Category Archives: Industry Cabinet Connectivity

6 Reasons Why Phoenix Contact PLC-Interface Relay Is No. 1 in the Market

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An experienced electrical engineer will be very familiar with compact relays. There are plenty of brands in the market and they are essential in many applications. Today, we are going to share with you why Phoenix Contact PLC-Interface relay is the cream of the crop.

  • High reliability by having no soldering points

Unlike most compact relays in the market, Phoenix Contact PLC-Interface relay is made up of a single metal stamp circuit without any soldering points. Soldering joints are generally lower in strength and are advised to be used in high temperature applications. Corrosion might happen if the flux residue is not removed. Thus, by removing the weak solder points, we increase the reliability of our PLC-Interface relay.

  • Push-in Technology increases efficiency

We cannot imagine the time without Push-in Technology. It saves up to 80% wiring effort as compared to the good old screw connection. It was first implemented in Phoenix Contact terminal block and has slowly taken over as the preferred connection technology in most of Phoenix Contact products. Using a simple spring mechanism with a striking orange button, Push-in technology has won the hearts of many users. It is now available in PLC-Interface relay.

  • Compactness and modularity saves space and reduces downtime

Real estate in the control cabinet is extremely precious. We are always trying to fit as many components as we can into the smallest possible control cabinet. With just 6,2mm thickness, you can fit over 160 pieces of PLC-Interface relay on a 1-meter DIN rail. By keeping the control cabinet small, you can save on the material cost. The modular system also ensures easy replacement of the relay in case of wear and tear. The pluggable relay reduces downtime needed for repair and maintenance.

  • Wide variety of accessories provides ease of wiring

Phoenix Contact PLC-Interface relay comes with many accessories such as built-in bridges for convenient distribution. This makes installation and wiring faster as compared to doing it manually with wires. We also have a wide range of marking materials for easy and appropriate labeling of the relays.

  • High availability with solid-state relay and other features

Solid-state relays are almost wear-free as they do not rely on mechanical movement to perform the switching. This gives the PLC-Interface relay a long service life. With integrated circuitry, PLC-Interface relays are protected against reverse polarity. Safety is further enhanced with the safe insulation between input and output (EN 50178). PLC-interface relay works well even in harsh and aggressive conditions. Rated IP 67, it is resistant against moisture and dust.  

  • We make smart relays smarter with PLC logic

Phoenix Contact is the pioneer to combine logic, interface and field connection. It gives the device the ability to switch and control the I/O signals, and combines the relays with analog modules. All can be achieved by simply plugging in a small controller into a standard PLC-Interface. With the width of 50mm, the small module provides up to 16 I/O signals. Extension modules can be added to increase up to 48 I/O signals. An intuitive software, Logic +, is also available for quick programming of the logic relay system.

Besides PLC-Interface relay, Phoenix Contact provides the best switching devices for all applications. To know more about the switch devices we have to offer, feel free to contact us at marketing@phoenixcontact.com.sg!

Sensor Actuator Cabling for Smart Manufacturing

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Source: https://commons.wikimedia.org/wiki/File:Fotothek_df_ps_0000315_Montagehalle_einer_Maschinenfabrik.jpg

Machine building has evolved greatly over the years. Traditionally, it was classified under heavy industries, usually on a smaller scale and served mostly local or regional areas. However, as a result of the industrial revolution, machines became larger and more complex. The process of producing machines had also become more complicated as well.

Automation is adopted to reduce the production cost and increase productivity. It also lessens the reliance on labour and improves the reliability and quality of machines. All the above mentioned qualities are needed for modern day machine makers to stay competitive in the market.

Data acquisition becomes crucial. In machine building, data such as temperature, pressure, speed and proximity etc. can be attained via sensors. These sensors collect information and send them back to the control system.

In the beginning, the sensors were wired directly to the control system without any organisation. This method of connection is messy. It also makes troubleshooting and maintenance difficult as it is challenging to isolate the defective sensors when a fault occurs. In addition, this way of connecting sensors requires a large amount of cables, leading to increased manufacturing cost of the machines. In many cases, cables take up the bulk of the cost involved in the set up.

