Category Archives: Industrial Electronics

Multi-point multiplexer for process use

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Phoenix Contact offers a solution combining the new RS-485 bus coupler with Radioline I/O wireless modules to provide customers with a multiplexer system specifically for process use.

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As in the Radioline wireless system, thumbwheels on the front provide a fast and simple way to address the head modules and easily perform I/O mapping of the expansion modules. This allows users to distribute I/O signals in an RS-485 bus system without any programming or software configuration.

In addition to operation by means of a two-wire RS-485 bus line with up to 99 stations, the new RS-485 stations can also expand the Radioline wireless system, so that I/O mapping can be extended to cover all media. Alternatively, the stations can also be operated in stand-alone mode on a Modbus/RTU master, thus allowing for direct connection to a controller.

For robust use in continuous industrial operation, the I/O expansion modules from the Radioline product family feature electrical channel-to-channel isolation and a wide operating range from –40 to +70 °C. The system also offers an extensive package of approvals including ATEX, IECEx, and UL certifications.

Powerful PV overvoltage protection

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The new VAL-MB product family from Phoenix Contact provides powerful and compact protective devices for photovoltaic applications with generator voltages of up to 1500 V DC. The protective devices are specially adapted to DC application requirements and certified by KEMA.

Longer inlet funnels and higher screw shafts provide additional protection against arcing. The product range includes protective devices for generator voltages of 600 V DC, 1000 V DC and 1500 V DC, as type-1/2 lightning current arresters, as well as pure type 2 surge protection devices. Variants are available with or without remote signaling contact. All protective devices have a short-circuit protection of 2000 A and can also be used in high-altitude plants up to 6000 meters in altitude.

Coupling relays for safety-related activation

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In recent years, safety-related activation has become increasingly important in the field of process technology.

As a result, with PSR-PC50, Phoenix Contact offers a coupling relay that has been specially developed for this area and that can be used according to SIL 3.

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The coupling relay was specially designed for failsafe controllers in the field of process technology. As such, all requirements for use in applications up to SIL 3 are fulfilled, according to IEC 61508. Internally, the device has six contacts that are switched in parallel as well as in series. In this way, the safety required is taken into account, as well as the necessary availability.

Continuous diagnosis poses a challenge for planners and planning engineers. Generally speaking, the controller diagnosis ends at the coupling module used. Often this is not sufficient for many users. To this end, the line/load monitoring function of the PSR-PC50 relay enables seamless diagnostics from the controller to the actuator. Open circuits as well as short circuits in the on-load voltage supply and diagnostic supply voltage are monitored. If an error occurs during normal operation, in all established safety systems it can be reported via the existing control line back to the corresponding digital output. In this way, the need for additional installation time and other digital inputs required for actuator readback is eliminated.

 

New highly compact isolation amplifiers with UL certification

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The Mini Analog Pro product family is the first line of 6-mm isolation amplifiers with plug-in connection technology. There are now four new product types that are UL 508 listed and thus can also be used in the USA and Canada.

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The expansion of the product line includes an analog frequency converter with limit value functionality for converting standard signals to frequency or PWM signals, a limit value switch with converter relay output for switching analog limit values, a constant voltage and current source, and a NAMUR insulation amplifier for proximity initiators and voltage-free and resistive switch contacts. The easy-to-configure modules are available with screw-in or push-in connection technology.

The Mini Analog Pro isolation amplifiers can be easily installed and operated in narrow spaces. Easily visible and accessible connection points and power measurements during operation ensure convenient use.

Intelligent Surge Protection for Process Technology

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Phoenix Contact’s Plugtrab PT-IQ surge protection devices for MCR and process technology warn plant operators before protection of the plant is lost. To achieve this, each voltage-limiting component in the protective plugs is continuously monitored. If the performance limit has been reached as a result of frequent surge voltages, this is indicated by a yellow signal on the protective device and via remote signaling. At this time, the arresters are still functional and the plant is protected. However, replacing the component is recommended to prevent unnecessary servicing.

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Plugtrab PT-IQ Ex protective devices are available for intrinsically safe areas. These devices can be installed in Ex Zone 2. The intrinsically safe protective circuits can be routed up to Ex Zone 0.

Thanks to multi-level monitoring and signaling, the plant operator always knows the status of protective devices and therefore has an overview of surge voltage protection in the plant. This intelligent surge voltage protection is available with traditional screw connection technology as well as innovative push-in connection technology. A controller supplies up to 28 protection modules with voltage and allows for connection of a central remote monitoring system.

Security Routers for Process Technology

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Security is becoming increasingly important in the process engineering industry. With the new MGuard security router, Phoenix Contact is addressing this trend.

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The security router meets the demanding hardware requirements of the process industry as well as the strict IT requirements for security products. Hardware features include an extended temperature range of -40 to +70 °C, IECEx and ATEX approvals for Ex Zones and corrosive gas testing in accordance with ISA-S71.04-1985 G3 Harsh Group A.

