know more about this product, please feel free to send us an enquiry at marketing@phoenixcontact.com.sg and a product presentation can be arranged to discuss in more detail.

Tunnel Lighting Control System

From chwong | June 25, 2018

Leave a reply

The need for tunnels is rapidly increasing in major cities around the world. Every day, we might be driving through a tunnel or underpass without actually realizing that we are entering an enclosed area which requires high levels of safety & attention.

One general question from the public is what makes tunnel lights so special? “The lights are only made for lighting up the tunnel, that’s it!”

Well, actually tunnel lights are about more than just lighting up the tunnel. Do you know that tunnel lights are the most critical during day time, when there is the most sunlight? Imagine you are entering a tunnel with no proper lighting control and what you see in front of you is a pitch black hole. This could be very dangerous as you are unable to see if there are any vehicles or objects in front of you.

Apart from that, stage lighting is needed in the tunnel as well. Stage lighting means that the brightness of the lights in the tunnel is being controlled individually or in a group. This process is very important as our human eyes need time to adapt to the change of brightness in the tunnel. Imagine there is no stage lighting and you are entering the tunnel during day time. It is the same effect if you turn on your room lights in a pitch black room conditions. You will be blinded and will not be able to see anything for a few seconds.

How are the lights being controlled? When do the lights know that it is daytime, night time, cloudy, snowy, etc.? The answer is simple – there is a luminance meter outside the tunnel which will measure the luminance and hence determine the condition of the surroundings outside the tunnel. The luminance meter will feedback all the information to a central lighting control unit and it will determine the switching on/off of lights in the tunnel. Conventionally, the lights are being controlled in groups (on/off only) and the brightness of each group of lights is fixed at one level only.

In today’s age of technology, there is a lighting control solution which is able to control the brightness of individual lightings, a “failsafe” mode which engages if there is a breakdown of communications in the tunnel, complete networking, control, monitoring of tunnel lights and many more. Phoenix Contact is able to offer the solutions for BTS (Basic Tunnel System), ATS (Advance Tunnel System) and TCS (Tunnel Control System).

For more information, feel free to contact us!

The Next Gen PLC

From Jiang | May 14, 2018

Leave a reply

Discover the next generation of PLC TECHNOLOGY

With an imminent changing of generations, one can expect “Generation Y” to outnumber “baby boomers” in the coming years. Where the automation industry is concerned, this means that the Gen Y users who are more familiar with high level languages (e.g C, C++ and C#) will increase gradually while on the other hand, the users of traditional IEC 61131 programming language will decrease in years to come. Therefore a user-selectable environment is needed to cater to the development of both types of users from various generations. With the PLCnext technology, program sequences from different programming languages can now be combined into a few different tasks or one single task. High-level language programs therefore become automatically deterministic like a classical PLC program.

PLCnext Technology forms the basis of the new, open control platform from Phoenix Contact. This solution is future-proof, flexible, and perfectly suited for the requirements of the Industrial Internet of Things (IIoT) and Industry 4.0, both for existing users who perform IEC 61131 programming and for users using high-level programming languages. PLCnext technology is the basis of a new, technologically leading generation of Phoenix Contact controls dedicated to the automation business of the future.

Interested to see how this works? Feel free to request a demonstration from us by leaving us an email at marketing@phoenixcontact.com.sg!

https://www.youtube.com/watch?v=ckcMJQ3S5VM&t=12s

Remote Monitoring of Recloser in Rural Areas

From Wayne Yang | April 9, 2018

Leave a reply

In the electric power distribution network, a recloser is a circuit breaker that can be closed automatically after it has opened due to an electrical fault. It is common to find reclosers in overhead transmission/distribution lines to clear commonly occurring electrical faults. Thus, a recloser is able to restore the power automatically to the line without human intervention.

Recloser

The status of the reclosers is critical to utility companies. In large country like Vietnam, there are thousands of reclosers installed throughout the country, many of which are found in rural areas. Maintenance engineers have to travel hundreds of kilometres periodically to check the status of individual reclosers.

The utility company in Vietnam had rolled out a project to upgrade their control system to centralize the monitoring of the recloser in a common location so as to reduce manpower cost and time as well as to improve productivity and efficiency. We recognized that laying hundreds of kilometres of copper or fibre optics cables to gather all the information from the various installed reclosers will cost a lot of time and money. The best solution to this problem: wireless applications. There are several wireless solutions available in the industry; however, using mobile connection is the only solution due to the large territorial distances and areas. We decided to propose our new TC Router.

TC Router

We presented and tested our TC Router with the system integrator highlighting the following points:

Extended temperature range, -40 °C to +70 °C (Ensures reliable operation even in the most extreme temperatures)
VPN connection and integrated firewall (Ensures secure connection)
Fallback to 2G (Ensures reliable connection)

Our customer was very pleased with our solution and had gained approval from the end user. Subsequently, we were awarded with the first batch of orders for 100 units of TC Router. Beside the energy industry, our TC Router can also be implemented in other industries such as Process, Water and Waste Water treatment as well.

If you are interested in learning more about our TC Router, feel free to contact us and we will get back to you!

HCS Handheld Housing

From beau | April 2, 2018

Leave a reply

The housing for portable devices

HCS is one of the devices from Phoenix Contact’s housing series. The ergonomic and lightweight design is suited for mobile operations such as real-time measuring of data, inspection and scanning devices.

Membrane keypads and display screens can be easily integrated into the HCS housing for ease of operating. HCS comes in many shapes and sizes, so customers can choose a suitable design, depending on the intended function and PCS sizes.