As a result, more and more machine builders start to adopt sensor and actuator cabling.  In sensor and actuator cabling, the sensors are connected to a distribution box via circular connectors. The distribution box is then connected to the control system via one master cable. Sensor and actuator cabling greatly reduces the amount of cables required in a set up. It also makes troubleshooting and maintenance easier. There is a LED light indicator (which turns red when a malfunction occurs) and a labelling option (for easy identification of the sensors) for each sensor on the distribution box.

Phoenix Contact offers a wide range of products, from distribution boxes to self-assembled connectors, for sensor and actuator cabling. The self-assembled connector comes with different connection technologies to minimise the installation time and eliminate the use of special tools. We advocate choosing the connection technologies based on your applications. Phoenix Contact had also incorporated the famous Push-in Technology into the self-assembled connector. It could be used with or without ferrules, depending on your preference.

If you prefer pre-fabricated connectors, Phoenix Contact can also cater to your exact needs. We offer different cable materials, from polyvinyl chloride (PVC) to high specification robotic cables of customisable length and a wide variety of header types. Other customisation options such as colour, printing and labelling can be done as well.

Furthermore, Phoenix Contact has a wide array of accessories such as distributor connectors, adapters and valve plug connectors as we strive to be the one-stop provider for sensor actuator cabling solutions.

Interested to know what we can provide for your applications, write to us at marketing@phoenixcontact.com.sg to request for a roadshow to know more!

How Many Cables Can a High Density HEAVYCON Connect?

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It is no secret that HEAVYCON is a great way to install and uninstall control cabinets as it saves you time and money. With HEAVYCON, the time taken to install and uninstall a control cabinet is reduced by 40% while labour cost is reduced by 30%. For applications where re-terminations are required, the savings on time and labour costs are even higher.

This is especially so with HEAVYCON modular, as it provides flexibility and allows for customisation without charging premiums. You can choose any signal, data and power modules from more than 50 modules in our product portfolio and snap them in easily into the newly improved snap-in frame.

When HEAVYCON meets Push-in Technology

Push-in technology is a direct and tool-less connection technology developed by Phoenix Contact. It uses a special contact spring for easy insertion of cables. It was first used in Phoenix Contact terminal blocks. The recognisable bright orange release button enables easy disconnection of cables using simple tools like screw drivers.

Push-in Technology has since been incorporated into HEAVYCON. This is basically an installer’s dream come true as it shortens installation time even more and make HEAVYCON even easier to use.

In 2018, Phoenix Contact had come up with a high density HEAVYCON module with Push-in technology.

This is the game changer as it allows for connection of up to 12 cores cable per module. Combined with a 6-slots frame, it can accommodate up to 72 cores cable in one single connector. This is the highest density heavy-duty connector with Push-in technology in the market to date. Such high density is only achievable via crimp technology in the past, which can be expensive due to investment in the special tools needed.

Also new, the M1 housing caters for application where only one specific module is needed. It eliminates the need for the snap-in frame which reduces the cost of ownership. Now you can get the same amount of convenience and flexibility with less amount of money.

For more information on the development of HEAVYCON with Push-in technology, stay tuned to our blog! If you have any queries, feel free to contact us at marketing@phoenixcontact.com.sg!

Plastic VS Aluminium – Heavycon Edition

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Heavy-duty connectors are typically made of aluminium as it is supposed to be tough and durable. However, being an innovative company and discontented with the current industrial norm, Phoenix Contact had come up with HEAVYCON EVO in plastic.

The plastic used in HEAVYCON EVO housing is not just any normal plastic, it is made of polyamide, reinforced with glass.

So, how strong is strong? Several tests were done to the plastic HEAVYCON including basic IP and NEMA tests in accordance with DIN EN 60529, NEMA 250. This ensures that the contact inserts within the plastic housing are protected against the ingress of dust and heavy jet water. The other tests include:

Vibration test in accordance to IEC 60068-2-6

Harmonic, sinusoidal vibration is applied to HEAVYCON plastic housing to simulate rotating, pulsating or oscillating forces. HEAVYCON plastic housing fulfils these requirements, making it ideal for heavy machinery application.

Temperature shock test in accordance to IEC 60512-11-4

We simulate significant temperature changes by switching HEAVYCON plastic housing between 2 chambers of extreme temperatures within seconds. The result is affirmative – HEAVYCON plastic housing is suitable to be used in applications with ambient temperature between -40 to 125 degree Celsius.