From a software point of view, existing MGuard security functions were enhanced with additional security components for OPC Classic, a protocol widely used in the industry. These include DPI (deep package inspection) and NAT (network address translation) functions. DPI allows for a high-quality OPC Classic firewall in the production facility, whereas NAT provides the option of integrating plants with identical IP addresses into a higher-level production network quickly, easily, and without address conflicts.

High-performance, safe coupling relays just 6 mm wide

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The new PSRmini safety modules from Phoenix Contact are the world’s slimmest safety relays with the power of a large safety relay. With their compact 6-mm width, they ensure high safety thanks to positively driven contacts. For users, these slim modules require up to 70 percent less space.

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A comprehensive package of tests and approvals ensures that the modules can also be flexibly used in applications and environments that exceed the norm. For example, the relays are G3-compliant according to ISA S71.04-1985 for use in especially corrosive atmospheres and are IECEx-certified, thereby facilitating the decentralized design of an application down to Ex Zone 2. Repeat tests in a process plant, which are prescribed by standards, can easily be performed visually and directly on the device. Complex manual measurements that are currently required when using standard relays that are not forcibly guided according to EN 50205 are therefore often unnecessary. In addition, in some common control systems, monitoring of the controls of the coupling module may be influenced in the event of an error, so that the repeat test, the so-called proof test, can be designed to be almost fully automated. This increases efficiency since downtime can be reduced without necessitating additional effort for required hardware or installation.

The compact design of the safety modules is made possible through Phoenix Contact’s newly developed relay technology. The design is based on a slim, powerful, and force-guided basic relay characterized by minimal space requirements, low energy consumption, and high system availability. Despite its compact width of just 6 mm, the component features the same performance as traditional EN 50205-compliant elementary relays with forced guidance. The elementary relay from Phoenix Contact consists of an NO and an NC contact and is suitable for a modular application configuration. To achieve the manufacturing precision required to meet Phoenix Contact’s high quality requirements, the elementary relay and all of its individual parts are manufactured entirely at Phoenix Contact.

Since only the 6-mm modules require a single enabling contact, applications can be built with new and improved cost-effectiveness. The termination carrier also provides the option of using system cabling solutions for quick, error-free commissioning and connection in the field. The complete PSRmini range of safety relays consists of 28 products for mechanical engineering and the process industry.

Pluggable lightning arrester with backup fuse

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The Flashtrab-SEC-Hybrid lightning arresters from Phoenix Contact are the world’s first pluggable type 1 lightning arresters with integrated arrester backup fuse without line follow current

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The products are based on the Safe Energy Control Technology (SEC) from Phoenix Contact, which enables even high discharge currents to be kept safely under control. With the new push-pull mechanism, the protective device plugs are easy to remove and latch after being inserted in the base element in a vibration-resistant manner. The integrated backup fuse allows the lightning arrester to be installed easily and flexibly.

In comparison to installations with separate backup fuses, the new devices save up to 60% space, reduce wiring costs and effort, and allow customers to freely choose the installation location. The type 1 lightning arrester is suitable for use in 230/400 V power supply systems without a back-up fuse.

DC/DC converters now available for more voltage levels

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The Quint Power product range from Phoenix Contact has been extended to include six new DC/DC converters, which cover additional voltage levels with increased functionality.

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In addition to the new devices for voltage levels 12 and 48 V DC, there are now two more devices on offer with wide range input. These convert input voltages in the range between 42 to 96 V DC and 67 to 154 V DC into an electrically isolated, adjustable 24 V DC output voltage. This means that the nominal voltage levels 60 and 110 V DC, such as those that arise in the energy sector, can be covered. Thanks to the electrical isolation between the input and output voltage, independent supply systems can be established, and monitored in a preventative manner. Two additional devices which are specially designed for the input voltage range for railway applications complete the product range. They satisfy railway standard EN 50155 with their protective coating. They can also be used in other demanding environments.

All DC/DC converters support Power Boost, which permanently supplies 1.25 times the nominal current. What’s more, the devices feature Selective Fuse Breaking Technology (SFB), which supplies six times the nominal current for 12 ms, thereby reliably tripping standard circuit breakers. Comprehensive diagnostics are provided through constant monitoring of the input and output voltage and output current. Preventive function monitoring visualizes critical operating states and reports them to the controller before errors can occur.

Optimum lighting for the control cabinet with LED technology

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With LED technology and integrated optics, the new PLD enclosure lights from Phoenix Contact provide bright control cabinet illumination which is adapted to the environment, even down to the lowest area of the cabinet.

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The lights are easy to install – no need for tools. The product range consists of two performance classes in addition to the cabling and mounting accessories. The class 600 lights have an AC wide range input and can be connected in series. They are switched on and off automatically via the integrated motion detector. A country-specific socket allows external devices to be operated even if the control cabinet is disconnected from the power supply.

The compact class 400 lights are supplied with 24 V DC. A choice of three light lengths and the swiveling light window ensures a perfect fit with a range of control cabinet widths and control cabinet panel installation depths. The lights can also be connected in series and can either be switched on and off manually using the integrated switch or automatically via the upstream door position switch.