IK shock test in accordance to IEC 62262

Shock is introduced by dropping a hammer of 1.7 kg mass from a height of 0.3m. HEAVYCON plastic housing is able to meet the mechanical requirements similar to the HEAVYCON aluminium housing.

Roll over test in accordance to DIN IEC 62196-1

This is a special test carried out on the plastic housing where a forklift truck weighing several tons rolls over it. HEAVYCON plastic housing is able to withstand high amounts of stress from heavy, moving loads without any adverse effects on its function. In fact, in Singapore, we proved it again by driving a car over the connector.

Dynamic load test

Besides the strength of the plastic housing, we have to ensure the latching mechanism is heavy-duty enough as well. In this test, we applied a force of 200N to the cable at an angle of 90 degree. This is to test the HEAVYCON EVO bayonet as well as the locking latch between the housing and panel mounting to make sure that they do not malfunction under extreme static load.

Through the tests we have done, we can conclude that plastic can be as strong as metal too, in this case aluminium. To find out more about the durability of our HEAVYCON EVO in plastic, leave us an email at marketing@phoenixcontact.com.sg!

Versatility for PCB in Standard Form Factors

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The ideal solution for embedded systems can be selected using universal housings from the UCS series. There are several things which need to be taken into consideration when selecting the universal housings, for example, the size of the PCB and how the PCB can be fixed into the enclosures as UCS series is characterized by a wide range of possible applications.

Things which can be offered:

UCS universal electronics housings have a modular configuration and enable easily adaptable solutions for almost all printed circuit boards in standard form factors. Hence, it is suitable for desktop, wall or DIN rail housings with a lateral length of 125 mm or 145 mm.

  • Material: Polycarbonate PC (UL V0)
  • Colors: Light gray (RAL 7035) or black (RAL 9005)
  • Depth: 47 mm and 67 mm
  • PCB Mounting: Fixed or flexible
  • Degree of Protection: IP40
  • Temperature Range: -40°C to +100°C

A custom interface is also one of the benefits which enable signals, data or power to turn into a single board computer and to a versatile electronics solution.

  • PCB terminal blocks and PCB connectors (wire-to-board)
  • PCB connectors (board-to-board)
  • M12 circular connectors
  • Data connectors for copper and fiber optics


Feel free to contact us at marketing@phoenixcontact.com.sg to find out more!

5 Ways to Terminate Cables into an Electrical Panel

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There are several criteria when it comes to choosing the right cable entry method into an electrical panel, such as ingress protection (IP) rating, ease of connection/ disconnection, cost of the connector etc. In this post, we have sorted out 6 different cable entry methods that Phoenix Contact has to offer.

  1. Cable Gland

The most common way to terminate cables into an electrical panel would be to use a cable gland. It is easy to use and comes in many variants such as different sizes, materials and with additional certifications such as ATEX. Cable glands are probably one of the most affordable cable entry methods mentioned in this article.

However, cable glands have its limitations too. It is difficult and time consuming to do multiple connections/disconnections with cable glands as the cables are terminated directly into the components within the electrical panel. In addition, the pre-cut holes on the gland plate are irreversible. It provides limited flexibility for mistakes and modifications.

  1. Heavy-duty Connector

As the name suggests, it is rugged and enables fast and easy connection/disconnection to the electrical panel. Cables are prewired into the connector base, which is mounted onto the panel while the field cables are prewired into the connector hood. The hood is then plugged into the base on the electrical panel for a complete connection up to IP 69K.

Heavy-duty connector is especially useful for portable applications and testing facilities as it allows quick connection and disconnection. Although heavy-duty connectors are more expensive than cable glands, it minimises time and labour needed for onsite installation and commissioning up to 80%. It also reduces errors that could occur during onsite installation.

Heavy-duty connectors are typically made from Aluminium. However, Heavycon EVO from Phoenix Contact also comes in plastic (polyamide with reinforced fibre glass) to support applications that do not require metal housings and provides cost savings of up to 30%. Besides that, the dual entry cable gland enhances the flexibility for onsite installation. Phoenix Contact’s well known Push-in Technology is also used in Heavycon to further reduce the installation time.

  1. Cable entry system

Cable entry system (CES) is similar to cable glands. However, it helps to arrange the cables neatly and systematically into the electrical panel. By better managing the cables, the gland plate can be better utilised. It works in a modular form where the cable sleeves can be flexibly combined depending on the wiring. The slotted sleeves also allow the use of sensor actuator cabling while cone sleeves come in handy when the cable diameter is not predefined.

The cut-out of CES is the same as that of heavy-duty connectors. Thus, they are interchangeable. However, CES is not a pluggable connector. Thus, it is not suitable for applications that require frequent connecting/disconnecting.

  1. CES Multigate

Similar to CES, multigate offers great cable management. However, unlike CES, multigate has prefixed cable entry. Each cable entry is a cone-shape membrane that is able to accommodate a range of cable diameters. This is especially suitable for panels with defined cable specifications. As the cables are well arranged, it is easier to isolate faulty lines, if any.

  1. Service interface

Service interfaces make maintenance, servicing, and diagnostics easier than ever. The front plate comes in different configurations of D-SUB, RJ45 and USB, offering numerous combinations.  The mounting frame offers up to IP 65 protection with locking mechanism for extra security. This reduces the need to open up the panel during programming or configuration.

There are many factors to consider when it comes to choosing the most suitable cable entry method to your electrical panels. Let us help you with the selection by leaving us an email at marketing@phoenixcontact.com.sg!

Comprehensive Solutions from Phoenix Contact

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In today’s market, customers are looking for vendors who can value add, making them stand out in the sea of competitors. One of the orders we often receive is to supply a complete package system from the cabinet to the components level.

Our collaboration with local partners makes Phoenix Contact the preferred solutions provider. Backed by comprehensive components from Phoenix Contact, control cabinets supplied and superior engineering services are the root of our initial success in the Process market in Indonesia.

Problems which the customer faced before are as follows:

  • Having to contact several vendors for the different scopes of supply, such as electrical components, control cabinet, wiring and installation
  • Managing the delivery time for each and every vendor
  • Complexities during the project management
  • Uncompetitive prices

With a complete solution provided by Phoenix Contact & our partners, customers will only have one point of contact related to all cabinet and components project requirements. This will ease the difficulties faced in terms of project management and therefore will ultimately reduce their overall cost.

Take a look at the example below of our recent success at this comprehensive solution.

Application: Metering Systems

Scope of supplies:

  • Control cabinet 800W x 800D x 2000H (in mm) & cabinet accessories
  • Redundant power supply system by Quint Power (QUINT-PS/1AC/24DC/10)
  • I/O Surge protection system with indicator: Termitrab Complete (TTC-6-1X2-F-M-24DC-UT-I)
  • Current splitter: MACX MCR-SL-RPSSI-2I
  • System cabling: Varioface (FLKM-D25 SUB/B + CABLE-D25SUB/B/S/100/KONFEK/S)
  • Front mounting industrial power socket and RJ 45 socket IP65
  • Interposing relay: PLC relay series (PLC-RSC- 24DC/21)
  • Accessories: fuse terminal block, AC socket power, cable duct, terminal & device marking, etc
  • Engineering services: wiring and installation, FAT supports

Below are the images of our solution:

Front mounting AC socket & RJ 45 socket

Front mounting AC socket & RJ 45 socket

Control Cabinet and wiring/installation services

Control Cabinet and wiring/installation services

Varioface system cabling

Varioface system cabling

Redundant power supply, interposing relay, fuse terminal block

Redundant power supply, interposing relay, fuse terminal block

TTC Surge protection with indicator and MACX current splitter

TTC Surge protection with indicator and MACX current splitter

If you would like to find out more, don’t hesitate to contact us!

Heavy-Duty Connector Solution for Machine Building

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Phoenix Contact’s Heavy-Duty Connector is an ideal solution to replace conventional cable glands if you want to have an easy and quick physical disconnection of power or signal. Many machine building system integrators are facing the following problems with regards to the cable gland design:

  • Difficult to dismantle and disconnect
  • Consumes a significant amount of panel space
  • Errors during installation

After going through the product technical information, our machine builder customer decided to replace most of the cable glands with Heavy-Duty Connectors due to their easy application. a photo of their panel is shown below.

Control Cabinet

Fig 1: Control Cabinet

Heavy-Duty Connector

Fig 2: Heavy-Duty Connector

Feature of Heavycon:

  • High corrosion resistance
  • Ensures secure power, data and signal transmission
  • Flexible single or double locking latches
  • Mounting and plug-in Compatible
  • EMC-ready
  • Ideal for operating in harsh environments

If you need any technical advice on your current project, feel free to contact us! I believe we can be your trusted partner to provide suitable solutions to fit your needs!

Cable Entry System – CES

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Have you ever left your earphones in your pocket and when you wanted to use them again, they emerge as a tangled ball of mess? Annoying, isn’t it?

Well, the wiring of current and conventional electrical panels brings about a similar problem. The above picture shows its set up and at a glance, three words pop up in my mind: Complex; Costly; Time-consuming.

So why is this so?

Firstly, in the current system, multiple holes of different sizes need to be drilled in accordance with the cable sizes. Imagine the hassle having to drill ten holes of different diameter just to see messy wires intertwined together.

Next, a common occurrence to such wiring systems is the need to add additional cables. If you are lucky, there will be enough space on the flange plate to drill the extra holes. However, if the space is insufficient, or if you need larger holes for new cables, you would most likely have to replace the entire electrical panel and redo the entire wiring system from scratch. Not only does this add on to the hassle, it also adds on to labour and cost.

Lastly, conventional wiring systems require more time to rectify problems in communication. This is due to the difficulty in identifying specific cables especially when they are bundled together. The troubleshooting process thus leads to longer downtime which means financial losses for the company.

The Solution

Phoenix Contact has thus come up with a solution to eliminate this problem. Our Cable Entry System (CES) comes with specific features to tackle the hassle of the conventional system.

Firstly, only one or two holes would have to be cut to enable installation of up to ten cables in the system, greatly reducing the set up time. Furthermore, the CES can cater to different cable diameters ranging from 2mm-24mm. All these can be easily installed by mounting the sleeves of varying sizes on to the robust metal reinforced frame.

Next, additional cables can be installed by removing the blind sleeves from the extra cable holes provided by the CES. In the event that the existing cable configuration has to be amended, the CES allows for easy reassembly just by replacing the sleeves with those of different cable diameters. This eliminates the trouble of cutting out new holes on the flange plate.

Lastly, the CES allows cables to be easily identified as the rectangular frame organizes the sleeves holding the cables in an orderly manner that is easy on the eyes.

Besides tackling the inconveniences of the conventional electrical panel wiring, the CES offers protection class of IP54, making it suitable for harsh environment conditions.

If your current electrical wiring system reminds you of your ball of tangled earphones, it‘s about time you switch to Phoenix Contact’s Cable Entry System. Our CES will be the solution to increasing your productivity and cost saving to your electrical panels wiring.

Interested to find out more? Contact us at marketing@phoenixcontact.com.sg!

System Cabling Solution for Process Industry

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One of the challenges which panel builders in the process industry face would be space saving on control cabinets. Many Process retrofitting jobs require panel builders to ensure the quantity of cabinets remain even though additional I/O’s are added. System cabling is one of the best solutions to save space in control cabinets.  One of our panel builders solved their problems by replacing terminal blocks with our VARIOFACE Interface Module for the project.

Problems:

  • Additional 150 I/O’s on current system
  • Additional Controller Module
  • Cabinet Quantities need to be remained

After going through the product technical information, panel builder engineers decided to replace most of the signals with our VIP Interface Module due to space constraints. There are a total of 115 units of VIP-3/SC/D37SUB/F installed in this project. Photos of the panel are shown below.

Control Cabinet

Fig 1: Control Cabinet

VIP Interface Board

Fig 2: VIP Interface Board

Features of Interface Module:

  • Compact design of control cabinet space
  • I/O marking for field wiring clearly identified
  • Flexible marking of modules
  • Metal mounting foot allows for easy installation and removal on din-rail
  • Allows flexible module mounting positions

In addition to the space saving advantage, the site engineer shared that it is also time saving and fault free during the wiring termination. When the panels are delivered, the end user saves valuable time when installing and troubleshooting

If you need any technical advice on your current project, feel free to contact us. I believe we can be your trusted partner to provide suitable solution to fit your application!